# Boeing Service Bulletin A3515: Revision 1

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- Document: [Boeing Service Bulletin A3515](https://openairdocs.org/service-documents/boeing/a3515.md)
- Title as filed: U.S. DOT/FAA - SB-707-00A3515-01
- Pages: 38
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## Text

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### Page 1

Commercial 
Airplanes
707
Service Bulletin
ALERT
Number: A3515
Original Issue: December 19, 2007
Revision 1: October 10, 2014
ATA System: 5510
SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection
and Repair
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:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 2007 Boeing.
Unpublished Work. All Rights Reserved.
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: December 19, 2007
A3515Revision 1: October 10, 2014
1 of 38
10.0

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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 5
B. Concurrent Requirements ...................................... 1 5
C. Reason ................................................ 1 5
D. Description .............................................. 1 6
E. Compliance .............................................. 1 6
F. Approval ............................................... 2 0
G. Manpower .............................................. 2 0
H. Weight and Balance Changes .................................... 2 1
I. Electrical Load Data ......................................... 2 1
J. References .............................................. 2 1
1. Existing Data: ......................................... 2 1
2. Data Supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2
K. Publications Affected ........................................ 2 2
L. Interchangeability and Intermixability of Parts ........................... 2 2
M. Software Accomplishment Summary ................................ 2 2
2. MATERIAL INFORMATION ........................................ 2 3
A. Material - Price and Availability ................................... 2 3
B. Industry Support Information .................................... 2 3
C. Parts Necessary for Each Airplane ................................. 2 3
1. Kits/Parts: ........................................... 2 3
2. Parts and Materials Supplied by the Operator: ........................ 2 3
3. Parts Modified and Reidentified: ............................... 2 4
4. Parts Removed and Not Replaced: .............................. 2 4
D. Parts Necessary to Change Spares ................................. 2 4
E. Special Tooling - Price and Availability ............................... 2 4
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 6
FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUTBOARD
- CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 -
INSPECTION .......................................... 3 1
FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION
.................................................. 3 3
FIGURE 3: HORIZONTAL STABILIZER - REAR SPAR - UPPER INBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION
.................................................. 3 4
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FIGURE 4: HORIZONTAL STABILIZER - REAR SPAR - LOWER OUTBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION
.................................................. 3 5
FIGURE 5: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION
.................................................. 3 6
FIGURE 6: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION -13.179 TO STABILIZER STATION 92.55 - INSPECTION
.................................................. 3 7
Appendix A: CONFIGURATION VERIFICATION - INSPECTION RESULTS FORM - MATERIAL DATA . 38
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### Page 5

Commercial 
Airplanes
707
Service Bulletin
ALERT
Revision Transmittal SheetNumber: A3515Original Issue: December 19, 2007
Revision 1: October 10, 2014
ATA System: 5510
SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection
and Repair
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1 are 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.
REASON FOR REVISION
This revision is sent to updated compliance table and wording to clarify requirements, provide clarifying information
for the Compliance requirements for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords,
to clarify Parts 3, 4 & 5 by removing unnecessary redundant wording, and to add reference to Federal Aviation
Administration (FAA) Airworthiness Directive AD 2012-17-13.
These sections were changed:
1. Summary, Background, added clarifying information for the Part 6 7079 aluminum chord replacement
with 7075 aluminum chords.
2. Summary, Compliance, added FAA Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1.
3. Paragraph 1.C., Reason, added clarifying information for the Part 6 7079 aluminum chord replacement
with 7075 aluminum chords.
4. Paragraph 1.E., Compliance, updated compliance table to clarify requirements, added clarifying
information for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords and added
FAA Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1.
5. Paragraph 1.F., Approval, added FAA Airworthiness Directive AD 2012-17-13.
6. Paragraph 1.J., References, added FAA Airworthiness Directives AD 85-12-01 R1 and AD 2012-17-13.
7. Paragraph 2.C.2., Parts and Materials Supplied by the Operator, removed footnote (c) and added parts
65-95600-703 and 65-95600-704 and footnotes (j) and (k).
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8. Paragraph 3.B.3., Work Instructions, removed unnecessary redundant wording.
9. Paragraph 3.B.4., Work Instructions, removed unnecessary redundant wording.
10. Paragraph 3.B.5., Work Instructions, removed unnecessary redundant wording.
11. Paragraph 3.B.6., Work Instructions, added clarifying information for the Part 6 7079 aluminum chord
replacement with 7075 aluminum chords.
12. Paragraph 3.B., Work Instructions, Figures 1 through 6 and Appendix A, changed all NDT callouts to
"in accordance with".
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 important changes.
REVISION HISTORY
December 19, 2007Original Issue:
October 10, 2014Revision 1:
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ALERTALERT

