# Boeing Alert Service Bulletin DC10-57A156: Boeing - Service Bulletin

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### Page 1

Commercial 
Airplanes
DC10
Service Bulletin
ALERT
Number: DC10-57A156
Original Issue: September 16, 2009
Revision 2: August 23, 2011
ATA System: 5711
SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between
Stations Xors=400 and Xors=417
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 © 2009 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Unpublished Work - All Rights Reserved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.
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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 3
B. Concurrent Requirements ...................................... 1 3
C. Reason ................................................ 1 3
D. Description .............................................. 1 3
E. Compliance .............................................. 1 7
F. Approval ............................................... 2 3
G. Manpower .............................................. 2 4
H. Weight and Balance Changes .................................... 2 4
I. Electrical Load Data ......................................... 2 4
J. References .............................................. 2 4
1. Existing Data .......................................... 2 4
2. Data supplied with this Service Bulletin ............................ 2 5
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 5
K. Publications Affected ........................................ 2 5
L. Interchangeability and Intermixability of Parts ........................... 2 6
2. MATERIAL INFORMATION ........................................ 2 7
A. Material - Price and Availability ................................... 2 7
B. Industry Support Information .................................... 2 7
C. Parts Necessary For Each Airplane ................................. 2 7
1. Kits/Parts ............................................ 2 7
2. Parts and Materials Supplied by the Operator ........................ 3 9
3. Parts Modified and Reidentified ................................ 3 9
4. Parts Removed and Not Replaced .............................. 4 0
D. Parts Necessary to Change Spares ................................. 4 0
E. Special Tooling - Price and Availability ............................... 4 0
F. Special Tooling Necessary to do this Service Bulletin ....................... 4 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 1
A. GENERAL INFORMATION ..................................... 4 1
B. WORK INSTRUCTIONS ....................................... 4 2
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Commercial 
Airplanes
DC10
Service Bulletin
ALERT
Revision Transmittal SheetNumber: DC10-57A156Original Issue: September 16, 2009
Revision 2: August 23, 2011
ATA System: 5711
SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between
Stations Xors=400 and Xors=417
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is related to
this service bulletin.
No more work is necessary on the airplane(s) changed in accordance with Revision 1 of this service bulletin.
REASON FOR REVISION
This revision is sent to instruct operators to contact The Boeing Company for repair instructions if cracks that
can not be removed by enlarging fastener hole(s) are found between Stations Xors=400 and inboard of Xors=408.
The data given in Information Notice DC10-57A156 IN 01 is included in this revision.
These sections were changed:
1. In Paragraph 1.D., Description, added new conditions to reflect station location limitations.
2. In Paragraph 1.E., Compliance, added NPRM information and added Compliance Tables to show added
conditions.
3. In Paragraph 1.F., Approval, changed approval statement.
4. In Paragraph 1.J.1., References, added NPRM information.
5. In Paragraph 1.J.2., Data supplied with this Service Bulletin, changed drawing revision level as applicable.
6. In Paragraph 2.A., Material - Price and Availability, added pricing and Reorder Lead Time (ROLT) information.
7. In Paragraph 2.C.1., Kits/Parts, corrected part numbers.
8. In Paragraph 3.A., General Information, added new notes and renumbered existing notes.
9. In Paragraph 3.B., Accomplishment Instructions, added new conditions and work steps.
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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 16, 2009Original Issue:
March 10, 2010Revision 1:
August 23, 2011Revision 2:
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Commercial 
Airplanes
DC10
Service Bulletin
ALERT
SummaryNumber: DC10-57A156Original Issue: September 16, 2009
Revision 2: August 23, 2011
ATA System: 5711
SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between
Stations Xors=400 and Xors=417
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
Operators have reported 3 instances of DC-10-10F/MD-10-10F airplanes having a fuel leak in the wing rear
spar lower cap at Station Xors=409. Affected airplanes had the gross weight doublers installed and operators
had previously accomplished Service Bulletin DC10-57-138. Investigation revealed the fuel leak was due to a
crack in the lower cap. This crack extended into all three legs (aft, forward, and vertical) of the spar cap.
Metallurgical analysis of the cracked portion of the spar cap determined that the crack was due to fatigue and
began at a fastener hole in the aft leg of the spar cap. Inspecting spar cap fastener holes for cracks, will determine
the condition of spar cap. Repairing cracks in the spar cap, will minimize crack migration. If not corrected, an
undetected crack in spar cap may lead to fuel leaks or cracking of the lower wing skin and structure causing
extensive spar cap repairs or replacement and possible inability to sustain the limit load.
ACTION
Refer to Paragraph 1.D., for Description.
EFFECTIVITY
DC-10-10, DC-10-10F, and MD-10-10F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected
airplanes.
COMPLIANCE
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is related to
this service bulletin.
Refer to Paragraph 1.E., for Compliance.
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INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN DC10-57A156
ALERT  ALERT
INSPECT/REPAIR WING REAR SPAR
LOWER CAP BETWEEN STATIONS
XORS=400 AND XORS=417
1859290
Original Issue: September 16, 2009
Revision 2: August 23, 2011  DC10-57A156
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Copyright © Unpublished Work - See page 1 for details.  9 of 47

