Commercial 

Airplanes 727

Service Bulletin

SPECIAL ATTENTION

Number: 727-55-0094

Original Issue: March 21, 2012

ATA System: 5520

SUBJECT: STABILIZERS - Horizontal Stabilizer - Elevator Rear Spar Stiffener Assembly, Inspection

and Replacement

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

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Copyright © 2012 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Unpublished Work - All Rights Reserved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

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3.0
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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 17

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

FIGURE 1: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSPECTION . . . . . 24

FIGURE 2: LEFT SIDE ELEVATOR UPPER SKIN PANEL - PARTIAL REMOVAL . . . . . . . . . . . 26

FIGURE 3: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - REMOVAL . . . . . . . 28

FIGURE 4: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION . . . . 30

FIGURE 5: LEFT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION . . . . . . . . . . . . . . 33

FIGURE 6: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSPECTION . . . . . 36

FIGURE 7: RIGHT SIDE ELEVATOR UPPER SKIN PANEL - PARTIAL REMOVAL . . . . . . . . . . 38

FIGURE 8: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - REMOVAL . . . . . . 40

FIGURE 9: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION . . . 42

FIGURE 10: RIGHT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION . . . . . . . . . . . . . 45

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BLANK PAGE
Commercial 

Airplanes 727

Service Bulletin

SPECIAL ATTENTION

Summary Number: 727-55-0094

Original Issue: March 21, 2012

ATA System: 5520

SUBJECT: STABILIZERS - Horizontal Stabilizer - Elevator Rear Spar Stiffener Assembly, Inspection

and Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin is sent to inspect for cracks in the elevator rear spar stiffener assembly at the Right Side

Elevator Station 56.70 and the Left Side Elevator Station 63.30. These locations are common to the Tab Control

Rod tunnel. Service Bulletin (SB) 727-55-0089 addresses elevator rear spar web cracking at the elevator tab

hinge fittings. That service bulletin contains a rear spar replacement modification. The elevator rear spar stiffener

assembly has been inspected as part of that service bulletin and, or as needed, replaced in the process of

replacing the elevator rear spar. Fit-up stress in the elevator rear spar stiffener assembly can be present after

accomplishment of SB 727-55-0089 and can cause cracking. During accomplishment of SB 727-55-0089 an

operator reported a crack on the elevator rear spar stiffener assembly. Undetected cracks in the elevator rear

spar stiffener assembly and spar web could adversely affect elevator stiffness, which can lead to elevator vibration

and possible interference with the tab control rod, which can result in unsafe flight conditions.

Boeing Service Related Problem (SRP) 727-SRP-55-0051 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

AD Related No Paragraph 1.E., Compliance

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected No Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required No Paragraph 2.C.1., Kits/Parts

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Planning Data Affected Reference

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Do a detailed inspection for cracks in the elevator rear spar stiffener assembly at the Right Side Elevator Station

56.70 and the Left Side Elevator Station 63.30. If any crack is found, remove the elevator rear spar stiffener

assembly and install a new elevator rear spar stiffener assembly, and shim as necessary to fill any gaps.

Repeat the inspections at the time given in Paragraph 1.E., Compliance.

EFFECTIVITY

All 727, 727-100, 727-100C, 727-200, 727-200F, 727C Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for

the list of affected airplane(s).

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 replacement given in this service bulletin.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

Group 1 17.90 17.90

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 727-55-0094

BLANK PAGE
Commercial 

Airplanes 727

Service Bulletin

SPECIAL ATTENTION

Number: 727-55-0094

Original Issue: March 21, 2012

ATA System: 5520

SUBJECT: STABILIZERS - Horizontal Stabilizer - Elevator Rear Spar Stiffener Assembly, Inspection

and Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D6-9825 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is for the airplane(s) shown below.

GROUP CONFIGURATION DESCRIPTION

1 - All 727, 727-100, 727-100C, 727-200, 727-200F, 727C airplanes.

