# Boeing Alert Service Bulletin MD80-57A242: Revision 1

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- Document: [Boeing Alert Service Bulletin MD80-57A242](https://openairdocs.org/service-documents/boeing/md80-57a242.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin - SB-MD80-57A242-01
- Pages: 71
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## Text

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### Page 1

Commercial 
Airplanes
MD80
Service Bulletin
ALERT
Number: MD80-57A242
Original Issue: May 08, 2009
Revision 1: January 07, 2011
ATA System: 5710
SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station
Xrs=164.000
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 730-774). An export license may be required before it is used for development, production or use by foreign
persons from specific countries. The controller of this data has the individual responsibility to abide by all export
laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET
Copyright © 2009 The Boeing Company
Unpublished Work - All Rights Reserved
Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable
subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more
information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the
Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
1. PLANNING INFORMATION ........................................ 1 1
A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5
B. Concurrent Requirements ...................................... 1 5
C. Reason ................................................ 1 5
D. Description .............................................. 1 6
E. Compliance .............................................. 1 9
F. Approval ............................................... 2 5
G. Manpower .............................................. 2 5
H. Weight and Balance Changes .................................... 2 7
I. Electrical Load Data ......................................... 2 7
J. References .............................................. 2 7
1. Existing Data: ......................................... 2 7
2. Data supplied with this Service Bulletin: ........................... 2 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 8
K. Publications Affected ........................................ 2 8
L. Interchangeability and Intermixability of Parts ........................... 2 8
2. MATERIAL INFORMATION ........................................ 2 9
A. Material - Price and Availability ................................... 2 9
B. Industry Support Information .................................... 3 0
C. Parts Necessary For Each Airplane ................................. 3 0
1. Kits/Parts: ........................................... 3 0
2. Parts and Materials Supplied by the Operator: ........................ 5 4
3. Parts Modified and Reidentified: ............................... 5 4
4. Parts Removed and Not Replaced: .............................. 5 5
D. Parts Necessary to Change Spares ................................. 5 5
E. Special Tooling - Price and Availability ............................... 5 5
F. Special Tooling Necessary to do this Service Bulletin ....................... 5 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 7
A. GENERAL INFORMATION ..................................... 5 7
B. WORK INSTRUCTIONS ....................................... 5 9
FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH
FREQUENCY INSPECTION .................................. 7 0
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Commercial 
Airplanes
MD80
Service Bulletin
ALERT
Revision Transmittal SheetNumber: MD80-57A242Original Issue: May 08, 2009
Revision 1: January 07, 2011
ATA System: 5710
SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station
Xrs=164.000
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-11-07 is related to this service bulletin.
REASON FOR REVISION
This revision is sent to incorporate engineering released subsequent to original release of this service bulletin,
which incorporates an option to do a splice repair of the upper and/or lower rear spar caps.
The information provided in Information Notices MD80-57A242 IN 01 and MD80-57A242 IN 02 are included in
this revision.
These sections were changed:
1. In Paragraph 1.A.1., Airplanes, added Groups 3 and 4.
2. In Paragraph 1.C., Reason, added spar splice option.
3. In Paragraph 1.D., Description, added Condition titles, Option 1 heading and Option 2 splice repair, and
added repair options for Condition 3.
4. In Paragraph 1.E., Compliance, added calender time information, Option 1 heading, Option 2 splice repair,
repair options for Condition 3, and Federal Aviation Administration (FAA) Airworthiness Directive information.
5. In Paragraph 1.F., Approval, added Alternative Method of Compliance statement.
6. In Paragraph 1.G., Manpower, added Groups 3 and 4 and a table for splice repair hours.
7. In Paragraph 1.J.1., Existing Data, changed Aircraft Maintenance Manual (AMM) references to reflect correct
chapter references.
8. In Paragraph 1.J.2., Data supplied with this Service Bulletin, added drawings and updated DCN/REV column.
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9. In Paragraph 1.K., Publications Affected, added Damage Tolerance Based Structural Inspection information.
10. In Paragraph 2.A., Material - Price and Availability, added Service Kits, expiration date, and unit price.
11. In Paragraph 2.C.1., Kits/Parts, changed Service Kit applicability table to add new kits, changed kit
descriptions, and added new kit parts list.
12. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, changed supplier address.
13. In Paragraph 2.C.3., Parts Modified and Reidentified, added parts changed based on repair configuration.
14. In Paragraph 3.A., General Information, added notes.
15. In Paragraph 3.B., Work Instructions, added Groups 3 and 4, Option 1 heading, Option 2 splice repair, and
repair options for Condition 3, removed one work step, resequenced work steps, and corrected Aircraft
Maintenance Manual Chapter references.
16. Changed note and scope of inspection in Figure 1 for clarity of work required.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location
of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY
May 08, 2009Original Issue:
January 07, 2011Revision 1:
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Commercial 
Airplanes
MD80
Service Bulletin
ALERT
SummaryNumber: MD80-57A242Original Issue: May 08, 2009
Revision 1: January 07, 2011
ATA System: 5710
SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station
Xrs=164.000
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
Two operators, while doing an investigation for fuel leaks, reported four instances of cracking of the wing rear
spar lower cap at the outboard flap, inboard drive hinge at station Xrs=164.000. Boeing has determined that
cracks are the result of material fatigue from normal flap operating loads. Inspecting this area for cracks will stop
any crack migration and ensure repairs are done before additional damage occurs. Installation of doublers or
doing a spar lower cap splice will help insure the structural integrity of the rear spar. If not corrected, fuel leaks
and damage to the wing skin or other structure may occur, resulting in flight disruptions and possible loss of the
structural integrity of the wing.
Service History
Landing CyclesFlight-Hours
35,286 to 39,33851,193 to 69,453
ACTION
Refer to Paragraph 1.D., for Description.
EFFECTIVITY
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87) and MD-88 Airplanes. Refer to
Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE
Refer to Paragraph 1.E., Compliance.
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INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service
bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN MD80-57A242
ALERT  ALERT
NSPECT / REPAIR UPPER ANI
LOWER REAR SPAR CAPS AT STA
Xrs=164.000
1676759
Original Issue: May 08, 2009
Revision 1: January 07, 2011  MD80-57A242
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Commercial 
Airplanes
MD80
Service Bulletin
ALERT
Number: MD80-57A242
Original Issue: May 08, 2009
Revision 1: January 07, 2011
ATA System: 5710
SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station
Xrs=164.000
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
Airplanes with a multi-component bulkhead with bolts at wing station
Xrs=137.750 and affected by Service Bulletin MD80-57-184.
-1
Airplanes that accomplished Service Bulletin MD80-57-184 temporary
repair.
1
Airplanes that did not accomplish Service Bulletin MD80-57-184
temporary repair.
2
Airplanes with a multi-component bulkhead with bolts at wing station
Xrs=137.750 and not affected by Service Bulletin MD80-57-184.
-2
Airplanes with a multi-component bulkhead without bolts at wing
station Xrs=137.750 and not affected by Service Bulletin
MD80-57-184.
-3
Airplanes with a machined bulkhead at wing station Xrs=137.750
and not affected by Service Bulletin MD80-57-184.
-4
Airplane Models:
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88
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GroupFuselage Num-
ber
1938
1941
1944
1948
1950
1952 - 953
1957
1962
1966 - 967
1969 - 971
1973
1978
1981
1986
1988
1992
1994 - 995
1999 - 1001
11004 - 1006
11011 - 1012
11016
11018 - 1019
11028
11031
11034
11043
11045
11047
11049
11051
11053
11055
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GroupFuselage Num-
ber
11057
11059 - 1060
11063 - 1071
11073
11075 - 1080
11082
11085
11087 - 1092
11095 - 1103
11105 - 1110
11112 - 1117
11119 - 1128
11130
11133 - 1145
11147 - 1172
11174 - 1181
11183 - 1203
11205 - 1206
11208 - 1223
11225 - 1260
11262 - 1290
11292
11294 - 1314
