Boeing SB A3364: SB-707-00A3364-04--, text

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Commercial Airplanes 707 Service Bulletin ALERT Number: A3364 Original Issue: June 29, 1979 Revision 4: February 21, 2017 ATA System: 5401 SUBJECT: NACELLE STRUT DIAGONAL BRACE END FITTING INSPECTION AND

MODIFICATION Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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:

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 1 of 57

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Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 2 of 57 BOEING SERVICE BULLETIN A3364

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Table of Contents

Revision Transmittal Sheet5

Summary9

1. PLANNING INFORMATION13

A. Effectivity13

1. Airplanes13

2. Spares Affected17

B. Concurrent Requirements17

C. Reason17

D. Description19

E. Compliance21

F. Approval23

G. Manpower24

H. Weight and Balance Changes25

I. Electrical Load Data25

J. References25

1. Existing Data:25

2. Data Supplied with this Service Bulletin:26

3. Installation Drawings Used in the Preparation of this Service Bulletin:26

K. Publications Affected26

L. Interchangeability and Intermixability of Parts27

M. Software Accomplishment Summary27

2. MATERIAL INFORMATION29

A. Material - Price and Availability29

B. Industry Support Information33

C. Parts Necessary for Each Airplane33

1. Kits/Parts33

2. Parts and Materials Supplied by the Operator40

3. Parts Modified and Reidentified40

4. Parts Removed and Not Replaced40

D. Parts Necessary to Change Spares41

E. Special Tooling - Price and Availability41

F. Special Tooling Necessary to do this Service Bulletin41

3. ACCOMPLISHMENT INSTRUCTIONS43

A. GENERAL INFORMATION43

B. WORK INSTRUCTIONS44

FIGURE 1: DETAILED INSPECTION OF FITTINGS AND DIAGONAL BRACE TUBE46

FIGURE 2: HIGH FREQUENCY EDDY CURRENT (HFEC) AND ALTERNATIVE DYE PENETRANT

INSPECTION OF DIAGONAL BRACE TUBE, FITTINGS AND MODIFICATION48

FIGURE 3: FITTING AND DIAGONAL BRACE TUBE REPLACEMENT52

APPENDIX A: PART DEMAND INTENT57

Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 3 of 57 BOEING SERVICE BULLETIN A3364

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Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 4 of 57 BOEING SERVICE BULLETIN A3364

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Commercial Airplanes 707 Service Bulletin ALERT Revision Transmittal SheetNumber: A3364Original Issue: June 29, 1979 Revision 4: February 21, 2017 ATA System: 5401 SUBJECT: NACELLE STRUT DIAGONAL BRACE END FITTING INSPECTION AND

MODIFICATION This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 82-24-03 is related to this service bulletin.

The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Effects of this Revision on airplanes on which Original Issue, Revision 1, Revision 2 or Revision 3 was previously done:

ActionConditionGroup Do a detailed inspection of the forward mating fitting, aft mating fitting, diagonal brace end fittings and diagonal brace tube. Compliance times have been changed.

All AirplanesAll Do a surface High Frequency Eddy Current (HFEC) inspection of the forward mating fitting, aft mating fitting and diagonal brace end fittings.

Compliance times have been changed.

Do an open hole HFEC inspection of the forward mating fitting, aft mating fitting, diagonal brace end fittings and diagonal brace tube.

Compliance times have been changed.

Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 5 of 57

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REASON FOR REVISION This revision is sent to change the inspection interval for all HFEC and alternative dye penetrant inspections, and to add detailed inspections of the diagonal brace tube around the fasteners at each diagonal brace end fitting for any crack and open hole HFEC inspections of the diagonal brace tube end fitting fastener holes. The option of shot peening parts has been removed from this service bulletin. The open hole HFEC inspection of the forward mating fitting lugs has been added. The surface HFEC inspection of the aft mating (drag) fitting lugs has been added.

The data given in Notice of Status Change 707 A3364NSC1, A3364NSC2 and A3364NSC3 is included in this revision.

Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph

3.A., General Information - Notes.

These sections were changed:

1. Added Summary, Concurrent Requirements.

2. In Summary, Background, revised paragraph, added references to Service Related Problem (SRP) and Fleet Team Digest (FTD).

3. In Summary, Action, revised paragraph.

4. In Summary, Effectivity, revised paragraph.

5. Added Summary, Compliance.

6. Added Summary, Industry Support Information.

7. In Summary, Manpower, revised paragraph.

8. In Summary, Material Information, revised paragraph.

9. In Summary, revised summary illustration.

10. In Paragraph 1.A.1., Airplanes, updated effectivity format, removed airplane variable numbers 00003, 00102, 00114, 00154-00156, 00450, 00451, 00602, 05828 and 05829, from the service bulletin effectivity.

11. Added Paragraph 1.B., Concurrent Requirements.

12. In Paragraph 1.C., Reason, revised paragraph, added references to SRP and FTD, added reason for revision.

13. In Paragraph 1.D., Description, revised paragraph, added effects of this revision and added tables for affected maintenance zones.

