**McDonnell Douglas** 

### Commercial **Airplanes** 

# DC9 Service Bulletin **Number: DC9-57-223** Original Issue: July 21, 2003 Revision 1: August 13, 2009 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 1 of 45 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 2 of 45 **BOEING SERVICE BULLETIN DC9-57-223**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 27 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 29 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 29 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION . 36 FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION . 42

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 3 of 45 **BOEING SERVICE BULLETIN DC9-57-223**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 4 of 45 **BOEING SERVICE BULLETIN DC9-57-223**

BLANK PAGE**McDonnell Douglas** 

### Commercial **Airplanes** 

# DC9 Service Bulletin **Revision Transmittal Sheet Number: DC9-57-223**  Original Issue: July 21, 2003 Revision 1: August 13, 2009 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps Inspection This Revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this service bulletin. No more work is necessary on DC-9-10/-20 airplanes as shown in the original issue of this service bulletin. More work is necessary on DC-9-30/-40/-50 airplanes changed as shown in the original issue of this service bulletin. Inspection of the horizontal flange of the center wing rear spar upper cap at station Xcw=58.500 to be accomplished at next repeat interval inspection. **REASON FOR REVISION** This revision is sent to add inspection of the horizontal flange of the left and right rear spar upper cap on DC-9-30/-40/-50 airplanes. These sections were changed: 1. In Paragraph 1.A.1., Airplanes, changed airplane groups. 2. In Paragraph 1.C., Reason, changed to include inspection of the horizontal flange on the inboard side of the rear spar upper cap. 3. In Paragraph 1.D., Description, changed as follows: a. Added Configurations 1, 2, and 3 to Group 1 and 2. b. Added affected maintenance zone tables. 4. In Paragraph 1.E., Compliance, added compliance tables. 5. In Paragraph 1.F., Approval, added Revision 1 and Airworthiness Directive No. 2004-23-11. 6. In Paragraph 1.G., Manpower, added note. 7. In Paragraph 1.H., Weight and Balance Changes, added statement for variable weight changes. 8. In Paragraph 1.J.1, Existing Data, added references previously omitted.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 5 of 459. In Paragraph 3.A., General Information, added new notes 1, 5, and 6. 10. In Paragraph 3.B., Work Instructions, added Configurations 1, 2, and 3 to Groups 1 and 2. 11. In Figure 1, added outboard view. 12. Added Figure 2 for horizontal flange inspection. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** July 21, 2003 Original Issue: August 13, 2009 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 6 of 45 **BOEING SERVICE BULLETIN DC9-57-223 McDonnell Douglas**  

### Commercial **Airplanes** 

# DC9 Service Bulletin **Summary Number: DC9-57-223**  Original Issue: July 21, 2003 Revision 1: August 13, 2009 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps Inspection **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Eleven operators have reported 12 instances of cracking in the vertical leg of the center wing rear spar upper cap at station Xcw=58.500. Further investigation by one operator reported finding two cracks in the horizontal flange on the inboard side of the rear spar upper cap. Investigation by Boeing has determined that cracks resulted from stress corrosion. Inspection of the center wing rear spar upper cap will determine if crack(s) exist. If any crack found is not corrected, fuel leaks and damage to the wing skin or other structure may occur resulting in flight disruptions and unscheduled maintenance. **Service History Landing Cycles**  **Flight-Hours** 25,150 to 88,029 20,100 to 76,183
**ACTION** Refer to Paragraph 1.D., for Description. **EFFECTIVITY** DC-9-14, DC-9-15, DC-9-15F, DC-9-21, DC-9-31, DC-9-32, DC-9-32(VC-9C), DC-9-32F, DC-9-32F(C-9A),DC-9-32F(C-9B), DC-9-33F, DC-9-34, DC-9-34F, DC-9-41 and DC-9-51 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this service bulletin. Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection and repairs given in this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 7 of 45**MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 8 of 45 **BOEING SERVICE BULLETIN DC9-57-223**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 9 of 45 **BOEING SERVICE BULLETIN DC9-57-223**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 10 of 45 **BOEING SERVICE BULLETIN DC9-57-223**

BLANK PAGE**McDonnell Douglas** 

### Commercial **Airplanes** 

# DC9 Service Bulletin **Number: DC9-57-223** Original Issue: July 21, 2003 Revision 1: August 13, 2009 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Left and Right Center Wing Rear Spar Upper Caps Inspection
**1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** DC-9-10 Airplanes

