### Commercial **Airplanes** 

# 757

Service Bulletin **ALERT Number:**  **757-53A0102** Original Issue: October 08, 2015 ATA System: 5330 **SUBJECT:** FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener

Row, at S-14R, STA 440-540 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2015 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. 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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.

Original Issue: October 08, 2015 757-53A0102 1of33 3.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 2of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**

BLANK PAGE**Table of Contents**

Summary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5 1. PLANNING INFORMATION

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. Spares Affected

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 13 C. Reason

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1. Existing Data:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 18 2. Data Supplied with this Service Bulletin:

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

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

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

. . . . . . . . . . . . . . . . . . . . . .. . . . . 18 M. Software Accomplishment Summary

. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 18 2. MATERIAL INFORMATION

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 19 C. Parts Necessary for Each Airplane

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 19 D. Parts Necessary to Change Spares

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Special Tooling - Price and Availability

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin

. . . . . . . . . . . . . . . . . . . . . . . 19 3. ACCOMPLISHMENT INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 21 B. WORK INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FIGURE 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA

440-540

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FIGURE 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT

S-14R, STA 440-540

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: EXTERNAL DFEC

INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 1)

. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INTERNAL HFEC

SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 APPENDIX C: OPEN AND CLOSE ACCESS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 3of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 4of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# 757

Service Bulletin **ALERT Summary**  **Number: 757-53A0102**  Original Issue: October 08, 2015 ATA System: 5330 **SUBJECT:** FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener

Row, at S-14R, STA 440-540 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** The inner skin of lap splices at Stringer S-14R, lower fastener row for 757-200, and 757-200CB models have been determined to be susceptible to Widespread Fatigue Damage (WFD). Cracking was found on the fatigue test article, and WFD analysis has identified the need for inspections. Currently, there have been no reports of cracking on airplanes in service. Inspections will mitigate a safety issue, allowing continued operation to the Limit of Validity (LOV). This action is necessary to find any fatigue crack in the skin panel. Accomplishment of the inspections in this service bulletin will make sure that any fuselage skin crack at Stringer S-14R, between STA 440 and STA 540 is found. Continued operation with any undetected skin crack could adversely affect the structural integrity of the airplane. The fuselage lap splice inner skin at the locations affected by this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 5of33This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information. **Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., ComplianceandParagraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator No Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required
**ACTION** This service bulletin gives instructions to do either Dual Frequency Eddy Current (DFEC) or High Frequency Eddy Current (HFEC) inspections of the fuselage lap splice, inner skin lower fastener row, at S-14R, STA 440-540 for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, repeat the inspections at the interval specified inParagraph 1.E., Compliance

. **EFFECTIVITY** All 757-200/-200CB Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Refer toParagraph 1.E., Compliance

. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspections given in this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 6of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT MANPOWER** 

Refer toParagraph 1.G., Manpower

. **MATERIAL INFORMATION** None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 7of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 8of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 757

Service Bulletin **ALERT Number:**  **757-53A0102** Original Issue: October 08, 2015 ATA System: 5330 **SUBJECT:** FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener

Row, at S-14R, STA 440-540 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 toService Bulletin Index D624N001PART 2 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. This service bulletin is applicable to all 757-200/-200CB Airplanes. The Variable Numbers and Group Information for the applicable airplanes is given below. **DESCRIPTION CONFIGURATION**  **GROUP** 757-200/-200CB Airplanes

- 1
Airplane Models: 757-200,757-200CB **Group Variable Number**  1 NA001 - NA002 1 NA005 1 NA008 1 NA021 - NA028 1 NA195

