# Boeing Alert Service Bulletin MD80-55A065: Revision 2

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- Document: [Boeing Alert Service Bulletin MD80-55A065](https://openairdocs.org/service-documents/boeing/md80-55a065.md)
- Title as filed: MD80-55A065 Rev 2
- Pages: 89
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### Page 1

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:
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Unpublished Work.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: April 25, 2007
MD80-55A065Revision 2: October 11, 2021
1 of 89
3.0

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Table of Contents
Revision Transmittal Sheet ............................................ 5
S u m m a r y  ...................................................... 7
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
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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.
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.
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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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
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.
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
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GroupFuselage Number
22132
22134 - 2135
22137
22139
22145
22148
22151 - 2152
22155
22167
22174
22176
22178
GroupFuselage Number
22180
22183
22185
22187
22189
22192
22196
22199
22201
22204
22206
22208
GroupFuselage Number
22214
22218
22234
22239
22241
22244
22247
22249
22252
22254
22264 - 2287
--
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
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. 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.
Revision 1 is sent to incorporate engineering changes subsequent to the release of the original issue
of this service bulletin, which added:
- splice repair option for the horizontal stabilizer lower aft panel
- a fatigue life enhancement option and an angle and different-sized fillers for the rear spar upper cap
splice
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- drawings for replacement of upper and lower aft panels and rear upper spar cap
- requirements to replace stop-drilled or trimmed -out panels within 4,000 flight cycles.
- removed requirements to do repetitive inspections for the horizontal stabilizer upper aft panel splice
installation and rear upper spar cap splice installation.
Revision 2 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.
D. Description
This service bulletin does an eddy current inspection of the left and right horizontal stabilizer upper and
lower aft skin panels and rear spar upper caps and does Parts 1, 2, and 3 as follows:
1. Part 1: Horizontal Stabilizer Upper Aft Skin Panels
a. Condition 1 (No cracks)
(1) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
b. Condition 2 (Crack Length 2.00 Inches or Shorter)
Option 1
(1) Stop drills end of crack.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
Option 2 NOTE: Option 2 is only applicable to cracks that can be removed by a maximum
trim out length of 1.75 inches.
(1) Trims out crack and installs filler.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
Option 3
(1) Installs horizontal stabilizer upper aft skin panel splice.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
Option 4
(1) Removes and replaces the horizontal stabilizer upper aft skin panel.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
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c. Condition 3 (Crack Length Longer than 2.0 Inches)
Option 1
(1) Installs horizontal stabilizer upper aft skin panel splice.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
Option 2
(1) Removes and replaces the horizontal stabilizer upper aft skin panel.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
2. Part 2: Horizontal Stabilizer Rear Spar Upper Caps
a. Condition 1 (No Cracks)
Option1
(1) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
Option2
(1) Installs bushings and cold works hole in the horizontal stabilizer rear spar upper caps.
(2) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
b. Condition 2 (Crack can be Removed with a Maximum Hole Diameter of 0.408 Inch, Upper
two Fastener Holes Only)
Option 1
(1) Remove crack and repair.
(2) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
Option 2
(1) Installs horizontal stabilizer rear spar upper cap splice.
(2) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
Option 3
(1) Removes and replaces the horizontal stabilizer rear spar upper cap.
(2) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
Option 4
(1) Installs horizontal stabilizer rear spar upper cap splice.
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(2) Installs bushings and cold works hole in the horizontal stabilizer rear spar upper caps.
(3) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
Option 5
(1) Removes and replaces the horizontal stabilizer rear spar upper cap.
(2) Installs bushings and cold works hole in the horizontal stabilizer rear spar upper caps.
(3) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
c. Condition 3 (Crack cannot be Removed with a Maximum Hole Diameter of 0.408 Inch or Any
Size Crack on Lower Fastener Hole)
Option 1
(1) Installs horizontal stabilizer rear spar upper cap splice.
(2) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
Option 2
(1) Removes and replaces the horizontal stabilizer rear spar upper cap.
(2) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
Option 3
(1) Installs horizontal stabilizer rear spar upper cap splice.
(2) Installs bushings and cold works hole in the horizontal stabilizer rear spar upper caps.
(3) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps
and splice.
Option 4
(1) Removes and replaces the horizontal stabilizer rear spar upper cap.
(2) Installs bushings and cold works hole in the horizontal stabilizer rear spar upper caps.
(3) Does repetitive eddy current inspection of the horizontal stabilizer rear spar upper caps.
3. Part 3: Horizontal Stabilizer Lower Aft Skin Panels
a. Condition 1 (No Cracks)
(1) Does repetitive eddy current inspection of the horizontal stabilizer lower aft skin panels.
b. Condition 2 (Crack Length 2.00 inches or Shorter)
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Option 1
(1) Stop drills end of crack.
(2) Does repetitive eddy current inspection of the horizontal stabilizer lower aft skin panel.
Option 2 NOTE: Option 2 is only applicable to cracks that can be removed by a maximum
trim out length of 1.75 inches.
(1) Trims out crack and installs filler.
(2) Does repetitive frequency eddy current inspection of the horizontal stabilizer lower aft
skin panels.
Option 3
(1) Installs horizontal stabilizer lower aft skin panel splice.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
Option 4
(1) Removes and replaces the horizontal stabilizer lower aft skin panel.
(2) Does repetitive eddy current inspection of the horizontal stabilizer lower aft skin panels.
c. Condition 3 (Crack Length Longer than 2.0 Inches)
Option 1
(1) Installs horizontal stabilizer lower aft skin panel splice.
(2) Does repetitive eddy current inspection of the horizontal stabilizer upper aft skin panels.
Option 2
(1) Removes and replaces the horizontal stabilizer lower aft skin panel.
(2) Does repetitive frequency eddy current inspection of the horizontal stabilizer lower aft
skin panels.
NOTE: If a crack is found, repair or replacement of the horizontal stabilizer skin panel is recommended
at the operator's earliest opportunity after stop drill or trim out, to reduce economic impact of
an unscheduled repair or replacement due to crack progression.
Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this
service bulletin. However, the repetitive inspection requirements remain applicable as given in
Compliance Paragraph 1.E., in this service bulletin.
Effects of this Revision on airplanes on which Original Issue or Revision 1 was previously done:
None.
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### Page 18