- 1 Airplanes that have accomplished this service bulletin and no crack found 1

Airplanes that have accomplished this service bulletin and did crack repair 2

Airplanes that have not accomplished this service bulletin 3 DC-9-20, 31, -32, -33, -34, -41, -51 Airplanes

- 2 Airplanes that have accomplished this service bulletin and no crack found 1

Airplanes that have accomplished this service bulletin and did crack repair 2

Airplanes that have not accomplished this service bulletin 3

Airplane Models: DC-9-14, DC-9-15, DC-9-15F, DC-9-21, DC-9-31, DC-9-32, DC-9-32(VC-9C), DC-9-32F, DC-9-32F(C-9A), DC-9-32F(C-9B), DC-9-33F, DC-9-34, DC-9-34F, DC-9-41, DC-9-51

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 11 of 45**Group Fuselage Num-**  **ber** 1 10 1 101 2 1014 2 1017 1 102 2 1021 2 1024 2 1027 2 103 2 1030 2 1033 2 1039 2 104 2 1042 2 1044 2 1046 2 1048 2 1050 2 1052 2 1054 2 1056 2 1058 2 108 2 1081 2 1084 1 115 2 117 2 123 - 124 1 125 1 127 1 129 2 130

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 12 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 132 - 133 2 135 - 138 1 139 - 141 2 144 - 145 1 147 1 15 2 150 - 151 2 154 1 156 2 159 1 16 1 165 2 167 - 169 1 17 1 170 2 172 2 174 2 177 1 178 2 179 1 18 2 180 2 183 1 184 - 186 2 187 2 189 1 19 2 190 - 191 2 193 1 194 2 195 2 198

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 13 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  1 2 2 200 2 205 1 207 2 208 2 213 - 214 1 216 2 218 1 219 2 220 - 221 1 224 2 227 1 228 2 229 1 23 2 230 2 232 - 233 1 234 2 235 - 237 2 239 - 240 2 243 2 246 - 247 2 249 2 251 - 252 2 255 - 256 2 258 - 259 2 261 2 263 - 264 2 266 - 268 2 270 2 272 - 273 2 275 - 276

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 14 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 278 - 283 2 286 1 29 2 292 2 294 - 298 1 30 2 300 - 302 2 304 2 308 - 312 2 314 2 317 - 319 1 32 2 320 - 324 2 326 2 329 2 331 2 335 2 337 2 339 1 34 2 340 2 342 - 343 2 347 1 35 2 351 2 353 - 354 2 359 2 364 - 365 2 367 2 369 1 37 2 370

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 15 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 376 - 377 2 382 - 387 2 389 1 39 2 390 - 391 2 394 - 395 2 397 2 399 1 4 2 401 - 402 1 405 1 41 2 411 2 413 2 415 - 416 2 421 2 423 2 425 2 427 2 429 2 438 - 439 2 444 - 447 1 45 2 450 - 452 2 458 - 459 1 46 2 460 2 462 2 464 - 465 2 467 - 469 2 474 2 476

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 16 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 479 - 480 2 482 - 483 2 485 - 492 2 497 - 499 1 50 2 501 - 502 2 505 2 507 1 51 2 511 - 512 2 514 - 515 2 517 - 518 2 520 - 521 2 525 2 527 2 529 - 530 2 533 - 536 2 538 - 539 1 54 2 540 - 541 2 543 - 545 2 547 - 548 1 55 2 550 - 552 2 554 - 555 2 557 2 559 1 56 2 560 2 562 2 564 2 566

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 17 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 568 - 569 1 57 2 573 2 575 - 576 2 583 - 584 2 589 1 59 2 593 2 596 - 599 2 601 - 602 2 604 - 607 2 609 1 61 2 610 - 611 2 616 - 619 1 62 2 621 - 624 2 630 2 632 - 633 2 637 - 638 1 64 2 641 - 647 2 650 2 653 - 656 2 658 - 659 2 661 - 662 2 664 - 665 2 668 - 669 1 67 2 670 - 671 2 673 2 675

