### 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.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 1 of 47 8.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 4 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT**

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### 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 DC10-57A156 Revision 2: August 23, 2011 5 of 47Vertical 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** September 16, 2009 Original Issue: March 10, 2010 Revision 1: August 23, 2011 Revision 2:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 10 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT**

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### 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 **DESCRIPTION CONFIGURATION**  **GROUP** 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. - 2Airplane Models: DC-10-10, DC-10-10F, MD-10-10F **Group Fuselage Num-**  **ber** 1 6 1 8 2 15 2 17 2 25 - 27

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 11 of 47**Group Fuselage Num-**  **ber**2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 12 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Group**  **Fuselage Num- ber** 2 321 2 323 2 344 2 347 2 351 2 353 2 379 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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** **Zone Model**  535, 635 MD-10-10F **Group 2: Affected Maintenance Zones** **Zone Model**  535, 635 DC-10-10, DC-10-10F, MD-10- 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 DC10-57A156 Revision 2: August 23, 2011 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) Compliance Time**  **Action Condition** 

- Within 1,750 flight cy- cles after the originalissue date on this service bulletin. Do Eddy Current Test High Frequency (ETHF) inspection for cracks on the left and rightwing 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

1,750 flight cycles. - Do 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. Condition 1 (No Crack Found)

- Before further flight. Do permanent repair in accor-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 inspectionof the lower wing skin in the repaired area. ANDDo the action specified by Condition 2A or 2B. 1,750 flight cycles. - Do ETHF inspection of the lower spar cap and HFEC inspectionof the lower wing skin in the repaired area. Condition 2A (No Crack Found in Repaired Area)

- Before further flight. Evaluate the crack and do the work of Condition 2, 3 or 4 as applicable. Condition 2B (AnyCrack Found in Repaired Area) AND

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 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) Compliance Time**  **Action Condition** 

- 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. ANDDo the action specified by Condition 2C or 2D. 1,750 flight cycles. - Do ETHF inspections in the un- 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)

- Before further flight. Evaluate the crack and do the work of Condition 2, 3 or 4 as applicable. Condition 2D (Any Crack Found)

- Before further flight. Establish the location of thecrack 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)

- Before further flight. Contact The Boeing Company 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)

- Before further flight. Do permanent repair. Condition 3B (Crack 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. ANDDo the action specified by Condition 3C or 3D. 4,550 flight cycles. - Do ETHF and Ultrasonic (UT) 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 DC10-57A156 Revision 2: August 23, 2011 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) Compliance Time**  **Action Condition** 

- Before further flight. Contact The Boeing Company for repair instructions and do the repair. Condition 3D (Any Crack Found)

- Before further flight. Establish the location of thecrack and do the action specified by Condition 4A or 4D. Condition 4 (Crack Found that Extends into the Vertical Leg of Spar Cap)

- Before further flight. Do the action specified in Table 2. Condition 4A (Crack Found that Extends into the Vertical Leg of Spar Cap is Between Station Xors=400 and Inboard of Xors=408)

- Before further flight. Do the action specified in Table 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)**  **Compliance Time Action**  **Condition**

- Before further flight. Do permanent repair. Condition 4A (Crack 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. ANDDo 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 DC10-57A156 Revision 2: August 23, 2011 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) Compliance Time**  **Action Condition** 

- Before further flight. Contact The Boeing Company 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)**  **Compliance Time Action**  **Condition**

- Before further flight. Do temporary repair. Condition 4D (Crack 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. ANDDo the action specified by Condition 4E or 4F. 1,650 flight cycles. - Do ETHF and Ultrasonic (UT) 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.

