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Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes MD90 Service Bulletin ALERT Number: MD90-57A026 Original Issue: February 11, 2010 Revision 1: February 23, 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 1 of 59 3.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 2 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT BLANK PAGE ### Page 3 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 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 3 E. Compliance .............................................. 1 6 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2 1. Existing Data: ......................................... 2 2 2. Data supplied with this Service Bulletin: ........................... 2 2 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 3 2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 6 C. Parts Necessary For Each Airplane ................................. 2 6 1. Kits/Parts: ........................................... 2 6 2. Parts and Materials Supplied by the Operator: ........................ 4 3 3. Parts Modified and Reidentified: ............................... 4 3 4. Parts Removed and Not Replaced: .............................. 4 3 D. Parts Necessary to Change Spares ................................. 4 3 E. Special Tooling - Price and Availability ............................... 4 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 4 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5 A. GENERAL INFORMATION ..................................... 4 5 B. WORK INSTRUCTIONS ....................................... 4 6 FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH FREQUENCY INSPECTION .................................. 5 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 3 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 4 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT BLANK PAGE ### Page 5 Commercial Airplanes MD90 Service Bulletin ALERT Revision Transmittal SheetNumber: MD90-57A026Original Issue: February 11, 2010 Revision 1: February 23, 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 the airplane(s) changed in accordance with the original issue of this service bulletin, however the repetitive inspections called for in the original issue are still required. 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 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 data given in Information Notice MD90-57A026 IN 01 is included in this revision. These sections were changed: 1. In Paragraph 1.C., Reason, added spar splice option. 2. In Paragraph 1.D., Description, added Condition titles, Option 1 heading and Option 2 splice repair, and added repair options for Condition 3. 3. In Paragraph 1.E., Compliance, added Option 1 heading, Option 2 splice repair, and repair options for Condition 3. 4. In Paragraph 1.F., Approval, added approval statement for Principle Structural Element (PSE) inspection requirements. 5. In Paragraph 1.G., Manpower, added a table for splice repair hours. 6. In Paragraph 1.J.1., Existing Data, changed Aircraft Maintenance Manual (AMM) references to reflect correct chapter references. 7. In Paragraph 1.J.2., Data supplied with this Service Bulletin, added drawings and updated DCN/REV column. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 5 of 59 ### Page 6 8. In Paragraph 2.A., Material - Price and Availability, added Service Kits, Reorder Lead Time (ROLT), and unit price. 9. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, changed supplier address. 10. In Paragraph 2.C.1., Kits/Parts, changed Service Kit applicability table to add new kits and added new kit parts list. 11. In Paragraph 2.C.3., Parts Modified and Reidentified, added parts changed based on repair configuration. 12. In Paragraph 3.A., General Information, removed one Note and renumbered remaining Notes. 13. In Paragraph 3.B., Work Instructions, added Option 1 heading, Option 2 splice repair, and repair options for Condition 3, changed work step order, and corrected Aircraft Maintenance Manual Chapter references. 14. Changed Figure 1 and Note 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 February 11, 2010Original Issue: February 23, 2011Revision 1: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 6 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 7 Commercial Airplanes MD90 Service Bulletin ALERT SummaryNumber: MD90-57A026Original Issue: February 11, 2010 Revision 1: February 23, 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 MD-80 operators, while doing an investigation for fuel leaks, reported five 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. No MD-90 failures have yet been reported but this is a fatigue issue and it was determined that MD-90s are also susceptible to cracking. Inspecting this area for cracks will stop any crack migration and ensure repairs are done before additional damage occurs. Installation of doublers or doing the spar cap splice will provide a permanent repair. 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. ACTION Refer to Paragraph 1.D., for Description. EFFECTIVITY MD-90-30 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. COMPLIANCE Refer to Paragraph 1.E., Compliance. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 7 of 59 ### Page 8 MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 8 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 9 (OCR) BOEING SERVICE BULLETIN MD90-57A026 ALERT ALERT INSPECT / REPAIR UPPER AND LOWER REAR SPAR CAPS AT STATION Xrs=164.000 1901591 Original Issue: February 11, 2010 Revision 1: February 23, 2011 MD90-57A026 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 59 ### Page 10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 10 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT BLANK PAGE ### Page 11 Commercial Airplanes MD90 Service Bulletin ALERT Number: MD90-57A026 Original Issue: February 11, 2010 Revision 1: February 23, 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 This service bulletin is for the airplanes shown below. DESCRIPTIONCONFIGURATIONGROUP MD-90 Airplanes with a Multi-component Bulkhead at Wing Station Xrs=137.750 -1 MD-90 Airplanes with a Machined Bulkhead at Wing Station Xrs=137.750 -2 Airplane Models: MD-90-30 GroupFuselage Num- ber 12094 - 2100 12115 12117 12120 12122 - 2123 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 11 of 59 ### Page 12 GroupFuselage Num- ber 12125 - 2126 12129 12131 12133 12136 12138 12140 - 2144 12146 - 2147 12149 - 2150 12153 - 2154 12156 - 2159 12161 - 2166 12169 - 2171 12173 12175 12177 12179 12181 12184 12186 12190 - 2191 12193 - 2195 12197 - 2198 12200 12202 - 2203 12205 12207 12209 - 2213 22215 - 2217 22219 - 2233 22235 - 2238 22240 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 12 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 13 GroupFuselage Num- ber 22242 - 2243 22245 22248 22250 - 2251 22253 22255 - 2256 22258 - 2263 22288 - 2290 14001 - 4002 2. Spares Affected None. B. Concurrent Requirements None. C. Reason Two MD-80 operators, while doing an investigation for fuel leaks, reported five 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. No MD-90 failures have yet been reported but this is a fatigue issue and it was determined that MD-90s are also susceptible to cracking. Inspecting this area for cracks will stop any crack migration and ensure repairs are done before additional damage occurs. Installation of doublers or doing the spar cap splice will provide a permanent repair. 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. 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 data given in Information Notice MD90-57A026 IN 01 is included in this revision. MD-80 Service History Landing CyclesFlight-Hours 32,958 to 39,33851,293 to 69,453 D. Description This service bulletin does Eddy Current Testing High Frequency (ETHF) inspection 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: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 13 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 14 Condition 1 (No Cracks) 1. Does repeat ETHF inspections. Condition 2 (Crack 2.0 Inches or Shorter and Not in the Rear Spar Lower Cap Forward Horizontal Leg Radius) 1. Does ETHF inspection on the aft side of the left and/or right wing rear spar upper cap, as applicable, at station Xrs=164.000 for cracks and based on inspection results does as follows: Condition 2a (No Crack in Rear Spar Upper Cap) a. Do Option 1 or Option 2 Option 1 (1) Does doubler repair to rear spar lower cap in accordance with Service Rework Drawing J060271. (2) Does repeat ETHF inspections of rear spar lower cap doubler repair. Option 2 (1) Does splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165. (2) Does Eddy Current Testing Low Frequency (ETLF) and Ultrasonic (UT) inspections of rear spar lower cap splice repair. Condition 2b (Crack 2.0 Inches or Shorter in Rear Spar Upper Cap) a. Do Option 1 or Option 2. NOTE: Operators can do Option 1 or Option 2 or any combination of Options 1 and 2. Option 1 (1) Does doubler repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060271. (2) Does ETHF inspection of rear spar upper and lower cap doubler repairs. Option 2 (1) Does splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165. (2) Does ETLF and UT inspections of rear spar lower cap splice repair. Condition 2c (Crack Longer than 2 Inches in Rear Spar Upper Cap) a. Do Option 1 or Option 2. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 14 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 15 Option 1 (1) 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. (2) Does ETHF inspections of rear spar lower cap splice repair. Option 2 (1) Does splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165. (2) Does ETLF and UT inspections of rear spar lower cap splice repair. Condition 3 (Crack Longer than 2.0 Inches or Crack in the Rear Spar Lower Cap Forward Horizontal Leg Radius) 1. Does ETHF inspection on the aft side of the left and/or right wing rear spar upper cap, as applicable, at station Xrs=164.000 for cracks and based on inspection results does as follows: Condition 3a (No Crack in Rear Spar Upper Cap) 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. Condition 3b (Crack 2.0 Inches or Shorter in Rear Spar Upper Cap) a. Do Option 1 or Option 2 Option 1 (1) 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 Service Rework Drawing J060165. (2) Does ETHF inspection of rear spar upper cap doubler repair. (3) Does ETLF and UT inspections of rear spar lower cap splice repair. Option 2 (1) Does splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165. (2) Does ETLF and UT inspections of rear spar lower cap splice repair. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 15 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 16 Condition 3c (Crack Longer than 2.0 Inches in Rear Spar Upper Cap) 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 the airplane(s) changed in accordance with the original issue of this service bulletin, however the repetitive inspections called for in the original issue are still required. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 511, 611MD-90-30 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. Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack at Station Xrs = 164.000 Repeat In- terval (Not to Ex- ceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 10,000 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 Instruction 3.B. All airplanes 2,550 flight cycles. --Do ETHF inspection of the left and right wing rear spar lower caps at station Xrs=164.000 in accordance with Accomplishment Instruction 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- tion 3.B.. Condition 2: Crack 2.0 Inches or Shorter and Not in the Rear Spar Lower Cap Forward Horizontal Leg Radius BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 16 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 17 Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack 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 Instruction 3.B. Condition 2a: No Crack in Rear Spar Upper Cap. AND 8,500 flight cycles. -13,500 flight cy- cles after doubler repair. Do ETHF inspection in the repaired area of the rear spar lower cap in accordance with Accomplishment Instruction 3.B. OR --Before further flight. Option 2: Do splice repair in accordance with Accomplishment Instruction 3.B. AND 3,000 flight cycles. -20,000 flight cy- cles 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 Instruction 3.B. --Before further flight. Option 1: Do doubler repair of rear spar upper and lower caps in accordance with Accomplishment Instruction 3.B. Condition 2b: Crack 2.0 Inches or Shorter in Rear Spar Upper Cap. (Operators may do Op- tion 1 or Option 2 or any combination of Op- tion 1 and 2.) AND 8,500 flight cycles. -13,500 flight cy- cles after doubler repair. Do ETHF inspection in the repaired area of the rear spar upper and lower caps in accordance with Ac- complishment Instruction 3.B. OR --Before further flight. Option 2: Do splice repair of rear spar upper and lower caps in accordance with Accomplishment Instruction 3.B. AND 3,000 flight cycles. -20,000 flight cy- cles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lower cap in accordance with Accomplish- ment Instruction 3.B. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 17 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 18 Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack 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 Instruction 3.B. Condition 2c: Crack Longer than 2.0 Inches in Rear Spar Upper Cap. AND 8,500 flight cycles. -13,500 flight cy- cles after doubler repair. Do ETHF inspection in the repaired area of the rear spar lower cap in accordance with Accomplishment Instruction 3.B. OR --Before further flight. Option 2: Do splice repair of rear spar upper and lower caps in accordance with Accomplishment Instruction 3.B. AND 3,000 flight cycles. -20,000 flight cy- cles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lower cap in accordance with Accomplish- ment Instruction 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- tion 3.B. Condition 3: Crack Longer than 2.0 Inches or Crack in the Rear Spar Lower Cap Forward Horizontal Leg Radius. -Before further flight. Do splice repair of rear spar lower cap in accordance with Accomplish- ment Instruction 3.B. Condition 3a: No Crack in Rear Spar Upper Cap. AND 3,000 flight cycles. 20,000 flight cy- cles after splice repair. Do ETLF and UT inspections in the repaired area of the lower rear spar cap in accordance with Accomplish- ment Instruction 3.B. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 18 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 19 Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack 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 Instruction 3.B. Condition 3b: Crack 2.0 Inches or Shorter in Rear Spar Upper Cap. AND 8,500 flight cycles. -13,500 flight cy- cles after doubler repair. Do ETHF inspection in the repaired area of the rear spar upper cap in accordance with Accomplishment Instruction 3.B. AND 3,000 flight cycles. -20,000 flight cy- cles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lower cap in accordance with Accomplish- ment Instruction 3.B. OR --Before further flight. Option 2: Do splice repair of rear spar upper and lower caps in accordance with Accomplishment Instruction 3.B. AND 3,000 flight cycles. -20,000 flight cy- cles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lower cap in accordance with Accomplish- ment Instruction 3.B. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 19 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 20 Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack 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 Instruction 3.B. Condition 3c: Crack Longer than 2.0 Inches in Rear Spar Upper Cap. AND 3,000 flight cycles. -20,000 flight cy- cles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lower cap in accordance with Accomplish- ment Instruction 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. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. In addition, the Manager of the FAA Los Angeles, Aircraft Certification Office approves the action (i.e. inspection or modification or repair) defined in this service bulletin as a method of compliance to the requirements of Principle Structural Element (PSE) 57.11.02.2 for those areas of the PSE addressed by 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 — Time to make the parts — Time to find the tools. — Time to make reference standards. 1. Use applicable table for Manpower as follows: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 20 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 21 TABLE 1: NO CRACK 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 0.51.02Open Access to Tanks 4.04.01Defuel 8.08.01Purge 200.0*400.0*2Repair 0.51.02Close Access 2.04.02Test BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 21 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 22 TABLE 3: SPLICE REPAIR Elapsed HoursTask HoursNumber of Per- sons Task 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. Non-Destructive Test Standard Practices Manual (NDTSPM) 01-00-01, 06-00-01, 06-10-01.001, Part 06, 06-20-01. b. MD-90 Aircraft Maintenance Manual (AMM) 06-35-00, 06-36-00, 12-11-01, 27-00-00, 27-10-00, 27-50-00, 27-50-01, 27-60-00, 28-00-00, 28-11-00 , 29-00-00, 32-10-00, 57-20-03, 57-40-01. c. MD90 Structural Repair Manual (SRM) 51-10-03, 51-10-05, 51-10-09, 51-20-00, 51-30-01, 51-30-02, 51-30-03, 51-30-05, 51-31-02, 51-40-00. d. MD-90 Airworthiness Limitations Instructions (ALI), Principal Structural Element (PSE) 57.11.02.2. 