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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0128 RB Original Issue:
September 17, 2025 ATA System: 5310 SUBJECT: FUSELAGE - Frames - STA 640 to STA 840 Frame Inner Chord Between Stringer S-21 and S-23 Inspection EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.
9E991ECCN:
Copyright © 2025 The Boeing Company Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: September 17, 2025 757-53A0128 RB 1 of 30
4.0
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 2 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
BLANK PAGE
Table of Contents
1. EFFECTIVITY .
.5
A. Airplanes5
B. Spares Affected6
2. CONCURRENT REQUIREMENTS6
3. COMPLIANCE6
4. APPROVAL12
5. ACCOMPLISHMENT INSTRUCTIONS13
A. General Information13
B. Work Instructions14
FIGURE 1: FUSELAGE - FRAMES STA 640 TO STA 840, STRINGER S-21L TO S-23L - GENERAL VISUAL
INSPECTION (GVI)19
FIGURE 2: FUSELAGE - FRAMES STA 640 TO STA 840, STRINGER S-21L TO S-23L - FRAME
INSPECTION22
FIGURE 3: FUSELAGE - FRAMES STA 640 TO STA 840, STRINGER S-21R TO S-23R - GENERAL
VISUAL INSPECTION (GVI)25
FIGURE 4: FUSELAGE - FRAMES STA 640 TO STA 840, STRINGER S-21R TO S-23R - FRAME
INSPECTION28
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 3 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 4 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
BLANK PAGE
Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0128 RB Original Issue:
September 17, 2025 ATA System: 5310 SUBJECT: FUSELAGE - Frames - STA 640 to STA 840 Frame Inner Chord Between Stringer S-21 and S-23 Inspection
THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING PROCESSES USED
TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1.
Effectivity A. Airplanes This bulletin is applicable to 757-200 Airplane(s), line number(s) 2-14, 16-17, 20-43, 46, 49-52, 54, 57-58, 61, 63-66, 71, 73-81, 84-85, 87, 89-102, 111-118, 120, 123, 126, 128-129, 133-135, 138, 144-146, 148, 150-151, 153-155, 157-161, 163-164, 166-168, 171, 173-175, 177, 179, 183, 187, 198, 200-203, 205-207, 210-211, 214, 216-218, 221-225, 227-230, 232-233, 238-239, 241, 244, 246-247, 251-252, 254, 256, 261-266, 270-272, 277-279, 282, 284, 286-288, 290-294, 298-299, 305-307, 310-313, 319-320, 323, 329, 331, 335, 338-339, 341-343, 346-347, 349, 352-355, 358-359, 361-364, 366-367, 372-374, 376-377, 380-381, 385-386, 389, 392-394, 396, 401, 405-406, 413-416, 420-421, 426-427, 429-431, 434-435, 439, 441-442, 445, 447-449, 453-456, 461-462, 465-467, 469, 475-476, 479-480, 487-488, 490, 492, 494, 497-502, 506, 508, 512-513, 515-516, 518, 524-525, 527, 531, 533-535, 539-540, 542-544, 546, 550-552, 554, 556, 559, 563-564, 567, 570-571, 584, 586, 589, 595, 601, 605, 607, 609-610, 613, 615, 622, 624, 630, 665, 669, 674, 685, 698, 718-719, 724, 727, 747, 751, 762, 773, 784-785, 789, 793-794, 798, 841, 844, 864, 867, 871-873, 877 in 1 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 757-200 airplanes equipped with Air Cargo Equipment (ACE) Cargo Loader provisions in the Forward Cargo Bay.
- 1 Airplane Models:
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 5 of 30
757-200 GroupVariable Number 1NA002 - NA028 1NA191 - NA199 1NA201 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 1NA501 - NA584 1NB021 - NB023 GroupVariable Number 1NB036 - NB041 1NB051 - NB053 1NB061 - NB070 1NB261 - NB264 1NB291 - NB299 1NB301 - NB302 1NB501 - NB514 1NB581 - NB583 GroupVariable Number 1ND221 1ND224 - ND225 1NE011 - NE088 1NE091 - NE094 1NE141 - NE150 1NT401 - NT409 1NT791 - NT796 -- B.
Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 757-53A0128 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0128 RB mandatory.
Accomplish the required action(s), based on the applicable condition(s) in Table 1 through Table 2, in accordance with Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Table 1: Fuselage - Frames STA 640 to STA 840, Stringer S-21L to S-23L - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0128 RB.
Before 37,000 total flight cycles.
Do a General Visual Inspection (GVI) or maintenance records check for any repair of the frames from STA 640 to STA 840, between stringer S-21L and S-23L.
All airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 6 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
Table 1: Fuselage - Frames STA 640 to STA 840, Stringer S-21L to S-23L - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0128 RB.
Do a GVI or maintenance records check for any repair of the frames from STA 640 to STA 840, between stringer S- 21L and S-23L.
All airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB.
-For airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB: Before 37,000 total flight cycles, or within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB, whichever occurs later.
CONDITION 1 (ACTION 1):
Contact The Boeing Company for alternative inspections to Requirements Bulletin 757- 53A0128 RB and do the inspections and applicable on-condition actions at each repair location.
CONDITION 1: ANY REPAIR FOUND.
For airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB: Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
-For airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB: Before 37,000 total flight cycles, or within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB, whichever occurs later.
CONDITION 1 (ACTION 2): Do a High Frequency Eddy Current (HFEC) surface inspection of the frames from STA 640 to STA 840, between stringer S- 21L and S-23L for any crack at any location without a repair. (a) For airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB: Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 7 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
Table 1: Fuselage - Frames STA 640 to STA 840, Stringer S-21L to S-23L - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 1.1 (ACTION 1):
Contact The Boeing Company for repair instructions and do the repair.
CONDITION 1.1: ANY CRACK FOUND.
6,000 flight cycles.-CONDITION 1.1 (ACTION 2):
Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21L and S-23L for any crack. (a) 6,000 flight cycles.-Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21L and S-23L for any crack. (a) CONDITION 1.2: NO CRACK FOUND.
-For airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB: Before 37,000 total flight cycles, or within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB, whichever occurs later.
Do a HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S- 21L and S-23L for any crack.
CONDITION 2: NO REPAIR FOUND.
For airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB: Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
-Before further flight.CONDITION 2.1 (ACTION 1):
Contact The Boeing Company for repair instructions and do the repair.
CONDITION 2.1: ANY CRACK FOUND.
6,000 flight cycles.-CONDITION 2.1 (ACTION 2):
Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21L and S-23L for any crack. (a) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 8 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
Table 1: Fuselage - Frames STA 640 to STA 840, Stringer S-21L to S-23L - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 6,000 flight cycles.-Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21L and S-23L for any crack. (a) CONDITION 2.2: NO CRACK FOUND.
(a) It is not required to do the HFEC inspections in accordance with Requirements Bulletin 757-53A0128 RB in the repair affected area(s) if the repair(s) meet all of the conditions that follow:
1.
The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
3. The FAA Form 8100-9 approval defines the repair affected area(s), states the post repair inspection plan for the repair affected area(s), and approves the inspection plan as an alternative inspection method to the inspection(s) in Requirements Bulletin 757-53A0128 RB.
Table 2: Fuselage - Frames STA 640 to STA 840, Stringer S-21R to S-23R - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0128 RB.
Before 37,000 total flight cycles.
Do a General Visual Inspection (GVI) or maintenance records check for any repair of the frames from STA 640 to STA 840, between stringer S-21R and S-23R.
All airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB.
-Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0128 RB.
Do a GVI or maintenance records check for any repair of the frames from STA 640 to STA 840, between stringer S- 21R and S-23R.
All airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 9 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
Table 2: Fuselage - Frames STA 640 to STA 840, Stringer S-21R to S-23R - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -For airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB: Before 37,000 total flight cycles, or within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB, whichever occurs later.
CONDITION 3 (ACTION 1):
Contact The Boeing Company for alternative inspections to Requirements Bulletin 757- 53A0128 RB and do the inspections and applicable on-condition actions at each repair location.
CONDITION 3: ANY REPAIR FOUND.
For airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB: Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
-For airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB: Before 37,000 total flight cycles, or within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB, whichever occurs later.
CONDITION 3 (ACTION 2): Do a High Frequency Eddy Current (HFEC) surface inspection of the frames from STA 640 to STA 840, between stringer S- 21R and S-23R for any crack at any location without a repair. (a) For airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB: Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 10 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
Table 2: Fuselage - Frames STA 640 to STA 840, Stringer S-21R to S-23R - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 3.1 (ACTION 1):
Contact The Boeing Company for repair instructions and do the repair.
CONDITION 3.1: ANY CRACK FOUND.
6,000 flight cycles.-CONDITION 3.1 (ACTION 2):
Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21R and S-23R for any crack. (a) 6,000 flight cycles.-Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21R and S-23R for any crack. (a) CONDITION 3.2: NO CRACK FOUND.
-For airplanes with less than 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757- 53A0128 RB: Before 37,000 total flight cycles, or within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB, whichever occurs later.
Do a HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S- 21R and S-23R for any crack.
CONDITION 4: NO REPAIR FOUND.
For airplanes with more than or equal to 42,000 total flight cycles as of the Original Issue date of Requirements Bulletin 757-53A0128 RB: Within 1,500 flight cycles after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
-Before further flight.CONDITION 4.1 (ACTION 1):
Contact The Boeing Company for repair instructions and do the repair.
CONDITION 4.1: ANY CRACK FOUND.
6,000 flight cycles.-CONDITION 4.1 (ACTION 2):
Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21R and S-23R for any crack. (a) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 11 of 30 REQUIREMENTS BULLETIN 757-53A0128
ALERTALERT
Table 2: Fuselage - Frames STA 640 to STA 840, Stringer S-21R to S-23R - Frame Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 6,000 flight cycles.-Repeat the HFEC surface inspection of the frames from STA 640 to STA 840, between stringer S-21R and S-23R for any crack. (a) CONDITION 4.2: NO CRACK FOUND.
(a) It is not required to do the HFEC inspections in accordance with Requirements Bulletin 757-53A0128 RB in the repair affected area(s) if the repair(s) meet all of the conditions that follow:
1.
The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0128 RB.
2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
3. The FAA Form 8100-9 approval defines the repair affected area(s), states the post repair inspection plan for the repair affected area(s), and approves the inspection plan as an alternative inspection method to the inspection(s) in Requirements Bulletin 757-53A0128 RB.
4. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document comply with the applicable regulations and are FAA approved, as well as European Union Aviation Safety Agency (EASA) approved for all EASA approved airplanes listed in this Requirements Bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
In addition, the Manager of the FAA Continued Operational Safety (COS) Branch approves the inspections defined in this requirements bulletin as an Alternative Method Of Compliance (AMOC) to the requirements of paragraph (g) and (h) of AD 2020-01-18 for the inspection of SSI 53-30-24 of the 757 Maintenance Planning Data (MPD) Document Section 9 Airworthiness Limitations (AWLs) and Certification Maintenance Requirements (CMRs), D622N001-9, affected by the inspection. This AMOC only applies to the areas inspected in accordance with this requirements bulletin and to the airplanes identified in this requirements bulletin. Operators of 757-200 airplanes must revise their FAA-approved maintenance or inspection program to comply with paragraph (g) and (h) of AD 2020-01-18 when incorporating the inspections specified in this requirements bulletin. All provisions of AD 2020-01-18 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 17, 2025 757-53A0128 RB 12 of 30 REQUIREMENTS BULLETIN 757-53A0128