Boeing ASB MD80-55A065: Revision 2, text

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Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-55A065 Original Issue: April 25, 2007 Revision 2: October 11, 2021 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Upper/Lower Aft Skin Panels and Rear Spar Upper Caps Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

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

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

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Table of Contents

Revision Transmittal Sheet5

S u m m a r y7

1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1

1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 8 F . A p p r o v a l ............................................... 3 5 G. Manpower .............................................. 3 5 H. Weight and Balance Changes .................................... 4 0 I. Electrical Load Data ......................................... 4 4 J . R e f e r e n c e s .............................................. 4 4

1. Existing Data: ......................................... 4 4

2. Data Supplied with this Service Bulletin: ........................... 4 5

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 5 K. Publications Affected ........................................ 4 5 L. Interchangeability and Intermixability of Parts ........................... 4 5 M. Software Accomplishment Summary ................................ 4 5

2. MATERIAL INFORMATION ........................................ 4 7 A. Material - Price and Availability ................................... 4 7 B. Industry Support Information .................................... 4 9 C. Parts Necessary for Each Airplane ................................. 4 9 1 . K i t s / P a r t s : ........................................... 4 9

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

3. Parts Modified and Reidentified: ............................... 6 3

4. Parts Removed and Not Replaced: .............................. 6 3 D. Parts Necessary to Change Spares ................................. 6 3 E. Special Tooling - Price and Availability ............................... 6 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 3

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 5 A. GENERAL INFORMATION ..................................... 6 5 B. WORK INSTRUCTIONS ....................................... 6 7 FIGURE 1: HORIZONTAL STABILIZER UPPER AFT SKIN PANELS - LEFT AND RIGHT - EDDY CURRENT INSPECTION .......................................... 7 7 FIGURE 2: HORIZONTAL STABILIZER REAR SPAR UPPER CAPS - LEFT AND RIGHT - EDDY CURRENT INSPECTION .......................................... 8 2 FIGURE 3: HORIZONTAL STABILIZER LOWER AFT SKIN PANELS - LEFT AND RIGHT - EDDY CURRENT INSPECTION .......................................... 8 5 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

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Commercial Airplanes MD80 Service Bulletin ALERT Revision Transmittal SheetNumber: MD80-55A065Original Issue: April 25, 2007 Revision 2: October 11, 2021 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Upper/Lower Aft Skin Panels and Rear Spar Upper Caps This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-10-04 is related to this service bulletin.

The effective date of AD 2007-10-04 is May 23, 2007.

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

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

None.

REASON FOR REVISION This revision is sent to provide new compliance times and repeat intervals for the high frequency eddy current surface and open hole inspections of the rear spar upper caps. The inspections given in Revision 1 do not provide at least two opportunities to reliably detect dual origin cracks before they reach critical length. Boeing received a report of a crack found during an inspection of the horizontal rear spar upper cap. The crack was found along fasteners in the upper rear spar and was longer than two inches. The report was for an MD-82 airplane with 69,799 flight hours and 38,520 flight cycles, and the crack was found prior to the mandated repeat inspection interval given in Revision 1 of this service bulletin.

These sections were changed:

1. Summary, Compliance, updated the Airworthiness Directive (AD) paragraph to include the effective date.

2. Paragraph 1.A.1., Airplanes; added applicable airplanes paragraph.

3. Paragraph 1.C., Reason; added reason for revision paragraph.

4. Paragraph 1.D., Description; added effects of this revision paragraph.

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5. Paragraph 1.E., Compliance; updated the Airworthiness Directive (AD) paragraph to include the effective date, updated initial and repeat inspection times in Compliance Table 9, Table 10, Table 13, Table 14, Table 17 and Table 18; changed to 'whichever occurs first' in the heading of Table 13, Table 14, Table 17 and Table 18; changed the Service Bulletin revision title in Compliance Table 1 and Table 21;

updated action statement in Table 1 and Table 16; and added statement to clarify actions in Table 1, Table 2, Table 3, Table 5, Table 6, Table 7, Table 8, Table 10, Table 13, Table 14, Table 17, Table 18, Table 22, Table 23, Table 25, Table 27, and Table 28; and added initial inspection requirement information.

6. Paragraph 1.F., Approval; updated the approval statement.

7. Paragraph 1.J., References; updated Data supplied by this Service Bulletin.

8. Paragraph 1.K., Publications Affected; updated publications table.

9. Paragraph 1.M., Software Accomplishment Summary; updated to include statement.

10. Paragraph 3.B.1., Work Instructions; added initial inspection requirement information.

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

Pages with no vertical lines have no changes.

REVISION HISTORY April 25, 2007Original Issue:

September 23, 2008Revision 1:

October 11, 2021Revision 2:

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Commercial Airplanes MD80 Service Bulletin ALERT SummaryNumber: MD80-55A065Original Issue: April 25, 2007 Revision 2: October 11, 2021 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Upper/Lower Aft Skin Panels and Rear Spar Upper Caps

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

CONCURRENT REQUIREMENTS None.