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 9of33**Group Variable Number**  1 NA197 - NA199 1 NA201 - NA213 1 NA215 - NA239 1 NA301 - NA305 1 NA342 - NA344 1 NA346 - NA352 1 NA392 - NA399 1 NA401 - NA408 1 NA441 - NA447 1 NA502 - NA505 1 NA509 - NA510 1 NA512 1 NA514 - NA535 1 NA537 - NA538 1 NA541 - NA546 1 NA548 - NA586 1 NB001 - NB004 1 NB021 - NB023 1 NB036 - NB041 1 NB052 - NB053 1 NB061 - NB068 1 NB070 - NB073 1 NB079 1 NB131 - NB148 1 NB161 - NB162 1 NB167 - NB168 1 NB201 - NB202 1 NB221 - NB228 1 NB230 1 NB236 1 NB239 1 NB261 - NB267 1 NB291 - NB299

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 10of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT Group**  **Variable Number** 1 NB301 - NB302 1 NB311 - NB312 1 NB321 - NB331 1 NB421 - NB424 1 NB426 - NB438 1 NB446 1 NB451 - NB454 1 NB501 - NB523 1 NB561 1 NB571 1 NB581 - NB583 1 NC001 - NC003 1 NC005 1 NC008 1 NC012 - NC013 1 NC017 - NC018 1 NC020 - NC022 1 NC024 1 NC026 1 NC029 - NC033 1 NC042 1 NC051 - NC052 1 NC056 - NC062 1 NC066 - NC084 1 NC091 - NC094 1 NC151 1 NC161 1 ND002 1 ND004 1 ND011 - ND027 1 ND029 - ND044 1 ND046 - ND059 1 ND111 - ND113

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 11of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT Group**  **Variable Number** 1 ND161 - ND166 1 ND168 - ND199 1 ND201 - ND203 1 ND221 - ND225 1 ND241 - ND248 1 ND301 - ND322 1 ND401 1 ND891 1 ND895 1 NE001 - NE004 1 NE006 - NE008 1 NE011 - NE030 1 NE032 - NE081 1 NE083 - NE088 1 NE092 - NE094 1 NE141 - NE150 1 NE161 - NE177 1 NE201 - NE204 1 NE301 1 NE311 - NE325 1 NJ001 - NJ004 1 NJ031 - NJ032 1 NJ551 - NJ555 1 NN001 - NN002 1 NN051 - NN052 1 NP901 - NP904 1 NT201 - NT202 1 NT231 - NT234 1 NT237 - NT240 1 NT242 1 NT245 - NT248 1 NT281 - NT289 1 NT341 - NT347

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 12of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT Group**  **Variable Number** 1 NT351 - NT360 1 NT371 - NT373 1 NT375 - NT379 1 NT381 - NT386 1 NT401 - NT409 1 NT411 - NT412 1 NT426 - NT427 1 NT431 - NT432 1 NT436 - NT438 1 NT441 - NT442 1 NT446 1 NT701 - NT769 1 NT791 - NT796 1 NT861 - NT862 1 NT881 - NT885 1 NT901 - NT903 1 NT905 - NT916 1 NT971 - NT985 1 NU031 - NU038 2. Spares Affected None. **B. Concurrent Requirements**  None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 13of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT C.**  **Reason**

The inner skin of lap splices at Stringer S-14R, lower fastener row for 757-200, and 757-200CB models have been determined to be susceptible to Widespread Fatigue Damage (WFD). Cracking was found on the fatigue test article, and WFD analysis has identified the need for inspections. Currently, there have been no reports of cracking on airplanes in service. Inspections will mitigate a safety issue, allowing continued operation to the Limit of Validity (LOV). This action is necessary to find any fatigue crack in the skin panel. Accomplishment of the inspections in this service bulletin will make sure that any fuselage skin crack at Stringer S-14R, between STA 440 and STA 540 is found. Continued operation with any undetected skin crack could adversely affect the structural integrity of the airplane. The fuselage lap splice inner skin at the locations affected by this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). **D. Description**  This service bulletin gives instructions to do either Dual Frequency Eddy Current (DFEC) or High Frequency Eddy Current (HFEC) inspections of the fuselage lap splice, inner skin lower fastener row, at S-14R, STA 440-540 for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, repeat the inspections at the interval specified inParagraph 1.E., Compliance