11316 - 1323
11325
11327 - 1334
11336 - 1342
11344 - 1350
11352 - 1395
11397 - 1451
11453 - 1469
21470 - 1477
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GroupFuselage Num-
ber
21479 - 1481
31482
21483 - 1503
21505 - 1513
31514
21515
31516 - 2007
32009 - 2016
32019 - 2034
32036 - 2069
32071 - 2093
32101 - 2114
32116
32118 - 2119
32121
32124
32127
32130
32132
32134 - 2135
32137
32139
32145
32148
32151 - 2152
32155
32167
32174
32176
32178
32180
32183
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GroupFuselage Num-
ber
32185
32187
32189
32192
32196
32199
32201
32204
32206
32208
32214
42218
42234
42239
42241
42244
42247
42249
42252
42254
42264 - 2287
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Two operators, while doing an investigation for fuel leaks, reported four instances of cracking of the
wing rear spar lower cap at the outboard flap, inboard drive hinge at station Xrs=164.000. Boeing has
determined that cracks are the result of material fatigue from normal flap operating loads. Inspecting
this area for cracks will stop any crack migration and ensure repairs are done before additional damage
occurs. Installation of doublers or doing a spar lower cap splice will help insure the structural integrity
of the rear spar. If not corrected, fuel leaks and damage to the wing skin or other structure may occur,
resulting in flight disruptions and possible loss of the structural integrity of the wing.
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Revision 1 is sent to incorporate engineering released subsequent to original release of this service
bulletin, which incorporates an option to do a splice repair of the upper and/or lower rear spar caps.
The information provided in Information Notices MD80-57A242 IN 01 and MD80-57A242 IN 02 are
included in this revision.
Service History
Landing CyclesFlight-Hours
35,286 to 37,00666,260 to 69,453
D. Description
Group 1, Configuration 1:
1. Continues repeat inspections in accordance with Service Bulletin MD80-57-184, Paragraph 1.D.(5),
Compliance.
Group 1, Configuration 2; Group 2-4:
1. Does Eddy Current, High Frequency inspection (ETHF) on the aft side of the left and right wing
rear spar lower caps at station Xrs=164.000 for cracks and based on inspection results does as
follows:
a. Condition 1 (No Crack)
Does repeat ETHF inspections.
b. Condition 2 (Lower Spar Cap has a Crack 2.0 Inches or Less in Length and Not in the Rear
Spar Cap Forward Horizontal Leg Radius)
Does ETHF on the aft side of the left and/or right wing rear spar upper cap at station
Xrs=164.000 for cracks and based on inspection results does as follows:
(1) Condition 2a (No Crack in Rear Spar Upper Cap):
Option 1
(a) Does doubler repair to rear spar lower cap in accordance with Service Rework
Drawing J060271.
(b) Does repeat ETHF inspections.
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Option 2
(a) Does splice repair to rear spar lower cap in accordance with Service Rework Drawing
J060165.
(b) Does Eddy Current, Low Frequency (ETLF) and Ultrasonic (UT) inspections of rear
spar lower cap splice repair.
(2) Condition 2b (Upper Spar Cap has a Crack 2.0 Inches or Less in Length and Not in the
Rear Spar Cap Forward Horizontal Leg Radius):
NOTE: Operators can do Option 1 or Option 2 or any combination of Options 1 and 2.
Option 1
(a) Does doubler repair to rear spar upper and lower caps in accordance with Service
Rework Drawing J060271.
(b) Does ETHF inspections of rear spar upper and lower cap doubler repairs.
Option 2
(a) Does splice repair to rear spar upper and lower caps in accordance with Service
Rework Drawing J060165.
(b) Does ETLF and UT inspections of rear spar lower cap splice repair.
(3) Condition 2c (Upper Spar Cap Has a Crack Longer than 2.0 Inches in Length or Crack
in the Rear Spar Cap Forward Horizontal Leg Radius):
Option 1
(a) Does splice repair to rear spar upper cap in accordance with Service Rework Drawing
J060165 and doubler repair to rear spar lower cap in accordance with Service Rework
Drawing J060271.
(b) Does ETHF inspections of rear spar lower cap doubler repair.
Option 2
(a) Does splice repair to rear spar upper and lower caps in accordance with Service
Rework Drawing J060165.
(b) Does ETLF and UT inspections of rear spar lower cap repair.
c. Condition 3 (Lower Spar Cap has a Crack Longer than 2.0 Inches in Length or Crack in Rear
Spar Cap Forward Horizontal Leg Radius)
Does ETHF inspection on the aft side of the left and/or right wing rear spar upper cap at station
Xrs=164.000 for cracks and based on inspection results does as follows:
(1) Condition 3a (No Crack in Rear Spar Upper Cap):
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(a) Does splice repair to rear spar lower cap in accordance with Service Rework Drawing
J060165.
(b) Does ETLF and UT inspections of rear spar lower cap splice repair.
(2) Condition 3b (Crack 2.0 Inches or Less in Length in Rear Spar Upper Cap and Not in the
Rear Spar Upper Cap Forward Horizontal Leg Radius):
Option 1
(a) Does doubler repair to rear spar upper cap in accordance with Service Rework
Drawing J060271 and splice repair to rear spar lower cap in accordance with Drawing
J060165.
(b) Does ETHF inspection of rear spar upper cap doubler repair.
(c) Does ETLF and UT inspections of rear spar lower cap splice repair.
Option 2
(a) Does splice repair to rear spar upper and lower caps in accordance with Service
Rework Drawing J060165.
(b) Does ETLF and UT inspections of rear spar lower cap splice repair.
(3) Condition 3c (Crack Longer than 2.0 Inches in Length in Rear Spar Upper Cap or Crack
in the Rear Spar Upper Cap Forward Horizontal Leg Radius):
(a) Does splice repair to rear spar upper and lower caps in accordance with Service
Rework Drawing J060165.
(b) Does ETLF and UT inspections of rear spar lower cap splice repair.
Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of
this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1-3:
Affected Maintenance Zones
ZoneModel
13, 14, 15, 16DC-9-81 (MD-81), DC-9-82
(MD-82), DC-9-83 (MD-83), DC-
9-87 (MD-87), MD-88
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Group 4:
Affected Maintenance Zones
ZoneModel
13, 14, 15, 16DC-9-83 (MD-83)
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-11-07 is related to this service
bulletin.
Group 1, Configuration 1:
1. No action is necessary for this service bulletin.
NOTE: Repeat inspections in accordance with Service Bulletin MD80-57-184, Paragraph 1.D.(5),
Compliance, are still required.
Group 1, Configuration 2; Group 2-4:
Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000
Repeat In-
terval
(Not to Ex-
ceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,360
flight cycles after
the original issue
date on this ser-
vice bulletin.
Before the accu-
mulation of
30,000 total flight
cycles.
Do Eddy Current, High Frequency
(ETHF) inspection of the left and
right wing rear spar lower cap at
station Xrs=164.000 in accordance
with Accomplishment Instructions
3.B.
All airplanes
Within
2,650 flight
cycles af-
ter doing
the ETHF
inspection.
--Do ETHF inspection of the left and
right wing rear spar lower caps at
station Xrs=164.000 in accordance
with Accomplishment Instructions
3.B.
Condition 1:
No Crack
Before further
flight.
Do ETHF inspection of the left
and/or right wing rear spar upper
cap at station Xrs=164.000 in accor-
dance with Accomplishment Instruc-
tions 3.B.
Condition 2:
Lower Spar Cap has a
Crack 2.0 Inches or
Less in Length and Not
in the Rear Spar Cap
Forward Horizontal Leg
Radius
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Group 1, Configuration 2; Group 2-4:
Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000
Repeat In-
terval
(Not to Ex-
ceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
--Before further
flight.
Option 1:
Do doubler repair of rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
Condition 2a
No Crack in Rear Up-
per Spar Cap.
AND
Within
7,000 flight
cycles af-
ter doing
the ETHF
inspection.
-Within 11,000
flight cycles after
doubler repair.
Do ETHF inspection in the repaired
area of the rear spar lower cap in
accordance with Accomplishment
Instructions 3.B.
OR
--Before further
flight.
Option 2:
Do splice repair in accordance with
Accomplishment Instructions 3.B.
AND
Within
2,900 flight
cycles af-
ter doing
the ETLF
and UT in-
spection.
-Within 22,000
flight cycles after
splice repair.
Do Eddy Current, Low Frequency
(ETLF) and Ultrasonic (UT) inspec-
tions in the repaired area of the rear
spar lower cap in accordance with
Accomplishment Instructions 3.B.
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Group 1, Configuration 2; Group 2-4:
Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000
Repeat In-
terval
(Not to Ex-
ceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
--Before further
flight.
Option 1:
Do doubler repair of rear spar upper
and lower caps in accordance with
Accomplishment Instructions 3.B.
Condition 2b:
Upper Spar Cap has a
Crack 2.0 Inches or
Less in Length and Not
in the Rear Spar Cap
Forward Horizontal Leg
Radius
AND
Within
7,000 flight
cycles af-
ter doing
the ETHF
inspection.
-Within 11,000
flight cycles after
doubler repair.
Do ETHF inspection in the repaired
area of the rear spar upper and
lower caps in accordance with Ac-
complishment Instructions 3.B.
OR
--Before further
flight.
Option 2:
Do splice repair of rear spar upper
and lower caps in accordance with
Accomplishment Instructions 3.B.
AND
Within
2,900 flight
cycles af-
ter doing
the ETLF
and UT in-
spection.
-Within 22,000
flight cycles after
splice repair.
Do ETLF and UT inspections in the
repaired area of the rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
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### Page 22

