### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-53A0131**  Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 **SUBJECT:** FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 1 of 52 5.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 2 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet ............................................ 5 Summary ..................................................... 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 23 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 25 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 25 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE . . . . . . . 31 FIGURE 2: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - RIGHT SIDE . . . . . . . 33 FIGURE 3: DET AILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 4: DET AILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FIGURE 5: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 FIGURE 6: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 3 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 4 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 767-53A0131** Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 **SUBJECT:** FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin. More work is necessary on airplanes that have been inspected as given in the initial release of this service bulletin. At the time of the next inspection, do the inspections as given in this revision. No airplane was added to the service bulletin effectivity. **REASON FOR REVISION** This revision is sent to give a clarification for the horizontal inner chord inspection and add surface HFEC inspection for the vertical inner chord. The following sections of the service bulletin are affected: — In SUBJECT, the words "and Vertical" was added to the title. — In Paragraph 1.D., Description, added Affected Maintenance Zones table. — In Paragraph 1.E., Compliance, added FAA AD 2006-24-04 reference. — In Figures 5 and 6, Detailed and Surface HFEC Inspections of Horizontal Inner Chord (Internal) - Left Side and Right Side, respectively; a clarification was added to inspect only the exposed surfaces of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips. — Additional surface HFEC inspection was added for the vertical inner chord installed on the aft of Station (STA) 1809.5 bulkhead in the area of Buttock Line (BL) 28.5, Water Line (WL) 257. The surface HFEC inspection is to the flange and fillet radius of the vertical inner chord around the four (4) fasteners that pass through both vertical and horizontal inner chord. Subsequent to the release of the original Service Bulletin 767-53A0131, one operator reported that the STA 1809.5 bulkhead vertical inner chord was found cracked at RBL 28.5, WL 257. The crack was discovered while accomplishing STA 1809.5 bulkhead inspection. Boeing Service Related Problem (SRP) 767-SRP-53-0320 is related to this vertical inner chord cracking. — The following sections of the service bulletin are affected by the addition of the surface HFEC inspection of the vertical inner chord:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 5 of 52— In Paragraph 1.E., Compliance, added compliance times for the vertical inner chord inspection. — In Figures 5 and 6, a detailed inspection of the aft side of the bulkhead structure was moved to Figures 7 and 8. — Figures 7 and 8 were added for the detailed and surface HFEC inspections of the vertical inner chord inspection.

Vertical lines are put on the left edge of each page show the location of important changes. **REVISION HISTORY** March 30, 2006 Original Issue: March 12, 2009 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 6 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Summary**  **Number: 767-53A0131** Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 **SUBJECT:** FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection 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** Accomplishment of the inspections in this service bulletin will make sure that cracks in the bulkhead structure at Station (STA) 1809.5 are found and repaired. If not repaired, cracks in the bulkhead structure at STA 1809.5 could become large and result in the inability of the STA 1809.5 bulkhead structure to carry horizontal stabilizer flight loads. This will have adverse effects on airplane controllability, and could cause loss of control of the airplane. Two operators have reported finding fatigue cracks in the forward outer chord of the STA 1809.5 airframe bulkhead. A total of seven outer chord cracks were found on four different airplanes. The outer chord cracks were located between stringers 4 and 8 (left side and right side), and were found on airplanes that had between 13,942 and 29,588 total flight cycles. A crack, similar to those found in the forward outer chords on operators airplanes, was also found on the Boeing fatigue test airplane. Three operators also reported finding a crack in the horizontal inner chord that spans between stringer 12L and stringer 12R. A total of seven horizontal chord cracks were found on seven different airplanes. The horizontal chord cracks were at the lower flange near Buttock Line (BL) 28, and were found on airplanes that had between 8,448 and 35,991 total flight cycles. In addition, one operator found small cracks in the external skin at STA 1809.5 between stringers 6 and 8 on the same airplane that also had approximately a one inch crack in the forward outer chord. After the original release of this service bulletin, one operator found a fatigue crack in the vertical inner chord while doing the detailed inspection of the horizontal inner chord. A surface High Frequency Eddy Current (HFEC) inspection was done to confirm the crack. The crack was found on the right side of the structure at a fastener hole near BL 28.5, Water Line (WL) 257; common to both the horizontal and vertical inner chord. The vertical inner chord crack was found on an airplane with 28,234 total flight cycles.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 7 of 52This service bulletin gives instructions to do inspections for cracks in the STA 1809.5 bulkhead forward outer chord, the horizontal inner chord, the vertical inner chord, and the external skin. If cracks are found in the forward outer chord, horizontal inner chord, or vertical inner chord, repairs per the applicable Structural Repair Manual (SRM) will be necessary. If cracks are found in the skin, Boeing will provide repair instructions. Boeing Service Related Problem (SRP) 767-SRP-53-0263 is related to the original issue of this service bulletin. Boeing SRP 767-SRP-53-0320 is related to this service bulletin. **ACTION** Get access to the upper skin on the outside of the airplane at STA 1809.5. Do an external detailed inspection of the skin on each side of the airplane, between stringers 3 and 10. Get access to the internal structure on the forward side of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure between stringers 3L and 10L, and between stringers 3R and 10R, in the area of the forward outer chord. Do a surface HFEC inspection of the forward outer chord for cracks between stringers 4L and 8L, and between stringers 4R and 8R. Get access to the internal structure on the forward and aft sides of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure at the intersection of the vertical inner chord and ends of the horizontal inner chord that spans between stringer 12L and stringer 12R on forward and aft sides of the STA 1809.5 bulkhead. Do a surface HFEC inspection for cracks in the ends of the horizontal inner chord. Do a surface HFEC inspection for cracks in the vertical inner chord common to the horizontal inner chord at approximately BL 28.5, WL 257. If cracks are found in the forward outer chord, horizontal inner chord, and/or vertical inner chord, repair as specified in the applicable Structural Repair Manual (SRM). If cracks are found in the skin, or if cracks are found in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord, contact Boeing for repair instructions. **EFFECTIVITY** All 767-200/-300/-300F/-400ER airplanes. Refer to Service Bulletin Paragraph 1.A.1. for effectivity. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin. Refer to Service Bulletin Paragraph 1.E. for information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 8 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT INDUSTRY SUPPORT INFORMATION**  Boeing warranty remedies are available for airplanes in warranty as of December 1, 2004. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  10.50 15.00 All
**MATERIAL INFORMATION** Operator Supplied Parts/Materials (if repairs are necessary).

