Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2866

Original Issue: December 04, 2013

ATA System: 5312

SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and

Replacement

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

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

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

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2013 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and

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ALERT ALERT

BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 24

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 26

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100) [Group 1, Configuration 2; Group

2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION

(STA 880 - STA 1100) [Group 1, Configuration 2; Group 2] . . . . . . . . . . . . . . . . . 38

FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100) [Group 1, Configuration

2; Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT [Group 1,

Configuration 2; Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

APPENDIX B: LOGIC DIAGRAM 2 - POST-REPLACEMENT TENSION TIE INSPECTION AND REPAIR [Group

1, Configuration 2; Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

ALERT

Summary Number: 747-53A2866

Original Issue: December 04, 2013

ATA System: 5312

SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and

Replacement

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

This service bulletin gives instructions for inspection, repair, and replacement of the upper deck tension ties on

stretched upper deck (SUD) airplanes that have been converted to Boeing Special Freighter (SF) or Boeing

Converted Freighter (BCF). Severed or disconnected tension ties at multiple locations could result in rapid

decompression and loss of structural integrity.

This service bulletin is for station locations from 880 to 1100 where floor beams were replaced with tension ties

during conversion to SF or BCF. Tension ties have been determined to be structure that is susceptible to

Widespread Fatigue Damage (WFD). WFD could cause multiple adjacent tension ties to become severed or

disconnected from the frames. For more information about WFD, refer to Boeing Service Letter 747-SL-53-088.

Accomplishment of the inspection and replacement actions in this service bulletin will ensure that tension tie

cracks are detected, and that cracked tension ties are repaired or replaced before they become severed.

Service Bulletin 747-53A2507 and 747-53A2559 are for inspection, repair, and modification of tension tie and

frame structure at station locations from 1120 to 1220 where tension ties were installed in production on the

same airplanes.

Boeing Service Related Problem (SRP) 747-SRP-53-0435 is related to this service bulletin.

Fleet Team Digest article 747 FTD 53-13006 is related to this service bulletin.

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

information.

Planning Data Affected Reference

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

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Planning Data Affected Reference

AD Related Yes Paragraph 1.E., Compliance

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

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

Publications Affected No Paragraph 1.K., Publications Affected

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

Operations Manual and/or FAA Approved Airplane Flight Manual)

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

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

by the Operator

Operator Supplied Parts/Materials Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

No action is required for airplanes that have not been converted by Boeing to SF or BCF configuration.

For airplanes that have been converted by Boeing to SF or BCF configuration, do the following actions:

INSPECTIONS:

– Get access to the tension tie structure from station 880 to station 1100. Do initial and repetitive detailed

inspections for cracks in the tension tie structure at each station location. For a longer repeat inspection

interval, also do HFEC inspection for cracks in the forward and aft tension tie channels around the fasteners.

If any cracks are found, get access to the frame structure at stations where tension ties were found cracked

and do a detailed inspection of the frame structure between stringer 3 and stringer 12 on both sides of the

airplane. Repair or replace any cracked structure.

REPLACEMENT:

– At each station from 880 to 1100, remove and discard the existing tension tie channels. Also, remove and

discard the existing straps and fillers at the outboard ends of the tension tie where the tension tie attaches

to the frame. Do HFEC inspection of all open holes in the frame structure where the tension tie was removed.

If a crack is found in a frame, contact Boeing for repair instructions and do the repair. Install new tension

tie channels, straps, and fillers. Before installation of permanent fasteners at the outboard ends of the

tension ties, cold work the fastener holes common to the frames and straps.

POST-REPLACEMENT INSPECTIONS:

– After replacement, restart initial and repetitive detailed (or detailed and HFEC) inspections beginning at the

post-replacement inspection threshold in accordance with this service bulletin.

