# Boeing Alert Service Bulletin MD80-55A069: No revision named

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- Document: [Boeing Alert Service Bulletin MD80-55A069](https://openairdocs.org/service-documents/boeing/md80-55a069.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin
SB-MD80-55A069-00
- Pages: 53
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### Page 1

Commercial 
Airplanes
MD80
Service Bulletin
ALERT
Number: MD80-55A069
Original Issue: January 19, 2011
ATA System: 5511
SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Horizontal Stabilizer
Center Section Left and Right Rib Hinge Bearing Lugs
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 730-774). An export license may be required before it is used for development, production or use by foreign
persons from specific countries. The controller of this data has the individual responsibility to abide by all export
laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET
Copyright © 2011 The Boeing Company
Unpublished Work - All Rights Reserved
Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable
subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more
information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the
Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
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Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
2. Spares Affected ........................................ 1 3
B. Concurrent Requirements ...................................... 1 3
C. Reason ................................................ 1 3
D. Description .............................................. 1 4
E. Compliance .............................................. 1 5
F. Approval ............................................... 1 7
G. Manpower .............................................. 1 8
H. Weight and Balance Changes .................................... 1 8
I. Electrical Load Data ......................................... 1 8
J. References .............................................. 1 8
1. Existing Data .......................................... 1 8
2. Data supplied with this Service Bulletin ............................ 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 9
K. Publications Affected ........................................ 1 9
L. Interchangeability and Intermixability of Parts ........................... 1 9
2. MATERIAL INFORMATION ........................................ 2 1
A. Material - Price and Availability ................................... 2 1
B. Industry Support Information .................................... 2 1
C. Parts Necessary For Each Airplane ................................. 2 1
1. Kits/Parts ............................................ 2 1
2. Parts and Materials Supplied by the Operator ........................ 2 2
3. Parts Modified and Reidentified ................................ 2 2
4. Parts Removed and Not Replaced .............................. 2 2
D. Parts Necessary to Change Spares ................................. 2 2
E. Special Tooling - Price and Availability ............................... 2 2
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3
A. GENERAL INFORMATION ..................................... 2 3
B. WORK INSTRUCTIONS ....................................... 2 4
FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS .............. 2 7
FIGURE 2: CRACK LENGTH MEASUREMENT .............................. 3 1
FIGURE 3: BLEND OUT REPAIR ..................................... 3 4
FIGURE 4: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS .............. 4 4
APPENDIX A: TEMPLATE/SHIELD SHOP AID ................................ 4 6
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Commercial 
Airplanes
MD80
Service Bulletin
ALERT
SummaryNumber: MD80-55A069Original Issue: January 19, 2011
ATA System: 5511
SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Horizontal Stabilizer
Center Section Left and Right Rib Hinge Bearing Lugs
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Boeing has received two reports of cracks being found on either the left or right MD-80 horizontal stabilizer
center section ribs. These cracks were found on the aft face of the horizontal stabilizer hinge bearing lugs.
Cracks were reported on MD-80 airplanes with between 23,700 and 41,963 flight-hours and 23,300 and 35,294
flight cycles. In addition, eleven cracks at the same location have been reported in either the left or right, or in
two cases, both of the MD-90 horizontal stabilizer center section ribs. Accordingly, MD-90 Alert Service Bulletin
MD90-55A016 has been issued. Investigation by Boeing has yet to establish the definitive cause of these cracks.
Performing an Eddy Current, High Frequency inspection of the affected area will determine the existence of any
crack. If not corrected, undetected cracks in the center section left and right rib hinge bearing lugs could spread
at the same time which would cause both hinge bearing lugs to fail, resulting in the horizontal stabilizer being
unable to sustain the required loads.
ACTION
This service bulletin gives instructions to do an Eddy Current, High Frequency inspection of the horizontal
stabilizer center section left and right rib hinge bearing lugs for cracks and does as follows:
CONDITION 1 (No Crack Found in Rib Hinge Bearing Lug)
1. Repeats the Eddy Current, High Frequency inspection at defined intervals.
CONDITION 2 (Crack Found in Rib Hinge Bearing Lug)
1. Measures the crack length and does as follows:
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CONDITION 2A (Crack Length Between Points 'A' and 'B' is Less Than or Equal to 0.15 Inch, and
Crack Length Between Points 'C' and 'D' is Less Than or Equal to 0.05 Inch)
a. Does blend out repair to remove crack.
b. Repetitively inspects blend out area for cracks, using Eddy Current, High Frequency inspection.