Airplane Models:

727, 727-100, 727-100C, 727-200, 727-200F, 727C

Variable Number Group

E0001 - E0042 1

E0101 - E0140 1

E0201 - E0216 1

E0301 - E0351 1

E0401 - E0423 1

E3001 - E3006 1

E3011 - E3014 1

E3021 - E3040 1

E3059 1

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Variable Number Group

E3061 - E3077 1

E3101 - E3103 1

E3111 - E3118 1

E3141 - E3152 1

E3171 - E3177 1

E3201 - E3206 1

E3221 - E3224 1

E3241 - E3290 1

E3341 - E3350 1

E3401 - E3421 1

E3451 - E3452 1

E3471 - E3474 1

E3501 - E3513 1

E3516 - E3523 1

E3551 - E3553 1

E3571 - E3578 1

E3601 - E3604 1

E3621 - E3622 1

E3651 - E3655 1

E3677 1

E3681 - E3684 1

E3701 - E3704 1

E3751 - E3755 1

E3781 - E3784 1

E5001 - E5011 1

E5031 - E5068 1

E5101 - E5116 1

E5141 - E5143 1

E5161 - E5164 1

E5201 - E5203 1

E5221 - E5245 1

E5251 - E5252 1

E5271 - E5281 1

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BOEING SERVICE BULLETIN 727-55-0094
Variable Number Group

E5301 - E5306 1

E5351 - E5353 1

E5381 - E5382 1

E5401 - E5424 1

E5426 - E5429 1

E5433 1

E5435 1

E5451 - E5455 1

E5481 - E5483 1

E5501 - E5502 1

QA001 - QA046 1

QA051 - QA099 1

QA101 - QA199 1

QA201 - QA225 1

QA301 - QA349 1

QA351 - QA376 1

QA378 1

QA401 - QA499 1

QA501 - QA537 1

QA551 - QA579 1

QA581 - QA585 1

QA601 - QA688 1

QA701 - QA753 1

QA801 - QA805 1

QA851 - QA899 1

QA901 - QA946 1

QA949 1

QB001 - QB002 1

QB031 - QB049 1

QB051 - QB068 1

QB101 - QB110 1

QB114 - QB119 1

QB121 - QB149 1

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Variable Number Group

QB151 - QB158 1

QB201 - QB220 1

QB301 - QB316 1

QB351 - QB352 1

QB401 - QB407 1

QB451 - QB458 1

QB501 - QB575 1

QB601 - QB629 1

QB651 1

QB701 - QB705 1

QB801 - QB810 1

QB901 - QB904 1

QD001 - QD012 1

QD031 - QD046 1

QD085 - QD088 1

QD101 - QD105 1

QD121 - QD127 1

QD141 - QD149 1

QD161 - QD164 1

QD191 - QD192 1

QD201 - QD239 1

QD281 - QD284 1

QD301 - QD305 1

QD321 - QD330 1

QD351 1

QD401 - QD403 1

QD407 1

QD410 1

QD421 - QD427 1

QD441 - QD453 1

QD471 - QD475 1

QD501 - QD518 1

QD551 - QD558 1

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BOEING SERVICE BULLETIN 727-55-0094
Variable Number Group

QD571 - QD572 1

QD581 - QD583 1

QD601 - QD607 1

QD621 - QD624 1

QD641 1

QD661 - QD663 1

QD681 - QD685 1

QD691 - QD692 1

QD701 - QD702 1

QD711 - QD717 1

QD741 1

QD761 - QD769 1

QD781 - QD782 1

QD791 1

QD801 - QD804 1

QD821 - QD828 1

QD901 - QD910 1

QD931 - QD932 1

QD951 - QD954 1

QD971 - QD973 1

QD991 - QD992 1

QE001 - QE002 1

QL001 - QL008 1

QL031 - QL032 1

QL081 1

QL501 - QL515 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

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BOEING SERVICE BULLETIN 727-55-0094
C. Reason

This service bulletin is sent to inspect for cracks in the elevator rear spar stiffener assembly at the Right