. The work in this service bulletin is done in the maintenance zone(s) given below. **Affected Maintenance Zones Zone**  **Model** 232 757-200, 757-200CB **E. Compliance**  The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. Two options are given for the inspection and the corresponding corrective action for any crack. Operators must do OPTION 1 or OPTION 2.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 14of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**A logic diagram showing compliance tasks and compliance times is included as an aid inAPPENDIX AandAPPENDIX B

. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. **Table 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440- 540 (OPTION 1)**  **Repeat Inter val (Not to**  **Exceed) Compliance Time (Whichever**  **Occurs Later) Action**  **Condition**

- Within 3,000flight cycles after the original issue date ofthis service bulletin. Before 40,000 total flight cycles.Do PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack.(a) All Airplanes

- - Before further flight. ACTION 1: Contact The Boeing Company for repair instructions and do the repair. CONDITION 1: ANY CRACK FOUND 12,000 flight cycles.(a)(b) - - ACTION 2:Repeat PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack at the unrepaired areas. 12,000 flight cycles.(a)(b) - - Repeat PART 1: EXTERNAL DFEC IN- SPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440- 540, for any crack. CONDITION 2: NO CRACK FOUND (a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected inspection areas, provided the repairs extend a minimum of three rows of fasteners common to the outermost repair doubler above and below the original group of lap splice fasteners. Damage Tolerance Inspection instructions specified in approval for existing repairs must continue. Inspections outside of the repaired region must continue in accordance with this service bulletin. (b) It is acceptable, at operator discretion, to use PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 15of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT Table 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R,** 

**STA 440-540 (OPTION 2) Repeat Inter**  **val (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 

- Within 3,000flight cycles after the original issue date ofthis service bulletin. Before 40,000 total flight cycles.Do PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack.(a) All Airplanes

- - Before further flight. ACTION 1: Contact The Boeing Company for repair instructions and do the repair. CONDITION 1: ANY CRACK FOUND 12,000 flight cycles.(a)(b) - - ACTION 2: Repeat PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNERSKIN LOWER FASTENER ROW, AT S14R, STA 440-540, for any crack at the unrepaired areas. 12,000 flight cycles.(a)(b) - - Repeat PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNERSKIN LOWER FASTENER ROW, AT S14R, STA 440-540, for any crack. CONDITION 3: NO CRACK FOUND (a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected inspection areas, provided the repairs extend a minimum of three rows of fasteners common to the outermost repair doubler above and below the original group of lap splice fasteners. Damage Tolerance Inspection instructions specified in approval for existing repairs must continue. Inspections outside of the repaired region must continue in accordance with this service bulletin. (b) It is acceptable, at operator discretion, to use PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 16of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT 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 inspect the work
• Time to cure the materials
• Time to make the parts
• Time to find the tools **OPTION 1** 1. EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 **Elapsed Hours Task Hours**  **Number of Persons Task**  3.50 3.50 1 FIGURE 1 3.50 3.50 TOTAL FOR EACH AIRPLANE (a) Hours for repairs are not included and are dependent on inspection findings. **OPTION 2** 1. INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 **Elapsed Hours Task Hours**  **Number of Persons Task**  1.60 3.20 2 OPEN ACCESS 3.50 3.50 1 FIGURE 2 1.60 3.20 2 CLOSE ACCESS 6.70 9.90 TOTAL FOR EACH AIRPLANE (a) Hours for repairs are not included and are dependent on inspection findings.

**H. Weight and Balance Changes**  None. **I. Electrical Load Data**  Not changed.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 17of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT J.**  **References**

1. Existing Data:
a. Boeing Service Letter757-SL-51-022 b. Service Bulletin IndexD624N001
c. Standard Overhaul Practices Manual (SOPM)20-50-01 d. 757 Aircraft Maintenance Manual (AMM)25-21-02,25-21-05,25-25-01
e. 757 Non-Destructive Testing (NDT) ManualPart 6, 51-00-01,Part 6, 51-00-19,Part 6, 53-00-11 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: **Title Drawing Number**  SKIN PANEL INSTL - STA 439 TO 661 STGR 14R TO 26L 143N3400 SKIN PANEL INSTL - STA 439 THRU 661 AND 781 THRU 900, STGR 10 TO 14 143N3200

