# Boeing Alert Service Bulletin MD80-55A072: No revision named - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2016-8845; AD 2016-25-06 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin MD80-55A072](https://openairdocs.org/service-documents/boeing/md80-55a072.md) - Title as filed: Boeing Alert Service Bulletin MD80-55A072, dated April 8, 2016 - Pages: 88 - PDF: https://openairdocs.org/files/sha256/4c/8e/4c8ed0c26378ea105e4cec457db0e174fcc940912b6dfbb1541e59981efa80cf - Page: https://openairdocs.org/service-documents/boeing/md80-55a072/file/4c8ed0c26378 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-55A072 Original Issue: April 08, 2016 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Lower Cap Inspection, Repair, and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2016 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 Unpublished Work.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April 08, 2016 MD80-55A072 1 of 88 3.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 2 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 31 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 43 3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 44 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 FIGURE 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP OPEN HOLE EDDY CURRENT HIGH FREQUENCY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 FIGURE 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SURFACE EDDY CURRENT HIGH FREQUENCY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FIGURE 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP BOLT INSTALLATION . . . . . . 67 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP EDDY CURRENT HIGH FREQUENCY (ETHF) INSPECTION. 70 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR . . . . . . . . . . 74 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 3 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 4 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 3: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A SPLICE REPAIR . . . . . . . . . . . 77 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 4: POST HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR ETHF INSPECTIONS . . . . . 79 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 5: POST HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT ETHF INSPECTIONS . . . . . 82 APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 6: POST HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR OR REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTIONS . . . . . . . . . . . . . . . 86 APPENDIX G: ADDITIONAL ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 APPENDIX H: PART DEMAND INTENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 4 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 5 Commercial Airplanes MD80 Service Bulletin ALERT SummaryNumber: MD80-55A072Original Issue: April 08, 2016 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Lower Cap Inspection, Repair, and Replacement 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 During normal maintenance, one operator found cracking in an MD-88 horizontal stabilizer rear spar lower cap. The affected airplane had accumulated 61,741 flight-hours and 45,985 landing cycles. Although the origin of the crack was destroyed from heavy rubbing and oxidation, lab analysis on the area adjacent to the crack shows that the crack was caused by fatigue. Such fatigue cracking, paired with cracking in the horizontal stabilizer upper and/or lower skin panels, rear spar upper cap inboard end, upper center skin panel, or rear spar upper cap barrel nut holes, could adversely affect the structural integrity of the airplane. This service bulletin gives instructions to inspect for cracking in the vertical flange of the horizontal stabilizer rear spar lower cap on MD-80 airplanes and gives subsequent corrective action if any crack is found. The inspections are similar to the inspections of the horizontal stabilizer rear spar upper caps in alert service bulletin MD80-55A065 R01. Boeing Fleet Team Digest (FTD) MD-80 FTD 55-15001 is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information. ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 5 of 88 ### Page 6 ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Air- plane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION Do an open hole or surface Eddy Current High Frequency (ETHF) inspection for any crack in the horizontal stabilizer rear spar lower caps. If no crack is found, do repeat ETHF inspection for any crack or do a fatigue life enhancement modification. If any crack is found, do one of the following based on inspection findings: 1. Bushing repair 2. Lower cap splice repair 3. Lower cap replacement 4. Lower cap splice repair with fatigue life enhancement modification 5. Lower cap replacement with fatigue life enhancement modification EFFECTIVITY All 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. COMPLIANCE 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 6 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 7 Operators are encouraged to complete the survey provided in APPENDIX H of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 7 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 8 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT BLANK PAGE ### Page 9 Commercial Airplanes MD80 Service Bulletin ALERT Number: MD80-55A072 Original Issue: April 08, 2016 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Lower Cap Inspection, Repair, and Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. 1. PLANNING INFORMATION A. Effectivity 1. Airplanes DESCRIPTIONCONFIGURATIONGROUP All DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), and MD-88 Airplanes. -1 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 1909 1917 1924 1938 1941 1944 1946 1948 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 9 of 88 ### Page 10 GroupFuselage Num- ber 1950 1952 - 953 1955 1957 - 958 1960 1962 - 963 1965 - 967 1969 1970 - 971 1973 - 975 1977 - 979 1981 1983 1985 - 986 1988 - 989 1991 - 992 1994 - 999 11000 - 1013 11015 - 1016 11018 - 1020 11022 - 1023 11025 - 1026 11028 - 1029 11031 - 1032 11034 - 1035 11037 - 1038 11040 - 1041 11043 11045 11047 11049 11051 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 10 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 11 GroupFuselage Num- ber 11053 11055 11057 11059 - 1080 11082 - 1083 11085 - 1099 11100 - 1199 11200 - 1299 11300 - 1399 11400 - 1499 11500 - 1599 11600 - 1699 11700 - 1799 11800 - 1899 11900 - 1999 12000 - 2007 12009 - 2016 12019 - 2034 12036 - 2069 12071 - 2093 12101 - 2114 12116 12118 - 2119 12121 12124 12127 - 2128 12130 12132 12134 - 2135 12137 12139 12145 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 11 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 12 GroupFuselage Num- ber 12148 12151 - 2152 12155 12167 12174 12176 12178 12180 12183 12185 12187 12189 12192 12196 12199 12201 12204 12206 12208 12214 12218 12234 12239 12241 12244 12247 12249 12252 12254 12264 - 2287 2. Spares Affected None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 12 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 13 B. Concurrent Requirements None. C. Reason During normal maintenance, one operator found cracking in an MD-88 horizontal stabilizer rear spar lower cap. The affected airplane had accumulated 61,741 flight-hours and 45,985 landing cycles. Although the origin of the crack was destroyed from heavy rubbing and oxidation, lab analysis on the area adjacent to the crack shows that the crack was caused by fatigue. Such fatigue cracking, paired with cracking in the horizontal stabilizer upper and/or lower skin panels, rear spar upper cap inboard end, upper center skin panel, or rear spar upper cap barrel nut holes, could adversely affect the structural integrity of the airplane. This service bulletin gives instructions to inspect for cracking in the vertical flange of the horizontal stabilizer rear spar lower cap on MD-80 airplanes and gives subsequent corrective action if any crack is found. The inspections are similar to the inspections of the horizontal stabilizer rear spar upper caps in alert service bulletin MD80-55A065 R01. Boeing Fleet Team Digest (FTD) MD-80 FTD 55-15001 is related to this service bulletin. D. Description Do an open hole or surface Eddy Current High Frequency (ETHF) inspection for any crack in the horizontal stabilizer rear spar lower caps. If no crack is found, do repeat ETHF inspection for any crack or do a fatigue life enhancement modification. If any crack is found, do one of the following based on inspection findings: 1. Bushing repair 2. Lower cap splice repair 3. Lower cap replacement 4. Lower cap splice repair with fatigue life enhancement modification 5. Lower cap replacement with fatigue life enhancement modification The work in this service bulletin is done in the maintenance zone(s) given below. 