Commercial 

Airplanes DC10

Service Bulletin

ALERT

Number: DC10-57A156

Original Issue: September 16, 2009

Revision 2: August 23, 2011

ATA System: 5711

SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between

Stations Xors=400 and Xors=417

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2009 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Unpublished Work - All Rights Reserved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Copyright © Unpublished Work - See page 1 for details.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: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

1 of 47

8.0
BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

2 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

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

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 25

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 39

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 40

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

3 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

4 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes DC10

Service Bulletin

ALERT

Revision Transmittal Sheet Number: DC10-57A156

Original Issue: September 16, 2009

Revision 2: August 23, 2011

ATA System: 5711

SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between

Stations Xors=400 and Xors=417

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is related to

this service bulletin.

No more work is necessary on the airplane(s) changed in accordance with Revision 1 of this service bulletin.

REASON FOR REVISION

This revision is sent to instruct operators to contact The Boeing Company for repair instructions if cracks that

can not be removed by enlarging fastener hole(s) are found between Stations Xors=400 and inboard of Xors=408.

The data given in Information Notice DC10-57A156 IN 01 is included in this revision.

These sections were changed:

1. In Paragraph 1.D., Description, added new conditions to reflect station location limitations.

2. In Paragraph 1.E., Compliance, added NPRM information and added Compliance Tables to show added

conditions.

3. In Paragraph 1.F., Approval, changed approval statement.

4. In Paragraph 1.J.1., References, added NPRM information.

5. In Paragraph 1.J.2., Data supplied with this Service Bulletin, changed drawing revision level as applicable.

6. In Paragraph 2.A., Material - Price and Availability, added pricing and Reorder Lead Time (ROLT) information.

7. In Paragraph 2.C.1., Kits/Parts, corrected part numbers.

8. In Paragraph 3.A., General Information, added new notes and renumbered existing notes.

9. In Paragraph 3.B., Accomplishment Instructions, added new conditions and work steps.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

5 of 47
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

Original Issue: September 16, 2009

Revision 1: March 10, 2010

Revision 2: August 23, 2011

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

6 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Commercial 

Airplanes DC10

Service Bulletin

ALERT

Summary Number: DC10-57A156

Original Issue: September 16, 2009

Revision 2: August 23, 2011

ATA System: 5711

SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between

Stations Xors=400 and Xors=417

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

Operators have reported 3 instances of DC-10-10F/MD-10-10F airplanes having a fuel leak in the wing rear

spar lower cap at Station Xors=409. Affected airplanes had the gross weight doublers installed and operators

had previously accomplished Service Bulletin DC10-57-138. Investigation revealed the fuel leak was due to a

crack in the lower cap. This crack extended into all three legs (aft, forward, and vertical) of the spar cap.

Metallurgical analysis of the cracked portion of the spar cap determined that the crack was due to fatigue and

began at a fastener hole in the aft leg of the spar cap. Inspecting spar cap fastener holes for cracks, will determine

the condition of spar cap. Repairing cracks in the spar cap, will minimize crack migration. If not corrected, an

undetected crack in spar cap may lead to fuel leaks or cracking of the lower wing skin and structure causing

extensive spar cap repairs or replacement and possible inability to sustain the limit load.

ACTION

Refer to Paragraph 1.D., for Description.

EFFECTIVITY

DC-10-10, DC-10-10F, and MD-10-10F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected

airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is related to

this service bulletin.

Refer to Paragraph 1.E., for Compliance.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

7 of 47
INDUSTRY SUPPORT INFORMATION

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

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

8 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

9 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

10 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes DC10

Service Bulletin

ALERT

Number: DC10-57A156

Original Issue: September 16, 2009

Revision 2: August 23, 2011

ATA System: 5711

SUBJECT: WINGS - Spars - Inspect/Repair Left and Right Wing Rear Spar Lower Cap Between

Stations Xors=400 and Xors=417

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

GROUP CONFIGURATION DESCRIPTION

MD-10 airplane fuselages 6 and 8 that were modified in accordance

with Service Modification Drawing SM10570022.

1 -

DC-10/MD-10 airplanes except for fuselages 6 and 8 that have been

modified in accordance with Service Modification Drawing

SM10570022.

2 -

Airplane Models:

DC-10-10, DC-10-10F, MD-10-10F

Fuselage Num- Group

ber

6 1

8 1

15 2

17 2

25 - 27 2

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

11 of 47
Fuselage Num- Group

ber

32 - 35 2

39 - 43 2

55 2

59 2

61 - 62 2

70 2

72 2

76 2

78 2

86 2

89 2

112 2

119 2

138 - 140 2

142 2

144 - 145 2

148 2

153 - 155 2

173 2

177 2

198 2

203 2

205 2

207 - 210 2

247 2

249 - 250 2

269 - 273 2

294 2

297 - 298 2

307 2

309 2

319 2

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

12 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Fuselage Num- Group

ber

321 2

323 2

344 2

347 2

351 2

353 2

379 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Operators have reported 3 instances of DC-10-10F/MD-10-10F airplanes having a fuel leak in the wing

rear spar lower cap at Station Xors=409. Affected airplanes had the gross weight doublers installed

and operators had previously accomplished Service Bulletin DC10-57-138. Investigation revealed the

fuel leak was due to a crack in the lower cap. This crack extended into all three legs (aft, forward, and

vertical) of the spar cap. Metallurgical analysis of the cracked portion of the spar cap determined that

the crack was due to fatigue and began at a fastener hole in the aft leg of the spar cap. Inspecting spar

cap fastener holes for cracks, will determine the condition of spar cap. Repairing cracks in the spar

cap, will minimize crack migration. If not corrected, an undetected crack in spar cap may lead to fuel

leaks or cracking of the lower wing skin and structure causing extensive spar cap repairs or replacement

and possible inability to sustain the limit load.

Revision 1 was sent to correct a drawing callout in the description.

Revision 2 is sent to instruct operators to contact The Boeing Company for repair instructions if cracks

that can not be removed by enlarging the fastener hole(s) are found between Stations Xors=400 and

inboard of Xors=408.

The data given in Information Notice DC10-57A156 IN 01 is included in this revision.

D. Description

This service bulletin provides instructions to do an Eddy Current Test High Frequency (ETHF) inspection

for cracks on the left and right wing rear spar lower cap between the outboard edge of the rear spar

lower cap splice at Station Xors=400 and Station Xors=417. Based on inspection results this service

bulletin does as follows:

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

13 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Condition 1 (No Crack)

1. Does repeat ETHF inspections.

Condition 2 (Crack at Fastener Hole that can be Removed by Hole Enlargement)

1. Does repair as follows:

a. If crack(s) are found on the left wing, does permanent repair in accordance with Service

Rework Drawing SR10570048-7001, Detail D..

b. If crack(s) are found on the right wing, does permanent repair in accordance with Service

Rework Drawing SR10570048-7003, Detail D.

2. Does repeat ETHF inspections of the spar cap and HFEC inspections of the lower wing skin in

the repaired area and does as follows:

Condition 2A (No Crack Found)

a. Does repeat ETHF inspections of the spar cap and HFEC inspections of the lower wing skin

in the repaired area.

Condition 2B (Any Crack Found)

a. Evaluates the crack and does the work of Condition 2, 3 or 4 as applicable.