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 9 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 10 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-53A0131**  Original Issue: March 30, 2006 Revision 1: March 12, 2009 ATA System: 5383 5385 **SUBJECT:** FUSELAGE - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection 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 Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. **NO TE:**  This Service Bulletin is for the airplanes identified below. The Effectivity list shown below is complete for airplanes through line number 983. Airplanes after line number 983 are also affected by this service bulletin, and are in Group(s): 1
**DESCRIPTION CONFIGURATION**  **GROUP** All 767-200/-300/-300F/-400ER airplanes.

- 1

Airplane Models: 767-200, 767-300, 767-300F, 767-400ER **Group Variable Number**  1 VA001 - VA020 1 VA301 - VA315 1 VA501 - VA530 1 VA701 - VA719

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 11 of 52**Group Variable Number**  1 VA801 - VA810 1 VB001 - VB002 1 VB051 - VB055 1 VB101 - VB125 1 VB201 - VB202 1 VB251 - VB253 1 VB281 - VB284 1 VB301 - VB302 1 VB321 - VB332 1 VB371 - VB373 1 VB401 1 VB441 - VB444 1 VE001 - VE003 1 VE021 - VE023 1 VE041 - VE043 1 VE061 - VE069 1 VE083 - VE086 1 VE101 - VE104 1 VE116 - VE118 1 VE121 - VE126 1 VE141 - VE152 1 VE171 - VE172 1 VF001 - VF002 1 VF041 - VF042 1 VF051 1 VF061 - VF062 1 VF071 - VF072 1 VF091 - VF093 1 VF101 - VF102 1 VF161 - VF162 1 VF171 - VF172 1 VF180 - VF184 1 VF251

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 12 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT Group**  **Variable Number** 1 VK001 - VK016 1 VK021 - VK022 1 VK031 - VK056 1 VK081 - VK113 1 VK131 - VK133 1 VK141 - VK148 1 VK161 - VK164 1 VK171 1 VK181 1 VK186 1 VL001 - VL006 1 VL011 1 VL701 - VL703 1 VL751 - VL755 1 VL806 - VL807 1 VL871 - VL873 1 VL891 - VL900 1 VL911 - VL914 1 VL931 - VL932 1 VL941 1 VN001 - VN041 1 VN051 - VN064 1 VN081 - VN099 1 VN111 - VN127 1 VN130 - VN137 1 VN151 - VN158 1 VN163 - VN168 1 VN171 - VN174 1 VN191 - VN198 1 VN211 - VN212 1 VN221 - VN225 1 VN231 - VN234 1 VN241 - VN243

