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

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ECCN: 9E991

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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

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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).

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

information.

Planning Data Affected Reference

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

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

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

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

Publications Affected No Paragraph 1.K., Publications Affected

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

Operations Manual and/or FAA Approved Airplane Flight Manual)

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

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

by the Operator

Operator Supplied Parts/Material No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

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 in Paragraph 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 to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspections given in this service bulletin.

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ALERT ALERT
MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

None.

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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 to Service Bulletin Index D624N001 PART 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.

GROUP CONFIGURATION DESCRIPTION

1 - 757-200/-200CB Airplanes

Airplane Models:

757-200, 757-200CB

Variable Number Group

NA001 - NA002 1

NA005 1

NA008 1

NA021 - NA028 1

NA195 1

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Variable Number Group

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 1

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Variable Number Group

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 1

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Variable Number Group

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 1

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ALERT ALERT
Variable Number Group

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 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

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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 in Paragraph 1.E., Compliance.

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

Affected Maintenance Zones

Model Zone

757-200, 757-200CB 232

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.

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BOEING SERVICE BULLETIN 757-53A0102

ALERT ALERT
A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX

A and APPENDIX 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 Interval (Not to

Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight cycles after the original

issue date of

this 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.

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ALERT ALERT
Table 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R,

STA 440-540 (OPTION 2)

Repeat Interval (Not to

Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight cycles after the original

issue date of

this 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 INNER

SKIN 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 INNER

SKIN 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.

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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

Task Number of Persons Task Hours Elapsed Hours

FIGURE 1 1 3.50 3.50

TOTAL FOR EACH AIRPLANE 3.50 3.50

(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

Task Number of Persons Task Hours Elapsed Hours

OPEN ACCESS 2 3.20 1.60

FIGURE 2 1 3.50 3.50

CLOSE ACCESS 2 3.20 1.60

TOTAL FOR EACH AIRPLANE 9.90 6.70

(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.

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J. References

1. Existing Data:

a. Boeing Service Letter 757-SL-51-022

b. Service Bulletin Index D624N001

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) Manual Part 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:

Drawing Number Title

143N3400 SKIN PANEL INSTL - STA 439 TO 661 STGR 14R TO 26L

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.

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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 in Paragraph 1.J., References, can be necessary. Examine

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

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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

– 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 to SOPM 20-50-01 for 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.

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7. Boeing Service Letter 757-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 to APPENDIX A, and APPENDIX B for 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 in Paragraph 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.

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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 with Paragraph 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

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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 with Paragraph 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 to APPENDIX C.

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

440-540

(SHEET 1 OF 2)

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

Step Task Name Location More Data

S-14R, STA 440 to (a)

STA 540

1 Inspect Inner Skin

(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 with 757 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)

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

S-14R, STA 440-540

(SHEET 1 OF 2)

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

Step Task Name Location More Data

S-14R, STA 440 to (a)

STA 540

1 Inspect Inner Skin

(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 with 757 NDT Manual Part 6, 51-00-01, or 757

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)

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ALERT ALERT
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary

source for compliance times. Information contained in Paragraph 3.B., Work Instructions is 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.

Title Description

EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R,

STA 440-540

PART 1

CONDITION 1 ANY CRACK FOUND

CONDITION 2 NO CRACK FOUND

2. The table below gives the description for the flag notes called out in the following logic diagram.

Flag Note Letter Description

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.

(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)

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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)

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ALERT ALERT
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary

source for compliance times. Information contained in Paragraph 3.B., Work Instructions is 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.

Title Description

INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW,

AT S-14R, STA 440-540

PART 2

CONDITION 1 ANY CRACK FOUND

CONDITION 3 NO CRACK FOUND

2. The table below gives the description for the flag notes called out in the following logic diagram.

Flag Note Letter Description

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.

(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)

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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)

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OPEN ACCESS

1. To open access, do as follows:

a. Remove and keep the Passenger Seats. Refer to 757 AMM 25-25-01 as an accepted procedure.

b. Remove and keep the Sidewall Panels. Refer to 757 AMM 25-21-02 as an accepted procedure.

c. Remove and keep the Sidewall Insulation. Refer to 757 AMM 25-21-05 as an accepted procedure.

CLOSE ACCESS

1. To close access, do as follows:

a. Install the kept Sidewall Insulation. Refer to 757 AMM 25-21-05 as an accepted procedure.

b. Install the kept Sidewall Panels. Refer to 757 AMM 25-21-02 as an accepted procedure.

c. Install the kept Passenger Seats. Refer to 757 AMM 25-25-01 as an accepted procedure.

APPENDIX C: OPEN AND CLOSE ACCESS

(SHEET 1 OF 1)

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ALERT ALERT