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 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 13 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 14 Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX A through APPENDIX F. The table that follows immediately below describes the service bulletin PARTS noted in the compliance tables. DescriptionTitle HORIZONTAL STABILIZER REAR SPAR LOWER CAP EDDY CURRENT HIGH FREQUENCY (ETHF) INSPECTION PART 1 POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR PART 2 POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A SPLICE REPAIR PART 3 HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIRPART 4 HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENTPART 5 HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FA- TIGUE LIFE ENHANCEMENT MODIFICATION PART 6 HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FA- TIGUE LIFE ENHANCEMENT MODIFICATION PART 7 HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONSPART 8 Table 1: Horizontal Stabilizer Rear Spar Lower Cap Eddy Current High Frequency (ETHF) Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles af- ter the original issue date of this service bul- letin. Before 20,000 total flight cy- cles. Do PART 1 for any crack.All Airplanes Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 14 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 15 Table 1: Horizontal Stabilizer Rear Spar Lower Cap Eddy Current High Frequency (ETHF) Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 11,000 flight cycles if an open hole ETHF inspection was previously done. --OPTION 1: Repeat PART 8 for any crack. CONDITION 1: NO CRACK FOUND ON THE LEFT SIDE 4,100 flight cycles if a surface ETHF inspection was previously done. --Before further flight. OPTION 2 (ACTION 1): Do a fatigue life enhance- ment modification. --Refer to Table 2 for compliance information relat- ed to post fa- tigue life en- hancement modification ETHF inspec- tions. OPTION 2 (ACTION 2): Do PART 2 for any crack. 11,000 flight cycles if an open hole ETHF inspection was previously done. --OPTION 1: Repeat PART 8 for any crack. CONDITION 2: NO CRACK FOUND ON THE RIGHT SIDE 4,100 flight cycles if a surface ETHF inspection was previously done. --Before further flight. OPTION 2 (ACTION 1): Do a fatigue life enhance- ment modification. --Refer to Table 2 for compliance information relat- ed to post fa- tigue life en- hancement modification ETHF inspec- tions. OPTION 2 (ACTION 2): Do PART 2 for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 15 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 16 Table 1: Horizontal Stabilizer Rear Spar Lower Cap Eddy Current High Frequency (ETHF) Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition --Before further flight. OPTION 1 (ACTION 1): Do a bushing repair. CONDITION 3: ON THE LEFT OR RIGHT SIDE, ANY CRACK FOUND IN THE LOWER TWO FAS- TENER HOLES THAT CAN BE REMOVED WITH A HOLE DIAMETER OF 0.408 INCHES OR LESS AND NO CRACK FOUND IN THE UPPER FASTEN- ER HOLE --Refer to Table 2 for compliance information relat- ed to post bush- ing repair ETHF inspections. OPTION 1 (ACTION 2): Do PART 2 for any crack. --Before further flight. OPTION 2 (ACTION 1): Do PART 4. (a) --Within 97,000 flight cycles af- ter doing a hori- zontal stabilizer rear spar lower cap splice re- pair. OPTION 2 (ACTION 2): Do PART 5 or PART 7. (b) --Before further flight. OPTION 3: Do PART 5. (c) --Before further flight. OPTION 4 (ACTION 1): Do PART 6. (d) --Within 97,000 flight cycles af- ter doing a hori- zontal stabilizer rear spar lower cap splice re- pair. OPTION 4 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instruc- tions and do the replace- ment. --Before further flight. OPTION 5: Do PART 7. (d) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 16 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 17 Table 1: Horizontal Stabilizer Rear Spar Lower Cap Eddy Current High Frequency (ETHF) Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition --Before further flight. OPTION 1 (ACTION 1): Do PART 4. CONDITION 4: ON THE LEFT OR RIGHT SIDE, ANY CRACK FOUND IN THE LOWER TWO FAS- TENER HOLES THAT CANNOT BE REMOVED WITH A MAXIMUM HOLE DIAMETER OF 0.408 INCHES OR ANY CRACK FOUND IN THE UPPER FASTENER HOLE (a) --Within 97,000 flight cycles af- ter doing a hori- zontal stabilizer rear spar lower cap splice re- pair. OPTION 1 (ACTION 2): Do PART 5 or PART 7. (b) --Before further flight. OPTION 2: Do PART 5. (c) --Before further flight. OPTION 3 (ACTION 1): Do PART 6. (d) --Within 97,000 flight cycles af- ter doing a hori- zontal stabilizer rear spar lower cap splice re- pair. OPTION 3 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instruc- tions and do the replace- ment. --Before further flight. OPTION 4: Do PART 7. (d) (a) Refer to Table 4 for compliance information related to post horizontal stabilizer rear spar lower cap splice repair ETHF inspections. (b) Refer to Table 5 for related compliance information if a horizontal stabilizer rear spar lower cap replacement was done or refer to Table 6 for related compliance information if a horizontal stabilizer rear spar lower cap replacement was done with a fatigue life enhancement modification. (c) Refer to Table 5 for compliance information related to post horizontal stabilizer rear spar lower cap re- placement ETHF inspections. (d) Refer to Table 6 for compliance information related to post horizontal stabilizer rear spar lower cap splice repair or replacement with fatigue life enhancement modification ETHF inspections. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 17 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 18 Table 2: Post Bushing Repair or Fatigue Life Enhancement Modification ETHF Inspection for Horizontal Stabilizer Rear Spar Lower Caps With No Splice Repair Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 2,000 flight cycles after doing a bushing repair. Do PART 2 for any crack.Airplanes that have a bushing repair installed Within 50,000 flight cycles after doing a fatigue life en- hancement modifi- cation. Airplanes that have a fa- tigue life enhancement modification installed 2,000 flight cycles if a bushing repair is installed. -Repeat PART 2 for any crack. CONDITION 5: NO CRACK FOUND 2,000 flight cycles if an oversize fa- tigue life enhance- ment modification is installed. 3,200 flight cycles if a nominal fatigue life enhancement modification is in- stalled. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 18 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 19 Table 2: Post Bushing Repair or Fatigue Life Enhancement Modification ETHF Inspection for Horizontal Stabilizer Rear Spar Lower Caps With No Splice Repair Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight. OPTION 1 (ACTION 1): Do PART 4. CONDITION 6: ANY CRACK FOUND IN HORI- ZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A BUSHING REPAIR (a) -Within 97,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap splice repair. OPTION 1 (ACTION 2): Do PART 5 or PART 7. (b) -Before further flight. OPTION 2: Do PART 5. (c) -Before further flight. OPTION 3 (ACTION 1): Do PART 6. (d) -Within 97,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap splice repair. OPTION 3 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instruc- tions and do the replace- ment. -Before further flight. OPTION 4: Do PART 7. (d) -Before further flight. Contact The Boeing Company for work instruc- tions and do the work. CONDITION 7: ANY CRACK FOUND IN HORI- ZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A FATIGUE LIFE ENHANCEMENT MODIFICATION (a) Refer to Table 4 for compliance information related to post horizontal stabilizer rear spar lower cap splice repair ETHF inspections. (b) Refer to Table 5 for related compliance information if a horizontal stabilizer rear spar lower cap replacement was done or refer to Table 6 for related compliance information if a hori- zontal stabilizer rear spar lower cap replacement was done with a fatigue life enhancement modification. (c) Refer to Table 5 for compliance information related to post horizontal stabilizer rear spar lower cap replacement ETHF inspections. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 19 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 20 Table 2: Post Bushing Repair or Fatigue Life Enhancement Modification ETHF Inspection for Horizontal Stabilizer Rear Spar Lower Caps With No Splice Repair Repeat Interval (Not to Exceed) Compliance TimeActionCondition (d) Refer to Table 6 for compliance information related to post horizontal stabilizer rear spar lower cap splice repair or replacement with fatigue life enhancement modification ETHF inspections. Table 3: Post Bushing Repair or Fatigue Life Enhancement Modification ETHF Inspection for Horizontal Stabilizer Rear Spar Lower Caps With A Splice Repair Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 2,000 flight cycles after doing a bushing repair. Do PART 3 for any crack.Airplanes that have a bushing repair installed Within 50,000 flight cycles after doing a fatigue life en- hancement modifi- cation. Airplanes that have a fa- tigue life enhancement modification installed 2,000 flight cycles if a bushing repair is installed. -Repeat PART 3 for any crack. CONDITION 8: NO CRACK FOUND 2,000 flight cycles if an oversize fa- tigue life enhance- ment modification is installed. 3,200 flight cycles if a nominal fatigue life enhancement modification is in- stalled. -Before further flight. OPTION 1: Do PART 5. CONDITION 9: ANY CRACK FOUND IN HORI- ZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A BUSHING REPAIR (a) -OPTION 2: Do PART 7. (b) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 20 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 21 Table 3: Post Bushing Repair or Fatigue Life Enhancement Modification ETHF Inspection for Horizontal Stabilizer Rear Spar Lower Caps With A Splice Repair Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight. Contact The Boeing Company for work instruc- tions and do the work. CONDITION 7: ANY CRACK FOUND IN HORI- ZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A FATIGUE LIFE ENHANCEMENT MODIFICATION (a) Refer to Table 5 for compliance information related to post horizontal stabilizer rear spar lower cap replacement ETHF inspections. (b) Refer to Table 6 for compliance information related to post horizontal stabilizer rear spar lower cap replacement with fatigue life enhancement modification ETHF inspections. Table 4: Post Horizontal Stabilizer Rear Spar Lower Cap Splice Repair ETHF Inspections Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 20,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap splice repair. Do PART 8 for any crack.Airplanes that have done a horizontal stabilizer rear spar lower cap splice repair 11,000 flight cycles if an open hole ETHF inspection was previously done. -OPTION 1: Repeat PART 8 for any crack. CONDITION 10: NO CRACK FOUND 4,100 flight cycles if a surface ETHF inspection was previously done. -Before further flight. OPTION 2 (ACTION 1): Do a fatigue life enhance- ment modification. -Refer to Table 3 for compliance infor- mation related to post fatigue life en- hancement modifi- cation ETHF in- spections. OPTION 2 (ACTION 2): Do PART 3 for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 21 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 22 Table 4: Post Horizontal Stabilizer Rear Spar Lower Cap Splice Repair ETHF Inspections Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight. OPTION 1 (ACTION 1): Do a bushing repair. CONDITION 11: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CAN BE REMOVED WITH A HOLE DIAMETER OF 0.408 INCHES OR LESS AND NO CRACK FOUND IN THE UPPER FASTENER HOLE -Refer to Table 3 for compliance infor- mation related to post bushing repair ETHF inspections. OPTION 1 (ACTION 2): Do PART 3 for any crack. -Before further flight. OPTION 2: Do PART 5. (a) -OPTION 3: Do PART 7. (b) -Before further flight. OPTION 1: Do PART 5. CONDITION 12: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CANNOT BE REMOVED WITH A MAXIMUM HOLE DIAME- TER OF 0.408 INCHES OR ANY CRACK FOUND IN THE UPPER FASTEN- ER HOLE (a) -OPTION 2: Do PART 7. (b) (a) Refer to Table 5 for compliance information related to post horizontal stabilizer rear spar lower cap replacement ETHF inspections. (b) Refer to Table 6 for compliance information related to post horizontal stabilizer rear spar lower cap replacement with fatigue life enhancement modification ETHF inspections. Table 5: Post Horizontal Stabilizer Rear Spar Lower Cap Replacement ETHF Inspections Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 20,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap replacement. Do PART 8 for any crack.Airplanes that have done a horizontal stabilizer rear spar lower cap replace- ment Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 22 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 23 Table 5: Post Horizontal Stabilizer Rear Spar Lower Cap Replacement ETHF Inspections Repeat Interval (Not to Exceed) Compliance TimeActionCondition 11,000 flight cycles if an open hole ETHF inspection was previously done. -OPTION 1: Repeat PART 8 for any crack. CONDITION 13: NO CRACK FOUND 4,100 flight cycles if a surface ETHF inspection was previously done. -Before further flight. OPTION 2 (ACTION 1): Do a fatigue life enhance- ment modification. -Refer to Table 2 for compliance infor- mation related to post fatigue life en- hancement modifi- cation ETHF in- spections. OPTION 2 (ACTION 2): Do PART 2 for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 23 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 24 Table 5: Post Horizontal Stabilizer Rear Spar Lower Cap Replacement ETHF Inspections Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight. OPTION 1 (ACTION 1): Do a bushing repair. CONDITION 14: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CAN BE REMOVED WITH A HOLE DIAMETER OF 0.408 INCHES OR LESS AND NO CRACK FOUND IN THE UPPER FASTENER HOLE -Refer to Table 2 for compliance infor- mation related to post bushing repair ETHF inspections. OPTION 1 (ACTION 2): Do PART 2 for any crack. -Before further flight. OPTION 2 (ACTION 1): Do PART 4. (a) -Within 97,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap splice repair. OPTION 2 (ACTION 2): Do PART 5 or PART 7. (b) -Before further flight. OPTION 3: Do PART 5. (c) -Before further flight. OPTION 4 (ACTION 1): Do PART 6. (d) -Within 97,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap splice repair. OPTION 4 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instruc- tions and do the replace- ment. -Before further flight. OPTION 5: Do PART 7. (d) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 24 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 25 Table 5: Post Horizontal Stabilizer Rear Spar Lower Cap Replacement ETHF Inspections Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight. OPTION 1 (ACTION 1): Do PART 4. CONDITION 15: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CANNOT BE REMOVED WITH A MAXIMUM HOLE DIAME- TER OF 0.408 INCHES OR ANY CRACK FOUND