# Boeing Alert Service Bulletin 767-53A0209: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2011-1168; AD 2012-22-17 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 767-53A0209](https://openairdocs.org/service-documents/boeing/767-53a0209.md) - Title as filed: Boeing - Service Bulletin - Pages: 301 - PDF: https://openairdocs.org/files/sha256/98/83/9883e7c9be777ebe19cf967ea0f176ba47aaaeeb5b553168cbf28248dc8592f9 - Page: https://openairdocs.org/service-documents/boeing/767-53a0209/file/9883e7c9be77 ## 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 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 1 of 301 3.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 2 of 301 BOEING SERVICE BULLETIN 767-53A0209 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 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 3 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 4 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 4 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 5 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 5 of 301 ### Page 6 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: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 6 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 7 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 7 of 301 ### Page 8 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, Config- uration 1 6.523.00Group 2-3, 5; Group 6, Config- uration 2-3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 8 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 9 Group 1-5; Group 6, Configuration 1-3: INSPECTION - HFEC Elapsed HoursTotal Task HoursAirplanes 7.0024.00Group 1, 4; Group 6, Config- uration 1 8.0026.00Group 2-3, 5; Group 6, Config- uration 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, Config- uration 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, Config- uration 1-3 Group 6, Configuration 4: None. MATERIAL INFORMATION Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 9 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 10 (OCR) 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 301 ### Page 11 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 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 11 of 301 ### Page 12 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 12 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 13 GroupVariable Number 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 2VB301 - VB302 2VB321 - 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 2VF101 - VF102 1VF161 - VF162 1VF171 - VF172 1VF180 - VF184 1VF251 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 13 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 14 GroupVariable Number 3VK001 - VK016 3VK021 - VK022 3VK031 - VK056 3VK081 - VK113 3VK141 - VK148 3VK161 - VK164 3VK171 3VK181 3VK186 3VL001 - VL006 3VL011 3VL701 - VL703 3VL751 - VL755 3VL931 - VL932 3VL941 3VN001 - VN041 3VN051 - VN064 3VN081 - VN099 3VN151 - VN158 3VN163 - VN168 3VN171 - VN174 5VN191 - VN197 3VN198 3VN211 - VN212 3VN221 - VN225 3VN231 - VN234 3VN241 - VN243 3VN251 - VN276 3VN291 - VN293 3VN301 - VN314 6VN387 3VN422 - VN427 3VN436 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 14 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 15 GroupVariable Number 3VN491 - VN513 3VN634 - VN636 3VN651 - VN658 3VN671 - VN672 3VN676 3VN681 - VN691 3VN731 - VN732 3VN751 - VN753 3VN791 - VN792 3VN811 - VN813 3VN931 - VN936 3VN966 - VN972 1VR051 - VR060 1VR081 1VR084 1VR086 - VR089 1VR106 - VR109 3VR401 3VR421 - VR423 3VR426 3VR441 3VR461 3VR471 - VR472 3VS061 3VS066 - VS070 3VS073 - VS078 3VS091 - VS104 3VS111 - VS113 3VS131 - VS133 3VS176 - VS177 3VS186 - VS187 3VS196 - VS203 3VS206 - VS208 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 15 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 16 GroupVariable Number 3VS231 3VS266 - VS274 3VS291 - VS293 3VS301 - VS303 3VS366 - VS367 3VS381 - VS382 3VS391 - VS392 3VS401 3VS466 - VS472 3VS486 3VS496 - VS497 3VS506 - VS507 3VS526 3VS546 - VS549 3VS701 - VS736 3VS751 - VS759 3VS821 - VS825 3VS841 - VS844 3VS861 3VS896 3VS901 - VS912 3VS921 - VS928 3VS931 - VS933 3VS941 3VS951 - VS954 3VS961 - VS968 3VS971 - VS976 1VV001 2. Spares Affected None. B. Concurrent Requirements None. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 16 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 17 C. Reason 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. Revision 1 is sent to incorporate minor clarifications resulting from a validation of this service bulletin and update the effectivity to add Group 6 airplanes. The data given in Information Notice 767-53A0209 IN 01 is included in this revision. D. Description 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. Revision 1: No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 17 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 18 Group 1-2, 4: Affected Maintenance Zones ZoneModel 241, 242767-200 Group 3, 5: Affected Maintenance Zones ZoneModel 241, 242767-300 Group 6: Affected Maintenance Zones ZoneModel 241, 242767-200, 767-300 E. 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. The following tables describe compliance for airplanes defined in groups. Group 1, 2, 3, and 6 are airplanes in a passenger configuration. Group 4 and 5 are airplanes changed, before the original issue date of this service bulletin, to a Special Freighter configuration and Boeing Converted Freighter configuration respectively. Compliance TableAirplane Table 1, Inspection and RepairGroup 1; Group 6, Configuration 1 (Passenger Airplane) Table 2, Post-Repair Inspection Table 3, Inspection and RepairGroup 2-3; Group 6, Configuration 2-3 (Passenger Airplane) Table 4, Post-Repair Inspection Table 5, Inspection and RepairGroup 4 (Special Freighter) Table 6, Post-Repair Inspection Table 7, Inspection and RepairGroup 5 (Boeing Converted Freighter) Table 8, Post-Repair Inspection Table 9, Inspection and RepairGroup 6, Configuration 4 (Passenger Airplane) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 18 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 19 Group 1; Group 6, Configuration 1: Table 1: STA 859.5 and 883.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 14,000 total flight cycles or within 3,000 flight cycles after the original issue date of this service bulletin, whichever occurs later. Do a Detailed Inspection or surface high frequency eddy current (HFEC) in- spection for any crack in the STA 859.5 and 883.5 frame inner chord transi- tion radius in accordance with Accomplishment In- structions, 3.B.2. Group 1; Group 6, Configu- ration 1 airplanes. 