3. Does repeat ETHF inspections of the lower spar cap in the unchanged areas on the left and right

wing rear spar lower cap between the outboard edge of the rear spar lower cap splice at Station

Xors=400 and Station Xors=417.

Condition 2C (No Crack Found)

a. Does repeat ETHF inspections of the lower spar cap in the unchanged areas.

Condition 2D (Any Crack Found)

a. Evaluates the crack and does the work of Conditions 2, 3 or 4 as applicable.

Condition 3 (Crack in Spar Cap Aft Leg at Fastener Hole(s) that Cannot be Removed by Hole

Enlargement but does not Extend into Vertical Leg)

1. Establishes the location of the crack and based on location does the work as follows:

Condition 3A (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=400

and Inboard of Xors=408)

a. Contacts The Boeing Company for repair instructions and does the repair.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

14 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Condition 3B (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=408

and Xors=417)

a. Does repair as follows:

(1) If crack(s) are found on the left wing, does permanent repair in accordance with Service

Rework Drawing SR10570048-7021.

(2) If crack(s) are found on the right wing, does permanent repair in accordance with Service

Rework Drawing SR10570048-7023.

b. Does repeat ETHF and Ultrasonic (UT) inspections of the repaired area and does as follows:

Condition 3C (No Crack Found)

Does repeat ETHF and Ultrasonic (UT) inspections of the repaired area.

Condition 3D (Any Crack Found)

Contacts The Boeing Company for repair instructions and does the repair.

Condition 4 (Crack that Extends into the Vertical Leg of Spar Cap)

1. Establish the location of the crack and do as follows:

Condition 4A (Crack is Between Station Xors=400 and Inboard of Xors=408)

a. Do permanent repair as follows:

If crack(s) are found on the left wing, does permanent repair in accordance with Service

Rework Drawing SR10570019-7013.

If crack(s) are found on the right wing, does permanent repair in accordance with Service

Rework Drawing SR10570019-7015.

b. Does repeat ETHF and UT inspections of the permanent repair(s) for cracks and does as

follows:

Condition 4B (No Crack Found in Permanent Repair)

Does repeat ETHF and UT inspections for cracks

Condition 4C (Any Crack Found in Permanent Repair)

Contacts The Boeing Company for repair instructions and does the repair.

Condition 4D (Crack is Between Station Xors=408 and Xors=417)

a. Do Option 1 or Option 2

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

15 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Option 1

(1) Does repair as follows:

Group 1:

If crack(s) are found on left wing, does temporary repair in accordance with Service

Rework Drawing SR10570048-7025.

Group 1:

If crack(s) are found on right wing, does temporary repair in accordance with Service

Rework Drawing SR10570048-7027.

Group 2:

If crack(s) are found on left wing, does temporary repair in accordance with Service

Rework Drawing SR10570048-7029.

Group 2:

If crack(s) are found on right wing, does temporary repair in accordance with Service

Rework Drawing SR10570048-7031.

(2) Does repeat ETHF and UT inspections for the service life of the temporary repair(s) for

cracks and does as follows:

Condition 4E (No Crack Found in Temporary Repair)

Does repeat ETHF and UT inspections for the service life of the temporary repair(s) for

cracks.

Condition 4F (Any Crack Found in Temporary Repair)

Contacts The Boeing Company for repair instructions and does the repair.

(3) Does permanent repair upon or prior to reaching the end of the service life of temporary

repair(s) as follows:

If a temporary repair was installed on the left wing, replaces temporary repair in accordance

with Paragraph 1.E., Compliance and Service Rework Drawing SR10570019-7013.

If a temporary repair was installed on the right wing, replaces temporary repair in

accordance with Paragraph 1.E., Compliance and Service Rework Drawing

SR10570019-7015.

(4) Does repeat ETHF and UT inspections of the permanent repair(s) for cracks and does

as follows:

Condition 4G (No Crack Found in Permanent Repair)

Does repeat ETHF and UT inspections for cracks.

Condition 4H (Any Crack Found in Permanent Repair)

Contacts The Boeing Company for repair instructions and does the repair.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

16 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Option 2

(1) Does repair as follows:

If crack(s) are found on left wing, does permanent repair in accordance with Service

Rework Drawing SR10570019-7013.

If crack(s) are found on right wing, does permanent repair in accordance with Service

Rework Drawing SR10570019-7015.

(2) Does repeat ETHF and UT inspections of the permanent repair(s) for cracks and does

as follows:

Condition 4I (No Crack Found in Permanent Repair)

Does repeat ETHF and UT inspections for cracks

Condition 4J (Any Crack Found in Permanent Repair)

Contacts The Boeing Company for repair instructions and does the repair.

Revision 2 - No more work is necessary on airplane(s) changed in accordance with Revision 1 of this

service bulletin.

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

Group 1:

Affected Maintenance Zones

Model Zone

MD-10-10F 535, 635

Group 2:

Affected Maintenance Zones

Model Zone

DC-10-10, DC-10-10F, MD-10- 535, 635

10F

E. Compliance

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-216-AD, is

related to this service bulletin.

Accomplish the required action(s), based on the applicable condition(s), in Table(s) 1 through 5, in

accordance with Paragraph 3. Accomplishment Instructions.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

17 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Table 1: Inspect Left and Right Side Wing Rear Spar Lower Caps for Cracks between the Outboard Edge

of the Rear Spar Lower Cap Splice at Station Xors=400 and Station Xors=417

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Within 1,750 flight cy- -

cles after the original

issue date on this service bulletin.

Do Eddy Current Test High

Frequency (ETHF) inspection

for cracks on the left and right

wing rear spar lower cap between the outboard edge of the

rear spar lower cap splice at

Station Xors=400 and Station

Xors=417.

All Airplanes

Do ETHF inspection for cracks - 1,750 flight cycles.

on the left and right wing rear

spar lower cap between the

outboard edge of the rear spar

lower cap splice at Station

Xors=400 and Station

Xors=417.

Condition 1 (No Crack

Found)

Do permanent repair in accor- Before further flight. -

dance with Accomplishment Instruction 3.B.

Condition 2 (Crack

Found at Fastener Hole

that can be Removed

by Hole Enlargement) AND

Within 1,750 flight cy- -

cles after repair is accomplished.

Do ETHF inspection of the lower

spar cap and HFEC inspection

of the lower wing skin in the repaired area.

AND

Do the action specified by Condition 2A or 2B.

Do ETHF inspection of the lower - 1,750 flight cycles.

spar cap and HFEC inspection

of the lower wing skin in the repaired area.

Condition 2A (No Crack

Found in Repaired

Area)

Evaluate the crack and do the Before further flight. -

work of Condition 2, 3 or 4 as

applicable.

Condition 2B (Any

Crack Found in Repaired Area)

AND

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

18 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Table 1: Inspect Left and Right Side Wing Rear Spar Lower Caps for Cracks between the Outboard Edge

of the Rear Spar Lower Cap Splice at Station Xors=400 and Station Xors=417

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Within 1,750 flight cy- -

cles after repair is accomplished.

Do ETHF inspections in the unchanged areas on the left and

right wing rear spar lower cap

between the outboard edge of

the rear spar lower cap splice at

Station Xors=400 and Station

Xors=417.

AND

Do the action specified by Condition 2C or 2D.

Do ETHF inspections in the un- - 1,750 flight cycles.

changed areas on the left and

right wing rear spar lower cap

between the outboard edge of

the rear spar lower cap splice at

Station Xors=400 and Station

Xors=417.