CONDITION 2B (Crack Length Between Points 'A' and 'B' is Greater Than 0.15 Inch, or Crack Length
Between Points 'C' and 'D' is Greater Than 0.05 Inch)
a. Replaces horizontal stabilizer center section rib.
b. Does Eddy Current, High Frequency inspections at a defined threshold.
EFFECTIVITY
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 Airplanes. Refer to Paragraph
1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE
The Federal Aviation Administration (FAA) will possibly release an 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., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service
bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Commercial 
Airplanes
MD80
Service Bulletin
ALERT
Number: MD80-55A069
Original Issue: January 19, 2011
ATA System: 5511
SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Horizontal Stabilizer
Center Section Left and Right Rib Hinge Bearing Lugs
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP
MD-80 airplanes with horizontal stabilizer rib(s) made from
7075-T7351 material.
-1
MD-80 airplanes with horizontal stabilizer rib(s) made from
7050-T7451 material.
-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 Num-
ber
1924
1938
1941
1944
1946
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GroupFuselage Num-
ber
1948
1950
1952 - 953
1955
1957
1960
1962
1965 - 967
1969 - 971
1973
1975
1977 - 979
1981
1983
1985 - 986
1988
1991 - 992
1994 - 995
1997
1999 - 1006
11008 - 1013
11016
11018 - 1019
11022
11025
11028
11031
11034 - 1035
11043
11045
11049
11051
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GroupFuselage Num-
ber
11053
11055
11057
11059 - 1060
11063 - 1080
11082 - 1083
11085
11088 - 1093
11095 - 1110
11112 - 1128
11130 - 1181
11183 - 1223
11225 - 1290
11292 - 1323
11325 - 1334
11336 - 1337
11339 - 1340
11342 - 1343
11345 - 1350
11352 - 1450
21451
21453 - 1477
21479 - 1503
21505 - 1666
21668 - 1701
21703 - 1771
21773 - 1787
21789 - 1843
21845 - 1915
21917 - 1924
21926 - 1994
21996 - 2007
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GroupFuselage Num-
ber
22009 - 2016
22019 - 2029
22031 - 2034
22036 - 2069
22071 - 2089
22091 - 2093
22101 - 2114
22116
22118 - 2119
22121
22124
22127
22130
22132
22134 - 2135
22137
22139
22145
22148
22151 - 2152
22155
22167
22174
22176
22178
22180
22183
22185
22187
22189
22192
22196
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GroupFuselage Num-
ber
22199
22201
22204
22206
22208
22214
22218
22234
22239
22241
22244
22247
22249
22252
22254
22264 - 2287
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Boeing has received two reports of cracks being found on either the left or right MD-80 horizontal
stabilizer center section ribs. These cracks were found on the aft face of the horizontal stabilizer hinge
bearing lugs. Cracks were reported on MD-80 airplanes with between 23,700 and 41,963 flight-hours
and 23,300 and 35,294 flight cycles. In addition, eleven cracks at the same location have been reported
in either the left or right, or in two cases, both of the MD-90 horizontal stabilizer center section ribs.
Accordingly, MD-90 Alert Service Bulletin MD90-55A016 has been issued. Investigation by Boeing has
yet to establish the definitive cause of these cracks. Performing an Eddy Current, High Frequency
inspection of the affected area will determine the existence of any crack. If not corrected, undetected
cracks in the center section left and right rib hinge bearing lugs could spread at the same time which
would cause both hinge bearing lugs to fail, resulting in the horizontal stabilizer being unable to sustain
the required loads.
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D. Description
This service bulletin gives instructions to do an Eddy Current, High Frequency inspection of the horizontal
stabilizer center section left and right rib hinge bearing lugs for cracks and does as follows:
CONDITION 1 (No Crack Found in Rib Hinge Bearing Lug)
1. Repeats the Eddy Current, High Frequency inspection at defined intervals.
CONDITION 2 (Crack Found in Rib Hinge Bearing Lug)
1. Measures the crack length and does as follows:
CONDITION 2A (Crack Length Between Points 'A' and 'B' is Less Than or Equal to 0.15 Inch,
and Crack Length Between Points 'C' and 'D' is Less Than or Equal to 0.05 Inch)
a. Does blend out repair to remove crack.
b. Repetitively inspects blend out area for cracks, using Eddy Current, High Frequency inspection.