3,000 flight cyclesWithin 3,000 flight cycles after the previous inspection. Do a Detailed Inspection for any crack in the STA 859.5 and 883.5 frame inner chord transition ra- dius in accordance with Accomplishment Instruc- tions, 3.B.2. No crack(s) found during a Detailed Inspection. See note (a) See note (b) 6,000 flight cyclesWithin 6,000 flight cycles after the previous inspection. Do a surface high frequen- cy eddy current (HFEC) inspection for any crack in the STA 859.5 and 883.5 frame inner chord transition radius in accor- dance with Accomplish- ment Instructions, 3.B.2. No crack(s) found during a surface HFEC inspection. See note (a) See note (b) -Before further flight.Do a Detailed Inspection for fillers installed be- tween the frame and stub-beam Any crack(s) found in the inner chord transition ra- dius during a Detailed In- spection or surface HFEC inspection. AND Do an open hole HFEC inspection for cracks in the frame inner chord, failsafe chord, frame web and stub beam, as appli- cable, in accordance with Accomplishment Instruc- tions 3.B.2 and 3.B.3. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 19 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 20 Group 1; Group 6, Configuration 1: Table 1: STA 859.5 and 883.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.Repair. See Appendix A in this Service Bulletin for additional filler data that is to be documented and sent to Boeing, then con- tact Boeing for repair data and do the repair provid- ed by Boeing. Filler(s) installed and the total thickness is greater than 0.125 inch. -Before further flight.Repair. See Appendix B in this Service Bulletin for data that is to be docu- mented and sent to Boe- ing, then contact Boeing for repair data and do the repair provided by Boe- ing. Any crack exists in holes 1/32 inch oversize nominal diameter or greater. -Before further flight.Trim out the inner chord transition radius crack and install a one or two- hole repair angle in accor- dance with Accomplish- ment Instructions 3.B.4. No filler(s) installed or filler(s) installed and the to- tal thickness is 0.125 inch or less AND No crack(s) found or crack(s) removed and holes are 1/32 inch over- size nominal or less. (a) Either Detailed Inspections or surface HFEC inspections can be performed so long as the repeat interval associated with each inspection is followed. (b) This inspection does not accomplish the work or satisfy the requirements given in the 767 Maintenance Planning Document (MPD) D622T001-9 and Appendix B or D622T001-DTR, Structural Significant Items (SSI) 53-50-I18 or 53-50-I24 as mandated by FAA Airworthiness Directive (AD) 2003-18-10. Group 1; Group 6, Configuration 1: Table 2: STA 859.5 and 883.5 Post-Repair Inspections (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition 12,000 flight cy- cles. Before 37,500 total flight cycles or within 12,000 flight cycles after repair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 1; Group 6, Configu- ration 1 airplanes, STA 859.5 and/or 883.5 frame repair installed. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 20 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 21 Group 1; Group 6, Configuration 1: Table 2: STA 859.5 and 883.5 Post-Repair Inspections (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.Contact Boeing for repair data and do the repair. Any crack found. Group 2-3; Group 6, Configuration 2-3: Table 3: STA 859.5, 883.5 and 903.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 14,000 total flight cycles or within 3,000 flight cycles after the original issue date of this service bulletin, whichever occurs later. Do a Detailed Inspection or surface high frequency eddy current (HFEC) in- spection for any crack in the STA 859.5, 883.5 and 903.5 frame inner chord transition radius in accor- dance with Accomplish- ment Instructions, 3.B.2. Group 2-3; Group 6, Config- uration 2-3 airplanes. 3,000 flight cyclesWithin 3,000 flight cycles after the previous inspection. Do a Detailed Inspection for any crack in the STA 859.5, 883.5 and 903.5 frame inner chord transi- tion radius in accordance with Accomplishment In- structions, 3.B.2. No crack(s) found during a Detailed Inspection. See note (a) See note (b) 6,000 flight cyclesWithin 6,000 flight cycles after the previous inspection. Do a surface high frequen- cy eddy current (HFEC) inspection for any crack in the STA 859.5, 883.5 and 903.5 frame inner chord transition radius in accordance with Accom- plishment Instructions, 3.B.2. No crack(s) found during a surface HFEC inspection. See note (a) See note (b) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 21 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 22 Group 2-3; Group 6, Configuration 2-3: Table 3: STA 859.5, 883.5 and 903.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.Do a Detailed Inspection for fillers installed be- tween the frame and stub-beam Any crack(s) found in the inner chord transition ra- dius during a Detailed In- spection or surface HFEC inspection. AND Do an open hole HFEC inspection for cracks in the frame inner chord, failsafe chord, frame web, doubler (STA 903.5) and stub beam, as applicable, in accordance with Ac- complishment Instruc- tions 3.B.2 and 3.B.3. -Before further flight.Repair. See Appendix A in this Service Bulletin for additional filler data that is to be documented and sent to Boeing, then con- tact Boeing for repair data and do the repair provid- ed by Boeing. Filler(s) installed and the total thickness is greater than 0.125 inch. -Before further flight.Repair. See Appendix B in this Service Bulletin for data that is to be docu- mented and sent to Boe- ing, then contact Boeing for repair data and do the repair provided by Boe- ing. Any crack exists in holes 1/32 inch oversize nominal diameter or greater. -Before further flight.Trim out the inner chord transition radius crack and install a one or two- hole repair angle in accor- dance with Accomplish- ment Instructions 3.B.4. No filler(s) installed or filler(s) installed and the to- tal thickness is 0.125 inch or less AND No crack(s) found or crack(s) removed and holes are 1/32 inch over- size nominal or less. (a) Either Detailed Inspections or surface HFEC inspections can be performed so long as the repeat interval associated with each inspection is followed. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 22 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 23 Group 2-3; Group 6, Configuration 2-3: Table 3: STA 859.5, 883.5 and 903.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition (b) This inspection does not accomplish the work or satisfy the requirements given in the 767 Maintenance Planning Document (MPD) D622T001-9 and Appendix B or D622T001-DTR, Structural Significant Items (SSI) 53-50-I18 or 53-50-I24 as mandated by FAA Airworthiness Directive (AD) 2003-18-10. Group 2-3; Group 6, Configuration 2-3: Table 4: STA 859.5, 883.5 and 903.5 Post-Repair Inspections (Passenger Airplane) Repeat Interval (Not to Exceed) Compliance TimeActionCondition 12,000 flight cy- cles. Before 37,500 total flight cycles or within 12,000 flight cycles after repair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 2-3; Group 6, Config- uration 2-3 airplanes, STA 859.5 frame repair in- stalled. 12,000 flight cy- cles. Before 35,500 total flight cycles or within 12,000 flight cycles after repair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 2; Group 6, Configu- ration 2 airplanes, STA 883.5 frame repair in- stalled. 12,000 flight cy- cles. Before 37,500 total flight cycles or within 12,000 flight cycles after repair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 3; Group 6, Configu- ration 3 airplanes, STA 883.5 frame repair in- stalled. 