Group 1, Configuration 2; Group 2-4:
Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000
Repeat In-
terval
(Not to Ex-
ceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
--Before further
flight.
Option 1:
Do splice repair of rear spar upper
cap and doubler repair of rear spar
lower cap in accordance with Accom-
plishment Instructions 3.B.
Condition 2c:
Upper Spar Cap Has a
Crack Longer than 2.0
Inches in Length or
Crack the Rear Spar
Cap Forward Horizontal
Leg Radius AND
Within
7,000 flight
cycles af-
ter doing
the ETHF
inspection.
-Within 11,000
flight cycles after
doubler repair.
Do ETHF inspection in the repaired
area of the rear spar lower cap in
accordance with Accomplishment
Instructions 3.B.
OR
--Before further
flight.
Option 2:
Do splice repair of rear spar upper
and lower caps in accordance with
Accomplishment Instructions 3.B.
AND
Within
2,900 flight
cycles af-
ter doing
the ETLF
and UT in-
spection.
-Within 22,000
flight cycles after
splice repair.
Do ETLF and UT inspections in the
repaired area of the rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
--Before further
flight.
Do ETHF inspection of the left
and/or right wing rear spar upper
cap at station Xrs=164.000 in accor-
dance with Accomplishment Instruc-
tions 3.B.
Condition 3:
Lower Spar Cap has a
Crack Longer than 2.0
Inches in Length or
Crack in the Rear Spar
Cap Forward Horizontal
Leg Radius.
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### Page 23

Group 1, Configuration 2; Group 2-4:
Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000
Repeat In-
terval
(Not to Ex-
ceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Before further
flight.
Do splice repair of rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
Condition 3a:
No crack in rear spar
upper cap.
AND
Within
2,900 flight
cycles af-
ter doing
the ETLF
and UT in-
spection.
Within 22,000
flight cycles after
splice repair.
Do ETLF and UT inspections in the
repaired area of the rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
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### Page 24

Group 1, Configuration 2; Group 2-4:
Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000
Repeat In-
terval
(Not to Ex-
ceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
--Before further
flight.
Option 1:
Do doubler repair of rear spar upper
cap and splice repair of rear spar
lower cap in accordance with Accom-
plishment Instructions 3.B.
Condition 3b:
Crack 2.0 Inches or
Less in Length in Rear
Spar Upper Cap and
Not in the Rear Spar
Upper Cap Forward
Horizontal Leg Radius AND
Within
7,000 flight
cycles af-
ter doing
the ETHF
inspection.
-Within 11,000
flight cycles after
doubler repair.
Do ETHF inspection in the repaired
area of the rear spar upper cap in
accordance with Accomplishment
Instructions 3.B.
AND
Within
2,900 flight
cycles af-
ter doing
the ETLF
and UT in-
spection.
-Within 22,000
flight cycles after
splice repair.
Do ETLF and UT inspections in the
repaired area of the rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
OR
--Before further
flight.
Option 2:
Do splice repair of rear spar upper
and lower caps in accordance with
Accomplishment Instructions 3.B.
AND
Within
2,900 flight
cycles af-
ter doing
the ETLF
and UT in-
spection.
-Within 22,000
flight cycles after
splice repair.
Do ETLF and UT inspections in the
repaired area of the rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
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### Page 25

Group 1, Configuration 2; Group 2-4:
Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000
Repeat In-
terval
(Not to Ex-
ceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
--Before further
flight.
Do splice repair of rear spar upper
and lower caps in accordance with
Accomplishment Instructions 3.B.
Condition 3c:
Crack Longer than 2.0
Inches in Length in
Rear Spar Upper Cap
or Crack in Rear Spar
Upper Cap Forward
Horizontal Leg Radius
AND
Within
2,900 flight
cycles af-
ter doing
the ETLF
and UT in-
spection.
-Within 22,000
flight cycles after
splice repair.
Do ETLF and UT inspections in the
repaired area of the rear spar lower
cap in accordance with Accomplish-
ment Instructions 3.B.
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.
In addition, the repair and inspections described in Paragraph 1.D has been shown to comply with the
applicable Federal Aviation Regulations and is approved by the Manager, Los Angeles Aircraft
Certification Office, FAA Northwest Mountain Region and is approved as an alternative method of
compliance with Paragraph (b) and (c) of Airworthiness Directive 2004-11-07 as it applies to repaired
structure.
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 table below shows an estimate of the task hours necessary to do the inspection/change/repair for
each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate
with operator task hour data if necessary. The estimate does not include lost time. These are some
examples of lost time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
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### Page 26

— Time to make the parts
— Time to find the tools.
— Time to make reference standards.
1. Group 1, Configuration 1:
Manpower is in accordance with Service Bulletin MD80-57-184, Paragraph 1.F., Manpower.
2. Group 1, Configuration 2; Group 2-4:
Use applicable table for Manpower as follows:
TABLE 1: NO CRACKS
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.51.02Open Access
2.04.02Inspect
0.51.02Close Access
3.06.0TOTAL FOR EACH WING
TABLE 2: DOUBLER REPAIR
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.51.02Open Access
2.04.02Inspect
0.51.02Open Access to
tanks.
4.04.01Defuel
8.08.01Purge
100.0*200.0*2Repair
0.51.02Close Access
2.04.02Test
117.5*223.0*TOTAL FOR EACH WING
* Actual task hours and elapsed hours for repair are contingent upon inspection
results.
TABLE 3: SPLICE REPAIR
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.51.02Open Access
2.04.02Inspect
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### Page 27

TABLE 3: SPLICE REPAIR
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.51.02Open Access to
tanks
4.04.01Defuel
8.08.01Purge
200.0*400.0*2Repair
0.51.02Close Access
2.04.02Test
317.5*423.0*TOTAL FOR EACH WING
* Actual task hours and elapsed hours for repair are contingent upon inspection
results.
H. Weight and Balance Changes
Weight and balance changes affected by incorporation of this service bulletin are contingent upon the
changes to each particular airplane. Weight data is to be computed by the operator by weighing parts
removed and parts installed during this change. Necessary revisions should be made to the appropriate
airplane weight and balance report.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Boeing Service Bulletin MD80-57-184.
b. Non-Destructive Test Standard Practices Manual (NDTSPM) 01-00-01, 06-00-01, 06-10-01.001.
Part 06, 06-20-01.
c. MD80 Aircraft Maintenance Manual (AMM) 06-21-00, 27-10-00, 27-51-01, 27-60-00, 28-00-00,
28-10-01, 29-00-00, 32-10-0, 32-10-00, 57-20-03, 57-40-01.
d. MD80 Structural Repair Manual (SRM) 51-10-03, 51-10-04, 51-20-00, 51-30-01, 51-30-02,
51-30-03, 51-30-05, 51-30-09, 51-30-11, 51-30-60.
e. MD80 Supplemental Inspection Document (SID) Volume II, L26-022, Section 57.80.012,
Sequence 1, Method 1.
2. Data supplied with this Service Bulletin:
No data is supplied with this service bulletin. To obtain the data necessary to support this service
bulletin submit a data request to:
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### Page 28

Data and Services Management
MS D800-0019
3855 Lakewood Boulevard
Long Beach, California 90846
Phone: (562) 593-6996
Fax: (562) 593-2001
E-mail: dse.boecom@boeing.com
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
-CDWGEDDY CURRENT INSPECTION - WING
REAR SPAR TEMPORARY REPAIR STA
Xrs=164
3668XXX
YUAEOSERVICE REWORK - WING REAR SPAR
CAP SPLICE SERVICE REWORK DWG
J060165
ZUAEO
VUAEO
WUAEO
AAUDWG
UTDWGSERVICE REWORK - TEMP REPAIR,
WING REAR SPAR XRS=164.000
J060271
--DWGINSPECTION - REAR SPAR AFT TANG
SERVICE NDI DRAWING
SN90570006
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.
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### Page 29