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 18 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 677 - 679 1 68 2 683 - 684 2 686 1 69 2 691 - 692 2 694 2 696 2 698 1 7 2 700 2 702 2 704 2 706 - 709 1 71 2 711 - 712 2 714 - 715 2 718 - 719 1 72 2 721 2 723 - 724 2 726 - 728 2 732 2 736 2 740 2 742 - 743 2 747 1 75 2 750 - 751 2 754 2 757 2 759

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 19 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  1 76 2 760 - 761 2 763 2 765 2 768 - 769 2 771 - 774 2 777 - 781 2 783 - 784 2 786 - 788 1 79 2 793 2 795 - 796 2 798 2 801 2 805 - 809 2 81 2 810 - 811 2 813 - 815 2 817 - 819 1 82 2 820 - 823 2 825 - 830 2 833 - 835 2 837 - 838 1 84 2 841 - 843 2 845 2 847 - 848 2 852 - 854 2 857 2 859 2 86

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 20 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 860 - 864 2 87 2 871 - 877 2 879 - 881 2 883 - 884 2 887 - 895 2 899 1 9 1 90 2 900 - 902 2 904 - 905 2 908 2 912 - 915 2 918 - 919 2 921 - 923 2 926 - 927 2 929 1 93 2 930 - 932 2 934 - 937 2 939 1 94 2 940 2 942 - 943 2 945 2 947 2 949 2 95 2 951 2 954 2 956 2 959

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 21 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group**  **Fuselage Num- ber**  2 96 2 961 2 964 2 968 1 97 2 98 2 980 2 982 2 984 2 987 2 99 2 990 2 993 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** Eleven operators have reported 12 instances of cracking in the vertical leg of the center wing rear spar upper cap at station Xcw=58.500. Further investigation by one operator reported finding two cracks in the horizontal flange on the inboard side of the rear spar upper cap. Investigation by Boeing has determined that cracks resulted from stress corrosion. Inspection of the center wing rear spar upper cap will determine if crack(s) exist. If any crack found is not corrected, fuel leaks and damage to the wing skin or other structure may occur resulting in flight disruptions and unscheduled maintenance. **Service History Landing Cycles**  **Flight-Hours** 25,150 to 88,029 20,100 to 76,183 Revision 1 is sent to add inspection of the horizontal flange of the left and right rear spar upper cap on DC-9 airplanes.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 22 of 45 **BOEING SERVICE BULLETIN DC9-57-223 D. Description**  This service bulletin provides instructions for a high frequency eddy current inspection of the left and right center wing rear spar upper cap at station Xcw=58.500 and accomplishes the following: **Group 1, Configuration 1, 3; Group 2, Configuration 1, 3:** 1. Do an Eddy Current, High Frequency (ETHF) inspection of the left and right rear spar upper cap vertical leg and horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead for crack(s) and based on inspection results do as follows: a. Condition 1 (No Crack) Do repetitive ETHF inspection at interval specified in Paragraph 1.E., Compliance. b. Condition 2 (Crack) Contact Boeing for repair instructions and do the repair. **Group 1-2, Configuration 2:** 1. Do an Eddy Current, High Frequency (ETHF) inspection of the left and right rear spar upper cap horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead for crack(s) and based on inspection results do as follows: a. Condition 1 (No Crack) Do repetitive ETHF inspection at interval specified in Paragraph 1.E., Compliance. b. Condition 2 (Crack) Contact Boeing for repair instructions and do the repair. Revision 1 - More work is necessary on DC-9 airplanes changed as shown in the original issue of this service bulletin. Inspection of the horizontal flange of the center wing rear spar upper cap at station Xcw=58.500 to be accomplished at next repeat interval inspection. The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 13, 14, 21, 22, 23 DC-9-14, DC-9-15, DC-9-15F

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 23 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group 2:** 
**Affected Maintenance Zones Zone**  **Model** 13, 14, 21, 22, 23 DC-9-21, DC-9-31, DC-9-32, DC-9-32(VC-9C), DC-9-32F,DC-9-32F(C-9A), DC-9-32F(C9B), DC-9-33F, DC-9-34, DC-9- 34F, DC-9-41, DC-9-51 **E. Compliance** Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this service bulletin. **Group 1-2, Configuration 1: Table 1: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Vertical Leg and Horizontal**  **Flange Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever Occurs First)**  **Action Condition**  Within 5 years after accomplishing ETHF inspection in accordance with the original issue of this service bulletin.Before the accumulation of 15,000 flight cycles after accomplishing ETHF inspection in accordance with the original issue of this service bulletin. Do Eddy Current, HighFrequency (ETHF) inspection of the left and right rear spar upper cap horizontal flange onthe inboard and outboard sides of station Xcw=58.500 bulkheadfor crack(s) in accordance with Accomplishment Instructions 3.B. All Airplanes

