# Boeing Alert Service Bulletin MD80-57A243: No revision named

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- Document: [Boeing Alert Service Bulletin MD80-57A243](https://openairdocs.org/service-documents/boeing/md80-57a243.md)
- Title as filed: U.S. DOT/FAA - Service Information
- Pages: 25
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## Text

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### Page 1 (OCR)

11-00376
12/21/2011
Enclosure A
Commercial
QADEING  Airplanes  MD80
Service Bulletin
= ALERT
Number:  MD80-57A243
Original Issue: December 20, 2011
ATA System: 5710
SUBJECT:  WINGS - Main Frame - Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive
Hinge 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.
ECCN: 9E991
BOLING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET
Copyright © 2011 The Boeing Company
Unpublished Work - All Rights Reserved
Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable
subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more
information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the
Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
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MD80-57A243
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2.0

### Page 2 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
BLANK PAGE
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BOEING PROPRIETARY -  MD80-57A243
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### Page 3 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Table of Contents
Summary.  5
1.  PLANNING INFORMATION  9
Effectivity .  9
1. Airplanes  9
2. Spares Affected  11
B  Concurrent Requirements  17
c.  Reason  11
D  Description  71
E  Compliance  12
F.  Approval  13
G  Manpower  13
Weight and Balance Changes.  14
Electrical Load Data  14
J.  References .  14
1.  Existing Data  14
2.  Data supplied with this Service Bulletin:  15
3.  Installation Drawings Used in the Preparation of this Service Bulletin:  15
K.  Publications Affected .  15
Interchangeability and Intermixability of Parts  15
2.  MATERIAL INFORMATION .  17
Material - Price and Availability .  17
B.  Industry Support Information  17
C.  Parts Necessary For Each Airplane.  17
1.  Kits/Parts:  17
2.  Parts and Materials Supplied by the Operator:  19
3.  Parts Modified and Reidentified:  20
4.  Parts Removed and Not Replaced  20
D.  Parts Necessary to Change Spares.  20
E.  Special Tooling - Price and Availability  20
F.  Special Tooling Necessary to do this Service Bulletin .  20
3.  ACCOMPLISHMENT INSTRUCTIONS  21
A. GENERAL INFORMATION  21
B. WORK INSTRUCTIONS  22
FIGURE 1: EDDY CURRENT, HIGH FREQUENCY INSPECTION - STRINGER 11 AT THE OUTBOARD
FLAP, INBOARD DRIVE HINGE AT STATION XRS=164.000 . .  .... 24
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### Page 4 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
BLANK PAGE
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MD80-57A243
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Commercial
@ SOEING  Airplanes  MD80
Service Bulletin
ALERT
Number:  MD80-57A243  Summary
Original Issue: December 20, 2011
ATA System:  5710
SUBJECT:  WINGS - Main Frame - Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive
Hinge 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
Three operators reported four instances of cracks found in Stringer 11 at the outboard flap, inboard drive hinge
at Station Xrs=164.000. The cracking occurs at the end fastener of the wing bulkhead clip attachment to the
stringer. The affected MD-80 airplanes had accrued between 27,675 through 64,279 flight-hours and 32,771
through 36,935 landing cycles when the cracks were found. The cracked stringers were found by chance, during
maintenance, except in one case when the rear spar cap had been removed during a spar cap splice repair.
Boeing investigation and analysis have shown that the Stringer 11 cracking is due to fatigue. If undetected, a
crack in the stringer may grow until the stringer severs, initiating a crack in the wing lower skin. Continuing
damage into the wing skin may result in the wing structure not being capable of sustaining the required loads.
Inspection of the affected areas will determine the condition of the stringer, prevent any crack migration, and
ensure repairs are done before additional damage occurs. A splice repair for crack found on the affected stringer
can be accomplished by installing a segment of stringer. If not corrected, fuel leaks and damage to the wing
skin or other structure may occur, resulting in possible loss of the structural integrity of the wing.