EFFECTIVITY

747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes. Refer to Paragraph 1.A., Effectivity, for

the list of affected airplanes.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
COMPLIANCE

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspections, repairs, or replacement procedures given in this

service bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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ALERT ALERT
Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2866

Original Issue: December 04, 2013

ATA System: 5312

SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and

Replacement

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is for the airplane(s) shown below.

GROUP CONFIGURATION DESCRIPTION

747-100B, 747-200B, 747-300, 747-400, and 747-400D airplanes,

built in a Stretched Upper Deck (SUD) configuration, or modified to

SUD by Boeing, except airplanes modified by Boeing to Special

Freighter (SF) or Boeing Converted Freighter (BCF) configuration

before release of the Original Issue of this service bulletin.

1 -

1 Airplanes that have not been modified by Boeing to SF or BCF.

Airplanes that are modified by Boeing to SF or BCF configuration

after release of the Original Issue of this service bulletin.

2

747-200B, 747-300, and 747-400 airplanes that have been modified

by Boeing to SF or BCF configuration before release of the Original

Issue of this service bulletin.

2 -

Airplane Models:

747-100B SUD, 747-200B, 747-300, 747-400, 747-400D

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Variable Number Group

RD381 - RD383 1

RD601 - RD602 2

RD603 - RD607 1

RD721 - RD722 1

RF001 - RF006 1

RM001 - RM007 1

RM010 - RM013 1

RM021 - RM022 1

RM024 1

RM026 - RM030 1

RM036 - RM045 1

RM051 - RM053 1

RM071 1

RM081 - RM084 1

RM091 1

RM096 - RM097 1

RM116 - RM117 1

RM126 - RM127 1

RM128 2

RM129 - RM132 1

RM136 - RM147 1

RM156 - RM158 1

RM166 - RM177 1

RM191 - RM192 1

RM231 - RM233 1

RM241 - RM246 1

RM261 - RM264 1

RM316 - RM318 1

RM331 - RM333 1

RM341 1

RM351 - RM355 1

RM366 - RM367 1

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Variable Number Group

RM401 - RM403 1

RM426 1

RM431 1

RM441 - RM443 1

RM445 1

RM801 - RM803 1

RM811 - RM813 1

RS001 - RS002 1

RS201 1

RS211 - RS212 1

RS221 - RS222 1

RS231 - RS241 1

RS251 - RS259 1

RS263 1

RS265 - RS268 1

RS271 - RS276 1

RS291 - RS292 1

RS301 - RS306 1

RS311 - RS320 1

RS331 - RS333 1

RS341 - RS342 1

RS699 1

RS701 - RS703 1

RS711 - RS713 1

RS721 - RS722 2

RS731 - RS732 1

RS741 2

RS742 1

RS743 2

RS751 - RS752 1

RS761 1

RS762 2

RS771 2

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ALERT ALERT
Variable Number Group