Condition 2C (No Crack

Found)

Evaluate the crack and do the Before further flight. -

work of Condition 2, 3 or 4 as

applicable.

Condition 2D (Any

Crack Found)

Establish the location of the Before further flight. -

crack and do the actions specified by Condition 3A or 3B.

Condition 3 (Crack

Found in Spar Cap Aft

Leg at Fastener Hole(s)

that Cannot be Removed by Hole Enlargement but does not Extend into Vertical Leg)

Contact The Boeing Company Before further flight. -

for repair instructions and do the

repair.

Condition 3A (Crack

Found in Spar Cap Aft

Leg at Fastener Hole(s)

Between Station

Xors=400 and Inboard

of Xors=408)

Condition 3B (Crack Do permanent repair. Before further flight. -

Found in Spar Cap Aft

Leg at Fastener Hole(s)

Between Station

Xors=408 and

Xors=417)

AND

Within 4,550 flight cy- -

cles after repair is accomplished.

Do ETHF and Ultrasonic (UT)

inspections in the repaired area.

AND

Do the action specified by Condition 3C or 3D.

Do ETHF and Ultrasonic (UT) - 4,550 flight cycles.

inspections in the repaired area.

Condition 3C (No Crack

Found)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

19 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Table 1: Inspect Left and Right Side Wing Rear Spar Lower Caps for Cracks between the Outboard Edge

of the Rear Spar Lower Cap Splice at Station Xors=400 and Station Xors=417

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Contact The Boeing Company Before further flight. -

for repair instructions and do the

repair.

Condition 3D (Any

Crack Found)

Establish the location of the Before further flight. -

crack and do the action specified by Condition 4A or 4D.

Condition 4 (Crack

Found that Extends into

the Vertical Leg of Spar

Cap)

Do the action specified in Table Before further flight. -

2.

Condition 4A (Crack

Found that Extends into

the Vertical Leg of Spar

Cap is Between Station

Xors=400 and Inboard

of Xors=408)

Do the action specified in Table Before further flight. -

3 (Option 1) or Table 5 (Option

2).

Condition 4D (Crack

Found that Extends into

the Vertical Leg of Spar

Cap is Between Station

Xors=408 and

Xors=417)

Table 2: Crack Found that Extends into the Vertical Leg of Spar Cap is Between Station Xors=400 and

Inboard of Xors=408

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Condition 4A (Crack Do permanent repair. Before further flight. -

Found that Extends into

the Vertical Leg of Spar

Cap is Between Station

Xors=400 and Inboard

of Xors=408)

AND

In accordance with DC- -

10 Supplemental Inspection Document

(SID) Volume II, Chapter 57-50-03, Principal

Structural Element

(PSE) 57.10.007 and

57.10.008.

Do ETHF and UT inspection of

the repaired.

AND

Do the action specified by Condition 4B or 4C.

In accordance with DC-10

Supplemental Inspection

Document (SID) Volume II,

Chapter 57-50-03, Principal

Structural Element (PSE)

57.10.007 and 57.10.008.

Do repeat ETHF and UT inspec- -

tion.

Condition 4B (No Crack

Found)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

20 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Table 2: Crack Found that Extends into the Vertical Leg of Spar Cap is Between Station Xors=400 and

Inboard of Xors=408

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Contact The Boeing Company Before further flight. -

for repair instructions and do the

repair.

Condition 4C (Any

Crack Found)

Table 3: Temporary Repair of Crack that Extends into the Vertical Leg of Spar Cap is Between Station

Xors=408 and Xors=417 (Option 1)

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Condition 4D (Crack Do temporary repair. Before further flight. -

Found that Extends into

the Vertical Leg of Spar

Cap is Between Station

Xors=408 and

Xors=417)

AND

Within 1,650 flight cy- -

cles after temporary repair is accomplished.

Do ETHF and Ultrasonic (UT)

in the repaired area.

AND

Do the action specified by Condition 4E or 4F.

Do ETHF and Ultrasonic (UT) - 1,650 flight cycles.

in the repaired area.

Condition 4E (No Crack

Found in Temporary

Repair) AND

Within 7,000 flight cy- -

cles after temporary repair is accomplished.

Do permanent repair as specified in Table 4.

Contact The Boeing Company Before further flight. -

for repair instructions and do the

repair.

Condition 4F (Any

Crack Found in Temporary Repair)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

21 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Table 4: Permanent Repair of Airplanes with Temporary Repair

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Within 7,000 flight cy- -

cles after temporary repair is accomplished.

Do permanent repair.

AND

All Airplanes with Temporary Repair

In accordance with DC- -

10 Supplemental Inspection Document

(SID) Volume II, Chapter 57-50-03, Principal

Structural Element

(PSE) 57.10.007 and

57.10.008.

Do ETHF and UT inspection of

the repaired area.

AND

Do the action specified by Condition 4G or 4H.

In accordance with DC-10

Supplemental Inspection

Document (SID) Volume II,

Chapter 57-50-03, Principal

Structural Element (PSE)

57.10.007 and 57.10.008.

Do repeat ETHF and Ultrasonic -

(UT) inspection.

Condition 4G (No Crack

Found)

Contact The Boeing Company Before further flight. -

for repair instructions and do the

repair.

Condition 4H (Any

Crack Found)

Table 5: Repair of Crack that Extends into the Vertical Leg of Spar Cap is Between Station Xors=408 and

Xors=417 (Option 2)

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Condition 4D (Crack Do permanent repair. Before further flight. -

Found that Extends into

the Vertical Leg of Spar

Cap is Between Station

Xors=408 and

Xors=417)

AND

In accordance with DC- -

10 Supplemental Inspection Document

(SID) Volume II, Chapter 57-50-03, Principal

Structural Element

(PSE) 57.10.007 and

57.10.008.

Do ETHF and UT inspection of

the repaired area.

AND

Do the action specified by Condition 4I or 4J.

In accordance with DC-10

Supplemental Inspection

Document (SID) Volume II,

Chapter 57-50-03, Principal

Structural Element (PSE)

57.10.007 and 57.10.008.

Do repeat ETHF and UT inspec- -

tion of the repaired area.

Condition 4I (No Crack

Found)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

22 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Table 5: Repair of Crack that Extends into the Vertical Leg of Spar Cap is Between Station Xors=408 and

Xors=417 (Option 2)

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Contact The Boeing Company Before further flight. -

for repair instructions and do the

repair.

Condition 4J (Any

Crack Found)

F. Approval

MD-10 Airplanes

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. 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.

In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.

inspection or repair) defined in this service bulletin as a method of compliance to the requirements of

MD-10 ALI PSE 57.10.007/008 and 98.26.22 as it applies to repaired structure. All provisions of MD-10

ALI PSE 57.10.007/008 and 98.26.22 that are not specifically referenced in the above statement remain

fully applicable and must be complied with.

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.

DC-10 Airplanes

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.

In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.

inspection or repair) defined in this service bulletin as an alternative method of compliance to the

requirements of paragraphs (a), (b) and (c) of Airworthiness Directive No. 98-26-22, Amendment

39-10965 and paragraph (j) of Airworthiness Directive No. 2005-14-10, Amendment 39-14187 as it

applies to repaired structure. All provisions of Airworthiness Directive No. 98-26-22 and No. 2005-14-10

that are not specifically referenced in the above statement remain fully applicable and must be complied

with.