Boeing Fleet Team Digest (FTD) MD-80 FT MD-80-FTD-57-10001 is related to this service bulletin.
ACTION
This service bulletin provides instructions to do an Eddy Current, High Frequency (ETHF) inspection for cracks
in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs=164.000. Refer to Paragraph 1.D.,
Description, for the required corrective action based on the results of the inspection.
EFFECTIVITY
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87) and MD-88 Airplanes. Refer to
Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
COMPLIANCE
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service
bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin
mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service
bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
INSPECT / REPAIR STRINGER 11
AT THE OUTBOARD FLAP  , INBOARD
DRIVE HINGE AT STATION Xrs=164.000
2108093
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
BLANK PAGE
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Commercial
@ ODEING  Airplanes  MD80
Service Bulletin
- ALERT
Number:  MD80-57A243
Original Issue: December 20, 2011
ATA System:  5710
SUBJECT:  WINGS - Main Frame - Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive
Hinge 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 BULLEȚIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1. PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplanes shown below.
GROUP  CONFIGURATION  | DESCRIPTION
1  Inspect/Repair Stringer 11 at the Outboard Flap, Inboard Drive Hinge
at Station Xrs=164.000
Airplane Models:
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88
Fuselage Num-  Group
ber
1326 - 2007
2009 - 2016
2019 - 2034
2036 - 2069
2071 - 2093
2101 - 2114
2116
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Fuselage Num-  Group
ber
2118 - 2119  1
2121
2124  1
2127 - 2128  1
2130
2132
2134 - 2135  1
2137  1
2139  1
2145
2148  1
2151 - 2152  1
2155  1
2167
2174  1
2176  1
2178  1
2180  1
2183  1
2185  1
2187
2189
2192
2196
2199  1
2201  1
2204
2206  1
2208
2214  1
2218  1
2234
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Fuselage Num-  Group
ber
2239
2241
2244
2247
2249
2252
2254
2264 - 2287
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Three operators reported four instances of cracks found in Stringer 11 at the outboard flap, inboard
drive hinge at Station Xrs= 164.000. The cracking occurs at the end fastener of the wing bulkhead clip
attachment to the stringer. The affected MD-80 airplanes had accrued between 27,675 through 64,279
flight-hours and 32,771 through 36,935 landing cycles when the cracks were found. The cracked
stringers were found by chance, during maintenance, except in one case when the rear spar cap had
been removed during a spar cap splice repair. Boeing investigation and analysis have shown that the
Stringer 11 cracking is due to fatigue. If undetected, a crack in the stringer may grow until the stringer
severs, initiating a crack in the wing lower skin. Continuing damage into the wing skin may result in the
wing structure not being capable of sustaining the required loads. Inspection of the affected areas will
determine the condition of the stringer, prevent any crack migration, and ensure repairs are done before
additional damage occurs. A splice repair for crack found on the affected stringer can be accomplished
by installing a segment of stringer. If not corrected, fuel leaks and damage to the wing skin or other
structure may occur, resulting in possible loss of the structural integrity of the wing.
Boeing Fleet Team Digest (FTD) MD-80 FTD MD-80-FTD-57-10001 is related to this service bulletin.
D. Description
This service bulletin provides instructions to do an Eddy Current, High Frequency (ETHF) inspection
for cracks in Stringer 11 at the outboard flap, inboard drive hinge at Station Xrs=164.000, and based
on inspection results does as follows:
Condition 1 (No Crack Found)
Does repeat ETHF inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge
at Station Xrs= 164:000.
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Condition 2 (Crack Found)
1. Does splice repair.
2. Does ETHF inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge at Station
Xrs=164.000.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
Model  Zone
DC-9-81 (MD-81), DC-9-82  13,14
(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.
Accomplish the required actions, based on the applicable conditions, in Table 1, in accordance with
Paragraph 3. Accomplishment Instructions.