**K. Publications Affected**  1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.
**L. Interchangeability and Intermixability of Parts**  Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. **M. Software Accomplishment Summary**  Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 18of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability**  None. **B. Industry Support Information**  Boeing warranty remedies are not available for the inspections 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**  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 inParagraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 19of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 20of33 **BOEING SERVICE BULLETIN 757-53A0102 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 toParagraph 1.J., References, for

definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 757 Structural Repair Manual, Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 757 Aircraft Maintenance Manual (AMM).

— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).

— Values for engine maintenance tasks are included in Chapter 70 of 757 Aircraft Maintenance Manual (AMM).

— Non-standard torque values for maintenance tasks are included in the applicable installation step.
4. Use the approved fastener, process and material substitutions in accordance with

SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer toSOPM 20-50-01for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 21of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**7. Boeing Service Letter757-SL-51-022, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 8. Refer toAPPENDIX A, andAPPENDIX Bfor logic diagram(s). Logic diagrams are

provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 9. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 10. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 11. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 12. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 13. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are inParagraph 1.E., Compliance

. 14. Some steps in the Work Instructions are labeled as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps labeled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including sub-steps and identified figures. Steps not labeled as RC may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC. This is provided that the RC steps, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. **B. WORK INSTRUCTIONS**  1. RC - Two options are given for the inspection and the corresponding corrective action for any crack. Operators must do OPTION 1 or OPTION 2. **NOTE:** It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected inspection areas, provided the repairs extend a minimum of three rows of fasteners common to the outermost repair doubler above and below the original group of lap splice fasteners. Damage Tolerance Inspection instructions specified in approval for existing repairs must continue. Inspections outside of the repaired region must continue in accordance with this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 22of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**a. OPTION 1: External Dual Frequency Eddy Current (DFEC) Inspection: (1) Do PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack. (a) CONDITION 1: ANY CRACK FOUND 1) ACTION 1: Contact The Boeing Company for repair instructions and do the repair. 2) ACTION 2: Repeat PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack at the unrepaired areas. **NOTE:** It is acceptable, at operator discretion, to use PART 2: INTERNAL

HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections. (b) CONDITION 2: NO CRACK FOUND 1) Repeat PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack, at the repeat interval in accordance withParagraph 1.E., Compliance

. **NOTE:** It is acceptable, at operator discretion, to use PART 2: INTERNAL

HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections. b. OPTION 2: Internal High Frequency Eddy Current (HFEC) Surface Inspection: (1) Do PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack. (a) CONDITION 1: ANY CRACK FOUND 1) ACTION 1: Contact The Boeing Company for repair instructions and do the repair. 2) ACTION 2: Repeat PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack at the unrepaired areas. **NOTE:** It is acceptable, at operator discretion, to use PART 1: EXTERNAL

DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections. (b) CONDITION 3: NO CRACK FOUND

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 23of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**1) Repeat PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack, at the repeat interval in accordance withParagraph 1.E., Compliance

. **NOTE:** It is acceptable, at operator discretion, to use PART 1: EXTERNAL

DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections. 2. Put the airplane back to a serviceable condition. **PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540**  1. Do an external DFEC inspection of the inner skin lower fastener row, for any crack, in accordance with FIGURE 1. **PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540**  1. Do an internal HFEC surface inspection of the inner skin lower fastener row, for any crack, in accordance with FIGURE 2. **NOTE:** To open and close access, refer toAPPENDIX C

.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 24of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT FIGURE 1:** **EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540**  **(SHEET 1 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 25of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. More Data Location Name Task Step (a) S-14R, STA 440 to STA 540 Inner Skin Inspect 1 (a) Do an external DFEC inspection of the inner skin for any crack along the lower fastener row, at Stringer S-14R from STA 440 to STA 540, in accordance with757 NDT Manual Part 6, 53-00-11

.