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown
below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares.
More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the
date Boeing gets the purchase order.
Unit Price as of the
Revision 01 date of
this Service Bulletin
(US Dollars)
ROLT as of
the Revision
01 date of this
Service Bul-
letin (Calen-
dar Days)
NameKit Number
43,417.0017Service KitSA09570242-3
43,517.0017Service KitSA09570242-5
40,435.0017Service KitSA09570242-7
40,435.0017Service KitSA09570242-9
74,903.0017Service KitSA09570242-11
76,744.0017Service KitSA09570242-13
80,082.0017Service KitSA09570242-15
77,920.0017Service KitSA09570242-17
140,805.0017Service KitSA09570242-19
140,805.0017Service KitSA09570242-21
205,700.0017Service KitSA09570242-23
205,700.0017Service KitSA09570242-25
140,118.0017Service KitSA09570242-27
138,473.0017Service KitSA09570242-29
70,974.0017Service KitSA09570242-31
76,359.0017Service KitSA09570242-33
205,257.0017Service KitSA09570242-35
203,095.0017Service KitSA09570242-37
140,127.0017Service KitSA09570242-39
140,127.0017Service KitSA09570242-41
76,924.0017Service KitSA09570242-43
74,762.0017Service KitSA09570242-45
202,352.0017Service KitSA09570242-47
203,095.0017Service KitSA09570242-49
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### Page 30

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars.
Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of the methods that follow:
1. Order on-line via ATA Spec 2000 or Boeing Part Page
2. Fax to (206) 662-7145
3. Mail to:
Spares Customer Support - MC 36-65
Boeing Spares Department
P.O. Box 3707
Seattle, Washington 98124-2207 USA
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 top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane.
Table 1: Service Kit Applicability
DescriptionDrawing ConfigurationService Kit
Doubler Repair for Cracks in Rear Spar Lower Cap (Left
Wing)
J060271-509SA09570242-3
Doubler Repair for Cracks in Rear Spar Lower Cap (Right
Wing)
J060271-510SA09570242-5
Doubler Repair for Cracks in Rear Spar Upper Cap (Left
Wing)
J060271-511SA09570242-7
Doubler Repair for Cracks in Rear Spar Upper Cap (Right
Wing)
J060271-512SA09570242-9
Doubler Repair for Cracks in Rear Spar Upper and Lower
Cap (Left Wing)
J060271-513SA09570242-11
Doubler Repair for Cracks in Rear Spar Upper and Lower
Cap (Right Wing)
J060271-514SA09570242-13
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### Page 31

Table 1: Service Kit Applicability
DescriptionDrawing ConfigurationService Kit
Splice Repair for Cracks in Rear Spar Lower Cap on air-
planes with a multi-component bulkhead with bolts at
wing station Xrs=137.750 (Left Wing)
J060165-511SA09570242-15
Splice Repair for Cracks in Rear Spar Lower Cap on air-
planes with a multi-component bulkhead with bolts at
wing station Xrs=137.750 (Right Wing)
J060165-512SA09570242-17
Splice Repair for Cracks in Rear Spar Upper Cap on air-
planes with a multi-component bulkhead with bolts at
wing station Xrs=137.750 (Left Wing)
J060165-513SA09570242-19
Splice Repair for Cracks in Rear Spar Upper Cap on air-
planes with a multi-component bulkhead with bolts at
wing station Xrs=137.750 (Right Wing)
J060165-514SA09570242-21
Splice Repair for Cracks in Rear Spar Upper and Lower
Caps on airplanes with a multi-component bulkhead with
bolts at wing station Xrs=137.750 (Left Wing)
J060165-515SA09570242-23
Splice Repair for Cracks in Rear Spar Upper and Lower
Caps on airplanes with a multi-component bulkhead with
bolts at wing station Xrs=137.750 (Right Wing)
J060165-516SA09570242-25
Splice Repair for Cracks in Rear Spar Upper Cap on air-
planes with a multi-component bulkhead without bolts at
wing station Xrs=137.750 (Left Wing)
J060165-517SA09570242-27
Splice Repair for Cracks in Rear Spar Upper Cap on air-
planes with a multi-component bulkhead without bolts at
wing station Xrs=137.750 (Right Wing)
J060165-518SA09570242-29
Splice Repair for Cracks in Rear Spar Lower Cap on air-
planes with a multi-component bulkhead without bolts at
wing station Xrs=137.750 (Left Wing)
J060165-519SA09570242-31
Splice Repair for Cracks in Rear Spar Lower Cap on air-
planes with a multi-component bulkhead without bolts at
wing station Xrs=137.750 (Right Wing)
J060165-520SA09570242-33
Splice Repair for Cracks in Rear Spar Upper and Lower
Caps on airplanes with a multi-component bulkhead
without bolts at wing station Xrs=137.750 (Left Wing)
J060165-521SA09570242-35
Splice Repair for Cracks in Rear Spar Upper and Lower
Caps on airplanes with a multi-component bulkhead
without bolts at wing station Xrs=137.750 (Right Wing)
J060165-522SA09570242-37
Splice Repair for Cracks in Rear Spar Upper Cap on air-
planes with a machined bulkhead at wing station
Xrs=137.750 (Left Wing)
J060165-523SA09570242-39
Splice Repair for Cracks in Rear Spar Upper Cap on air-
planes with a machined bulkhead at wing station
Xrs=137.750 (Right Wing)
J060165-524SA09570242-41
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### Page 32

Table 1: Service Kit Applicability
DescriptionDrawing ConfigurationService Kit
Splice Repair for Cracks in Rear Spar Lower Cap on air-
planes with a machined bulkhead at wing station
Xrs=137.750 (Left Wing)
J060165-525SA09570242-43
Splice Repair for Cracks in Rear Spar Lower Cap on air-
planes with a machined bulkhead at wing station
Xrs=137.750 (Right Wing)
J060165-526SA09570242-45
Splice Repair for Cracks in Rear Spar Upper and Lower
Caps on airplanes with a machined bulkhead at wing
station Xrs=137.750 (Left Wing)
J060165-527SA09570242-47
Splice Repair for Cracks in Rear Spar Upper and Lower
Caps on airplanes with a machined bulkhead at wing
station Xrs=137.750 (Right Wing)
J060165-528SA09570242-49
Service Kit SA09570242
NotesNameQTYNew Part Number
-13-11-9-7-5-3
WASHER11..112917053-501
WASHER11..112917053-509
NUT ASSY4646272719193D0006-4
SPACER CONI-
CAL
26262626..4894213-1
SPACER CONI-
CAL
1818..18184894213-501
SPACER9797505047474894213-503
CONICAL SPAC-
ER
77..774894213-505
CONICAL SPAC-
ER
8844444894213-547
STIFFENER1111119910010-39
CLIP...1..9924775-27
CLIP..1...9924775-28
PIN44..44HL328-6-10
PIN44..44HL328-6-18
PIN6666..HL328-6-8
PIN2020141466HL328-8-10
PIN33..33HL328-8-6
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### Page 33

Service Kit SA09570242
NotesNameQTYNew Part Number
-13-11-9-7-5-3
PIN55..55HL328-8-8
PIN33..33HL329-6-14
PIN22..22HL329-6-16
PIN1515..1515HL329-6-5
PIN16161616..HL329-6-6
PIN, OVERSIZE....44HLT1001PB-6-10
PIN, OVERSIZE2828262622HLT1001PB-6-12
PIN, OVERSIZE15157788HLT1001PB-6-14
PIN, OVERSIZE88..88HLT1001PB-6-16
PIN, OVERSIZE22..22HLT1001PB-6-18
PIN, OVERSIZE22..22HLT1001PB-8-10
PIN, OVERSIZE1212221010HLT1001PB-8-12
PIN, OVERSIZE484829291919HLT1001PB-8-14
PIN, OVERSIZE771166HLT1001PB-8-16
PIN, OVERSIZE292918181111HLT1001PB-8-18
PIN11116655HLT428-6-8
PIN262613131313HLT428-8-10
PIN525232322020HLT428-8-12
PIN22..22HLT428-8-8
PIN, OVERSIZE1111..HLT629-8-6
PIN, OVERSIZE22..22HLT629-8-7
SHIM11....J060271-13
SHIM11....J060271-17
SHIM..1111J060271-19
SHIM..1111J060271-21
DOUBLER.1.1..J060271-27
DOUBLER1.1...J060271-28
FILLER11..11J060271-31
CLIP.1...1J060271-33
CLIP1...1.J060271-34
CLIP.1...1J060271-35
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### Page 34