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ALERTALERT
BLANK PAGE

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Commercial 
Airplanes
DC10
Service Bulletin
ALERT
Number: DC10-57A156
Original Issue: September 16, 2009
Revision 2: August 23, 2011
ATA System: 5711
SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between
Stations Xors=400 and Xors=417
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
DESCRIPTIONCONFIGURATIONGROUP
MD-10 airplane fuselages 6 and 8 that were modified in accordance
with Service Modification Drawing SM10570022.
-1
DC-10/MD-10 airplanes except for fuselages 6 and 8 that have been
modified in accordance with Service Modification Drawing
SM10570022.
-2
Airplane Models:
DC-10-10, DC-10-10F, MD-10-10F
GroupFuselage Num-
ber
16
18
215
217
225 - 27
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GroupFuselage Num-
ber
232 - 35
239 - 43
255
259
261 - 62
270
272
276
278
286
289
2112
2119
2138 - 140
2142
2144 - 145
2148
2153 - 155
2173
2177
2198
2203
2205
2207 - 210
2247
2249 - 250
2269 - 273
2294
2297 - 298
2307
2309
2319
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GroupFuselage Num-
ber
2321
2323
2344
2347
2351
2353
2379
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Operators have reported 3 instances of DC-10-10F/MD-10-10F airplanes having a fuel leak in the wing
rear spar lower cap at Station Xors=409. Affected airplanes had the gross weight doublers installed
and operators had previously accomplished Service Bulletin DC10-57-138. Investigation revealed the
fuel leak was due to a crack in the lower cap. This crack extended into all three legs (aft, forward, and
vertical) of the spar cap. Metallurgical analysis of the cracked portion of the spar cap determined that
the crack was due to fatigue and began at a fastener hole in the aft leg of the spar cap. Inspecting spar
cap fastener holes for cracks, will determine the condition of spar cap. Repairing cracks in the spar
cap, will minimize crack migration. If not corrected, an undetected crack in spar cap may lead to fuel
leaks or cracking of the lower wing skin and structure causing extensive spar cap repairs or replacement
and possible inability to sustain the limit load.
Revision 1 was sent to correct a drawing callout in the description.
Revision 2 is sent to instruct operators to contact The Boeing Company for repair instructions if cracks
that can not be removed by enlarging the fastener hole(s) are found between Stations Xors=400 and
inboard of Xors=408.
The data given in Information Notice DC10-57A156 IN 01 is included in this revision.
D. Description
This service bulletin provides instructions to do an Eddy Current Test High Frequency (ETHF) inspection
for cracks on the left and right wing rear spar lower cap between the outboard edge of the rear spar
lower cap splice at Station Xors=400 and Station Xors=417. Based on inspection results this service
bulletin does as follows:
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Condition 1 (No Crack)
1. Does repeat ETHF inspections.
Condition 2 (Crack at Fastener Hole that can be Removed by Hole Enlargement)
1. Does repair as follows:
a. If crack(s) are found on the left wing, does permanent repair in accordance with Service
Rework Drawing SR10570048-7001, Detail D..
b. If crack(s) are found on the right wing, does permanent repair in accordance with Service
Rework Drawing SR10570048-7003, Detail D.
2. Does repeat ETHF inspections of the spar cap and HFEC inspections of the lower wing skin in
the repaired area and does as follows:
Condition 2A (No Crack Found)
a. Does repeat ETHF inspections of the spar cap and HFEC inspections of the lower wing skin
in the repaired area.
Condition 2B (Any Crack Found)
a. Evaluates the crack and does the work of Condition 2, 3 or 4 as applicable.
3. Does repeat ETHF inspections of the lower spar cap in the unchanged areas on the left and right
wing rear spar lower cap between the outboard edge of the rear spar lower cap splice at Station
Xors=400 and Station Xors=417.
Condition 2C (No Crack Found)
a. Does repeat ETHF inspections of the lower spar cap in the unchanged areas.
Condition 2D (Any Crack Found)
a. Evaluates the crack and does the work of Conditions 2, 3 or 4 as applicable.
Condition 3 (Crack in Spar Cap Aft Leg at Fastener Hole(s) that Cannot be Removed by Hole
Enlargement but does not Extend into Vertical Leg)
1. Establishes the location of the crack and based on location does the work as follows:
Condition 3A (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=400
and Inboard of Xors=408)
a. Contacts The Boeing Company for repair instructions and does the repair.
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Condition 3B (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=408
and Xors=417)
a. Does repair as follows:
(1) If crack(s) are found on the left wing, does permanent repair in accordance with Service
Rework Drawing SR10570048-7021.
(2) If crack(s) are found on the right wing, does permanent repair in accordance with Service
Rework Drawing SR10570048-7023.
b. Does repeat ETHF and Ultrasonic (UT) inspections of the repaired area and does as follows:
Condition 3C (No Crack Found)
Does repeat ETHF and Ultrasonic (UT) inspections of the repaired area.
Condition 3D (Any Crack Found)
Contacts The Boeing Company for repair instructions and does the repair.
Condition 4 (Crack that Extends into the Vertical Leg of Spar Cap)
1. Establish the location of the crack and do as follows:
Condition 4A (Crack is Between Station Xors=400 and Inboard of Xors=408)
a. Do permanent repair as follows:
If crack(s) are found on the left wing, does permanent repair in accordance with Service
Rework Drawing SR10570019-7013.
If crack(s) are found on the right wing, does permanent repair in accordance with Service
Rework Drawing SR10570019-7015.
b. Does repeat ETHF and UT inspections of the permanent repair(s) for cracks and does as
follows:
Condition 4B (No Crack Found in Permanent Repair)
Does repeat ETHF and UT inspections for cracks
Condition 4C (Any Crack Found in Permanent Repair)
Contacts The Boeing Company for repair instructions and does the repair.
Condition 4D (Crack is Between Station Xors=408 and Xors=417)
a. Do Option 1 or Option 2
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Option 1
(1) Does repair as follows:
Group 1:
If crack(s) are found on left wing, does temporary repair in accordance with Service
Rework Drawing SR10570048-7025.
Group 1:
If crack(s) are found on right wing, does temporary repair in accordance with Service
Rework Drawing SR10570048-7027.
Group 2:
If crack(s) are found on left wing, does temporary repair in accordance with Service
Rework Drawing SR10570048-7029.
Group 2:
If crack(s) are found on right wing, does temporary repair in accordance with Service
Rework Drawing SR10570048-7031.
(2) Does repeat ETHF and UT inspections for the service life of the temporary repair(s) for
cracks and does as follows:
Condition 4E (No Crack Found in Temporary Repair)
Does repeat ETHF and UT inspections for the service life of the temporary repair(s) for
cracks.
Condition 4F (Any Crack Found in Temporary Repair)
Contacts The Boeing Company for repair instructions and does the repair.
(3) Does permanent repair upon or prior to reaching the end of the service life of temporary
repair(s) as follows:
If a temporary repair was installed on the left wing, replaces temporary repair in accordance
with Paragraph 1.E., Compliance and Service Rework Drawing SR10570019-7013.
If a temporary repair was installed on the right wing, replaces temporary repair in
accordance with Paragraph 1.E., Compliance and Service Rework Drawing
SR10570019-7015.
(4) Does repeat ETHF and UT inspections of the permanent repair(s) for cracks and does
as follows:
Condition 4G (No Crack Found in Permanent Repair)
Does repeat ETHF and UT inspections for cracks.
Condition 4H (Any Crack Found in Permanent Repair)
Contacts The Boeing Company for repair instructions and does the repair.
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Option 2
(1) Does repair as follows:
If crack(s) are found on left wing, does permanent repair in accordance with Service
Rework Drawing SR10570019-7013.
If crack(s) are found on right wing, does permanent repair in accordance with Service
Rework Drawing SR10570019-7015.
(2) Does repeat ETHF and UT inspections of the permanent repair(s) for cracks and does
as follows:
Condition 4I (No Crack Found in Permanent Repair)
Does repeat ETHF and UT inspections for cracks
Condition 4J (Any Crack Found in Permanent Repair)
Contacts The Boeing Company for repair instructions and does the repair.
Revision 2 - No more work is necessary on airplane(s) changed in accordance with Revision 1 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
535, 635MD-10-10F
Group 2:
Affected Maintenance Zones
ZoneModel
535, 635DC-10-10, DC-10-10F, MD-10-
10F
E. Compliance
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is
related to this service bulletin.
Accomplish the required action(s), based on the applicable condition(s), in Table(s) 1 through 5, in
accordance with Paragraph 3. Accomplishment Instructions.
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Table 1: Inspect Left and Right Side Wing Rear Spar Lower Caps for Cracks between the Outboard Edge
of the Rear Spar Lower Cap Splice at Station Xors=400 and Station Xors=417
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Within 1,750 flight cy-
cles after the original
issue date on this ser-
vice bulletin.
Do Eddy Current Test High
Frequency (ETHF) inspection
for cracks on the left and right
wing rear spar lower cap be-
tween the outboard edge of the
rear spar lower cap splice at
Station Xors=400 and Station
Xors=417.
All Airplanes
1,750 flight cycles.-Do ETHF inspection for cracks
on the left and right wing rear
spar lower cap between the
outboard edge of the rear spar
lower cap splice at Station
Xors=400 and Station
Xors=417.
Condition 1 (No Crack
Found)
-Before further flight.Do permanent repair in accor-
dance with Accomplishment In-
struction 3.B.
Condition 2 (Crack
Found at Fastener Hole
that can be Removed
by Hole Enlargement) AND
-Within 1,750 flight cy-
cles after repair is ac-
complished.
Do ETHF inspection of the lower
spar cap and HFEC inspection
of the lower wing skin in the re-
paired area.
AND
Do the action specified by Con-
dition 2A or 2B.
1,750 flight cycles.-Do ETHF inspection of the lower
spar cap and HFEC inspection
of the lower wing skin in the re-
paired area.
Condition 2A (No Crack
Found in Repaired
Area)
-Before further flight.Evaluate the crack and do the
work of Condition 2, 3 or 4 as
applicable.
Condition 2B (Any
Crack Found in Re-
paired Area)
AND
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Table 1: Inspect Left and Right Side Wing Rear Spar Lower Caps for Cracks between the Outboard Edge
of the Rear Spar Lower Cap Splice at Station Xors=400 and Station Xors=417
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Within 1,750 flight cy-
cles after repair is ac-
complished.
Do ETHF inspections in the un-
changed areas on the left and
right wing rear spar lower cap
between the outboard edge of
the rear spar lower cap splice at
Station Xors=400 and Station
Xors=417.
AND
Do the action specified by Con-
dition 2C or 2D.
1,750 flight cycles.-Do ETHF inspections in the un-
changed areas on the left and
right wing rear spar lower cap
between the outboard edge of
the rear spar lower cap splice at
Station Xors=400 and Station
Xors=417.
Condition 2C (No Crack
Found)
-Before further flight.Evaluate the crack and do the
work of Condition 2, 3 or 4 as
applicable.
Condition 2D (Any
Crack Found)
-Before further flight.Establish the location of the
crack and do the actions speci-
fied by Condition 3A or 3B.
Condition 3 (Crack
Found in Spar Cap Aft
Leg at Fastener Hole(s)
that Cannot be Re-
moved by Hole Enlarge-
ment but does not Ex-
tend into Vertical Leg)
-Before further flight.Contact The Boeing Company
for repair instructions and do the
repair.
Condition 3A (Crack
Found in Spar Cap Aft
Leg at Fastener Hole(s)
Between Station
Xors=400 and Inboard
of Xors=408)
-Before further flight.Do permanent repair.Condition 3B (Crack
Found in Spar Cap Aft
Leg at Fastener Hole(s)
Between Station
Xors=408 and
Xors=417)
AND
-Within 4,550 flight cy-
cles after repair is ac-
complished.
Do ETHF and Ultrasonic (UT)
inspections in the repaired area.
AND
Do the action specified by Con-
dition 3C or 3D.
4,550 flight cycles.-Do ETHF and Ultrasonic (UT)
inspections in the repaired area.
Condition 3C (No Crack
Found)
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Table 1: Inspect Left and Right Side Wing Rear Spar Lower Caps for Cracks between the Outboard Edge
of the Rear Spar Lower Cap Splice at Station Xors=400 and Station Xors=417
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Before further flight.Contact The Boeing Company
for repair instructions and do the
repair.
Condition 3D (Any
Crack Found)
-Before further flight.Establish the location of the
crack and do the action speci-
fied by Condition 4A or 4D.
Condition 4 (Crack
Found that Extends into
the Vertical Leg of Spar
Cap)
-Before further flight.Do the action specified in Table
2.
Condition 4A (Crack
Found that Extends into
the Vertical Leg of Spar
Cap is Between Station
Xors=400 and Inboard
of Xors=408)
-Before further flight.Do the action specified in Table
3 (Option 1) or Table 5 (Option
2).
Condition 4D (Crack
Found that Extends into
the Vertical Leg of Spar
Cap is Between Station
Xors=408 and
Xors=417)
Table 2: Crack Found that Extends into the Vertical Leg of Spar Cap is Between Station Xors=400 and
Inboard of Xors=408
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Before further flight.Do permanent repair.Condition 4A (Crack
Found that Extends into
the Vertical Leg of Spar
Cap is Between Station
Xors=400 and Inboard
of Xors=408)
AND
-In accordance with DC-
10 Supplemental In-
spection Document
(SID) Volume II, Chap-
ter 57-50-03, Principal
Structural Element
(PSE) 57.10.007 and
57.10.008.
Do ETHF and UT inspection of
the repaired.
AND
Do the action specified by Con-
dition 4B or 4C.
In accordance with DC-10
Supplemental Inspection
Document (SID) Volume II,
Chapter 57-50-03, Principal
Structural Element (PSE)
57.10.007 and 57.10.008.
-Do repeat ETHF and UT inspec-
tion.
Condition 4B (No Crack
Found)
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### Page 21