### Page 7

Commercial 
Airplanes
707
Service Bulletin
ALERT
SummaryNumber: A3515Original Issue: December 19, 2007
Revision 1: October 10, 2014
ATA System: 5510
SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection
and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Boeing Service Related Problem (SRP) 707-SRP-55-0033 is related to this service bulletin.
1. ISSUE 1 - Stress Corrosion Cracking in Chords Made from 7079 Aluminum in the Horizontal Stabilizer
Rear Spar
Boeing has received numerous reports of stress corrosion cracking in the chord segments made from
7079 aluminum in the 707 horizontal stabilizer rear spar This is a material that is known to be susceptible
to stress corrosion cracking. Early reports led to Boeing Service Bulletins 707-3356 and 707-3381.
Incorporation of the modifications in those service bulletins has helped to slow the development of
stress corrosion cracks. Boeing Service Bulletin 707-A3515 continues the inspections of 707-3356 and
707-3381, but at shorter intervals, and in concurrence with the necessary actions that are the subject
of Issue 2 below, until the 7079 aluminum chord segments are replaced by ones made from 7075. The
actions of this service bulletin addressing Issue 1 are necessary to adequately detect development of
stress corrosion cracking in 7079 aluminum chords.
2. ISSUE 2 - Early Fatigue Cracking in the Inboard Segment of the Upper Chord in the Horizontal Stabilizer
Rear Spar
Boeing has received three reports of fatigue cracking in the upper chord of the horizontal stabilizer rear
spar at a location near the side of the body. In all cases the fatigue prevention and fail safety
improvement modifications of Boeing Service Bulletin 707-A3313 had been incorporated. The fatigue
cracking is considered to be early in the life of the modified structure. The fatigue cracks are generated
by frequent use of the airplanes for training flights that include multiple Touch and Goes. This frequent
use of the airplane for this type of training has been most prevalent with military operators of commercial
model 707 and 720 airplanes. The actions of this service bulletin are necessary to adequately detect
early fatigue cracking.
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### Page 8

3. CONFIGURATION
The ability to move the horizontal stabilizer to a different airplane is of significance to Issue 1 and Issue
2. Parts made from 7079 have been discovered on airplanes not originally delivered with those parts.
Therefore, to adequately address Issue 1, it is necessary to determine the horizontal stabilizer rear
spar chord configuration on the airplane. It is also necessary to carefully maintain a record of that
configuration until all 7079 horizontal stabilizer rear spar chord segments have been removed from the
fleet. Regarding Issue 2, since horizontal stabilizers can be moved to different airplanes, it is necessary
to implement the inspections for early fatigue cracking on all effective airplanes at the time stated in
the 1.E Compliance section, regardless of the current usage of the airplane.
ACTION (PRR 18101-2RS)
Cycle Definition: To adequately account for in-flight training maneuvers, incorporate the cycle counting procedure
defined in this service bulletin.
Configuration Check: To Maintain configuration identity, determine the material for each horizontal stabilizer
rear spar chord segment addressed by this service bulletin. Maintain the configuration identity indefinitely.
Inspections: Complete the inspections for stress corrosion cracking and fatigue cracking in accordance with the
methods and times stated in this service bulletin.
Repair: Contact Boeing for repair instructions or replace the cracked part with a spare part made from 7075
aluminum.
EFFECTIVITY
All 707-300, 707-300B, 707-300C and 707-400 Airplanes. See Paragraph 1.A.1 for effectivity.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1 are related
to this service bulletin.
See Service Bulletin Paragraph 1.E. for compliance information.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service
bulletin.
MANPOWER
See Service Bulletin Paragraph 1.G. for manpower information.
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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ALERTALERT

### Page 9 (OCR)

BOEING SERVICE BULLETIN A3515
ALERT  ALERT
LEFRONT SPAR
STAB STA
92.55
CREAR SPAR
STAB STA
182.55  - ELEVATOR
HINGE
STAB STA
272.55
CHORD
A-A
LEFT HORIZONTAL STABILIZER SHOWN,
RIGHT OPPOSITE
DEFINE CHORD MATERIAL
INSPECT CHORDS  496408
REPAIR AS NECESSARY
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### Page 10

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ALERTALERT
BLANK PAGE

### Page 11

Commercial 
Airplanes
707
Service Bulletin
ALERT
Number: A3515
Original Issue: December 19, 2007
Revision 1: October 10, 2014
ATA System: 5510
SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection
and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent
production airplanes. Refer to PRR 18101-2RS for data about this change.
Refer to Service Bulletin Index Document D6-1647 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP
All horizontal stabilizer rear spar chords made from 7079-T6.-1
Horizontal stabilizer rear spar upper inboard and upper outboard
chords made of 7079-T6.
-2
Left side horizontal stabilizer rear spar upper inboard chords made
from 7079-T6.
-3
All horizontal stabilizer rear spar chords made from 7075-T73511.-4
Airplane Models:
707-300, 707-300B, 707-300C, 707-400
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GroupVariable Number
102001 - 02020
102101 - 02121
102201 - 02207
102301 - 02303
102401 - 02418
104001 - 04005
104020 - 04022
104101 - 04106
104201 - 04218
104271 - 04272
104301 - 04303
105001 - 05060
105101 - 05138
105201 - 05208
105301 - 05312
105401
105601 - 05605
105631 - 05635
105701 - 05703
105801 - 05802
105821 - 05827
105831 - 05833
105851 - 05854
105891 - 05892
105921 - 05923
105941 - 05942
105961 - 05970
106001 - 06002
106101
106401 - 06404
406451
406461
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GroupVariable Number
107001 - 07017
107041 - 07059
107071 - 07081
107101 - 07109
107181
107191
107201 - 07208
107210
107212 - 07215
107251 - 07271
107401 - 07407
107451 - 07458
107501 - 07504
107601 - 07626
107661 - 07662
107681 - 07684
107701 - 07702
107801 - 07821
107901 - 07907
108001 - 08008
108021
108051 - 08056
108071 - 08077
108101 - 08104
108121 - 08129
108141 - 08144
108151 - 08153
108171 - 08173
108191 - 08192
108201 - 08208
308209 - 08210
108221 - 08224
108241 - 08244
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### Page 14