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 13 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT Group**  **Variable Number** 1 VN251 - VN276 1 VN291 - VN293 1 VN301 - VN314 1 VN371 - VN372 1 VN376 1 VN381 - VN388 1 VN421 - VN427 1 VN436 1 VN471 - VN472 1 VN491 - VN513 1 VN531 - VN532 1 VN536 - VN537 1 VN541 - VN542 1 VN546 - VN547 1 VN551 1 VN556 - VN557 1 VN561 - VN562 1 VN631 - VN638 1 VN651 - VN658 1 VN671 - VN672 1 VN676 1 VN681 - VN691 1 VN731 - VN732 1 VN751 - VN753 1 VN791 - VN792 1 VN811 - VN813 1 VN921 - VN922 1 VN931 - VN936 1 VN951 - VN953 1 VN966 - VN972 1 VQ001 - VQ021 1 VQ071 - VQ086 1 VQ111

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 14 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT Group**  **Variable Number** 1 VR051 - VR060 1 VR081 1 VR084 1 VR086 - VR089 1 VR106 - VR109 1 VR201 - VR211 1 VR251 1 VR256 - VR260 1 VR266 - VR267 1 VR401 1 VR421 - VR423 1 VR426 1 VR441 1 VR461 1 VR471 - VR472 1 VS051 - VS056 1 VS061 1 VS066 - VS070 1 VS073 - VS078 1 VS091 - VS104 1 VS111 - VS113 1 VS131 - VS133 1 VS136 - VS137 1 VS176 - VS177 1 VS186 - VS187 1 VS196 - VS203 1 VS206 - VS208 1 VS211 1 VS216 - VS217 1 VS231 1 VS246 - VS248 1 VS261 - VS263 1 VS266 - VS274

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 15 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT Group**  **Variable Number** 1 VS291 - VS293 1 VS301 - VS303 1 VS306 - VS311 1 VS316 1 VS321 - VS324 1 VS331 - VS333 1 VS336 - VS337 1 VS366 - VS367 1 VS381 - VS382 1 VS391 - VS392 1 VS401 1 VS426 - VS428 1 VS466 - VS472 1 VS486 1 VS496 - VS497 1 VS506 - VS507 1 VS526 1 VS546 - VS549 1 VS701 - VS736 1 VS751 - VS759 1 VS821 - VS825 1 VS841 - VS844 1 VS861 1 VS881 - VS883 1 VS891 1 VS896 1 VS901 - VS912 1 VS916 1 VS921 - VS922 1 VS931 - VS933 1 VT501 1 VT511 - VT513 1 VT521 - VT523