Table 1: Inspect Stringer 11 for Crack at the Outboard Flap. Inboard Drive Hinge at Station Xrs=164.000
Condition  Action  Compliance Time  Repeat
(Whichever Occurs Later)  Interval
(Not to
Exceed)
All airplanes  Do Eddy Current, High Frequency  Before the accumula- Within 8,710 flight cy-
(ETHF) inspection for cracks in  tion of 19,000 total  cles after the original
Stringer 11 at the outboard flap,  flight cycles.  issue date on this
inboard drive hinge at Station  service bulletin.
Xrs=164.000.
Condition 1:  Do ETHF inspection for cracks in -  29,000 flight
(No Crack  Stringer 11 at the outboard flap,  cycles.
Found)  inboard drive hinge at Station
Xrs=164.000. (a)
Condition 2:  Do splice repair.  Before further flight.
(Crack Found)
AND
Do ETHF inspection for cracks in | 60,000 flight cycles  29,000 flight
Stringer 11 at the outboard flap,  after splice repair.  cycles.
inboard drive hinge at Station
Xrs-164.000. (b)
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Table 1: Inspect Stringer 11 for Crack at the Outboard Flap, Inboard Drive Hinge at Station Xrs=164.000
Condition  Action  Compliance Time  Repeat
(Whichever Occurs Later)  Interval
(Not to
Exceed)
(a) If any crack is found, do the actions specified by Condition 2.
(b) If any crack is found at this inspection after splice repair, contact Boeing and do the repair in accordance
with Boeing's instructions.
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
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/repair for each
wing. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with
operator task hour data if necessary. The estimate does not include lost time. These are some examples
of lost time:
Time to adjust to the workplace
Time to schedule the work
Time to examine the work
Time to cure the materials
Time to make the parts
Time to find the tools
Time to make reference standards.
Condition 1 (No Crack Found)
Task  Number of Persons  Task Hours  Elapsed Hours
Defuel Tank  4.0  4.0
Purge Tank  8.0  8.0
FIGURE 1  1.0  1.0
TOTAL FOR EACH WING  13.0  13.0
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Condition 2 (Crack Found)
Task  Number of Persons  | Task Hours  Elapsed Hours
Defuel Tank  4.0  4.0
Purge Tank  8.0  8.0
FIGURE 1  1.0  1.0
Splice Repair  2  80.0  40.0
TOTAL FOR EACH WING  93,0  53.0
H.  Weight and Balance Changes
Condition 1 (No Crack Found)
1. None.
Condition 2 (Crack Found)
1. DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), MD-88
Mfr's Empty
Approximate Sta- Weight (MEW)  Moment Change
Airplane  tion (Inches)  LBS  (MEW) IN.-LBS
Left Wing Only  965.0  + 7.3  + 7044.5
Right Wing Only  965.0  + 7,3  + 7044.5
Both Wings  965.0  + 14.6  + 14089.0
2.  DC-9-87 (MD-87)
Mfr's Empty
Approximate Sta-  Weight (MEW)  Moment Change
Airplane  tion (Inches)  LBS  (MEW) IN.-LBS
Left Wing Only  851.0  + 7.3  + 6212.3
Right Wing Only  851.0  + 7.3  + 6212.3
Both Wings  851.0  + 14.6  + 12424.6
Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Non-Destructive Test Standard Practices Manual (NDTSPM) 06-10-01.001.
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### Page 15 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
b. MD-80 Aircraft Maintenance Manual (AMM) 06-21-00, 12-11-01, 28-00-00, 28-10-01.
c. MD-80 Fleet Team Digest (FTD) MD-80-FTD-57-10001.
d. MD-80 Structural Repair Manual (SRM) 51, 51-30-09.
