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Commercial Airplanes 767 Service Bulletin Number: 767-53A0209 Original Issue: September 30, 2010 Revision 1: July 27, 2011 ATA System: 5350 SUBJECT: FUSELAGE - Main Frame - Section 45 STA 859.5, 883.5 and 903.5, Left and Right Side BL 89, Below WL 200 - Frame Inner Chord Transition Radius - Inspection and Repair 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, KC-10, KDC-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.

Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 1 of 301

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Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 2 of 301 BOEING SERVICE BULLETIN 767-53A0209

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Table of Contents

Revision Transmittal Sheet5

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 1 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 7 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F. Approval ............................................... 2 9 G. Manpower .............................................. 2 9 H. Weight and Balance Changes .................................... 3 1 I. Electrical Load Data ......................................... 3 4 J. References .............................................. 3 5

1. Existing Data .......................................... 3 5

2. Data supplied with this Service Bulletin ............................ 3 5

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 3 5 K. Publications Affected ........................................ 3 5 L. Interchangeability and Intermixability of Parts ........................... 3 6

2. MATERIAL INFORMATION ........................................ 3 7 A. Material - Price and Availability ................................... 3 7 B. Industry Support Information .................................... 3 9 C. Parts Necessary For Each Airplane ................................. 3 9

1. Kits/Parts ............................................ 3 9

2. Parts and Materials Supplied by the Operator ........................ 4 6

3. Parts Modified and Reidentified ................................ 4 6

4. Parts Removed and Not Replaced .............................. 4 6 D. Parts Necessary to Change Spares ................................. 4 6 E. Special Tooling - Price and Availability ............................... 4 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 7

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 0 FIGURE 1: INNER CHORD INSPECTION ................................. 5 6 FIGURE 2: FRAME TO STUB-BEAM FILLER INSPECTION ....................... 6 0 FIGURE 3: STATION 859.5 INNER CHORD OPEN HOLE INSPECTION [Group 1-5; Group 6, Configuration 1-3] ............................................... 6 2 FIGURE 4: STATION 883.5 INNER CHORD OPEN HOLE INSPECTION [Group 1-5; Group 6, Configuration 1-3] ............................................... 6 5 FIGURE 5: STATION 903.5 INNER CHORD OPEN HOLE INSPECTION FOR A ONE HOLE TRIM OUT REPAIR [Group 2-3, 5; Group 6, Configuration 2-3] ..................... 6 8 FIGURE 6: STATION 903.5 INNER CHORD OPEN HOLE INSPECTION FOR A TWO HOLE TRIM OUT REPAIR [Group 2-3, 5; Group 6, Configuration 2-3] ..................... 7 1 FIGURE 7: STATION 859.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION (-1) [Group 1-3; Group 6, Configuration 1-3] ......................... 7 4

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FIGURE 8: STATION 859.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION (-2) [Group 1-3; Group 6, Configuration 1-3] ......................... 8 4 FIGURE 9: STATION 883.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION

- TWO RADIUS FILLER INSTL (-5) [Group 3, 5; Group 6, Configuration 3] ......... 9 4 FIGURE 10: STATION 883.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION

- TWO RADIUS FILLER INSTL (-6) [Group 3, 5; Group 6, Configuration 3] ........ 1 0 4 FIGURE 11: STATION 883.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION

- THREE RADIUS FILLER INSTL (-3) [Group 1-2, 4; Group 6, Configuration 1-2] .... 1 1 4 FIGURE 12: STATION 883.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION

- THREE RADIUS FILLER INSTL (-4) [Group 1-2, 4; Group 6, Configuration 1-2] .... 1 2 4 FIGURE 13: STATION 903.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A ONE HOLE TRIM OUT REPAIR (-7) [Group 2; Group 6, Configuration 2] .... 1 3 4 FIGURE 14: STATION 903.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A ONE HOLE TRIM OUT (-8) [Group 2; Group 6, Configuration 2] ......... 1 4 3 FIGURE 15: STATION 903.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A TWO HOLE TRIM OUT (-9) [Group 2; Group 6, Configuration 2] ......... 1 5 2 FIGURE 16: STATION 903.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A TWO HOLE TRIM OUT (-10) [Group 2; Group 6, Configuration 2] ......... 1 6 1 FIGURE 17: STATION 903.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A ONE HOLE TRIM OUT (-11) [Group 3; Group 6, Configuration 3] ......... 1 7 0 FIGURE 18: STATION 903.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A ONE HOLE TRIM OUT (-12) [Group 3; Group 6, Configuration 3] ......... 1 7 9 FIGURE 19: STATION 903.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A TWO HOLE TRIM OUT (-13) [Group 3; Group 6, Configuration 3] ......... 1 8 8 FIGURE 20: STATION 903.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A TWO HOLE TRIM OUT (-14) [Group 3; Group 6, Configuration 3] ......... 1 9 7 FIGURE 21: STATION 859.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION

- FREIGHTER CONVERSION (-1) [Group 4-5] ....................... 2 0 6 FIGURE 22: STATION 859.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION

- FREIGHTER CONVERSION (-2) [Group 4-5] ....................... 2 1 6 FIGURE 23: STATION 903.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A ONE HOLE TRIM OUT - FREIGHTER CONVERSION (-11) [Group 5] ...... 2 2 6 FIGURE 24: STATION 903.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A ONE HOLE TRIM OUT - FREIGHTER CONVERSION (-12) [Group 5] ...... 2 3 5 FIGURE 25: STATION 903.5 LEFT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A TWO HOLE TRIM OUT - FREIGHTER CONVERSION (-13) [Group 5] ...... 2 4 4 FIGURE 26: STATION 903.5 RIGHT SIDE INNER CHORD CRACK REMOVAL AND REPAIR INSTALLATION FOR A TWO HOLE TRIM OUT- FREIGHTER CONVERSION (-14) [Group 5] ...... 2 5 4 FIGURE 27: POST-REPAIR INSPECTION - STA 859.5 [Group 1-5; Group 6, Configuration 1-3] . . . 264 FIGURE 28: POST-REPAIR INSPECTION - STA 883.5 [Group 1-5; Group 6, Configuration 1-3] . . . 268 FIGURE 29: POST-REPAIR INSPECTION - STA 903.5 - ONE HOLE TRIM OUT [Group 2-3, 5; Group 6, Configuration 2-3] ....................................... 2 7 2 FIGURE 30: POST REPAIR INSPECTION - STA 903.5 - TWO HOLE TRIM OUT [Group 2-3, 5; Group 6, Configuration 2-3] ....................................... 2 7 6 APPENDIX A: FILLER DATA ......................................... 2 8 0 APPENDIX B: HOLE INSPECTION DATA .................................. 2 9 1

Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 4 of 301 BOEING SERVICE BULLETIN 767-53A0209

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Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-53A0209Original Issue: September 30, 2010 Revision 1: July 27, 2011 ATA System: 5350 SUBJECT: FUSELAGE - Main Frame - Section 45 STA 859.5, 883.5 and 903.5, Left and Right Side BL 89, Below WL 200 - Frame Inner Chord Transition Radius - Inspection and Repair This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-18-10 is related to this service bulletin.

No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.

Group 6 of this service bulletin effectivity was added in this revision. Affected 767-200 passenger airplanes after line number 1023 were added to Group 6 of this service bulletin effectivity. Also affected 767-300 passenger airplanes after line number 1023 were moved from Group 3 to Group 6 of this service bulletin effectivity.

REASON FOR REVISION As a part of a service bulletin validation program, this change was completed on airplane VN015 by Service Bulletin 767-53A0209, original issue before the release of Revision 1 of this service bulletin. The repairs completed on airplane VN015 by Service Bulletin 767-53A0209, original issue is equivalent to the release of Revision 1 of this service bulletin. Airplane VN015 has the configuration of a Group 3 airplane. Also, the effectivity was updated to add Group 6 airplanes.

This revision is sent to incorporate minor clarifications resulting from a validation of this service bulletin.