12,000 flight cy- cles. Before 37,500 total flight cycles or within 12,000 flight cycles after repair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 2-3; Group 6, Config- uration 2-3 airplanes, STA 903.5 one hole trim out frame repair installed. 12,000 flight cy- cles. Before 34,000 total flight cycles or within 12,000 flight cycles after repair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 2-3; Group 6, Config- uration 2-3 airplanes, STA 903.5 two hole trim out frame repair installed. -Before further flight.Contact Boeing for repair data and do the repair. Any crack found. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 23 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 24 Group 4: Table 5: STA 859.5 and 883.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Special Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 11,000 total flight cycles or within 2,400 flight cycles after the original issue date of this service bulletin, whichever occurs later. Do a Detailed Inspection or surface high frequency eddy current (HFEC) in- spection for any crack in the STA 859.5 and 883.5 frame inner chord transi- tion radius in accordance with Accomplishment In- structions, 3.B.2. Group 4 airplane. 2,400 flight cyclesWithin 2,400 flight cycles after the previous inspection. Do a Detailed Inspection for any crack in the STA 859.5 and 883.5 frame inner chord transition ra- dius in accordance with Accomplishment Instruc- tions, 3.B.2. No crack(s) found during a Detailed Inspection. See note (a) See note (b) 4,800 flight cyclesWithin 4,800 flight cycles after the previous inspection. Do a surface high frequen- cy eddy current (HFEC) inspection for any crack in the STA 859.5 and 883.5 frame inner chord transition radius in accor- dance with Accomplish- ment Instructions, 3.B.2. No crack(s) found during a surface HFEC inspection. See note (a) See note (b) -Before further flight.Do a Detailed inspection for fillers installed be- tween the frame and sub- beam Any crack(s) found in the inner chord transition ra- dius during a Detailed In- spection or surface HFEC inspection. AND Do an open hole HFEC inspection for cracks in the frame inner chord, failsafe chord, frame web and stub beam, as appli- cable, in accordance with Accomplishment Instruc- tions 3.B.2 and 3.B.3. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 24 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 25 Group 4: Table 5: STA 859.5 and 883.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Special Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition Before further flight.Repair. See Appendix A in this service bulletin for additional filler data that is to be documented and sent to Boeing, then con- tact Boeing for repair data and do the repair provid- ed by Boeing. Filler(s) installed and the total thickness is greater than 0.125 inch. -Before further flight.Repair. See Appendix B in this Service Bulletin for data that is to be docu- mented and sent to Boe- ing, then contact Boeing for repair data and do the repair provided by Boe- ing. Any crack exists in holes 1/32 inch oversize nominal diameter or greater. -Before further flight.Trim out the inner chord transition radius crack and install a one or two- hole repair angle in accor- dance with Accomplish- ment Instructions 3.B.4. No filler(s) installed or filler(s) installed and the to- tal thickness is 0.125 inch or less AND No crack(s) found or crack(s) removed and holes are 1/32 inch over- size nominal or less. (a) Either Detailed Inspections or surface HFEC inspections can be performed so long as the repeat interval associated with each inspection is followed. (b) This inspection does not accomplish the work or satisfy the requirements given in the 767 Maintenance Planning Document (MPD) D622T001-9 and Appendix B or D622T001-DTR, Structural Significant Items (SSI) 53-50-I18 or 53-50-I24 as mandated by FAA Airworthiness Directive (AD) 2003-18-10. Group 4: Table 6: STA 859.5 and 883.5 Post-Repair Inspections (Special Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition 9,600 flight cycles.Before 30,000 total flight cycles or within 9,600 flight cycles after re- pair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 4 airplane, STA 859.5 and/or 883.5 frame repair installed. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 25 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 26 Group 4: Table 6: STA 859.5 and 883.5 Post-Repair Inspections (Special Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.Contact Boeing for repair data and do the repair. Any crack(s) found. Group 5: Table 7: STA 859.5, 883.5 and 903.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Boeing Converted Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 11,000 total flight cycles or within 2,400 flight cycles after the original issue date of this service bulletin, whichever occurs later. Do a Detailed Inspection or surface high frequency eddy current (HFEC) in- spection for any crack in the STA 859.5, 883.5 and 903.5 frame inner chord transition radius in accor- dance with Accomplish- ment Instructions, 3.B.2. Group 5 airplanes. 2,400 flight cyclesWithin 2,400 flight cycles after the previous inspection. Do a Detailed Inspection for any crack in the STA 859.5, 883.5 and 903.5 frame inner chord transi- tion radius in accordance with Accomplishment In- structions, 3.B.2. No crack(s) found during a Detailed Inspection. See note (a) See note (b) 4,800 flight cyclesWithin 4,800 flight cycles after the previous inspection. Do a surface high frequen- cy eddy current (HFEC) inspection for any crack in the STA 859.5, 883.5 and 903.5 frame inner chord transition radius in accordance with Accom- plishment Instructions, 3.B.2. No crack(s) found during a surface HFEC inspection. See note (a) See note (b) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 26 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 27 Group 5: Table 7: STA 859.5, 883.5 and 903.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Boeing Converted Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.Do a Detailed inspection for fillers installed be- tween the frame and stub-beam Any crack(s) found in the inner chord transition ra- dius during a Detailed In- spection or surface HFEC inspection. AND Do an open hole HFEC inspection for cracks in the frame inner chord, failsafe chord, frame web, doubler (STA 903.5) and stub beam, as applicable, in accordance with Ac- complishment Instruc- tions 3.B.2 and 3.B.3. Before further flight.Repair. See Appendix A in this service bulletin for additional filler data that is to be documented and sent to Boeing, then con- tact Boeing for repair data and do the repair provid- ed by Boeing. Filler(s) installed and the total thickness is greater than 0.125 inch. -Before further flight.Repair. See Appendix B in this Service Bulletin for data that is to be docu- mented and sent to Boe- ing, then contact Boeing for repair data and do the repair provided by Boe- ing. Any crack exists in holes 1/32 inch oversize nominal diameter or greater. -Before further flight.Trim out the inner chord transition radius crack and install a one or two- hole repair angle in accor- dance with Accomplish- ment Instructions 3.B.4. No filler(s) installed or filler(s) installed and the to- tal thickness is 0.125 inch or less AND No crack(s) found or crack(s) removed and holes are 1/32 inch over- size nominal or less. (a) Either Detailed Inspections or surface HFEC inspections can be performed so long as the repeat interval associated with each inspection is followed. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 27 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 28 Group 5: Table 7: STA 859.5, 883.5 and 903.5, Left and Right Side Inner Chord Transition Radius Inspection and Repair (Boeing Converted Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition (b) This inspection does not accomplish the work or satisfy the requirements given in the 767 Maintenance Planning Document (MPD) D622T001-9 and Appendix B or D622T001-DTR, Structural Significant Items (SSI) 53-50-I18 or 53-50-I24 as mandated by FAA Airworthiness Directive (AD) 2003-18-10. Group 5: Table 8: STA 859.5, 883.5 and 903.5 Post-Repair Inspections (Boeing Converted Freighter) Repeat Interval (Not to Exceed) Compliance TimeActionCondition 9,600 flight cycles.Before 30,000 total flight cycles or within 9,600 flight cycles after re- pair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 5 airplanes, STA 859.5 frame repair in- stalled. 9,600 flight cycles.Before 28,000 total flight cycles or within 9,600 flight cycles after re- pair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 5 airplanes, STA 883.5 frame repair in- stalled. 9,600 flight cycles.Before 30,000 total flight cycles or within 9,600 flight cycles after re- pair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 5 airplanes, STA 903.5 one hole trim out frame repair installed. 9,600 flight cycles.Before 27,000 total flight cycles or within 9,600 flight cycles after re- pair installation, whichever is later. Do post-repair Detailed and high frequency eddy current (HFEC) inspec- tions in accordance with Accomplishment Instruc- tions 3.B.5. Group 5 airplanes, STA 903.5 two hole trim out frame repair installed. -Before further flight.Contact Boeing for repair data and do the repair. Any crack found. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 28 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 29 Group 6, Configuration 4: Table 9: Inspection and Repair Repeat Interval (Not to Exceed) Compliance TimeActionCondition --No work is necessary in accordance with this ser- vice bulletin. Group 6, Configuration 4 airplanes.(a) (a) These airplanes do not have Type III overwing exit doors. 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. The Manager of the FAA Seattle Aircraft Certification Office approves the repair and post-repair inspections defined in this service bulletin with the corresponding compliance times specified in paragraph 1.E., "Compliance," of SB 767-53A0209, Revision 1 as an alternative method of compliance to the inspections, defined in Appendix B of D622T001-DTR Structural Significant Items 53-50-I18, 53-50-I24 and certain locations of 53-50-I06A and 53-50-I22A that are covered by the repairs of this service bulletin and the Maintenance Planning Document D622T001-9, required by paragraphs (c) and (d) of AD 2003-18-10. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (e) of the AD. All provisions of AD 2003-18-10 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. 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 inspect the work  Time to cure the materials  Time to make the parts  Time to find the tools. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 29 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 30 Group 1-5; Group 6, Configuration 1-3: INSPECTION Elapsed HoursTask HoursNumber of Per- sons Task 2.5010.004Open Access 2.5010.00TOTAL FOR EACH AIRPLANE 1.50 (a), (b)3.00 (a), (b)2Detailed Inspection (Left and Right Side) 1.503.00TOTAL FOR EACH AIRPLANE 3.00 (a), (b)6.00 (a), (b)2Surface HFEC In- spection (Left and Right Side) 3.006.00TOTAL FOR EACH AIRPLANE 2.5010.004Close Access 9.5029.00TOTAL FOR EACH AIRPLANE (a) Subtract these hours from the airplane total if this inspection was not per- formed. (b) Hours are for the inspection of both left and right side Stations 859.5, 883.5, 903.5. Less time will be required for airplanes with one Type III overwing exit door. Group 1-5; Group 6, Configuration 1-3: REPAIR INSTALLATION Elapsed HoursTask HoursNumber of PersonsTask 3.253.251Open Hole HFEC In- spection 2.252.251Crack Removal 4.008.002Repair Installation 2.5010.004Close Access 12.00 (a)23.50 (a)TOTAL FOR EACH AIRPLANE (a) Total is for one frame repair installation. Group 1-5; Group 6, Configuration 1-3: POST-REPAIR INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 2.5010.004Open Access BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 30 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 31 Group 1-5; Group 6, Configuration 1-3: POST-REPAIR INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 2.50 (a)5.00 (a)2Post-Repair Inspec- tion 2.5010.004Close Access 7.5025.00TOTAL FOR EACH AIRPLANE (a) Hours are for one repaired frame. Group 6, Configuration 4: INSPECTION AND REPAIR Elapsed HoursTask HoursNumber of PersonsTask ---None H. Weight and Balance Changes Group 1; Group 6, Configuration 1: 767-200 Airplanes with One Type III Overwing Exit Door Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +687.1+0.8STA 859.5 (Left) +687.1+ 0.8STA 859.5 (Right) +1374.2+1.6TOTAL STA 859.5 (Left/Right) +919.5+1.0STA 883.5 (Left) +919.5+1.0STA 883.5 (Right) +1839.0+2.0TOTAL STA 883.5 (Left/Right) Group 2; Group 6, Configuration 2: 767-200 Airplanes with Two Type III Overwing Exit Doors Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +687.1+0.8STA 859.5 (Left) +687.1+0.8STA 859.5 (Right) +1374.2+1.6TOTAL STA 859.5 (Left/Right) +919.5+1.0STA 883.5 (Left) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 31 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 32 Group 2; Group 6, Configuration 2: 767-200 Airplanes with Two Type III Overwing Exit Doors Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +919.5+1.0STA 883.5 (Right) +1839.0+2.0TOTAL STA 883.5 (Left/Right) +857.9+0.95STA 903.5 One Hole Trim Repair (Left) +857.9+0.95STA 903.5 One Hole Trim Repair (Right) +1715.7+1.9TOTAL STA 903.5 One Hole Trim Re- pair (Left/Right) +912.0+1.0STA 903.5 Two Hole Trim Repair (Left) +912.0+1.0STA 903.5 Two Hole Trim Repair (Right) +1824.0+2.0TOTAL STA 903.5 Two Hole Trim Re- pair (Left/Right) Group 3; Group 6, Configuration 3: 767-300 Airplanes with One or Two Type III Overwing Exit Doors Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +687.1+0.8STA 859.5 (Left) +687.1+0.8STA 859.5 (Right) +1374.2+1.6TOTAL STA 859.5 (Left/Right) +795.7+0.9STA 883.5 (Left) +795.7+0.9STA 883.5 (Right) +1591.4+1.8TOTAL STA 883.5 (Left/Right) +857.9+0.95STA 903.5 One Hole Trim Repair (Left) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 32 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 33 Group 