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: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 22 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 23 ADCNDCN/REVSheetTitleDrawing No -CDWGEDDY CURRENT INSPECTION - WING REAR SPAR TEMPORARY REPAIR STA Xrs=164.000 3668XXX YUAEOSERVICE REWORK - WING REAR SPAR CAP SPLICE SERVICE REWORK DWG J060165 WUAEO VUAEO ZUAEO AAUDWG UTDWGSERVICE REWORK - TEMPORARY RE- PAIR, WING REAR SPAR, STATION Xrs=164.000 J060271 --DWGINSPECTION, REAR SPAR - LOWER CAP AT Xrs=192.00 SN90570001 --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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 23 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 24 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 24 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT BLANK PAGE ### Page 25 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the date of this Service Bulletin (US Dollars) ROLT as of the date of this Ser- vice Bulletin (Cal- endar Days) NameKit Number $40,558.00120Service KitSA90570026-3 40,558.00120Service KitSA90570026-5 42,624.00120Service KitSA90570026-7 42,624.00120Service KitSA90570026-9 80,026.00120Service KitSA90570026-11 80,026.00120Service KitSA90570026-13 138,297.00120Service KitSA90570026-15 138,297.00120Service KitSA90570026-17 81,125.00120Service KitSA90570026-19 81,125.00120Service KitSA90570026-21 192,024.00120Service KitSA90570026-23 192,024.00120Service KitSA90570026-25 138,306.00120Service KitSA90570026-27 138,306.00120Service KitSA90570026-29 72,115.00120Service KitSA90570026-31 72,115.00120Service KitSA90570026-33 192,043.00120Service KitSA90570026-35 192,043.00120Service KitSA90570026-37 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 25 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 26 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. Group 1: Table 1: Service Kit Applicability DescriptionDrawing ConfigurationService Kit Doubler Repair for Crack in Rear Spar Upper Cap (Left Wing) J060271-511SA90570026-3 Doubler Repair for Crack in Rear Spar Upper Cap (Right Wing) J060271-512SA90570026-5 Doubler Repair for Crack in Rear Spar Lower Cap (Left Wing) J060271-517SA90570026-7 Doubler Repair for Crack in Rear Spar Lower Cap (Right Wing) J060271-518SA90570026-9 Doubler Repair for Crack in Rear Spar Upper and Lower Cap (Left Wing) J060271-519SA90570026-11 Doubler Repair for Crack in Rear Spar Upper and Lower Cap (Right Wing) J060271-520SA90570026-13 Splice Repair for Crack in Rear Spar Upper Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Left Wing) J060165-517SA90570026-15 Splice Repair for Crack in Rear Spar Upper Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Right Wing) J060165-518SA90570026-17 Splice Repair for Crack in Rear Spar Lower Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Left Wing) J060165-519SA90570026-19 Splice Repair for Crack in Rear Spar Lower Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Right Wing) J060165-520SA90570026-21 Splice Repair for Crack in Rear Spar Upper and Lower Caps on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Left Wing) J060165-521SA90570026-23 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 26 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 27 Group 1: Table 1: Service Kit Applicability DescriptionDrawing ConfigurationService Kit Splice Repair for Crack in Rear Spar Upper and Lower Caps on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Right Wing) J060165-522SA90570026-25 Group 2: Table 1: Service Kit Applicability DescriptionDrawing ConfigurationService Kit Doubler Repair for Crack in Rear Spar Upper Cap (Left Wing) J060271-511SA90570026-3 Doubler Repair for Crack in Rear Spar Upper Cap (Right Wing) J060271-512SA90570026-5 Doubler Repair for Crack in Rear Spar Lower Cap (Left Wing) J060271-517SA90570026-7 Doubler Repair for Crack in Rear Spar Lower Cap (Right Wing) J060271-518SA90570026-9 Doubler Repair for Crack in Rear Spar Upper and Lower Cap (Left Wing) J060271-519SA90570026-11 Doubler Repair for Crack in Rear Spar Upper and Lower Cap (Right Wing) J060271-520SA90570026-13 Splice Repair for Crack in Rear Spar Upper Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Left Wing) J060165-523SA90570026-27 Splice Repair for Crack in Rear Spar Upper Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Right Wing) J060165-524SA90570026-29 Splice Repair for Crack in Rear Spar Lower Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Left Wing) J060165-525SA90570026-31 Splice Repair for Crack in Rear Spar Lower Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Right Wing) J060165-526SA90570026-33 Splice Repair for Crack in Rear Spar Upper and Lower Caps on airplanes with a machined bulkhead at wing station Xrs=137.750 (Left Wing) J060165-527SA90570026-35 Splice Repair for Crack in Rear Spar Upper and Lower Caps on airplanes with a machined bulkhead at wing station Xrs=137.750 (Right Wing) J060165-528SA90570026-37 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 27 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 28 Kit SA90570026 NotesNameQTYNew Part Number -13-11-9-7-5-3 WASHER1111..2917053-501 WASHER1111..2917053-509 NUT ASSY4646464627273D0006-4 SPACER CONICAL2626..26264894213-1 SPACER CONICAL18181818..4894213-501 SPACER9797474750504894213-503 CONICAL SPACER7777..4894213-505 CONICAL SPACER8844444894213-547 STIFFENER1111119910010-39 CLIP.....19924775-27 CLIP....1.9924775-28 PIN4444..HL328-6-10 PIN4444..HL328-6-18 PIN66..66HL328-6-8 PIN2020661414HL328-8-10 PIN3333..HL328-8-6 PIN5555..HL328-8-8 PIN3333..HL329-6-14 PIN2222..HL329-6-16 PIN15151515..HL329-6-5 PIN1616..1616HL329-6-6 PIN, OVERSIZE..44..HLT1001PB-6-10 PIN, OVERSIZE2828222626HLT1001PB-6-12 PIN, OVERSIZE15158877HLT1001PB-6-14 PIN, OVERSIZE8888..HLT1001PB-6-16 PIN, OVERSIZE2222..HLT1001PB-6-18 PIN, OVERSIZE2222..HLT1001PB-8-10 PIN, OVERSIZE1616141422HLT1001PB-8-12 PIN, OVERSIZE484819192929HLT1001PB-8-14 PIN, OVERSIZE776611HLT1001PB-8-16 PIN, OVERSIZE292911111818HLT1001PB-8-18 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 28 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 29 Kit SA90570026 NotesNameQTYNew Part Number -13-11-9-7-5-3 PIN11115566HLT428-6-8 PIN262613131313HLT428-8-10 PIN525220203232HLT428-8-12 PIN2222..HLT428-8-8 PIN, OVERSIZE11..11HLT629-8-6 PIN, OVERSIZE2222..HLT629-8-7 SHIM11....J060271-13 SHIM11....J060271-17 SHIM..1111J060271-19 SHIM..1111J060271-21 DOUBLER.1...1J060271-27 