Table 2: Crack Found that Extends into the Vertical Leg of Spar Cap is Between Station Xors=400 and
Inboard of Xors=408
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Before further flight.Contact The Boeing Company
for repair instructions and do the
repair.
Condition 4C (Any
Crack Found)
Table 3: Temporary Repair of Crack that Extends into the Vertical Leg of Spar Cap is Between Station
Xors=408 and Xors=417 (Option 1)
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Before further flight.Do temporary repair.Condition 4D (Crack
Found that Extends into
the Vertical Leg of Spar
Cap is Between Station
Xors=408 and
Xors=417)
AND
-Within 1,650 flight cy-
cles after temporary re-
pair is accomplished.
Do ETHF and Ultrasonic (UT)
in the repaired area.
AND
Do the action specified by Con-
dition 4E or 4F.
1,650 flight cycles.-Do ETHF and Ultrasonic (UT)
in the repaired area.
Condition 4E (No Crack
Found in Temporary
Repair) AND
-Within 7,000 flight cy-
cles after temporary re-
pair is accomplished.
Do permanent repair as speci-
fied in Table 4.
-Before further flight.Contact The Boeing Company
for repair instructions and do the
repair.
Condition 4F (Any
Crack Found in Tempo-
rary Repair)
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Table 4: Permanent Repair of Airplanes with Temporary Repair
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Within 7,000 flight cy-
cles after temporary re-
pair is accomplished.
Do permanent repair.
AND
All Airplanes with Tem-
porary Repair
-In accordance with DC-
10 Supplemental In-
spection Document
(SID) Volume II, Chap-
ter 57-50-03, Principal
Structural Element
(PSE) 57.10.007 and
57.10.008.
Do ETHF and UT inspection of
the repaired area.
AND
Do the action specified by Con-
dition 4G or 4H.
In accordance with DC-10
Supplemental Inspection
Document (SID) Volume II,
Chapter 57-50-03, Principal
Structural Element (PSE)
57.10.007 and 57.10.008.
-Do repeat ETHF and Ultrasonic
(UT) inspection.
Condition 4G (No Crack
Found)
-Before further flight.Contact The Boeing Company
for repair instructions and do the
repair.
Condition 4H (Any
Crack Found)
Table 5: Repair of Crack that Extends into the Vertical Leg of Spar Cap is Between Station Xors=408 and
Xors=417 (Option 2)
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Before further flight.Do permanent repair.Condition 4D (Crack
Found that Extends into
the Vertical Leg of Spar
Cap is Between Station
Xors=408 and
Xors=417)
AND
-In accordance with DC-
10 Supplemental In-
spection Document
(SID) Volume II, Chap-
ter 57-50-03, Principal
Structural Element
(PSE) 57.10.007 and
57.10.008.
Do ETHF and UT inspection of
the repaired area.
AND
Do the action specified by Con-
dition 4I or 4J.
In accordance with DC-10
Supplemental Inspection
Document (SID) Volume II,
Chapter 57-50-03, Principal
Structural Element (PSE)
57.10.007 and 57.10.008.
-Do repeat ETHF and UT inspec-
tion of the repaired area.
Condition 4I (No Crack
Found)
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### Page 23