CONDITION 2B (Crack Length Between Points 'A' and 'B' is Greater Than 0.15 Inch, or Crack
Length Between Points 'C' and 'D' is Greater Than 0.05 Inch)
a. Replaces horizontal stabilizer center section rib.
b. Does Eddy Current, High Frequency inspections at a defined threshold.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
37, 38DC-9-81 (MD-81), DC-9-82
(MD-82), DC-9-83 (MD-83), DC-
9-87 (MD-87), MD-88
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E. Compliance
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to
this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this
service bulletin mandatory.
Group 1:
Table 1 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
Before the accumu-
lation of 23,000 to-
tal flight cycles, or
within 4383 flight
cycles after the
original issue date
on this service bul-
letin, whichever oc-
curs later.
Do an Eddy Current, High
Frequency inspection of the
aft face of the horizontal
stabilizer center section left
and right rib hinge lugs in
accordance with Accom-
plishment Instructions,
Paragraph 3.B.2.
All Airplanes
Within 8200 flight
cycles from last in-
spection.
Within 8200 flight
cycles from last in-
spection.
Do an Eddy Current, High
Frequency inspection of the
aft face of the uncracked
horizontal stabilizer center
section rib hinge lugs in ac-
cordance with Accomplish-
ment Instructions, Para-
graph 3.B.2.
CONDITION 1
(No Crack Found in Rib
Hinge Bearing Lug)
(a)
Before further
flight.
Measure crack length in ac-
cordance with Accomplish-
ment Instructions, Para-
graph 3.B.2.
CONDITION 2
(Crack Found In Rib Hinge
Bearing Lug)
Before further
flight.
Blend out crack in accor-
dance with Accomplishment
Instructions, Paragraph
3.B.2.
CONDITION 2A
(Crack Length Between
Points 'A' and 'B' is Less
Than or Equal to 0.15 Inch,
and Crack Length Between
Points 'C' and 'D' is Less
Than or Equal to 0.05 Inch.)
AND
Within 3900 flight
cycles.
Within 15,600 flight
cycles after blend
out.
Do an Eddy Current, High
Frequency inspection of the
blend out on the center
section rib hinge bearing lug
in accordance with Accom-
plishment Instructions,
Paragraph 3.B.2.
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Group 1:
Table 1 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
Before further
flight.
Replace horizontal stabilizer
center section rib.
CONDITION 2B
(Crack Length Between
Points 'A' and 'B' is Greater
Than 0.15 Inch, OR Crack
Length Between Points 'C'
and 'D' is Greater Than 0.05
Inch.)
AND
Within 11,300 flight
cycles from last in-
spection.
Before the accumu-
lation of 23,000 to-
tal flight cycles af-
ter the installation
of the new rib.
Do an Eddy Current, High
Frequency inspection of the
aft face of the replaced hor-
izontal stabilizer center
section rib hinge lug in ac-
cordance with Accomplish-
ment Instructions, Para-
graph 3.B.2.
(a)
(a) For MD-80 operators to take advantage of the rib material change to 7050-T7451 and the
associated repeat inspection cycles, they must have all horizontal stabilizer records in accor-
dance with fuselage number if they relocated the horizontal stabilizer to a different fuselage
number after production delivery. Otherwise they must use the lower (8200 flight cycles) repeat
inspection interval.
Group 2:
Table 2 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
Before the accumu-
lation of 23,000 to-
tal flight cycles, or
within 4383 flight
cycles after the
original issue date
on this service bul-
letin, whichever oc-
curs later.
Do an Eddy Current, High
Frequency inspection of the
aft face of the horizontal
stabilizer center section left
and right rib hinge lugs in
accordance with Accom-
plishment Instructions,
Paragraph 3.B.2.
All Airplanes
Within 11,300 flight
cycles from last in-
spection.
Within 11,300 flight
cycles from last in-
spection.
Do an Eddy Current, High
Frequency inspection of the
aft face of the uncracked
horizontal stabilizer center
section rib hinge lugs in ac-
cordance with Accomplish-
ment Instructions, Para-
graph 3.B.2.
CONDITION 1
(No Crack Found in Rib
Hinge Bearing Lug)
(a)
Before further
flight.
Measure crack length in ac-
cordance with Accomplish-
ment Instructions, Para-
graph 3.B.2.
CONDITION 2
(Crack Found In Rib Hinge
Bearing Lug)
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Group 2:
Table 2 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
Before further
flight.
Blend out crack in accor-
dance with Accomplishment
Instructions, Paragraph
3.B.2.
CONDITION 2A
(Crack Length Between
Points 'A' and 'B' is Less
Than or Equal to 0.15 Inch,
and Crack Length Between
Points 'C' and 'D' is Less
Than or Equal to 0.05 Inch.)