14. Added Paragraph 1.E., Compliance.

15. In Paragraph 1.F., Approval, revised and added paragraph, added Alternative Method of Compliance (AMOC) statement.

16. In Paragraph 1.G., Manpower, revised paragraph and tables.

Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 6 of 57 BOEING SERVICE BULLETIN A3364

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17. In Paragraph 1.H., Weight and Balance Changes, revised table.

18. Added Paragraph 1.I., Electrical Load Data.

19. In Paragraph 1.J.1., Existing Data, updated the list of references.

20. Added Paragraph 1.J.3., Installation Drawings Used in the Preparation of this Service Bulletin.

21. Added Paragraph 1.K.2., Damage Tolerance Based Structural Inspections.

22. Added Paragraph 1.L., Interchangeability and Intermixability of Parts.

23. Added Paragraph 1.M., Software Accomplishment Summary.

24. In Paragraph 2.A., Material - Price and Availability, revised the paragraph, updated kit/part table.

25. Added Paragraph 2.B., Industry Support Information.

26. In Paragraph 2.C.1., Parts Necessary for Each Airplane, added paragraph, added note, corrected part number.

27. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added paragraph, added table.

28. Added Paragraph 2.C.3., Parts Modified and Reidentified.

29. Added Paragraph 2.C.4., Parts Removed and Not Replaced.

30. In Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin, revised paragraph.

31. Added Paragraph 3.A., General Information.

32. In Paragraph 3.B., Work Instructions, revised work instructions.

33. In Figures 1 thru 3, revised circle note numbers, revised steps.

34. Added Appendix A, Part Demand Intent survey.

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

Pages with no vertical lines have no changes.

REVISION HISTORY June 29, 1979Original Issue:

November 30, 1979Revision 1:

December 20, 1979Revision 2:

May 29, 1981Revision 3:

February 21, 2017Revision 4:

Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 7 of 57 BOEING SERVICE BULLETIN A3364

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Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 8 of 57 BOEING SERVICE BULLETIN A3364

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Commercial Airplanes 707 Service Bulletin ALERT SummaryNumber: A3364Original Issue: June 29, 1979 Revision 4: February 21, 2017 ATA System: 5401 SUBJECT: NACELLE STRUT DIAGONAL BRACE END FITTING INSPECTION AND

MODIFICATION

THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND As of the Revision 3 date of this service bulletin, 29 operators have reported 66 cracked diagonal brace end fittings, 45 cracked forward mating fittings and 9 cracked aft mating fittings on airplanes with 23,200 to 63,200 flight-hours (8,300 to 34,200 flights). Cracking is attributed to fatigue in the end fittings and stress corrosion or fatigue in the mating fittings.

The inboard and outboard nacelle struts are also supported by the more critical midspar fittings which are inspected/replaced in service bulletin 707A3183 Revision 6. Service Bulletin 707A3183 Revision 6 has been created to address the fracture of the midspar fitting that resulted in the separation of the inboard strut and engine from the airplane. Service Bulletin 707A3183 Revision 6 has new detailed inspections and High Frequency Eddy Current (HFEC) inspections. Existing service and regulatory actions for other nacelle strut fittings are insufficient to ensure timely detection of cracking which could lead to separation of an engine. As a result, Service Bulletin 707A3364 Revision 4 has been created to align the HFEC inspection intervals of the diagonal brace tube, end fittings, and mating fittings with those for the midspar fittings.

Subsequent to release of Revision 3 of this service bulletin, an operator had reported complete separation of the body of an outboard nacelle strut diagonal brace forward end fitting as a result of a crack which ran circumferentially around the forward row of fastener holes. The airplane had accumulated 43,773 flight-hours and 14,735 flights. The fitting had previously been detail inspected in accordance with this service bulletin, but the cracking was not detected until the brace was removed during major overhaul.

Boeing Service Related Problem (SRP) 707-SRP-54-0155 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 707 FTD 54-05001 is related to this service bulletin.

Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 9 of 57

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ACTION Do detailed inspections and HFEC inspections of the nacelle strut diagonal brace end fittings, diagonal brace tube, forward mating fitting and aft mating fitting (or alternative dye penetrant inspection of vertical webs on aft mating fitting), and repeat the inspections at the intervals specified in Paragraph 1.E., Compliance.

If any crack is found in the nacelle strut diagonal brace end fittings, diagonal brace tube, forward mating fitting or aft mating fitting, do the repair in accordance with this service bulletin. If any crack cannot be repaired in accordance with this service bulletin, replace the cracked part in accordance with this service bulletin, or contact The Boeing Company for repair instructions and do the repair. Parts oversized beyond the limits specified in this service bulletin must be replaced. Modified or replaced parts must continue the repeat inspections.

EFFECTIVITY All 707 and 720 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 82-24-03 is related to this service bulletin.

The effective date of AD 82-24-03 is November 23, 1982.

Refer to Paragraph 1.E., Compliance.

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

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Operator Supplied Parts/Materials.

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

Operators are encouraged to complete the survey provided in APPENDIX A of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Original Issue: June 29, 1979 A3364Revision 4: February 21, 2017 10 of 57 BOEING SERVICE BULLETIN A3364