Service Kit SA09570242
NotesNameQTYNew Part Number
-13-11-9-7-5-3
CLIP1...1.J060271-36
SPACER22..22J060271-37
DOUBLER.1.1..J060271-39
DOUBLER1.1...J060271-40
DOUBLER.1.1..J060271-41
DOUBLER1.1...J060271-42
DOUBLER.1...1J060271-43
DOUBLER1...1.J060271-44
DOUBLER.1...1J060271-45
DOUBLER1...1.J060271-46
DOUBLER.1...1J060271-47
DOUBLER1...1.J060271-48
FILLER11..11J060271-49
FILLER11..11J060271-51
SHIM11..11J060271-53
STIFFENER111111J060271-57
TEE.1...1J060271-65
TEE1...1.J060271-66
RADIUS BLOCK.1...1J060271-67
RADIUS BLOCK1...1.J060271-68
RIVET222222MS20470AD6-10D
RIVET2222..MS20470AD6-8D
RIVET333333MS20470AD6-9D
RIVET161616161616MS20470AD8-12D
NUT10510557574848MS21042L3
NUT1961961071078989MS21042L4
NUTPLATE22..22MS21059L3
WASHER505022222828NAS1252-10H
WASHER282814141414NAS1252-416H
WASHER24242424..NAS1401-3D3
BOLT44..44PIC239-3-10
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Service Kit SA09570242
NotesNameQTYNew Part Number
-13-11-9-7-5-3
BOLT33..33PIC239-3-15
BOLT..33..PIC239-3-17
BOLT22..22PIC239-3-6
WASHER555535352020S2931983-30A06
WASHER18018095958585S2931983-40A06
Service Kit SA09570242
NotesNameQTYNew Part Number
-25-23-21-19-17-15
NUT ASSY2222222215153D0006-3
NUT ASSY21621615515561613D0006-4
NUT ASSY5757404017173D0006-5
PIN4444..3D0097-10X12
PIN4444..3D0097-10X13
PIN12121212..3D0097-10X17
PIN16161616..3D0097-10X18
PIN4444..3D0097-10X20
PIN21212121..3D0097-8X10
PIN11111111..3D0097-8X11
PIN1111..3D0097-8X12
PIN3333..3D0097-8X13
PIN4444..3D0097-8X14
PIN12121212..3D0097-8X15
PIN12121212..3D0097-8X16
PIN1717..17173D0097-10X14
PIN2222..3D0097-6-7
PIN774433HL325-6-10
PIN2222..HL325-6-11
PIN772255HL325-6-12
PIN15151515..HL325-6-13
PIN22..22HL325-6-14
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
35 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 36

Service Kit SA09570242
NotesNameQTYNew Part Number
-25-23-21-19-17-15
PIN11..11HL325-6-8
PIN....55HL325-6-9
PIN....77HL325-8-5
PIN2323..2323HL325-8-6
PIN....22HL325-8-7
PIN....88HL325-8-8
PIN, OVERSIZE77..77HLT1001PB-6-6
PIN4444..HLT425-6-13
PIN....77HLT425-8-10
PIN....1717HLT425-8-11
PIN....3131HLT425-8-9
PIN1010101044HLT426-10-18
PIN444456563535HLT426-6-10
PIN242424241818HLT426-6-12
PIN4444..HLT426-6-13
PIN22221818HLT426-6-14
PIN664422HLT426-6-15
PIN884444HLT426-6-16
PIN....22HLT426-6-17
PIN....33HLT426-6-3
PIN11119999HLT426-6-4
PIN2323..2222HLT426-6-5
PIN575741417474HLT426-6-6
PIN505030302222HLT426-6-7
PIN779988HLT426-6-8
PIN909077779898HLT426-8-10
PIN99991010HLT426-8-11
PIN1041041051059999HLT426-8-12
PIN1919331616HLT426-8-13
PIN101020201010HLT426-8-14
PIN....3131HLT426-8-15
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
36 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 37

Service Kit SA09570242
NotesNameQTYNew Part Number
-25-23-21-19-17-15
PIN77121211HLT426-8-16
PIN....5858HLT426-8-17
PIN....1818HLT426-8-18
PIN....2424HLT426-8-19
PIN....1616HLT426-8-22
PIN....1010HLT426-8-24
PIN323232322828HLT426-8-4
PIN232320202222HLT426-8-5
PIN282828282626HLT426-8-6
PIN44111616HLT426-8-7
PIN838374748383HLT426-8-8
PIN2222..HLT426-8-9
66..66HLT426-10-7
PIN99..99HLT427-10-18
PIN1212..1212HLT427-10-20
PIN3535..3535HLT427-10-22
PIN66..66HLT427-10-24
PIN22..22HLT427-10-26
PIN55..55HLT427-6-10
PIN22221212HLT427-6-11
PIN101010101010HLT427-6-12
PIN66..66HLT427-6-14
PIN2222..HLT427-6-7
PIN11..22HLT427-6-8
PIN....66HLT427-6-9
PIN4343993434HLT427-8-10
PIN....1919HLT427-8-11
PIN4949..4949HLT427-8-12
PIN2222..HLT427-8-13
PIN2424222222HLT427-8-14
PIN554411HLT427-8-15
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
37 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 38

Service Kit SA09570242
NotesNameQTYNew Part Number
-25-23-21-19-17-15
PIN3636223636HLT427-8-16
PIN22225656HLT427-8-17
PIN202020201515HLT427-8-18
PIN2121212122HLT427-8-19
PIN662244HLT427-8-20
PIN332211HLT427-8-21
PIN22..22HLT427-8-22
PIN222222HLT427-8-23
PIN1313..1313HLT427-8-24
PIN2222..HLT427-8-25
PIN2222..HLT427-8-26
PIN11111111..HLT427-8-27
PIN....1010HLT427-8-28
PIN1313..1313HLT427-8-6
PIN111144HLT427-8-8
PIN555555HLT427-8-9
PIN5555..HLT437-6-6
PIN2222..HLT437-6-7
ANGLE1...1.J060165-10
FILLER.1...1J060165-13
FILLER1...1.J060165-14
FILLER11..11J060165-15
FILLER11..11J060165-17
FILLER11..11J060165-19
TEE....11J060165-21
STIFFENER11..11J060165-23
PLATE......J060165-25
PLATE11....J060165-27
ANGLE.1.1..J060165-31
ANGLE1.1...J060165-32
FILLER.1.1..J060165-33
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
38 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 39

Service Kit SA09570242
NotesNameQTYNew Part Number
-25-23-21-19-17-15
FILLER1.1...J060165-34
FILLER.1.1..J060165-35
FILLER1.1...J060165-36
ANGLE.1.1..J060165-37
ANGLE1.1...J060165-38
DOUBLER.1.1..J060165-39
DOUBLER1.1...J060165-40
FILLER1111..J060165-41
FILLER1111..J060165-43
FILLER1111..J060165-45
FILLER1111..J060165-47
FILLER1111..J060165-49
ANGLE.1...1J060165-5
TEE11....J060165-51
STIFFENER111111J060165-53
SPLICE111111J060165-55
SPACER11..11J060165-57
SPACER11..11J060165-59
ANGLE1...1.J060165-6
DOUBLER.1...1J060165-61
DOUBLER1...1.J060165-62
SPAR CAP.1...1J060165-63
SPAR CAP1...1.J060165-64
SPLICE111111J060165-65
BUSHING77..77J060165-67
SPAR CAP.1.1..J060165-69
FILLER.1...1J060165-7
SPAR CAP1.1...J060165-70
FILLER1...1.J060165-8
ANGLE.1...1J060165-9
RIVET3333..MS20426AD6-12D
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
39 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 40

Service Kit SA09570242
NotesNameQTYNew Part Number
-25-23-21-19-17-15
RIVET....22MS20426AD6-8D
RIVET....55MS20470AD4-6D
RIVET....1010MS20470AD5-7D
RIVET....22MS20470AD5-9D
RIVET636363637171MS20470AD6-10D
RIVET101010101010MS20470AD6-11D
RIVET222222222929MS20470AD6-12D
RIVET444444MS20470AD6-14D
RIVET....44MS20470AD6-15D
RIVET....44MS20470AD6-16D
RIVET484848485858MS20470AD6-8D
RIVET2222..MS20470AD6-9D
RIVET585858585050MS20470AD8-10D
RIVET....44MS20470AD8-11D
RIVET333333333333MS20470AD8-12D
RIVET....2828MS20470AD8-13D
RIVET363636363636MS20470AD8-14D
RIVET....44MS20470AD8-16D
RIVET....11MS20470AD8-17D
RIVET....66MS20470AD8-18D
RIVET....11MS20470AD8-19D
RIVET....55MS20470AD8-7D
RIVET....1818MS20470AD8-9D
NUT273273218218180180MS21042L3
NUT549549549549536536MS21042L4
NUT848410108484MS21042L5
NUT222222MS21042L6
CHANNEL....11MS21064L5-11-4
BOLT22..22NAS1203-4
BOLT77..77NAS1203-8
BOLT....88NAS1204-12
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
40 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 41