IN THE UPPER FASTEN- ER HOLE (a) -Within 97,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap splice repair. OPTION 1 (ACTION 2): Do PART 5 or PART 7. (b) -Before further flight. OPTION 2: Do PART 5. (c) -Before further flight. OPTION 3 (ACTION 1): Do PART 6. (d) -Within 97,000 flight cycles after doing a horizontal stabiliz- er rear spar lower cap splice repair. OPTION 3 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instruc- tions and do the replace- ment. -Before further flight. OPTION 4: Do PART 7. (d) (a) Refer to Table 4 for compliance information related to post horizontal stabilizer rear spar lower cap splice repair ETHF inspections. (b) Refer to Table 5 for related compliance information if a horizontal stabilizer rear spar lower cap replacement was done or refer to Table 6 for related compliance information if a hori- zontal stabilizer rear spar lower cap replacement was done with a fatigue life enhancement modification. (c) Refer to Table 5 for compliance information related to post horizontal stabilizer rear spar lower cap replacement ETHF inspections. (d) Refer to Table 6 for compliance information related to post horizontal stabilizer rear spar lower cap splice repair or replacement with fatigue life enhancement modification ETHF inspections. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 25 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 26 Table 6: Post Horizontal Stabilizer Rear Spar Lower Cap Splice Repair or Replacement With Fatigue Life Enhancement Modification ETHF Inspections Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 50,000 flight cycles after doing a fatigue life en- hancement modifi- cation. Do a surface ETHF in- spection for any crack. Airplanes that have done a horizontal stabilizer rear spar lower cap splice repair or replacement with a fa- tigue life enhancement modification 3,200 flight cycles.-Repeat surface ETHF in- spection for any crack. CONDITION 16: NO CRACK FOUND -Before further flight. Contact The Boeing Company for work instruc- tions and do the work. CONDITION 17: ANY CRACK FOUND 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. G. Manpower The tables below show an estimate of the task hours necessary to do the inspection, modification, repair, and replacement for each side of the horizontal stabilizer. 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. Horizontal Stabilizer Rear Spar Lower Cap Open Hole Eddy Current High Frequency (ETHF) Inspection Elapsed HoursTask HoursNumber of PersonsTask 0.50.51Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 26 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 27 Horizontal Stabilizer Rear Spar Lower Cap Open Hole Eddy Current High Frequency (ETHF) Inspection Elapsed HoursTask HoursNumber of PersonsTask 1.51.51FIGURE 1 0.20.21FIGURE 3 0.50.51Close Access 2.72.7TOTAL FOR EACH SIDE OF THE HORIZON- TAL STABILIZER Horizontal Stabilizer Rear Spar Lower Cap Surface ETHF Inspection Elapsed HoursTask HoursNumber of PersonsTask 1.51.51FIGURE 2 1.51.5TOTAL FOR EACH SIDE OF THE HORIZON- TAL STABILIZER Bushing Repair For Horizontal Stabilizer Rear Spar Lower Caps With or Without a Splice Repair Elapsed HoursTask HoursNumber of PersonsTask 8.016.02Remove - Elevator 0.50.51Access 6.06.01Install - Horizontal Stabilizer Rear Spar Lower Cap Bushing Repair 0.50.51Close Access 8.016.02Install - Elevator 23.039.0TOTAL FOR EACH SIDE OF THE HORIZON- TAL STABILIZER Fatigue Life Enhancement Modification For Horizontal Stabilizer Rear Spar Lower Caps With or Without a Splice Repair Elapsed HoursTask HoursNumber of PersonsTask 8.016.02Remove - Elevator 0.50.51Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 27 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 28 Fatigue Life Enhancement Modification For Horizontal Stabilizer Rear Spar Lower Caps With or Without a Splice Repair Elapsed HoursTask HoursNumber of PersonsTask 13.026.02Install - Horizontal Stabilizer Rear Spar Lower Cap Fatigue Life Enhancement Modification 0.50.51Close Access 8.016.02Install - Elevator 30.059.0TOTAL FOR EACH SIDE OF THE HORIZON- TAL STABILIZER Horizontal Stabilizer Rear Spar Lower Cap Splice Repair or Replacement Elapsed HoursTask HoursNumber of PersonsTask 8.048.06Remove - Horizontal Stabilizer 8.016.02Remove - Elevator 6.012.02Remove - Leading Edge 72.0216.03Install - Horizontal Stabilizer Rear Spar Lower Cap Splice Repair OR Replace - Horizontal Stabilizer Rear Spar Lower Cap 6.012.02Install - Leading Edge 8.016.02Install - Elevator 8.048.06Install - Horizontal Stabilizer 116.0368.0TOTAL FOR EACH SIDE OF THE HORIZON- TAL STABILIZER Horizontal Stabilizer Rear Spar Lower Cap Splice Repair or Replacement With Fatigue Life Enhancement Modification Elapsed HoursTask HoursNumber of PersonsTask 8.048.06Remove - Horizontal Stabilizer Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 28 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 29 Horizontal Stabilizer Rear Spar Lower Cap Splice Repair or Replacement With Fatigue Life Enhancement Modification Elapsed HoursTask HoursNumber of PersonsTask 8.016.02Remove - Elevator 6.012.02Remove - Leading Edge 72.0216.03Install - Horizontal Stabilizer Rear Spar Lower Cap Splice Repair OR Replace - Horizontal Stabilizer Rear Spar Lower Cap 13.026.02Install - Horizontal Stabilizer Rear Spar Lower Cap Fatigue Life Enhancement Modification 6.012.02Install - Leading Edge 8.016.02Install - Elevator 8.048.06Install - Horizontal Stabilizer 129.0394.0TOTAL FOR EACH SIDE OF THE HORIZON- TAL STABILIZER Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 29 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 30 H. Weight and Balance Changes There are no weight and balance changes for bushing repairs, fatigue life enhancement modifications, or horizontal stabilizer rear spar lower cap replacements with or without a bushing repair or fatigue life enhancement modification. The table below gives the weight and balance changes for horizontal stabilizer rear spar lower cap splice repairs with or without a bushing repair or fatigue life enhancement modification: Moment Change (MEW) IN.-LBS Mfr's Empty Weight (MEW) LBS Approximate Station (Inch- es)AirplaneCondition, Option, Action +10014.0 (a)+6.0 (a)1669.0DC-9-81 (MD-81)CONDITION 3: OPTION 2 (ACTION 1) AND OPTION 4 (ACTION 1) DC-9-82 (MD-82) CONDITION 4: OPTION 1 (ACTION 1) AND OPTION 3 (ACTION 1) DC-9-83 (MD-83) MD-88 CONDITION 6: OPTION 1 (ACTION 1) AND OPTION 3 (ACTION 1) +8760.0 (a)+6.0 (a)1460.0DC-9-87 (MD-87) CONDITION 14:OPTION 2 (ACTION 1) AND OPTION 4 (ACTION 1) CONDITION 15: OPTION 1 (ACTION 1) AND OPTION 3 (ACTION 1) (a) Weight and Balance data for one side of the horizontal stabilizer. I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Boeing Service Bulletin MD80-55A065 R01 b. Non-Destructive Test Standard Practices Manual (NDTSPM) 06-00-06, 06-00-07, 06-10-01.001, 06-10-01.003 c. Standard Overhaul Practices Manual (SOPM) 20-50-01 d. MD-80 Aircraft Maintenance Manual (AMM) 06-23-00, 27-30-02, 55-10-00, 55-10-01 e. MD-80 Fleet Team Digest (FTD) 55-15001 f. MD-80 Structural Repair Manual (SRM) 51, 51-30-9 2. Data Supplied with this Service Bulletin: a. Drawings: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 30 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 31 ADCNDCN/REVSheetTitleDrawing No --DWGRear Spar, Cap Splice Repair-Inbd Lower Horiz Stabilizer SR09550035 --DWGSpar Cap Replacement, Lower Rear, Hori- zontal Stabilizer SR09550036 --DWGModification and Repair - Lwr Rear Spar Cap, Horiz Stab SR09550037 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. K. Publications Affected 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. 