AND Do an ETHF inspection of the left and right rear spar upper cap vertical leg on the inboard andoutboard sides of station Xcw=58.500 bulkhead for crack(s) in accordance with Accomplishment Instructions 3.B.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 24 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group 1-2, Configuration 1:**  **Table 1: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Vertical Leg and Horizontal Flange**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs First) Action**  **Condition** 15,000 flight cycles or 5 years, whichever occurs first.Do repeat ETHF inspection of the left and right rear spar upper capvertical leg and horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkheadfor crack(s) in accordance with Accomplishment Instructions 3.B. Condition 1 No crack

Before further flight. Contact Boeing for re- pair instructions and do the repair. Condition 2 Crack

**Group 1-2, Configuration 2: Table 2: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Horizontal Flange**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs First)**  **Action Condition**  Within 5 years after accomplishing ETHF inspection in accordance with the original issue of this service bulletin.Before the accumulation of 15,000 flight cycles after accomplishing ETHF inspection in accordance with the original issue of this service bulletin.Do Eddy Current, High Frequency (ETHF) inspectionof horizontal flange in accordance with Accomplishment Instructions 3.B. All Airplanes

15,000 flight cycles or 5 years, whichever occurs first. Do repeat ETHF inspectionof horizontal flange in accordance with Accomplishment Instructions 3.B. Condition 1 No crack

Before further flight. Contact Boeing for repairinstructions and do the repair. Condition 2 Crack

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 25 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group 1-2, Configuration 3:**  **Table 6: Inspection for Crack(s) on the Left and Right Rear Spar Upper Cap Vertical Leg and Horizontal Flange**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs First)**  **Action Condition**  Within 15,000 flight cyclesBefore the accumulation of 25,000 total flight cycles.Do Eddy Current, High Frequency (ETHF) inspection of the left and right rear spar upper cap vertical leg and horizontal flange on the inboard and outboard sides of station Xcw=58.500bulkhead for crack(s) in accordance with Accomplishment Instructions 3.B. All Airplanes OR5 years after the effective date of AD 2004-23-11.

15,000 flight cycles or 5 years, whichever occurs first. Do repeat ETHF inspection of the left and right rear spar upper cap vertical leg and horizontal flange on the inboard and outboard sides of station Xcw=58.500bulkhead for crack(s) in accordance with Accomplishment Instructions 3.B. Condition 1 No crack

Before further flight. Contact Boeing for repairinstructions and do the repair. Condition 2 Crack

**F. Approval** The resultant modification described in Paragraph 1.D has been shown to comply with the applicable Federal Aviation Regulations, and Revision 1 is approved by the Manager, Los Angeles Aircraft Certification Office, FAA Northwest Mountain Region, and is approved as an alternative method of compliance with Paragraphs (c), (f), and (i) of Airworthiness Directive No. 2004-23-11. **G. Manpower** The table below shows an estimate of the task hours necessary to do this inspection 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 26 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Elapsed**  **Hours Task Hours**  **Number of Persons**  **Task**

2.0 4.0 2 Defuel 4.0 8.0 2 Purge 0.5 1.0 2 Open Access 1.5 3.0 2 Inspect 0.5 1.0 2 Close Access 8.5 17.0 TOTAL FOR EACH AIRPLANE NOTE: If repair required, actual task hours and elapsed hours are contingent upon inspection findings and Boeing disposition and are to be estimated by the operator. **H. Weight and Balance Changes** Weight and balance changes affected by incorporation of this service bulletin are contingent upon the changes to each particular airplane. Weight data is to be computed by the operator by weighing parts removed and parts installed during this change. Necessary revisions should be made to the appropriate airplane weight and balance report. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Non-Destructive Test Standard Practices Manual (NDTSPM) 01-00-03, 06-00-03, 06-00-04, 06-10-01.001 and 06-20-01. b. Standard Wiring Practices Manual (SWPM) 20-10-01. c. DC9 Aircraft Maintenance Manual (AMM) 06-11-01, 06-11-02, 28-00-00 and 28-10-01. d. Federal Aviation Administration (FAA) Airworthiness Directive 2004-23-11 is related to this service bulletin. 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**ADCN DCN/REV**  **Sheet Title**  **Document Number**