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:
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:
Drawing No  Title  Sheet  DCN/REV  ADCN
SR09570100  STRINGER 11 REPAIR, LOWER WING,  DWG
Xrs=164.000
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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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
BLANK PAGE
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
2. MATERIAL INFORMATION
A. Material - Price and Availability
Condition 1 (No Crack Found)
1. None.
Condition 2 (Crack Found)
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:
a. Order on-line via ATA Spec 2000 or The Boeing PART Page
b. 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
Kit Number  Name  ROLT as of the  Unit Price as of
original issue  the original issue
date of this Ser-  date of this Ser-
vice Bulletin (Cal- vice Bulletin (US
endar Days)  Dollars)
SA09570243-3  Service Kit, Stringer 11 Splice Repair  120  $ 17,759.00
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:
Condition 1 (No Crack Found)
a. None.
Condition 2 (Crack Found)
a. To get the kits/parts shown below, refer to Paragraph 2.A.; Material - Price and Availability.
NOTE:  One top kit per wing and the items shown in Paragraph 2.C.2., Parts and Materials
Supplied by the Operator, are necessary for each airplane.
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Kit SA09570243
New Part Number  QTY Name  Existing Part  Notes
Number
-З
3D0006-3  40  NUT ASSEMBLY  (a)
3D0006-4  64  NUT ASSEMBLY  (a)
HLT435-8-12  PIN
HLT435-8-14  2  PIN
HLT436-10-12  PIN
HLT436-10-21  PIN
HLT436-6-13  2  PIN
HLT436-8-5  2  PIN
HLT436-8-7  4  PIN
HLT439-6-10  2  PIN
HLT439-6-11  2  PIN
HLT439-6-12  4  PIN
HLT439-6-13  1  PIN
HLT439-6-14  2  SPIN
HLT439-6-9  12  PIN
HLT439-8-10  6  PIN
HLT439-8-11  9  PIN
HLT439-8-12  12  PIN
HLT439-8-13  22  PIN
HLT439-8-7  4  PIN
HST112-8-14  2  PIN, OVERSIZE
MS21042L3  13  NUT
MS21042L4  2  NUT
MS21042L5  4  NUT
NAS1252-10L  2  WASHER  (a)
NAS1252-416L  2  WASHER  (a)
NAS1252-516L  4  WASHER  (a)
NAS1401-3D3  17  WASHER
NAS1401-4D3  52  WASHER
S4931920-6-6  8  PIN  (a)
S4931920-6-7  ￾7  PIN  (a)
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BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Kit SA09570243
New Part Number  QTY | Name  Existing Part  Notes
Number
-3
S4931920-6-8  13  PIN  (a)
S4931920-8-4  2  PIN  (a)
SR09570100-11  1  ANGLE
SR09570100-12  ANGLE
SR09570100-3  STRINGER
SR09570100-7  2  ANGLE
SR09570100-9  2  CHANNEL
(a) Approved equivalent parts are listed in the Approved Equivalent Parts
List (AEPL). Refer to the AEPL, Drawing 7595071.
2. Parts and Materials Supplied by the Operator:
Condition 1 (No Crack Found)
a. None.
Condition 2 (Crack Found)
a. Materials necessary to complete the action in this service bulletin.
Part Number / Specifica- QTY  Name  Notes
tion
PR-1422 B-2  1 Quart  Sealant  (a)
(DMS 2082)
or
Equivalent
Alodine 1200S  1 Quart  MC Coating, Chemical  (b)
(DPM 1453-5)  Film
or
Equivalent
#833K086 Base;  1 Pint  Coating, Fuel Tank, Inte-  |(a)
#930K088 Curing Solution  gral
(DMS 1850 Type 4
Composition C)
or
Equivalent
(a) Can be purchased from: PRC - DeSoto International, Incorporated. 11601 United Street, Mojave, California
93501, CAGE 85570.
(b) Can be purchased from: Henkel Corporation. 32100 Stephenson Highway, Madison Heights, Michigan
48071. CAGE 1N6B3.
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### Page 20 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
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
Condition 1 (No Crack Found)
1. None.
Condition 2 (Crack Found)
1. The MD-80 SRM 51-30-09 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.
F. Special Tooling Necessary to do this Service Bulletin
Condition 1 (No Crack Found)
1. 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.
