# Boeing Alert Service Bulletin 767-53A0131: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2010-0033; AD 2011-14-02 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 767-53A0131](https://openairdocs.org/service-documents/boeing/767-53a0131.md) - Title as filed: U.S.DOT/FAA - Service Bulletin - Pages: 52 - PDF: https://openairdocs.org/files/sha256/40/dd/40dd8c8177dc9d346f7aaa9eedc31cae5ba074b11935084f15fe793533cc9fdc - Page: https://openairdocs.org/service-documents/boeing/767-53a0131/file/40dd8c8177dc ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0131 Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 SUBJECT: FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P .O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 1 of 52 5.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 2 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ..................................................... 7 1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1 1. Airplanes ............................................ 1 1 2. Spares Affected ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F . Approval ............................................... 2 1 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 3 J. References .............................................. 2 3 1. Existing Data: .......................................... 2 3 2. Data supplied with this Service Bulletin: ........................... 2 3 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ......................................... 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 4 2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 5 1. Kits/Parts: ............................................ 2 5 2. Parts and Materials Supplied by the Operator: ........................ 2 5 3. Parts Modified and Reidentified: ................................ 2 5 4. Parts Removed and Not Replaced: .............................. 2 5 D. Parts Necessary to Change Spares ................................. 2 5 E. Special Tooling - Price and Availability ............................... 2 5 F . Special Tooling Necessary to do this Service Bulletin ....................... 2 5 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 7 FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE ....... 3 1 FIGURE 2: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - RIGHT SIDE ....... 3 3 FIGURE 3: DET AILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE .......................................... 3 5 FIGURE 4: DET AILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE ......................................... 3 8 FIGURE 5: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - LEFT SIDE ................................... 4 1 FIGURE 6: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - RIGHT SIDE .................................. 4 4 FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - LEFT SIDE .......................................... 4 7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 3 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 4 FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - RIGHT SIDE ......................................... 5 0 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 4 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 5 Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-53A0131Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 SUBJECT: FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin. More work is necessary on airplanes that have been inspected as given in the initial release of this service bulletin. At the time of the next inspection, do the inspections as given in this revision. No airplane was added to the service bulletin effectivity. REASON FOR REVISION This revision is sent to give a clarification for the horizontal inner chord inspection and add surface HFEC inspection for the vertical inner chord. The following sections of the service bulletin are affected: — In SUBJECT, the words "and Vertical" was added to the title. — In Paragraph 1.D., Description, added Affected Maintenance Zones table. — In Paragraph 1.E., Compliance, added FAA AD 2006-24-04 reference. — In Figures 5 and 6, Detailed and Surface HFEC Inspections of Horizontal Inner Chord (Internal) - Left Side and Right Side, respectively; a clarification was added to inspect only the exposed surfaces of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips. — Additional surface HFEC inspection was added for the vertical inner chord installed on the aft of Station (STA) 1809.5 bulkhead in the area of Buttock Line (BL) 28.5, Water Line (WL) 257. The surface HFEC inspection is to the flange and fillet radius of the vertical inner chord around the four (4) fasteners that pass through both vertical and horizontal inner chord. Subsequent to the release of the original Service Bulletin 767-53A0131, one operator reported that the STA 1809.5 bulkhead vertical inner chord was found cracked at RBL 28.5, WL 257. The crack was discovered while accomplishing STA 1809.5 bulkhead inspection. Boeing Service Related Problem (SRP) 767-SRP-53-0320 is related to this vertical inner chord cracking. — The following sections of the service bulletin are affected by the addition of the surface HFEC inspection of the vertical inner chord: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 5 of 52 ### Page 6 — In Paragraph 1.E., Compliance, added compliance times for the vertical inner chord inspection. — In Figures 5 and 6, a detailed inspection of the aft side of the bulkhead structure was moved to Figures 7 and 8. — Figures 7 and 8 were added for the detailed and surface HFEC inspections of the vertical inner chord inspection. Vertical lines are put on the left edge of each page show the location of important changes. REVISION HISTORY March 30, 2006Original Issue: March 12, 2009Revision 1: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 6 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 7 Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-53A0131Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 SUBJECT: FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY . IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. CONCURRENT REQUIREMENTS None. BACKGROUND Accomplishment of the inspections in this service bulletin will make sure that cracks in the bulkhead structure at Station (STA) 1809.5 are found and repaired. If not repaired, cracks in the bulkhead structure at STA 1809.5 could become large and result in the inability of the STA 1809.5 bulkhead structure to carry horizontal stabilizer flight loads. This will have adverse effects on airplane controllability, and could cause loss of control of the airplane. Two operators have reported finding fatigue cracks in the forward outer chord of the STA 1809.5 airframe bulkhead. A total of seven outer chord cracks were found on four different airplanes. The outer chord cracks were located between stringers 4 and 8 (left side and right side), and were found on airplanes that had between 13,942 and 29,588 total flight cycles. A crack, similar to those found in the forward outer chords on operators airplanes, was also found on the Boeing fatigue test airplane. Three operators also reported finding a crack in the horizontal inner chord that spans between stringer 12L and stringer 12R. A total of seven horizontal chord cracks were found on seven different airplanes. The horizontal chord cracks were at the lower flange near Buttock Line (BL) 28, and were found on airplanes that had between 8,448 and 35,991 total flight cycles. In addition, one operator found small cracks in the external skin at STA 1809.5 between stringers 6 and 8 on the same airplane that also had approximately a one inch crack in the forward outer chord. After the original release of this service bulletin, one operator found a fatigue crack in the vertical inner chord while doing the detailed inspection of the horizontal inner chord. A surface High Frequency Eddy Current (HFEC) inspection was done to confirm the crack. The crack was found on the right side of the structure at a fastener hole near BL 28.5, Water Line (WL) 257; common to both the horizontal and vertical inner chord. The vertical inner chord crack was found on an airplane with 28,234 total flight cycles. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 7 of 52 ### Page 8 This service bulletin gives instructions to do inspections for cracks in the STA 1809.5 bulkhead forward outer chord, the horizontal inner chord, the vertical inner chord, and the external skin. If cracks are found in the forward outer chord, horizontal inner chord, or vertical inner chord, repairs per the applicable Structural Repair Manual (SRM) will be necessary. If cracks are found in the skin, Boeing will provide repair instructions. Boeing Service Related Problem (SRP) 767-SRP-53-0263 is related to the original issue of this service bulletin. Boeing SRP 767-SRP-53-0320 is related to this service bulletin. ACTION Get access to the upper skin on the outside of the airplane at STA 1809.5. Do an external detailed inspection of the skin on each side of the airplane, between stringers 3 and 10. Get access to the internal structure on the forward side of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure between stringers 3L and 10L, and between stringers 3R and 10R, in the area of the forward outer chord. Do a surface HFEC inspection of the forward outer chord for cracks between stringers 4L and 8L, and between stringers 4R and 8R. Get access to the internal structure on the forward and aft sides of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure at the intersection of the vertical inner chord and ends of the horizontal inner chord that spans between stringer 12L and stringer 12R on forward and aft sides of the STA 1809.5 bulkhead. Do a surface HFEC inspection for cracks in the ends of the horizontal inner chord. Do a surface HFEC inspection for cracks in the vertical inner chord common to the horizontal inner chord at approximately BL 28.5, WL 257. If cracks are found in the forward outer chord, horizontal inner chord, and/or vertical inner chord, repair as specified in the applicable Structural Repair Manual (SRM). If cracks are found in the skin, or if cracks are found in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord, contact Boeing for repair instructions. EFFECTIVITY All 767-200/-300/-300F/-400ER airplanes. Refer to Service Bulletin Paragraph 1.A.1. for effectivity. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin. Refer to Service Bulletin Paragraph 1.E. for information. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 8 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 9 INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of December 1, 2004. Please refer to Paragraph 2.B., Industry Support Information. MANPOWER Elapsed HoursTotal Task HoursAirplanes 10.5015.00All MATERIAL INFORMATION Operator Supplied Parts/Materials (if repairs are necessary). BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 9 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 10 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT SEE A DO A SURFACE HFEC INSPECTION OF THE FORWARD OUTER CHORD BETWEEN S-4 AND S-8. DO AN EXTERNAL STA S-2L DETAILED INSPECTION 1809.50 OF THE SKIN STA S-3L SEVEN INCHES FORWARD 1809.50 AND AFT OF STA S-4L 1809.5, BETWEEN S-3 AND S-10. _ S-6L DO A DETAILED INSPECTION OF THE \ S-7L FORWARD OUTER CHORD AND SURROUNDING STRUCTURE BETWEEN , S-8L S-3 AND S-10. UP S-10L → FWD DO A DETAILED INSPECTION OF THE HORIZONTAL INNER DO A SURFACE HFEC CHORD, VERTICAL INNER INSPECTION OF THE CHORD, AND SURROUNDING END OF THE STRUCTURE FORWARD AND AFT HORIZONTAL INNER OF STA 1809.50 BULKHEAD. CHORD. LEFT SIDE SHOWN RIGHT SIDE OPPOSITE DO A SURFACE HFEC INSPECTION OF THE VERTICAL INNER CHORD. Original Issue: March 30, 2006 Revision 1: March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 52 ### Page 11 Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0131 Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 SUBJECT: FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY . IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. 