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.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

23 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
G. Manpower

The table below shows an estimate of the task hours necessary to do this modification 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.

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 3.4 1.7

Inspect 1 2.0 2.0

Do Repair 2 - -

(a)

Close Access 2 4.0 2.0

Test 1 2.0 2.0

TOTAL FOR EACH AIRPLANE 11.4 7.7

(a) Hours will vary depending on type of repair.

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. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM)

2009-NM-216-AD .

b. Non-Destructive Test Standard Practices Manual (NDTSPM) Part 06, 06-20-01.

c. DC-10, MD-10 Aircraft Maintenance Manual (AMM) 06-35-00, 06-36-00, 12-11-02, 12-11-05,

28-00-00.

d. DC-10, MD-10 Structural Repair Manual (SRM) 51-12-01.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

24 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
e. DC-10 Supplemental Inspection Document (SID) Volume II, Chapter 57-50-03, Principal

Structural Element (PSE) 57.10.007 and 57.10.008.

f. Service Modification Drawing SM10570022.

g. FAA Airworthiness Directive 98-26-22 and 2005-14-10.

h. MD-10 Airworthiness Limitations Instructions (ALI) Chapter 57, Principal Structural Element

(PSE) 57.10.007 and 57.10.008.

2. Data supplied with this Service Bulletin

No data is supplied with this service bulletin. To obtain the data necessary to support this service

bulletin submit a data request to:

Data and Services Management

MS D800-0019

3855 Lakewood Boulevard

Long Beach, California 90846

Phone: (562) 593-6996

Fax: (562) 593-2001

E-mail: dse.boecom@boeing.com

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

REPAIR-CAP, LWR, REAR SPAR OUTER AEO - L

WING SERVICE REWORK DRAWING

SR10570019

DWG K -

SERVICE REWORK - TEMPORARY RE- DWG K -

PAIR, REAR SPAR LWR CAP, DC-10-

10/15 SERVICE REWORK DRAWING

SR10570048

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

None.

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. DTI requirements for the structure affected

are contained in Paragraph 1.E., Compliance of this service bulletin.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

25 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
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: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

26 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the Revision 2

date of this Service Bulletin (US

Dollars)

ROLT as of the

Revision 2 date of

this Service Bulletin (Weeks)

Kit Number Name

SA10570156-3 Service Kit 17 $6.60

SA10570156-5 Service Kit 17 6.60

SA10570156-7 Service Kit 17 75,398.00

SA10570156-9 Service Kit 17 75,520.00

SA10570156-11 Service Kit 17 93,777.00

SA10570156-13 Service Kit 17 99,777.00

SA10570156-15 Service Kit 17 91,919.00

SA10570156-17 Service Kit 17 100,365.00

SA10570156-19 Service Kit 17 610,016.00

SA10570156-21 Service Kit 17 610,549.00

B. Industry Support Information

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

C. Parts Necessary For Each Airplane

1. Kits/Parts

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

27 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
SERVICE KIT APPLICABILITY

Service Kit Drawing Configuration

SA10570156-3 SR10570048-7001

SA10570156-5 SR10570048-7003

SA10570156-7 SR10570048-7021

SA10570156-9 SR10570048-7023

SA10570156-11 SR10570048-7025

SA10570156-13 SR10570048-7027

SA10570156-15 SR10570048-7029

SA10570156-17 SR10570048-7031

SA10570156-19 SR10570019-7013

SA10570156-21 SR10570019-7015

Service Kit SA10570156

New Part Number QTY Name Notes

-3 -5 -7 -9 -19 -21

3D0006-3 . . 4 4 50 50 NUT ASSY .

3D0006-4 122 122 NUT ASSY .

3D0006-5 1 1 30 30 286 286 NUT ASSY .

3D0006-6 . . 15 15 66 66 NUT ASSY .

HLT335TB-10-10 . . . . 9 9 PIN .

HLT335TB-10-11 . . . . 7 7 PIN .

HLT335TB-10-12 . . . . 1 1 PIN .

HLT335TB-10-13 . . . . 11 11 PIN .

HLT335TB-10-14 . . . . 2 2 PIN .

HLT335TB-12-11 . . . . 30 30 PIN .

HLT335TB-12-13 . . . . 18 18 PIN .

HLT335TB-12-14 . . . . 12 12 PIN .

HLT335TB-12-17 . . . . 1 1 PIN .

HLT335TB-12-19 . . . . 1 1 PIN .

HLT335TB-14-14 . . . . 30 30 PIN .

HLT335TB-14-15 . . . . 2 2 PIN .

HLT335TB-14-16 . . . . 4 4 PIN .

HLT335TB-14-17 . . . . 2 2 PIN .

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

28 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Service Kit SA10570156

New Part Number QTY Name Notes

-3 -5 -7 -9 -19 -21

HLT335TB-14-18 . . . . 12 12 PIN .

HLT335TB-14-19 . . . . 2 2 PIN .

HLT335TB-14-20 . . . . 6 6 PIN .

HLT335TB-14-21 . . . . 8 8 PIN .

HLT335TB-14-22 . . . . 6 6 PIN .

HLT335TB-14-23 . . . . 4 4 PIN .

HLT335TB-14-24 . . . . 3 3 PIN .

HLT335TB-14-25 . . . . 16 16 PIN .

HLT335TB-14-26 . . . . 3 3 PIN .

HLT335TB-14-28 . . . . 2 2 PIN .

HLT335TB-6-4 . . . . 8 8 PIN .

HLT335TB-6-6 . . . . 24 24 PIN .

HLT336TB-10-10 . . . . 22 22 PIN .

HLT336TB-10-11 . . . . 37 37 PIN .

HLT336TB-10-12 . . . . 8 8 PIN .

HLT336TB-10-13 . . . . 9 9 PIN .

HLT336TB-10-15 . . . . 5 5 PIN .

HLT336TB-10-16 . . . . 3 3 PIN .

HLT336TB-10-17 . . . . 4 4 PIN .

HLT336TB-10-18 . . . . 11 11 PIN .

HLT336TB-10-19 . . . . 9 9 PIN .

HLT336TB-10-20 . . . . 8 8 PIN .

HLT336TB-10-21 . . . . 3 3 PIN .

HLT336TB-10-22 . . . . 3 3 PIN .

HLT336TB-10-23 . . . . 2 2 PIN .

HLT336TB-10-24 . . . . 6 6 PIN .

HLT336TB-10-25 . . . . 2 2 PIN .

HLT336TB-10-26 . . . . 2 2 PIN .

HLT336TB-10-28 . . . . 2 2 PIN .

HLT336TB-10-30 . . . . 2 2 PIN .

HLT336TB-10-8 . . . . 12 12 PIN .

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

29 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Service Kit SA10570156

New Part Number QTY Name Notes

-3 -5 -7 -9 -19 -21

HLT336TB-10-9 . . . . 46 46 PIN .

HLT336TB-12-13 . . . . 1 1 PIN .

HLT336TB-12-30 . . . . 2 2 PIN .

HLT336TB-12-9 . . . . 1 1 PIN .

HLT336TB-14-20 . . . . 1 1 PIN .

HLT336TB-14-22 . . . . 2 2 PIN .

HLT336TB-14-23 . . . . 2 2 PIN .

HLT336TB-14-25 . . . . 3 3 PIN .