The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
33, 34DC-9-81 (MD-81)
Group 2:
Affected Maintenance Zones
ZoneModel
33, 34DC-9-81 (MD-81), DC-9-82
(MD-82), DC-9-83 (MD-83), DC-
9-87 (MD-87), MD-88
E. 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.
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.
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.
Horizontal Stabilizer Upper Aft Skin Panels:
Table 1 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - All Airplanes
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 854 flight
cycles after the
Original Issue
date of this ser-
vice bulletin.
Before the accu-
mulation of
20,000 total
flight cycles.
Do initial eddy current inspection of
horizontal stabilizer as given in Accom-
plishment Instructions 3.B.1. using:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
All Airplanes
or
Scan1 and 2 - high frequency
Scan 3, Method 2 - high frequency
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Table 2 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - Condition 1
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time
(Whichever Occurs
Later)
ActionCondition
2,600 flight cy-
cles.
--Do eddy current inspection as given in Accomplishment
Instructions 3.B.1. Part 1. for the conditions that follow:
Condition 1
- No Cracks
--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cy-
cles.
--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - High frequency
Table 3 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - Condition 2, Option 1
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichev-
er Occurs Later)
ActionCondition
--
Before further
flight.
Option 1 - Do items (1), (2) and (3) as follows:
(1) Stop drill end of crack as given in Accomplish-
ment Instructions 3.B.1. Part 1.
Condition 2
- Crack
Length 2.0
Inches or
Shorter AND
500 flight cy-
cles.
--(2) Do high frequency eddy current inspection
as given in Accomplishment Instructions 3.B.1.
Part 1. for the conditions that follow:
Length of crack is 1.75 inches or shorter.
or
200 flight cy-
cles.
--Length of crack is 1.76 to 2.00 inches.
AND
--Within 4,000
flight cycles
after stop drill
repair. (a)
(3) Do Option 3 or 4 as given in Accomplishment
Instructions 3.B.1. Part 1.
(a) Follow the compliance and repeat inspection requirements given until the work of Option 3 or 4 is done,
then follow the compliance and repeat inspection requirements of Option 3 or 4.
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Table 4 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - Condition 2, Option 2
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 2 - Do items (1), (2) and (3) as
follows:
Condition 2 -
Crack Length
2.0 Inches or
Shorter
(1) Trim out crack and install filler as
given in Accomplishment Instructions
3.B.1. Part 1.
AND
1,000 flight cy-
cles.
--(2) Do high frequency eddy current in-
spection as given in Accomplishment
Instructions 3.B.1. Part 1.
AND
--Within 4,000
flight cycles af-
ter trim out re-
pair. (a)
(3) Do Option 3 or 4 as given in Accom-
plishment Instructions 3.B.1. Part 1.
(a) Follow the compliance and repeat inspection requirements given until the work of Option 3 or 4 is done,
then follow the compliance and repeat inspection requirements of Option 3 or 4.
Table 5 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - Condition 2, Option 3
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 3 - Do items (1) and (2) as fol-
lows:
Condition 2 -
Crack Length
2.0 Inches or
Shorter
(1) Install horizontal stabilizer upper aft
skin panel splice as given in Accom-
plishment Instructions 3.B.1. Part 1.
AND
2,600 flight cy-
cles.
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 1. for the conditions that follow:
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cy-
cles.
--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
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Table 6 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - Condition 2, Option 4
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 4 - Do items (1) and (2) as fol-
lows:
Condition 2 -
Crack Length
2.0 Inches or
Shorter
(1) Remove and replace horizontal
stabilizer upper aft skin panel as given
in Accomplishment Instructions 3.B.1.
Part 1.
AND
2,600 flight cy-
cles.
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 1. for the conditions that follow:
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cy-
cles.
--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
Table 7 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - Condition 3, Option 1
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 1 - Do items (1) and (2) as fol-
lows:
Condition 3 -
Crack Length
Longer than
2.0 Inches
(1) Install horizontal stabilizer upper aft
skin panel splice as given in Accom-
plishment Instructions 3.B.1. Part 1.
AND
2,600 flight cy-
cles.
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 1. for the conditions that follow:
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cy-
cles.
--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
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Table 8 - Inspect Horizontal Stabilizer Upper Aft Skin Panels for Cracks - Condition 3, Option 2
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 2 - Do items (1) and (2) as fol-
lows:
Condition 3 -
Crack Length
Longer than
2.0 Inches
(1) Remove and replace horizontal
stabilizer upper aft skin panel as given
in Accomplishment Instructions 3.B.1.
Part 1.
AND
2,600 flight cy-
cles.
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 1. for the conditions that follow:
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cy-
cles.
--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
Horizontal Stabilizer Rear Spar Upper Caps:
Table 9 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - All Airplanes
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs Later)
ActionCondition
-Within 854 flight
cycles after the
Original Issue
date of this ser-
vice bulletin.
Before the accumu-
lation of 20,000 to-
tal flight cycles.
Do initial high frequency eddy
current inspection of horizontal
stabilizer as given in Accom-
plishment Instructions 3.B.1.
Method 3: (with bolt removed).
All Airplanes
or
Method 4: (with bolt not re-
moved).
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### Page 23

Table 10 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 1, Option 1
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time (Whichever Occurs First)ActionCondition
3,980 flight
cycles.
Within 11,000 flight cycles after the
last inspection was done as given
in the Original Issue, or Revision 1,
of this service bulletin.
Within 3,980 flight cy-
cles after the Revision
2 date of this service
bulletin.
Option 1: Do high fre-
quency eddy current in-
spection as given in
Accomplishment Instruc-
tions 3.B.1. Part 2. for
the conditions that fol-
low:
Condition 1
- No Cracks
If prior inspection done
by Method 3:
(with bolt removed).
OR
1,300 flight
cycles.
Within 4,100 flight cycles after the
last inspection was done as given
in the Original Issue, or Revision 1,
of this service bulletin.
Within 1,300 flight cy-
cles after the Revision
2 date of this service
bulletin.
If prior inspection done
by Method 4:
(with bolt not removed).
Table 11 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 1, Option 2
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs Later)
ActionCondition
--
Before the repeat
interval as given in
Method 3 or 4 of
Option 1.
Option 2 - Do items (1) and (2)
as follows:
(1) Install bushings and cold
work hole as given in Accom-
plishment Instructions 3.B.1.
Part 2.
Condition 1 -
No Cracks
AND
3,200 flight cycles.-Before the accumu-
lation of 50,000 to-
tal flight cycles af-
ter the installation
of bushings.
(2) Do high frequency eddy
current inspection (Method 4,
with bolt not removed) as given
in Accomplishment Instructions
3.B.1. Part 2.
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Table 12 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 2, Option 1
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs Later)
ActionCondition
--
Before further
flight.
Option 1 - Do items (1) and (2)
as follows:
Condition 2 -
Crack can be
removed with a
maximum hole
diameter of
0.408 inch, up-
per two fasten-
er holes only
(1) Remove crack and repair
as given in Accomplishment
Instructions 3.B.1. Part 2.
AND
2,000 flight cycles.-Within 2,000 flight
cycles after repair.
(2) Do high frequency eddy
current inspection as given in
Accomplishment Instructions
3.B.1. Part 2.
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### Page 25