These sections were changed:

1. Summary Background and Paragraph 1.C., Reason, added validation information.

2. Paragraph 1.A.1., Airplanes, added Group 6 airplanes and updated the Group/Configuration table.

3. Paragraph 1.D., Description, added revision information.

4. Paragraph 2.A., updated kit price and availability table.

5. Paragraph 2.E. and Paragraph 2.F., added special tooling information.

6. Accomplishment Instructions, added standard notes and a repair caution note.

7. Figure 1, clarified inspection requirements and added STA 883.5 view.

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8. Figure 7 and 8, added reference to coldwork tool off-set adapter.

9. All figures, revised trim detail to indicate a minimum radius.

10. All sections, removed "edge distance" wording and replaced with "edge margin", "edge margins" or "distance" as applicable.

11. All sections with Group/Configuration applicability was updated to address Group 6 airplanes.

The data given in Information Notice 767-53A0209 IN 01 is included in this revision.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY September 30, 2010Original Issue:

July 27, 2011Revision 1:

Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 6 of 301 BOEING SERVICE BULLETIN 767-53A0209

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Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-53A0209Original Issue: September 30, 2010 Revision 1: July 27, 2011 ATA System: 5350 SUBJECT: FUSELAGE - Main Frame - Section 45 STA 859.5, 883.5 and 903.5, Left and Right Side BL 89, Below WL 200 - Frame Inner Chord Transition Radius - Inspection and Repair

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of this service bulletin will inspect frame inner chords for cracks at Station 859.5, 883.5 and

903.5, LBL and RBL 89, below the passenger cabin floor (WL 200), on airplanes with Type III overwing exit doors. Cracks in the frame inner chord transition radius can propagate and intersect fastener holes in the frame chord. These cracks can further propagate into the frame structure and adjacent structure and become large.

Large cracks in frames and adjacent structure may adversely affect the structural integrity of the airplane.

Station 859.5, 883.5 and 903.5 frames join the outboard side of body stub beam fittings located below the passenger cabin floor.

Boeing has received multiple operator reports of cracks found in frame inner chords at both left and right side Station 859.5, 883.5 and 903.5 on airplanes with Type III overwing exit doors. The reports indicate a crack length range from 0.10 inch up to 1.8 inch that originates from the inner chord transition radius, and in some cases the crack has intersected adjacent fastener holes. Boeing analysis has determined the cause for cracks in the frame inner chords to be a result of stress concentration at the transition radius. Boeing has also determined that these frame inner chords are susceptible to cracking only on airplanes with Type III overwing exit doors.

The work accomplished in this service bulletin will inspect the frame inner chord transition radius for cracks at Station 859.5, 883.5 and 903.5, LBL and RBL 89, below WL 200, on airplanes with Type III overwing exit doors and install a repair if cracks are found.

Boeing Service Related Problem (SRP) 767-SRP-53-0321 is related to this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-18-10 is related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane VN015 by Service Bulletin 767-53A0209, original issue before the release of Revision 1 of this service bulletin. The repairs completed on airplane VN015 by Service Bulletin 767-53A0209, original issue is equivalent to the release of Revision 1 of this service bulletin. Airplane VN015 has the configuration of a Group 3 airplane.

Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 7 of 301

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ACTION (PRR B12901-89RS) Group 1-5; Group 6, Configuration 1-3:

Do a Detailed Inspection or a surface high frequency eddy current (HFEC) inspection of the frame inner chord transition radius for cracks at Station 859.5, 883.5 and 903.5, LBL and RBL 89, below WL 200. If no cracks are found, do repeat Detailed or HFEC inspections. If any crack is found, accomplish additional inspections and applicable repairs in accordance with this service bulletin.

Group 6, Configuration 4:

No work is necessary. This configuration is for airplanes not yet delivered that will have no Type III overwing exit doors, which do not have the affected frame inner chords.

EFFECTIVITY 767-200/-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an 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 2003-18-10 is related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.