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 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 31 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 32 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 32 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT BLANK PAGE ### Page 33 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) NameKit Number 27,471.0090SERVICE KIT - LFT LWR SPAR CAP SPLICE REPAIR SA09550072-3 27,471.0090SERVICE KIT - RT LWR SPAR CAP SPLICE REPAIR SA09550072-5 30,045.0090SERVICE KIT - LFT LWR SPAR CAP RE- PLACEMENT SA09550072-7 30,045.0090SERVICE KIT - RT LWR SPAR CAP RE- PLACEMENT SA09550072-9 27,620.0090SERVICE KIT - LFT LWR SPAR CAP SPLICE REPAIR WITH FATIGUE LIFE EN- HANCEMENT MODIFICATION SA09550072-11 27,620.0090SERVICE KIT - RT LWR SPAR CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCE- MENT MODIFICATION SA09550072-13 31,408.0090SERVICE KIT - LFT LWR SPAR CAP RE- PLACEMENT WITH FATIGUE LIFE EN- HANCEMENT MODIFICATION SA09550072-15 31,408.0090SERVICE KIT - RT LWR SPAR CAP RE- PLACEMENT WITH FATIGUE LIFE EN- HANCEMENT MODIFICATION SA09550072-17 569.0090SERVICE KIT - BUSHING REPAIRSA09550072-19 1,267.0090SERVICE KIT - FATIGUE LIFE ENHANCE- MENT MODIFICATION NOMINAL SA09550072-21 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 33 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 34 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) NameKit Number 6,648.0090SERVICE KIT - FATIGUE LIFE ENHANCE- MENT MODIFICATION OVERSIZE SA09550072-23 Operators are encouraged to complete the survey provided in APPENDIX H of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. 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 To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One service kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each side of the horizontal stabilizer based on inspection findings. Kits should be ordered as follows: Service KitRepair, Replacement, or Modification Options SA09550072-3 (Left Side)Horizontal stabilizer rear spar lower cap splice repair SA09550072-5 (Right Side) SA09550072-7 (Left Side)Horizontal stabilizer rear spar lower cap replacement SA09550072-9 (Right Side) SA09550072-11 (Left Side)Horizontal stabilizer rear spar lower cap splice repair with fatigue life enhance- ment modification SA09550072-13 (Right Side) SA09550072-15 (Left Side)Horizontal stabilizer rear spar lower cap replacement with fatigue life enhance- ment modification SA09550072-17 (Right Side) SA09550072-19Horizontal stabilizer rear spar lower cap bushing repair SA09550072-21 (Nominal)Horizontal stabilizer rear spar lower cap fatigue life enhancement modification SA09550072-23 (Oversize) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 34 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 35 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -13-11-9-7-5-3 --.....-SA09550072-3 --....-.SA09550072-5 --...-..SA09550072-7 --..-...SA09550072-9 --.-....SA09550072-11 ---.....SA09550072-13 --NUT..33..113LH7940T064 --NUT..44..113LH7940T070 --BARREL NUT..11..113LH7940T080 (a)-NUT BARREL..22..117LH7940T098 --NUT ASSY2424999924243D0006-3 --NUT ASSY..55..3D0006-4 --BOLT..22..3D0031-9-34 --NUT..22..3D0043-5 (b)-SPAR CAP...1..5918000-523 (c)-SPAR CAP..1...5918000-524 --BUSHING22....7090-040 --BUSHING22....7090-043 --WASHER..22..73232-9-28.7 --HI LOCK..11..HL327-6-10 --PIN..22..HL328-6-10 --PIN..55..HLT434-6-3 --PIN..7373..HLT434-6-4 --PIN..3232..HLT434-6-5 --PIN88181888HLT434-6-6 --PIN..1818..HLT434-6-7 --PIN88252588HLT434-6-8 --PIN1414221414HLT434-6-9 --PIN44..44HLT434-6-11 --HILOK..22..HLT434-8-7 --HILOK..11..HLT434-8-8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 35 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 36 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -13-11-9-7-5-3 --PIN..8484..HLT435-6-4 --PIN22787822HLT435-6-5 --PIN22101022HLT435-6-6 --PIN44131344HLT435-6-7 --PIN1414441414HLT435-6-8 --PIN1515..1515HLT435-6-9 --WASHER..22..MS20002-5 --WASHER..11..MS20002-6 --WASHER..11..MS20002-7 --WASHER..22..MS20002C5 --WASHER..33..MS20002C6 --WASHER..44..MS20002C7 --WASHER..11..MS20002C8 --RIVET..66..MS20426AD3-4D --RIVET..11..MS20426AD5-8D --RIVET..4545..MS20426AD5-9D --RIVET..9595..MS20426AD6-8D --RIVET..5757..MS20426AD6-9D --RIVET..44..MS20426AD6-10D --RIVET..2020..MS20470AD5-8D --RIVET44..44MS20470AD6-8D --RIVET..106106..MS20470E5-6D --RIVET..2020..MS20470E5-7D --RIVET..5252..MS20470E6-7D --RIVET..2626..MS20470E6-8D --NUT51512982985151MS21042L3 --NUT332233MS21042L4 --NUTPLATE..55..MS21075L3 --BOLT..22..MS21250-05018 --BOLT..11..MS21250-06020 --BOLT..11..MS21250-06022 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 36 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 37 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -13-11-9-7-5-3 --BOLT..22..MS21250-06024 --BOLT..11..MS21250-07020 --BOLT..11..MS21250-07024 --BOLT..11..MS21250-07026 --BOLT..11..MS21250-08028 --BOLT..22..MS21250H07060 --RIVET..88..NAS1097KE5-8D --RIVET..77..NAS1097KE5-9D --RIVET..4444..NAS1097KE6-8D --RIVET..5959..NAS1097KE6-9D --RIVET..44..NAS1097KE6-11D --WASHER..7878..NAS1149F0332P --WASHER..2424..NAS1149F0463P --WASHER..1414..NAS1149FN816P --WASHER41413233234141NAS1252-10L --WASHER..33..NAS1252-416L --RADIUS WASHER1414..1414NAS1401-3D3 --SCREW..1414..NAS1403-2 --SCREW..2020..NAS1403-4 --SCREW..3030..NAS1403-5 --SCREW..44..NAS1403-8 --WASHER..2323..NAS1587A3C --SCREW..11..NAS333CPA4-5 --RETAINER..33..NAS578-6B --RETAINER..44..NAS578-7B --RETAINER..11..NAS578-8B --SCREW..2424..NAS602-7P --WASHER336633NAS620-416L --BOLT..66..NAS6203-10 --BOLT..88..NAS6203-6 --BOLT336633NAS6204-13 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 37 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 38 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -13-11-9-7-5-3 --BOLT..2424..NAS6204-4 --NUT..3131..NAS679A3 --NUT..77..NAS679A4 --BOLT..11..PIC239-3-4 --BOLT..22..PIC239-4-4 --PIN..44..S4931919-6-5 --PIN..88..S4931920-6-4 --PIN..1010..S4931920-6-5 --PIN..1414..S4931920-6-6 --PIN444444S4931920-6-7 --PIN..66..S4931920-6-8 --PIN..55..S4931920-6-11 --PIN..33..S4931920-8-13 --PIN..11..S4931920-8-16 --DOUBLER.1...1SR09550035-3 --DOUBLER1...1.SR09550035-4 --ANGLE.1...1SR09550035-5 --ANGLE1...1.SR09550035-6 --ANGLE.1...1SR09550035-7 --ANGLE1...1.SR09550035-8 --SPACER11..11SR09550035-9 --SPACER11..11SR09550035-11 (d)-SHIM11..11SR09550035-13 (d)-SHIM11..11SR09550035-15 (d)-SHIM11..11SR09550035-17 --ANGLE11..11SR09550035-19 (e)-SPAR.1...1SR09550035-21 (f)-SPAR1...1.SR09550035-22 (a) 3D0011-9 barrel nut and 3D0012-9 retainer may be substituted for 117LH7940T-098 barrel nut. (b) 5918000-527 is an alternate part for 5918000-523. (c) 5918000-528 is an alternate part for 5918000-524. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 38 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 39 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -13-11-9-7-5-3 (d) Use as required. (e) May be made from 5918000-523/-527/ or -531. (f) May be made from 5918000-534/-538/ or -532. Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -23-21-19-17-15 --....-SA09550072-15 --...-.SA09550072-17 --..-..SA09550072-19 --.-...SA09550072-21 ---....SA09550072-23 --NUT...33113LH7940T064 --NUT...44113LH7940T070 --BARREL NUT...11113LH7940T080 (a)-NUT BARREL...22117LH7940T098 --NUT ASSY...99993D0006-3 --NUT ASSY...553D0006-4 --BOLT...223D0031-9-34 --NUT...223D0043-5 (b)-SPAR CAP....15918000-523 (c)-SPAR CAP...1.5918000-524 --BUSHING.2.227090-040 --BUSHING2....7090-041 --BUSHING2....7090-042 --BUSHING.2.227090-043 --BUSHING2....7090-044 --BUSHING2....7090-045 --WASHER...2273232-9-28.7 --HI LOCK...11HL327-6-10 --PIN...22HL328-6-10 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 39 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 40 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -23-21-19-17-15 --PIN...55HLT434-6-3 --PIN...7373HLT434-6-4 --PIN...3232HLT434-6-5 --PIN...1818HLT434-6-6 --PIN...1818HLT434-6-7 --PIN...2525HLT434-6-8 --PIN...22HLT434-6-9 --HILOK...22HLT434-8-7 --HILOK...11HLT434-8-8 --PIN11...HLT434-8-13 --PIN...8484HLT435-6-4 --PIN...7878HLT435-6-5 --PIN...1010HLT435-6-6 --PIN...1313HLT435-6-7 --PIN...44HLT435-6-8 --PIN11...HLT634-8-13 --WASHER...22MS20002-5 --WASHER...11MS20002-6 --WASHER...11MS20002-7 --WASHER...22MS20002C5 --WASHER...33MS20002C6 --WASHER...44MS20002C7 --WASHER...11MS20002C8 --RIVET...66MS20426AD3-4D --RIVET...11MS20426AD5-8D --RIVET...4545MS20426AD5-9D --RIVET...9595MS20426AD6-8D --RIVET...5757MS20426AD6-9D --RIVET...44MS20426AD6-10D --RIVET...2020MS20470AD5-8D --RIVET...106106MS20470E5-6D Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 40 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 41 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -23-21-19-17-15 --RIVET...2020MS20470E5-7D --RIVET...5252MS20470E6-7D --RIVET...2626MS20470E6-8D --NUT...298298MS21042L3 --NUT33322MS21042L4 --NUTPLATE...55MS21075L3 --BOLT...22MS21250-05018 --BOLT...11MS21250-06020 --BOLT...11MS21250-06022 --BOLT...22MS21250-06024 --BOLT...11MS21250-07020 --BOLT...11MS21250-07024 --BOLT...11MS21250-07026 --BOLT...11MS21250-08028 --BOLT...22MS21250H07060 --RIVET...88NAS1097KE5-8D --RIVET...77NAS1097KE5-9D --RIVET...4444NAS1097KE6-8D --RIVET...5959NAS1097KE6-9D --RIVET...44NAS1097KE6-11D --WASHER...7878NAS1149F0332P --WASHER...2424NAS1149F0463P --WASHER...1414NAS1149FN816P --WASHER...323323NAS1252-10L --WASHER...33NAS1252-416L --SCREW...1414NAS1403-2 --SCREW...2020NAS1403-4 --SCREW...3030NAS1403-5 --SCREW...44NAS1403-8 --WASHER...2323NAS1587A3C --SCREW...11NAS333CPA4-5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 41 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 42 Kit SA09550072 NotesExisting Part Number NameQtyNew Part Number -23-21-19-17-15 --RETAINER...33NAS578-6B --RETAINER...44NAS578-7B --RETAINER...11NAS578-8B --SCREW...2424NAS602-7P --WASHER13366NAS620-416L --BOLT...66NAS6203-10 --BOLT...88NAS6203-6 --BOLT.2166NAS6204-13 --BOLT..2..NAS6204-15 --BOLT2....NAS6204-16 --BOLT...2424NAS6204-4 --NUT...3131NAS679A3 --NUT...77NAS679A4 --BOLT...11PIC239-3-4 --BOLT...22PIC239-4-4 --PIN...44S4931919-6-5 --PIN...88S4931920-6-4 --PIN...1010S4931920-6-5 --PIN...1414S4931920-6-6 --PIN...44S4931920-6-7 --PIN...66S4931920-6-8 --PIN...55S4931920-6-11 --PIN...33S4931920-8-13 --PIN...11S4931920-8-16 --WASHER2.2..SR09550037-3 --WASHER2....SR09550037-5 --BUSHING..2..SR09550037-7 (a) 3D0011-9 barrel nut and 3D0012-9 retainer may be substituted for 117LH7940T-098 barrel nut (b) 5918000-527 is an alternate part for 5918000-523. (c) 5918000-528 is an alternate part for 5918000-524. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 42 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 43 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals and drawings given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. NotesNameQTYPart Number / Specification (a) (b)SealantAs-Re- quired PR-1422, Class B- 1/2 or B-2 (DMS 2082 Class B-1/2 or B-2, Grade 1) (a) (c)Alodine 600As-Re- quired DPM 1453-8 or -10 (a) (b)Primer, Fluid ResistantAs-Re- quired 515-700 (Base) with 910-704 (Cata- lyst) (DMS 1786 Type 1, Composi- tion A) OR (a) (d) OR 44GN054 Compo- nent I with 44GN054 Compo- nent II (DMS 1786 Type 1, Composi- tion D) (a) (d)Primer, Fluid Resistant Touch-Up KitAs-Re- quired 44GN054 2TU or 4TU (DMS 1786 Type 2, Comp. B) (a) (e)Topcoat, Impact ResistantAs-Re- quired 24F40-106 (DMS 2143 Type 1, Class 1, Composition C; DN3635) (a) (e)Primer, Impact ResistantAs-Re- quired 10P20-26 (Base) with EC-234 (Cata- lyst) (DMS 2144 Composition C) (a) (f)Suppressant Fume and SprayAs-Re- quired Fumetrol 140 (a) Or approved equivalent. (b) Can be purchased from: PRC-DeSoto International, INC. PPG Aerospace 11601 United Street Mojave, California 93501 CAGE: 85570 (c) Can be purchased from: Henkel Corporation 32100 Stephenson Highway Madison Heights, Michigan 48071 CAGE: 1N6B3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 43 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 44 NotesNameQTYPart Number / Specification (d) Can be purchased from: PRC-DeSoto International, INC. PPG Aerospace, Deft 17451 Von Karman Avenue Irvine, California 92614 CAGE: 33461 (e) Can be purchased from: Akzo Nobel Aerospace Coatings INC. 1 E Water Street Waukegan, Illinois 60085 CAGE: 91342 (f) Can be purchased from: Atotech USA, INC. 1750 Overview Drive Rock Hill, South Car- olina 29730 CAGE: 0RP46 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 MD-80 SRM 51-30-9 gives data about cold working tools and sleeves necessary to do the work given in this service bulletin. These tools are available from industry sources. Engineering, service, and a kit of cold working tools made for this change are available from Fatigue Technology, Inc. or West Coast Industries, Inc. • Refer To: FTI Kit Number: FTI-MD80-52A072-1 Fatigue Technology, Inc. P.O. Box C-88388 Seattle, WA 98188 USA Phone Number (206) 246-2010 Fax (206) 244-9886 • Refer To: WCI Kit Number: WCI-MD80-55A-072 West Coast Industries, Inc. 14900 Whitman Avenue North Seattle, WA 98133-6532 USA Phone Number (206) 365-7513 Fax (206) 365-7483 F. Special Tooling Necessary to do this Service Bulletin Cold working tools are necessary to do the change given in this service bulletin. To get the cold working tools, refer to Paragraph 2.E., Special Tooling - Price and Availability. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 44 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 45 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. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Equivalent parts are listed in the AEPL, Drawing 7595071. 3. Use the approved fastener and process material substitutions, in accordance with MD-80 SRM 51. 4. If the length of any fastener specified in this service bulletin does not meet installation standards given in Structural Repair Manual (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. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 5. A 1/8-inch thick stack of the same type washers called for in this service bulletin is the maximum thickness which may be used under fastener head or nut to counteract accumulation of tolerances. EXCEPTION: When the available fastener length increments are greater than 1/16-inch, a 3/16-inch thick stack of the same type washers may be used. 6. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are in MD-80 SRM 51 – Torque Values: — Values for structural fasteners are given in MD-80 Structural Repair Manual, Chapter 51. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 45 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 46 — Values for airframe maintenance tasks are included in Chapter 20 of MD-80 Aircraft Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). — Values for engine maintenance tasks are included in Chapter 70 of MD-80 Aircraft Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step. 7. Obey all of the warnings and cautions given in the specified manual sections. 8. Refer to APPENDIX A through APPENDIX F for logic diagrams. Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 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. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U' or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U' or 'Y' as an alternative to the '-' (dash) number part. Boeing Drawing SE10000000, Sheets 5.0 and 6.0 contain more data. 11. 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. 12. 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. 13. 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. 14. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 15. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 16. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 46 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 47 17. Some steps in the Work Instructions are labeled as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps labeled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including sub-steps and identified figures. Steps not labeled as RC may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC. This is provided that the RC steps, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. B. WORK INSTRUCTIONS PART 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP EDDY CURRENT HIGH FREQUENCY (ETHF) INSPECTION 1. RC - Do PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS for any crack in the left and right sides of the horizontal stabilizer. a. CONDITION 1: NO CRACK FOUND ON THE LEFT SIDE (1) Do one of the following options: (a) OPTION 1: REPEAT INSPECTIONS 1) If removed, install bolts in accordance with FIGURE 3. NOTE: Refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) Repeat PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS for any crack at the repeat interval given in Paragraph 1.E., Compliance. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 2 (ACTION 1): Do a fatigue life enhancement modification in accordance with Service Rework Drawing SR09550037-7001 (Nominal) or SR09550037-7005 (Oversize). NOTE: Refer to APPENDIX G for fatigue life enhancement modification access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) OPTION 2 (ACTION 2): Do PART 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR for any crack. b. CONDITION 2: NO CRACK FOUND ON THE RIGHT SIDE (1) Do one of the following options: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 47 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 48 (a) OPTION 1: REPEAT INSPECTIONS 1) If removed, install bolts in accordance with FIGURE 3. NOTE: Refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) Repeat PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS for any crack at the repeat interval given in Paragraph 1.E., Compliance. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 2 (ACTION 1): Do a fatigue life enhancement modification in accordance with Service Rework Drawing SR09550037-7003 (Nominal) or SR09550037-7007 (Oversize). NOTE: Refer to APPENDIX G for fatigue life enhancement modification access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) OPTION 2 (ACTION 2): Do PART 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR for any crack. c. CONDITION 3: ON THE LEFT OR RIGHT SIDE, ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CAN BE REMOVED WITH A HOLE DIAMETER OF 0.408 INCHES OR LESS AND NO CRACK FOUND IN THE UPPER FASTENER HOLE (1) Do one of the following options for the affected side: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP BUSHING REPAIR 1) OPTION 1 (ACTION 1): Do a bushing repair in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550037-7011SR09550037-7009 NOTE: Refer to APPENDIX G for bushing repair access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) OPTION 1 (ACTION 2): Do PART 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 48 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 49 (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR 1) OPTION 2 (ACTION 1): Do PART 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR. 2) OPTION 2 (ACTION 2): Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT or PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. (c) OPTION 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. (d) OPTION 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 4 (ACTION 1): Do PART 6: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. 2) OPTION 4 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instructions and do the replacement. (e) OPTION 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. d. CONDITION 4: ON THE LEFT OR RIGHT SIDE, ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CANNOT BE REMOVED WITH A MAXIMUM HOLE DIAMETER OF 0.408 INCHES OR ANY CRACK FOUND IN THE UPPER FASTENER HOLE (1) Do one of the following options: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR 1) OPTION 1 (ACTION 1): Do PART 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR. 2) OPTION 1 (ACTION 2): Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT or PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 49 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 50 (c) OPTION 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 3 (ACTION 1): Do PART 6: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. 2) OPTION 3 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instructions and do the replacement. (d) OPTION 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. 2. Put the airplane back to a serviceable condition. PART 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR 1. Do a surface ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 2. a. CONDITION 5: NO CRACK FOUND (1) Repeat PART 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR for any crack at the repeat interval given in Paragraph 1.E., Compliance. b. CONDITION 6: ANY CRACK FOUND IN HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A BUSHING REPAIR (1) Do one of the following options: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR 1) OPTION 1 (ACTION 1): Do PART 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR. 2) OPTION 1 (ACTION 2): Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT or PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 50 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 51 (c) OPTION 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 3 (ACTION 1): Do PART 6: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. 2) OPTION 3 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instructions and do the replacement. (d) OPTION 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. c. CONDITION 7: ANY CRACK FOUND IN HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A FATIGUE LIFE ENHANCEMENT MODIFICATION (1) Contact The Boeing Company for work instructions and do the work. PART 3: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A SPLICE REPAIR 1. Do a surface ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 2. a. CONDITION 8: NO CRACK FOUND (1) Repeat PART 3: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A SPLICE REPAIR for any crack at the repeat interval given in Paragraph 1.E., Compliance. b. CONDITION 9: ANY CRACK FOUND IN HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A BUSHING REPAIR (1) Do one of the following options: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. c. CONDITION 7: ANY CRACK FOUND IN HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A FATIGUE LIFE ENHANCEMENT MODIFICATION Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 51 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 52 (1) Contact The Boeing Company for work instructions and do the work. PART 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR 1. Do a horizontal stabilizer rear spar lower cap splice repair in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550035-7003SR09550035-7001 NOTE: Refer to APPENDIX G for horizontal stabilizer rear spar lower cap splice repair access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2. Do PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS for any crack. a. CONDITION 10: NO CRACK FOUND (1) Do one of the following options: (a) OPTION 1: REPEAT INSPECTIONS 1) If removed, install bolts in accordance with FIGURE 3. NOTE: Refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) Repeat PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS for any crack at the repeat interval given in Paragraph 1.E., Compliance. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 2 (ACTION 1): Do a fatigue life enhancement modification in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550037-7003 (Nominal)SR09550037-7001 (Nominal) SR09550037-7007 (Oversize)SR09550037-7005 (Oversize) NOTE: Refer to APPENDIX G for fatigue life enhancement modification access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) OPTION 2 (ACTION 2): Do PART 3: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A SPLICE REPAIR for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 52 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 53 b. CONDITION 11: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CAN BE REMOVED WITH A HOLE DIAMETER OF 0.408 INCHES OR LESS AND NO CRACK FOUND IN THE UPPER FASTENER HOLE (1) Do one of the following options: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP BUSHING REPAIR 1) OPTION 1 (ACTION 1): Do a bushing repair in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550037-7011SR09550037-7009 NOTE: Refer to APPENDIX G for bushing repair access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) OPTION 1 (ACTION 2): Do PART 3: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH A SPLICE REPAIR for any crack. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. (c) OPTION 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. c. CONDITION 12: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CANNOT BE REMOVED WITH A MAXIMUM HOLE DIAMETER OF 0.408 INCHES OR ANY CRACK FOUND IN THE UPPER FASTENER HOLE (1) Do one of the following options: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 53 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 54 PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1. Do a horizontal stabilizer rear spar lower cap replacement in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550036-7003SR09550036-7001 NOTE: Refer to APPENDIX G for horizontal stabilizer rear spar lower cap replacement access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2. Do PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS for any crack. a. CONDITION 13: NO CRACK FOUND (1) Do one of the following options: (a) OPTION 1: REPEAT INSPECTIONS 1) If removed, install bolts in accordance with FIGURE 3. NOTE: Refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) Repeat PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS for any crack at the repeat interval given in Paragraph 1.E., Compliance. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 2 (ACTION 1): Do a fatigue life enhancement modification in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550037-7003 (Nominal)SR09550037-7001 (Nominal) SR09550037-7007 (Oversize)SR09550037-7005 (Oversize) NOTE: Refer to APPENDIX G for fatigue life enhancement modification access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) OPTION 2 (ACTION 2): Do PART 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 54 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 55 b. CONDITION 14: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CAN BE REMOVED WITH A HOLE DIAMETER OF 0.408 INCHES OR LESS AND NO CRACK FOUND IN THE UPPER FASTENER HOLE (1) Do one of the following options: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP BUSHING REPAIR 1) OPTION 1 (ACTION 1): Do a bushing repair in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550037-7011SR09550037-7009 NOTE: Refer to APPENDIX G for bushing repair access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2) OPTION 1 (ACTION 2): Do PART 2: POST BUSHING REPAIR OR FATIGUE LIFE ENHANCEMENT MODIFICATION ETHF INSPECTION FOR HORIZONTAL STABILIZER REAR SPAR LOWER CAPS WITH NO SPLICE REPAIR for any crack. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR 1) OPTION 2 (ACTION 1): Do PART 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR. 2) OPTION 2 (ACTION 2): Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT or PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. (c) OPTION 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. (d) OPTION 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 4 (ACTION 1): Do PART 6: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. 2) OPTION 4 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instructions and do the replacement. (e) OPTION 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 55 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 56 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. c. CONDITION 15: ANY CRACK FOUND IN THE LOWER TWO FASTENER HOLES THAT CANNOT BE REMOVED WITH A MAXIMUM HOLE DIAMETER OF 0.408 INCHES OR ANY CRACK FOUND IN THE UPPER FASTENER HOLE (1) Do one of the following options: (a) OPTION 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR 1) OPTION 1 (ACTION 1): Do PART 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR. 2) OPTION 1 (ACTION 2): Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT or PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. (b) OPTION 2: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT 1) Do PART 5: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT. (c) OPTION 3: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) OPTION 3 (ACTION 1): Do PART 6: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. 2) OPTION 3 (ACTION 2): Contact The Boeing Company for horizontal stabilizer rear spar lower cap replacement instructions and do the replacement. (d) OPTION 4: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1) Do PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION. PART 6: HORIZONTAL STABILIZER REAR SPAR LOWER CAP SPLICE REPAIR WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1. Do a horizontal stabilizer rear spar lower cap splice repair and fatigue life enhancement modification in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550035-7007SR09550035-7005 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 56 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 57 NOTE: Refer to APPENDIX G for horizontal stabilizer rear spar lower cap splice repair with fatigue life enhancement modification access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2. Do a surface ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 2. a. CONDITION 16: NO CRACK FOUND (1) Repeat surface ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 2 at the repeat interval given in Paragraph 1.E., Compliance. b. CONDITION 17: ANY CRACK FOUND (1) Contact The Boeing Company for work instructions and do the work. PART 7: HORIZONTAL STABILIZER REAR SPAR LOWER CAP REPLACEMENT WITH FATIGUE LIFE ENHANCEMENT MODIFICATION 1. Do a horizontal stabilizer rear spar lower cap replacement and fatigue life enhancement modification in accordance with the applicable Service Rework Drawing below: RIGHT HORIZONTAL STABILIZERLEFT HORIZONTAL STABILIZER SR09550036-7007SR09550036-7005 NOTE: Refer to APPENDIX G for horizontal stabilizer rear spar lower cap replacement with fatigue life enhancement modification access. Also refer to APPENDIX G for open hole ETHF inspection close access information if an open hole ETHF inspection was done. 2. Do a surface ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 2. a. CONDITION 16: NO CRACK FOUND (1) Repeat surface ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 2 at the repeat interval given in Paragraph 1.E., Compliance. b. CONDITION 17: ANY CRACK FOUND (1) Contact The Boeing Company for work instructions and do the work. PART 8: HORIZONTAL STABILIZER REAR SPAR LOWER CAP ETHF INSPECTIONS 1. Do one of the following options: a. OPTION 1: OPEN HOLE ETHF INSPECTION NOTE: Refer to APPENDIX G for open hole ETHF inspection access information. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 57 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 58 (1) Do an open hole ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 1. b. OPTION 2: SURFACE ETHF INSPECTION (1) Do a surface ETHF inspection for any crack in the horizontal stabilizer rear spar lower cap in accordance with FIGURE 2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 08, 2016 MD80-55A072 58 of 88 BOEING SERVICE BULLETIN MD80-55A072 ALERTALERT ### Page 59 (OCR) BOEING SERVICE BULLETIN MD80-55A072 ALERT ALERT B NBD LOOKING FORWARD) (LEFT SIDE Xh=7.234 2428090 FIGURE 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP OPEN HOLE EDDY CURRENT HIGH FREQUENCY INSPECTION (SHEET 1 OF 5) Original Issue: April 08, 2016 Export Controlled ECCN: 9E991 - BOEING MD80-55A072 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 88 ### Page 60 (OCR) BOEING SERVICE BULLETIN MD80-55A072 ALERT ALERT LOOKING INBOARD -WD B-B LOOKING INBOARD FWD C-C 2429366 FIGURE 1: HORIZONTAL STABILIZER REAR SPAR LOWER CAP OPEN HOLE EDDY CURRENT HIGH FREQUENCY INSPECTION (SHEET 2 OF 5) Original Issue: April 08, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING MD80-55A072 Work - See page 1 for details. 60 of 88 The text continues at https://openairdocs.org/service-documents/boeing/md80-55a072/file/4c8ed0c26378.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). 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