RS781 - RS782 1

RS786 2

RT001 - RT014 1

RT021 - RT022 2

RT031 - RT033 2

RT034 - RT035 1

RT041 - RT047 1

RT061 2

RT071 - RT072 2

RT073 - RT074 1

RT075 2

RT101 - RT103 1

RT121 1

RT131 - RT137 1

RT151 - RT152 1

RT161 2

RT162 - RT163 1

RT164 2

RT165 - RT168 1

RT401 - RT412 1

RT431 - RT447 1

RT451 - RT455 1

RT456 2

RT457 - RT460 1

RT461 2

RT462 - RT469 1

RT471 - RT499 1

RT501 2

RT502 - RT505 1

RT506 - RT510 2

RT511 - RT512 1

RT513 2

RT514 - RT515 1

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Variable Number Group

RT516 2

RT517 1

RT518 - RT520 2

RT521 - RT523 1

RT524 2

RT525 1

RT526 2

RT527 1

RT528 2

RT529 1

RT530 2

RT531 - RT535 1

RT551 - RT568 1

RT571 1

RT572 - RT579 2

RT580 - RT591 1

RT601 - RT630 1

RT633 - RT641 1

RT642 2

RT643 - RT653 1

RT654 - RT657 2

RT671 - RT673 1

RT681 - RT682 1

RT691 - RT692 2

RT693 - RT699 1

RT701 - RT704 1

RT711 - RT717 1

RT741 - RT742 1

RT744 - RT750 1

RT751 - RT752 2

RT753 - RT757 1

RT776 - RT777 1

RT781 - RT782 2

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Variable Number Group

RT783 - RT784 1

RT801 - RT803 1

RT811 - RT814 1

RT831 - RT836 1

RT837 2

RT861 - RT864 1

RT877 - RT880 1

RT931 - RT932 1

RT945 - RT949 1

RT951 - RT955 1

RT966 1

RT967 2

RU001 - RU006 1

RU016 - RU017 1

RU031 - RU032 1

RU051 - RU052 1

RU060 - RU062 1

RU081 - RU083 1

RU101 - RU102 1

RU121 - RU132 1

RU801 - RU809 1

RU831 - RU841 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions for inspection, repair, and replacement of the upper deck tension

ties on stretched upper deck (SUD) airplanes that have been converted to Boeing Special Freighter

(SF) or Boeing Converted Freighter (BCF). Severed or disconnected tension ties at multiple locations

could result in rapid decompression and loss of structural integrity.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
This service bulletin is for station locations from 880 to 1100 where floor beams were replaced with

tension ties during conversion to SF or BCF. Tension ties have been determined to be structure that

is susceptible to Widespread Fatigue Damage (WFD). WFD could cause multiple adjacent tension ties

to become severed or disconnected from the frames. For more information about WFD, refer to Boeing

Service Letter 747-SL-53-088.

Accomplishment of the inspection and replacement actions in this service bulletin will ensure that

tension tie cracks are detected, and that cracked tension ties are repaired or replaced before they

become severed.

Service Bulletin 747-53A2507 and 747-53A2559 are for inspection, repair, and modification of tension

tie and frame structure at station locations from 1120 to 1220 where tension ties were installed in

production on the same airplanes.

Boeing Service Related Problem (SRP) 747-SRP-53-0435 is related to this service bulletin.

Fleet Team Digest article 747 FTD 53-13006 is related to this service bulletin.

D. Description

No action is required for airplanes that have not been converted by Boeing to SF or BCF configuration.

For airplanes that have been converted by Boeing to SF or BCF configuration, do the following actions:

INSPECTIONS:

– Get access to the tension tie structure from station 880 to station 1100. Do initial and repetitive

detailed inspections for cracks in the tension tie structure at each station location. For a longer

repeat inspection interval, also do HFEC inspection for cracks in the forward and aft tension tie

channels around the fasteners. If any cracks are found, get access to the frame structure at stations

where tension ties were found cracked and do a detailed inspection of the frame structure between

stringer 3 and stringer 12 on both sides of the airplane. Repair or replace any cracked structure.

REPLACEMENT:

– At each station from 880 to 1100, remove and discard the existing tension tie channels. Also,

remove and discard the existing straps and fillers at the outboard ends of the tension tie where

the tension tie attaches to the frame. Do HFEC inspection of all open holes in the frame structure

where the tension tie was removed. If a crack is found in a frame, contact Boeing for repair

instructions and do the repair. Install new tension tie channels, straps, and fillers. Before installation

of permanent fasteners at the outboard ends of the tension ties, cold work the fastener holes

common to the frames and straps.

POST-REPLACEMENT INSPECTIONS:

– After replacement, restart initial and repetitive detailed (or detailed and HFEC) inspections beginning

at the post-replacement inspection threshold in accordance with this service bulletin.

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

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Group 1:

Affected Maintenance Zones

Model Zone

747-100B SUD, 747-200B, 747- 225, 226

300, 747-400, 747-400D

Group 2:

Affected Maintenance Zones

Model Zone

747-200B, 747-300, 747-400 225, 226

E. Compliance

Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When

more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION

numbers for that CONDITION number or OPTION number.