3; Group 6, Configuration 3: 767-300 Airplanes with One or Two Type III Overwing Exit Doors Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +857.9+0.95STA 903.5 One Hole Trim Repair (Right) +1715.7+1.9TOTAL STA 903.5 One Hole Trim Re- pair (Left/Right) +912.0+1.0STA 903.5 Two Hole Trim Repair (Left) +912.0+1.0STA 903.5 Two Hole Trim Repair (Right) +1824.0+2.0TOTAL STA 903.5 Two Hole Trim Re- pair (Left/Right) Group 4: 767-200 Special Freighter (SF) Airplane with One Type III Overwing Exit Door Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +1357.25+1.6STA 859.5 (Left) +1357.25+1.6STA 859.5 (Right) +2748.5+3.2TOTAL STA 859.5 (Left/Right) +954.8+1.1STA 883.5 (Left) +954.8+1.1STA 883.5 (Right) +1909.6+2.2TOTAL STA 883.5 (Left/Right) Group 5: 767-300 Boeing Converted Freighter (BCF) Airplanes with Two Type III Overwing Exit Doors Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +1357.25+1.6STA 859.5 (Left) +1357.25+1.6STA 859.5 (Right) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 33 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 34 Group 5: 767-300 Boeing Converted Freighter (BCF) Airplanes with Two Type III Overwing Exit Doors Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +2748.5+3.2TOTAL STA 859.5 (Left/Right) +954.8+1.1STA 883.5 (Left) +954.8+1.1STA 883.5 (Right) +1909.6+2.2TOTAL STA 883.5 (Left/Right) +993.3+1.1STA 903.5 One Hole Trim Repair (Left) +993.3+1.1STA 903.5 One Hole Trim Repair (Right) +1986.6+2.2TOTAL STA 903.5 One Hole Trim Re- pair (Left/Right) +1083.6+1.2STA 903.5 Two Hole Trim Repair (Left) +1083.6+1.2STA 903.5 Two Hole Trim Repair (Right) +2167.2+2.4TOTAL STA 903.5 Two Hole Trim Re- pair (Left/Right) Group 6, Configuration 4: None. I. Electrical Load Data Not changed. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 34 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 35 J. References 1. Existing Data a. Engineering Change Memo PRR B12901-89RS b. Service Related Problem (SRP) 767-SRP-53-0321 c. Maintenance Planning Document (MPD) D622T001-9 and Appendix B Structural Significant Item (SSI) 53-50-I06A, 53-50-I18, 53-50-I22A and 53-50-I24, D622T001-DTR. d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-18-10 e. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-01, 20-50-19 f. 767 Aircraft Maintenance Manual (AMM) 25-21-01, 25-25-01, 25-27-01, 53-01-01 g. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-16, Part 6, 51-00-19 h. 767-200 Structural Repair Manual (SRM) 51-40-09 i. 767-300 Structural Repair Manual (SRM) 51-40-09 j. 767-300BCF Structural Repair Manual (SRM) 51-40-09 k. Boeing Parts Standards Document D-590 l. Boeing Drawing 012W6100 2. Data supplied with this Service Bulletin None. 3. Installation Drawings Used in the Preparation of this Service Bulletin None. K. Publications Affected 1. Publications: Chapter-SectionPublication D043T520767 Weight and Balance Manual 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 35 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 36 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: September 30, 2010 767-53A0209Revision 1: July 27, 2011 36 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 37 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. If there is a limit in the quantity of kits, a supply sequence is given by Spares. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 1 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 1 date of this Service Bul- letin (Calendar Days) QTYDateNameKit Number $7,901.00525(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 859.5, LEFT SIDE Group 1-5; Group 6, Configuration 1- 3 691T0003-1 $8,293.00525(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 859.5, RIGHT SIDE Group 1-5; Group 6, Configuration 1- 3 691T0003-2 $8,173.00525(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 883.5, LEFT SIDE Group 1-2, 4; Group 6, Configura- tion 1-2 691T0003-3 $8,173.00525(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 883.5, RIGHT SIDE Group 1-2, 4; Group 6, Configura- tion 1-2 691T0003-4 $8,158.00525(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 883.5, LEFT SIDE Group 3, 5; Group 6, Configuration 3 691T0003-5 $8,327.00525(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 883.5, RIGHT SIDE Group 3, 5; Group 6, Configuration 3 691T0003-6 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 37 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 38 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 1 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 1 date of this Service Bul- letin (Calendar Days) QTYDateNameKit Number $3,954.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, LEFT SIDE Group 2; Group 6, Configuration 2 691T0003-7 $3,954.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, RIGHT SIDE Group 2; Group 6, Configuration 2 691T0003-8 $4,439.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, LEFT SIDE Group 2; Group 6, Configuration 2 691T0003-9 $4,456.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, RIGHT SIDE Group 2; Group 6, Configuration 2 691T0003-10 $3,898.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, LEFT SIDE Group 3, 5; Group 6, Configuration 3 691T0003-11 $3,898.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, RIGHT SIDE Group 3, 5; Group 6, Configuration 3 691T0003-12 $4,364.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, LEFT SIDE Group 3, 5; Group 6, Configuration 3 691T0003-13 $4,364.00200(c)05/12/2011TOP KIT - INNER CHORD MODIFICA- TION, STATION 903.5, RIGHT SIDE Group 3, 5; Group 6, Configuration 3 691T0003-14 $1,074.00525(c)05/12/2011KIT - ALTERED CON- FIGURATION FASTEN- ER KIT FOR INNER CHORD MODIFICA- TION, STA 859.5 Group 4-5 691T0003-39 (a) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 38 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 39 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 1 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 1 date of this Service Bul- letin (Calendar Days) QTYDateNameKit Number $383.00172(c)05/12/2011KIT - ALTERED CON- FIGURATION FASTEN- ER KIT FOR INNER CHORD MODIFICA- TION, STA 903.5 Group 5 691T0003-40 (b) (a) Used on Boeing Special Freighter (SF) and Boeing Converted Freighter (BCF) configurations. (b) Used on Boeing Converted Freighter (BCF) configurations. (c) Refer to the Boeing Parts Page on MyBoeingFleet.com or contact Spares for available quantity. B. Industry Support Information Boeing warranty remedies are not available for the configuration changes and/or repair procedures given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One specified top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, is necessary for a repaired frame. Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3-2-1 TOP KIT - INNER CHORD MODIFI- CATION, STATION 859.5, LEFT SIDE .....-691T0003-1 TOP KIT - INNER CHORD MODIFI- CATION, STATION 859.5, RIGHT SIDE ....-.691T0003-2 TOP KIT - INNER CHORD MODIFI- CATION, STATION 883.5, LEFT SIDE ...-..691T0003-3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 39 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 40 Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3-2-1 TOP KIT - INNER CHORD MODIFI- CATION, STATION 883.5, RIGHT SIDE ..