- Before further flight. Contact The Boeing Company for repair instructions and do the repair. Condition 4F (AnyCrack Found in Temporary Repair)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 21 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Table 4: Permanent Repair of Airplanes with Temporary Repair**  **Repeat Interval (Not to Exceed)**  **Compliance Time Action**  **Condition**

- Within 7,000 flight cy-cles after temporary repair is accomplished. Do permanent repair. ANDAll 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. ANDDo 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)

- Before further flight. Contact The Boeing Company 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)**  **Compliance Time Action**  **Condition**

- Before further flight. Do permanent repair. Condition 4D (Crack 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. ANDDo 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 DC10-57A156 Revision 2: August 23, 2011 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) Compliance Time**  **Action Condition** 

- Before further flight. Contact The Boeing Company 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 DC10-57A156 Revision 2: August 23, 2011 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. **Elapsed Hours Task Hours**  **Number of Persons Task**  1.7 3.4 2 Open Access 2.0 2.0 1 Inspect

- - 2 Do Repair (a) 2.0 4.0 2 Close Access 2.0 2.0 1 Test 7.7 11.4 TOTAL FOR EACH AIRPLANE (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 DC10-57A156 Revision 2: August 23, 2011 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: **ADCN DCN/REV**  **Sheet Title**  **Drawing No** L - AEO REPAIR-CAP, LWR, REAR SPAR OUTER WING SERVICE REWORK DRAWING SR10570019

- K DWG

- K DWG SERVICE REWORK - TEMPORARY RE- 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 Ser vice Bulletin (US**  **Dollars) ROLT as of the**  **Revision 2 date of this Service Bul** 

**letin (Weeks) Name**  **Kit Number** $6.60 17 Service Kit SA10570156-3 6.60 17 Service Kit SA10570156-5 75,398.00 17 Service Kit SA10570156-7 75,520.00 17 Service Kit SA10570156-9 93,777.00 17 Service Kit SA10570156-11 99,777.00 17 Service Kit SA10570156-13 91,919.00 17 Service Kit SA10570156-15 100,365.00 17 Service Kit SA10570156-17 610,016.00 17 Service Kit SA10570156-19 610,549.00 17 Service Kit SA10570156-21 **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 DC10-57A156 Revision 2: August 23, 2011 27 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT SERVICE KIT APPLICABILITY** **Drawing Configuration Service Kit**  SR10570048-7001 SA10570156-3 SR10570048-7003 SA10570156-5 SR10570048-7021 SA10570156-7 SR10570048-7023 SA10570156-9 SR10570048-7025 SA10570156-11 SR10570048-7027 SA10570156-13 SR10570048-7029 SA10570156-15 SR10570048-7031 SA10570156-17 SR10570019-7013 SA10570156-19 SR10570019-7015 SA10570156-21 **Service Kit SA10570156 Notes**  **Name QTY**  **New Part Number -21**  **-19 -9**  **-7 -5**  **-3**

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

. NUT ASSY 122 122 3D0006-4

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 28 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Service Kit SA10570156**  **Notes Name**  **QTY New Part Number**  **-21 -19**  **-9 -7**  **-5 -3** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 29 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Service Kit SA10570156**  **Notes Name**  **QTY New Part Number**  **-21 -19**  **-9 -7**  **-5 -3** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 30 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Service Kit SA10570156**  **Notes Name**  **QTY New Part Number**  **-21 -19**  **-9 -7**  **-5 -3** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

. BOLT . . 2 2 . . NAS7402-13

. BOLT . . 2 2 . . NAS7402-14

. BOLT . . 4 4 . . NAS7402-15

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

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

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

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

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

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

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 31 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Service Kit SA10570156**  **Notes Name**  **QTY New Part Number**  **-21 -19**  **-9 -7**  **-5 -3** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

. SPLICE 1 . . . . . SR10570019-10

. SUPPORT . 1 . . . . SR10570019-11

. SUPPORT 1 . . . . . SR10570019-12

. SUPPORT . 1 . . . . SR10570019-13

. SUPPORT 1 . . . . . SR10570019-14

. CLIP . 1 . . . . SR10570019-15

. CLIP 1 . . . . . SR10570019-16

. CLIP . 1 . . . . SR10570019-17

. CLIP 1 . . . . . SR10570019-18

. CLIP 1 1 . . . . SR10570019-19

. CLIP . 1 . . . . SR10570019-23

. CLIP 1 . . . . . SR10570019-24

. CLIP . 1 . . . . SR10570019-25

. CLIP 1 . . . . . SR10570019-26

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 32 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Service Kit SA10570156**  **Notes Name**  **QTY New Part Number**  **-21 -19**  **-9 -7**  **-5 -3** 