Service Kit SA09570242
NotesNameQTYNew Part Number
-25-23-21-19-17-15
BOLT....44NAS1204-13
BOLT....11NAS1204-14
BOLT....77NAS1205-15
WASHER273273228228180180NAS1252-10H
WASHER542542542542542542NAS1252-416H
WASHER919110108181NAS1252-516H
WASHER121212121212NAS1252-616H
BOLT....11NAS1704-8
BOLT....2222NAS6205-10
BOLT....88NAS6205-16
BOLT....88NAS6205-26
BOLT22..22NAS6206-10
BOLT2222..NAS6206-12
NUT1717..1717NAS679A5
BOLT44..44PIC239-3-10
BOLT33..33PIC239-3-15
PIN6666..S4931917-8X10
PIN6666..S4931917-8X11
PIN1111..S4931917-8X13
PIN1111..S4931917-8X16
PIN1111..S4931917-8X9
Service Kit SA09570242
NotesNameQTYNew Part Number
-37-35-33-31-29-27
NUT ASSY2222151522223D0006-3
NUT ASSY21621674741551553D0006-4
NUT ASSY5757171740403D0006-5
PIN44..443D0097-10X12
PIN44..443D0097-10X13
PIN1212..12123D0097-10X17
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
41 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 42

Service Kit SA09570242
NotesNameQTYNew Part Number
-37-35-33-31-29-27
PIN1616..16163D0097-10X18
PIN44..443D0097-10X20
PIN17171717..3D0097-10X14
PIN22..223D0097-6-7
PIN2121..21213D0097-8X10
PIN1111..11113D0097-8X11
PIN11..113D0097-8X12
PIN33..333D0097-8X13
PIN44..443D0097-8X14
PIN1212..12123D0097-8X15
PIN1212..12123D0097-8X16
PIN773344HL325-6-10
PIN22..22HL325-6-11
PIN775522HL325-6-12
PIN1515..1515HL325-6-13
PIN2222..HL325-6-14
PIN1111..HL325-6-8
PIN5555..HL325-6-9
PIN23232323..HL325-8-6
PIN2222..HL325-8-7
PIN8888..HL325-8-8
PIN, OVERSIZE7777..HLT1001PB-6-6
PIN44..44HLT425-6-13
PIN7777..HLT425-8-10
PIN17171717..HLT425-8-11
PIN31313131..HLT425-8-9
PIN6666..HLT426-10-7
PIN44441010HLT426-10-18
PIN444435355656HLT426-6-10
PIN242418182424HLT426-6-12
PIN44..44HLT426-6-13
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
42 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 43

Service Kit SA09570242
NotesNameQTYNew Part Number
-37-35-33-31-29-27
PIN1818181822HLT426-6-14
PIN662244HLT426-6-15
PIN884444HLT426-6-16
PIN2222..HLT426-6-17
PIN3333..HLT426-6-3
PIN11119999HLT426-6-4
PIN22222222..HLT426-6-5
PIN747474744141HLT426-6-6
PIN505022223030HLT426-6-7
PIN888899HLT426-6-8
PIN989898988585HLT426-8-10
PIN1010101099HLT426-8-11
PIN108108108108109109HLT426-8-12
PIN1919161633HLT426-8-13
PIN141414142424HLT426-8-14
PIN31313131..HLT426-8-15
PIN77111212HLT426-8-16
PIN58585858..HLT426-8-17
PIN18181818..HLT426-8-18
PIN24242424..HLT426-8-19
PIN16161616..HLT426-8-22
PIN10101010..HLT426-8-24
PIN323228283232HLT426-8-4
PIN232322222020HLT426-8-5
PIN282826262828HLT426-8-6
PIN1616161611HLT426-8-7
PIN838383837474HLT426-8-8
PIN22..22HLT426-8-9
PIN9999..HLT427-10-18
PIN12121212..HLT427-10-20
PIN35353535..HLT427-10-22
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
43 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 44

Service Kit SA09570242
NotesNameQTYNew Part Number
-37-35-33-31-29-27
PIN6666..HLT427-10-24
PIN2222..HLT427-10-26
PIN5555..HLT427-6-10
PIN1212121222HLT427-6-11
PIN101010101010HLT427-6-12
PIN6666..HLT427-6-14
PIN22..22HLT427-6-7
PIN2222..HLT427-6-8
PIN6666..HLT427-6-9
PIN4343343499HLT427-8-10
PIN19191919..HLT427-8-11
PIN49494949..HLT427-8-12
PIN22..22HLT427-8-13
PIN2424222222HLT427-8-14
PIN551144HLT427-8-15
PIN3636363622HLT427-8-16
PIN5656565622HLT427-8-17
PIN202015152020HLT427-8-18
PIN2121222121HLT427-8-19
PIN664422HLT427-8-20
PIN331122HLT427-8-21
PIN2222..HLT427-8-22
PIN222222HLT427-8-23
PIN13131313..HLT427-8-24
PIN22..22HLT427-8-25
PIN22..22HLT427-8-26
PIN1111..1111HLT427-8-27
PIN10101010..HLT427-8-28
PIN13131313..HLT427-8-6
PIN444411HLT427-8-8
PIN555555HLT427-8-9
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
44 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 45

Service Kit SA09570242
NotesNameQTYNew Part Number
-37-35-33-31-29-27
PIN55..55HLT437-6-6
ANGLE1.1...J060165-10
FILLER.1.1..J060165-13
FILLER1.1...J060165-14
FILLER1111..J060165-15
FILLER1111..J060165-17
FILLER1111..J060165-19
TEE..1111J060165-21
STIFFENER1111..J060165-23
PLATE1111..J060165-27
ANGLE.1...1J060165-31
ANGLE1...1.J060165-32
FILLER.1...1J060165-33
FILLER1...1.J060165-34
FILLER.1.1.1J060165-35
FILLER1.1.1.J060165-36
ANGLE.1...1J060165-37
ANGLE1...1.J060165-38
DOUBLER.1...1J060165-39
DOUBLER1...1.J060165-40
FILLER11..11J060165-41
FILLER11..11J060165-43
FILLER11..11J060165-45
FILLER11..11J060165-47
FILLER11..11J060165-49
ANGLE.1.1..J060165-5
TEE11....J060165-51
STIFFENER111111J060165-53
SPLICE111111J060165-55
SPACER1111..J060165-57
SPACER1111..J060165-59
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
45 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 46

Service Kit SA09570242
NotesNameQTYNew Part Number
-37-35-33-31-29-27
ANGLE1.1...J060165-6
DOUBLER.1.1..J060165-61
DOUBLER1.1...J060165-62
SPAR CAP.1.1..J060165-63
SPAR CAP1.1...J060165-64
SPLICE111111J060165-65
BUSHING7777..J060165-67
SPAR CAP.1...1J060165-69
FILLER.1.1..J060165-7
SPAR CAP1...1.J060165-70
FILLER1.1...J060165-8
ANGLE.1.1..J060165-9
RIVET33..33MS20426AD6-12D
RIVET1818181844MS20426AD6-14D
RIVET2222..MS20426AD6-8D
RIVET5555..MS20470AD4-6D
RIVET2222..MS20470AD5-9D
RIVET636371716363MS20470AD6-10D
RIVET101010101010MS20470AD6-11D
RIVET222229292222MS20470AD6-12D
RIVET444444MS20470AD6-14D
RIVET4444..MS20470AD6-15D
RIVET4444..MS20470AD6-16D
RIVET484858584848MS20470AD6-8D
RIVET22..22MS20470AD6-9D
RIVET585850505858MS20470AD8-10D
RIVET4444..MS20470AD8-11D
RIVET333333333333MS20470AD8-12D
RIVET28282828..MS20470AD8-13D
RIVET424242424242MS20470AD8-14D
RIVET4444..MS20470AD8-16D
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
46 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 47