-...691T0003-4 TOP KIT - INNER CHORD MODIFI- CATION, STATION 883.5, LEFT SIDE .-....691T0003-5 TOP KIT - INNER CHORD MODIFI- CATION, STATION 883.5, RIGHT SIDE -.....691T0003-6 REPAIR ANGLE.....1691T0003-15 REPAIR ANGLE....1.691T0003-16 REPAIR ANGLE...1..691T0003-17 REPAIR ANGLE..1...691T0003-18 REPAIR ANGLE.1....691T0003-19 REPAIR ANGLE1.....691T0003-20 SOLID FILLER....11691T0003-30 TAPERED FILLER222222691T0003-31 SOLID FILLER1111..691T0003-32 TAPERED FILLER....11691T0003-34 TAPERED FILLER1111..691T0003-35 (a)BOLT TITANIUM O/S 111111BACB30NX12K15X (a)BOLT TITANIUM O/S 333322BACB30NX14K15X (a)BOLT, PROTRUD- ING HD 111111BACB30NX14K16X (a)BOLT, PROTRUD- ING HD 112211BACB30NX8K10X (a)BOLT, PROTRUD- ING HD ..11..BACB30NX8K10Y (a)BOLT, PROTRUD- ING HD 11..11BACB30NX8K11X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 40 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 41 Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3-2-1 (a)BOLT, PROTRUD- ING HD 11....BACB30NX8K11Y (a)BOLT, PROTRUD- ING HD ....11BACB30NX8K7X (a)BOLT, PROTRUD- ING HD 444444BACB30NX8K8X (a)BOLT, PROTRUD- ING HD 222211BACB30NX8K9X (a)BOLT, PROTRUD- ING HD ....11BACB30NX8K9Y COLLAR111111BACC30BH12 COLLAR, PRELOAD 444433BACC30BH14 COLLAR333333BACC30BH8 COLLAR111122BACC30R8 FILLER223355BACF3H06LC008HN (b)WASHER, PLAIN222222BACW10BP61DP (b)WASHER, PLAIN888866BACW10BP71DP (b)WASHER101010101010BACW10P417CG COLLAR555555HL75-8APBW (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 012T2100 are used to determine the part numbers used as substitutes. (b) There are more parts than are necessary Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -12-11-10-9-8-7 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, RIGHT SIDE ..-...691T0003-10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 41 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 42 Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -12-11-10-9-8-7 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, LEFT SIDE .-....691T0003-11 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, RIGHT SIDE -.....691T0003-12 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, LEFT SIDE .....-691T0003-7 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, RIGHT SIDE ....-.691T0003-8 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, LEFT SIDE ...-..691T0003-9 REPAIR ANGLE.....1691T0003-21 REPAIR ANGLE....1.691T0003-22 REPAIR ANGLE...1..691T0003-23 REPAIR ANGLE..1...691T0003-24 REPAIR ANGLE.1....691T0003-25 REPAIR ANGLE1.....691T0003-26 SOLID FILLER..11..691T0003-29 SOLID FILLER11..11691T0003-33 TAPERED FILLER..11..691T0003-36 (a)BOLT, PROTRUD- ING HD ..1111BACB30MY8K7X (a)BOLT, PROTRUD- ING HD ..1111BACB30MY8K8X (a)BOLT, PROTRUD- ING HD 333333BACB30NX16K15X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 42 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 43 Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -12-11-10-9-8-7 (a)BOLT, PROTRUD- ING HD 222222BACB30NX16K16X (a)BOLT, PROTRUD- ING HD 222211BACB30NX8K10X (a)BOLT, PROTRUD- ING HD ..3322BACB30NX8K11X (a)BOLT, PROTRUD- ING HD 11....BACB30NX8K7X (a)BOLT, PROTRUD- ING HD 11....BACB30NX8K8X (a)BOLT, PROTRUD- ING HD 445533BACB30NX8K9X COLLAR..2222BACC30AG8 COLLAR337733BACC30BH8 COLLAR555555BACC30X16 FILLER227766BACF3H06LC008HN (b)WASHER, PLAIN101010101010BACW10BP81DP (b)WASHER6610101010BACW10P417CG COLLAR553333HL75-8APBW (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 012T2100 are used to determine the part numbers used as substitutes. (b) There are more parts than are necessary Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -40-39-14-13 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, LEFT SIDE ...-691T0003-13 TOP KIT - INNER CHORD MODIFI- CATION, STATION 903.5, RIGHT SIDE ..-.691T0003-14 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 43 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 44 Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -40-39-14-13 KIT - ALTERED CONFIGURATION FASTENER KIT FOR INNER CHORD MODIFI- CATION, STA 859.5 .-..691T0003-39 KIT - ALTERED CONFIGURATION FASTENER KIT FOR INNER CHORD MODIFI- CATION, STA 903.5 -...691T0003-40 REPAIR ANGLE...1691T0003-27 REPAIR ANGLE..1.691T0003-28 SOLID FILLER..11691T0003-29 TAPERED FILLER..11691T0003-36 (a)BOLT TITANIUM O/S .1..BACB30NX12K15Y (a)BOLT, HEX DRIVE.2..BACB30NX14K15Y (a)BOLT, PROTRUD- ING HD .1..BACB30NX14K16Y (a)BOLT, PROTRUD- ING HD ..33BACB30NX16K15X (a)BOLT, PROTRUD- ING HD 3...BACB30NX16K15Y (a)BOLT, PROTRUD- ING HD ..22BACB30NX16K16X (a)BOLT, PROTRUD- ING HD 2...BACB30NX16K16Y (a)BOLT, PROTRUD- ING HD ..44BACB30NX8K10X (a)BOLT, PROTRUD- ING HD ..11BACB30NX8K7X (a)BOLT, PROTRUD- ING HD ..11BACB30NX8K8X (a)BOLT, PROTRUD- ING HD ..66BACB30NX8K9X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 44 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 45 Kit 691T0003 NotesExisting Part Number NameQTYNew Part Number -40-39-14-13 COLLAR.1..BACC30AC12 COLLAR.3..BACC30AC14 COLLAR5...BACC30AC16 COLLAR..77BACC30BH8 COLLAR..55BACC30X16 FILLER..22BACF3H06LC008HN (b)WASHER, PLAIN..1010BACW10BP81DP (b)WASHER..66BACW10P417CG COLLAR..55HL75-8APBW (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D- 590 and Boeing Drawing 012T2100 are used to determine the part numbers used as substi- tutes. (b) There are more parts than are necessary Figure/Kit Tables Figure 16151413121110987Kit 691T0003 ---------1691T0003-1 --------1-691T0003-2 -----1----691T0003-3 ----1-----691T0003-4 -------1--691T0003-5 ------1---691T0003-6 ---1------691T0003-7 --1-------691T0003-8 -1--------691T0003-9 1--------691T0003-10 Figure 26252423222120191817Kit 691T0003 -----1----691T0003-1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 45 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 46 Figure 26252423222120191817Kit 691T0003 ----1-----691T0003-2 ---1-----1691T0003-11 --1-----1-691T0003-12 -1-----1--691T0003-13 1-----1---691T0003-14 ---11----691T0003-39 1111------691T0003-40 2. Parts and Materials Supplied by the Operator NotesNameQTYPart Number / Specification (a)Sealant-BMS5-95, Type I, Class B or C (a)Primer-BMS10-11, Type 1 -Laminated Shim-BACS40R( )( )( )F (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. 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 The 767-200 SRM 51-40-09, 767-300 SRM 51-40-09, 767-300BCF SRM 51-40-09 Figure 1 as applicable gives data about cold working tools and sleeves necessary to do the work given in this service bulletin. These tools are available from industry sources. Engineering, service, and a kit of cold working tools made for this change are available from Fatigue Technology, Inc. or West Coast Industries, Inc.  