GroupVariable Number
108251
108261
108271
108301 - 08320
108324 - 08330
108333
108401 - 08410
108451 - 08452
108471 - 08475
108501 - 08502
108551 - 08553
108581 - 08582
109001 - 09006
109101 - 09102
309103 - 09105
409106 - 09107
409161 - 09167
109201 - 09202
209203
409204
309221 - 09223
409227
209231
309232
409251
409271
409281
409286 - 09290
409411
409421
409438
409441
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### Page 15

2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Boeing Service Related Problem (SRP) 707-SRP-55-0033 is related to this service bulletin.
1. ISSUE 1 - Stress Corrosion Cracking in Chords made from 7079 Aluminum in the Horizontal
Stabilizer Rear Spar
Boeing has received numerous reports of stress corrosion cracking in the chord segments made
from 7079 aluminum in the 707 horizontal stabilizer rear spar. This is a material that is known to
be susceptible to stress corrosion cracking. Early reports led to Boeing Service Bulletins 707-3356
and 707-3381. Incorporation of the modifications in those service bulletins has helped to slow the
development of stress corrosion cracks. Boeing Service Bulletin 707-A3515 continues the
inspections of 707-3356 and 707-3381, but at shorter intervals, and in concurrence with the
necessary actions that are the subject of Issue 2 below, until the 7079 aluminum chord segments
are replaced by ones made from 7075. The actions of this service bulletin addressing Issue 1 are
necessary to adequately detect development of stress corrosion cracking in 7079 aluminum chords.
2. ISSUE 2 - Early Fatigue Cracking in the Inboard Segment of the Upper Chord in the Horizontal
Stabilizer Rear Spar
Boeing has received three reports of fatigue cracking in the upper chord of the horizontal stabilizer
rear spar at a location near the side of the body. In all cases the fatigue prevention and fail safety
improvement modifications of Boeing Service Bulletin 707-A3313 had been incorporated. The
fatigue cracking is considered to be early in the life of the modified structure. The fatigue cracks
are generated by frequent use of the airplanes for training flights that include multiple Touch and
Goes. This frequent use of the airplane for this type of training has been most prevalent with military
operators of commercial model 707 and 720 airplanes.
The actions of this service bulletin are necessary to adequately detect early fatigue cracking.
3. CONFIGURATION
The ability to move the horizontal stabilizer to a different airplane is of significance to Issue 1 and
Issue 2. Parts made from 7079 have been discovered on airplanes not originally delivered with
those parts. Therefore, to adequately address Issue 1, it is necessary to determine the horizontal
stabilizer rear spar chord configuration on the airplane. It is also necessary to carefully maintain
a record of that configuration until all 7079 horizontal stabilizer rear spar chord segments have
been removed from the fleet. Regarding Issue 2, since horizontal stabilizers can be moved to
different airplanes, it is necessary to implement the inspections for early fatigue cracking on all
effective airplanes at the time stated in the 1.E Compliance section, regardless of the current usage
of the airplane.
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A3515Revision 1: October 10, 2014
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ALERTALERT

### Page 16

Revision 1 is sent to updated compliance table and wording to clarify requirements, provide clarifying
information for the Compliance requirements for the Part 6 7079 aluminum chord replacement with
7075 aluminum chords, to clarify Parts 3, 4 & 5 by removing unnecessary redundant wording, and to
add reference to Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-17-13.
D. Description
Cycle Definition: To adequately account for in-flight training maneuvers, incorporate the cycle counting
procedure defined in this service bulletin.
Configuration Check: To Maintain configuration identity, determine the material for each horizontal
stabilizer rear spar chord segment addressed by this service bulletin. Maintain the configuration identity
indefinitely.
Inspections: Complete the inspections for stress corrosion cracking and fatigue cracking in accordance
with the methods and times stated in this service bulletin.
Repair: Contact Boeing for repair instructions or replace the cracked part with a spare part made from
7075 aluminum.
Revision 1 - No more work is necessary on airplanes 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.
Group 1:
Affected Maintenance Zones
ZoneModel
3-93, 3-94707-300, 707-300B, 707-300C,
707-400
Group 2-3:
Affected Maintenance Zones
ZoneModel
3-93, 3-94707-300C
Group 4:
Affected Maintenance Zones
ZoneModel
3-93, 3-94707-300B, 707-300C
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1
are related to this service bulletin.
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### Page 17

Boeing recommends the following:
Applicable to all rear spar chord segments (upper inboard, upper outboard, lower inboard, lower outboard
and center) made from 7079, do the Part 6 - Chord Replacement within 48 months after the Revision
1 date of this service bulletin.
Table 1: Determine Flight Cycles and Material of Horizontal Stabilizer Rear Spar Chord Segments
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
-At time of original service bulletin
release.
Determine flight cycles as given
in Accomplishment Instructions
paragraph 3.B.1. Part 1.
All airplanes
180 calendar
days or 250 flight
cycles, whichever
occurs first. (a)
Within 180 calendar days after the
original release date of this service
bulletin.
Determine material of the left and
right side horizontal stabilizer rear
spar chord segments as given in
Accomplishment Instructions
Paragraph 3.B.2. Part 2. (c)
All airplanes
N/ABefore further flight following the
horizontal stabilizer replacement.
Airplanes on which
the horizontal stabiliz-
er is being replaced
with a different hori-
zontal stabilizer.
--Inspect and repair the horizontal
stabilizer rear spar chord seg-
ments made from 7075 as given
in Table 2. (b) (c)
Airplanes with hori-
zontal stabilizer rear
spar chord segments
made from 7075 as
found in the Accom-
plishment Instruc-
tions Paragraph
3.B.2 Part 2. (c)
--Inspect and repair the horizontal
stabilizer rear spar chord seg-
ments made from 7079 as given
in Table 3. (b) (c)
Airplanes with hori-
zontal stabilizer rear
spar chord segments
made from 7079 as
found in the Accom-
plishment Instruc-
tions Paragraph
3.B.2 Part 2. (c)
(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."
(b) If you have a mixture of 7075 chord segments and 7079 chord segments, use Tables 2 and 3.
(c) Spar chord segments are as defined in APPENDIX A.
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### Page 18