Table 13 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 2, Option 2
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs First)
ActionCondition
--
Before further
flight.
Option 2 - Do items (1), (2) and
(3) as follows:
Condition 2 -
Crack can be
removed with a
maximum hole
diameter of
0.408 inch, up-
per two fasten-
er holes only
(1) Install horizontal stabilizer
rear spar upper cap splice as
given in Accomplishment In-
structions 3.B.1. Part 2.
AND
--Within 20,000 flight
cycles after repair.
(2) Do high frequency eddy
current inspection as given in
Accomplishment Instructions
3.B.1. Part 2. for the conditions
that follow:
3,980 flight cycles.Within 11,000
flight cycles after
the last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 3,980 flight
cycles after the
Revision 2 date of
this service bul-
letin.
If prior inspection done by
Method 3:
(with bolt removed)
OR
1,300 flight cycles.Within 4,100 flight
cycles after the
last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 1,300 flight
cycles after the
Revision 2 date of
this service bul-
letin.
If prior inspection done by
Method 4:
(with bolt not removed)
AND
--Within 97,000 flight
cycles after installa-
tion of splice.
(3) Replace splice repair with
new horizontal stabilizer rear
spar upper cap as given in Ac-
complishment Instructions
3.B.1. Part 2.
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### Page 26

Table 14 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 2, Option 3
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs First)
ActionCondition
--
Before further
flight.
Option 3 - Do items (1) and (2)
as follows:
Condition 2 -
Crack can be
removed with a
maximum hole
diameter of
0.408 inch, up-
per two fasten-
er holes only
(1) Remove and replace hori-
zontal stabilizer rear spar up-
per cap as given in Accomplish-
ment Instructions 3.B.1. Part
2.
AND
--Within 20,000 flight
cycles after repair.
(2) Do high frequency eddy
current inspection as given in
Accomplishment Instructions
3.B.1. Part 2. for the conditions
that follow:
3,980 flight cycles.Within 11,000
flight cycles after
the last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 3,980 flight
cycles after the
Revision 2 date of
this service bul-
letin.
If prior inspection done by
Method 3:
(with bolt removed).
OR
1,300 flight cycles.Within 4,100 flight
cycles after the
last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 1,300 flight
cycles after the
Revision 2 date of
this service bul-
letin.
If prior inspection done by
Method 4:
(with bolt not removed).
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### Page 27

Table 15 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 2, Option 4
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs Later)
ActionCondition
--
Before further
flight.
Option 4 - Do items (1), (2) and
(3) as Follows:
Condition 2 -
Crack can be
removed with a
maximum hole
diameter of
0.408 inch, up-
per two fasten-
er holes only
(1) Install horizontal stabilizer
rear spar upper cap splice as
given in Accomplishment In-
structions 3.B.1. Part 2.
AND
--Before further
flight.
(2) Install bushings and cold
work hole as given in Accom-
plishment Instructions 3.B.1.
Part 2.
AND
3,200 flight cycles.-Before the accumu-
lation of 50,000 to-
tal flight cycles af-
ter the installation
of bushings.
(3) Do high frequency eddy
current inspection (Method 4,
with bolt not removed) as given
in Accomplishment Instructions
3.B.1. Part 2.
Table 16 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks Condition 2, Option 5
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs Later)
ActionCondition
--
Before further
flight.
Option 5 - Do items (1), (2) and
(3) as follows:
Condition 2 -
Crack can be
removed with a
maximum hole
diameter of
0.408 inch, up-
per two fasten-
er holes only
(1) Remove and replace hori-
zontal stabilizer rear spar up-
per cap as given in Accomplish-
ment Instructions 3.B.1. Part
2.
AND
--Before further
flight.
(2) Install bushings and cold
work hole as given in Accom-
plishment Instructions 3.B.1.
Part 2.
AND
3,200 flight cycles.-Before the accumu-
lation of 50,000 to-
tal flight cycles af-
ter the installation
of bushings.
(3) Do high frequency eddy
current inspection (Method 4,
with bolt not removed) as given
in Accomplishment Instructions
3.B.1. Part 2.
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### Page 28

Table 17 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 3, Option 1
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs First)
ActionCondition
--
Before further
flight.
Option 1 - Do items (1), (2) and
(3) as follows:
Condition 3 -
Crack cannot
be removed
with a maxi-
mum hole diam-
eter of 0.408
inch or any size
crack on lower
fastener hole.
(1) Install horizontal stabilizer
rear spar upper cap splice as
given in Accomplishment In-
structions 3.B.1. Part 2.
AND
--Within 20,000 flight
cycles after repair.
(2) Do high frequency eddy
current inspection as given in
Accomplishment Instructions
3.B.1. Part 2. for the conditions
that follow:
3,980 flight cycles.Within 11,000
flight cycles after
the last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 3,980 flight
cycles after the
Revision 2 date of
this service bul-
letin.
Prior inspection done by
Method 3:
(with bolt removed).
OR
1,300 flight cycles.Within 4,100 flight
cycles after the
last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 1,300 flight
cycles after the
Revision 2 date of
this service bul-
letin.
Prior inspection done by
Method 4:
(with bolt not removed).
AND
--Within 97,000 flight
cycles after installa-
tion of splice.
(3) Replace splice repair with
new horizontal stabilizer rear
spar upper cap as given in Ac-
complishment Instructions
3.B.1. Part 2.
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### Page 29

Table 18 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 3, Option 2
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs First)
ActionCondition
--
Before further
flight.
Option 2 - Do items (1) and (2)
as follows:
Condition 3 -
Crack cannot
be removed
with a maxi-
mum hole diam-
eter of 0.408
inch or any size
crack on lower
fastener hole.
(1) Remove and replace hori-
zontal stabilizer rear spar up-
per cap as given in Accomplish-
ment Instructions 3.B.1. Part
2.
AND
--Within 20,000 flight
cycles after repair.
(2) Do high frequency eddy
current inspection as given in
Accomplishment Instructions
3.B.1. Part 2. for the conditions
that follow:
3,980 flight cycles.Within 11,000
flight cycles after
the last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 3,980 flight
cycles after the
Revision 2 date of
this service bul-
letin.
Prior inspection done by
Method 3:
(with bolt removed).
OR
1,300 flight cycles.Within 4,100 flight
cycles after the
last inspection
was done as given
in the Original Is-
sue, or Revision 1,
of this service bul-
letin.
Within 1,300 flight
cycles after the
Revision 2 date of
this service bul-
letin.
Prior inspection done by
Method 4:
(with bolt not removed).
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### Page 30

Table 19 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 3, Option 3
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs Later)
ActionCondition
--
Before further
flight.
Option 3 - Do items (1) and (2)
as Follows:
Condition 3 -
Crack cannot
be removed
with a maxi-
mum hole diam-
eter of 0.408
inch or any size
crack on lower
fastener hole.
(1) Install horizontal stabilizer
rear spar upper cap splice as
given in Accomplishment In-
structions 3.B.1. Part 2.
AND
--Before further
flight.
(2) Install bushings and cold
work hole as given in Accom-
plishment Instructions 3.B.1.
Part 2.
AND
3,200 flight cycles.-Before the accumu-
lation of 50,000 to-
tal flight cycles af-
ter the installation
of bushings.
(3) Do high frequency eddy
current inspection (Methods 4,
with bolt not removed) as given
in Accomplishment Instructions
3.B.1. Part 2.
Table 20 - Inspect Horizontal Stabilizer Rear Spar Upper Caps for Cracks - Condition 3, Option 4
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Oc-
curs Later)
ActionCondition
--
Before further
flight.
Option 4 - Do items (1), (2) and
(3) as Follows:
Condition 3 -
Crack cannot
be removed
with a maxi-
mum hole diam-
eter of 0.408
inch or any size
crack on lower
fastener hole.
(1) Remove and replace hori-
zontal stabilizer rear spar up-
per cap as given in Accomplish-
ment Instructions 3.B.1. Part
2.
AND
--Before further
flight.
(2) Install bushings and cold
work hole as given in Accom-
plishment Instructions 3.B.1.
Part 2.
AND
3,200 flight cycles.-Before the accumu-
lation of 50,000 to-
tal flight cycles af-
ter the installation
of bushings.
(3) Do high frequency eddy
current inspection (Method 4,
with bolt not removed) as given
in Accomplishment Instructions
3.B.1. Part 2.
Horizontal Stabilizer Lower Aft Skin Panels:
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### Page 31