Refer To: FTI Kit Number: FTI-767-53A0209-1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 46 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 47 Fatigue Technology, Inc. P.O. Box C-88388 Seattle, WA 98188 USA Phone Number (206) 246-2010 Fax (206) 244-9886  Refer To: WCI Kit Number: WCI-767-53A-0209-1 West Coast Industries, Inc. 14900 Whitman Avenue North Seattle, WA 98133-6532 USA Phone Number (206) 365-7513 Fax (206) 365-7483 F. Special Tooling Necessary to do this Service Bulletin Cold working tools are necessary to do the change given in this service bulletin. To get the cold working tools, refer to Paragraph 2.E., Special Tooling - Price and Availability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 47 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 48 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 48 of 301 BOEING SERVICE BULLETIN 767-53A0209 BLANK PAGE ### Page 49 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. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margin, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are in 767 SRM, Chapter 51 – Torque limits to tighten nuts and bolts are in 767 SRM, Chapter 51 5. Use the approved fastener and process material substitutions in accordance with 767 SRM, Chapter 51. 6. If the length of any fastener specified in this service bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. 7. 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. 8. These work instructions refer to procedures included in 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 "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 49 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 50 9. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 10. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 11. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. B. WORK INSTRUCTIONS Group 6, Configuration 4: No work is necessary in accordance with this service bulletin. These airplanes do not have Type III overwing exit doors. Group 1-5; Group 6, Configuration 1-3: 1. ACCESS a. Group 1-3; Group 6, Configuration 1-3: Passenger Compartment (1) Remove passenger compartment seats as necessary. Refer to 767 AMM 25-25-01 as an accepted procedure. (2) Remove passenger floor coverings as necessary. Refer to 767 AMM 25-27-01 as an accepted procedure. (3) Remove passenger compartment sidewall panels as necessary. Refer to 767 AMM 25-21-02 as an accepted procedure. (4) Remove passenger compartment floor panels as necessary. Refer to 767 AMM 53-01-01 as an accepted procedure. b. Group 4-5: Freighter Main Deck Cargo Compartment (1) Remove main deck cargo compartment sidewall panels as necessary. Refer to 767 AMM 25-59-01 as an accepted procedure. (2) Remove main deck cargo compartment floor panels as necessary. Refer to 767 AMM 53-01-06 as an accepted procedure. 2. INSPECTION a. Group 1, 4; Group 6, Configuration 1: At Station 859.5 and 883.5, LBL and RBL 89, Below WL 200 do a Detailed Inspection or surface high frequency eddy current (HFEC) inspection of the frame inner chord transition radius for any crack in accordance with Figure 1. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 50 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 51 Group 2-3, 5; Group 6, Configuration 2-3: At Station 859.5, 883.5 and 903.5, LBL and RBL 89, Below WL 200 do a Detailed Inspection or surface high frequency eddy current (HFEC) inspection of the frame inner chord transition radius for any crack in accordance with Figure 1. b. If no crack(s) found, do repeat Detailed Inspection or surface HFEC inspection in accordance with Paragraph 1.E., Compliance. (1) Put the airplane back to a serviceable condition, go to paragraph 3.B.6. c. If any crack is found, do a Detailed Inspection of the frame for one or more fillers installed between the frame and stub-beam in accordance with Figure 2. If there is no filler(s) installed, go to paragraph 3.B.3. If one or more fillers are installed, measure the total filler thickness. If the the total thickness is 0.125 inch or less, go to paragraph 3.B.3. If one or more fillers are installed and the measured total filler thickness is greater than 0.125 inch, do the open hole HFEC inspection for cracks in the frame inner chord, failsafe chord, frame web, doubler (Station 903.5) and stub-beam in accordance with paragraph 3.B.3. (1) If no crack(s) found, do NOT proceed to paragraph 3.B.4 repair installation. See Appendix A in this Service Bulletin for additional filler data that is to be documented and sent to Boeing, then contact Boeing for repair data and do the repair provided by Boeing. (2) If any crack is found, follow the instructions to remove a crack indication in accordance with paragraph 3.B.3. Do NOT proceed to paragraph 3.B.4 repair installation. Send Appendix A filler data and Appendix B hole data to Boeing, and then contact Boeing for repair data and do the repair provided by Boeing. 3. OPEN HOLE INSPECTION a. Group 1, 4; Group 6, Configuration 1: At Station 859.5 and 883.5, LBL and RBL 89, Below WL 200 remove fasteners and do an open hole high frequency eddy current (HFEC) inspection for any crack in the frame inner chord, failsafe chord, frame web and stub-beam as applicable in accordance with Figures 3 and 4. If no crack(s) found, go to paragraph 3.B.4. If any crack is found, oversize the hole in accordance with Figures 3 or 4 and then do a repeat open hole HFEC inspection to ensure no further crack indication exists. If a crack indication still exists and the hole diameter is 1/32 inch greater than the specified nominal diameter DO NOT FURTHER OVERSIZE THE HOLE. See Appendix B in this Service Bulletin for data that is to be documented and sent to Boeing, then contact Boeing for repair data and do the repair provided by Boeing. b. Group 2-3, 5; Group 6, Configuration 2-3: At Station 859.5, 883.5 and 903.5, LBL and RBL 89, Below WL 200 remove fasteners and do an open hole high frequency eddy current (HFEC) inspection for any crack(s) in the frame inner chord, failsafe chord, frame web, doubler (Station 903.5) and stub-beam as applicable in accordance with Figures 3, 4 and 5 or 6. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 51 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 52 If no crack(s) found, go to paragraph 3.B.4. If any crack is found, oversize the hole as specified in accordance with Figures 3, 4 and 5 or 6 and then do a repeat open hole HFEC inspection to ensure no further crack indication exists. If a crack indication still exists and the hole diameter is 1/32 inch greater than the specified nominal diameter DO NOT FURTHER OVERSIZE THE HOLE. See Appendix B in this Service Bulletin for data that is to be documented and sent to Boeing, then contact Boeing for repair data and do the repair provided by Boeing. CAUTION: THE REPAIRS IN THIS SERVICE BULLETIN SHOULD BE DONE AT NO MORE THAN TWO LOCATIONS ON ONE SIDE OF THE AIRPLANE AT A TIME WITHOUT SPECIAL JACKING AND SUPPORT OF THE AIRPLANE. CONTACT BOEING IF SPECIAL JACKING AND SUPPORT INSTRUCTIONS ARE NEEDED. 