. CLIP . 1 . . . . SR10570019-27

. CLIP 1 . . . . . SR10570019-28 (a) TAPE 1 1 . . . . SR10570019-29

. SPLICE . 1 . . . . SR10570019-3

. CLIP . 1 . . . . SR10570019-31

. CLIP 1 . . . . . SR10570019-32

. CLIP . 1 . . . . SR10570019-33

. CLIP 1 . . . . . SR10570019-34

. CAP . 1 . . . . SR10570019-35

. CAP 1 . . . . . SR10570019-36

. CLIP . 1 . . . . SR10570019-37

. CLIP 1 . . . . . SR10570019-38

. SPLICE 1 . . . . . SR10570019-4

. SPLICE . 1 . . . . SR10570019-5

. SPLICE 1 . . . . . SR10570019-6

. SPLICE . 1 . . . . SR10570019-7

. SPLICE 1 . . . . . SR10570019-8

. SPLICE . 1 . . . . SR10570019-9 (a) BUSHING . . . . 1 1 SR10570048-31

. DOUBLER . . . 1 . . SR10570048-39

. DOUBLER . . 1 . . . SR10570048-40

. FAIRING . . . 1 . . SR10570048-41

. FAIRING . . 1 . . . SR10570048-42

. FAIRING . . . 1 . . SR10570048-47

. FAIRING . . 1 . . . SR10570048-48

. FILLER . . 1 1 . . SR10570048-49

. FILLER . . 1 1 . . SR10570048-53 (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 DC10-57A156 Revision 2: August 23, 2011 33 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Group 1:**  **Service Kit SA10570156 Name**  **QTY New Part Number**  **-13 -11**  NUT ASSY 4 4 3D0006-3 NUT ASSY 30 30 3D0006-5 NUT ASSY 15 15 3D0006-6 CLIP 2 2 ARC0430-31 PIN 10 10 HLT334-5-4 PIN 4 4 HLT434-6-3 NUT 10 10 MS21042L08 NUT 14 14 MS21042L3 NUT 10 10 MS21042L4 NUT 49 49 MS21042L5 WASHER 14 14 NAS1252-10L WASHER 10 10 NAS1252-416L WASHER 49 49 NAS1252-516L WASHER 10 10 NAS1252-8L BOLT 2 2 NAS7402-13 BOLT 2 2 NAS7402-14 BOLT 4 4 NAS7402-15 PIN, OVERSIZE 1 1 S4931919-10X15 PIN, OVERSIZE 1 1 S4931919-10X16 PIN, OVERSIZE 2 2 S4931919-10X17 PIN, OVERSIZE 1 1 S4931919-10X18 PIN, OVERSIZE 2 2 S4931919-10X19 PIN, OVERSIZE 1 1 S4931919-10X20 PIN, OVERSIZE 2 2 S4931919-10X21 PIN, OVERSIZE 2 2 S4931919-10X23 PIN, OVERSIZE 4 4 S4931919-10X24 PIN, OVERSIZE 13 13 S4931919-10X25 PIN, OVERSIZE 1 1 S4931919-10X27 PIN, OVERSIZE 1 1 S4931919-12X16 PIN, OVERSIZE 3 3 S4931919-12X17