Table 5: Repair of Crack that Extends into the Vertical Leg of Spar Cap is Between Station Xors=408 and
Xors=417 (Option 2)
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Before further flight.Contact The Boeing Company
for repair instructions and do the
repair.
Condition 4J (Any
Crack Found)
F. Approval
MD-10 Airplanes
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. 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.
In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.
inspection or repair) defined in this service bulletin as a method of compliance to the requirements of
MD-10 ALI PSE 57.10.007/008 and 98.26.22 as it applies to repaired structure. All provisions of MD-10
ALI PSE 57.10.007/008 and 98.26.22 that are not specifically referenced in the above statement remain
fully applicable and must be complied with.
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.
DC-10 Airplanes
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.
In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.
inspection or repair) defined in this service bulletin as an alternative method of compliance to the
requirements of paragraphs (a), (b) and (c) of Airworthiness Directive No. 98-26-22, Amendment
39-10965 and paragraph (j) of Airworthiness Directive No. 2005-14-10, Amendment 39-14187 as it
applies to repaired structure. All provisions of Airworthiness Directive No. 98-26-22 and No. 2005-14-10
that are not specifically referenced in the above statement remain fully applicable and must be complied
with.
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.
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G. Manpower
The table below shows an estimate of the task hours necessary to do this modification 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.
Elapsed HoursTask HoursNumber of PersonsTask
1.73.42Open Access
2.02.01Inspect
--2Do Repair
(a)
2.04.02Close Access
2.02.01Test
7.711.4TOTAL FOR EACH AIRPLANE
(a) Hours will vary depending on type of repair.
H. Weight and Balance Changes
Weight and balance changes affected by incorporation of this service bulletin are contingent upon the
changes to each particular airplane. Weight data is to be computed by the operator by weighing parts
removed and parts installed during this change. Necessary revisions should be made to the appropriate
airplane weight and balance report.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data
a. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM)
2009-NM-216-AD .
b. Non-Destructive Test Standard Practices Manual (NDTSPM) Part 06, 06-20-01.
c. DC-10, MD-10 Aircraft Maintenance Manual (AMM) 06-35-00, 06-36-00, 12-11-02, 12-11-05,
28-00-00.
d. DC-10, MD-10 Structural Repair Manual (SRM) 51-12-01.
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### Page 25

e. DC-10 Supplemental Inspection Document (SID) Volume II, Chapter 57-50-03, Principal
Structural Element (PSE) 57.10.007 and 57.10.008.
f. Service Modification Drawing SM10570022.
g. FAA Airworthiness Directive 98-26-22 and 2005-14-10.
h. MD-10 Airworthiness Limitations Instructions (ALI) Chapter 57, Principal Structural Element
(PSE) 57.10.007 and 57.10.008.
2. Data supplied with this Service Bulletin
No data is supplied with this service bulletin. To obtain the data necessary to support this service
bulletin submit a data request to:
Data and Services Management
MS D800-0019
3855 Lakewood Boulevard
Long Beach, California 90846
Phone: (562) 593-6996
Fax: (562) 593-2001
E-mail: dse.boecom@boeing.com
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
L-AEOREPAIR-CAP, LWR, REAR SPAR OUTER
WING SERVICE REWORK DRAWING
SR10570019
-KDWG
-KDWGSERVICE REWORK - TEMPORARY RE-
PAIR, REAR SPAR LWR CAP, DC-10-
10/15 SERVICE REWORK DRAWING
SR10570048
3. Installation Drawings Used in the Preparation of this Service Bulletin
None.
K. Publications Affected
1. Publications:
None.
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.
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### Page 26

L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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### Page 27

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. 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 2
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 2 date of
this Service Bul-
letin (Weeks)
NameKit Number
$6.6017Service KitSA10570156-3
6.6017Service KitSA10570156-5
75,398.0017Service KitSA10570156-7
75,520.0017Service KitSA10570156-9
93,777.0017Service KitSA10570156-11
99,777.0017Service KitSA10570156-13
91,919.0017Service KitSA10570156-15
100,365.0017Service KitSA10570156-17
610,016.0017Service KitSA10570156-19
610,549.0017Service KitSA10570156-21
B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes 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.
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### Page 28

SERVICE KIT APPLICABILITY
Drawing ConfigurationService Kit
SR10570048-7001SA10570156-3
SR10570048-7003SA10570156-5
SR10570048-7021SA10570156-7
SR10570048-7023SA10570156-9
SR10570048-7025SA10570156-11
SR10570048-7027SA10570156-13
SR10570048-7029SA10570156-15
SR10570048-7031SA10570156-17
SR10570019-7013SA10570156-19
SR10570019-7015SA10570156-21
Service Kit SA10570156
NotesNameQTYNew Part Number
-21-19-9-7-5-3
.NUT ASSY505044..3D0006-3
.NUT ASSY1221223D0006-4
.NUT ASSY2862863030113D0006-5
.NUT ASSY66661515..3D0006-6
.PIN99....HLT335TB-10-10
.PIN77....HLT335TB-10-11
.PIN11....HLT335TB-10-12
.PIN1111....HLT335TB-10-13
.PIN22....HLT335TB-10-14
.PIN3030....HLT335TB-12-11
.PIN1818....HLT335TB-12-13
.PIN1212....HLT335TB-12-14
.PIN11....HLT335TB-12-17
.PIN11....HLT335TB-12-19
.PIN3030....HLT335TB-14-14
.PIN22....HLT335TB-14-15
.PIN44....HLT335TB-14-16
.PIN22....HLT335TB-14-17
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### Page 29