Side Elevator Station 56.70 and the Left Side Elevator Station 63.30. These locations are common to

the Tab Control Rod tunnel. Service Bulletin (SB) 727-55-0089 addresses elevator rear spar web

cracking at the elevator tab hinge fittings. That service bulletin contains a rear spar replacement

modification. The elevator rear spar stiffener assembly has been inspected as part of that service

bulletin and, or as needed, replaced in the process of replacing the elevator rear spar. Fit-up stress in

the elevator rear spar stiffener assembly can be present after accomplishment of SB 727-55-0089 and

can cause cracking. During accomplishment of SB 727-55-0089 an operator reported a crack on the

rear spar stiffener assembly. Undetected cracks in the elevator rear spar stiffener assembly and spar

web could adversely affect elevator stiffness, which can lead to elevator vibration and possible

interference with the tab control rod, which can result in unsafe flight conditions.

Boeing Service Related Problem (SRP) 727-SRP-55-0051 is related to this service bulletin.

D. Description

Do a detailed inspection for cracks in the elevator rear spar stiffener assembly at the Right Side Elevator

Station 56.70 and the Left Side Elevator Station 63.30. If any crack is found, remove the elevator rear

spar stiffener assembly and install a new elevator rear spar stiffener assembly, and shim as necessary

to fill any gaps.

Repeat the inspections at the time given in Paragraph 1.E., Compliance.

NOTE: If the damaged area is more than the specified limits, write to Boeing for repair

instructions. Give the size and location of the damage. When possible, send sketches

and photographs. If the damage includes corrosion, send data on the length, width,

and largest depth of clean up.

1.

Send to:

BOEING COMMERCIAL AIRPLANES GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones

Model Zone

727, 727-100, 727-100C, 727- 3-93, 3-94

200, 727-200F, 727C

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.

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BOEING SERVICE BULLETIN 727-55-0094
Table 1: Inspection for cracks in the Elevator Rear Spar Stiffener Assembly

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

4,000 flight hours,

3,000 flight cycles,

or 24 months,

whichever occurs

first. (a)

Within 4,000 flight

hours, 3,000 flight

cycles, or 24

months, whichever

occurs first from

the original issue

date of this service

bulletin.

Do a Detailed Inspection

for cracks in the elevator

rear spar stiffener assembly in accordance with

Accomplishment Instructions 3.B., PART 2 and

PART 3.

All airplanes.

Before further -

flight.

Replace the left elevator

rear spar stiffener assembly in accordance with

Accomplishment Instructions 3.B., PART 4.

Any crack found in the left

elevator rear spar stiffener

assembly.

Before further -

flight.

Replace the right elevator

rear spar stiffener assembly in accordance with

Accomplishment Instructions 3.B., PART 5.

Any crack found in the right

elevator rear spar stiffener

assembly.

(a) The replacement of the elevator rear spar stiffener assembly in accordance with Accomplishment Instructions 3.B., PART 4 or PART 5 terminates the inspections given in Table

1 for the replaced elevator rear spar stiffener assembly only. After replacement of the elevator rear spar stiffener assembly, do the post modification inspections in accordance with

Table 2.

Table 2: Post Modification Inspection for cracks in the Elevator Rear Spar Stiffener Assembly

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

4,000 flight hours,

3,000 flight cycles,

or 24 months,

whichever occurs

first.

Within 96 months

after the replacement of the elevator rear spar stiffener assembly.

Do a Detailed Inspection

of the replaced elevator

rear spar stiffener assembly in accordance with the

applicable Accomplishment Instructions 3.B.,

PART 2 or PART 3.

All airplanes with an elevator rear spar stiffener assembly replaced in accordance with this service bulletin.

Before further (a)

flight.

Replace the left elevator

rear spar stiffener assembly in accordance with

Accomplishment Instructions 3.B., PART 4.

Any crack found in the left

elevator rear spar stiffener

assembly.