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 34 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Group 1:**  **Service Kit SA10570156 Name**  **QTY New Part Number**  **-13 -11**  PIN, OVERSIZE 2 2 S4931919-12X18 PIN, OVERSIZE 2 2 S4931919-12X19 PIN, OVERSIZE 2 2 S4931919-12X20 PIN, OVERSIZE 2 2 S4931919-12X21 PIN, OVERSIZE 1 1 S4931919-12X22 PIN, OVERSIZE 2 2 S4931919-12X27 PIN, OVERSIZE 3 3 S4931919-14X20 PIN, OVERSIZE 5 5 S4931919-14X21 PIN, OVERSIZE 9 9 S4931919-14X22 PIN, OVERSIZE 1 1 S4931919-14X23 PIN, OVERSIZE 2 2 S4931919-14X24 PIN, OVERSIZE 4 4 S4931919-14X25 PIN, OVERSIZE 4 4 S4931919-14X26 PIN, OVERSIZE 11 11 S4931919-14X27 PIN 10 10 S4931919-6-5 PIN, OVERSIZE 2 2 S4931919-6X15 PIN, OVERSIZE 2 2 S4931919-6X16 PIN, OVERSIZE 1 1 S4931920-10X13 PIN, OVERSIZE 4 4 S4931920-10X14 PIN, OVERSIZE 19 16 S4931920-10X15 PIN, OVERSIZE 5 8 S4931920-10X16 PIN, OVERSIZE 16 14 S4931920-10X17 PIN, OVERSIZE 2 4 S4931920-10X18 PIN, OVERSIZE 2 2 S4931920-10X19 PIN, OVERSIZE 2 2 S4931920-8X11 PIN, OVERSIZE 8 8 S4931920-8X12 NUT ASSY 39 39 S4933816-7 ANGLE . 1 SR10570048-13 ANGLE 1 . SR10570048-14 TEE . 1 SR10570048-15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 35 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Group 1:**  **Service Kit SA10570156 Name**  **QTY New Part Number**  **-13 -11**  TEE 1 . SR10570048-16 SUPPORT 1 . SR10570048-19 SUPPORT 1 . SR10570048-21 FILLER 1 1 SR10570048-23 SHIM 1 1 SR10570048-25 SHIM 1 . SR10570048-27 SHIM 1 . SR10570048-29 DOUBLER . 1 SR10570048-39 DOUBLER 1 . SR10570048-40 FAIRING . 1 SR10570048-41 FAIRING 1 . SR10570048-42 STRAP . 1 SR10570048-45 STRAP 1 . SR10570048-46 FAIRING . 1 SR10570048-47 FAIRING 1 . SR10570048-48 FILLER 1 1 SR10570048-49 FILLER 1 1 SR10570048-53 ANGLE . 1 SR10570048-55 ANGLE 1 . SR10570048-56 **Group 2: Service Kit SA10570156**  **Name QTY**  **New Part Number -17**  **-15** NUT ASSY 4 4 3D0006-3 NUT ASSY 30 30 3D0006-5 NUT ASSY 15 15 3D0006-6 BRACKET . 1 ARB4195-1 BRACKET 1 . ARB4195-2 PIN 10 10 HLT334-5-4

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 36 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Group 2:**  **Service Kit SA10570156 Name**  **QTY New Part Number**  **-17 -15**  NUT 10 10 MS21042L08 NUT 10 10 MS21042L3 NUT 10 10 MS21042L4 NUT 49 49 MS21042L5 WASHER 10 10 NAS1252-10L WASHER 10 10 NAS1252-416L WASHER 49 49 NAS1252-516L WASHER 10 10 NAS1252-8L BOLT 2 2 NAS7402-13 BOLT 2 2 NAS7402-14 BOLT 4 4 NAS7402-15 PIN, OVERSIZE 1 1 S4931919-10X15 PIN, OVERSIZE 1 1 S4931919-10X16 PIN, OVERSIZE 2 2 S4931919-10X17 PIN, OVERSIZE 1 1 S4931919-10X18 PIN, OVERSIZE 2 2 S4931919-10X19 PIN, OVERSIZE 1 1 S4931919-10X20 PIN, OVERSIZE 2 2 S4931919-10X21 PIN, OVERSIZE 2 2 S4931919-10X23 PIN, OVERSIZE 4 4 S4931919-10X24 PIN, OVERSIZE 13 13 S4931919-10X25 PIN, OVERSIZE 1 1 S4931919-10X27 PIN, OVERSIZE 1 1 S4931919-12X16 PIN, OVERSIZE 3 3 S4931919-12X17 PIN, OVERSIZE 2 2 S4931919-12X18 PIN, OVERSIZE 2 2 S4931919-12X19 PIN, OVERSIZE 2 2 S4931919-12X20 PIN, OVERSIZE 2 2 S4931919-12X21 PIN, OVERSIZE 1 1 S4931919-12X22 PIN, OVERSIZE 2 2 S4931919-12X27