Table 21 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - All Airplanes
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 854
flight cycles af-
ter the Original
Issue date of
this service bul-
letin.
Before the ac-
cumulation of
20,000 total
flight cycles.
Do initial eddy current inspection of
horizontal stabilizer as given in Accom-
plishment Instructions 3.B.1.
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
All Airplanes
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
Table 22 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - Condition 1
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
2,600 flight cycles.
--Do eddy current inspection as given in
Accomplishment Instructions 3.B.1. Part
3. for the conditions that follow:
Condition 1 -
No Cracks
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cycles.--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
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Table 23 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - Condition 2, Option 1
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichev-
er Occurs Later)
ActionCondition
--
Before further
flight.
Option 1 - Do items (1), (2) and (3) as follows:
(1) Stop drill end of crack as given in Accomplish-
ment Instructions 3.B.1. Part 3.
Condition 2
- Crack
Length 2.0
Inches or
Shorter AND
500 flight cy-
cles.
--(2) Do high frequency eddy current inspection
as given in Accomplishment Instructions 3.B.1.
Part 3. for the conditions that follow:
Length of crack is 1.75 inches or shorter.
or
200 flight cy-
cles.
--Length of crack is 1.76 to 2.00 inches.
AND
--Within 4,000
flight cycles
after stop drill
repair. (a)
(3) Do Option 3 or 4 as given in Accomplishment
Instructions 3.B.1. Part 3.
(a) Follow the compliance and repeat inspection requirements given until the work of Options 3 or 4 is done,
then follow the compliance and repeat inspection requirements of Options 3 or 4.
Table 24 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - Condition 2, Option 2
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 2 - Do items (1), (2) and (3) as
follows:
Condition 2 -
Crack Length
2.0 Inches or
Shorter
(1)Trim out crack and install filler as
given in Accomplishment Instructions
3.B.1. Part 3.
AND
1,000 flight cycles.--(2) Do high frequency eddy current in-
spection as given in Accomplishment
Instructions 3.B.1. Part 3.
AND
--Within 4,000
flight cycles af-
ter trim out re-
pair. (a)
(3) Do Option 3 or 4 as given in Accom-
plishment Instructions 3.B.1. Part 3.
(a) Follow the compliance and repeat inspection requirements given until the work of Options 3 or 4 is done,
then follow the compliance and repeat inspection requirements of Options 3 or 4.
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Table 25 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - Condition 2, Option 3
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 3 - Do items (1) and (2) as fol-
lows:
Condition 2 -
Crack Length
2.0 Inches or
Shorter
(1) Install horizontal stabilizer lower aft
skin panel splice as given in Accomplish-
ment Instructions 3.B.1. Part 3.
AND
2,600 flight cycles
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 3. for the conditions that follow:
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cycles.--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
Table 26 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - Condition 2, Option 4
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 4 - Do items (1) and (2) as fol-
lows:
Condition 2 -
Crack Length
2.0 Inches or
Shorter
(1) Remove and replace horizontal sta-
bilizer lower aft skin panel as given in
Accomplishment Instructions 3.B.1. Part
3.
AND
2,600 flight cycles.
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 3.
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cycles.--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
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Table 27 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - Condition 3, Option 1
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 1 - Do items (1) and (2) as fol-
lows:
Condition 3 -
Crack Length
Longer than
2.0 Inches
(1) Install horizontal stabilizer lower aft
skin panel splice as given in Accomplish-
ment Instructions 3.B.1. Part 3.
AND
2,600 flight cycles
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 3. for the conditions that follow:
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cycles.--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
Table 28 - Inspect Horizontal Stabilizer Lower Aft Skin Panels for Cracks - Condition 3, Option 2
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--
Before further
flight.
Option 2 - Do items (1) and (2) as fol-
lows:
Condition 3 -
Crack Length
Longer than
2.0 Inches
(1) Remove and replace horizontal sta-
bilizer lower aft skin panel as given in
Accomplishment Instructions 3.B.1. Part
3.
AND
2,600 flight cycles.
-Within 20,000
flight cycles af-
ter repair.
(2) Do eddy current inspection as given
in Accomplishment Instructions 3.B.1.
Part 3. for the conditions that follow:
If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 1 - low frequency
or
2,000 flight cycles.--If prior inspection done by:
Scan 1 and 2 - high frequency
Scan 3, Method 2 - high frequency
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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
Union 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.
In addition, the Manager of the FAA Los Angeles ACO Branch approves accomplishment of the
inspection, repair and modification defined in this bulletin revision as an alternative method of compliance
to accomplishing the requirements of paragraph (f) and (g) of AD 2007-10-04. All provisions of AD
2007-10-04 that are not specifically referenced in the above statement remain fully applicable and must
be complied with accordingly.
G. Manpower
The table below shows an estimate of the task hours necessary to do the Inspection/change/repair 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.
— Time to make reference standards.
All Airplanes:
Eddy Current Inspection (all parts)
Elapsed HoursTask HoursNumber of PersonsTask
6.012.02Remove/Install bolts
in spar cap*
4.08.02Inspect
4.0 - 10.08.0 - 20.0TOTAL FOR EACH AIRPLANE
* Removal of bolts is required for Method 1 inspection only.
Part 1: Horizontal Stabilizer Upper Aft Skin Panel
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Condition 2, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
2.04.02Stop Drill Repair
2.04.0TOTAL FOR EACH AFT SKIN PANEL
Condition 2, Option 2
Elapsed HoursTask HoursNumber of PersonsTask
4.08.02Trim out Repair
4.08.0TOTAL FOR EACH AFT SKIN PANEL
Condition 2, Option 3; Condition 3, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
168.0504.03Install Horizontal
Stabilizer Upper Aft
Skin Panel Splice
Repair
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
8.048.06Install - Horizontal
Stabilizer
212.0656.0TOTAL FOR EACH AFT SKIN PANEL
Condition 2, Option 4; Condition 3, Option 2
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
168.0504.03Remove and re-
place Horizontal
Stabilizer Upper Aft
Skin Panel
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Condition 2, Option 4; Condition 3, Option 2
Elapsed HoursTask HoursNumber of PersonsTask
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
8.048.06Install - Horizontal
Stabilizer
212.0656.0TOTAL FOR EACH AFT SKIN PANEL
Part 2: Horizontal Stabilizer Rear Spar Upper Cap
Condition 1, Option 2