HLT336TB-14-26 . . . . 1 1 PIN .

HLT336TB-14-27 . . . . 4 4 PIN .

HLT336TB-14-28 . . . . 1 1 PIN .

HLT435-10-10 . . . . 2 2 PIN .

HLT435-10-11 . . . . 2 2 PIN .

HLT435-8-10 . . . . 12 12 PIN .

HLT435-8-11 . . . . 13 13 PIN .

HLT435-8-12 . . . . 2 2 PIN .

HLT436-6-14 . . . . 1 1 PIN .

HLT436-8-10 . . . . 10 10 PIN .

HLT436-8-11 . . . . 10 10 PIN .

HLT436-8-13 . . . . 9 9 PIN .

HLT436-8-14 . . . . 9 9 PIN .

HLT436-8-15 . . . . 12 12 PIN .

HLT436-8-16 . . . . 12 12 PIN .

HLT436-8-17 . . . . 5 5 PIN .

HLT436-8-18 . . . . 6 6 PIN .

HLT436-8-19 . . . . 2 2 PIN .

HLT436-8-21 . . . . 2 2 PIN .

HLT436-8-25 . . . . 4 4 PIN OVERSIZED .

HLT436-8-4 . . . . 3 3 PIN .

HLT436-8-7 . . . . 1 1 PIN .

HLT436-8-8 . . . . 4 4 PIN .

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

30 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Service Kit SA10570156

New Part Number QTY Name Notes

-3 -5 -7 -9 -19 -21

HLT436-8-9 . . . . 4 4 PIN .

HLT439-10-15 . . . . 2 2 HI-LOK PIN .

HLT439-10-16 . . . . 2 2 PIN .

HLT635-10-13 . . . . 8 8 PIN .

HLT635-10-14 . . . . 8 8 PIN .

HLT635-10-16 . . . . 5 5 PIN .

HLT635-10-17 . . . . 7 7 PIN .

HLT635-10-18 . . . . 7 7 PIN .

HLT635-10-19 . . . . 12 12 PIN .

HLT635-10-20 . . . . 2 2 PIN .

HLT635-6-12 . . . . 1 1 PIN .

HLT635-6-13 . . . . 1 1 PIN .

HLT635-6-14 . . . . 2 2 PIN .

HLT635-6-15 . . . . 3 3 PIN .

HLT635-6-16 . . . . 1 1 PIN .

HLT635-6-17 . . . . 5 5 PIN .

HLT635-6-18 . . . . 2 2 PIN .

HLT635-6-19 . . . . 1 1 PIN .

HLT635-6-20 . . . . 1 1 PIN .

HLT635-8-17 . . . . 1 1 PIN .

HLT635-8-20 . . . . 1 1 PIN .

NAS7402-13 . . 2 2 . . BOLT .

NAS7402-14 . . 2 2 . . BOLT .

NAS7402-15 . . 4 4 . . BOLT .

S4931919-10-11 1 1 . . . . PIN .

S4931919-10X15 . . 1 1 . . PIN, OVERSIZE .

S4931919-10X16 . . 1 1 . . PIN, OVERSIZE .

S4931919-10X17 . . 2 2 . . PIN, OVERSIZE .

S4931919-10X18 . . 1 1 . . PIN, OVERSIZE .

S4931919-10X19 . . 2 2 . . PIN, OVERSIZE .

S4931919-10X20 . . 1 1 . . PIN, OVERSIZE .

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

31 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Service Kit SA10570156

New Part Number QTY Name Notes

-3 -5 -7 -9 -19 -21

S4931919-10X21 . . 8 8 . . PIN, OVERSIZE .

S4931919-10X22 . . 13 13 . . PIN, OVERSIZE .

S4931919-10X23 . . 1 1 . . PIN, OVERSIZE .

S4931919-12X16 . . 1 1 . . PIN, OVERSIZE .

S4931919-12X17 . . 3 3 . . PIN, OVERSIZE .

S4931919-12X18 . . 2 2 . . PIN, OVERSIZE .

S4931919-12X19 . . 2 2 . . PIN, OVERSIZE .

S4931919-12X20 . . 2 2 . . PIN, OVERSIZE .

S4931919-12X21 . . 2 2 . . PIN, OVERSIZE .

S4931919-12X22 . . 1 1 . . PIN, OVERSIZE .

S4931919-12X27 . . 2 2 . . PIN, OVERSIZE .

S4931919-14X20 . . 5 5 . . PIN, OVERSIZE .

S4931919-14X21 . . 2 2 . . PIN, OVERSIZE .

S4931919-14X22 . . 25 25 . . PIN, OVERSIZE .

S4931919-6X15 . . 2 2 . . PIN, OVERSIZE .

S4931919-6X16 . . 2 2 . . PIN, OVERSIZE .

S4933816-7 . . 32 32 114 114 NUT ASSY .

SR10570019-10 . . . . . 1 SPLICE .

SR10570019-11 . . . . 1 . SUPPORT .

SR10570019-12 . . . . . 1 SUPPORT .

SR10570019-13 . . . . 1 . SUPPORT .

SR10570019-14 . . . . . 1 SUPPORT .

SR10570019-15 . . . . 1 . CLIP .

SR10570019-16 . . . . . 1 CLIP .

SR10570019-17 . . . . 1 . CLIP .

SR10570019-18 . . . . . 1 CLIP .

SR10570019-19 . . . . 1 1 CLIP .

SR10570019-23 . . . . 1 . CLIP .

SR10570019-24 . . . . . 1 CLIP .

SR10570019-25 . . . . 1 . CLIP .

SR10570019-26 . . . . . 1 CLIP .

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

32 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Service Kit SA10570156

New Part Number QTY Name Notes

-3 -5 -7 -9 -19 -21

SR10570019-27 . . . . 1 . CLIP .

SR10570019-28 . . . . . 1 CLIP .

SR10570019-29 . . . . 1 1 TAPE (a)

SR10570019-3 . . . . 1 . SPLICE .

SR10570019-31 . . . . 1 . CLIP .

SR10570019-32 . . . . . 1 CLIP .

SR10570019-33 . . . . 1 . CLIP .

SR10570019-34 . . . . . 1 CLIP .

SR10570019-35 . . . . 1 . CAP .

SR10570019-36 . . . . . 1 CAP .

SR10570019-37 . . . . 1 . CLIP .

SR10570019-38 . . . . . 1 CLIP .

SR10570019-4 . . . . . 1 SPLICE .

SR10570019-5 . . . . 1 . SPLICE .

SR10570019-6 . . . . . 1 SPLICE .

SR10570019-7 . . . . 1 . SPLICE .

SR10570019-8 . . . . . 1 SPLICE .

SR10570019-9 . . . . 1 . SPLICE .

SR10570048-31 1 1 . . . . BUSHING (a)

SR10570048-39 . . 1 . . . DOUBLER .

SR10570048-40 . . . 1 . . DOUBLER .

SR10570048-41 . . 1 . . . FAIRING .

SR10570048-42 . . . 1 . . FAIRING .

SR10570048-47 . . 1 . . . FAIRING .

SR10570048-48 . . . 1 . . FAIRING .

SR10570048-49 . . 1 1 . . FILLER .

SR10570048-53 . . 1 1 . . FILLER .