Logic diagrams corresponding to each compliance table are included in APPENDIX A. The logic

diagrams only show the conditions and actions, and are for reference only.

Group 1, Configuration 1:

No action is required. If a Group 1, Configuration 1 airplane is converted to BCF in the future, then it

becomes a Configuration 2 airplane and the actions in the following tables will apply.

Group 1, Configuration 2; Group 2:

Table 1: Tension Tie Inspection, Repair, and Replacement

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 2,000 -

flight cycles after the Original

Issue date of

this service bulletin.

Within 10,000

flight cycles after conversion

to SF or BCF

configuration.

Do PART 1: TENSION TIE DETAILED INSPECTION for cracks.

-ORDo PART 2: TENSION TIE DETAILED and HIGH FREQUENCY

EDDY CURRENT INSPECTION

for cracks.

All airplanes.

(a)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Group 1, Configuration 2; Group 2:

Table 1: Tension Tie Inspection, Repair, and Replacement

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

2,000 flight cycles

if PART 1 inspection was previously

done.

OPTION 1: Do/Repeat PART 1: - -

TENSION TIE DETAILED INSPECTION for cracks.

CONDITION 1:

NO TENSION TIE

CRACK FOUND.

OPTION 2: Do/Repeat PART 2:

TENSION TIE DETAILED and

HIGH FREQUENCY EDDY

CURRENT INSPECTION for

cracks.

-OR5,000 flight cycles

if PART 2 inspection was previously

done.

OPTION 3: Do PART 5: TENSION TIE REPLACEMENT.

(a)

Do PART 3: FRAME DETAILED Before further flight. -

INSPECTION for cracks.

CONDITION 2:

TENSION TIE

CRACK FOUND.

ACTION 1: Contact Boeing for Before further flight. -

repair instructions and do the repair.

CONDITION 3:

FRAME CRACK

FOUND.

ACTION 2: Do PART 4: TEN- Before further flight. -

SION TIE REPAIR.

Do PART 4: TENSION TIE RE- Before further flight. -

PAIR.

CONDITION 4:

NO FRAME

CRACK FOUND.

2,000 flight cycles

if PART 1 inspection was previously

done.

OPTION 1: Do/Repeat PART 1: - -

TENSION TIE DETAILED INSPECTION for cracks.

CONDITION 5:

TENSION TIE

CRACK HAS

BEEN REPAIRED. OPTION 2: Do/Repeat PART 2:

TENSION TIE DETAILED and

HIGH FREQUENCY EDDY

CURRENT INSPECTION for

cracks.

-OR5,000 flight cycles

if PART 2 inspection was previously

done.

OPTION 3: Do PART 5: TENSION TIE REPLACEMENT.

(a)

Within 2,000 -

flight cycles after the Original

Issue date of

this service bulletin.

Within 22,000

flight cycles after conversion

to SF or BCF

configuration.

Do PART 5: TENSION TIE REPLACEMENT.

(a) (b)

All airplanes.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Group 1, Configuration 2; Group 2:

Table 1: Tension Tie Inspection, Repair, and Replacement

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Contact Boeing for repair instruc- Before further flight. -

tions and do the repair.

Frame crack is

found during accomplishment of

PART 5: TENSION TIE REPLACEMENT.

Do Post-Replacement Tension See Compliance Table 2. -

Tie Inspection and Repair actions

in accordance with Compliance

Table 2.

Tension Tie replacement has

been done in accordance with

Paragraph 3.B.,

Work Instructions,

PART 5 of this

service bulletin.

(a) Accomplishment of PART 5: TENSION TIE REPLACEMENT is terminating action for the initial and

repetitive inspections specified in this table. However, post-replacement inspections are required as

specified in "Table 2: Post-Replacement Tension Tie Inspection and Repair".