Elapsed HoursTask HoursNumber of PersonsTask
6.012.02Remove bolts in
spar cap
1.02.02Install bushing and
cold work hole
6.012.02Install bolts in spar
cap
13.026.0TOTAL FOR EACH SPAR CAP
Condition 2, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
6.06.01Remove Crack and
Repair
6.06.0TOTAL FOR EACH SPAR CAP
Condition 2, Option 2; Condition 3, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
72.0216.03Install Horizontal
Stabilizer rear spar
upper cap splice
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
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Condition 2, Option 2; Condition 3, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Install - Horizontal
Stabilizer
116.0368.0TOTAL FOR EACH SPAR CAP
Condition 2, Option 3; Condition 3, Option 2
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
72.0216.03Install Horizontal
Stabilizer rear spar
upper cap
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
8.048.06Install - Horizontal
Stabilizer
116368.0TOTAL FOR EACH SPAR CAP
Condition 2, Option 4; Condition 3, Option 3
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
72.0216.03Install Horizontal
Stabilizer rear spar
upper cap splice
13.026.02Install bushing/cold
work hole
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
8.048.06Install - Horizontal
Stabilizer
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Condition 2, Option 4; Condition 3, Option 3
Elapsed HoursTask HoursNumber of PersonsTask
129.0394.0TOTAL FOR EACH SPAR CAP
Condition 2, Option 5; Condition 3, Option 4
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
72.0216.03Install Horizontal
Stabilizer rear spar
upper cap
13.026.02Install bushing/cold
work hole
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
8.048.06Install - Horizontal
Stabilizer
129394.0TOTAL FOR EACH SPAR CAP
Part 3: Horizontal Stabilizer Lower Aft Skin Panel
Condition 2, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
2.04.02Stop drill repair
2.04.0TOTAL FOR EACH AFT SKIN PANEL
Condition 2, Option 2
Elapsed HoursTask HoursNumber of PersonsTask
4.08.02Trim out Repair
4.08.0TOTAL FOR EACH AFT SKIN PANEL
Condition 2, Option 3; Condition 3, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
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Condition 2, Option 3; Condition 3, Option 1
Elapsed HoursTask HoursNumber of PersonsTask
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
168.0504.03Install Horizontal
Stabilizer Lower Aft
Skin Panel Splice
Repair
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
8.048.06Install - Horizontal
Stabilizer
212.0656.0TOTAL FOR EACH AFT SKIN PANEL
Condition 2, Option 4; Condition 3, Option 2
Elapsed HoursTask HoursNumber of PersonsTask
8.048.06Remove - Horizon-
tal Stabilizer
8.016.02Remove - Elevators
6.012.02Remove - Leading
Edge
168.0504.03Remove and re-
place Horizontal
Stabilizer Lower Aft
Skin Panel
6.012.02Install - Leading
Edge
8.016.02Install - Elevators
8.048.06Install - Horizontal
Stabilizer
212.0656.0TOTAL FOR EACH AFT SKIN PANEL
NOTE: Total task hours are dependent of actual condition of each airplane. The conditions can range
from no crack found to the unlikely possibility of cracks found on the rear spar upper caps
with cracks on the upper and lower aft skin panel, on both the left and right horizontal stabilizer.
H. Weight and Balance Changes
Part 1: Horizontal Stabilizer Upper Aft Skin Panel
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Group 1-2:
Condition 1; Condition 2, Options 1 and 2
None.
Group 1:
Condition 2, Option 3; Condition 3, Option 1
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+8754.2+5.21683.5DC-9-81 (MD-81)SR09550028-7001
+8754.2+5.21683.5DC-9-81 (MD-81)SR09550028-7003
Group 2:
Condition 2, Option 3; Condition 3, Option 1
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+5387.2+3.21683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550028-7001
+5387.2+3.21683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550028-7003
+4718.4+3.21474.5DC-9-87 (MD-87)SR09550028-7001
+4718.4+3.21474.5DC-9-87 (MD-87)SR09550028-7003
Group 1:
Condition 2, Option 4; Condition 3, Option 2
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+1683.5+1.01683.5DC-9-81 (MD-81)SR09550031-7017
+1683.5+1.01683.5DC-9-81 (MD-81)SR09550031-7019
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Group 2:
Condition 2, Option 4; Condition 3, Option 2
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+1683.5+1.01683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550031-7017
+1683.5+1.01683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550031-7019
+1474.5+1.01474.5DC-9-87 (MD-87)SR09550031-7017
+1474.5+1.01474.5DC-9-87 (MD-87)SR09550031-7019
Part 2: Horizontal Stabilizer Rear Spar Upper Cap
Group 1-2:
Condition 1; Condition 2, Options 1 and 3; Condition 3, Option 2
None.
Group 1:
Condition 2, Option 2; Condition 3, Option 1
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+5312.3+3.21660.1DC-9-81 (MD-81)SR09550027-7001
+5312.3+3.21660.1DC-9-81 (MD-81)SR09550027-7003
Group 2:
Condition 2, Option 2; Condition 3, Option 1
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+5312.3+3.21660.1DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550027-7001
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Group 2:
Condition 2, Option 2; Condition 3, Option 1
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+5312.3+3.21660.1DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550027-7003
+4643.5+3.21451.1DC-9-87 (MD-87)SR09550027-7001
+4643.5+3.21451.1DC-9-87 (MD-87)SR09550027-7003
Part 3: Horizontal Stabilizer Lower Aft Skin Panel
Group 1-2:
Condition 1; Condition 2, Options 1 and 2
None.
Group 1:
Condition 2, Option 3; Condition 3, Option 1
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+12289.6+7.31683.5DC-9-81 (MD-81)SR09550029-7001
+12289.6+7.31683.5DC-9-81 (MD-81)SR09550029-7003
Group 2:
Condition 2, Option 3; Condition 3, Option 1
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+12289.6+7.31683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550029-7001
+12289.6+7.31683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550029-7003
+7667.4+5.31474.5DC-9-87 (MD-87)SR09550029-7001
+7667.4+5.31474.5DC-9-87 (MD-87)SR09550029-7003
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Group 1:
Condition 2, Option 4; Condition 3, Option 2
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+5218.9+3.11683.5DC-9-81 (MD-81)SR09550031-7013
+5218.9+3.11683.5DC-9-81 (MD-81)SR09550031-7015
Group 2:
Condition 2, Option 4; Condition 3, Option 2
Moment
Change (MEW)
IN.-LBS
Mfr's Empty
Weight (MEW)
LBS
Approximate
Station (Inch-
es)
AirplaneConfiguration
+1683.5+1.01683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550031-7009
+1683.5+1.01683.5DC-9-81 (MD-81)
DC-9-82 (MD-82)
DC-9-83 (MD-83)
MD-88
SR09550031-7011
+1474.5+1.01474.5DC-9-87 (MD-87)SR09550031-7009
+1474.5+1.01474.5DC-9-87 (MD-87)SR09550031-7011
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. DC-9, MD-80 Structural Repair Manual (SRM) 51-10-02A, 51-10-03, 51-10-04, 51-20-00,
51-30-01, 51-30-02, 51-30-03, 51-30-05, 51-30-09, 51-30-11.
b. MD-80 Aircraft Maintenance Manual (AMM) 27-30-02, 55-10-00, 55-10-01.
c. Multi Operator Message (MOM) 1-300151711-1, dated March 15, 2007.
d. Multi Operator Message (MOM) 1-309950983-5, dated April 4, 2007.
e. Approved Equivalent Parts Lists (AEPL) 7595091.
f. Nondestructive Testing Standard Practices Manual NDTSPM 01-00-01 and NDTSPM 06-00-01.
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### Page 45