AND
Within 5800 flight
cycles.
Within 15,600 flight
cycles after blend
out.
Do an Eddy Current, High
Frequency inspection of the
blend out on the center
section rib hinge bearing lug
in accordance with Accom-
plishment Instructions,
Paragraph 3.B.2.
Before further
flight.
Replace horizontal stabilizer
center section rib.
CONDITION 2B
(Crack Length Between
Points 'A' and 'B' is Greater
Than 0.15 Inch, OR Crack
Length Between Points 'C'
and 'D' is Greater Than 0.05
Inch.)
AND
Within 11,300 flight
cycles from last in-
spection.
Before the accumu-
lation of 23,000 to-
tal flight cycles af-
ter the installation
of the new rib.
Do an Eddy Current, High
Frequency inspection of the
aft face of the replaced hor-
izontal stabilizer center
section rib hinge lug in ac-
cordance with Accomplish-
ment Instructions, Para-
graph 3.B.2.
(a)
(a) For MD-80 operators to take advantage of the rib material change to 7050-T7451 and the
associated repeat inspection cycles, they must have all horizontal stabilizer records in accor-
dance with fuselage number if they relocated the horizontal stabilizer to a different fuselage
number after production delivery. Otherwise they must use the lower (8200 flight cycles) repeat
inspection interval.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
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G. Manpower
The table below shows an estimate of the task hours necessary to do this inspection for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
 Time to adjust to the workplace
 Time to schedule the work
 Time to inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
Elapsed HoursTask HoursNumber of PersonsTask
1.02.02Open Access
2.02.01Inspect
1.02.02Close Access
4.06.0TOTAL FOR EACH AIRPLANE
NOTE: The Manpower totals listed do not include the hours required to accomplish any blend out
repair(s) or replacement of center section rib(s), if required. Operators are to estimate the task
hours required based on inspection results.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data
a. Boeing Service Bulletin MD90-55A016.
b. Non-Destructive Test Standard Practice Manual (NDTSPM) 06-10-01.001.
c. MD-80 Aircraft Maintenance Manual (AMM) 06-23-00.
d. MD-80 Structural Repair Manual (SRM) 51-10-3.
2. Data supplied with this Service Bulletin
None.
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3. Installation Drawings Used in the Preparation of this Service Bulletin
ChangeTitleDocument Number
B Memo 1RIB CRACK REPAIR - HORIZ STAB,
STA XH=6.625
SR90550001
This drawing was used to prepare this service bulletin. This drawing is not necessary to make the
specified changes, and is not supplied with this service bulletin. This drawing may not be applicable
to all airplane configurations or operators.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected
are contained in Paragraph 1.E., Compliance of this service bulletin.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
NOTE: Parts are only required for Condition 2B.
Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary for Each Airplane if needed,
as shown below. If there is a limit to the quantity of available parts, a supply sequence is given by
Spares. More parts become available as shown in the Reorder Lead Time (ROLT). Operators are
encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price (US
Dollars)
ROLT (Calendar
Days)
NamePart Number
$14,500.00TBDRIB CRACK REPAIR - HORIZ STAB, STA-
TION XH=6.625 - LEFT
9911846-509
14,500.00TBDRIB CRACK REPAIR - HORIZ STAB, STA-
TION XH=6.625 - RIGHT
9911846-510
The parts are subject to the terms and conditions of the Boeing standard purchase order
acknowledgment. Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing Part Page
2. Fax to (206) 662-7145
B. Industry Support Information
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this
service bulletin.
C. Parts Necessary For Each Airplane
1. Kits/Parts
NOTE: Parts are only required for Condition 2B.
To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
Group 1:
Existing Part
Number
NameQTYNew Part Number
9911846-505 orRIB CRACK REPAIR - HORIZ
STAB, STATION XH=6.625 -
LEFT
19911846-509
9911846-507 or
9911846-509
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Group 1:
Existing Part
Number
NameQTYNew Part Number
9911846-506 orRIB CRACK REPAIR - HORIZ
STAB, STATION XH=6.625 -
RIGHT
19911846-510
9911846-508 or
9911846-510
Group 2:
Existing Part
Number
NameQTYNew Part Number
9911846-509RIB CRACK REPAIR - HORIZ
STAB, STATION XH=6.625 -
LEFT
19911846-509
9911846-510RIB CRACK REPAIR - HORIZ
STAB, STATION XH=6.625 -
RIGHT
19911846-510
2. Parts and Materials Supplied by the Operator
None.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this
Service Bulletin. Tool price and supply data are not given.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY
ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE
PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE
CAN OCCUR.
CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE
TO THE AIRPLANE OR EQUIPMENT.
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s)
give the recommended sequence of steps. The sequence of steps to do this service
bulletin can be changed.
2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
3. Equivalent parts are listed in the AEPL, Drawing 7595071.
4. Use the approved fastener and process material substitutions, in accordance with
Structural Repair Manual (SRM) 51.
5. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
6. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch.
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
7. Obey all of the warnings and cautions given in the specified manual sections.
8. A Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate access procedures may be required.
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9. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
10. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
11. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
12. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
13. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
The removed part can be discarded if a new or serviceable part is installed.
14. This service bulletin includes functional test procedures for the systems changed by
this service bulletin. More functional tests can possibly be necessary in accordance
with standard maintenance practices because of interruption to other airplane systems.
B. WORK INSTRUCTIONS
1. Remove and keep access panels. Refer to MD-80 AMM 06-23-00.
LocationAccess Panel
Left side lower horizontal stabilizer fairing3703A
Right side lower horizontal stabilizer fairing3804A
2. Do the Eddy Current, High Frequency (ETHF) inspection of the aft face of the center section left
and right rib hinge bearing lugs for cracks in accordance with FIGURE 1 and do as follows:
CONDITION 1 (NO CRACK FOUND IN RIB HINGE BEARING LUG)
a. Install kept access panels. Refer to MD-80 AMM 06-23-00.
LocationAccess Panel
Left side lower horizontal stabilizer fairing3703A
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LocationAccess Panel
Right side lower horizontal stabilizer fairing3804A
b. Put the airplane back to a serviceable condition.
c. Report inspection results, both positive and negative, fuselage number, and cycles and flight
hours of affected airplane, through your local field service representative or by one of the
methods that follow:
— Mail: Boeing - Long Beach Division
P.O. Box 1771
Long Beach, California 90801
Attn: Senior Manager Technical and Fleet Support
Structures/Payloads & Repair Design
ATA CODE: 5511
Service Engineering D800-0032
(Service Bulletin MD80-55A069)
— Email: dse.boecom@boeing.com
ATA CODE: 5511
— Fax: Long Beach Service Engineering
FAX: (206) 766-5683
ATA CODE: 5511
d. Repeat the ETHF inspection of any uncracked horizontal stabilizer hinge bearing lugs in
accordance with FIGURE 1, at intervals defined in Paragraph 1.E., Compliance Table 1 or
Table 2.
CONDITION 2 (CRACK FOUND IN RIB HINGE BEARING LUG)
a. Measure the length of the crack in accordance with FIGURE 2 and do as follows:
CONDITION 2A (CRACK LENGTH BETWEEN POINTS 'A' AND 'B' IS LESS THAN OR
EQUAL TO 0.15 INCH AND CRACK LENGTH BETWEEN POINTS 'C' AND 'D' IS LESS
THAN OR EQUAL TO 0.05 INCH)
(1) Report inspection results, both positive and negative, fuselage number, and cycles and
flight hours of affected airplane, through your local field service representative or by one
of the methods that follow:
— Mail: Boeing - Long Beach Division
P.O. Box 1771
Long Beach, California 90801
Attn: Senior Manager Technical and Fleet Support
Structures/Payloads & Repair Design
ATA CODE: 5511
Service Engineering D800-0032
(Service Bulletin MD80-55A069)
— Email: dse.boecom@boeing.com
ATA CODE: 5511
— Fax: Long Beach Service Engineering
FAX: (206) 766-5683
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ATA CODE: 5511
(2) Do blend out repair in accordance with FIGURE 3.
NOTE: Drawings for a locally manufactured template/shield shop aid that can be used
to help define the blend out area are available in APPENDIX A.
(3) Install kept access panels. Refer to MD-80 AMM 06-23-00.
LocationAccess Panel
Left side lower horizontal stabilizer fairing3703A
Right side lower horizontal stabilizer fairing3804A
(4) Put the airplane back to a serviceable condition.
(5) Inspect blend out area for cracks in accordance with FIGURE 4 at intervals defined in
Paragraph 1.E., Compliance Table 1 or Table 2.
CONDITION 2B (CRACK LENGTH BETWEEN POINTS 'A' AND 'B' IS GREATER THAN
0.15 INCH OR CRACK LENGTH BETWEEN POINTS 'C' AND 'D' IS GREATER THAN 0.05
INCH)
(1) Replace horizontal stabilizer center section rib.