1. PLANNING INFORMATION A. Effectivity 1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. NOTE: This Service Bulletin is for the airplanes identified below. The Effectivity list shown below is complete for airplanes through line number 983. Airplanes after line number 983 are also affected by this service bulletin, and are in Group(s): 1 DESCRIPTIONCONFIGURATIONGROUP All 767-200/-300/-300F/-400ER airplanes.-1 Airplane Models: 767-200, 767-300, 767-300F , 767-400ER GroupVariable Number 1VA001 - VA020 1VA301 - VA315 1VA501 - VA530 1VA701 - VA719 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 11 of 52 ### Page 12 GroupVariable Number 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB332 1VB371 - VB373 1VB401 1VB441 - VB444 1VE001 - VE003 1VE021 - VE023 1VE041 - VE043 1VE061 - VE069 1VE083 - VE086 1VE101 - VE104 1VE116 - VE118 1VE121 - VE126 1VE141 - VE152 1VE171 - VE172 1VF001 - VF002 1VF041 - VF042 1VF051 1VF061 - VF062 1VF071 - VF072 1VF091 - VF093 1VF101 - VF102 1VF161 - VF162 1VF171 - VF172 1VF180 - VF184 1VF251 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 12 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 13 GroupVariable Number 1VK001 - VK016 1VK021 - VK022 1VK031 - VK056 1VK081 - VK113 1VK131 - VK133 1VK141 - VK148 1VK161 - VK164 1VK171 1VK181 1VK186 1VL001 - VL006 1VL011 1VL701 - VL703 1VL751 - VL755 1VL806 - VL807 1VL871 - VL873 1VL891 - VL900 1VL911 - VL914 1VL931 - VL932 1VL941 1VN001 - VN041 1VN051 - VN064 1VN081 - VN099 1VN111 - VN127 1VN130 - VN137 1VN151 - VN158 1VN163 - VN168 1VN171 - VN174 1VN191 - VN198 1VN211 - VN212 1VN221 - VN225 1VN231 - VN234 1VN241 - VN243 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 13 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 14 GroupVariable Number 1VN251 - VN276 1VN291 - VN293 1VN301 - VN314 1VN371 - VN372 1VN376 1VN381 - VN388 1VN421 - VN427 1VN436 1VN471 - VN472 1VN491 - VN513 1VN531 - VN532 1VN536 - VN537 1VN541 - VN542 1VN546 - VN547 1VN551 1VN556 - VN557 1VN561 - VN562 1VN631 - VN638 1VN651 - VN658 1VN671 - VN672 1VN676 1VN681 - VN691 1VN731 - VN732 1VN751 - VN753 1VN791 - VN792 1VN811 - VN813 1VN921 - VN922 1VN931 - VN936 1VN951 - VN953 1VN966 - VN972 1VQ001 - VQ021 1VQ071 - VQ086 1VQ111 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 14 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 15 GroupVariable Number 1VR051 - VR060 1VR081 1VR084 1VR086 - VR089 1VR106 - VR109 1VR201 - VR211 1VR251 1VR256 - VR260 1VR266 - VR267 1VR401 1VR421 - VR423 1VR426 1VR441 1VR461 1VR471 - VR472 1VS051 - VS056 1VS061 1VS066 - VS070 1VS073 - VS078 1VS091 - VS104 1VS111 - VS113 1VS131 - VS133 1VS136 - VS137 1VS176 - VS177 1VS186 - VS187 1VS196 - VS203 1VS206 - VS208 1VS211 1VS216 - VS217 1VS231 1VS246 - VS248 1VS261 - VS263 1VS266 - VS274 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 15 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 16 GroupVariable Number 1VS291 - VS293 1VS301 - VS303 1VS306 - VS311 1VS316 1VS321 - VS324 1VS331 - VS333 1VS336 - VS337 1VS366 - VS367 1VS381 - VS382 1VS391 - VS392 1VS401 1VS426 - VS428 1VS466 - VS472 1VS486 1VS496 - VS497 1VS506 - VS507 1VS526 1VS546 - VS549 1VS701 - VS736 1VS751 - VS759 1VS821 - VS825 1VS841 - VS844 1VS861 1VS881 - VS883 1VS891 1VS896 1VS901 - VS912 1VS916 1VS921 - VS922 1VS931 - VS933 1VT501 1VT511 - VT513 1VT521 - VT523 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 16 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 17 GroupVariable Number 1VT531 - VT533 1VT541 - VT543 1VV001 1VW701 - VW721 1VW851 2. Spares Affected None. B. Concurrent Requirements None. C. Reason Accomplishment of the inspections in this service bulletin will make sure that cracks in the bulkhead structure at Station (STA) 1809.5 are found and repaired. If not repaired, cracks in the bulkhead structure at STA 1809.5 could become large and result in the inability of the STA 1809.5 bulkhead structure to carry horizontal stabilizer flight loads. This will have adverse effects on airplane controllability, and could cause loss of control of the airplane. Two operators have reported finding fatigue cracks in the forward outer chord of the STA 1809.5 airframe bulkhead. A total of seven outer chord cracks were found on four different airplanes.The outer chord cracks were located between stringers 4 and 8 (left side and right side), and were found on airplanes that had between 13,942 and 29,588 total flight cycles. A crack, similar to those found in the forward outer chords on operators airplanes, was also found on the Boeing fatigue test airplane. Three operators also reported finding a crack in the horizontal inner chord that spans between stringer 12L and stringer 12R. A total of seven horizontal chord cracks were found on seven different airplanes. The horizontal chord cracks were at the lower flange near Buttock Line (BL) 28, and were found on airplanes that had between 8,448 and 35,991 total flight cycles. In addition, one operator found small cracks in the external skin at STA 1809.5 between stringers 6 and 8 on the same airplane that also had approximately a one inch crack in the forward outer chord. After the original release of this service bulletin, one operator found a fatigue crack in the vertical inner chord while doing the detailed inspection of the horizontal inner chord. A surface High Frequency Eddy Current (HFEC) inspection was done to confirm the crack. The crack was found on the right side of the structure at a fastener hole near BL 28.5, Water Line (WL) 257; common to both the horizontal and vertical inner chord. The vertical inner chord crack was found on an airplane with 28,234 total flight cycles. This service bulletin gives instructions to do inspections for cracks in the STA 1809.5 bulkhead forward outer chord, the horizontal inner chord, the vertical inner chord, and the external skin. If cracks are found in the forward outer chord, horizontal inner chord, or vertical inner chord, repairs per the applicable Structural Repair Manual (SRM) will be necessary. If cracks are found in the skin, Boeing will provide repair instructions. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 17 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 18 Boeing Service Related Problem (SRP) 767-SRP-53-0263 is related to the original issue of this service bulletin. Boeing SRP 767-SRP-53-0320 is related to this service bulletin. Federal Aviation Administration (FAA) has issued an Airworthiness Directive FAA AD 2006-24-04, which requires incorporation of this service bulletin. Revision 1 is sent to give the following information in this service bulletin: — In SUBJECT, the words "and Vertical" was added to the title. — In Paragraph 1.D., Description, added Affected Maintenance Zones table. — In Paragraph 1.E., Compliance, FAA AD 2006-24-04 was added. — In FIGURE 5 and FIGURE 6, Detailed and Surface HFEC Inspections of Horizontal Inner Chord (Internal) - Left Side and Right Side, respectively; a clarification was added to inspect only the exposed surfaces of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips. — Additional surface HFEC inspection was added for the vertical inner chord installed on the aft of STA 1809.5 bulkhead in the area of BL 28.5, WL 257.The surface HFEC inspection is to the flange and fillet radius of the vertical inner chord around the four (4) fasteners that pass through both vertical and horizontal inner chord. — The following sections of the service bulletin are affected by the addition of the surface HFEC inspection of the vertical inner chord: — In Paragraph 1.E., Compliance, added compliance times for the vertical inner chord inspection. — In FIGURE 5 and FIGURE 6, a detailed inspection of the aft side of the bulkhead structure was moved to FIGURE 7 and FIGURE 8. — FIGURE 7 and FIGURE 8 were added for the detailed and surface HFEC inspections of the vertical inner chord inspection. D. Description Get access to the upper skin on the outside of the airplane at STA 1809.5. Do an external detailed inspection of the skin on each side of the airplane, between stringers 3 and 10. Get access to the internal structure on the forward side of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure between stringers 3L and 10L, and between stringers 3R and 10R, in the area of the forward outer chord. Do a surface HFEC inspection of the forward outer chord for cracks between stringers 4L and 8L, and between stringers 4R and 8R. Get access to the internal structure on the forward and aft sides of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure at the intersection of vertical inner chord and ends of the horizontal inner chord that spans between stringer 12L and stringer 12R on forward and aft sides of the STA 1809.5 bulkhead. Do a surface HFEC inspection for cracks in the ends of the horizontal inner chord. Do a surface HFEC inspection for cracks in the vertical inner chord common to the horizontal inner chord at approximately BL 28.5, WL 257. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 18 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 19 If cracks are found in the forward outer chord, horizontal inner chord, and/or vertical inner chord, repair as specified in the applicable Structural Repair Manual (SRM). If cracks are found in the skin, or if cracks are found in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord, contact Boeing for repair instructions. Because of common access, operators should consider doing the inspections, repairs, and/or modifications given in the following service bulletins at the same time as the inspections and/or repairs given in this service bulletin: — For 767 airplanes, line numbers 1 - 709: Boeing Service Bulletin 767-53A0078 "FUSELAGE - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and Modification". — For 767-200, -300, and -300F airplanes, line numbers 811 - 887, 889, 890: Boeing Service Bulletin 767-53-0110 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework". — For 767-400 airplanes, line numbers 809 - 878: Boeing Service Bulletin 767-53-0111 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework". — For all 767 airplanes: Boeing Service Bulletin 767-53-0118 "FUSELAGE - Section 48 - STA 1725.5 Aft Skin and Bulkhead Outer Chord Strap - Inspection and Repair". Revision 1 - More work is necessary on airplanes that have been inspected as given in the initial release of this service bulletin. At the time of the next inspection, do the inspections as given in this revision. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 313, 314767-200, 767-300, 767-300F , 767-400ER E. Compliance The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin. Boeing recommends that operators do the inspections given in this service bulletin at the times shown in Table 1. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 19 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 20 Table 1: Recommended Compliance times for STA 1809.5 Bulkhead Forward Outer Chord, Horizontal and Vertical Inner Chord, and Skin Inspections Repeat Interval (Not to Exceed) Compliance Time (Whichever Oc- curs Later) ActionCondition 6,000 flight cy- cles Within 3,000 flight cycles after the date on the origi- nal issue of this service bulletin Before 15,000 to- tal flight cycles Do PART 1 - Detailed Inspec- tion of Skin. Detailed and HFEC Inspections of Forward Outer Chord - Left Side (a) All Airplanes Do PART 2 - Detailed Inspec- tion of Skin. Detailed and HFEC Inspections of Forward Outer Chord - Right Side (b) Do PART 3 - Detailed and HFEC Inspections of Horizontal Inner Chord - Left Side (c) Do PART 4 - Detailed and HFEC Inspections of Horizontal Inner Chord - Right Side (d) 6,000 flight cy- cles Within 3,000 flight cycles after the date on the origi- nal issue of the Service Bulletin Before 15,000 to- tal flight cycles Do PART 5 - Detailed and HFEC Inspections of Vertical Inner Chord - Left Side (e) Airplanes on which Boeing Service Bulletin 767- 53A0131, PARTS 1-4, have not been accomplished. Do PART 6 - Detailed and HFEC Inspections of Vertical Inner Chord - Right Side (f) 6,000 flight cy- cles Within 3,000 flight cycles after the date on Revision 01 of the service bulletin Before 15,000 to- tal flight cycles or within 6,000 flight cycles after the previous PARTS 1-4 inspection, which ever occurs later Do PART 5 - Detailed and