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 16 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT Group**  **Variable Number** 1 VT531 - VT533 1 VT541 - VT543 1 VV001 1 VW701 - VW721 1 VW851 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** Accomplishment of the inspections in this service bulletin will make sure that cracks in the bulkhead structure at Station (STA) 1809.5 are found and repaired. If not repaired, cracks in the bulkhead structure at STA 1809.5 could become large and result in the inability of the STA 1809.5 bulkhead structure to carry horizontal stabilizer flight loads. This will have adverse effects on airplane controllability, and could cause loss of control of the airplane. Two operators have reported finding fatigue cracks in the forward outer chord of the STA 1809.5 airframe bulkhead. A total of seven outer chord cracks were found on four different airplanes.The outer chord cracks were located between stringers 4 and 8 (left side and right side), and were found on airplanes that had between 13,942 and 29,588 total flight cycles. A crack, similar to those found in the forward outer chords on operators airplanes, was also found on the Boeing fatigue test airplane. Three operators also reported finding a crack in the horizontal inner chord that spans between stringer 12L and stringer 12R. A total of seven horizontal chord cracks were found on seven different airplanes. The horizontal chord cracks were at the lower flange near Buttock Line (BL) 28, and were found on airplanes that had between 8,448 and 35,991 total flight cycles. In addition, one operator found small cracks in the external skin at STA 1809.5 between stringers 6 and 8 on the same airplane that also had approximately a one inch crack in the forward outer chord. After the original release of this service bulletin, one operator found a fatigue crack in the vertical inner chord while doing the detailed inspection of the horizontal inner chord. A surface High Frequency Eddy Current (HFEC) inspection was done to confirm the crack. The crack was found on the right side of the structure at a fastener hole near BL 28.5, Water Line (WL) 257; common to both the horizontal and vertical inner chord. The vertical inner chord crack was found on an airplane with 28,234 total flight cycles. This service bulletin gives instructions to do inspections for cracks in the STA 1809.5 bulkhead forward outer chord, the horizontal inner chord, the vertical inner chord, and the external skin. If cracks are found in the forward outer chord, horizontal inner chord, or vertical inner chord, repairs per the applicable Structural Repair Manual (SRM) will be necessary. If cracks are found in the skin, Boeing will provide repair instructions.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 17 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**Boeing Service Related Problem (SRP) 767-SRP-53-0263 is related to the original issue of this service bulletin. Boeing SRP 767-SRP-53-0320 is related to this service bulletin. Federal Aviation Administration (FAA) has issued an Airworthiness Directive FAA AD 2006-24-04, which requires incorporation of this service bulletin. Revision 1 is sent to give the following information in this service bulletin: — In SUBJECT, the words "and Vertical" was added to the title. — In Paragraph 1.D., Description, added Affected Maintenance Zones table. — In Paragraph 1.E., Compliance, FAA AD 2006-24-04 was added. — In FIGURE 5 and FIGURE 6, Detailed and Surface HFEC Inspections of Horizontal Inner Chord (Internal) - Left Side and Right Side, respectively; a clarification was added to inspect only the exposed surfaces of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips. — Additional surface HFEC inspection was added for the vertical inner chord installed on the aft of STA 1809.5 bulkhead in the area of BL 28.5, WL 257.The surface HFEC inspection is to the flange and fillet radius of the vertical inner chord around the four (4) fasteners that pass through both vertical and horizontal inner chord. — The following sections of the service bulletin are affected by the addition of the surface HFEC inspection of the vertical inner chord: — In Paragraph 1.E., Compliance, added compliance times for the vertical inner chord inspection. — In FIGURE 5 and FIGURE 6, a detailed inspection of the aft side of the bulkhead structure was moved to FIGURE 7 and FIGURE 8. — FIGURE 7 and FIGURE 8 were added for the detailed and surface HFEC inspections of the vertical inner chord inspection.
**D. Description** Get access to the upper skin on the outside of the airplane at STA 1809.5. Do an external detailed inspection of the skin on each side of the airplane, between stringers 3 and 10. Get access to the internal structure on the forward side of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure between stringers 3L and 10L, and between stringers 3R and 10R, in the area of the forward outer chord. Do a surface HFEC inspection of the forward outer chord for cracks between stringers 4L and 8L, and between stringers 4R and 8R. Get access to the internal structure on the forward and aft sides of the STA 1809.5 bulkhead. Do a detailed inspection for cracks in the structure at the intersection of vertical inner chord and ends of the horizontal inner chord that spans between stringer 12L and stringer 12R on forward and aft sides of the STA 1809.5 bulkhead. Do a surface HFEC inspection for cracks in the ends of the horizontal inner chord. Do a surface HFEC inspection for cracks in the vertical inner chord common to the horizontal inner chord at approximately BL 28.5, WL 257.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 18 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**If cracks are found in the forward outer chord, horizontal inner chord, and/or vertical inner chord, repair as specified in the applicable Structural Repair Manual (SRM). If cracks are found in the skin, or if cracks are found in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord, contact Boeing for repair instructions. Because of common access, operators should consider doing the inspections, repairs, and/or modifications given in the following service bulletins at the same time as the inspections and/or repairs given in this service bulletin: — For 767 airplanes, line numbers 1 - 709: Boeing Service Bulletin 767-53A0078 "FUSELAGE - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and Modification". — For 767-200, -300, and -300F airplanes, line numbers 811 - 887, 889, 890: Boeing Service Bulletin 767-53-0110 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework". — For 767-400 airplanes, line numbers 809 - 878: Boeing Service Bulletin 767-53-0111 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework". — For all 767 airplanes: Boeing Service Bulletin 767-53-0118 "FUSELAGE - Section 48 - STA 1725.5 Aft Skin and Bulkhead Outer Chord Strap - Inspection and Repair". Revision 1 - More work is necessary on airplanes that have been inspected as given in the initial release of this service bulletin. At the time of the next inspection, do the inspections as given in this revision. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 313, 314 767-200, 767-300, 767-300F, 767-400ER **E. Compliance** The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2006-24-04 is related to this service bulletin. Boeing recommends that operators do the inspections given in this service bulletin at the times shown in Table 1.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 19 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT T**  **ab le 1:** **Recommended Compliance times f or ST**  **A 1809.5 Bulkhead Forwar d Outer Chor** **d, Horizontal**  **and V**  **er tical** **Inner Chor d,** **and Skin Inspections Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever Oc**  **curs Later) Action**  **Condition** 6,000 flight cycles Within 3,000 flight cycles after thedate on the original issue of this service bulletinBefore 15,000 total flight cyclesDo PART 1 - Detailed Inspection of Skin. Detailed and HFEC Inspections of Forward Outer Chord - Left Side (a) All Airplanes