Service Kit SA10570156
NotesNameQTYNew Part Number
-21-19-9-7-5-3
.PIN1212....HLT335TB-14-18
.PIN22....HLT335TB-14-19
.PIN66....HLT335TB-14-20
.PIN88....HLT335TB-14-21
.PIN66....HLT335TB-14-22
.PIN44....HLT335TB-14-23
.PIN33....HLT335TB-14-24
.PIN1616....HLT335TB-14-25
.PIN33....HLT335TB-14-26
.PIN22....HLT335TB-14-28
.PIN88....HLT335TB-6-4
.PIN2424....HLT335TB-6-6
.PIN2222....HLT336TB-10-10
.PIN3737....HLT336TB-10-11
.PIN88....HLT336TB-10-12
.PIN99....HLT336TB-10-13
.PIN55....HLT336TB-10-15
.PIN33....HLT336TB-10-16
.PIN44....HLT336TB-10-17
.PIN1111....HLT336TB-10-18
.PIN99....HLT336TB-10-19
.PIN88....HLT336TB-10-20
.PIN33....HLT336TB-10-21
.PIN33....HLT336TB-10-22
.PIN22....HLT336TB-10-23
.PIN66....HLT336TB-10-24
.PIN22....HLT336TB-10-25
.PIN22....HLT336TB-10-26
.PIN22....HLT336TB-10-28
.PIN22....HLT336TB-10-30
.PIN1212....HLT336TB-10-8
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### Page 30

Service Kit SA10570156
NotesNameQTYNew Part Number
-21-19-9-7-5-3
.PIN4646....HLT336TB-10-9
.PIN11....HLT336TB-12-13
.PIN22....HLT336TB-12-30
.PIN11....HLT336TB-12-9
.PIN11....HLT336TB-14-20
.PIN22....HLT336TB-14-22
.PIN22....HLT336TB-14-23
.PIN33....HLT336TB-14-25
.PIN11....HLT336TB-14-26
.PIN44....HLT336TB-14-27
.PIN11....HLT336TB-14-28
.PIN22....HLT435-10-10
.PIN22....HLT435-10-11
.PIN1212....HLT435-8-10
.PIN1313....HLT435-8-11
.PIN22....HLT435-8-12
.PIN11....HLT436-6-14
.PIN1010....HLT436-8-10
.PIN1010....HLT436-8-11
.PIN99....HLT436-8-13
.PIN99....HLT436-8-14
.PIN1212....HLT436-8-15
.PIN1212....HLT436-8-16
.PIN55....HLT436-8-17
.PIN66....HLT436-8-18
.PIN22....HLT436-8-19
.PIN22....HLT436-8-21
.PIN OVERSIZED44....HLT436-8-25
.PIN33....HLT436-8-4
.PIN11....HLT436-8-7
.PIN44....HLT436-8-8
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### Page 31

Service Kit SA10570156
NotesNameQTYNew Part Number
-21-19-9-7-5-3
.PIN44....HLT436-8-9
.HI-LOK PIN22....HLT439-10-15
.PIN22....HLT439-10-16
.PIN88....HLT635-10-13
.PIN88....HLT635-10-14
.PIN55....HLT635-10-16
.PIN77....HLT635-10-17
.PIN77....HLT635-10-18
.PIN1212....HLT635-10-19
.PIN22....HLT635-10-20
.PIN11....HLT635-6-12
.PIN11....HLT635-6-13
.PIN22....HLT635-6-14
.PIN33....HLT635-6-15
.PIN11....HLT635-6-16
.PIN55....HLT635-6-17
.PIN22....HLT635-6-18
.PIN11....HLT635-6-19
.PIN11....HLT635-6-20
.PIN11....HLT635-8-17
.PIN11....HLT635-8-20
.BOLT..22..NAS7402-13
.BOLT..22..NAS7402-14
.BOLT..44..NAS7402-15
.PIN....11S4931919-10-11
.PIN, OVERSIZE..11..S4931919-10X15
.PIN, OVERSIZE..11..S4931919-10X16
.PIN, OVERSIZE..22..S4931919-10X17
.PIN, OVERSIZE..11..S4931919-10X18
.PIN, OVERSIZE..22..S4931919-10X19
.PIN, OVERSIZE..11..S4931919-10X20
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### Page 32

Service Kit SA10570156
NotesNameQTYNew Part Number
-21-19-9-7-5-3
.PIN, OVERSIZE..88..S4931919-10X21
.PIN, OVERSIZE..1313..S4931919-10X22
.PIN, OVERSIZE..11..S4931919-10X23
.PIN, OVERSIZE..11..S4931919-12X16
.PIN, OVERSIZE..33..S4931919-12X17
.PIN, OVERSIZE..22..S4931919-12X18
.PIN, OVERSIZE..22..S4931919-12X19
.PIN, OVERSIZE..22..S4931919-12X20
.PIN, OVERSIZE..22..S4931919-12X21
.PIN, OVERSIZE..11..S4931919-12X22
.PIN, OVERSIZE..22..S4931919-12X27
.PIN, OVERSIZE..55..S4931919-14X20
.PIN, OVERSIZE..22..S4931919-14X21
.PIN, OVERSIZE..2525..S4931919-14X22
.PIN, OVERSIZE..22..S4931919-6X15
.PIN, OVERSIZE..22..S4931919-6X16
.NUT ASSY1141143232..S4933816-7
.SPLICE1.....SR10570019-10
.SUPPORT.1....SR10570019-11
.SUPPORT1.....SR10570019-12
.SUPPORT.1....SR10570019-13
.SUPPORT1.....SR10570019-14
.CLIP.1....SR10570019-15
.CLIP1.....SR10570019-16
.CLIP.1....SR10570019-17
.CLIP1.....SR10570019-18
.CLIP11....SR10570019-19
.CLIP.1....SR10570019-23
.CLIP1.....SR10570019-24
.CLIP.1....SR10570019-25
.CLIP1.....SR10570019-26
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### Page 33

Service Kit SA10570156
NotesNameQTYNew Part Number
-21-19-9-7-5-3
.CLIP.1....SR10570019-27
.CLIP1.....SR10570019-28
(a)TAPE11....SR10570019-29
.SPLICE.1....SR10570019-3
.CLIP.1....SR10570019-31
.CLIP1.....SR10570019-32
.CLIP.1....SR10570019-33
.CLIP1.....SR10570019-34
.CAP.1....SR10570019-35
.CAP1.....SR10570019-36
.CLIP.1....SR10570019-37
.CLIP1.....SR10570019-38
.SPLICE1.....SR10570019-4
.SPLICE.1....SR10570019-5
.SPLICE1.....SR10570019-6
.SPLICE.1....SR10570019-7
.SPLICE1.....SR10570019-8
.SPLICE.1....SR10570019-9
(a)BUSHING....11SR10570048-31
.DOUBLER...1..SR10570048-39
.DOUBLER..1...SR10570048-40
.FAIRING...1..SR10570048-41
.FAIRING..1...SR10570048-42
.FAIRING...1..SR10570048-47
.FAIRING..1...SR10570048-48
.FILLER..11..SR10570048-49
.FILLER..11..SR10570048-53
(a) Parts to be fabricated/procured by operator - not included in kit.
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### Page 34