g. FAA Airworthiness Directive AD 2007-10-04.
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
ChangeTitleDrawing Number
DAStructural Assembly - Horizontal Stabilizer Outer Panel, Front
Spar to Rear Spar
5922575
BFStabilizer Assembly - Complete Horizontal5930603
DCSpar Assembly - Horizontal Stabilizer, Rear9918401
These drawings were used to prepare this service bulletin. These drawings were necessary to
make the specified changes, and are not supplied with this service bulletin. This drawing may not
be applicable to all airplane configurations or operators.
K. Publications Affected
Chapter-SectionPublication
53-55On Aircraft Maintenance Planning (OAMP)
55-10Structural Repair Manual
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.
Export Controlled ECCN: 9E991
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### Page 46

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### Page 47

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown
below. Contact Boeing Spares for pricing and availability.
Part 1:
Condition 2, Option 3; Condition 3, Option 1
NameKit Number
Full Panel Splice Kit - Upper LeftSA09550065-13
Full Panel Splice Kit - Upper RightSA09550065-15
Condition 2, Option 4; Condition 3, Option 2
NameKit Number
Full Panel Replacement Kit - Upper LeftSA09550065-49
Full Panel Replacement Kit - Upper RightSA09550065-51
Part 2:
Condition 1, Option 2; Condition 2, Option 4; Condition 2, Option 5 Condition 3, Option 1;
Condition 3, Option 2
NameKit Number
Forcemate Bushing Kit - NominalSA09550065-61
Forcemate Bushing Kit - OversizeSA09550065-63
Condition 2, Option 1
NameKit Number
Bushing Repair KitSA09550065-11
Condition 2, Option 2; Condition 3, Option 1
NameKit Number
Full Spar Kit - Upper LeftSA09550065-3
Full Spar Kit - Upper RightSA09550065-5
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### Page 48

Condition 2, Option 3; Condition 3, Option 2
NameKit Number
Full Spar Cap Replacement Kit - Upper LeftSA09550065-53
Full Spar Cap Replacement Kit - Upper RightSA09550065-55
Full Spar Cap Replacement Kit - Lower LeftSA09550065-57
Full Spar Cap Replacement Kit - Lower RightSA09550065-59
Part 3:
Condition 2, Option 3; Condition 3, Option 1
NameKit Number
Full Panel Splice Kit - Lower LeftSA09550065-33
Full Panel Splice Kit - Lower RightSA09550065-35
Condition 2, Option 4; Condition 3, Option 2
NameKit Number
Full Panel Replacement Kit - Lower LeftSA09550065-41
Full Panel Replacement Kit - Lower RightSA09550065-43
Full Panel Replacement Kit - Lower LeftSA09550065-45
Full Panel Replacement Kit - Lower RightSA09550065-47
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars.
Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of the methods that
follow:
1. Order on-line via ATA Spec 2000 or Boeing Part Page.
2. Fax to (206) 662-7145.
3. Spares Customer Support - MC 36-65
Boeing Spares Department
P.O. Box 3707
Seattle, Washington 98124-2207 USA
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### Page 49

B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair
procedures given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts:
To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: Combination of service kits/parts and the items shown in Paragraph 2.C.2., Parts and
Materials Supplied by the Operator, are necessary for each airplane based on inspection
results and repair option.
Service Bulletin kits are determined by the SR drawing configuration repair/modification required
for your airplane. Service Bulletin kits relative to Service Rework Drawing are as follows:
SB KitNameSR Drawing Config-
uration
SA09550065-3FULL SPAR SPLICE KIT - UPPER LEFTSR09550027-7001
SA09550065-5FULL SPAR SPLICE KIT - UPPER RIGHTSR09550027-7003
SA09550065-11BUSHING REPAIR KITSR09550027-7005
SA09550065-13FULL PANEL SPLICE KIT - UPPER LEFTSR09550028-7001
SA09550065-15FULL PANEL SPLICE KIT - UPPER RIGHTSR09550028-7003
SA09550065-33FULL PANEL SPLICE KIT - LOWER LEFTSR09550029-7001
SA09550065-35FULL PANEL SPLICE KIT - LOWER RIGHTSR09550029-7003
SA09550065-41FULL PANEL REPLACEMENT KIT -LOWER
LEFT
SR09550031-7009
SA09550065-43FULL PANEL REPLACEMENT KIT -LOWER
RIGHT
SR09550031-7011
SA09550065-45FULL PANEL REPLACEMENT KIT -LOWER
LEFT
SR09550031-7013
SA09550065-47FULL PANEL REPLACEMENT KIT -LOWER
RIGHT
SR09550031-7015
SA09550065-49FULL PANEL REPLACEMENT KIT -UPPER
LEFT
SR09550031-7017
SA09550065-51FULL PANEL REPLACEMENT KIT -UPPER
RIGHT
SR09550031-7019
SA09550065-53FULL SPAR CAP REPLACEMENT KIT -UP-
PER LEFT
SR09550030-7001
SA09550065-57FULL SPAR CAP REPLACEMENT KIT -
LOWER LEFT
SR09550030-7003
Export Controlled ECCN: 9E991
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### Page 50

SB KitNameSR Drawing Config-
uration
SA09550065-55FULL SPAR CAP REPLACEMENT KIT -UP-
PER RIGHT
SR09550030-7005
SA09550065-59FULL SPAR CAP REPLACEMENT KIT -
LOWER RIGHT
SR09550030-7007
SA09550065-61FORCEMATE BUSHING KIT- NOMINALSR09550032-7001/-
7005
SA09550065-63FORCEMATE BUSHING KIT- OVERSIZESR09550032-7003/-
7007
Part 1 - Horizontal Stabilizer Upper Aft Skin Panels:
Part 1 - Condition 2, Option 3; Condition 3, Option 1:
Kit SA09550065
NameQTYNew Part Number
Note-19-17-15-13
(a)PANEL SPLICE INSTALLATION
KIT - UPPER LEFT
.-.1SA09550065-17
(b)PANEL SPLICE INSTALLATION
KIT - UPPER RIGHT
-.1.SA09550065-19
NUT - BARREL99..117LH7940T-064
NUT ASSEMBLY115115..3D0006-3
BOLT99..3D0031-6-26
FILLER1818..5930603-7
WASHER99..73232-6-12.4
PIN9797..HLT435-6-4
PIN5959..HLT435-6-5
PIN1919..HLT435-6-6
PIN1818..HLT439-8-3
PIN4444..HLT439-8-4
PIN1010..HLT439-8-5
RIVET1616..MS20426AD5-7D
RIVET22..MS20426AD6-10D
RIVET1010..MS20426AD6-8D
RIVET2424..MS20470AD6-8D
NUT77..MS21042L08
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### Page 51