Do PART 2 - Detailed Inspection of Skin. Detailed and HFEC Inspections of Forward Outer Chord - Right Side (b) Do PART 3 - Detailed and HFEC Inspections of Horizontal Inner Chord - Left Side (c) Do PART 4 - Detailed and HFEC Inspections of Horizontal Inner Chord - Right Side (d) 6,000 flight cycles Within 3,000 flight cycles after thedate on the original issue of the Service BulletinBefore 15,000 total flight cycles Do PART 5 - Detailed and HFEC Inspections of Vertical Inner Chord - Left Side (e) Airplanes on which Boeing Service Bulletin 767- 53A0131, PARTS 1-4, have not been accomplished. Do PART 6 - Detailed and HFEC Inspections of Vertical Inner Chord - Right Side (f) 6,000 flight cycles Within 3,000 flight cycles after the date on Revision 01 of the service bulletinBefore 15,000 total flight cycles or within 6,000 flight cycles after the previous PARTS 1-4 inspection, which ever occurs later Do PART 5 - Detailed and HFEC Inspections of Vertical Inner Chord - Left Side (e) Airplanes on which Boeing Service Bulletin 767- 53A0131, PARTS1-4, have been accomplished. Do PART 6 - Detailed and HFEC Inspections of Vertical Inner Chord - Right Side (f)

- - Before further flightRepair as given in the Accomplishment Instructions, Paragraphs 3.B.3 through 3.B.9, as applicable. Crack found

(a) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 9, 767-300 SRM 53-80-08, Repair 9, 767-300F SRM 53-80-08, Repair 9, or 767-400 SRM 53-80-08, Repair 9 is terminating action for the PART 1 repeat inspections of this service bulletin. Continue the PART 2, PART 3, PART 4, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (b) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 9, 767-300 SRM 53-80-08, Repair 9, 767-300F SRM 53-80-08, Repair 9, and 767-400 SRM 53-80-08, Repair 9 is terminating action for the PART 2 repeat inspections of this service bulletin. Continue the PART 1, PART 3, PART 4, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 20 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT T**  **ab le 1:** **Recommended Compliance times f or ST**  **A 1809.5 Bulkhead Forwar d Outer Chor** **d, Horizontal**  **and V**  **er tical** **Inner Chor d,** **and Skin Inspections Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever Oc**  **curs Later) Action**  **Condition** (c) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 10, 767-300 SRM 53-80-08, Repair 10, 767-300F SRM 53-80-08, Repair 10, and 767-400 SRM 53-80-08, Repair 10 is terminating action for the PART 3 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 4, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (d) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 10, 767-300 SRM 53-80-08, Repair 10, 767-300F SRM 53-80-08, Repair 10, and 767-400 SRM 53-80-08, Repair 10 is terminating action for the PART 4 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 3, PART 5, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (e) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 11, 767-300 SRM 53-80-08, Repair 11, 767-300F SRM 53-80-08, Repair 11, and 767-400 SRM 53-80-08, Repair 11 is terminating action for the PART 5 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 3, PART 4, and PART 6 inspections, at the repeat interval given, unless those inspections have also been terminated. (f) Accomplishment of a repair as given in 767-200 SRM 53-80-08, Repair 11, 767-300 SRM 53-80-08, Repair 11, 767-300F SRM 53-80-08, Repair 11, and 767-400 SRM 53-80-08, Repair 11 is terminating action for the PART 6 repeat inspections of this service bulletin. Continue the PART 1, PART 2, PART 3, PART 4, and PART 5 inspections, at the repeat interval given, unless those inspections have also been terminated. **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. This service bulletin has been approved by the FAA. In addition, the Manager of the Seattle Aircraft Certification Office approves the repair procedures and the inspection methods specified in Table 1, under paragraph 1.E., "Compliance," of Service Bulletin 767-53A0131, Revision 1, as an AMOC to the repair procedures and the inspection methods specified in Table 1 under paragraph 1.E., "Compliance," of Service Bulletin 767-53A0131, dated March 30, 2006, required by paragraph (f) and (g) of AD 2006-24-04. All provisions of AD 2006-24-04 that are not specifically referenced in the preceeding sentence remain fully applicable and must be complied with.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 21 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT 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 examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