MANPOWER Group 1-5; Group 6, Configuration 1-3:

INSPECTION - DETAILED Elapsed HoursTotal Task HoursAirplanes

6.0022.00Group 1, 4;

Group 6, Configuration 1

6.523.00Group 2-3, 5;

Group 6, Configuration 2-3

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Group 1-5; Group 6, Configuration 1-3:

INSPECTION - HFEC Elapsed HoursTotal Task HoursAirplanes

7.0024.00Group 1, 4;

Group 6, Configuration 1

8.0026.00Group 2-3, 5;

Group 6, Configuration 2-3 Group 1-5; Group 6, Configuration 1-3:

REPAIR INSTALLATION (ONE FRAME) Elapsed HoursTotal Task HoursAirplanes

12.0023.50Group 1-5;

Group 6, Configuration 1-3 Group 1-5; Group 6, Configuration 1-3:

POST-REPAIR INSPECTION (ONE FRAME) Elapsed HoursTotal Task HoursAirplanes

7.5025.00Group 1-5;

Group 6, Configuration 1-3 Group 6, Configuration 4:

None.

MATERIAL INFORMATION Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability

Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 9 of 301 BOEING SERVICE BULLETIN 767-53A0209

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BOEING SERVICE BULLETIN 767-53A0209 STA

903.5 STA

883.5 GROUP 1, 4 AIRPLANES STA 859.5, 883.5 STA GROUP 2, 3, 5 AIRPLANES 859.5 STA 859.5, 883.5, 903.5

DO A DETAILED OR SURFACE HFEC

INSPECTION FOR CRACKS IN THE

FRAME INNER CHORD TRANSITION

RADIUS AND INSTALL A REPAIR IF CRACKS ARE FOUND.

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE 1958368 Original Issue: September 30, 2010 Revision 1: July 27, 2011 767-53A0209

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes This service bulletin is for the airplanes shown below. Refer to PRR B12901-89RS for data about this change.

Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below is complete for airplanes through line number 1018. At least one airplane after line number 1018 is also affected by this service bulletin, and these airplanes are in Group(s) 3,6.

These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) \"get effectivity\" result when they are added to the MBF Fleet Profile Page.

DESCRIPTIONCONFIGURATIONGROUP 767-200 passenger airplanes through line number 1023 with one Type III overwing exit door.

-1 767-200 passenger airplanes through line number 1023 with two Type III overwing exit doors.

-2 767-300 passenger airplanes through line number 1023 with one or two Type III overwing exit doors.

-3 767-200 passenger airplane with one Type III overwing exit door, VA511, changed to a Special Freighter (SF) configuration which is given in Boeing Service Bulletin 767-53-0125.

-4

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DESCRIPTIONCONFIGURATIONGROUP 767-300 passenger airplanes with two Type III overwing exit doors, changed to a Boeing Converted Freighter (BCF) configuration.

-5 767-300 passenger airplane VN191, changed to a BCF configuration which is given in Boeing Service Bulletin 767-53-0140.

1 767-300 passenger airplane VN192, changed to a BCF configuration which is given in Boeing Service Bulletin 767-53-0148.

2 767-300 passenger airplane VN193, changed to a BCF configuration which is given in Boeing Service Bulletin 767-53-0150.

3 767-300 passenger airplane VN194, changed to a BCF configuration which is given in Boeing Service Bulletin 767-53-0154.

4 767-300 passenger airplane VN195, VN196 and VN197 changed to a BCF configuration which is given in Boeing Service Bulletin 767-53-0157.

5 767-200 and 767-300 passenger airplanes after line number 1024.

These airplanes are not yet delivered and the configuration is unknown.

-6 767-200 passenger airplanes with one Type III overwing exit door.1 767-200 passenger airplanes with two Type III overwing exit doors.2 767-300 passenger airplanes with one or two Type III overwing exit doors.

3 Airplanes with no Type III overwing exit doors.4 Airplane Models:

767-200, 767-300 GroupVariable Number 6VA001 1VA002 - VA020 1VA301 - VA315 1VA501 - VA510 4VA511 1VA512 - VA530 1VA701 - VA719

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