Condition 2 (Crack Found)
1. Cold working tools are necessary to do the change given in this service bulletin. Refer to Service
Rework Drawing SR09570100, General Notes 29 and 35. To get the cold working tools, refer to
Paragraph 2.E., Special Tooling - Price and Availability.
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### Page 21 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
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.  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.
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 limits to tighten nuts and bolts are in MD-80 SRM 51.
7.  Obey all of the warnings and cautions given in the specified manual sections.
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### Page 22 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
8.  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
9.  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.
10.  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.
11.  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.
12.  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
WARNING: BEFORE MOVING FLAP/SLAT HANDLE, MAKE CERTAIN THAT AREAS AROUND
FLAPS AND SLATS ARE CLEAR OF PERSONNEL AND EQUIPMENT.
1. Defuel and purge left and right fuel tanks. Refer to MD-80 AMM 12-11-01, MD-80 AMM 28-00-00
and MD-80 AMM 28-10-01 as accepted procedures.
2. Remove and retain door number 1307C and 1355C on the left wing main tank and door number
1410C and 1454C on the right wing main tank and attaching parts. Refer to MD-80 AMM 06-21-00.
3. Prepare fuel tank for entry and gain access to the area of inspection of Stringer 11 at the outboard
flap, inboard drive hinge at Station Xrs=164.000.
4. Do an in-tank Eddy Current, High Frequency (ETHF) inspection for cracks in Stringer 11 at the
outboard flap, inboard drive hinge at Station Xrs=164.000 in accordance with FIGURE 1, and
based on inspection results do as follows:
Condition 1 (No Crack Found)
a. Do repeat ETHF inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge
at Station Xrs=164.000 in accordance with FIGURE 1, at intervals specified in Paragraph 1. E.,
Compliance.
Condition 2 (Crack Found)
a. Do splice repair in accordance with Service Rework SR09570100-7003.
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### Page 23 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
b. Do ETHF inspection for cracks in Stringer 11 at the outboard flap, inboard drive hinge at
Station Xrs=164.000 in accordance with Service Rework Drawing SR09570100, Zone 15, at
intervals specified in Paragraph 1.E., Compliance.
5. Put the airplane back to a serviceable condition.
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### Page 24 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
Xrs=164.000  Xrs= 164:000
STA
Xrs=164.000
ANGLE  •STRINGER 11
CRACK
(TYPICAL)
ANGLE
A-A
VIEW LOOKING AFT  LEFT SIDE SHOWN  2108122
RIGHT SIDE OPPOSITE
FIGURE 1: EDDY CURRENT, HIGH FREQUENCY INSPECTION - STRINGER 11 AT THE OUTBOARD FLAP,
INBOARD DRIVE HINGE AT STATION XRS-164.000
(SHEET 1 OF 2)
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### Page 25 (OCR)

BOEING SERVICE BULLETIN MD80-57A243
ALERT  ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for each airplane.
STEP  TASK  NAME  IDENTIFICATION  QTY  MORE DATA
1  Inspect  Stringer  5919236-503, -504  1  (a)
or
5919236-507, -508
(a) Perform an Eddy Current, High Frequency (ETHF) surface inspection of Stringer 11 in the area of the
bulkhead at Station Xrs = 164.000. Scan the forward face of the vertical flange of the stringer, around
the four fasteners common with the angles shown. Scan looking for cracks originating at the fastener
holes and propagating in the vertical direction. Scan around fasteners in accordance with NDTSPM
06-10-01.001, Procedure 1. Use calibration scan method "K" and Scan Method 44.
FIGURE 1: EDDY CURRENT, HIGH FREQUENCY INSPECTION - STRINGER 11 AT THE OUTBOARD FLAP,
INBOARD DRIVE HINGE AT STATION XRS=164.000
(SHEET 2 OF 2)
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