0.50 1.00 2.0 Open Access 1.00 1.00 1 Figure 1 - Detailed Inspection of Skin - Left Side (a) 1.00 1.00 1 Figure 2 - Detailed Inspection of Skin - Right Side (a) 1.75 3.50 2 Figure 3 - Detailed and Surface HFEC Inspections of Forward Outer Chord - Left Hand (a) 1.75 3.50 2 Figure 4 - Detailed and Surface HFEC Inspections of Forward Outer Chord - Right Hand (a) 1.00 1.00 1 Figure 5 - Detailed and Surface HFEC Inspections of Horizontal Inner Chord - Left Hand (a) 1.00 1.00 1 Figure 6 - Detailed and Surface HFEC Inspections of Horizontal Inner Chord - Right Hand (a) 1.00 1.00 1 Figure 7 - Detailed and Surface HFEC Inspections of Vertical Inner Chord - Left Hand (a) 1.00 1.00 1 Figure 8 - Detailed and Surface HFEC Inspections of Vertical Inner Chord - Right Hand (a) 0.50 1.00 2.0 Close Access 10.50 15.00 TOTAL FOR EACH AIRPLANE (a) Additional time will be required for repairs if cracks are found. **H. Weight and Balance Changes** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 22 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT I. Electrical Load Data**  Not changed. **J. References** 1. Existing Data: a. 767-200 Structural Repair Manual (SRM) 53-80-08 b. 767-300 Structural Repair Manual (SRM) 53-80-08 c. 767-300F Structural Repair Manual (SRM) 53-80-08 d. 767-400 Structural Repair Manual (SRM) 53-80-08 e. 767 Aircraft Maintenance Manual (AMM) 06-42-00 f. 767 Non-Destructive Testing (NDT) Manual, Part 6, 51-00-01 or 51-00-19 g. Boeing Service Bulletin 767-53-0110 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework" h. Boeing Service Bulletin 767-53-0111 "FUSELAGE - Section 48 - Body Station 1809 Bulkhead - Forward Outer Chord Inspection and Fastener Hole Rework" i. Boeing Service Bulletin 767-53-0118 "FUSELAGE - Section 48 - STA 1725.5 Aft Skin and Bulkhead Outer Chord Strap - Inspection and Repair" j. Boeing Service Bulletin 767-53A0078 "FUSELAGE - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and Modification" k. Boeing Service Related Problem (SRP) 767-SRP-53-0263 l. Standard Overhaul Practices Manual (SOPM) 20-30-03 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  Bulkhead Installation - Upper, Horizontal Stabilizer Pivot, STA 1809.5 148T2140 This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin.This drawing may not be applicable to all airplane configurations or operators.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 23 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT K. Publications Affected**  None. **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: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 24 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** None. **B. Industry Support Information** Boeing warranty remedies are available for 767 airplanes in warranty as of December 1, 2004. For inspection task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours, parts, and/or special tools are required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: None. **NO TE:**  No parts or materials are required for inspection. However, if repairs are necessary, the materials shown in the applicable Structural Repair Manual sections will be necessary. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 25 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 26 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CA UTION:**  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. **NO TE:**  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. 4. 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. 5. These work instructions refer to procedures included on 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 "as given in" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS** 1. Do the initial PART 1 through PART 6 inspections within the compliance time given in Paragraph 1.E., Compliance. 2. If no cracks are found, repeat PART 1 through PART 6 inspections at the repeat interval given in Paragraph 1.E., Compliance. 3. If cracks are found in the skin, or if cracks are found in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord, do the following: a. Repair the skin and/or structure before further flight. Contact Boeing for repair instructions. b. Repeat PART 1 through PART 6 inspections at the interval given in Paragraph 1.E., Compliance, except for any inspections that have been terminated by accomplishing terminating action. 4. If cracks are found in the forward outer chord during a PART 1 inspection, do the following:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 27 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 9, or 767-300 SRM 53-80-08, Repair 9, or 767-300F SRM 53-80-08, Repair 9, or 767-400 SRM 53-80-08, Repair 9. b. Repeat PART 2, PART 3, PART 4, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.4.a. terminates the PART 1 repetitive inspections given in Paragraph 1.E., Compliance. 5. If cracks are found in the forward outer chord during a PART 2 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 9, or 767-300 SRM 53-80-08, Repair 9, or 767-300F SRM 53-80-08, Repair 9, or 767-400 SRM 53-80-08, Repair 9. b. Repeat PART 1, PART 3, PART 4, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.5.a. terminates the PART 2 repetitive inspections given in Paragraph 1.E., Compliance. 6. If cracks are found in the horizontal inner chord during a PART 3 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 10, or 767-300 SRM 53-80-08, Repair 10, or 767-300F SRM 53-80-08, Repair 10, or 767-400 SRM 53-80-08, Repair 10. b. Repeat PART 1, PART 2, PART 4, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.6.a. terminates the PART 3 repetitive inspections given in Paragraph 1.E., Compliance. 7. If cracks are found in the horizontal inner chord during a PART 4 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 10, or 767-300 SRM 53-80-08, Repair 10, or 767-300F SRM 53-80-08, Repair 10, or 767-400 SRM 53-80-08, Repair 10. b. Repeat PART 1, PART 2, PART 3, PART 5, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.7.a. terminates the PART 4 repetitive inspections given in Paragraph 1.E., Compliance. 8. If cracks are found in the vertical inner chord during a PART 5 inspection, do the following:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 28 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 11, or 767-300 SRM 53-80-08, Repair 11, or 767-300F SRM 53-80-08, Repair 11, or 767-400 SRM 53-80-08, Repair 11. b. Repeat PART 1, PART 2, PART 3, PART 4, and PART 6 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.8.a. terminates the PART 5 repetitive inspections given in Paragraph 1.E., Compliance. 9. If cracks are found in the vertical inner chord during a PART 6 inspection, do the following: a. Before further flight, repair as given in 767-200 SRM 53-80-08, Repair 11, or 767-300 SRM 53-80-08, Repair 11, or 767-300F SRM 53-80-08, Repair 11, or 767-400 SRM 53-80-08, Repair 11. b. Repeat PART 1, PART 2, PART 3, PART 4, and PART 5 inspections at the interval given in Paragraph 1.E., Compliance, unless those inspections have been terminated by accomplishing terminating action. Accomplishment of the applicable repair as given in paragraph 3.B.9.a. terminates the PART 6 repetitive inspections given in Paragraph 1.E., Compliance. 10. Put the airplane back to a serviceable condition. **P**