- T DWG Spar Cap-Rear Upper Center Wing 5911304 HZ HW DWG Spar Instl-Rear, Wing 9910010

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 27 of 45 **BOEING SERVICE BULLETIN DC9-57-223**These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. **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: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 28 of 45 **BOEING SERVICE BULLETIN DC9-57-223 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** None. **B. Industry Support Information** Boeing warranty remedies are not available for the inspection given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: None. 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** The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Tool price and supply data are not given. **F. Special Tooling Necessary to do this Service Bulletin** To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available. **NOTE:**Designate instrument model used when ordering probe. Equipment /material substitutions producing results equivalent to those defined may also be used. Refer to Part 01, NDTSPM 01-00-03 and Part 06, NDTSPM 06-00-03 for equipment/material information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 29 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Notes**  **Name Tool Number**  May be fabricated by the operator. Eddy Current Reference Standard DAC GSET AL.01 Refer to Part 06, NDTSPM 06-00-04. (a) Eddy Current Flaw Detector NDT24 or Equivalent (b) Eddy Current, High Frequency Probe MP901-50B operating at 50-500 kHz or Equivalent

CAGE Staveley Instruments Can be purchased from: (a) 0M421 1329 East Kemper Road Cincinnati, Ohio 45246 61100 NDT Engineering Corporation Can be purchased from: (b) 19620 Russell Road Kent, Washington 98032