Table 2: Inspect and Repair Horizontal Stabilizer Rear Spar Upper Inboard Chord Segments Made From
7075 Material
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
500 flight cycles.
(a)
Within 180 calendar days or 500
flight cycles after the original re-
lease date of this service bulletin,
whichever occurs first. (a) (c)
Inspect and repair the upper in-
board chord segment from stabi-
lizer station -13.179 to 92.55 as
given in Accomplishment Instruc-
tions Paragraph 3.B.3. Part 3. (d)
Airplanes with hori-
zontal stabilizer rear
spar upper inboard
chord segment made
from 7075. (d)
N/ABefore further flight following the
horizontal stabilizer replacement.
(c)
Airplanes on which
the horizontal stabiliz-
er is being replaced
with a different hori-
zontal stabilizer hav-
ing the upper inboard
chord segment made
from 7075. (d)
500 flight cycles.
(a)
Within 4000 flight cycles after the
date of upper chord inboard seg-
ment replacement. (a) (d)
Inspect and repair the upper in-
board chord segment from stabi-
lizer station -13.179 to 92.55 as
given in Accomplishment Instruc-
tions Paragraph 3.B.3. Part 3. (b)
(d)
Airplanes on which
the horizontal stabiliz-
er rear spar upper in-
board chord segment
is replaced as given
in Accomplishment
Instructions Para-
graph 3.B.6 Part 6.
(d)
(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."
(b) Continued inspections are only necessary for rear spar upper inboard chord segments made from 7075.
Continued inspections are not necessary for other spar chord segments replaced with 7075 parts.
(c) When you replace the rear spar upper inboard chord segment as given in Accomplishment Instructions
Paragraph 3.B.6 Part 6, you can defer that chord segment inspection given in Accomplishment Instructions
Paragraph 3.B.3. Part 3 for a maximum of 4,000 flight cycles.
(d) Spar chord segments are as defined in APPENDIX A.
Table 3: Inspect and Repair Horizontal Stabilizer Rear Spar Upper and Lower Chord Segments Made
From 7079 Material
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
180 calendar
days or 250 flight
cycles, whichever
occurs first. (a)
Within 180 calendar days or 250
flight cycles after the original re-
lease date of this service bulletin,
whichever occurs first. (a)
Inspect and repair the upper in-
board chord segment from stabi-
lizer station -13.179 to 92.55 as
given in Accomplishment Instruc-
tions Paragraph 3.B.3. Part 3. (c)
Airplanes with hori-
zontal stabilizer rear
spar upper inboard
chord segment made
from 7079. (c)
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Table 3: Inspect and Repair Horizontal Stabilizer Rear Spar Upper and Lower Chord Segments Made
From 7079 Material
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
180 calendar
days or 1000
flight cycles,
whichever occurs
first. (a)
Within 180 calendar days or 1000
flight cycles after the original re-
lease date of this service bulletin,
whichever occurs first. (a)
Inspect and repair the web
flanges of the rear spar upper and
lower chord segments made from
7079, from stabilizer station 92.55
to 272.55 as given in Accomplish-
ment Instructions Paragraph
3.B.4. Part 4. (b) (c)
Airplanes with any of
the following horizon-
tal stabilizer rear spar
chord segments
made from 7079:
upper inboard, upper
outboard, lower in-
board, lower out-
board. (c) Inspect and repair the forwardskin flanges of the rear spar up-
per and lower chord segments
made from 7079, from stabilizer
station -13.179 to 272.55 as given
in Accomplishment Instructions
Paragraph 3.B.5. Part 5. (b) (c)
N/ABefore further flight following the
horizontal stabilizer replacement.
(c)
Do the Part 6 - Chord Replace-
ment, for all rear spar chord seg-
ments made from 7079. (c)
Airplanes on which
the horizontal stabiliz-
er is being replaced
with a different hori-
zontal stabilizer hav-
ing rear spar chord
segments made from
7079. (c)
-Before further flight.Do Boeing service bulletin 707-
3381 Part II - Preventative Modifi-
cation as given in Accomplish-
ment Instructions Paragraphs
3.B.4 Part 4 and 3.B.5 Part 5 or
replace the chord as given in Ac-
complishment Instructions Para-
graph 3.B.6 Part 6.
Airplanes with hori-
zontal stabilizers that
have rear spar chord
segments made from
7079 for which the
Service Bulletin 707-
3381 Part II - Preven-
tative Modification is
not completed. (c)
(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."
(b) Only those chord segments made from 7079 material require the inspection and repair given in the Ac-
complishment Instructions Paragraphs 3.B.4. Part 4 and 3.B.5. Part 5. Chord segments made from 7075
material do not require the inspection and repair given in the Accomplishment Instructions Paragraphs
3.B.4. Part 4 and 3.B.5. Part 5.
(c) Spar chord segments are as defined in APPENDIX A.
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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 Part 3 inspections of this service bulletin supersede and replace the 707 Supplemental Structural
Inspection Document (SSID) inspections 55-A25-03, 55-A35-03 and 55-A45-03 mandated by Paragraph
A of AD 85-12-01 R1. The inspections contained in this service bulletin have been reviewed and
approved by the Manager of the FAA Seattle Aircraft Certification Office as an alternative method of
compliance to the requirements of Paragraph A of AD 85-12-01 R1 for SSID items 55-A25-03, 55-A35-03
and 55-A45-03 covered by this service bulletin. All other provisions of AD 85-12-01 R1 that are not
specifically referenced above remain fully applicable and must be complied with.
In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the flight cycle counting
