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.

ECCN: 9E991

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Unpublished Work - All Rights Reserved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.

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5.0
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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: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)

- LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 4: DETAILED 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

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
FIGURE 8: DETAILED AND SURFACE HFEC INSPECTIONS OF VERTICAL INNER CHORD (INTERNAL)

- RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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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:

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— 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

Original Issue: March 30, 2006

Revision 1: March 12, 2009

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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.

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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 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.

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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

Airplanes Total Task Hours Elapsed Hours

All 15.00 10.50

MATERIAL INFORMATION

Operator Supplied Parts/Materials (if repairs are necessary).

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
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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.

NOTE: 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

GROUP CONFIGURATION DESCRIPTION

1 - All 767-200/-300/-300F/-400ER airplanes.

Airplane Models:

767-200, 767-300, 767-300F, 767-400ER

Variable Number Group

VA001 - VA020 1

VA301 - VA315 1

VA501 - VA530 1

VA701 - VA719 1

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Variable Number Group

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 1

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
Variable Number Group

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 1

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
Variable Number Group

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 1

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
Variable Number Group

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 1

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
Variable Number Group

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 1

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
Variable Number Group

VT531 - VT533 1

VT541 - VT543 1

VV001 1

VW701 - VW721 1

VW851 1

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.

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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.

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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

Model Zone

767-200, 767-300, 767-300F, 313, 314

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.

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
Table 1: Recommended Compliance times for STA 1809.5 Bulkhead Forward Outer Chord, Horizontal

and Vertical Inner Chord, and Skin Inspections

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs Later)Condition Action

6,000 flight cyclesWithin 3,000 flight

cycles after the

date on the original issue of this

service bulletin

Before 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 cyclesWithin 3,000 flight

cycles after the

date on the original issue of the

Service Bulletin

Before 15,000 total flight cyclesDo 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 cyclesWithin 3,000 flight

cycles after the

date on Revision

01 of the service

bulletin

Before 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, PARTS

1-4, have been accomplished.

Do PART 6 - Detailed and

HFEC Inspections of Vertical

Inner Chord - Right Side (f)

Before further - -

flight

Repair 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.

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
Table 1: Recommended Compliance times for STA 1809.5 Bulkhead Forward Outer Chord, Horizontal

and Vertical Inner Chord, and Skin Inspections

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs Later)Condition Action

(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.

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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.

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2.0 1.00 0.50

Figure 1 - Detailed Inspection of Skin - 1 1.00 1.00

Left Side (a)

Figure 2 - Detailed Inspection of Skin - 1 1.00 1.00

Right Side (a)

Figure 3 - Detailed and Surface HFEC 2 3.50 1.75

Inspections of Forward Outer Chord - Left

Hand (a)

Figure 4 - Detailed and Surface HFEC 2 3.50 1.75

Inspections of Forward Outer Chord -

Right Hand (a)

Figure 5 - Detailed and Surface HFEC 1 1.00 1.00

Inspections of Horizontal Inner Chord -

Left Hand (a)

Figure 6 - Detailed and Surface HFEC 1 1.00 1.00

Inspections of Horizontal Inner Chord -

Right Hand (a)

Figure 7 - Detailed and Surface HFEC 1 1.00 1.00

Inspections of Vertical Inner Chord - Left

Hand (a)

Figure 8 - Detailed and Surface HFEC 1 1.00 1.00

Inspections of Vertical Inner Chord - Right

Hand (a)

Close Access 2.0 1.00 0.50

TOTAL FOR EACH AIRPLANE 15.00 10.50

(a) Additional time will be required for repairs if cracks are found.

H. Weight and Balance Changes

None.

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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:

Drawing Number Title

148T2140 Bulkhead Installation - Upper, Horizontal Stabilizer Pivot, STA 1809.5

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.

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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.

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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.

NOTE: 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.

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT

BLANK PAGE
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.

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:

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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:

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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.

PART 1 - DETAILED INSPECTION OF SKIN (EXTERNAL). DETAILED AND HFEC INSPECTIONS

OF FORWARD 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.

PART 2 - DETAILED INSPECTION OF SKIN (EXTERNAL). DETAILED AND HFEC INSPECTIONS

OF FORWARD 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.

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
PART 3 - DETAILED AND HFEC INSPECTIONS OF HORIZONTAL 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.

PART 4 - DETAILED AND HFEC INSPECTIONS OF HORIZONTAL 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.

PART 5 - DETAILED AND HFEC INSPECTIONS OF VERTICAL 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 .

PART 6 - DETAILED AND HFEC INSPECTIONS OF VERTICAL 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.

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ALERT ALERT
FIGURE 1: DETAILED INSPECTION OF SKIN (EXTERNAL) - STA 1809.5 - LEFT SIDE

(SHEET 1 OF 2)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Skin - -

Do a detailed inspection in the

area shown.

2 Inspect Skin - -

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

(SHEET 2 OF 2)

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

(SHEET 1 OF 2)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Skin - -

Do a detailed inspection in the

area shown.

2 Inspect Skin - -

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

(SHEET 2 OF 2)

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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)

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

NOTE: Pay special attention to the radius of the Forward Outer Chord during the following inspections.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Bulkhead Structure - -

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 Outer - -

Chord and Bulkhead Structure

2 Inspect

FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)

- LEFT SIDE

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Do a Surface HFEC inspection

in 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

3 Inspect

FIGURE 3: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)

- LEFT SIDE

(SHEET 3 OF 3)

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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)

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Original Issue: March 30, 2006

Revision 1 March 12, 2009 767-53A0131

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.

NOTE: Pay special attention to the radius of the Forward Outer Chord during the following inspections.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Bulkhead Structure - -

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 Outer - -

Chord and Bulkhead Structure

2 Inspect

FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)

- RIGHT SIDE

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Do a Surface HFEC inspection

in 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

3 Inspect

FIGURE 4: DETAILED AND SURFACE HFEC INSPECTIONS OF FORWARD OUTER CHORD (INTERNAL)

- RIGHT SIDE

(SHEET 3 OF 3)

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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)

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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

Revision 1 March 12, 2009 767-53A0131

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.

NOTE: Pay special attention to the machined step radii and the flange in the area indicated.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Bulkhead Structure - -

Do a detailed inspection in the

area 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 Inner - -

Chord and Bulkhead Structure

2 Inspect

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

3 Inspect

(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)

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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)

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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

Revision 1 March 12, 2009 767-53A0131

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.

NOTE: Pay special attention to the machined step radii and the flange in the area indicated.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Bulkhead Structure - -

Do a detailed inspection in the

area 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 Inner - -

Chord and Bulkhead Structure

2 Inspect

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

3 Inspect

(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)

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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)

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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

Revision 1 March 12, 2009 767-53A0131

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.

NOTE: Pay special attention to the fillet radii and the flange in the area indicated.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Bulkhead Structure - -

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 and

a minimum of 5.0 inches inboard and outboard from the

HFEC inspection area.(a)

Vertical Inner - -

Chord and Bulkhead Structure

2 Inspect

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

3 Inspect

(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)

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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)

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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

Revision 1 March 12, 2009 767-53A0131

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.

NOTE: Pay special attention to the fillet radii and the flange in the area indicated.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in the inspection area shown.

Removal of finish is not necessary. Refer to SOPM 20-30-

03.

1 Clean Bulkhead Structure - -

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 and

a minimum of 5.0 inches inboard and outboard from the

HFEC inspection area.(a)

Vertical Inner - -

Chord and Bulkhead Structure

2 Inspect

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

3 Inspect

(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)

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BOEING SERVICE BULLETIN 767-53A0131

ALERT ALERT