DOUBLER1...1.J060271-28 FILLER1111..J060271-31 CLIP.1.1..J060271-33 CLIP1.1...J060271-34 CLIP.1.1..J060271-35 CLIP1.1...J060271-36 SPACER2222..J060271-37 DOUBLER.1...1J060271-39 DOUBLER1...1.J060271-40 DOUBLER.1...1J060271-41 DOUBLER1...1.J060271-42 DOUBLER.1.1..J060271-43 DOUBLER1.1...J060271-44 DOUBLER.1.1..J060271-45 DOUBLER1.1...J060271-46 DOUBLER.1.1..J060271-47 DOUBLER1.1...J060271-48 FILLER1111..J060271-49 FILLER1111..J060271-51 SHIM1111..J060271-53 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 29 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 30 Kit SA90570026 NotesNameQTYNew Part Number -13-11-9-7-5-3 STIFFENER111111J060271-57 TEE.1.1..J060271-65 TEE1.1...J060271-66 RADIUS BLOCK.1.1..J060271-67 RADIUS BLOCK1.1...J060271-68 RIVET222222MS20470AD6-10D RIVET22..22MS20470AD6-8D RIVET333333MS20470AD6-9D RIVET161616161616MS20470AD8-12D NUT10510548485757MS21042L3 NUT1961968989107107MS21042L4 NUTPLATE2222..MS21059L3 WASHER505028282222NAS1252-10H WASHER282814141414NAS1252-416H WASHER2424..2424NAS1401-3D3 BOLT4444..PIC239-3-10 BOLT4444..PIC239-3-12 BOLT3333..PIC239-3-15 BOLT33..33PIC239-3-17 BOLT2222..PIC239-3-6 WASHER555520203535S2931983-30A06 WASHER18018085859595S2931983-40A06 Kit SA90570026 NotesNameNew Part Number -25-23-21-19-17-15 NUT ASSY2222151522223D0006-3 NUT ASSY21621674741551553D0006-4 NUT ASSY5757171740403D0006-5 PIN44..443D0097-10X12 PIN44..443D0097-10X13 PIN17171717..3D0097-10X14 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 30 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 31 Kit SA90570026 NotesNameNew Part Number -25-23-21-19-17-15 PIN1212..12123D0097-10X17 PIN1616..16163D0097-10X18 PIN44..443D0097-10X20 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 PIN44441010HLT426-10-18 PIN444435355656HLT426-6-10 PIN242418182424HLT426-6-12 PIN44..44HLT426-6-13 PIN1818181822HLT426-6-14 PIN662244HLT426-6-15 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 31 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 32 Kit SA90570026 NotesNameNew Part Number -25-23-21-19-17-15 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 PIN1616191933HLT426-8-13 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 PIN6666HLT426-10-7 PIN9999..HLT427-10-18 PIN12121212..HLT427-10-20 PIN35353535..HLT427-10-22 PIN6666..HLT427-10-24 PIN2222..HLT427-10-26 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 32 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 33 Kit SA90570026 NotesNameNew Part Number -25-23-21-19-17-15 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 PIN55..55HLT437-6-6 ANGLE1.1...J060165-10 FILLER.1.1..J060165-13 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 33 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 34 Kit SA90570026 NotesNameNew Part Number -25-23-21-19-17-15 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 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 34 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 35 Kit SA90570026 NotesNameNew Part Number -25-23-21-19-17-15 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 RIVET1111..MS20470AD8-17D RIVET6666..MS20470AD8-18D RIVET1111..MS20470AD8-19D RIVET5555..MS20470AD8-7D RIVET18181818..MS20470AD8-9D BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 35 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 36 Kit SA90570026 NotesNameNew Part Number -25-23-21-19-17-15 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 Kit SA90570026 NotesNameNew Part Number -37-35-33-31-29-27 NUT ASSY2222151522223D0006-3 NUT ASSY21621674741551553D0006-4 NUT ASSY5757171740403D0006-5 PIN44..443D0097-10X12 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 36 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 37 Kit SA90570026 NotesNameNew Part Number -37-35-33-31-29-27 PIN44..443D0097-10X13 PIN17171717..3D0097-10X14 PIN1212..12123D0097-10X17 PIN1616..16163D0097-10X18 PIN44..443D0097-10X20 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 37 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 38 Kit SA90570026 NotesNameNew Part Number -37-35-33-31-29-27 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 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: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 38 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 39 Kit SA90570026 NotesNameNew Part Number -37-35-33-31-29-27 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 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 39 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 40 Kit SA90570026 NotesNameNew Part Number -37-35-33-31-29-27 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 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 40 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 41 Kit SA90570026 NotesNameNew Part Number -37-35-33-31-29-27 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 RIVET5555..MS20426AD4-6D RIVET33..33MS20426AD6-12D RIVET1818181844MS20426AD6-14D RIVET2222..MS20426AD6-8D 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 RIVET424242423636MS20470AD8-14D RIVET4444..MS20470AD8-16D RIVET1111..MS20470AD8-17D RIVET6666..MS20470AD8-18D RIVET1111..MS20470AD8-19D BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 41 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 42 Kit SA90570026 NotesNameNew Part Number -37-35-33-31-29-27 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 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: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 42 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 43 2. Parts and Materials Supplied by the Operator: CAGESupplierQTYPart Number/Specification 92108PRC - DeSoto International, IncorporatedAs Re- quired PR-1422 B-2 Sealant (DMS 2082) or P.O. Box 1800 Equivalent Sylmar, California 91342 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 applicable to all repair/modification configurations. NotesNew Part NumberNameQTYExisting Part Number (a) (b) (c)J060271-59ANGLE19919474-1 or 9919474-501 or 9919474-503 J060271-60ANGLE19919474-2 or 9919474-502 or 9919474-504 J060271-61CAP19919472-23 J060271-62CAP19919472-24 (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. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 43 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 44 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 44 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 45 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE CAN OCCUR. CAUTION: 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 and process material substitutions, in accordance with MD-90 SRM, Chapter 51, Volume 2. 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-90 SRM, Chapter 51. — Torque limits to tighten nuts and bolts are in MD-90 SRM,Chapter 51. 8. Use of equivalent parts as given in the AEPL, Drawing 7595091, is permitted. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 45 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 46 9. Obey all of the warnings and cautions given in the specified manual sections and Service Rework Drawings. 10. Refer to the following MD-90 SRM Chapters as and accepted procedure for the applicable operation: MD90 SRM 51-10-03, Volume 2 - Corrosion/Erosion Control And Prevention. MD90 SRM 51-10-05, Volume 2 - Drilling, Countersinking, And Dimpling. MD90 SRM 51-10-09, Volume 2 - Cold-Working of Holes And Countersinks. MD90 SRM 51-20-00, Volume 2 - Repair Sealing. MD90 SRM 51-30-01, Volume 2 - Bolts, Screws And Washers. MD90 SRM 51-30-02, Volume 2 - Rivets. MD90 SRM 51-30-03, Volume 2 - Lockbolts. MD90 SRM 51-30-05, Volume 2 - Hi-Lok Fasteners MD90 SRM 51-31-02, Volume 2 - Conical Spacers. MD90 SRM 51-40-00, Volume 2 - 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. B. WORK INSTRUCTIONS WARNING: BEFORE MOVING FLAP/SLAT HANDLE, MAKE CERTAIN THAT AREAS AROUND FLAPS AND SLATS ARE CLEAR OF PERSONNEL AND EQUIPMENT. 1. Extend wing flaps to full down position. Refer to MD-90 AMM 27-00-00 as an accepted procedure. WARNING: BEFORE OPERATING FLAPS, MAKE CERTAIN THAT AREAS AROUND FLAPS ARE CLEAR OF PERSONNEL AND EQUIPMENT. 2. Depressurize left and right hydraulic systems. Refer to MD-90 AMM 29-00-00 as an accepted procedure. 3. Open main landing gear doors and install door keepers. Refer to MD-90 AMM 32-10-00 as an accepted procedure. 4. Open inboard and center Bent Up Trailing Edge (BUTE) doors. Refer to MD-90 AMM 57-20-03 as an accepted procedure. 5. At Operator's option for ease of access to the inspection area, remove and retain the fixed flap fairing by removing and retaining its attaching parts. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 46 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 47 6. Clean the 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 crack. 7. Fabricate DAC GSET AL.01 reference standard. Refer to NDTSPM Part 06, 06-20-01 as an accepted procedure. 8. Do Eddy Current, High Frequency (ETHF) inspection on the aft side of the left and right wing rear spar lower caps at station Xrs=164.000 for crack in accordance with Figure 1 and Service Rework Drawing J060271, General Note 29, and based on findings do as follows: CONDITION 1: NO CRACK a. Close inboard and center bent up trailing edge (BUTE) doors. Refer to MD-90 AMM 57-20-03 as an accepted procedure. b. If removed, install kept fixed flap fairing. c. Remove door keepers and close main landing gear doors. Refer to MD-90 AMM 32-10-00 as an accepted procedure. d. Pressurize left and right hydraulic systems. Refer to MD-90 AMM 29-00-00 as an accepted procedure. WARNING: BEFORE OPERATING FLAPS, MAKE CERTAIN THAT AREAS AROUND FLAPS ARE CLEAR OF PERSONNEL AND EQUIPMENT. e. Retract wing flaps. Refer to MD-90 AMM 27-50-00 as an accepted procedure. f. Put the airplane back to a serviceable condition. g. Do repeat ETHF inspection on the aft side of the left and right wing rear spar lower caps at station Xrs=164.000 in accordance with Paragraph 1.E., Compliance. CONDITION 2: CRACK 2.0 INCHES OR SHORTER AND NOT IN THE REAR SPAR LOWER 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 MD-90 AMM 27-10-00 and MD-90 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 MD-90 AMM 12-11-01, MD-90 AMM 28-00-00 and MD-90 AMM 28-11-00 as accepted procedures. c. Remove and retain door number 520DT on the left wing main tank and/or door number 620CT on the right wing main tank and attaching parts as required. Refer to MD-90 AMM 06-35-00 and MD-90 AMM 06-36-00. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 47 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 48 d. Prepare left and/or right wing fuel tanks, as required, for entry and gain access to reach attachments of flap hinge fitting at station Xrs=164.000. Refer to MD-90 AMM 28-00-00 as an accepted procedure. e. Remove and retain the inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. f. Do Eddy Current High Frequency (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 Service Rework Drawing J060271, General Note 29, and based on inspection results, do as follows: Condition 2a: No Crack in Rear Spar Upper Cap (1) Do Option 1 or Option 2: Option 1 (a) 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 SA90570026-7-J060271-517Lower SA90570026-9J060271-518-Lower (b) Do repeat ETHF inspections of rear spar lower cap repair in accordance with Service Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E., Compliance. Option 2 (a) Do splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: Group 1: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-19-J060165-519Lower SA90570026-21J060165-520-Lower Group 2: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-31-J060165-525Lower BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 48 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 49 Group 2: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-33J060165-526-Lower (b) Do Eddy Current Low Frequency (ETLF) and Ultrasonic (UT) inspections of rear spar lower cap splice repair in accordance with Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E., Compliance. (2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. (3) Install door number 520DT on the left wing