procedures, inspections or modifications defined in this service bulletin as an alternative method of
compliance to the requirements of paragraphs (g), (h), (i), (j), (k), (l), and (m) of AD 2012-17-13 pertaining
to Boeing Alert Service Bulletin 707 A3515, dated December 19, 2007. When the service bulletin
specifies contacting Boeing for repair instructions, the repair must be approved by the FAA in accordance
with paragraph (n) of the AD. All provisions of AD 2012-17-13 that are not specifically referenced in
this paragraph remain fully applicable and must be complied with accordingly.
G. Manpower
The table below shows an estimate of the task-hours necessary to do this service bulletin for each
airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with
operator task-hour data if necessary. The estimate does not include lost time. These are some examples
of lost time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.51.02Open Access
(a)(a)-Part 1
0.5(b)1.0(b)2Part 2
6.526.04Part 3
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Elapsed HoursTask HoursNumber of Per-
sons
Task
8.032.04Part 4
6.024.04Part 5
(c)(c)(c)Part 6
0.51.02Close Access
(d)(d)TOTAL FOR EACH AIRPLANE
(a) Considered Lost Time. Not able to estimate.
(b) Covers conductivity test only, does not include maintenance record review.
(c) No estimate is available.
(d) No total is given because of the variability in time required for Part 1, Part 2
and Part 6 activities.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 18101-2RS
b. Boeing Service Bulletin 707-3356, 707-3381
c. Service Related Problem (SRP) 707-SRP-55-0033.
d. 707 Supplemental Structural Inspection Document (SSID) D6-44860, Revision P, Item
55-A25-03, 55-A35-03 and 55-A45-03.
e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2012-17-13, 85-12-01 R1
f. Standard Overhaul Practices Manual (SOPM) 20-41-05
g. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-12, 20-10-19
h. 707, 720 Non-Destructive Testing (NDT) Manual Part 1, 51-01-00, Part 6, 51-00-00, Part 6,
55-10-07
i. 707 Aircraft Maintenance Manual (AMM) 27-07-31
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2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None.
K. Publications Affected
None.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
None.
B. Industry Support Information
Boeing warranty remedies are not available for the inspection procedures given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts:
None.
2. Parts and Materials Supplied by the Operator:
NotesNameQTYPart Number / Specification
(a) (d)Upper Chord, Inboard, Left Side165-95600-887
(a) (e)Upper Chord, Inboard, Right Side165-95600-888
(a) (f)Lower Chord, Inboard, Left Side165-95600-701
(a) (g)Lower Chord, Inboard, Right Side165-95600-702
(a) (j)Center Rear Spar, Left Side165-95600-703
(a) (k)Center Rear Spar, Right Side165-95600-704
(a) (h)Upper Chord, Outboard, Left Side165C80665-165
(a) (h)Lower Chord, Outboard, Right Side165C80665-165
(a) (i)Lower Chord, Outboard, Left Side165C80665-166
(a) (i)Upper Chord, Outboard, Right Side165C80665-166
(b)Corrosion Inhibiting compound1 PintBMS 3-23 Type II
(a) Discard the existing part.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(c)  This note has been deleted.
(d) 65-95600-887 is the same as 65-3321-27 plus two 66-11433-4 bushings.
(e) 65-95600-888 is the same as 65-3321-28 plus two 66-11433-4 bushings.
(f) 65-95600-701 is the same as 65-3322-15 plus two 69-38158-1 bushings plus two 69-38158-2 bushings.
(g) 65-95600-702 is the same as 65-3322-16 plus two 69-38158-1 bushings plus two 69-38158-2 bushings.
(h) 65C80665-165 is the same as 65-05201-3.
(i) 65C80665-166 is the same as 65-05201-4.
(j) 65-95600-703 is the same as 65-3323-27 plus two 66-11433-2 bushings.
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NotesNameQTYPart Number / Specification
(k) 65-95600-704 is the same as 65-3323-28 plus two 66-11433-2 bushings.
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 operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this
Service Bulletin. Tool price and supply data are not given.
F. Special Tooling Necessary to do this Service Bulletin
See 707, 720 NDT Manual Part 1, 51-01-00.
– 8MIT65-6088
– 9MIT65-6088
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3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– 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 and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque limits to tighten nuts and bolts are in SRM Chapter 51
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51. Alternate fasteners are listed in SRM Chapter 51.
5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,
and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.
6. The necessary conditions for selection of clamp type and size are included in SWPM
20-10-12. If any wire bundle support clamp specified in this service bulletin does not
make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted
procedure to select a clamp that fits correctly.
7. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
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.
9. Boeing Service Letter 707-SL-51-029 Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
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10. Refer to APPENDIX A, for configuration verification, inspection, material data results
form..
11. 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.
12. 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.
13. 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.
The removed part can be discarded if a new or serviceable part is installed.
14. This service bulletin includes functional test procedures for the systems changed by