(a) Parts to be fabricated/procured by operator - not included in kit.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

33 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Group 1:

Service Kit SA10570156

New Part Number QTY Name

-11 -13

3D0006-3 4 4 NUT ASSY

3D0006-5 30 30 NUT ASSY

3D0006-6 15 15 NUT ASSY

ARC0430-31 2 2 CLIP

HLT334-5-4 10 10 PIN

HLT434-6-3 4 4 PIN

MS21042L08 10 10 NUT

MS21042L3 14 14 NUT

MS21042L4 10 10 NUT

MS21042L5 49 49 NUT

NAS1252-10L 14 14 WASHER

NAS1252-416L 10 10 WASHER

NAS1252-516L 49 49 WASHER

NAS1252-8L 10 10 WASHER

NAS7402-13 2 2 BOLT

NAS7402-14 2 2 BOLT

NAS7402-15 4 4 BOLT

S4931919-10X15 1 1 PIN, OVERSIZE

S4931919-10X16 1 1 PIN, OVERSIZE

S4931919-10X17 2 2 PIN, OVERSIZE

S4931919-10X18 1 1 PIN, OVERSIZE

S4931919-10X19 2 2 PIN, OVERSIZE

S4931919-10X20 1 1 PIN, OVERSIZE

S4931919-10X21 2 2 PIN, OVERSIZE

S4931919-10X23 2 2 PIN, OVERSIZE

S4931919-10X24 4 4 PIN, OVERSIZE

S4931919-10X25 13 13 PIN, OVERSIZE

S4931919-10X27 1 1 PIN, OVERSIZE

S4931919-12X16 1 1 PIN, OVERSIZE

S4931919-12X17 3 3 PIN, OVERSIZE

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

34 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Group 1:

Service Kit SA10570156

New Part Number QTY Name

-11 -13

S4931919-12X18 2 2 PIN, OVERSIZE

S4931919-12X19 2 2 PIN, OVERSIZE

S4931919-12X20 2 2 PIN, OVERSIZE

S4931919-12X21 2 2 PIN, OVERSIZE

S4931919-12X22 1 1 PIN, OVERSIZE

S4931919-12X27 2 2 PIN, OVERSIZE

S4931919-14X20 3 3 PIN, OVERSIZE

S4931919-14X21 5 5 PIN, OVERSIZE

S4931919-14X22 9 9 PIN, OVERSIZE

S4931919-14X23 1 1 PIN, OVERSIZE

S4931919-14X24 2 2 PIN, OVERSIZE

S4931919-14X25 4 4 PIN, OVERSIZE

S4931919-14X26 4 4 PIN, OVERSIZE

S4931919-14X27 11 11 PIN, OVERSIZE

S4931919-6-5 10 10 PIN

S4931919-6X15 2 2 PIN, OVERSIZE

S4931919-6X16 2 2 PIN, OVERSIZE

S4931920-10X13 1 1 PIN, OVERSIZE

S4931920-10X14 4 4 PIN, OVERSIZE

S4931920-10X15 16 19 PIN, OVERSIZE

S4931920-10X16 8 5 PIN, OVERSIZE

S4931920-10X17 14 16 PIN, OVERSIZE

S4931920-10X18 4 2 PIN, OVERSIZE

S4931920-10X19 2 2 PIN, OVERSIZE

S4931920-8X11 2 2 PIN, OVERSIZE

S4931920-8X12 8 8 PIN, OVERSIZE

S4933816-7 39 39 NUT ASSY

SR10570048-13 1 . ANGLE

SR10570048-14 . 1 ANGLE

SR10570048-15 1 . TEE

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

35 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Group 1:

Service Kit SA10570156

New Part Number QTY Name

-11 -13

SR10570048-16 . 1 TEE

SR10570048-19 . 1 SUPPORT

SR10570048-21 . 1 SUPPORT

SR10570048-23 1 1 FILLER

SR10570048-25 1 1 SHIM

SR10570048-27 . 1 SHIM

SR10570048-29 . 1 SHIM

SR10570048-39 1 . DOUBLER

SR10570048-40 . 1 DOUBLER

SR10570048-41 1 . FAIRING

SR10570048-42 . 1 FAIRING

SR10570048-45 1 . STRAP

SR10570048-46 . 1 STRAP

SR10570048-47 1 . FAIRING

SR10570048-48 . 1 FAIRING

SR10570048-49 1 1 FILLER

SR10570048-53 1 1 FILLER

SR10570048-55 1 . ANGLE

SR10570048-56 . 1 ANGLE

Group 2:

Service Kit SA10570156

New Part Number QTY Name

-15 -17

3D0006-3 4 4 NUT ASSY

3D0006-5 30 30 NUT ASSY

3D0006-6 15 15 NUT ASSY

ARB4195-1 1 . BRACKET

ARB4195-2 . 1 BRACKET

HLT334-5-4 10 10 PIN

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

36 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Group 2:

Service Kit SA10570156

New Part Number QTY Name

-15 -17

MS21042L08 10 10 NUT

MS21042L3 10 10 NUT

MS21042L4 10 10 NUT

MS21042L5 49 49 NUT

NAS1252-10L 10 10 WASHER

NAS1252-416L 10 10 WASHER

NAS1252-516L 49 49 WASHER

NAS1252-8L 10 10 WASHER

NAS7402-13 2 2 BOLT

NAS7402-14 2 2 BOLT

NAS7402-15 4 4 BOLT

S4931919-10X15 1 1 PIN, OVERSIZE

S4931919-10X16 1 1 PIN, OVERSIZE

S4931919-10X17 2 2 PIN, OVERSIZE

S4931919-10X18 1 1 PIN, OVERSIZE

S4931919-10X19 2 2 PIN, OVERSIZE

S4931919-10X20 1 1 PIN, OVERSIZE

S4931919-10X21 2 2 PIN, OVERSIZE

S4931919-10X23 2 2 PIN, OVERSIZE

S4931919-10X24 4 4 PIN, OVERSIZE

S4931919-10X25 13 13 PIN, OVERSIZE

S4931919-10X27 1 1 PIN, OVERSIZE

S4931919-12X16 1 1 PIN, OVERSIZE

S4931919-12X17 3 3 PIN, OVERSIZE

S4931919-12X18 2 2 PIN, OVERSIZE

S4931919-12X19 2 2 PIN, OVERSIZE

S4931919-12X20 2 2 PIN, OVERSIZE

S4931919-12X21 2 2 PIN, OVERSIZE

S4931919-12X22 1 1 PIN, OVERSIZE

S4931919-12X27 2 2 PIN, OVERSIZE

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

37 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Group 2:

Service Kit SA10570156

New Part Number QTY Name

-15 -17

S4931919-14X20 3 3 PIN, OVERSIZE

S4931919-14X21 5 5 PIN, OVERSIZE

S4931919-14X22 9 9 PIN, OVERSIZE

S4931919-14X23 1 1 PIN, OVERSIZE

S4931919-14X24 2 2 PIN, OVERSIZE

S4931919-14X25 4 4 PIN, OVERSIZE

S4931919-14X26 4 4 PIN, OVERSIZE

S4931919-14X27 11 11 PIN, OVERSIZE

S4931919-6-5 10 10 PIN

S4931919-6X15 2 2 PIN, OVERSIZE

S4931919-6X16 2 2 PIN, OVERSIZE

S4931920-10X13 1 1 PIN, OVERSIZE

S4931920-10X14 4 4 PIN, OVERSIZE

S4931920-10X15 16 19 PIN, OVERSIZE

S4931920-10X16 8 5 PIN, OVERSIZE

S4931920-10X17 12 14 PIN, OVERSIZE

S4931920-10X18 6 4 PIN, OVERSIZE

S4931920-10X19 2 2 PIN, OVERSIZE

S4931920-8X11 2 2 PIN, OVERSIZE

S4931920-8X12 8 8 PIN, OVERSIZE

S4933816-7 39 39 NUT ASSY

SR10570048-13 1 . ANGLE

SR10570048-14 . 1 ANGLE

SR10570048-15 1 . TEE

SR10570048-16 . 1 TEE

SR10570048-17 1 . BRACKET

SR10570048-18 . 1 BRACKET

SR10570048-19 . 1 SUPPORT

SR10570048-21 . 1 SUPPORT

SR10570048-23 1 1 FILLER

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

38 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Group 2:

Service Kit SA10570156

New Part Number QTY Name

-15 -17

SR10570048-25 1 1 SHIM

SR10570048-27 . 1 SHIM

SR10570048-29 . 1 SHIM

SR10570048-39 1 . DOUBLER

SR10570048-40 . 1 DOUBLER

SR10570048-41 1 . FAIRING

SR10570048-42 . 1 FAIRING

SR10570048-45 1 . STRAP

SR10570048-46 . 1 STRAP

SR10570048-47 1 . FAIRING

SR10570048-48 . 1 FAIRING

SR10570048-49 1 1 FILLER

SR10570048-51 1 . ANGLE

SR10570048-52 . 1 ANGLE

SR10570048-53 1 1 FILLER

2. Parts and Materials Supplied by the Operator

Part Number / Specifica- QTY Name Notes

tion

PR-1422 B-2 1 Pint Sealing Compound (a) (b)

(DMS 2082 or Equivalent)

1.00 Diameter X 1.00 Bar,

Aluminium 7075-T7351.

SR10570048-31 1 Bushing

Material Specification

QQ-A-225/9 TEMP T7351

(a) Refer to Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(b) Can be purchased from: PRC-DeSoto International, Incorporated CAGE

P. O. Box 1800 92108

Sylmar, California 91342

3. Parts Modified and Reidentified

None.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

39 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

The DC-10 Structural Repair Manual Volume II, DC-10, MD-10 SRM 51-12-01 gives data about cold

working tools and sleeves necessary to do the work given in this service bulletin. These tools are

available from industry sources.

F. Special Tooling Necessary to do this Service Bulletin

Cold working tools are necessary to do the change given in this service bulletin. To get the cold working

tools, refer to Paragraph 2.E., Special Tooling - Price and Availability.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

40 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
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.

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. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Equivalent parts are listed in the AEPL, Drawing 7595071.

3. Use the approved fastener and process material substitutions, in accordance with

DC-10, MD-10 SRM Chapter 51.

4. 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.

5. A 1/8-inch thick stack of the same type washers called for in this service bulletin is

the maximum thickness which may be used under fastener head or nut to counteract

accumulation of tolerances.

EXCEPTION: When the available fastener length increments are greater than

1/16-inch, a 3/16-inch thick stack of the same type washers may be used.

6. 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

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

41 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
– 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 limits to tighten nuts and bolts are in SRM Chapter 51.

7. Obey all of the warnings and cautions given in the specified manual sections.

8. 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.

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. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

12. These work instructions include repairs to left and right wings. Repairs are only

required on the wing where crack(s) are found.

B. WORK INSTRUCTIONS

1. Open wing trailing edge lower access door 551AB (left wing) and 651AB (right wing). Refer to

DC-10, MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for the

right wing locations.

2. Remove and keep rear spar access doors 541HB, 541JB, and attaching parts (left wing) and

641HB, 641JB, and attaching parts (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left

wing locations and DC-10, MD-10 AMM 06-36-00 for the right wing locations.

3. Fabricate DAC GSET AL.01 reference standard. Refer to NDTSPM Part 06, 06-20-01 as an

accepted procedure.

4. Do ETHF inspection for cracks in the left and right wing rear spar lower caps between the outboard

edge of the rear spar lower cap splice at Station Xors=400 and Station Xors=417 in accordance

with DC-10 Supplemental Inspection Document (SID) Volume II, Chapter 57-50-03, Sequence 1,

Method 1, Principal Structural Element (PSE) 57.10.007 and 57.10.008. Based on findings do as

follows:

Condition 1 (No Crack)

a. Do repeat ETHF inspections as described in Paragraph 3.B.3., Work Instructions, at intervals

as specified in Paragraph 1.E., Compliance.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

42 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Condition 2 (Crack at Fastener Hole that can be Removed by Hole Enlargement)

a. Do permanent repair in accordance with:

Service Rework Drawing SR10570048-7001, Detail D if crack(s) found on left wing.

Service Rework Drawing SR10570048-7003, Detail D if crack(s) found on right wing.

b. Do ETHF inspections of the spar cap and HFEC inspections of the lower wing skin in the

repaired area in accordance with Service Rework Drawing SR10570048 inspection

requirements at intervals as specified in Paragraph1.E., Compliance for cracks and do as

follows:

Condition 2A (No Crack Found)

(1) Do repeat ETHF inspections of the spar cap and HFEC inspections of the lower wing

skin in the repaired area in accordance with Service Rework Drawing SR10570048

inspection requirements at intervals as specified in Paragraph1.E., Compliance.

Condition 2B (Any Crack Found)

(1) Evaluate the crack and do the work of Condition 2, 3 or 4 as applicable.

c. Do repeat ETHF inspection for cracks in the unchanged areas of the left and right wing rear

spar lower caps between the outboard edge of the rear spar lower cap splice at Station

Xors=400 and Station Xors=417 in accordance with DC-10 Supplemental Inspection Document

(SID) Volume II, Chapter 57-50-03, Sequence 1, Method 1, Principal Structural Element (PSE)

57.10.007 and 57.10.008. Based on findings do as follows:

Condition 2C (No Crack Found)

(1) Do ETHF inspection for cracks in the left and right wing rear spar lower caps between

the outboard edge of the rear spar lower cap splice at Station Xors=400 and Station

Xors=417 in accordance with DC-10 Supplemental Inspection Document (SID) Volume

II, Chapter 57-50-03, Sequence 1, Method 1, Principal Structural Element (PSE) 57.10.007

and 57.10.008 at intervals as specified in Paragraph 1.E., Compliance.

Condition 2D (Any Crack Found)

(1) Evaluate the crack and do the work of Condition 2, 3 or 4 as applicable.

Condition 3 (Crack in Spar Cap Aft Leg at Fastener Hole(s) that Can not be Removed by

Hole Enlargement but does not Extend into Vertical Leg)

a. Establish the location of the crack and do the work based on location.

Condition 3A (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=400

and Inboard of Xors=408)

(1) Contact The Boeing Company for repair instructions and do the repair.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

43 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Condition 3B (Crack in Spar Cap Aft Leg at Fastener Hole(s) is Between Station Xors=408

and Xors=417)

(1) Defuel airplane. Refer to DC-10, MD-10 AMM 12-11-05 as an accepted procedure.

(2) Remove and keep wing fuel tank access covers 534AT and 534BT (left wing) and 634AT

and 634BT (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing locations

and DC-10, MD-10 AMM 06-36-00 for the right wing locations.