Part 1 - Condition 2, Option 3; Condition 3, Option 1:
Kit SA09550065
NameQTYNew Part Number
Note-19-17-15-13
NUT216216..MS21042L3
NUT7272..MS21042L4
RIVET3737..NAS1097AD6-8D
RIVET2929..NAS1097KE6-9D
RIVET44..NAS1097KE8-11D
WASHER77..NAS1149FN832P
BOLT77..NAS1202-3
WASHER216216..NAS1252-10L
WASHER7272..NAS1252-416L
BOLT22..PIC239-4-5
PIN2222..S4931919-6-2
PIN2424..S4931919-6-3
PIN7272..S4931919-6-4
PIN1818..S4931919-6-5
PIN1616..S4931920-6-3
PIN88..S4931920-6-4
SPLICE11..SR09550028-11
SPLICE11..SR09550028-13
PANEL (STUB)...1SR09550028-3
PANEL (STUB)..1.SR09550028-4
STIFFENER33..SR09550028-5
DOUBLER11..SR09550028-7
SPLICE11..SR09550028-9
(a) SA09550065-17 is a sub kit of SA09550065-13
(b) SA09550065-19 is a sub kit of SA09550065-15
Export Controlled ECCN: 9E991
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### Page 52

Part 1 - Condition 2, Option 4; Condition 3, Option 2:
Kit SA09550065
Existing Part Num-
ber
NameQTYNew Part Number
-51-49
NUT - BARREL99117LH7940T-064
FILLER18183964835-509
NUT ASSY1071073D0006-3
BOLT993D0031-6-26
WASHER9973232-6-12.4
HI-LOK2222HLT435-6-3
PIN107107HLT435-6-4
PIN6363HLT435-6-5
PIN44HLT435-6-6
PIN125125HLT439-8-3
PIN4444HLT439-8-4
PIN44HLT439-8-6
RIVET1616MS20426AD5-6D
RIVET9696MS20426AD5-7D
RIVET22MS20426AD6-10D
RIVET4242MS20426AD6-7D
RIVET150150MS20426AD6-8D
RIVET1212MS20470AD5-6D
RIVET88MS20470AD5-7D
RIVET1616MS20470AD6-7D
RIVET4848MS20470AD6-8D
NUT77MS21042L08
NUT104104MS21042L3
NUT173173MS21042L4
RIVET1616NAS1097AD6-8D
RIVET1212NAS1097KE5-7D
RIVET1616NAS1097KE6-7D
RIVET5757NAS1097KE6-8D
RIVET6363NAS1097KE6-9D
RIVET44NAS1097KE8-10D
Export Controlled ECCN: 9E991
Copyright © Unpublished
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### Page 53

Part 1 - Condition 2, Option 4; Condition 3, Option 2:
Kit SA09550065
Existing Part Num-
ber
NameQTYNew Part Number
-51-49
WASHER77NAS1149FN832P
BOLT77NAS1202-3
WASHER104104NAS1252-10L
WASHER173173NAS1252-416L
BOLT22PIC239-3-4
BOLT11PIC239-4-4
BOLT11PIC239-4-5
PIN77S4931919-6-3
PIN66S4931919-6-4
PIN66S4931919-6-5
Part 2 - Horizontal Stabilizer Rear Spar Upper Caps:
Part 2 - Condition 1, Option2; Condition 2, Option 4; Condition 2, Option 5; Condition 3
Option 1; Condition 3, Option 2:
Kit SA09550065
Existing Part
Number
NameQTYNew Part Number
-63-61
BUSHING.27090-040
BUSHING2.7090-041
BUSHING2.7090-042
BUSHING.27090-043
BUSHING2.7090-044
BUSHING2.7090-045
HI-LOK11HLT434-8-13
PIN11HLT634-8-13
NUT11MS21042L4
WASHER11NAS1252-416L
WASHER.2NAS620-416L
BOLT.2NAS6204-13
BOLT2.NAS6204-15
Export Controlled ECCN: 9E991
Copyright © Unpublished
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### Page 54

Part 2 - Condition 1, Option2; Condition 2, Option 4; Condition 2, Option 5; Condition 3
Option 1; Condition 3, Option 2:
Kit SA09550065
Existing Part
Number
NameQTYNew Part Number
-63-61
NUT22NAS679A4
WASHER2.SR09550032-3
WASHER2.SR09550032-5
Part 2 - Condition 2, Option 1:
Kit SA09550065
NameQTYNew Part Number
-11
BUSHING REPAIR KIT-SA09550065-11
WASHER3NAS620-416L
BOLT3NAS6204-13
NUT3NAS679A4
BUSHING2SR09550027-15
WASHER2SR09550027-17
Part 2 - Condition 2, Option 2; Condition 3, Option 1:
Kit SA09550065
NotesNameQTYNew Part Num-
ber -9-7-5-3
(a)SPAR SPLICE INSTALLATION
KIT - UPPER LEFT
.-.1SA09550065-7
(b)SPAR SPLICE INSTALLATION
KIT - UPPER RIGHT
-.1.SA09550065-9
NUT ASSEMBLY2424..3D0006-3
ANGLE11..9918401-59
PIN44..HLT434-6-11
PIN88..HLT434-6-6
PIN88..HLT434-6-8
PIN1414..HLT434-6-9
PIN22..HLT435-6-5
Export Controlled ECCN: 9E991
Copyright © Unpublished
Work - See page 1 for details.
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### Page 55

Part 2 - Condition 2, Option 2; Condition 3, Option 1:
Kit SA09550065
NotesNameQTYNew Part Num-
ber -9-7-5-3
PIN22..HLT435-6-6
PIN44..HLT435-6-7
PIN1414..HLT435-6-8
PIN1515..HLT435-6-9
NUT5151..MS21042L3
WASHER4545..NAS1252-10L
RADIUS WASHER1010..NAS1401-3D3
WASHER33..NAS620-416L
BOLT33..NAS6204-13
NUT33..NAS679A4
PIN44..S4931920-6-6
SPACER11..SR09550027-11
(c)SPAR CAP (STUB)...1SR09550027-13
(d)SPAR CAP (STUB)..1.SR09550027-14
SPACER11..SR09550027-19
SPACER11..SR09550027-23
SPACER11..SR09550027-25
ANGLE.1..SR09550027-3
ANGLE1...SR09550027-4
ANGLE.1..SR09550027-5
ANGLE1...SR09550027-6
DOUBLER.1..SR09550027-7
DOUBLER1...SR09550027-8
SPACER11..SR09550027-9
(a) SA09550065-7 is a sub kit of SA09550065-3
(b) SA09550065-9 is a sub kit of SA09550065-5
(c) May be made from 5918000-526
(d) May be made from 5918000-525
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### Page 56