BACKGROUND Operators reported instances of cracks on MD-80 airplanes in the horizontal stabilizer upper aft skin panels at the aft inboard corner, station XH = 8.2 and in the rear spar upper caps adjacent to the horizontal stabilizer aft skin panel at station XH = 10.0. Originally cracks were found during operators' maintenance visual inspections.

The cracks reported as of the release of this service bulletin are: 9 instances of rear spar upper cap cracks on airplanes that had accumulated between 30,000 to 39,000 flight cycles and 45,000 to 56,000 flight-hours, 19 instances of upper aft skin panel cracks on airplanes that had accumulated between 23,000 to 46,000 flight cycles and 37,000 to 60,000 flight-hours and 1 instance of lower aft skin panel crack on an airplane that had accumulated 37,000 flight cycles and 47,000 flight-hours. The cause of the cracking is still under Boeing investigation. Inspection of affected areas will determine the condition of the horizontal stabilizer upper/lower aft skin panels and rear spar upper caps. Incorporation of this repair/change will minimize the possibility of crack growth of the horizontal stabilizer aft skin panels and the rear spar upper cap. If not corrected, undetected cracks in the fail-safe structure may not sustain limit load and ultimately lead to the loss of overall structural integrity of the horizontal stabilizer.

ACTION Refer to Paragraph 1.D., for Description.

EFFECTIVITY DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87) and MD-88 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

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COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-10-04 is related to this service bulletin.

The effective date of AD 2007-10-04 is May 23, 2007.

Refer to Paragraph 1.E., for Compliance.

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

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing and Operator Supplied Kits/Parts.

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

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes This bulletin is applicable to DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 Airplane(s), line number(s) 938, 941, 944, 948, 950, 952-953, 957-958, 962, 966-967, 969-971, 973, 978, 981, 985-986, 988, 992, 994-995, 997, 999, 1000-1006, 1011-1013, 1015-1016, 1018-1020, 1025, 1028, 1031-1032, 1034-1035, 1043, 1045, 1047, 1049, 1051, 1053, 1055, 1057, 1059-1060, 1063-1071, 1073, 1075-1080, 1082-1083, 1085, 1087-1093, 1095-1110, 1112-1145, 1147-1172, 1174-1203, 1205-1206, 1208-1223, 1225-1260, 1262-1292, 1294-1314, 1316-1325, 1327-1342, 1344-1451, 1453-1503, 1505-1701, 1703-1771, 1773-1787, 1789-1843, 1845-1915, 1917-1924, 1926-1994, 1996-2007, 2009-2016, 2019-2029, 2031-2034, 2036-2069, 2071-2093, 2101-2114, 2116, 2118-2119, 2121, 2124, 2127, 2130, 2132, 2134-2135, 2137, 2139, 2145, 2148, 2151-2152, 2155, 2167, 2174, 2176, 2178, 2180, 2183, 2185, 2187, 2189, 2192, 2196, 2199, 2201, 2204, 2206, 2208, 2214, 2218, 2234, 2239, 2241, 2244, 2247, 2249, 2252, 2254, 2264-2287 in 2 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.

This service bulletin is for the airplanes shown below. The service bulletin is divided into two groups to account for the differences in weight and balance only. All Paragraphs in this service bulletin are applicable to both Groups 1 and 2 except as noted in Paragraph 1.H, Weight and Balance Changes.

NOTE: Airplanes that have been inspected as given in Multi Operator Messages (MOM) 1-300151711-1, dated March 15, 2007 or 1-309950983-5, dated April 4, 2007 have complied with initial inspection requirements as given in Service Bulletin MD80-55A065.

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DESCRIPTIONCONFIGURATIONGROUP Applicable to DC-9-81 (MD-81) airplanes with thinner horizontal stabilizer upper aft skin panels.

-1 Applicable to all MD-80 airplanes other than those in Group 1.-2 Airplane Models:

DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 GroupFuselage Number 1938 1941 1944 1948 1950 1952 - 953 1957 2958 1962 2966 - 967 2969 - 971 2973 2978 2981 2985 - 986 2988 2992 2994 - 995 2997 2999 - 1006 21011 - 1013 21015 - 1016 21018 - 1020 21025 21028 GroupFuselage Number 21031 - 1032 21034 - 1035 21043 21045 21047 21049 21051 21053 21055 21057 21059 - 1060 21063 - 1071 21073 21075 - 1080 21082 - 1083 21085 21087 - 1093 21095 - 1110 21112 - 1145 21147 - 1172 21174 - 1203 21205 - 1206 21208 - 1223 21225 - 1260 21262 - 1292 GroupFuselage Number 21294 - 1314 21316 - 1325 21327 - 1342 21344 - 1451 21453 - 1503 21505 - 1701 21703 - 1771 21773 - 1787 21789 - 1843 21845 - 1915 21917 - 1924 21926 - 1994 21996 - 2007 22009 - 2016 22019 - 2029 22031 - 2034 22036 - 2069 22071 - 2093 22101 - 2114 22116 22118 - 2119 22121 22124 22127 22130 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

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