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 37 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Group 2:**  **Service Kit SA10570156 Name**  **QTY New Part Number**  **-17 -15**  PIN, OVERSIZE 3 3 S4931919-14X20 PIN, OVERSIZE 5 5 S4931919-14X21 PIN, OVERSIZE 9 9 S4931919-14X22 PIN, OVERSIZE 1 1 S4931919-14X23 PIN, OVERSIZE 2 2 S4931919-14X24 PIN, OVERSIZE 4 4 S4931919-14X25 PIN, OVERSIZE 4 4 S4931919-14X26 PIN, OVERSIZE 11 11 S4931919-14X27 PIN 10 10 S4931919-6-5 PIN, OVERSIZE 2 2 S4931919-6X15 PIN, OVERSIZE 2 2 S4931919-6X16 PIN, OVERSIZE 1 1 S4931920-10X13 PIN, OVERSIZE 4 4 S4931920-10X14 PIN, OVERSIZE 19 16 S4931920-10X15 PIN, OVERSIZE 5 8 S4931920-10X16 PIN, OVERSIZE 14 12 S4931920-10X17 PIN, OVERSIZE 4 6 S4931920-10X18 PIN, OVERSIZE 2 2 S4931920-10X19 PIN, OVERSIZE 2 2 S4931920-8X11 PIN, OVERSIZE 8 8 S4931920-8X12 NUT ASSY 39 39 S4933816-7 ANGLE . 1 SR10570048-13 ANGLE 1 . SR10570048-14 TEE . 1 SR10570048-15 TEE 1 . SR10570048-16 BRACKET . 1 SR10570048-17 BRACKET 1 . SR10570048-18 SUPPORT 1 . SR10570048-19 SUPPORT 1 . SR10570048-21 FILLER 1 1 SR10570048-23

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 38 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT Group 2:**  **Service Kit SA10570156 Name**  **QTY New Part Number**  **-17 -15**  SHIM 1 1 SR10570048-25 SHIM 1 . SR10570048-27 SHIM 1 . SR10570048-29 DOUBLER . 1 SR10570048-39 DOUBLER 1 . SR10570048-40 FAIRING . 1 SR10570048-41 FAIRING 1 . SR10570048-42 STRAP . 1 SR10570048-45 STRAP 1 . SR10570048-46 FAIRING . 1 SR10570048-47 FAIRING 1 . SR10570048-48 FILLER 1 1 SR10570048-49 ANGLE . 1 SR10570048-51 ANGLE 1 . SR10570048-52 FILLER 1 1 SR10570048-53 2. Parts and Materials Supplied by the Operator **Notes Name**  **QTY Part Number / Specifica-**  **tion** (a) (b) Sealing Compound 1 Pint PR-1422 B-2 (DMS 2082 or Equivalent) 1.00 Diameter X 1.00 Bar, Aluminium 7075-T7351. Bushing 1 SR10570048-31 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. CAGE PRC-DeSoto International, Incorporated (b) Can be purchased from: 92108 P. O. Box 1800 Sylmar, California 91342 3. Parts Modified and Reidentified None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 16, 2009 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 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 DC10-57A156 Revision 2: August 23, 2011 47 of 47 **BOEING SERVICE BULLETIN DC10-57A156 ALERT**  **ALERT**