Service Kit SA09570242
NotesNameQTYNew Part Number
-37-35-33-31-29-27
RIVET1111..MS20470AD8-17D
RIVET6666..MS20470AD8-18D
RIVET1111..MS20470AD8-19D
RIVET5555..MS20470AD8-7D
RIVET18181818..MS20470AD8-9D
NUT273273191191218218MS21042L3
NUT565565565565565565MS21042L4
NUT848484841010MS21042L5
BOLT2222..NAS1203-4
BOLT7777..NAS1203-8
BOLT8888..NAS1204-12
BOLT4444..NAS1204-13
BOLT1111..NAS1204-14
BOLT7777..NAS1205-15
WASHER273273191191228228NAS1252-10H
WASHER558558558558558558NAS1252-416H
WASHER919181811010NAS1252-516H
WASHER141414141010NAS1252-616H
BOLT1111..NAS1704-8
BOLT22222222..NAS6205-10
BOLT8888..NAS6205-16
BOLT8888..NAS6205-26
NUT17171717..NAS679A5
BOLT4444..PIC239-3-10
BOLT3333..PIC239-3-15
PIN66..66S4931917-8X10
PIN66..66S4931917-8X11
PIN11..11S4931917-8X13
PIN11..11S4931917-8X16
PIN11..11S4931917-8X9
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
47 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 48

Service Kit SA09570242
NotesNameQTYNew Part Number
-49-47-45-43-41-39
NUT ASSY2222151522223D0006-3
NUT ASSY21621674741551553D0006-4
NUT ASSY5757171740403D0006-5
PIN44..443D0097-10X12
PIN44..443D0097-10X13
PIN1212..12123D0097-10X17
PIN1616..16163D0097-10X18
PIN44..443D0097-10X20
PIN17171717..3D0097-10X14
PIN22..223D0097-6-7
PIN2121..21213D0097-8X10
PIN1111..11113D0097-8X11
PIN11..113D0097-8X12
PIN33..333D0097-8X13
PIN44..443D0097-8X14
PIN1212..12123D0097-8X15
PIN1212..12123D0097-8X16
PIN773344HL325-6-10
PIN22..22HL325-6-11
PIN775522HL325-6-12
PIN1515..1515HL325-6-13
PIN2222..HL325-6-14
PIN1111..HL325-6-8
PIN5555..HL325-6-9
PIN23232323..HL325-8-6
PIN2222..HL325-8-7
PIN8888..HL325-8-8
PIN, OVERSIZE7777..HLT1001PB-6-6
PIN44..44HLT425-6-13
PIN7777..HLT425-8-10
PIN17171717..HLT425-8-11
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
48 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 49

Service Kit SA09570242
NotesNameQTYNew Part Number
-49-47-45-43-41-39
PIN31313131..HLT425-8-9
PIN44441010HLT426-10-18
PIN444435355656HLT426-6-10
PIN242418182424HLT426-6-12
PIN44..44HLT426-6-13
PIN1818181822HLT426-6-14
PIN662244HLT426-6-15
PIN884444HLT426-6-16
PIN2222..HLT426-6-17
PIN3333..HLT426-6-3
PIN11119999HLT426-6-4
PIN22222222..HLT426-6-5
PIN747474744141HLT426-6-6
PIN505022223030HLT426-6-7
PIN888899HLT426-6-8
PIN989898987777HLT426-8-10
PIN1010101099HLT426-8-11
PIN108108108108105105HLT426-8-12
PIN1919161633HLT426-8-13
PIN141414142020HLT426-8-14
PIN31313131..HLT426-8-15
PIN77111212HLT426-8-16
PIN58585858..HLT426-8-17
PIN18181818..HLT426-8-18
PIN24242424..HLT426-8-19
PIN16161616..HLT426-8-22
PIN10101010..HLT426-8-24
PIN323228283232HLT426-8-4
PIN232322222020HLT426-8-5
PIN282826262828HLT426-8-6
PIN1616161611HLT426-8-7
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2009
MD80-57A242Revision 1: January 07, 2011
49 of 71
BOEING SERVICE BULLETIN MD80-57A242
ALERTALERT

### Page 50

Service Kit SA09570242
NotesNameQTYNew Part Number
-49-47-45-43-41-39
PIN838383837474HLT426-8-8
PIN22..22HLT426-8-9
PIN6666..HLT426-10-7
PIN9999..HLT427-10-18
PIN12121212..HLT427-10-20
PIN35353535..HLT427-10-22
PIN6666..HLT427-10-24
PIN2222..HLT427-10-26
PIN5522..HLT427-6-10
PIN1212121222HLT427-6-11
PIN101010101010HLT427-6-12
PIN6666..HLT427-6-14
PIN22..22HLT427-6-7
PIN2222..HLT427-6-8
PIN66....HLT427-6-9
PIN4343343499HLT427-8-10
PIN19191919..HLT427-8-11
PIN49494949..HLT427-8-12
PIN22..22HLT427-8-13
PIN2424222222HLT427-8-14
PIN551144HLT427-8-15
PIN3636363622HLT427-8-16
PIN5656565622HLT427-8-17
PIN202015152020HLT427-8-18
PIN2121222121HLT427-8-19
PIN664422HLT427-8-20
PIN331122HLT427-8-21
PIN2222..HLT427-8-22
PIN222222HLT427-8-23
PIN13131313..HLT427-8-24
PIN22..22HLT427-8-25
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### Page 51

Service Kit SA09570242
NotesNameQTYNew Part Number
-49-47-45-43-41-39
PIN22..22HLT427-8-26
PIN1111..1111HLT427-8-27
PIN10101010..HLT427-8-28
PIN131313131313HLT427-8-6
PIN444411HLT427-8-8
PIN555555HLT427-8-9
PIN55..55HLT437-6-6
ANGLE1.1...J060165-10
FILLER.1.1..J060165-13
FILLER1.1...J060165-14
FILLER1111..J060165-15
FILLER1111..J060165-17
FILLER1111..J060165-19
TEE..1111J060165-21
STIFFENER1111..J060165-23
PLATE1111..J060165-27
ANGLE.1...1J060165-31
ANGLE1...1.J060165-32
FILLER.1...1J060165-33
FILLER1...1.J060165-34
FILLER.1...1J060165-35
FILLER1...1.J060165-36
ANGLE.1...1J060165-37
ANGLE1...1.J060165-38
DOUBLER.1...1J060165-39
DOUBLER1...1.J060165-40
FILLER11..11J060165-41
FILLER11..11J060165-43
FILLER11..11J060165-45
FILLER11..11J060165-47
FILLER11..11J060165-49
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### Page 52

Service Kit SA09570242
NotesNameQTYNew Part Number
-49-47-45-43-41-39
ANGLE.1.1..J060165-5
TEE11....J060165-51
STIFFENER111111J060165-53
SPLICE111111J060165-55
SPACER1111..J060165-57
SPACER1111..J060165-59
ANGLE1.1...J060165-6
DOUBLER.1.1..J060165-61
DOUBLER1.1...J060165-62
SPAR CAP.1.1..J060165-63
SPAR CAP1.1...J060165-64
SPLICE111111J060165-65
BUSHING7777..J060165-67
SPAR CAP.1...1J060165-69
FILLER.1.1..J060165-7
SPAR CAP1...1.J060165-70
FILLER1.1...J060165-8
ANGLE.1.1..J060165-9
RIVET33..33MS20426AD6-12D
RIVET1818181844MS20426AD6-14D
RIVET2222..MS20426AD6-8D
RIVET5555..MS20470AD4-6D
RIVET2222..MS20470AD5-9D
RIVET636371716363MS20470AD6-10D
RIVET101010101010MS20470AD6-11D
RIVET222229292222MS20470AD6-12D
RIVET444444MS20470AD6-14D
RIVET4444..MS20470AD6-15D
RIVET4444..MS20470AD6-16D
RIVET484858584848MS20470AD6-8D
RIVET22..22MS20470AD6-9D
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### Page 53