(2) Inspect replaced rib hinge bearing lug for cracks in accordance with FIGURE 1 at intervals
defined in Paragraph 1.E., Compliance Table 1 or Table 2.
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BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
FWD ||
2030317
FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS
(SHEET 1 OF 4)
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### Page 28 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
TYPICAL CRACK
2030318
FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS
(SHEET 2 OF 4)
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### Page 29 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
TYPICAL CRACK
2030319
FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS
(SHEET 3 OF 4)
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### Page 30

The step number shown below agree with the number shown in the circle symbol in the figure.
ActionStep
Perform an Eddy Current, High Frequency (ETHF) surface inspection of the rib at the hinge
bearing lug aft radius at approximately Stations Yh=76.000 and Xh=6.625. Scan the lug radius as
shown, looking for cracks propagating across the radius. Refer to NDTSPM 06-10-01.001 (ETHF
- Procedure 1). Use Calibration Method "G" and Scan Method "69".
1
Perform an Eddy Current, High Frequency surface inspection of the rib at the hinge bearing lug
aft radius at approximately Stations Yh=76.000 and Xh=6.625. Scan the lug radius as shown,
slightly above the scan done in Step 1, looking for cracks propagating in the vertical direction.
Refer to NDTSPM 06-10-01.001 (ETHF - Procedure 1). Use Calibration Method "C" and Scan
Method "62".
2
FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS
(SHEET 4 OF 4)
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BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
2030320
FIGURE 2: CRACK LENGTH MEASUREMENT
(SHEET 1 OF 3)
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### Page 32 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
TYPICAL CRACK
PT "A"
PT "B'
• "C"
"D"
B
FIGURE 2: CRACK LENGTH MEASUREMENT
(SHEET 2 OF 3)
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### Page 33

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
ActionStep
Measure the crack length from end point (Point A) to where crack intersects the chamfer (Point
B) on the outboard face of the hinge lug. Do not include the measurement of crack length in
chamfer. Record measurement.
1
Measure the crack length from end point (Point D) to where crack intersects the chamfer (Point
C) on the aft face of the hinge lug. Do not include measurement of crack length in the chamfer.
Record measurement.
2
FIGURE 2: CRACK LENGTH MEASUREMENT
(SHEET 3 OF 3)
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BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
FWD |
FIGURE 3: BLEND OUT REPAIR
(SHEET 1 OF 10)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
LOWER SKIN
SURFACE
PT 2 E  0.58
D
O PT 1
1.59  0.05
(NORMAL TO LOWER SKIN  CONST
PANEL SURFACE)
(3) PT 4
2030323
FIGURE 3: BLEND OUT REPAIR
(SHEET 2 OF 10)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
LOWER SKIN
SURFACE
0.50  0.19
4 РТ З
INBD
C-C
FIGURE 3: BLEND OUT REPAIR
(SHEET 3 OF 10)
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### Page 37 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
(BLEND 'A) €1
BLEND 'A'
V-SHAPE
TYPICAL CRACK LOCATION
D-D
2030325
FIGURE 3: BLEND OUT REPAIR
(SHEET 4 OF 10)
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### Page 38 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
PT 2
- 0.58
' PT 1
0.050
(NORMAL TO LOWER  1.59  CONST
SKIN PANEL SURFACE)
6>7
BLEND 'A' AREA
\PT4
E
FIGURE 3: BLEND OUT REPAIR
(SHEET 5 OF 10)
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### Page 39 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
LOWER SKIN  - PT 1
PANEL SURFACE
0.05
• 0.23
0.50
— PT 3
BLEND 'A' AREA
F-F
2030327
FIGURE 3: BLEND OUT REPAIR
(SHEET 6 OF 10)
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### Page 40 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
G  2030328
FIGURE 3: BLEND OUT REPAIR
(SHEET 7 OF 10)
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MD80-55A069
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### Page 41 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
LOWER SKIN
SURFACE
90
• TAPER
DIRECTION
-PT 4
(BLEND 'B')
2030329
FIGURE 3: BLEND OUT REPAIR
(SHEET 8 OF 10)
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### Page 42 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
LOWER SKIN
SURFACE
PT 1  1 INCH RADIUS
_ -
1.65
PT 4
INBD
J-J
FIGURE 3: BLEND OUT REPAIR
(SHEET 9 OF 10)
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### Page 43

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
ActionStep
Locate Point 1. Point 1 is identified as the intersecting point of a line offset from the horizontal stabi-
lizer lower surface 0.050 inch, and the outboard edge of the chamfer on the hinge lug.