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BOEING SERVICE BULLETIN 727-55-0094
Table 2: Post Modification Inspection for cracks in the Elevator Rear Spar Stiffener Assembly

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further (a)

flight.

Replace the right elevator

rear spar stiffener assembly in accordance with

Accomplishment Instructions 3.B., PART 5.

Any crack found in the right

elevator rear spar stiffener

assembly.

(a) The replacement of the elevator rear spar stiffener assembly in accordance with Accomplishment Instructions 3.B., PART 4 or PART 5 does not terminate the inspections given

in Table 2.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

G. Manpower

The table below shows an estimate of the task hours necessary to do this service bulletin for each

airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with

operator task hour data if necessary. The estimate does not include lost time. These are some examples

of lost time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 1.50 1.50

FIGURE 1 1 1.00 1.00

FIGURE 2 1 2.50 2.50

FIGURE 3 1 0.60 0.60

FIGURE 4 1 0.60 0.60

FIGURE 5 1 2.50 2.50

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BOEING SERVICE BULLETIN 727-55-0094
Task Number of Persons Task Hours Elapsed Hours

FIGURE 6 1 1.00 1.00

FIGURE 7 1 2.50 2.50

FIGURE 8 1 0.60 0.60

FIGURE 9 1 0.60 0.60

FIGURE 10 1 2.50 2.50

Close Access 1 1.50 1.50

Test 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 17.90 17.90

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

J. References

1. Existing Data

a. Boeing Service Bulletin 727-55-0089

b. Standard Overhaul Practices Manual (SOPM) 20-50-12

c. 727 Aircraft Maintenance Manual (AMM) 27-30-00, 27-30-11

d. Service Bulletin Index D6-9825

e. Boeing Service Related Problem (SRP) 727-SRP-55-0051

2. Data supplied with this Service Bulletin

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin

Drawing Number Title

65-16935 REAR SPAR INSTL - INBD. ELEV HORIZ STAB

The table above lists the applicable drawing used to prepare this service bulletin. The drawing is

not necessary to make the specified changes, and is not supplied with this service bulletin. The

drawing may not be applicable to all airplane configurations or operators.

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BOEING SERVICE BULLETIN 727-55-0094
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 but no new DTIs are necessary.

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 727-55-0094
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection and/or repair given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

Part Number / QTY Name Notes

Specification

69-19144-1 2 Stiffener Assembly (a) (c)

BACS40R020B052F 8 Shim (a)

BACR15BB5D5C 10 Rivet (a) (b) (d)

BACR15CE5D5C 96 Rivet (a) (b) (d)

BACR15CE5D6C 12 Rivet (a) (b) (d)

BACR15FP5E3C 32 Rivet (a) (b) (d)

BACR15FP5E2C 20 Rivet (a) (b) (d)

BACB30VW5P03UX 4 Bolt, Blind (a) (b)

BACR15BA5D4C 4 Rivet (a) (b) (e)

(a) Quantities shown are for both the left and right side elevator rear spar stiffener assembly

replacement.

(b) Refer to 727 Structural Repair Manual Chapter 51 for alternate fasteners.

(c) The Boeing Company (V81205), 7755 E. Marginal Way, Seattle, WA 98108-4002, USA.

(d) It is acceptable to use an oversize rivet of 1/32.

(e) Use to make countersink repair washer.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

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D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BOEING SERVICE BULLETIN 727-55-0094
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. 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 and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque limits to tighten nuts and bolts are in SRM Chapter 51

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

6. 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.

7. 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.

8. 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.

B. WORK INSTRUCTIONS

1. PART 1 - PREPARATION

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a. Depressurize the elevator hydraulic systems A and B. Refer to 727 AMM 27-30-00 as an

accepted procedure.

2. PART 2 - LEFT SIDE INSPECTION

a. Prepare the area for safe work. Refer to Part 1 as an accepted procedure.

b. Get access to the aft section of the left elevator rear spar (stiffener assembly). Refer to FIGURE

1 for stiffener assembly location and access.

c. Do a detailed inspection of the upper surface of the stiffener assembly in accordance with

FIGURE 1.