Group 1:
Service Kit SA10570156
NameQTYNew Part Number
-13-11
NUT ASSY443D0006-3
NUT ASSY30303D0006-5
NUT ASSY15153D0006-6
CLIP22ARC0430-31
PIN1010HLT334-5-4
PIN44HLT434-6-3
NUT1010MS21042L08
NUT1414MS21042L3
NUT1010MS21042L4
NUT4949MS21042L5
WASHER1414NAS1252-10L
WASHER1010NAS1252-416L
WASHER4949NAS1252-516L
WASHER1010NAS1252-8L
BOLT22NAS7402-13
BOLT22NAS7402-14
BOLT44NAS7402-15
PIN, OVERSIZE11S4931919-10X15
PIN, OVERSIZE11S4931919-10X16
PIN, OVERSIZE22S4931919-10X17
PIN, OVERSIZE11S4931919-10X18
PIN, OVERSIZE22S4931919-10X19
PIN, OVERSIZE11S4931919-10X20
PIN, OVERSIZE22S4931919-10X21
PIN, OVERSIZE22S4931919-10X23
PIN, OVERSIZE44S4931919-10X24
PIN, OVERSIZE1313S4931919-10X25
PIN, OVERSIZE11S4931919-10X27
PIN, OVERSIZE11S4931919-12X16
PIN, OVERSIZE33S4931919-12X17
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### Page 35

Group 1:
Service Kit SA10570156
NameQTYNew Part Number
-13-11
PIN, OVERSIZE22S4931919-12X18
PIN, OVERSIZE22S4931919-12X19
PIN, OVERSIZE22S4931919-12X20
PIN, OVERSIZE22S4931919-12X21
PIN, OVERSIZE11S4931919-12X22
PIN, OVERSIZE22S4931919-12X27
PIN, OVERSIZE33S4931919-14X20
PIN, OVERSIZE55S4931919-14X21
PIN, OVERSIZE99S4931919-14X22
PIN, OVERSIZE11S4931919-14X23
PIN, OVERSIZE22S4931919-14X24
PIN, OVERSIZE44S4931919-14X25
PIN, OVERSIZE44S4931919-14X26
PIN, OVERSIZE1111S4931919-14X27
PIN1010S4931919-6-5
PIN, OVERSIZE22S4931919-6X15
PIN, OVERSIZE22S4931919-6X16
PIN, OVERSIZE11S4931920-10X13
PIN, OVERSIZE44S4931920-10X14
PIN, OVERSIZE1916S4931920-10X15
PIN, OVERSIZE58S4931920-10X16
PIN, OVERSIZE1614S4931920-10X17
PIN, OVERSIZE24S4931920-10X18
PIN, OVERSIZE22S4931920-10X19
PIN, OVERSIZE22S4931920-8X11
PIN, OVERSIZE88S4931920-8X12
NUT ASSY3939S4933816-7
ANGLE.1SR10570048-13
ANGLE1.SR10570048-14
TEE.1SR10570048-15
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Group 1:
Service Kit SA10570156
NameQTYNew Part Number
-13-11
TEE1.SR10570048-16
SUPPORT1.SR10570048-19
SUPPORT1.SR10570048-21
FILLER11SR10570048-23
SHIM11SR10570048-25
SHIM1.SR10570048-27
SHIM1.SR10570048-29
DOUBLER.1SR10570048-39
DOUBLER1.SR10570048-40
FAIRING.1SR10570048-41
FAIRING1.SR10570048-42
STRAP.1SR10570048-45
STRAP1.SR10570048-46
FAIRING.1SR10570048-47
FAIRING1.SR10570048-48
FILLER11SR10570048-49
FILLER11SR10570048-53
ANGLE.1SR10570048-55
ANGLE1.SR10570048-56
Group 2:
Service Kit SA10570156
NameQTYNew Part Number
-17-15
NUT ASSY443D0006-3
NUT ASSY30303D0006-5
NUT ASSY15153D0006-6
BRACKET.1ARB4195-1
BRACKET1.ARB4195-2
PIN1010HLT334-5-4
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Group 2:
Service Kit SA10570156
NameQTYNew Part Number
-17-15
NUT1010MS21042L08
NUT1010MS21042L3
NUT1010MS21042L4
NUT4949MS21042L5
WASHER1010NAS1252-10L
WASHER1010NAS1252-416L
WASHER4949NAS1252-516L
WASHER1010NAS1252-8L
BOLT22NAS7402-13
BOLT22NAS7402-14
BOLT44NAS7402-15
PIN, OVERSIZE11S4931919-10X15
PIN, OVERSIZE11S4931919-10X16
PIN, OVERSIZE22S4931919-10X17
PIN, OVERSIZE11S4931919-10X18
PIN, OVERSIZE22S4931919-10X19
PIN, OVERSIZE11S4931919-10X20
PIN, OVERSIZE22S4931919-10X21
PIN, OVERSIZE22S4931919-10X23
PIN, OVERSIZE44S4931919-10X24
PIN, OVERSIZE1313S4931919-10X25
PIN, OVERSIZE11S4931919-10X27
PIN, OVERSIZE11S4931919-12X16
PIN, OVERSIZE33S4931919-12X17
PIN, OVERSIZE22S4931919-12X18
PIN, OVERSIZE22S4931919-12X19
PIN, OVERSIZE22S4931919-12X20
PIN, OVERSIZE22S4931919-12X21
PIN, OVERSIZE11S4931919-12X22
PIN, OVERSIZE22S4931919-12X27
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### Page 38

Group 2:
Service Kit SA10570156
NameQTYNew Part Number
-17-15
PIN, OVERSIZE33S4931919-14X20
PIN, OVERSIZE55S4931919-14X21
PIN, OVERSIZE99S4931919-14X22
PIN, OVERSIZE11S4931919-14X23
PIN, OVERSIZE22S4931919-14X24
PIN, OVERSIZE44S4931919-14X25
PIN, OVERSIZE44S4931919-14X26
PIN, OVERSIZE1111S4931919-14X27
PIN1010S4931919-6-5
PIN, OVERSIZE22S4931919-6X15
PIN, OVERSIZE22S4931919-6X16
PIN, OVERSIZE11S4931920-10X13
PIN, OVERSIZE44S4931920-10X14
PIN, OVERSIZE1916S4931920-10X15
PIN, OVERSIZE58S4931920-10X16
PIN, OVERSIZE1412S4931920-10X17
PIN, OVERSIZE46S4931920-10X18
PIN, OVERSIZE22S4931920-10X19
PIN, OVERSIZE22S4931920-8X11
PIN, OVERSIZE88S4931920-8X12
NUT ASSY3939S4933816-7
ANGLE.1SR10570048-13
ANGLE1.SR10570048-14
TEE.1SR10570048-15
TEE1.SR10570048-16
BRACKET.1SR10570048-17
BRACKET1.SR10570048-18
SUPPORT1.SR10570048-19
SUPPORT1.SR10570048-21
FILLER11SR10570048-23
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### Page 39