4. REPAIR INSTALLATION a. Station 859.5 (1) Group 1-3; Group 6, Configuration 1-3: If applicable, remove crack and install a left side inner chord repair in accordance with Figure 7. (2) Group 1-3; Group 6, Configuration 1-3: If applicable, remove crack and install a right side inner chord repair in accordance with Figure 8. (3) Group 4-5: If applicable, remove crack and install a left side inner chord repair in accordance with Figure 21. (4) Group 4-5: If applicable, remove crack and install a right side inner chord repair in accordance with Figure 22. (5) Put the airplane back to a serviceable condition, go to paragraph 3.B.6. b. Station 883.5 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 52 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 53 (1) Group 3, 5; Group 6, Configuration 3: If applicable, remove crack and install a left side, two radius filler inner chord repair in accordance with Figure 9. (2) Group 3, 5; Group 6, Configuration 3: If applicable, remove crack and install a right side, two radius filler inner chord repair in accordance with Figure 10. (3) Group 1-2, 4; Group 6, Configuration 1-2: If applicable, remove crack and install a left side, three radius filler inner chord repair in accordance with Figure 11. (4) Group 1-2, 4; Group 6, Configuration 1-2: If applicable, remove crack and install a right side, three radius filler inner chord repair in accordance with Figure 12. (5) Put the airplane back to a serviceable condition, go to paragraph 3.B.6. c. Station 903.5 (1) Group 2; Group 6, Configuration 2: If applicable, remove crack and install a left side, one hole trim out inner chord repair in accordance with Figure 13. (2) Group 2; Group 6, Configuration 2: If applicable, remove crack and install a right side, one hole trim out inner chord repair in accordance with Figure 14. (3) Group 2; Group 6, Configuration 2: If applicable, remove crack and install a left side, two hole trim out inner chord repair in accordance with Figure 15. (4) Group 2; Group 6, Configuration 2: If applicable, remove crack and install a right side, two hole trim out inner chord repair in accordance with Figure 16. (5) Group 3; Group 6, Configuration 3: If applicable, remove crack and install a left side, one hole trim out inner chord repair in accordance with Figure 17. (6) Group 3; Group 6, Configuration 3: If applicable, remove crack and install a right side, one hole trim out inner chord repair in accordance with Figure 18. (7) Group 3; Group 6, Configuration 3: If applicable, remove crack and install a left side, two hole trim out inner chord repair in accordance with Figure 19. (8) Group 3; Group 6, Configuration 3: If applicable, remove crack and install a right side, two hole trim out inner chord repair in accordance with Figure 20. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 53 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 54 (9) Group 5: If applicable, remove crack and install a left side, one hole trim out inner chord repair in accordance with Figure 23. (10) Group 5: If applicable, remove crack and install a right side, one hole trim out inner chord repair in accordance with Figure 24. (11) Group 5: If applicable, remove crack and install a left side, two hole trim out inner chord repair in accordance with Figure 25. (12) Group 5: If applicable, remove crack and install a right side, two hole trim out inner chord repair in accordance with Figure 26. (13) Put the airplane back to a serviceable condition, go to paragraph 3.B.6. 5. POST-REPAIR INSPECTION a. Group 1-3; Group 6, Configuration 1-3: Passenger Compartment, refer to paragraph 3.B.1 as an accepted procedure for access. b. Group 4-5: Freighter Main Deck Cargo Compartment, refer to paragraph 3.B.1 as an accepted procedure for access. c. Group 1-5; Group 6, Configuration 1-3: Station 859.5, do post-repair inspections in accordance with Figure 27. d. Group 1-5; Group 6, Configuration 1-3: Station 883.5, do post-repair inspections in accordance with Figure 28. e. Group 2-3, 5; Group 6, Configuration 2-3: Station 903.5, do one hole trim out post-repair inspections in accordance with Figure 29. f. Group 2-3, 5; Group 6, Configuration 2-3: Station 903.5, do two hole trim out post-repair inspections in accordance with Figure 30. g. Put the airplane back to a serviceable condition, go to paragraph 3.B.6. 6. CLOSE ACCESS a. Group 1-3; Group 6, Configuration 1-3: Passenger Compartment BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 54 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 55 (1) Install passenger compartment floor panels as necessary. Refer to 767 AMM 53-01-01 as an accepted procedure. (2) Install passenger compartment sidewall panels as necessary. Refer to 767 AMM 25-21-02 as an accepted procedure. (3) Install passenger floor coverings as necessary. Refer to 767 AMM 25-27-01 as an accepted procedure. (4) Install passenger compartment seats necessary. Refer to 767 AMM 25-25-01 as an accepted procedure. b. Group 4-5: Freighter Main Deck Cargo Compartment (1) Install main deck cargo compartment sidewall panels as necessary. Refer to 767 AMM 25-59-01 as an accepted procedure. (2) Install main deck cargo compartment floor panels as necessary. Refer to 767 AMM 53-01-06 as an accepted procedure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1: July 27, 2011 55 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 56 (OCR) BOEING SERVICE BULLETIN 767-53A0209 STA 903.5 STA 883.5 STA 859.5 1779327 FIGURE 1: INNER CHORD INSPECTION (SHEET 1 OF 4) Original Issue: September 30, 2010 Revision 1 July 27, 2011 767-53A0209 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 301 ### Page 57 (OCR) BOEING SERVICE BULLETIN 767-53A0209 INNER CHORD FAIL-SAFE ~ CHORD OUTER CHORD FRAME WEB TYPICAL CRACK STUB BEAM TRANSITION RADIUS LEFT SIDE SHOWN RIGHT SIDE OPPOSITE INSPECTION (TYPICAL) AREA 1779712 FIGURE 1: INNER CHORD INSPECTION (SHEET 2 OF 4) Original Issue: September 30, 2010 Revision 1 July 27, 2011 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. ### Page 58 (OCR) BOEING SERVICE BULLETIN 767-53A0209 INNER CHORD FRAME WEB FAIL-SAFE CHORD OUTER CHORD TYPICAL CRACK STUB BEAM TRANSITION RADIUS LEFT SIDE SHOWN RIGHT SIDE OPPOSITE INSPECTION STA 883.5 (TYPICAL) AREA 2067177 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. FIGURE 1: INNER CHORD INSPECTION (SHEET 3 OF 4) Original Issue: September 30, 2010 Revision 1 July 27, 2011 BOEING PROPRIETARY - 767-53A0209 Copyright © Unpublished Work - See page 1 for details. 58 of 301 ### Page 59 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (a)--Inner ChordInspect1 (a) Do a Detailed Inspection or surface high frequency eddy current (HFEC) inspection of the frame inner chord surface and transition radius for cracks. Do HFEC inspection in accordance with 767 NDT Part 6, 51-00-19. FIGURE 1: INNER CHORD INSPECTION (SHEET 4 OF 4) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2010 767-53A0209Revision 1 July 27, 2011 59 of 301 BOEING SERVICE BULLETIN 767-53A0209 ### Page 60 (OCR) BOEING SERVICE BULLETIN 767-53A0209 INNER CHORD OUTER CHORD FRAME WEB 1 (TYPICAL EDGE OF FILLEF STUB BEAM 1) (TYPICAL EDGE OF FILLE! TYPICAL CRACK STA 859.5 (SHOWN) RIGHT SIDE OPPOSITE LEFT SIDE SHOWN STA 883.5 (SIMILAR) STA 903.5 (SIMILAR) 1956113 (TYPICAL) FIGURE 2: FRAME TO STUB-BEAM FILLER INSPECTION (SHEET 1 OF 2) Original Issue: September 30, 2010 Revision 1 July 27, 2011 BOEING PROPRIETARY - 767-53A0209 Copyright © Unpublished Work - See page 1 for details. 60 of 301 The text continues at https://openairdocs.org/service-documents/boeing/767-53a0209/file/9883e7c9be77.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.