(1) If any crack is found, replace the stiffener assembly in accordance with PART 4.

d. Get access to the tab rod cut-out. Refer to FIGURE 1 for stiffener assembly location.

e. Do a detailed inspection of the lower surface of the stiffener assembly in accordance with

FIGURE 1.

(1) If any crack is found, replace the stiffener assembly in accordance with PART 4.

f. If work on the elevators is complete, put the airplane back to a serviceable condition. Refer

to part 6 as an accepted procedure.

3. PART 3 - RIGHT SIDE INSPECTION

a. Prepare the area for safe work. Refer to Part 1 as an accepted procedure.

b. Get access to the aft section of the right elevator rear spar (stiffener assembly). Refer to

FIGURE 6 for stiffener assembly location and access.

c. Do a detailed inspection of the upper surface of the stiffener assembly in accordance with

FIGURE 6.

(1) If any crack is found, replace the stiffener assembly in accordance with PART 5.

d. Get access to the tab rod cut-out. Refer to FIGURE 6 for stiffener assembly location.

e. Do a detailed inspection of the lower surface of the stiffener assembly in accordance with

FIGURE 6.

(1) If any crack is found, replace the stiffener assembly in accordance with PART 5.

f. If work on the elevators is complete, put the airplane back to a serviceable condition. Refer

to part 6 as an accepted procedure.

4. PART 4 - LEFT SIDE STIFFENER ASSEMBLY REPLACEMENT

a. Prepare the area for safe work. Refer to Part 1 as an accepted procedure.

b. Remove and keep the left side elevator tab. Refer to 727 AMM 27-30-11 as an accepted

procedure.

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c. Partially remove the upper skin panel of the elevator, and get access to the stiffener assembly

in accordance with FIGURE 2 .

d. Remove the stiffener assembly in accordance with FIGURE 3.

e. Install new stiffener assembly in accordance with FIGURE 4.

f. Install the partially removed upper skin panel in accordance with FIGURE 5.

g. Install the kept left side elevator tab. Refer to 727 AMM 27-30-11 as an accepted procedure.

h. If work on the elevators is complete, put the airplane back to a serviceable condition. Refer

to part 6 as an accepted procedure.

5. PART 5 - RIGHT SIDE STIFFENER ASSEMBLY REPLACEMENT

a. Prepare the area for safe work. Refer to Part 1 as an accepted procedure.

b. Remove and keep the right side elevator tab. Refer to 727 AMM 27-30-11 as an accepted

procedure.

c. Partially remove the upper skin panel of the elevator, and get access to the stiffener assembly

in accordance with FIGURE 7 .

d. Remove the stiffener assembly in accordance with FIGURE 8.

e. Install new stiffener assembly in accordance with FIGURE 9.

f. Install the partially removed upper skin panel in accordance with FIGURE 10.

g. Install the kept right side elevator tab. Refer to 727 AMM 27-30-11 as an accepted procedure.

h. If work on the elevators is complete, put the airplane back to a serviceable condition. Refer

to part 6 as an accepted procedure.

6. PART 6 - PREPARE FOR SERVICE

a. Pressurize the elevator hydraulic systems A and B. Refer to 727 AMM 27-30-00 as an accepted

procedure.

b. Do a functional test of the elevator tab. Refer to 727 AMM 27-30-00 as an accepted procedure.

c. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 727-55-0094
FIGURE 1: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 727-55-0094
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 this figure.

Step Task Name Identification Qty More Data

Elevator Rear Spar 69-19144-1 1 (a) (c)

Stiffener Assembly,

Upper Surface

1 Inspect

Elevator Rear Spar 69-19144-1 1 (b) (c)

Stiffener Assembly,

Lower Surface

2 Inspect

(a) Do a detailed inspection of the upper surface of the elevator rear spar stiffener assembly for cracks.