HFEC Inspections of Vertical Inner Chord - Left Side (e) Airplanes on which Boeing Service Bulletin 767- 53A0131, PARTS 1-4, have been ac- complished. Do PART 6 - Detailed and HFEC Inspections of Vertical Inner Chord - Right Side (f) --Before further flight Repair as given in the Accom- plishment Instructions, Para- graphs 3.B.3 through 3.B.9, as applicable. Crack found (a) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 9, 767-300 SRM 53-80-08, Repair 9, 767-300F SRM 53-80-08, Repair 9, or 767-400 SRM 53-80-08, Repair 9 is terminating action for the PART 1 repeat inspections of this service bulletin. Continue the PART 2, PART 3, PART 4, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (b) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 9, 767-300 SRM 53-80-08, Repair 9, 767-300F SRM 53-80-08, Repair 9, and 767-400 SRM 53-80-08, Repair 9 is terminating action for the PART 2 repeat inspections of this service bulletin. Continue the PART 1, PART 3, PART 4, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 20 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 21 Table 1: Recommended Compliance times for STA 1809.5 Bulkhead Forward Outer Chord, Horizontal and Vertical Inner Chord, and Skin Inspections Repeat Interval (Not to Exceed) Compliance Time (Whichever Oc- curs Later) ActionCondition (c) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 10, 767-300 SRM 53-80-08, Repair 10, 767-300F SRM 53-80-08, Repair 10, and 767-400 SRM 53-80-08, Repair 10 is terminating action for the PART 3 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 4, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (d) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 10, 767-300 SRM 53-80-08, Repair 10, 767-300F SRM 53-80-08, Repair 10, and 767-400 SRM 53-80-08, Repair 10 is terminating action for the PART 4 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 3, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (e) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 11, 767-300 SRM 53-80-08, Repair 11, 767-300F SRM 53-80-08, Repair 11, and 767-400 SRM 53-80-08, Repair 11 is terminating action for the PART 5 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 3, PART 4, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (f) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 11, 767-300 SRM 53-80-08, Repair 11, 767-300F SRM 53-80-08, Repair 11, and 767-400 SRM 53-80-08, Repair 11 is terminating action for the PART 6 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 3, PART 4, and PART 5 inspections, at the repeat interval given, unless those inspections have also been terminated. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA).The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the Manager of the Seattle Aircraft Certification Office approves the repair procedures and the inspection methods specified in Table 1, under paragraph 1.E., "Compliance," of Service Bulletin 767-53A0131, Revision 1, as an AMOC to the repair procedures and the inspection methods specified in Table 1 under paragraph 1.E., "Compliance," of Service Bulletin 767-53A0131, dated March 30, 2006, required by paragraph (f) and (g) of AD 2006-24-04. All provisions of AD 2006-24-04 that are not specifically referenced in the preceeding sentence remain fully applicable and must be complied with. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 21 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 22 G. Manpower The table below shows an estimate of the task-hours necessary to do this service bulletin for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary.The estimate does not include lost time.These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. Elapsed HoursTask-HoursNumber of Per- sons Task 0.501.002.0Open Access 1.001.001Figure 1 - Detailed Inspection of Skin - Left Side (a) 1.001.001Figure 2 - Detailed Inspection of Skin - Right Side (a) 1.753.502Figure 3 - Detailed and Surface HFEC Inspections of Forward Outer Chord - Left Hand (a) 1.753.502Figure 4 - Detailed and Surface HFEC Inspections of Forward Outer Chord - Right Hand (a) 1.001.001Figure 5 - Detailed and Surface HFEC Inspections of Horizontal Inner Chord - Left Hand (a) 1.001.001Figure 6 - Detailed and Surface HFEC Inspections of Horizontal Inner Chord - Right Hand (a) 1.001.001Figure 7 - Detailed and Surface HFEC Inspections of Vertical Inner Chord - Left Hand (a) 1.001.001Figure 8 - Detailed and Surface HFEC Inspections of Vertical Inner Chord - Right Hand (a) 0.501.002.0Close Access 10.5015.00TOTAL FOR EACH AIRPLANE (a) Additional time will be required for repairs if cracks are found. H. Weight and Balance Changes None. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 22 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 23 I. Electrical Load Data Not changed. J. References 1. Existing Data: a. 767-200 Structural Repair Manual (SRM) 53-80-08 b. 767-300 Structural Repair Manual (SRM) 53-80-08 c. 767-300F Structural Repair Manual (SRM) 53-80-08 d. 767-400 Structural Repair Manual (SRM) 53-80-08 e. 767 Aircraft Maintenance Manual (AMM) 06-42-00 f. 767 Non-Destructive Testing (NDT) Manual, Part 6, 51-00-01 or 51-00-19 g. Boeing Service Bulletin 767-53-0110 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework" h. Boeing Service Bulletin 767-53-0111 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework" i. Boeing Service Bulletin 767-53-0118 "FUSELAGE - Section 48 - STA 1725.5 Aft Skin and Bulkhead Outer Chord Strap - Inspection and Repair" j. Boeing Service Bulletin 767-53A0078 "FUSELAGE - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and Modification" k. Boeing Service Related Problem (SRP) 767-SRP-53-0263 l. Standard Overhaul Practices Manual (SOPM) 20-30-03 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Bulkhead Installation - Upper, Horizontal Stabilizer Pivot, STA 1809.5148T2140 This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin.This drawing may not be applicable to all airplane configurations or operators. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 23 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 24 K. Publications Affected None. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 24 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 25 2. MATERIAL INFORMATION A. Material - Price and Availability None. B. Industry Support Information Boeing warranty remedies are available for 767 airplanes in warranty as of December 1, 2004. For inspection task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours, parts, and/or special tools are required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. C. Parts Necessary For Each Airplane 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: None. NOTE: No parts or materials are required for inspection. However, if repairs are necessary, the materials shown in the applicable Structural Repair Manual sections will be necessary. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 25 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 26 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 26 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT BLANK PAGE ### Page 27 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches — Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. 4. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 5. These work instructions refer to procedures included on other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "as given in" are included in the instruction, the procedure in the Boeing document must be used. B. WORK INSTRUCTIONS 1. Do the initial PART 1 through PART 6 inspections within the compliance time given in Paragraph 1.E., Compliance. 2. If no cracks are found, repeat PART 1 through PART 6 inspections at the repeat interval given in Paragraph 1.E., Compliance. 3. If cracks are found in the skin, or if cracks are found in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord, do the following: a. Repair the skin and/or structure before further flight. Contact Boeing for repair instructions. b. Repeat PART 1 through PART 6 inspections at the interval given in Paragraph 1.E., Compliance, except for any inspections that have been terminated by accomplishing terminating action. 4. If cracks are found in the forward outer chord during a PART 1 inspection, do the following: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 27 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 28 a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 9, or 767-300 SRM 53-80-08, Repair 9, or 767-300F SRM 53-80-08, Repair 9, or 767-400 SRM 53-80-08, Repair 9. b. Repeat PART 2, PART 3, PART 4, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.4.a. terminates the PART 1 repetitive inspections given in Paragraph 1.E., Compliance. 5. If cracks are found in the forward outer chord during a PART 2 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 9, or 767-300 SRM 53-80-08, Repair 9, or 767-300F SRM 53-80-08, Repair 9, or 767-400 SRM 53-80-08, Repair 9. b. Repeat PART 1, PART 3, PART 4, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.5.a. terminates the PART 2 repetitive inspections given in Paragraph 1.E., Compliance. 6. If cracks are found in the horizontal inner chord during a PART 3 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 10, or 767-300 SRM 53-80-08, Repair 10, or 767-300F SRM 53-80-08, Repair 10, or 767-400 SRM 53-80-08, Repair 10. b. Repeat PART 1, PART 2, PART 4, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.6.a. terminates the PART 3 repetitive inspections given in Paragraph 1.E., Compliance. 7. If cracks are found in the horizontal inner chord during a PART 4 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 10, or 767-300 SRM 53-80-08, Repair 10, or 767-300F SRM 53-80-08, Repair 10, or 767-400 SRM 53-80-08, Repair 10. b. Repeat PART 1, PART 2, PART 3, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.7.a. terminates the PART 4 repetitive inspections given in Paragraph 1.E., Compliance. 8. If cracks are found in the vertical inner chord during a PART 5 inspection, do the following: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 28 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 29 a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 11, or 767-300 SRM 53-80-08, Repair 11, or 767-300F SRM 53-80-08, Repair 11, or 767-400 SRM 53-80-08, Repair 11. b. Repeat PART 1, PART 2, PART 3, PART 4, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.8.a. terminates the PART 5 repetitive inspections given in Paragraph 1.E., Compliance. 9. If cracks are found in the vertical inner chord during a PART 6 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 11, or 767-300 SRM 53-80-08, Repair 11, or 767-300F SRM 53-80-08, Repair 11, or 767-400 SRM 53-80-08, Repair 11. b. Repeat PART 1, PART 2, PART 3, PART 4, and PART 5 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.9.a. terminates the PART 6 repetitive inspections given in Paragraph 1.E., Compliance. 10. Put the airplane back to a serviceable condition. PART 1 - DETAILED INSPECTION OF SKIN (EXTERNAL). DETAILED AND HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE 1. Get access to the exterior of the airplane skin at STA 1809.5 between stringers 3L and 10L. 2. Do a detailed inspection of the exterior of the skin for cracks, as given in FIGURE 1. 3. Get access to the forward side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 4. Do detailed and surface HFEC inspections of the forward outer chord and surrounding structure between stringers 3L and 10L, as given in FIGURE 3. PART 2 - DETAILED INSPECTION OF SKIN (EXTERNAL). DETAILED AND HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE 1. Get access to the exterior of the airplane skin at STA 1809.5 between stringers 3R and 10R. 2. Do a detailed inspection of the exterior of the skin for cracks, as given in FIGURE 2. 3. Get access to the forward side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 4. Do detailed and surface HFEC inspections of the forward outer chord and surrounding structure between stringers 3R and 10R, as given in FIGURE 4. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 29 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 30 PART 3 - DETAILED AND HFEC INSPECTIONS OF HORIZONTAL INNER CHORD - LEFT SIDE 1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the end of the horizontal inner chord and surrounding structure on the left side of the STA 1809.5 bulkhead, as given in FIGURE 5. PART 4 - DETAILED AND HFEC INSPECTIONS OF HORIZONTAL INNER CHORD - RIGHT SIDE 1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the end of the horizontal inner chord and surrounding structure on the right side of the STA 1809.5 bulkhead, as given in FIGURE 6. PART 5 - DETAILED AND HFEC INSPECTIONS OF VERTICAL INNER CHORD - LEFT SIDE 1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the vertical inner chord and surrounding structure on the left side of the STA 1809.5 bulkhead, as given in FIGURE 7 . PART 6 - DETAILED AND HFEC INSPECTIONS OF VERTICAL INNER CHORD - RIGHT SIDE 1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the vertical inner chord and surrounding structure on the right side of the STA 1809.5 bulkhead, as given in FIGURE 8. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1: March 12, 2009 30 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 31 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT STA 1809.50 SEE 7.00 •7.00- S-3L STA 1809.50 • S-4L S-5L S-6L S-7L - S-8L INSPECTION (1) 2) AREA -- S-10L FWD C U38055 FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE (SHEET 1 OF 2) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 52 ### Page 32 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --SkinClean1 Do a detailed inspection in the area shown. --SkinInspect2 FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 32 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 33 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT STA 1809.50 -7.00 - •7.00- SEE S-3R STA S-4R 1809.50 S-5R S-6R S-7R S-8R X2) INSPECTION S-10R AREA > FWD U38778 FIGURE 2: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - RIGHT SIDE (SHEET 1 OF 2) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 52 ### Page 34 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --SkinClean1 Do a detailed inspection in the area shown. --SkinInspect2 FIGURE 2: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - RIGHT SIDE (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 34 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 35 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT SEE (A 5-2L 1809.50 STA STA S-3L 1809.50 NS-4L S-5L S-OL S-7L DETAILED INSPECTION S-8L AREA S-10L SURFACE HFEC(1 INSPECTION AREA UP > FWD U38839 FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE (SHEET 1 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 52 ### Page 36 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTE: Pay special attention to the radius of the Forward Outer Chord during the following inspections. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --Bulkhead StructureClean1 Do a detailed inspection of the Forward Outer Chord in the area shown. Also do a detailed inspection of the Bulkhead Structure a minimum of 1.0 inch past the flanges of the Forward Outer Chord. --Forward Outer Chord and Bulk- head Structure Inspect2 FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE (SHEET 2 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 36 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 37 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Do a Surface HFEC inspection in the area shown, between S- 4L and S-8L, as given in 767 NDT, Part 6, 51-00-01 or 51- 00-19. --Forward Outer Chord Inspect3 FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 37 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 38 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT SEE S-2R S-3R STA STA 1809.50 S-4R 1809.50 S-5R S-6R S-7R S-8R DETAILED INSPECTION AREA S-10R SURFACE HFEC INSPECTION AREA UP FWD › INBD U38842 FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE (SHEET 1 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 52 ### Page 39 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTE: Pay special attention to the radius of the Forward Outer Chord during the following inspections. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --Bulkhead StructureClean1 Do a detailed inspection of the Forward Outer Chord in the area shown. Also do a detailed inspection of the Bulkhead Structure a minimum of 1.0 inch past the flanges of the Forward Outer Chord. --Forward Outer Chord and Bulk- head Structure Inspect2 FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE (SHEET 2 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 39 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 40 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Do a Surface HFEC inspection in the area shown, between S- 4R and S-8R, as given in 767 NDT, Part 6, 51-00-01 or 51- 00-19. --Forward Outer Chord Inspect3 FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 40 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 41 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT S-2L SEE STA S-3L 1809.50 S-4L STA S-5L 1809.50 S-6L | S-7L , S-8L S-10L UP , FWD EXISTING SPLICE STRAPS, RADIUS FILLERS AND SUPPORT CLIPS NOT SHOWN FOR CLARITY. U38892 FIGURE 5: DETAILED AND SURFACE AFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - LEFT SIDE (SHEET 1 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 52 ### Page 42 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT BL BL 28.5 37.0 ++++#+ ++++++. SPECIAL ATTENTION DETAILED INSPECTION AREA 1.00- A-A UP SURFACE HFEC INSPECTION AREA INBD < 3.0 MIN. 3.0 MIN. UP → FWD B—B FIGURE 5: DETAILED AND SURFACE HFECINSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - LEFT SIDE (SHEET 2 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 52 ### Page 43 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTE: Pay special attention to the machined step radii and the flange in the area indicated. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --Bulkhead StructureClean1 Do a detailed inspection in the area shown. Inspect the for- ward side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below the Horizontal Inner Chord, and a minimum of 5.0 inches inboard and outboard from the HFEC inspection area.