this service bulletin. More functional tests can possibly be necessary in accordance
with standard maintenance practices because of interruption to other airplane systems.
15. Some Boeing parts are supplied in a temporary configuration. Those parts are
identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is
permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'
(dash) part number. Boeing Drawing 005W0900 contains more data.
B. WORK INSTRUCTIONS
1. Part 1 - Cycle Counting Procedure
a. Determine flight cycles.
NOTE: The term "flight cycle" wherever stated in this bulletin is defined as any one of the
following:
1. A complete flight cycle (takeoff and full stop landing).
2. Any touch-and-go cycle within a flight cycle for which the airplane makes
a runway approach, with or without runway contact.
2. Part 2 - Configuration Records Inspection
a. Refer to APPENDIX A for definition of the inboard and outboard segments of the left and right
horizontal stabilizer rear spar upper and lower chords. Determine the material of all of the
spar chord segments listed in APPENDIX A using one of the following methods.
(1) Review the airplanes maintenance records or the previously completed APPENDIX A
data sheet to identify the location of the upper and lower chords on the horizontal stabilizer
rear spar that are made from 7079. If the material cannot be conclusively determined, do
step (2).
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(2) Do a conductivity test to determine whether each upper chord and lower chord segment
on the horizontal stabilizer rear spar listed in APPENDIX A is made from 7079-T6 or
7075-T73511 material in accordance with 707, 720 NDT, Part 6, 51-00-00, Figure 20,
dated April 5, 2004.
b. Optional.
(1) Record the material of each upper chord and lower chord segment on the APPENDIX A
data sheet. Describe any existing repairs in the "Comments" field.
(2) Retain the APPENDIX A data sheet with the airplane records.
3. Part 3 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Inboard - Upper Chord - Stabilizer
Station -13.179 to 92.55.
Upper Chords, Horizontal Stabilizer Rear Spar, Inboard Segment, Made From 7075 and 7079
a. Do a special detailed inspection of the upper chord.
(1) Inspect for cracks in the forward flange of the chord along the fasteners common to the
skin. Inspect from the inboard edge of the inspar skin to 25.5 inches outboard in
accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 1.
(2) Inspect for cracks in the space between the inspar skin and the forward edge of the
exposed upper surface of the chord. Inspect from the side of the body outboard to Stabilizer
Station 92.55 in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 2.
(3) Inspect for cracks in the space between the trailing edge skin and the aft edge of the
exposed upper surface of the chord. Inspect from the side of the body outboard to Stabilizer
Station 92.55 in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 2.
(4) Inspect for cracks in the aft flange of the chord along the fasteners common to the skin.
Inspect from the inboard edge of the trailing edge skin to 25.5 inches outboard in
accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 3.
(5) Inspect for cracks along the forward and aft edges of the exposed upper surface of the
chord. Inspect from the side of the body outboard to Stabilizer Station 92.55 in accordance
with 707, 720 NDT Manual Part 6, 55-10-07, Figure 7.
b. If a crack is found:
(1) Contact Boeing for repair instructions or
(2) Replace the spar chord as given in Accomplishment Instructions Paragraph 3.B.6. Part
6.
c. Apply corrosion inhibiting compound BMS 3-23 or equivalent to the exposed area of the chord.
Refer to SOPM 20-41-05 as an accepted procedure.
d. Put the airplane back to a serviceable condition.
4. Part 4 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Upper and Lower Chord - Web
Flange - Stabilizer Station 92.55 to 272.55
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Upper and Lower Chords, Horizontal Stabilizer Rear Spar, Made From 7079
a. Remove and keep the elevator balance bay number 2 through number 5 panels. Refer to 707
AMM 27-07-31 as an accepted procedure.
b. Remove and keep the cove shells and supporting structures as required to get access to the
aft surface of the vertical flanges of the upper and lower chords.
c. Do a High Frequency Eddy Current (HFEC) inspection of the web flanges of the upper and
lower chords between stabilizer station 92.55 and 272.55 for cracks as given in FIGURE 1.
d. If a crack is found:
(1) Replace the spar chord as given in Accomplishment Instructions Paragraph 3.B.6. Part
6 or
(2) Complete steps (a) and (b) that follow:
(a) Determine if the crack meets the limits defined in Boeing Service Bulletin 707-3356
and has been repaired according to Boeing Service Bulletin 707-3356.
1) For each crack that meets the limits of Boeing Service Bulletin 707-3356, Part
III - Repair, Notes (a) and (b), contact Boeing for new repair instructions.
2) For each crack that has been repaired according to Boeing Service Bulletin
707-3356, Part III - Repair Paragraph C, determine if the crack still meets the
limits of Boeing Service Bulletin 707-3356, Part III - Repair Paragraph C, and
determine if the crack meets the following supplemental limits:
a) The crack path must be within the limits as given in FIGURE 1, View B-B.
b) The crack must terminate in an existing fastener hole.
c) There must be two or more fastener locations in the repair area as given
in FIGURE 1, View B-B that have no cracks indicated in the adjacent spaces.
d) A stiffener bay with a crack in the upper chord must not also have a crack