(b) Do a detailed inspection of the lower surface of the elevator rear spar stiffener assembly for cracks, inspect

the exposed area along the length of the stiffener to within 0.5 inches from the vertical web.

(c) Use of a Borescope is acceptable for this inspection.

FIGURE 1: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSPECTION

(SHEET 2 OF 2)

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FIGURE 2: LEFT SIDE ELEVATOR UPPER SKIN PANEL - PARTIAL REMOVAL

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 727-55-0094
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 this figure.

Step Task Name Identification Qty More Data

1 Remove Fasteners - - (a)

CAUTION: WHEN YOU LIFT THE UPPER SKIN PANEL MAKE SURE YOU DO NOT CREASE THE UPPER

SKIN PANEL.

2 Lift Upper Skin Panel - 1 (b)

(a) Remove the fasteners shown as a circle symbol first. If access to the rear spar stiffener assembly is not

possible continue to remove the fasteners moving forward until access is possible.

(b) Lift back the skin panel fastener row by fastener row to get access to the elevator rear spar stiffener assembly.

FIGURE 2: LEFT SIDE ELEVATOR UPPER SKIN PANEL - PARTIAL REMOVAL

(SHEET 2 OF 2)

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FIGURE 3: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - REMOVAL

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 727-55-0094
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 this figure.

Step Task Name Identification Qty More Data

Elevator Rear Spar 69-19144-1 1 -

Stiffener Assembly

1 Remove

Remove Fasteners - 17 -

FIGURE 3: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - REMOVAL

(SHEET 2 OF 2)

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FIGURE 4: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 727-55-0094
FIGURE 4: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 727-55-0094
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 this figure.

Step Task Name Identification Qty More Data

Elevator Rear Spar 69-19144-1 1 (a)

Stiffener Assembly

1 Install (New)

Install (New) Shim BACS40R020B052F 2 (b) (c) (d)

(a) Any gaps are not to exceed 0.003 inches.

(b) Install shims as necessary to fill any gaps greater than 0.003 inches.

(c) Cut shims to match the profile of the elevator rear spar stiffener assembly.

(d) Make sure there is clearance for the tab rod cutout in the rear spar.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

A Rivet BACR15BB5D5C 5 0.159 - 0.171 (a)

B Rivet BACR15CE5D5C 12 0.159 - 0.171 (a)

(a) It is acceptable to use an oversize rivet of 1/32.

FIGURE 4: LEFT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 727-55-0094
FIGURE 5: LEFT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 727-55-0094
FIGURE 5: LEFT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 727-55-0094
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 this figure.

Step Task Name Identification Qty More Data

1 Install (Kept) Upper Skin Panel - 1 -

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

A Rivet BACR15CE5D5C 36 0.159 - 0.171 (c)

B Rivet BACR15CE5D6C 6 0.159 - 0.171 (c)

C Rivet BACR15FP5E2C 10 0.176 - 0.180 (c)

D Rivet BACR15FP5E3C 16 0.176 - 0.180 (c)

E Rivet BACR15CE5D6C 6 0.159 - 0.171 (a) (c)

F Rivet BACR15CE5D5C 6 0.159 - 0.171 (a) (c)

G Bolt, Blind BACB30VW5P03UX 2 0.180 - 0.183 (b)

(a) Use as necessary if additional fasteners were removed for access.

(b) Make a repair washer from BACR15BA5D4C rivets to fill countersink.

(c) It is acceptable to use an oversize rivet of 1/32.

FIGURE 5: LEFT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 727-55-0094
FIGURE 6: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 727-55-0094
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 this figure.

Step Task Name Identification Qty More Data

Elevator Rear Spar 69-19144-1 1 (a) (c)

Stiffener Assembly,

Upper Surface

1 Inspect

Elevator Rear Spar 69-19144-1 1 (b) (c)

Stiffener Assembly,

Lower Surface

2 Inspect

(a) Do a detailed inspection of the upper surface of the elevator rear spar stiffener assembly for cracks.