Part 2 - Condition 2, Option 3; Condition 3, Option 2:
Kit SA09550065
Existing Part
Number
NameQTYNew Part Number
-59-57-55-53
NUT3333113LH7940T064
NUT4444113LH7940T070
BARREL NUT1111113LH7940T080
NUT BARREL2222117LH7940T-098
NUT ASSY999999993D0006-3
NUT ASSY55553D0006-4
BARREL NUTSUBSUBSUBSUB3D0011-9
RETAINERSUBSUBSUBSUB3D0012-9
BOLT22223D0031-9-34
NUT22..3D0043-5
5918000-523
5918000-527
SPAR CAP.1..5918000-523
5918000-524
5918000-528
SPAR CAP1...5918000-524
5918000-525
5918000-529
SPAR CAP..1.5918000-525
5918000-526
5918000-530
SPAR CAP...15918000-526
WASHER ASSY222273232-9-28.7
PIN33..HLT434-6-10
PIN5555HLT434-6-11
PIN5555HLT434-6-3
PIN73737272HLT434-6-4
PIN32323232HLT434-6-5
PIN18181818HLT434-6-6
PIN18181818HLT434-6-7
PIN25252525HLT434-6-8
PIN2222HLT434-6-9
HILOK3333HLT434-8-13
HILOK2222HLT434-8-16
HILOK22..HLT434-8-7
Export Controlled ECCN: 9E991
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### Page 57

Part 2 - Condition 2, Option 3; Condition 3, Option 2:
Kit SA09550065
Existing Part
Number
NameQTYNew Part Number
-59-57-55-53
HILOK1111HLT434-8-8
PIN82828484HLT435-6-4
PIN78787777HLT435-6-5
PIN101099HLT435-6-6
PIN13131313HLT435-6-7
PIN4444HLT435-6-8
WASHER2222MS20002-5
WASHER1111MS20002-6
WASHER1111MS20002-7
WASHER2222MS20002C5
WASHER3333MS20002C6
WASHER4444MS20002C7
WASHER1111MS20002C8
RIVET6666MS20426AD3-4D
RIVET1111MS20426AD5-8D
RIVET45454545MS20426AD5-9D
RIVET4444MS20426AD6-10D
RIVET95959595MS20426AD6-8D
RIVET57575757MS20426AD6-9D
RIVET20202020MS20470AD5-8D
RIVET106106106106MS20470E5-6D
RIVET20202020MS20470E5-7D
RIVET52525252MS20470E6-7D
RIVET26262626MS20470E6-8D
NUT295295291291MS21042L3
NUT22..MS21042L4
NUTPLATE5555MS21075L3
BOLT2222MS21250-05018
BOLT1111MS21250-06020
BOLT1111MS21250-06022
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### Page 58

Part 2 - Condition 2, Option 3; Condition 3, Option 2:
Kit SA09550065
Existing Part
Number
NameQTYNew Part Number
-59-57-55-53
BOLT1111MS21250-06024
BOLT1111MS21250-07020
BOLT1111MS21250-07024
BOLT1111MS21250-07026
BOLT1111MS21250-08028
BOLT.1.1MS21250H07060
RIVET8888NAS1097KE5-8D
RIVET7777NAS1097KE5-9D
RIVET4444NAS1097KE6-11D
RIVET44444444NAS1097KE6-8D
RIVET59595959NAS1097KE6-9D
WASHER78787878NAS1149F0332P
WASHER24242424NAS1149F0463P
WASHER14141414NAS1149FN816P
WASHER320320316316NAS1252-10L
WASHER33..NAS1252-416L
SCREW14141414NAS1403-2
SCREW20202020NAS1403-4
SCREW30303030NAS1403-5
SCREW4444NAS1403-8
WASHER23232323NAS1587A3C
SCREW1111NAS333CPA4-5
RETAINER3333NAS578-6B
RETAINER4444NAS578-7B
RETAINER1111NAS578-8B
SCREW24242424NAS602-7P
WASHER6666NAS620-416L
BOLT6666NAS6203-10
BOLT8888NAS6203-6
BOLT6666NAS6204-13
Export Controlled ECCN: 9E991
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### Page 59

Part 2 - Condition 2, Option 3; Condition 3, Option 2:
Kit SA09550065
Existing Part
Number
NameQTYNew Part Number
-59-57-55-53
BOLT24242424NAS6204-4
NUT34343131NAS679A3
NUT7777NAS679A4
BOLT1111PIC239-3-4
BOLT2222PIC239-4-4
PIN4444S4931919-6-5
PIN8888S4931920-6-4
PIN10101010S4931920-6-5
PIN14141414S4931920-6-6
PIN4444S4931920-6-7
PIN6666S4931920-6-8
Part 3 - Horizontal Stabilizer Lower Aft Skin Panels:
Part 3 - Condition 2, Option 3; Condition 3, Option 1:
Kit SA09550065
NoteNameQTYNew Part Number
-39-37-35-33
(a)PANEL SPLICE INSTALLATION
KIT - LOWER LEFT
.-.1SA09550065-37
(b)PANEL SPLICE INSTALLATION
KIT - LOWER RIGHT
-.1.SA09550065-39
NUT - BARREL99..117LH7940T-064
NUT ASSY123123..3D0006-3
BOLT99..3D0031-6-26
FILLER1818..5930603-7
WASHER99..73232-6-12.4
PIN9797..HLT435-6-4
PIN5959..HLT435-6-5
PIN1515..HLT435-6-6
PIN88..HLT435-6-7
Export Controlled ECCN: 9E991
Copyright © Unpublished
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### Page 60

Part 3 - Condition 2, Option 3; Condition 3, Option 1:
Kit SA09550065
NoteNameQTYNew Part Number
-39-37-35-33
PIN44..HLT439-8-3
PIN4444..HLT439-8-4
PIN1010..HLT439-8-5
RIVET66..MS20426AD4-6D
RIVET1616..MS20426AD5-7D
RIVET22..MS20426AD6-10D
RIVET1010..MS20426AD6-8D
RIVET1818..MS20470AD6-8D
NUT212212..MS21042L3
NUT5858..MS21042L4
RIVET1616..NAS1097AD6-8D
RIVET1212..NAS1097KE6-9D
RIVET44..NAS1097KE8-11D
WASHER212212..NAS1252-10L
WASHER5858..NAS1252-416L
STIFFENER33..SR09550028-5
PIN2222..S4931919-6-2
PIN5656..S4931919-6-3
PIN3636..S4931919-6-4
PIN1616..S4931919-6-5
PIN1616..S4931920-6-3
PIN88..S4931920-6-4
SPLICE11..SR09550029-11
SPLICE11..SR09550029-13
STRAP22..SR09550029-15
SHIM11..SR09550029-17
PANEL...1SR09550029-3
PANEL..1.SR09550029-4
DOUBLER11..SR09550029-7
SPLICE11..SR09550029-9
Export Controlled ECCN: 9E991
Copyright © Unpublished
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