in the upper or lower chord of either of the adjacent stiffener bays.
e) A stiffener bay with a crack in the lower chord must not also have a crack
in the upper or lower chord of either of the adjacent stiffener bays.
3) For a crack that meets the limits of Boeing Service Bulletin 707-3356, Part III -
Repair Paragraph C, but is not repaired as given in Boeing Service Bulletin
707-3356, Part III - Repair Paragraph C, accomplish the repair as given in Boeing
Service Bulletin 707-3356, Part III - Repair Paragraph C. Obey the supplemental
limits that follow:
a) The crack path must be within the limits as given in FIGURE 1, View B-B.
b) The crack must terminate in an existing fastener hole.
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c) There must be two or more fastener locations in the repair area as given
in FIGURE 1, View B-B that have no crack indicated in the adjacent spaces.
d) A stiffener bay with a crack in the upper chord must have no crack in the
upper or lower chord of either of the adjacent stiffener bays.
e) A stiffener bay with a crack in the lower chord must have no crack in the
upper or lower chord of either of the adjacent stiffener bays.
4) For a crack that meets the limits of Boeing Service Bulletin 707-3356, Part III -
Repair Paragraph D, accomplish the repair according to Boeing Service Bulletin
707-3356, Part III - Repair Paragraph D, unless already accomplished.
5) For a crack that does not meet the limits defined in the preceding paragraphs
1., 2., 3., & 4. above, contact Boeing for new repair instructions.
(b) Determine if all 7079 upper and lower chord segments installed on the horizontal
stabilizer have had Boeing Service Bulletin 707-3356 Part II, Group 1 Preventative
Modification done. If not yet accomplished, do the Boeing Service Bulletin 707-3356
Part II, Group 1 Preventative Modification on all 7079 chord segments still installed
on the horizontal stabilizer.
NOTE: Boeing Service Bulletin 707-3356 Part II, Group 1 Preventative Modification
is applicable to airplanes for which all chord segments (upper and lower
inboard, upper and lower outboard) are made from 7079. It is therefore
inclusive of all configurations where 7079 chord segments remain. Since
7079 chords may have been replaced with 7075 chords, it is only necessary
to do the modification where the 7079 chord segments are identified.
e. Apply corrosion inhibiting compound BMS 3-23 or equivalent to the exposed area of the
horizontal stabilizer rear spar chords. Refer to SOPM 20-41-05 as an accepted procedure.
f. Restore the airplane to a serviceable condition.
5. Part 5 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Upper and Lower Chord - Forward
Skin Flange - Stabilizer Station -13.179 to 272.55
Upper and Lower Chords of the Horizontal Stabilizer Rear Spar Made From 7079
a. Remove and keep the elevator balance bay number 0 through number 5 panels. Refer to 707
AMM 27-07-31 as an accepted procedure.
b. Do a Low Frequency Eddy Current (LFEC) inspection of the forward skin flange of the upper
chord between stabilizer station 182.55 and 272.55 for cracks as given in FIGURE 2.
c. Do a LFEC inspection of the forward skin flange of the upper chord between stabilizer station
92.55 and 182.55 for cracks as given in FIGURE 3.
d. Do a LFEC inspection of the forward skin flange of the lower chord between stabilizer station
182.55 and 272.55 for cracks as given in FIGURE 4.
e. Do a LFEC inspection of the forward skin flange of the lower chord between stabilizer station
92.55 and 182.55 for cracks as given in FIGURE 5.
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f. Do a LFEC inspection of the forward skin flange of the lower chord between stabilizer station
-13.179 and 92.55 for cracks as given in FIGURE 6.
g. If a crack is found:
(1) Replace the lower chord as given in Accomplishment Instructions Paragraph 3.B.6. Part
6 or
(2) Complete steps (a) and (b) that follow:
(a) Contact Boeing for repair instructions.
(b) Determine if all 7079 upper and lower chord segments installed on the horizontal
stabilizer have had Service Bulletin 707-3381 Part II - Preventative Modification
accomplished. If not yet accomplished, do the Service Bulletin 707-3381 Part II -
Preventative Modification on all 7079 chord segments still installed on the horizontal
stabilizer.
NOTE: Service Bulletin 707-3381 Part II - Preventative Modification is applicable
to airplanes for which all chord segments (upper and lower inboard, upper
and lower outboard) are made from 7079. It is therefore inclusive of all
configurations where 7079 chord segments remain. Since 7079 chords may
have been replaced with 7075 chords, it is only necessary to do the
modification where the 7079 chord segments are identified.
h. Apply corrosion inhibiting compound BMS 3-23 or equivalent to exposed area of the upper
and lower chords. Refer to SOPM 20-41-05 as an accepted procedure.
i. Restore the airplane to a serviceable condition.
6. Part 6 - Chord Replacement
a. Replace the applicable rear spar chord segment or segments according to standard procedures
and instructions supplied with the applicable parts kits and tooling. Reference assembly
drawing 65-3321, 65-3322 and 65-3323 for the rear spar upper, lower and center inboard
chords respectively.
b. Upon completion of chord replacement, revise the data on the APPENDIX A data sheet to
match the chord configuration currently on the airplane.
c. Retain the updated APPENDIX A data sheet with the airplane records
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 19, 2007
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BOEING SERVICE BULLETIN A3515
ALERTALERT