1
Locate Point 2. Point 2 is identified as the point on a line offset from the horizontal stabilizer lower
surface 0.050 inch, and 0.58 inch forward of Point 1.
2
Locate Point 4. Point 4 is identified as the point located 1.59 inch measured normal to the horizontal
stabilizer lower surface at the aft edge of the hinge lug.
3
Locate Point 3. Point 3 is identified as the point located 0.19 inch from the inboard edge of the hinge
lug, and 0.50 inch from the horizontal stabilizer lower surface.
4
Blend out the crack. (Blend 'A') Do not exceed the limits of the area defined by points 1, 2, 3, and 4.
The blend out should form a "V" shape, with the deepest portion of the "V" being in the area of the
crack, and approximately 127 degrees between the legs of the "V". Maintain a 0.25 inch radius at the
bottom of the "V". The majority of the blend should be at approximately 45 degrees from the outboard
face of the lug. It is recommended that a 0.50 inch diameter ball grinder be used to do the blend out.
Remove only enough material to remove the crack. Do not remove more than 0.25 inch of material
total depth as measured from a line drawn between the points B and C that were established in Figure
2.
5
Do an Eddy Current, High Frequency (ETHF) inspections during material removal to verify crack has
been removed. Scan the blend out as shown, looking for cracks in the upper forward to lower aft di-
rection. Scan the blend out and give more attention to the outside periphery. Refer to NDTSPM 06-
10-01.001 (ETHF - Procedure 1). Use Calibration Method "G" and Scan Method "69". If crack still is
not removed, repeat Steps 5 and 6.
6
Once the crack has been removed, remove an additional 0.050 inch of material to ensure that a crack
that is too small to detect has been removed. Finish blend out to a 63 micro-inch finish.
7
Do a taper of the outboard face of the lug. (Blend 'B') The taper begins at a line between Point 4 and
tangent to the radius on the aft portion of the bearing lug surface, and extends upward and aft to a
point 1.65 inches above Point 4. Finish blend out to a 63 micro-inch finish.
8
Break all reworked edges to a 0.12 inch radius. If adjacent structure prevents using a 0.12 inch radius,
use the largest radius possible in the area.
9
Apply FR Protection to the rework area. Refer to MD-80 SRM 51-10-3.10
(Not
Shown)
FIGURE 3: BLEND OUT REPAIR
(SHEET 10 OF 10)
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BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
POSSIBLE
CRACK
FWD
2030331
FIGURE 4: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS
(SHEET 1 OF 2)
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### Page 45

The step number shown below agree with the number shown in the circle symbol in the figure.
ActionStep
Perform an Eddy Current, High Frequency Surface inspection of Blend 'A' area at the hinge
bearing lug aft radius. Scan the blend out as shown, looking for cracks in the upper forward to
lower aft direction. Scan the blend out and give more attention to the outside periphery. Refer to
NDTSPM 06-10-01.001 (ETHF - Procedure 1). Use Calibration Method "G" and Scan Method "69".
1
FIGURE 4: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS
(SHEET 2 OF 2)
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### Page 46

This appendix provides instructions for the fabrication and usage of a template/shield shop aid to assist in
simplifying the identification of the extents of the blend out area, if required, identified in FIGURE 3.
This appendix provides instructions to build a template/shield for use on the left hand hinge bearing lug. A mirror
image template/shield is required for the right hand hinge bearing lug.
FABRICATION
1. Fabricate all parts from 0.050 Inch CRES Sheet, Type 321, per Aerospace Material Specification (AMS)
5510 or equivalent.
2. Identification of parts and assemblies at operator's option, and per operator's shop practice.
3. Fusion weld with Gas Tungsten Arc Welding (GTAW).
4. It is acceptable to fusion weld from opposite side than that specified by the welding symbol.
5. If surfaces on -3 and -9 parts are distorted by welding, straighten surfaces to within +/- .010 inch before
use.