(3) Prepare (purge) wing fuel tanks for entry. Refer to DC-10, MD-10 AMM 28-00-00 as an

accepted procedure.

(4) Do permanent repair in accordance with:

Service Rework Drawing SR10570048-7021 if crack(s) found on left wing.

Service Rework Drawing SR10570048-7023 if crack(s) found on right wing.

(5) Install kept wing fuel tank access covers 534AT and 534BT (left wing) and 634AT and

634BT (right wing) in accordance with DC-10, MD-10 AMM 28-00-00. Refer to DC-10,

MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for

the right wing locations.

(6) Refuel airplane and check for leaks in the work areas. Refer to DC-10, MD-10 AMM

12-11-02 for refueling procedures.

(7) Do repeat ETHF and UT inspections in the repaired area in accordance with Service

Rework Drawing SR10570048 inspection requirements at intervals as specified in

Paragraph 1.E., Compliance for cracks and do as follows:

Condition 3C (No Crack Found)

(a) Do repeat ETHF and UT inspections in the repaired area in accordance with Service

Rework Drawing SR10570048 inspection requirements at intervals as specified in

Paragraph 1.E., Compliance.

Condition 3D (Any Crack Found)

(a) Contact The Boeing Company for repair instructions and do the repair.

Condition 4 (Crack Extends Into the Vertical Leg of Spar Cap)

a. Establish the location of the crack and do the work based on location.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

44 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Condition 4A (Crack is Between Station Xors=400 and Inboard of Xors=408)

(1) Defuel airplane. Refer to DC-10, MD-10 AMM 12-11-05 as an accepted procedure.

(2) Remove and keep wing fuel tank access covers 534AT and 534BT (left wing) and 634AT

and 634BT (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing locations

and DC-10, MD-10 AMM 06-36-00 for the right wing locations.

(3) Prepare (purge) wing fuel tanks for entry. Refer to DC-10, MD-10 AMM 28-00-00 as an

accepted procedure.

(4) Do permanent repair in accordance with:

Service Rework Drawing SR10570019-7013 if crack(s) found on left wing.

Service Rework Drawing SR10570019-7015 if crack(s) found on right wing.

(5) Install kept wing fuel tank access covers 534AT and 534BT (left wing) and 634AT and

634BT (right wing) in accordance with DC-10, MD-10 AMM 28-00-00. Refer to DC-10,

MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for

the right wing locations.

(6) Refuel airplane and check for leaks in the work areas. Refer to DC-10, MD-10 AMM

12-11-02 for refueling procedures.

(7) Do ETHF and UT inspections of the repaired area in accordance with Service Rework

Drawing SR10570019 inspection requirements for cracks at intervals specified by

Paragraph1.E., Compliance and do as follows:

Condition 4B (No Crack Found in Permanent Repair)

(a) Do ETHF and UT inspections in the repaired area in accordance with Service Rework

Drawing SR10570019 inspection requirements at intervals specified by Paragraph1.E.,

Compliance.

Condition 4C (Any Crack Found in Permanent Repair)

(a) Contact The Boeing Company for repair instructions and do the repair.

Condition 4D (Crack is Between Station Xors=408 and Xors=417)

(1) Defuel airplane. Refer to DC-10, MD-10 AMM 12-11-05 as an accepted procedure.

(2) Remove and keep wing fuel tank access covers 534AT and 534BT (left wing) and 634AT

and 634BT (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing locations

and DC-10, MD-10 AMM 06-36-00 for the right wing locations.

(3) Prepare (purge) wing fuel tanks for entry. Refer to DC-10, MD-10 AMM 28-00-00 as an

accepted procedure.

(4) Do Option 1 or Option 2

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

45 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Option 1

(a) Do temporary repair in accordance with:

Group 1:

Service Rework Drawing SR10570048-7025 if crack(s) found on left wing.

Group 1:

Service Rework Drawing SR10570048-7027 if crack(s) found on right wing.

Group 2:

Service Rework Drawing SR10570048-7029 if crack(s) found on left wing.

Group 2:

Service Rework Drawing SR10570048-7031 if crack(s) found on right wing.

(b) Do ETHF and UT inspections in the repaired area in accordance with Service Rework

Drawing SR10570048 inspection requirements for cracks at intervals specified by

Paragraph 1.E., Compliance and do as follows:

Condition 4E (No Crack Found in Temporary Repair)

Do ETHF and UT inspections in the repaired area in accordance with Service Rework

Drawing SR10570048 inspection requirements at intervals specified by Paragraph

1.E., Compliance.

Condition 4F (Any Crack Found in Temporary Repair)

Contact The Boeing Company for repair instructions and do the repair.

(c) Remove temporary repair upon or prior to reaching the end of its service life at interval

specified in Paragraph 1.E., Compliance. Replace temporary repair as follows:

INSTRUCTIONS FOR REPLACING THE TEMPORARY REPAIR

1) Do permanent repair in accordance with:

Service Rework Drawing SR10570019-7013 if temporary repair installed on left

wing.

Service Rework Drawing SR10570019-7015 if temporary repair installed on right

wing.

2) Do ETHF and UT inspections in the repaired area in accordance with Service

Rework Drawing SR10570019 inspection requirements at intervals specified by

Paragraph 1.E., Compliance for cracks and do as follows:

Condition 4G (No Crack Found in Permanent Repair)

Do ETHF and UT inspections in the repaired area in accordance with Service

Rework Drawing SR10570019 inspection requirements at intervals specified by

Paragraph 1.E., Compliance.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

46 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT
Condition 4H (Any Crack Found in Permanent Repair)

Contact The Boeing Company for repair instructions and do the repair.

Option 2

(a) Do permanent repair in accordance with:

Service Rework Drawing SR10570019-7013 on left wing.

Service Rework Drawing SR10570019-7015 on right wing.

(b) Do ETHF and UT inspections in the repaired area in accordance with Service Rework

Drawing SR10570019 inspection requirements at intervals specified by Paragraph

1.E., Compliance for cracks and do as follows:

Condition 4I (No Crack Found in Permanent Repair)

Do ETHF and UT inspections in the repaired area in accordance with Service Rework

Drawing SR10570019 inspection requirements at intervals specified by Paragraph

1.E., Compliance.

Condition 4J (Any Crack Found in Permanent Repair)

Contact The Boeing Company for repair instructions and do the repair.

(5) Install kept wing fuel tank access covers 534AT and 534BT (left wing) and 634AT and

634BT (right wing) in accordance with DC-10, MD-10 AMM 28-00-00. Refer to DC-10,

MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for

the right wing locations.

(6) Refuel airplane and check for leaks in the work areas. Refer to DC-10, MD-10 AMM

12-11-02 for refueling procedures.

5. Install kept rear spar access doors 541HB, 541JB and attaching parts (left wing) and 641HB,

641JB and attaching parts (right wing). Refer to DC-10, MD-10 AMM 06-35-00 for the left wing

locations and DC-10, MD-10 AMM 06-36-00 for the right wing locations.

6. Close wing trailing edge lower access door 551AB (left wing) and 651AB (right wing). Refer to

DC-10, MD-10 AMM 06-35-00 for the left wing locations and DC-10, MD-10 AMM 06-36-00 for the

right wing locations.

7. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: September 16, 2009

Revision 2: August 23, 2011 DC10-57A156

47 of 47

BOEING SERVICE BULLETIN DC10-57A156

ALERT ALERT