### Page 31 (OCR)

BOEING SERVICE BULLETIN А3515
ALERT  ALERT
¡EFRONT SPAR
STAB STA
47.55
STAB STA
92.55
CREAR SPAR
STAB STA
137.55
STAB STA
182.55  •@ELEVATOR
STAB STA  HINGE
227.55
STAB STA
272.55
BALANCE
CHORD  BALANCE  BAY NO.O
BAY NO.1
1101 102. 101 101 101  BALANCE
BALANCE  BAY NO.2
BAY NO.4  BALANCE
BALANCE  BAY NO.3
BAY NO.5
A-A
LEFT HORIZONTAL STABILIZER SHOWN,
RIGHT OPPOSITE
496234
FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUTBOARD
- CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 - INSPECTION
(SHEET 1 OF 2)
Original Issue: December 19, 2007
Revision 1 October 10, 2014  PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  A3515
Work - See page 1 for details.  31 of 38

### Page 32

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
--Number 2, 3, 4 and 5Balance BayAccess1
See Table 1.(a)2-Chord Web FlangeInspect2
(a) Do a High Frequency Eddy Current (HFEC) inspection of the left and right side horizontal stabilizer rear
spar upper and lower inboard and outboard chord web flange between stabilizer station 92.55 and 272.55 for
any cracking. Use a pencil probe to scan the aft surface of the chord vertical flange between fasteners and
along the tangent line of the flange fillet in accordance with 707, 720 NDT, Part 6, 51-00-00, Figure 4.
Table 1
Balance Bay to Inspect7079 Chord Segment
2,3Upper Inboard
2,3Lower Inboard
4,5Upper Outboard
4,5Lower Outboard
FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUTBOARD
- CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 - INSPECTION
(SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING
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BOEING SERVICE BULLETIN A3515
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### Page 33

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear
spar upper outboard chord forward skin flange between stabilizer station 182.55 and 272.55 for any cracking
in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION
(SHEET 1 OF 1)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 19, 2007
A3515Revision 1 October 10, 2014
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BOEING SERVICE BULLETIN A3515
ALERTALERT

### Page 34

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear
spar upper inboard chord forward skin flange between stabilizer station 92.55 and 182.55 for any cracking
in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
FIGURE 3: HORIZONTAL STABILIZER - REAR SPAR - UPPER INBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION
(SHEET 1 OF 1)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 19, 2007
A3515Revision 1 October 10, 2014
34 of 38
BOEING SERVICE BULLETIN A3515
ALERTALERT

### Page 35

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear
spar lower outboard chord forward skin flange between stabilizer station 182.55 and 272.55 for any cracking
in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
FIGURE 4: HORIZONTAL STABILIZER - REAR SPAR - LOWER OUTBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION
(SHEET 1 OF 1)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 19, 2007
A3515Revision 1 October 10, 2014
35 of 38
BOEING SERVICE BULLETIN A3515
ALERTALERT

### Page 36

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a) (b)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear
spar lower inboard chord forward skin flange between stabilizer station 92.55 and 182.55 for any cracking in
accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
(b) Exclude inspection of areas not accessible due to interference with any vortex generators mounted on
the lower surface. However, if any cracks are found at any of the first six (6) inspectable fasteners on either
side of the vortex generator, remove the vortex generator and inspect all fastener locations.
FIGURE 5: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION
(SHEET 1 OF 1)
Export Controlled ECCN: 9E991 - BOEING
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Work - See page 1 for details.
Original Issue: December 19, 2007
A3515Revision 1 October 10, 2014
36 of 38
BOEING SERVICE BULLETIN A3515
ALERTALERT

### Page 37

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a) (b)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear
spar lower inboard chord forward skin flange between stabilizer station -13.179 and 92.55 for any cracking
in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
(b) Exclude inspection of areas not accessible due to interference with any vortex generators mounted on the
lower surface. However, if any cracks are found at any of the first six (6) inspectable fasteners on either side
of the vortex generator, remove the vortex generator and inspect all fastener locations.
FIGURE 6: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN
FLANGE - STABILIZER STATION -13.179 TO STABILIZER STATION 92.55 - INSPECTION
(SHEET 1 OF 1)
Export Controlled ECCN: 9E991 - BOEING
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BOEING SERVICE BULLETIN A3515
ALERTALERT

### Page 38

FLIGHT CYCLES:FLIGHT HOURS:AIRPLANE REGISTRY:
LEFT SIDE Horizontal Stabilizer
Stabilizer Serial Number (a):Stabilizer Part Number (a):
Spar Chord Material (b): (from Part 2 - Configuration
Check)
LocationSpar Chord Seg-
ment
Side of Body to SSTA 182.55Upper Inboard
Side of Body to SSTA 182.55Lower Inboard
SSTA 182.55 to Stabilizer TipUpper Outboard
SSTA 182.55 to Stabilizer TipLower Outboard
RIGHT SIDE Horizontal Stabilizer
Stabilizer Serial Number (a):Stabilizer Part Number (a):
Spar Chord Material (b) (from Part 2 - Configuration
Check)
LocationSpar Chord Seg-
ment
Side of Body to SSTA 182.55Upper Inboard
Side of Body to SSTA 182.55Lower Inboard
SSTA 182.55 to Stabilizer TipUpper Outboard
SSTA 182.55 to Stabilizer TipLower Outboard
Record the horizontal stabilizer part number and serial number as recorded on the data
plate.
(a)
Record spar chord material, 7079-T6 or 7075-T73511, as determined from maintenance
record review, or electrical conductivity test. Do the electrical conductivity test in accordance
with 707 Non-Destructive Testing (NDT) Manual D6-48023 Part 6, 51-00-00, Figure 20,
dated April 5, 2004, and Boeing Process Specification BAC5946, Table I, Page 12, Revision
(AA) dated July 9, 2001.
(b)
Comments:
.
.
.
.
.
.
Appendix A: CONFIGURATION VERIFICATION - INSPECTION RESULTS FORM - MATERIAL DATA
(SHEET 1 OF 1)
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