6. Tack or continuous weld -11 to the sub assembly from sub-assembly step 3.
7. Trim -7 as shown.
8. Cut or grind radius on -7 as shown.
APPENDIX A:  TEMPLATE/SHIELD SHOP AID
(SHEET 1 OF 8)
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### Page 47 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
4.59 + .25
1.83
3 x R.25 25/  -3
1.47
2.42
2.40
1.43
R1.00 ‡ 25/
- 2.30
-5
2030333
APPENDIX A: TEMPLATE/SHIELD SHOP AID
(SHEET 2 OF 8)
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### Page 48 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
7.09
• 6.67
2 x R.25 + .25,
.021 -
• R.19
R.25
R1.50
3.32
~3 X R.50  1.25
2.23
1.97  1.82
1.11
1.13
1.00
5.65
6.57
-7
• 50 + .25  .00
2 x R.25 + .10
2 x.50:00
.48  - 2.00
R 1.50 + .25  - .00
-9
-11
APPENDIX A: TEMPLATE/SHIELD SHOP AID
(SHEET 3 OF 8)
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### Page 49 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
FUSION WELD
1.85 Д
131° 25
2.32
1.18 + .00  - .15  HEEL INTERSECTION POINT
- 2.40 -
SUB ASSEMBLY STEP 1
DIMENSIONS NOTED WITH W SYMBOL
ARE FOR THE FINAL CONFORMANCE
INSPECTION PURPOSE ONLY, NOT FOR
FABRICATION.
2.60 +.10  - .00
64° 12'
FUSION WELD
GRIND WELD FLUSH
ON THIS SURFACE
SUB ASSEMBLY STEP 2
A-A
2030335
APPENDIX A: TEMPLATE/SHIELD SHOP AID
(SHEET 4 OF 8)
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### Page 50 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
90°
(VIEW ANGLE)
FUSION WELD
1.15 +.00  - 15 TRUE
90°
1.15 +.00  -.15 TRUE
DIMENSIONS NOTED WITH  SYMBOL  FUSION WELD
ARE FOR THE FINAL CONFORMANCE
INSPECTION PURPOSE ONLY, NOT FOR
FABRICATION.
SUB ASSEMBLY STEP 3
126° 43'  112° 56'
REMOVE ANY WELD
PENETRATION ON
THIS SIDE FLUSH
TO SURFACE
B-B  C-C  2030336
APPENDIX A: TEMPLATE/SHIELD SHOP AID
(SHEET 5 OF 8)
Original Issue: January 19, 2011
BOEING PROPRIETARY -  MD80-55A069
Copyright © Unpublished Work - See page 1 for details.  50 of 53

### Page 51 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
-1.40
. 47
1.82 Д
2.17 f  • 3
D-D  DIMENSIONS NOTED WITH & SYMBOL
ARE FOR THE FINAL CONFORMANCE
INSPECTION PURPOSE ONLY, NOT FOR
FABRICATION.
2 X R.25 ‡ 25 TRUE
FUSION WELD
- 9
TRIM -7 AS SHOWN
.75
.50
\5
-2x 36
FUSION WELD
→ 2.50
FINAL ASSEMBLY STEP 4  2030337
APPENDIX A: TEMPLATE/SHIELD SHOP AID
(SHEET 6 OF 8)
Original Issue: January 19, 2011
MD80-55A069
Copyright © Unpublished Work - See page 1 for details.  BOEING PROPRIETARY -  51 of 53

### Page 52

DIRECTIONS FOR TEMPLATE/SHIELD SHOP AID USE
1. After identifying points 1, 2, 3, and 4 in accordance with the instructions in FIGURE 3, place template/shield
on lug. Push upper portion of template/shield against the lower surface of the horizontal stabilizer, and the
push the outer portion of the template/shield against the outboard surface of the lug.
2. Slide the template/shield fore and aft until the lower portion of the template is on Point 4, and check that
the template/shield is aligned with Point 2.
NOTE: The aft face of the template/shield may not be in contact with the aft face of the lug when the
template/shield is aligned with Points 2 and 4.
3. Using an appropriate marker, trace the template/shield shape on the aft face of the lug, and on the outboard
face of the lug, to visually define the shape of the blend out area. Do not exceed the limits of the blend out
area defined by Points 1, 2, 3, and 4 established in Figure 3 if they are different than the area defined by
the template/shield.
The template/shield may be secured to the lug and used as a shield to help while grinding the crack out in
accordance with FIGURE 3.
APPENDIX A:  TEMPLATE/SHIELD SHOP AID
(SHEET 7 OF 8)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2011
MD80-55A069
52 of 53
BOEING SERVICE BULLETIN MD80-55A069
ALERTALERT

### Page 53 (OCR)

BOEING SERVICE BULLETIN MD80-55A069
ALERT  ALERT
RIB ASSEMBLY
OUTBOARD LUG SURFACE
TEMPLATE / SHIELD USAGE
2030338
APPENDIX A: TEMPLATE/SHIELD SHOP AID
(SHEET 8 OF 8)
Original Issue: January 19, 2011
Copyright © Unpublished Work - See page 1 for details.  BOEING PROPRIETARY -  MD80-55A069  53 of 53

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