Service Kit SA09570242
NotesNameQTYNew Part Number
-49-47-45-43-41-39
RIVET585850505858MS20470AD8-10D
RIVET4444..MS20470AD8-11D
RIVET333333333333MS20470AD8-12D
RIVET28282828..MS20470AD8-13D
RIVET424242423636MS20470AD8-14D
RIVET4444..MS20470AD8-16D
RIVET1111..MS20470AD8-17D
RIVET6666..MS20470AD8-18D
RIVET1111..MS20470AD8-19D
RIVET5555..MS20470AD8-7D
RIVET18181818..MS20470AD8-9D
NUT273273191191218218MS21042L3
NUT565565565565549549MS21042L4
NUT848484841010MS21042L5
BOLT2222..NAS1203-4
BOLT7777..NAS1203-8
BOLT8888..NAS1204-12
BOLT4444..NAS1204-13
BOLT1111..NAS1204-14
BOLT7777..NAS1205-15
WASHER273273191191228228NAS1252-10H
WASHER558558558558542542NAS1252-416H
WASHER919181811010NAS1252-516H
WASHER141414141212NAS1252-616H
BOLT1111..NAS1704-8
BOLT22222222..NAS6205-10
BOLT8888..NAS6205-16
BOLT8888..NAS6205-26
NUT17171717..NAS679A5
BOLT4444..PIC239-3-10
BOLT3333..PIC239-3-15
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### Page 54

Service Kit SA09570242
NotesNameQTYNew Part Number
-49-47-45-43-41-39
PIN66..66S4931917-8X10
PIN66..66S4931917-8X11
PIN11..11S4931917-8X13
PIN11..11S4931917-8X16
PIN11..11S4931917-8X9
2. Parts and Materials Supplied by the Operator:
CAGESupplierQTYPart Number/Specifi-
cation
92108PRC-DeSoto International, IncorporatedAs Re-
quired
PR-1422 B-2 Sealant
(DMS 2082) P.O. Box 1800
or Sylmar, California 91342
Equivalent
3. Parts Modified and Reidentified:
The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the
number of parts changed on each airplane.
NOTE: Not all repair configurations require part modifications.
NotesNew Part NumberNameQTYExisting Part
Number
(a) (b) (c)J060271-59CAP19919474-1
or
9919474-501
or
9919474-503
J060271-60CAP19919474-2
or
9919474-502
or
9919474-504
J060271-61ANGLE19919472-23
J060271-62ANGLE19919472-24
(a) Make the change in accordance with in this service bulletin.
(b) There is no equivalent Boeing part number for the changed part. Identify on the part that
the change done in accordance with this service bulletin was made.
(c) This part is not used in production.
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4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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BLANK PAGE

### Page 57

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: 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.
CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE
TO THE AIRPLANE OR EQUIPMENT.
NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s)
give the recommended sequence of steps. The sequence of steps to do this service
bulletin can be changed.
2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
3. Equivalent parts are listed in the AEPL, Drawing 7595071.
4. Use the approved fastener substitutions and process material substitutions in
accordance with MD-80 SRM, Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet the
installation standards in SRM Chapter 51, then a fastener of the same specification,
or an approved substitute, with a length which meets the installation standards in
SRM Chapter 51 may be used.
6. 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.
7. 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, Chapter 51.
— Torque limits to tighten nuts and bolts are in MD-80 SRM,Chapter 51.
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### Page 58

8. Refer to the Standard Wiring Practices Manual 20-10-01 for the wire installation
procedures.
9. Obey all of the warnings and cautions given in the specified manual sections and
Service Rework Drawings.
10. Refer to the following MD-80 SRM Chapters as and accepted procedure for the
applicable operation:
MD80 SRM 51-10-03 - Corrosion and Dissimilar Metals Protection.
MD80 SRM 51-10-04 - Drilling and Countersinking.
MD80 SRM 51-20-00 - Sealing Methods.
MD80 SRM 51-30-01 - Installing Bolts, Screws, and Washers.
MD80 SRM 51-30-02 - Removing and Installing Rivets.
MD80 SRM 51-30-03 - Removing and Installing Lockbolts.
MD80 SRM 51-30-05 - Removing and Installing Hi-Loks.
MD80 SRM 51-30-09 - Split Sleeve Cold Work.
MD80 SRM 51-30-11 - Conical Spacers (Countersink Washers).
MD80 SRM 51-30-60 - Substitution and Interchangeability
11. Follow applicable safety instructions and precautions in accordance with NDTSPM
01-00-01 and NDTSPM 06-00-01.
12. A Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate procedures may be required.
13. 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.
14. 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.
15. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
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### Page 59

16. 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.
17. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
The removed part can be discarded if a new or serviceable part is installed.
18. This service bulletin includes functional test procedures for the systems changed by
this service bulletin. More functional tests can possibly be necessary in accordance
with standard maintenance practices because of interruption to other airplane systems.
B. WORK INSTRUCTIONS
Group 1, Configuration 1:
Continue repeat inspections in accordance with Service Bulletin MD80-57-184, Paragraph 2.AZ.,
Accomplishment Instructions.
Group 1, Configuration 2; Group 2-4:
1. Fabricate DAC GSET AL.01 reference standard. Refer to NDTSPM Part 06, 06-20-01 as an
accepted procedure.
WARNING: BEFORE MOVING FLAP/SLAT HANDLE, MAKE CERTAIN THAT AREAS AROUND
FLAPS AND SLATS ARE CLEAR OF PERSONNEL AND EQUIPMENT.
2. Extend wing flaps to full down position. Refer to MD80 AMM 27-51-01 as an accepted procedure.
3. Depressurize left and right hydraulic systems. Refer to MD80 AMM 29-00-00 as an accepted
procedure.
4. Open main landing gear doors and install door keepers. Refer to MD80 AMM 32-10-00 as an
accepted procedure.
5. Open or remove and retain inboard and center bent up trailing edge (BUTE) doors. Refer to MD80
AMM 57-20-03 as an accepted procedure to remove BUTE doors.
6. Open access door 1501C (left wing) and 1601C (right wing). Refer to MD80 AMM 06-21-00.
7. At operators option for ease of access, remove the fixed portion of the flap hinge fairing.
8. Clean area at top of flap hinge fitting and around and under flap hinge fitting and visually inspect
for evidence of fuel leakage or if fuel tanks have been drained, visually inspect for cracks.
9. Do Eddy Current, High Frequency inspection (ETHF) on the aft side of the left and right wing rear
spar lower caps at station Xrs=164.000 for cracks in accordance with Figure 1 and Drawing
J060271, General Note 29, and based on findings do as follows:
CONDITION 1: NO CRACK
a. Do repeat inspect on the aft side of the left and right wing rear spar lower caps at station
Xrs=164.000.
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### Page 60

CONDITION 2: LOWER SPAR CAP HAS A CRACK 2.0 INCHES OR LESS IN LENGTH AND
NOT IN THE REAR SPAR CAP FORWARD HORIZONTAL LEG RADIUS
a. Disconnect aileron control, aileron trim, aileron bus, and outboard spoiler mechanical cables
at nearest turnbuckles to station Xrs=164.000, left and right sides. Refer to MD80 AMM
27-10-00, MD80 AMM 27-51-01, and MD80 AMM 27-60-00 as accepted procedures.
NOTE: Only cables which run through the lightening hole of flap hinge fitting at station
Xrs=164.000 need to be disconnected.
b. Defuel and purge left and right fuel tanks if/as required. Refer to MD80 AMM 28-00-00 and
MD80 AMM 28-10-01 as accepted procedures.
c. Remove and retain door number 1307 on the left wing main tank and door number 1410 on
the right wing main tank and attaching parts. Refer to MD80 AMM 06-21-00.
d. Prepare fuel tanks for entry and gain access to fuel tanks as required to reach attachments
of flap hinge fitting at station Xrs=164.000.
e. Remove and retain the inboard hinge fitting for the left and/or right wing outboard flap attaching
parts (including any shims) at station Xrs=164.000. Refer to MD80 AMM 57-40-01 as an
accepted procedure.
f. Do ETHF inspection on the aft side of the left and/or right wing rear spar upper cap at station
Xrs=164.000 for cracks in accordance with Figure 1 and Drawing J060271, General Note 29
and based on inspection results do as follows:
Condition 2a: No Crack in Rear Upper Spar Cap
(1) Repair the lower spar lower cap using Option 1 or Option 2 as follows:
(a) Option 1:
1) Do doubler repair to rear spar lower cap in accordance with Service Rework
Drawing J060271 using the applicable service kit as follows:
Service KitConfigurationRear Spar Cap Repair
Right WingLeft Wing
SA09570242-3-J060271-509Lower
SA09570242-5J060271-510-Lower
2) Do ETHF inspections of rear spar lower cap repair in accordance with Service
Sketch 3668XXX Revision C.
(b) Option 2:
1) Do splice repair to rear spar lower cap in accordance with Service Rework
Drawing J060165 using the applicable service kit as follows:
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