(b) Do a detailed inspection of the lower surface of the elevator rear spar stiffener assembly for cracks, inspect

the exposed area along the length of the stiffener to within 0.5 inches from the vertical web.

(c) Use of a Borescope is acceptable for this inspection.

FIGURE 6: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSPECTION

(SHEET 2 OF 2)

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FIGURE 7: RIGHT SIDE ELEVATOR UPPER SKIN PANEL - PARTIAL REMOVAL

(SHEET 1 OF 2)

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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 this figure.

Step Task Name Identification Qty More Data

1 Remove Fasteners - - (a)

CAUTION: WHEN YOU LIFT THE UPPER SKIN PANEL MAKE SURE YOU DO NOT CREASE THE UPPER

SKIN PANEL.

2 Lift Skin Panel - 1 (b)

(a) Remove the fasteners shown as a circle symbol first. If access to the rear spar stiffener assembly is not

possible continue to remove the fasteners moving forward until access is possible.

(b) Lift back the skin panel fastener row by fastener row to get access to the elevator rear spar stiffener assembly..

FIGURE 7: RIGHT SIDE ELEVATOR UPPER SKIN PANEL - PARTIAL REMOVAL

(SHEET 2 OF 2)

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FIGURE 8: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - REMOVAL

(SHEET 1 OF 2)

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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 this figure.

Step Task Name Identification Qty More Data

Elevator Rear Spar 69-19144-1 - -

Stiffener Assembly

1 Remove

Remove Fasteners - 17 -

FIGURE 8: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - REMOVAL

(SHEET 2 OF 2)

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FIGURE 9: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION

(SHEET 1 OF 3)

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FIGURE 9: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 727-55-0094
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 this figure.

Step Task Name Identification Qty More Data

Elevator Rear Spar 69-19144-1 1 (a)

Stiffener Assembly

1 Install (New)

Install (New) Shim BACS40R020B052F 2 (b) (c) (d)

(a) Any gaps are not to exceed 0.003 inches.

(b) Install shims as necessary to take-up any gaps.

(c) Cut shims to match the profile of the elevator rear spar stiffener assembly.

(d) Make sure there is clearance for the tab rod cutout in the rear spar.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

A Rivet BACR15BB5D5 5 0.159 - 0.171 (a)

B Rivet BACR15CE5D5C 12 0.159 - 0.171 (a)

(a) It is acceptable to use an oversize rivet of 1/32.

FIGURE 9: RIGHT SIDE ELEVATOR REAR SPAR STIFFENER ASSEMBLY - INSTALLATION

(SHEET 3 OF 3)

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FIGURE 10: RIGHT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION

(SHEET 1 OF 3)

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FIGURE 10: RIGHT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION

(SHEET 2 OF 3)

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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 this figure.

Step Task Name Identification Qty More Data

1 Close Skin Panel - 1 (a)

(a) If any additional fasteners were removed for access forward of the ones shown, replace with Code E

fasteners at the center section of the doubler and Code F fasteners at the two outside sections of the

doubler.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

A Rivet BACR15CE5D5C 36 0.159 - 0.171 (c)

B Rivet BACR15CE5D6C 6 0.159 - 0.171 (c)

C Rivet BACR15FP5E2C 10 0.176 - 0.180 (c)

D Rivet BACR15FP5E3C 16 0.176 - 0.180 (c)

E Rivet BACR15CE5D6C 6 0.159 - 0.171 (a) (c)

F Rivet BACR15CE5D5C 6 0.159 - 0.171 (a) (c)

G Bolt, Blind BACB30VW5P03UX 2 0.180 - 0.183 (b)

(a) Use as necessary.

(b) Make a repair washer from MS20426D5-4 rivets to fill countersink.

(c) It is acceptable to use an oversize rivet of 1/32.

FIGURE 10: RIGHT SIDE ELEVATOR UPPER SKIN PANEL - INSTALLATION

(SHEET 3 OF 3)

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