Group 2:
Service Kit SA10570156
NameQTYNew Part Number
-17-15
SHIM11SR10570048-25
SHIM1.SR10570048-27
SHIM1.SR10570048-29
DOUBLER.1SR10570048-39
DOUBLER1.SR10570048-40
FAIRING.1SR10570048-41
FAIRING1.SR10570048-42
STRAP.1SR10570048-45
STRAP1.SR10570048-46
FAIRING.1SR10570048-47
FAIRING1.SR10570048-48
FILLER11SR10570048-49
ANGLE.1SR10570048-51
ANGLE1.SR10570048-52
FILLER11SR10570048-53
2. Parts and Materials Supplied by the Operator
NotesNameQTYPart Number / Specifica-
tion
(a) (b)Sealing Compound1 PintPR-1422 B-2
(DMS 2082 or Equivalent)
1.00 Diameter X 1.00 Bar,
Aluminium 7075-T7351.
Bushing1SR10570048-31
Material Specification
QQ-A-225/9 TEMP T7351
(a) Refer to Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
CAGEPRC-DeSoto International, Incorporated(b) Can be purchased from:
92108P. O. Box 1800
Sylmar, California 91342
3. Parts Modified and Reidentified
None.
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4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
The DC-10 Structural Repair Manual Volume II, DC-10, MD-10 SRM 51-12-01 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.
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.
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### Page 41

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY
ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE
PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE
CAN OCCUR.
WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY
ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE
PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE
CAN OCCUR.
CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE
TO THE AIRPLANE OR EQUIPMENT.
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. Equivalent parts are listed in the AEPL, Drawing 7595071.
3. Use the approved fastener and process material substitutions, in accordance with
DC-10, MD-10 SRM Chapter 51.
4. 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.
5. A 1/8-inch thick stack of the same type washers called for in this service bulletin is
the maximum thickness which may be used under fastener head or nut to counteract
accumulation of tolerances.
EXCEPTION: When the available fastener length increments are greater than
1/16-inch, a 3/16-inch thick stack of the same type washers may be used.
6. 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
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– 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.
7. Obey all of the warnings and cautions given in the specified manual sections.
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. 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.
10. 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.
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. These work instructions include repairs to left and right wings. Repairs are only
required on the wing where crack(s) are found.
B. WORK INSTRUCTIONS
1. Open wing trailing edge lower access door 551AB (left wing) and 651AB (right wing). Refer to
DC-10, MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for the
right wing locations.
2. Remove and keep rear spar access doors 541HB, 541JB, and attaching parts (left wing) and
641HB, 641JB, and attaching parts (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left
wing locations and DC-10, MD-10 AMM 06-36-00 for the right wing locations.
3. Fabricate DAC GSET AL.01 reference standard. Refer to NDTSPM Part 06, 06-20-01 as an
accepted procedure.
4. Do ETHF inspection for cracks in the left and right wing rear spar lower caps between the outboard
edge of the rear spar lower cap splice at Station Xors=400 and Station Xors=417 in accordance
with DC-10 Supplemental Inspection Document (SID) Volume II, Chapter 57-50-03, Sequence 1,
Method 1, Principal Structural Element (PSE) 57.10.007 and 57.10.008. Based on findings do as
follows:
Condition 1 (No Crack)
a. Do repeat ETHF inspections as described in Paragraph 3.B.3., Work Instructions, at intervals
as specified in Paragraph 1.E., Compliance.
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Condition 2 (Crack at Fastener Hole that can be Removed by Hole Enlargement)
a. Do permanent repair in accordance with:
Service Rework Drawing SR10570048-7001, Detail D if crack(s) found on left wing.
Service Rework Drawing SR10570048-7003, Detail D if crack(s) found on right wing.
b. Do ETHF inspections of the spar cap and HFEC inspections of the lower wing skin in the
repaired area in accordance with Service Rework Drawing SR10570048 inspection
requirements at intervals as specified in Paragraph1.E., Compliance for cracks and do as
follows:
Condition 2A (No Crack Found)
(1) Do repeat ETHF inspections of the spar cap and HFEC inspections of the lower wing
skin in the repaired area in accordance with Service Rework Drawing SR10570048
inspection requirements at intervals as specified in Paragraph1.E., Compliance.
Condition 2B (Any Crack Found)
(1) Evaluate the crack and do the work of Condition 2, 3 or 4 as applicable.
c. Do repeat ETHF inspection for cracks in the unchanged areas of the left and right wing rear
spar lower caps between the outboard edge of the rear spar lower cap splice at Station
Xors=400 and Station Xors=417 in accordance with DC-10 Supplemental Inspection Document
(SID) Volume II, Chapter 57-50-03, Sequence 1, Method 1, Principal Structural Element (PSE)
57.10.007 and 57.10.008. Based on findings do as follows:
Condition 2C (No Crack Found)
(1) Do ETHF inspection for cracks in the left and right wing rear spar lower caps between
the outboard edge of the rear spar lower cap splice at Station Xors=400 and Station
Xors=417 in accordance with DC-10 Supplemental Inspection Document (SID) Volume
II, Chapter 57-50-03, Sequence 1, Method 1, Principal Structural Element (PSE) 57.10.007
and 57.10.008 at intervals as specified in Paragraph 1.E., Compliance.
Condition 2D (Any Crack Found)
(1) Evaluate the crack and do the work of Condition 2, 3 or 4 as applicable.
Condition 3 (Crack in Spar Cap Aft Leg at Fastener Hole(s) that Can not be Removed by
Hole Enlargement but does not Extend into Vertical Leg)
a. Establish the location of the crack and do the work based on location.
Condition 3A (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=400
and Inboard of Xors=408)
(1) Contact The Boeing Company for repair instructions and do the repair.
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Condition 3B (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=408
and Xors=417)
(1) Defuel airplane. Refer to DC-10, MD-10 AMM 12-11-05 as an accepted procedure.
(2) Remove and keep wing fuel tank access covers 534AT and 534BT (left wing) and 634AT
and 634BT (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing locations
and DC-10, MD-10 AMM 06-36-00 for the right wing locations.
(3) Prepare (purge) wing fuel tanks for entry. Refer to DC-10, MD-10 AMM 28-00-00 as an
accepted procedure.
(4) Do permanent repair in accordance with:
Service Rework Drawing SR10570048-7021 if crack(s) found on left wing.
Service Rework Drawing SR10570048-7023 if crack(s) found on right wing.
(5) Install kept wing fuel tank access covers 534AT and 534BT (left wing) and 634AT and
634BT (right wing) in accordance with DC-10, MD-10 AMM 28-00-00. Refer to DC-10,
MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for
the right wing locations.
(6) Refuel airplane and check for leaks in the work areas. Refer to DC-10, MD-10 AMM
12-11-02 for refueling procedures.
(7) Do repeat ETHF and UT inspections in the repaired area in accordance with Service
Rework Drawing SR10570048 inspection requirements at intervals as specified in
Paragraph 1.E., Compliance for cracks and do as follows:
Condition 3C (No Crack Found)
(a) Do repeat ETHF and UT inspections in the repaired area in accordance with Service
Rework Drawing SR10570048 inspection requirements at intervals as specified in
Paragraph 1.E., Compliance.
Condition 3D (Any Crack Found)
(a) Contact The Boeing Company for repair instructions and do the repair.
Condition 4 (Crack Extends Into the Vertical Leg of Spar Cap)
a. Establish the location of the crack and do the work based on location.
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### Page 45