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 30 of 45 **BOEING SERVICE BULLETIN DC9-57-223 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION WARNING:** IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE CAN OCCUR. **CAUTION:**ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE TO THE AIRPLANE OR EQUIPMENT. **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. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. – Tolerance on rivet and bolt edge margin is plus or minus 0.06 inch – Angular tolerance is plus or minus 30 minutes – Hole dimensions for standard solid rivets are given in DC-9 SRM, Chapter 51 – Torque limits to tighten nuts and bolts are given in DC-9 SRM, Chapter 51. 4. Obey all of the warnings and cautions given in the specified manual sections. 5. 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. 6. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 31 of 45 **BOEING SERVICE BULLETIN DC9-57-223 B. WORK INSTRUCTIONS**  **Group 1, Configuration 1, 3; Group 2, Configuration 1, 3: Airplanes that have Accomplished the Initial Release of this Service Bulletin and no Crack(s)**  **Found or Airplanes that have not Accomplished the Initial Release of this Service Bulletin** 1. Fabricate DAC GSET AL.01 reference standard. Refer to Part 06, NDTSPM 06-20-01. 2. Defuel and purge left, right, and center main fuel tanks. Refer to DC9 AMM 28-00-00 and DC9 AMM 28-10-01 as an accepted procedure. 3. Remove and keep the doors and attaching parts as follows: **Group 1, Configuration 1, 3:**
**Notes Location**  **Door Number**  Refer to DC9 AMM 06-11-01 for door locations. Left Wing Main Tank 1307 Right Wing Main Tank 1410 Refer to DC9 AMM 06-11-02 for door locations. Center Wing Tank (left side) 2301 Center Wing Tank (right side) 2302 **Group 2, Configuration 1, 3:**
**Notes Location**  **Door Number**  Refer to DC9 AMM 06-11-01 for door locations. Left Wing Main Tank 1307ARight Wing Main Tank 1410A Refer to DC9 AMM 06-11-02 for door locations. Center Wing Tank (left side) 2301ACenter Wing Tank (right side) 2302A4. Do Eddy Current, High Frequency (ETHF) inspection of the left and right rear spar upper cap vertical leg and horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead for crack(s) in accordance with Figure 1 using the procedures that follow: **Procedure 1** a. Use calibration scan method "M" and calibrate on the N8 notch using DAC GSET AL.01 in accordance with NDTSPM 06-10-01.001, Procedure 1. b. Scan center wing rear spar upper cap vertical leg with Method 66 in accordance with Figure 1.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 32 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Procedure 2**  a. Use scan method "C" or "G" and calibrate on the N2 or N8 notch using DAC GSET AL.01 in accordance with NDTSPM 06-10-01.001, Procedure 1. b. Scan center wing rear spar upper cap vertical leg with Methods 62 and 69, as applicable in accordance with Figure 1. **Procedure 3** a. Use scan method "K" and calibrate on the N3 notch using DAC GSET AL.01 in accordance with NDTSPM 06-10-01.001, Procedure 1. b. Scan center wing rear spar upper cap horizontal flange with Method 44 in accordance with Figure 2. 5. Based on ETHF test results do as follows: **Condition 1 (No Crack)** a. Do repeat inspection of the rear spar upper cap vertical leg and horizontal flange for crack(s). **Condition 2 (Crack)** a. Contact Boeing for repair instructions and do the repair. Direct inquires to: Email dse.boecom@boeing.com ATA CODE: 5710 OR Long Beach Service Engineering FAX: (206) 766-5683 ATA CODE: 5710 OR Boeing Company P.O. Box 1771 Long Beach, California 90801-9939 Attn: Senior Manager: Technical Customer Support - Airframe Engineering ATA CODE: 5710 Service Engineering D800-0032 (Service Bulletin DC9-57-223) 6. Reinstall all removed items using kept attaching parts. 7. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 33 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Group 1-2, Configuration 2:**  **Airplanes that have Accomplished the Initial Release of this Service Bulletin and did Crack Repair.**  1. Fabricate DAC GSET AL.01 reference standard. Refer to Part 06, NDTSPM 06-20-01. 2. Defuel and purge left, right, and center main fuel tanks. Refer to DC9 AMM 28-00-00 and DC9 AMM 28-10-01 as an accepted procedure. 3. Remove and keep the doors and attaching parts as follows: **Group 1, Configuration 2:**
**Notes Location**  **Door Number**  Refer to DC9 AMM 06-11-01 for door locations. Left Wing Main Tank 1307 Right Wing Main Tank 1410 Refer to DC9 AMM 06-11-02 for door locations. Center Wing Tank (left side) 2301 Center Wing Tank (right side) 2302 **Group 2, Configuration 2:**
**Notes Location**  **Door Number**  Refer to DC9 AMM 06-11-01 for door locations. Left Wing Main Tank 1307ARight Wing Main Tank 1410A Refer to DC9 AMM 06-11-02 for door locations. Center Wing Tank (left side) 2301ACenter Wing Tank (right side) 2302A4. Do Eddy Current, High Frequency inspection (ETHF) of the horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead for crack(s) using the procedures that follow: a. Use scan method "K" and calibrate on the N3 notch using DAC GSET AL.01 in accordance with NDTSPM 06-10-01.001, Procedure 1. b. Scan center wing rear spar upper cap horizontal flange with Method 44 in accordance with Figure 2. 5. Based on ETHF test do as follows: **Condition 1 (No Crack)** a. Do repeat inspection of the horizontal flange on the inboard and outboard sides of station Xcw=58.500 bulkhead.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 34 of 45 **BOEING SERVICE BULLETIN DC9-57-223 Condition 2 (Crack)**  a. Contact Boeing for repair instructions and do the repair. Direct inquires to: Email dse.boecom@boeing.com ATA CODE: 5710 OR Long Beach Service Engineering FAX: (206) 766-5683 ATA CODE: 5710 OR Boeing Company P.O. Box 1771 Long Beach, California 90801-9939 Attn: Senior Manager: Technical Customer Support - Airframe Engineering ATA CODE: 5710 Service Engineering D800-0032 (Service Bulletin DC9-57-223) 6. Reinstall all removed items using kept attaching parts. 7. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1: August 13, 2009 35 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION**  **(SHEET 1 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 36 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION**  **(SHEET 2 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 37 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION**  **(SHEET 3 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 38 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION**  **(SHEET 4 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 39 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION**  **(SHEET 5 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 40 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 1: LEFT AND RIGHT WING CENTER REAR SPAR CAP - VERTICAL LEG INSPECTION**  **(SHEET 6 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 41 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 42 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 43 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 44 of 45 **BOEING SERVICE BULLETIN DC9-57-223 FIGURE 2: LEFT AND RIGHT WING CENTER REAR SPAR CAP - UPPER FLANGE INSPECTION**  **(SHEET 4 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 21, 2003 DC9-57-223 Revision 1 August 13, 2009 45 of 45 **BOEING SERVICE BULLETIN DC9-57-223**