**FIGURE 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA**  **440-540 (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 26of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT FIGURE 2:** **INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540**  **(SHEET 1 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 27of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. More Data Location Name Task Step (a) S-14R, STA 440 to STA 540 Inner Skin Inspect 1 (a) Do an internal HFEC surface inspection of the inner skin for any crack along the lower fastener row, at Stringer S-14R from STA 440 to STA 540, in accordance with757 NDT Manual Part 6, 51-00-01, or757 NDT Manual Part 6, 51-00-19

.

**FIGURE 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT**  **S-14R, STA 440-540 (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 28of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**Logic diagrams are provided as an aid only. Information contained inParagraph 1.E., Complianceis the primary

source for compliance times. Information contained inParagraph 3.B., Work Instructionsis the prim ary source for tasks required for compliance. 1. The table below gives the description for the parts and conditions called out in the following logic diagram.**Description Title**  EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R,

STA 440-540 PART 1 ANY CRACK FOUND CONDITION 1 NO CRACK FOUND CONDITION 2 2. The table below gives the description for the flag notes called out in the following logic diagram.

**Description Flag Note Letter**  It is not necessary to do inspections in accordance with this service bulletin in areas where

existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected inspection areas, provided the repairs extend a minimum of three rows of fasteners common to the outermost repair doubler above and below the original group of lap splice fasteners. Damage Tolerance Inspection instructions specified in approval for existingrepairs must continue. Inspections outside of the repaired region must continue in accordance with this service bulletin. (a)

It is acceptable, at operator discretion, to use PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections. (b)

**APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: EXTERNAL DFEC**  **INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 1) (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 29of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT APPENDIX A:** **LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: EXTERNAL DFEC**

**INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 1) (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 30of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**Logic diagrams are provided as an aid only. Information contained inParagraph 1.E., Complianceis the primary

source for compliance times. Information contained inParagraph 3.B., Work Instructionsis the primary source for tasks required for compliance. 1. The table below gives the description for the parts and conditions called out in the following logic diagram.**Description Title**  INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW,

AT S-14R, STA 440-540 PART 2 ANY CRACK FOUND CONDITION 1 NO CRACK FOUND CONDITION 3 2. The table below gives the description for the flag notes called out in the following logic diagram.

**Description Flag Note Letter**  It is not necessary to do inspections in accordance with this service bulletin in areas where

existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected inspection areas, provided the repairs extend a minimum of three rows of fasteners common to the outermost repair doubler above and below the original group of lap splice fasteners. Damage Tolerance Inspection instructions specified in approval for existingrepairs must continue. Inspections outside of the repaired region must continue in accordance with this service bulletin. (a)

It is acceptable, at operator discretion, to use PART 1: EXTERNAL DFEC INSPECTION

OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections. (b)

**APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INTERNAL HFEC**  **SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 2) (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 31of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT APPENDIX B:** **LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INTERNAL HFEC**

**SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 2) (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 32of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT OPEN ACCESS**  1. To open access, do as follows:
a. Remove and keep the Passenger Seats. Refer to757 AMM 25-25-01as an accepted procedure. b. Remove and keep the Sidewall Panels. Refer to757 AMM 25-21-02as an accepted procedure.
c. Remove and keep the Sidewall Insulation. Refer to757 AMM 25-21-05as an accepted procedure. **CLOSE ACCESS** 1. To close access, do as follows:
a. Install the kept Sidewall Insulation. Refer to757 AMM 25-21-05as an accepted procedure. b. Install the kept Sidewall Panels. Refer to757 AMM 25-21-02as an accepted procedure.
c. Install the kept Passenger Seats. Refer to757 AMM 25-25-01as an accepted procedure.

**APPENDIX C: OPEN AND CLOSE ACCESS** 

**(SHEET 1 OF 1)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 08, 2015 757-53A0102 33of33 **BOEING SERVICE BULLETIN 757-53A0102 ALERT**  **ALERT**