main tank and door number 620ET on the right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM 06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure. NOTE: In addition to monitoring the fuel tank access doors for leaks during the installation, monitor all areas of the rear spar changed during the accomplishment of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed areas. (4) Install previously removed 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 MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures. (5) Go to work step 3.B.9. Condition 2b: Crack 2.0 Inches or Shorter in Rear Spar Upper Cap (1) Do Option 1 or Option 2. NOTE: Operators can do Option 1 or Option 2 or any combination of Options 1 and 2. Option 1 (a) Do doubler repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060271 using the applicable service kit as follows: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-11-J060271-519Upper and Lower SA90570026-13J060271-520-Upper and Lower (b) Do repeat ETHF inspections of rear spar lower cap repair in accordance with Service Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E., Compliance. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 49 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 50 Option 2 (a) Do splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: Group 1: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-23-J060165-521Upper and Lower SA90570026-25J060165-522-Upper and Lower Group 2: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-35-J060165-527Upper and Lower SA90570026-37J060165-528-Upper and Lower (b) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E., Compliance. (2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. (3) Install door number 520DT on the left wing main tank and door number 620ET on the right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM 06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure. NOTE: In addition to monitoring the fuel tank access doors for leaks during the installation, monitor all areas of the rear spar changed during the accomplishment of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed areas. (4) Install previously removed 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 MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures. (5) Go to work step 3.B.9. Condition 2c: Crack Longer than 2.0 Inches in Rear Spar Upper Cap (1) Do Option 1 or Option 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 50 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 51 Option 1 (a) Do doubler repair to rear spar lower cap in accordance with Service Rework Drawing J060271 and splice repair to rear spar upper cap in accordance with Service Rework Drawing J060165. using the applicable service kit as follows: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-7-J060271-517Lower SA90570026-9J060271-518-Lower SA90570026-15-J060165-517Upper SA90570026-17J060165-518-Upper Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-7-J060271-517Lower SA90570026-9J060271-518-Lower SA90570026-27-J060165-523Upper SA90570026-29J060165-524-Upper (b) Do repeat ETHF inspections of rear spar lower cap doubler repair in accordance with Service Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E., Compliance. Option 2 (a) Do splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-23-J060165-521Upper and Lower SA90570026-25J060165-522-Upper and Lower Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-33-J060165-527Upper and Lower BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 51 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 52 Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-35J060165-528-Upper and Lower (b) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E., Compliance. (2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. (3) Install door number 520DT on the left wing main tank and door number 620ET on the right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM 06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure. NOTE: In addition to monitoring the fuel tank access doors for leaks during the installation, monitor all areas of the rear spar changed during the accomplishment of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed areas. (4) Install previously removed 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 MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures. (5) Go to work step 3.B.9. CONDITION 3: CRACK LONGER THAN 2.0 INCHES OR CRACK IN THE REAR SPAR LOWER 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 MD-90 AMM 27-10-00 and MD-90 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 MD-90 AMM 12-11-01, MD-90 AMM 28-00-00 and MD-90 AMM 28-11-00 as accepted procedures. c. Remove and retain door number 520DT on the left wing main tank and/or door number 620CT on the right wing main tank and attaching parts as required. Refer to MD-90 AMM 06-35-00 and MD-90 AMM 06-36-00. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 52 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 53 d. Prepare fuel tanks for entry and gain access to fuel tanks as required to reach attachments in vicinity of wing flap inboard hinge fitting. e. Remove and retain the inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. f. Do Eddy Current High Frequency (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 Service Rework Drawing J060271, General Note 29, and based on inspection results, do as follows: Condition 3a: No Crack in Rear Spar Upper Cap (1) Do splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: Group 1: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-19-J060165-519Lower SA90570026-21J060165-520-Lower Group 2: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-31-J060165-525Lower SA90570026-33J060165-526-Lower (2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E., Compliance. (3) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. (4) Install door number 520DT on the left wing main tank and door number 620ET on the right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM 06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 53 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 54 NOTE: In addition to monitoring the fuel tank access doors for leaks during the installation, monitor all areas of the rear spar changed during the accomplishment of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed areas. (5) Install previously removed 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 MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures. (6) Go to work step 3.B.9. Condition 3b: Crack 2.0 Inches or Shorter in Rear Spar Upper Cap (1) Do Option 1 or Option 2 Option 1 (a) Do 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 Service Rework Drawing J060165. using the applicable service kit as follows: Group 1: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-3-J060271-511Upper SA90570026-5J060271-512-Upper SA90570026-19-J060165-519Lower SA90570026-21J060165-520-Lower Group 2: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-3-J060271-511Upper SA90570026-5J060271-512-Upper SA90570026-31-J060165-525Lower SA90570026-33J060165-526-Lower (b) Do ETHF inspections of rear spar upper cap doubler repair in accordance with Service Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E., Compliance. (c) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E., Compliance. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 54 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 55 Option 2 (a) Do splice repair to rear spar upper and lower cap in accordance with Service Rework Drawing J060165, using the applicable service kit as follows: Group 1: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-23-J060165-521Upper and Lower SA90570026-25J060165-522-Upper and Lower Group 2: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-35-J060165-527Upper and Lower SA90570026-37J060165-528-Upper and Lower (b) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E., Compliance. (2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. (3) Install door number 520DT on the left wing main tank and door number 620ET on the right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM 06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure. NOTE: In addition to monitoring the fuel tank access doors for leaks during the installation, monitor all areas of the rear spar changed during the accomplishment of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed areas. (4) Install previously removed 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 MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures. (5) Go to work step 3.B.9. Condition 3c: Crack Longer than 2.0 Inches in Rear Spar Upper Cap (1) Do splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165, using the applicable service kit as follows: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 55 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 56 Group 1: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-23-J060165-521Upper and Lower SA90570026-25J060165-522-Upper and Lower Group 2: Service KitConfigurationRear Spar Cap Repair Right WingLeft Wing SA90570026-35-J060165-527Upper and Lower SA90570026-37J060165-528-Upper and Lower (2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E., Compliance. (3) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as an accepted procedure. (4) Install door number 520DT on the left wing main tank and door number 620ET on the right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM 06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure. NOTE: In addition to monitoring the fuel tank access doors for leaks during the installation, monitor all areas of the rear spar changed during the accomplishment of this service bulletin for fuel leaks. No fuel leaks are allowed in the repaired areas. (5) Install previously removed 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 MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures. (6) Go to work step 3.B.9. 9. Close inboard and center Bent Up Trailing Edge (BUTE) doors. Refer to MD-90 AMM 57-20-03 as an accepted procedure. 10. If removed, install kept fixed flap fairing(s) using retained attaching parts. 11. 12. Remove door keepers and close main landing gear doors. Refer to MD-90 AMM 32-10-00 as an accepted procedure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 56 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 57 13. Pressurize left and right hydraulic systems. Refer to MD-90 AMM 29-00-00 as an accepted procedure. 14. Retract wing flaps to full up position. Refer to MD-90 AMM 27-50-00 as an accepted procedure. 15. Put the airplane back to a serviceable condition. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 11, 2010 MD90-57A026Revision 1: February 23, 2011 57 of 59 BOEING SERVICE BULLETIN MD90-57A026 ALERTALERT ### Page 58 (OCR) BOEING SERVICE BULLETIN MD90-57A026 ALERT ALERT STATION Xrs=164.000 SCAN DIRECTION SCAN DIRECTION REAR SPAR LOOKING FORWARD LEFT SIDE SHOWN 1901593 FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH FREQUENCY INSPECTION (SHEET 1 OF 2) Original Issue: February 11, 2010 Revision 1 February 23, 2011 MD90-57A026 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 59 ### Page 59 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. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (a) (b)15911301-XXXLower Rear Spar CapInspect (Scan 1) Eddy Current Testing High Frequency (ETHF) 1 (a) (b)15911300-XXXUpper Rear Spar CapInspect (Scan 2) Eddy Current Testing High Frequency (ETHF) 2 Note: Inspec- tion not re- quired when Lower Rear Spar Cap has no crack. (a) Use calibration scan method "R" and calibrate the N2 notch using DAC GSET AL.01 in accordance with NDTSPM 06-10-01.001 , Procedure 1. Scan wing rear spar upper and lower caps with method 45. (b) The -XXX represents the different dash numbered spar caps that may exist on the airplane. FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH FREQUENCY INSPECTION (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 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