Condition 4A (Crack is Between Station Xors=400 and Inboard of Xors=408)
(1) Defuel airplane. Refer to DC-10, MD-10 AMM 12-11-05 as an accepted procedure.
(2) Remove and keep wing fuel tank access covers 534AT and 534BT (left wing) and 634AT
and 634BT (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing locations
and DC-10, MD-10 AMM 06-36-00 for the right wing locations.
(3) Prepare (purge) wing fuel tanks for entry. Refer to DC-10, MD-10 AMM 28-00-00 as an
accepted procedure.
(4) Do permanent repair in accordance with:
Service Rework Drawing SR10570019-7013 if crack(s) found on left wing.
Service Rework Drawing SR10570019-7015 if crack(s) found on right wing.
(5) Install kept wing fuel tank access covers 534AT and 534BT (left wing) and 634AT and
634BT (right wing) in accordance with DC-10, MD-10 AMM 28-00-00. Refer to DC-10,
MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for
the right wing locations.
(6) Refuel airplane and check for leaks in the work areas. Refer to DC-10, MD-10 AMM
12-11-02 for refueling procedures.
(7) Do ETHF and UT inspections of the repaired area in accordance with Service Rework
Drawing SR10570019 inspection requirements for cracks at intervals specified by
Paragraph1.E., Compliance and do as follows:
Condition 4B (No Crack Found in Permanent Repair)
(a) Do ETHF and UT inspections in the repaired area in accordance with Service Rework
Drawing SR10570019 inspection requirements at intervals specified by Paragraph1.E.,
Compliance.
Condition 4C (Any Crack Found in Permanent Repair)
(a) Contact The Boeing Company for repair instructions and do the repair.
Condition 4D (Crack is Between Station Xors=408 and Xors=417)
(1) Defuel airplane. Refer to DC-10, MD-10 AMM 12-11-05 as an accepted procedure.
(2) Remove and keep wing fuel tank access covers 534AT and 534BT (left wing) and 634AT
and 634BT (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing locations
and DC-10, MD-10 AMM 06-36-00 for the right wing locations.
(3) Prepare (purge) wing fuel tanks for entry. Refer to DC-10, MD-10 AMM 28-00-00 as an
accepted procedure.
(4) Do Option 1 or Option 2
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### Page 46

Option 1
(a) Do temporary repair in accordance with:
Group 1:
Service Rework Drawing SR10570048-7025 if crack(s) found on left wing.
Group 1:
Service Rework Drawing SR10570048-7027 if crack(s) found on right wing.
Group 2:
Service Rework Drawing SR10570048-7029 if crack(s) found on left wing.
Group 2:
Service Rework Drawing SR10570048-7031 if crack(s) found on right wing.
(b) Do ETHF and UT inspections in the repaired area in accordance with Service Rework
Drawing SR10570048 inspection requirements for cracks at intervals specified by
Paragraph 1.E., Compliance and do as follows:
Condition 4E (No Crack Found in Temporary Repair)
Do ETHF and UT inspections in the repaired area in accordance with Service Rework
Drawing SR10570048 inspection requirements at intervals specified by Paragraph
1.E., Compliance.
Condition 4F (Any Crack Found in Temporary Repair)
Contact The Boeing Company for repair instructions and do the repair.
(c) Remove temporary repair upon or prior to reaching the end of its service life at interval
specified in Paragraph 1.E., Compliance. Replace temporary repair as follows:
INSTRUCTIONS FOR REPLACING THE TEMPORARY REPAIR
1) Do permanent repair in accordance with:
Service Rework Drawing SR10570019-7013 if temporary repair installed on left
wing.
Service Rework Drawing SR10570019-7015 if temporary repair installed on right
wing.
2) Do ETHF and UT inspections in the repaired area in accordance with Service
Rework Drawing SR10570019 inspection requirements at intervals specified by
Paragraph 1.E., Compliance for cracks and do as follows:
Condition 4G (No Crack Found in Permanent Repair)
Do ETHF and UT inspections in the repaired area in accordance with Service
Rework Drawing SR10570019 inspection requirements at intervals specified by
Paragraph 1.E., Compliance.
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Condition 4H (Any Crack Found in Permanent Repair)
Contact The Boeing Company for repair instructions and do the repair.
Option 2
(a) Do permanent repair in accordance with:
Service Rework Drawing SR10570019-7013 on left wing.
Service Rework Drawing SR10570019-7015 on right wing.
(b) Do ETHF and UT inspections in the repaired area in accordance with Service Rework
Drawing SR10570019 inspection requirements at intervals specified by Paragraph
1.E., Compliance for cracks and do as follows:
Condition 4I (No Crack Found in Permanent Repair)
Do ETHF and UT inspections in the repaired area in accordance with Service Rework
Drawing SR10570019 inspection requirements at intervals specified by Paragraph
1.E., Compliance.
Condition 4J (Any Crack Found in Permanent Repair)
Contact The Boeing Company for repair instructions and do the repair.
(5) Install kept wing fuel tank access covers 534AT and 534BT (left wing) and 634AT and
634BT (right wing) in accordance with DC-10, MD-10 AMM 28-00-00. Refer to DC-10,
MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for
the right wing locations.
(6) Refuel airplane and check for leaks in the work areas. Refer to DC-10, MD-10 AMM
12-11-02 for refueling procedures.
5. Install kept rear spar access doors 541HB, 541JB and attaching parts (left wing) and 641HB,
641JB and attaching parts (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing
locations and DC-10, MD-10 AMM 06-36-00 for the right wing locations.
6. Close wing trailing edge lower access door 551AB (left wing) and 651AB (right wing). Refer to
DC-10, MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for the
right wing locations.
7. Put the airplane back to a serviceable condition.
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