(a) --Horizontal Inner Chord and Bulk- head Structure Inspect2 Do a Surface HFEC inspection of the vertical and horizontal flanges in the inspection area shown, as given in 767 NDT, Part 6, 51-00-01 or 51-00-19. (a) --Horizontal Inner Chord Inspect3 (a) Inspect only the exposed surfaces including edges of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips. FIGURE 5: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - LEFT SIDE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 43 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 44 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT SEE A S-2R S-3R STA 1809.50 S-4R STA 1809.50 S-5R S-6R S-7R S-8R S-10R UP FWD EXISTING SPLICE STRAPS, RADIUS FILLERS AND SUPPORT CLIPS NOT SHOWN FOR CLARITY. U38891 FIGURE 6: DETAILED AND SURFACE HFECINSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - RIGHT SIDE (SHEET 1 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 52 ### Page 45 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT BL BL 37.0 28.5 ++++++ *+++++ +*+++++ ++++ + + .SPECIAL ATTENTION 2) DETAILED INSPECTION AREA SURFACE HFEC UP 1.00 INSPECTION A-A AREA › INBD 3.0 MIN. 3.0 MIN. UP FWDE U38898 B—B FIGURE 6: DETAILED AND SURFACE HFECINSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - RIGHT SIDE (SHEET 2 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 52 ### Page 46 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTE: Pay special attention to the machined step radii and the flange in the area indicated. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --Bulkhead StructureClean1 Do a detailed inspection in the area shown. Inspect the for- ward side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below the Horizontal Inner Chord, and a minimum of 5.0 inches inboard and outboard from the HFEC inspection area. (a) --Horizontal Inner Chord and Bulk- head Structure Inspect2 Do a Surface HFEC inspection of the vertical and horizontal flanges in the inspection area shown, as given in 767 NDT, Part 6, 51-00-01 or 51-00-19. (a) --Horizontal Inner Chord Inspect3 (a) Inspect only the exposed surfaces including edges of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips. FIGURE 6: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - RIGHT SIDE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 46 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 47 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT SEE D STA 1809.50 STA 1809.50 S-3L ...... S-4L UP FWD EXISTING SPLICE PLATES AND BRACKETS NOT SHOWN FOR CLARITY. 1551362 FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - LEFT SIDE (SHEET 1 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 52 ### Page 48 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT BL BL 37.0 28.5 + + + +++++ + + + + + SPECIAL → ATTENTION 3.0 MIN. + + • + + + 3,0 MIN. 2) DETAILED INSPECTION AREA UP SURFACE HFEC 1 INSPECTION A-A AREA → INBD T • 5.0 5.0 1.5 MIN. MIN. MIN. FWD B-B 1551426 FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - LEFT SIDE (SHEET 2 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 52 ### Page 49 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTE: Pay special attention to the fillet radii and the flange in the area indicated. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --Bulkhead StructureClean1 Do a detailed inspection in the area shown. Inspect the aft side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below and a minimum of 5.0 inches in- board and outboard from the HFEC inspection area.(a) --Vertical Inner Chord and Bulk- head Structure Inspect2 Do a Surface HFEC inspection of the vertical flanges in the inspection area shown, as given in 767 NDT, Part 6, 51- 00-01 or 51-00-19.(a) --Vertical Inner Chord Inspect3 (a) Inspect only the exposed surfaces including edges of the vertical inner chord. This inspection does not require removal of any adjacent structure or fasteners. FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - LEFT SIDE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 49 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT ### Page 50 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT SEE A STA STA 1809.50 1809.50 S-3R S-4R UP INED FWD EXISTING SPLICE PLATES AND BRACKETS NOT SHOWN FOR CLARITY. 1551706 FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - RIGHT SIDE (SHEET 1 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 52 ### Page 51 (OCR) BOEING SERVICE BULLETIN 767-53A0131 ALERT ALERT BL BL 28„5 37.0 + + + + + + SPECIAL ATTENTION 3.0 MIN. + + + 3.0 MIN. + DETAILED INSPECTION AREA UP 13) SURFACE HFEC A-A INSPECTION INBD AREA 1.5 MIN. 5.0 5.0 MIN. MIN- FWD B—B 1551702 FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - RIGHT SIDE (SHEET 2 OF 3) Original Issue: March 30, 2006 Revision 1 March 12, 2009 767-53A0131 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 52 ### Page 52 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTE: Pay special attention to the fillet radii and the flange in the area indicated. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP in the inspection area shown. Removal of finish is not neces- sary. Refer to SOPM 20-30- 03. --Bulkhead StructureClean1 Do a detailed inspection in the area shown. Inspect the aft side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below and a minimum of 5.0 inches in- board and outboard from the HFEC inspection area.(a) --Vertical Inner Chord and Bulk- head Structure Inspect2 Do a Surface HFEC inspection of the vertical flanges in the inspection area shown, as given in 767 NDT, Part 6, 51- 00-01 or 51-00-19.(a) --Vertical Inner Chord Inspect3 (a) Inspect only the exposed surfaces including edges of the vertical inner chord. This inspection does not require removal of any adjacent structure or fasteners. FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - RIGHT SIDE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131Revision 1 March 12, 2009 52 of 52 BOEING SERVICE BULLETIN 767-53A0131 ALERTALERT --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. 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