**AR T 1 - DET**  **AILED INSPECTION OF SKIN (EXTERNAL). DET**  **AILED AND HFEC INSPECTIONS OF FOR** **W ARD OUTER CHORD (INTERNAL) - LEFT SIDE**  1. Get access to the exterior of the airplane skin at STA 1809.5 between stringers 3L and 10L. 2. Do a detailed inspection of the exterior of the skin for cracks, as given in FIGURE 1. 3. Get access to the forward side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 4. Do detailed and surface HFEC inspections of the forward outer chord and surrounding structure between stringers 3L and 10L, as given in FIGURE 3. **P**

**AR T 2 - DET**  **AILED INSPECTION OF SKIN (EXTERNAL). DET**  **AILED AND HFEC INSPECTIONS OF FOR** **W ARD OUTER CHORD (INTERNAL) - RIGHT SIDE**  1. Get access to the exterior of the airplane skin at STA 1809.5 between stringers 3R and 10R. 2. Do a detailed inspection of the exterior of the skin for cracks, as given in FIGURE 2. 3. Get access to the forward side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 4. Do detailed and surface HFEC inspections of the forward outer chord and surrounding structure between stringers 3R and 10R, as given in FIGURE 4.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 29 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT P**  **AR T 3 - DET**  **AILED AND HFEC INSPECTIONS OF HORIZONT AL INNER CHORD - LEFT SIDE**  1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the end of the horizontal inner chord and surrounding structure on the left side of the STA 1809.5 bulkhead, as given in FIGURE 5. **P**

**AR T 4 - DET**  **AILED AND HFEC INSPECTIONS OF HORIZONT AL INNER CHORD - RIGHT SIDE**  1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the end of the horizontal inner chord and surrounding structure on the right side of the STA 1809.5 bulkhead, as given in FIGURE 6. **P**

**AR T 5 - DET**  **AILED AND HFEC INSPECTIONS OF VER** **TICAL INNER CHORD - LEFT SIDE** 1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the vertical inner chord and surrounding structure on the left side of the STA 1809.5 bulkhead, as given in FIGURE 7 . **P**

**AR T 6 - DET**  **AILED AND HFEC INSPECTIONS OF VER** **TICAL INNER CHORD - RIGHT SIDE** 1. Get access to the forward side and aft side of the STA 1809.5 bulkhead. Get access through access panel 312AR. Refer to 767 AMM 06-42-00. 2. Do detailed and HFEC inspections of the vertical inner chord and surrounding structure on the right side of the STA 1809.5 bulkhead, as given in FIGURE 8.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1: March 12, 2009 30 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 31 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Skin Clean 1

Do a detailed inspection in the area shown. - - Skin Inspect 2

**FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 32 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 2: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - RIGHT SIDE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 33 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Skin Clean 1

Do a detailed inspection in the area shown. - - Skin Inspect 2

**FIGURE 2: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - RIGHT SIDE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 34 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)**  **- LEFT SIDE (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 35 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NO TE:**  Pay special attention to the radius of the Forward Outer Chord during the following inspections.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Bulkhead Structure Clean 1

Do a detailed inspection of the Forward Outer Chord in the area shown. Also do a detailed inspection of the Bulkhead Structure a minimum of 1.0 inch past the flanges of the Forward Outer Chord. - - Forward OuterChord and Bulkhead Structure Inspect 2

**FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 36 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Do a Surface HFEC inspectionin the area shown, between S4L and S-8L, as given in 767 NDT, Part 6, 51-00-01 or 51- 00-19. - - Forward Outer Chord Inspect 3

**FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - LEFT SIDE**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 37 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)**  **- RIGHT SIDE (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 38 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NO TE:**  Pay special attention to the radius of the Forward Outer Chord during the following inspections.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Bulkhead Structure Clean 1

Do a detailed inspection of the Forward Outer Chord in the area shown. Also do a detailed inspection of the Bulkhead Structure a minimum of 1.0 inch past the flanges of the Forward Outer Chord. - - Forward OuterChord and Bulkhead Structure Inspect 2

**FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 39 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Do a Surface HFEC inspectionin the area shown, between S4R and S-8R, as given in 767 NDT, Part 6, 51-00-01 or 51- 00-19. - - Forward Outer Chord Inspect 3

**FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL) - RIGHT SIDE**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 40 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 5: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL)**  **- LEFT SIDE (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 41 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 5: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL)**  **- LEFT SIDE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 42 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NO TE:**  Pay special attention to the machined step radii and the flange in the area indicated.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Bulkhead Structure Clean 1

Do a detailed inspection in thearea shown. Inspect the forward side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below the Horizontal Inner Chord, and a minimum of 5.0 inches inboard and outboard from the HFEC inspection area.(a) - - Horizontal InnerChord and Bulkhead Structure Inspect 2

Do a Surface HFEC inspection of the vertical and horizontal flanges in the inspection area shown, as given in 767 NDT, Part 6, 51-00-01 or 51-00-19. (a) - - Horizontal Inner Chord Inspect 3

(a) Inspect only the exposed surfaces including edges of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips.

**FIGURE 5: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - LEFT SIDE**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 43 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 6: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL)**  **- RIGHT SIDE (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 44 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 6: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL)**  **- RIGHT SIDE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 45 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NO TE:**  Pay special attention to the machined step radii and the flange in the area indicated.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Bulkhead Structure Clean 1

Do a detailed inspection in thearea shown. Inspect the forward side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below the Horizontal Inner Chord, and a minimum of 5.0 inches inboard and outboard from the HFEC inspection area. (a) - - Horizontal InnerChord and Bulkhead Structure Inspect 2

Do a Surface HFEC inspection of the vertical and horizontal flanges in the inspection area shown, as given in 767 NDT, Part 6, 51-00-01 or 51-00-19. (a) - - Horizontal Inner Chord Inspect 3

(a) Inspect only the exposed surfaces including edges of the ends of the horizontal inner chord without the removal of existing splice straps, radius fillers, and support clips.

**FIGURE 6: DETAILED AND SURFACE HFEC INSPECTIONS OF HORIZONTAL INNER CHORD (INTERNAL) - RIGHT SIDE**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 46 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) -**  **LEFT SIDE (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 47 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) -**  **LEFT SIDE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 48 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NO TE:**  Pay special attention to the fillet radii and the flange in the area indicated.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Bulkhead Structure Clean 1

Do a detailed inspection in the area shown. Inspect the aft side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below anda minimum of 5.0 inches inboard and outboard from the HFEC inspection area.(a) - - Vertical InnerChord and Bulkhead Structure Inspect 2

Do a Surface HFEC inspection of the vertical flanges in the inspection area shown, as given in 767 NDT, Part 6, 51- 00-01 or 51-00-19.(a) - - Vertical Inner Chord Inspect 3

(a) Inspect only the exposed surfaces including edges of the vertical inner chord. This inspection does not require removal of any adjacent structure or fasteners.

**FIGURE 7: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - LEFT SIDE**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 49 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) -**  **RIGHT SIDE (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 50 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) -**  **RIGHT SIDE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 51 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NO TE:**  Pay special attention to the fillet radii and the flange in the area indicated.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in the inspection area shown.Removal of finish is not necessary. Refer to SOPM 20-30- 03. - - Bulkhead Structure Clean 1

Do a detailed inspection in the area shown. Inspect the aft side of the Bulkhead Structure. Inspect a minimum of 3.0 inches above and below anda minimum of 5.0 inches inboard and outboard from the HFEC inspection area.(a) - - Vertical InnerChord and Bulkhead Structure Inspect 2

Do a Surface HFEC inspection of the vertical flanges in the inspection area shown, as given in 767 NDT, Part 6, 51- 00-01 or 51-00-19.(a) - - Vertical Inner Chord Inspect 3

(a) Inspect only the exposed surfaces including edges of the vertical inner chord. This inspection does not require removal of any adjacent structure or fasteners.

**FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL) - RIGHT SIDE**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 30, 2006 767-53A0131 Revision 1 March 12, 2009 52 of 52 **BOEING SERVICE BULLETIN 767-53A0131 ALERT**  **ALERT**