(b) Due to the after-modification requirements, and the possibility that it will be necessary to replace the

tension ties again, Boeing does not recommend tension tie replacement prior to 13,000 total flight-cycles.

Group 1, Configuration 2; Group 2:

Table 2: Post-Replacement Tension Tie Inspection and Repair

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Within 10,000 flight -

cycles after the

tension ties were

replaced in accordance with Paragraph 3.B., Work

Instructions,

PART5 of this service bulletin.

Do PART 1: TENSION TIE DETAILED INSPECTION for cracks.

-ORDo PART 2: TENSION TIE DETAILED and HIGH FREQUENCY

EDDY CURRENT INSPECTION

for cracks.

Tension Tie replacement

has been done in accordance with Paragraph 3.B.,

Work Instructions, PART 5

of this service bulletin.

2,000 flight cycles if PART

1 inspection was previously done.

OPTION 1: Do/Repeat PART 1: -

TENSION TIE DETAILED INSPECTION for cracks.

CONDITION 1: NO TENSION TIE CRACK FOUND.

-OR5,000 flight cycles if PART

2 inspection was previously done.

OPTION 2: Do/Repeat PART 2:

TENSION TIE DETAILED and

HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Group 1, Configuration 2; Group 2:

Table 2: Post-Replacement Tension Tie Inspection and Repair

Repeat Interval (Not to

Exceed)

Condition Action Compliance Time

Before further -

flight.

Do PART 3: FRAME DETAILED

INSPECTION for cracks.

CONDITION 2: TENSION

TIE CRACK FOUND.

Before further -

flight.

ACTION 1: Contact Boeing for repair instructions and do the repair.CONDITION 3: FRAME

CRACK FOUND.

Before further -

flight.

ACTION 2: Do PART 4: TENSION

TIE REPAIR.

Before further -

flight.

Do PART 4: TENSION TIE REPAIR.CONDITION 4: NO

FRAME CRACK FOUND.

2,000 flight cycles if PART

1 inspection was previously done.

OPTION 1: Do/Repeat PART 1: -

TENSION TIE DETAILED INSPECTION for cracks.

CONDITION 5: TENSION

TIE CRACK HAS BEEN

REPAIRED.

-OR5,000 flight cycles if PART

2 inspection was previously done.

OPTION 2: Do/Repeat PART 2:

TENSION TIE DETAILED and

HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle ACO

approves the accomplishment of the inspection, repair, and replacement procedures with corresponding

compliance times specified in Tables 1 and 2 under Paragraph 1.E., "Compliance" of Service Bulletin

747-53A2866, Original Issue, as an AMOC to the inspection requirements of paragraphs (h) and (i) of

AD 2004-07-22 R1, for the inspection of Structural Significant Item (SSI) F-19A, F-19B, F-19D, F-20A,

F-20C, and F-20E of the Supplemental Structural Inspection Document (SSID) D6-35022, Revision G,

dated December 2000, and Revision TR-08-001, dated June 2006. This AMOC only applies to the

areas where tension ties were inspected or replaced in accordance with this service bulletin. When

this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be

approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD 2004-07-22 R1

that are not specifically referenced in this paragraph, including the initial inspection threshold per

paragraph (i) of AD 2004-07-22 R1, remain fully applicable and must be complied with accordingly.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
G. Manpower

The table below shows an estimate of the task hours necessary to do the inspection and replacement

actions 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.

INSPECTION and POST-REPLACEMENT INSPECTION

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 15.00 3.75

FIGURE 1: Tension Tie De- 4 16.00 4.00

tailed Inspection (a)

FIGURE 2: Tension Tie De- 4 134.00 33.50

tailed and High Frequency

Eddy Current Inspection (a)

FIGURE 3: Frame Detailed 2 6.00 3.00

Inspection (b)

Restoration 4 15.00 3.75

TOTAL FOR EACH AIRPLANE 46.00 11.50

(a) The Total for Each Airplane is based on FIGURE 1 inspection. FIGURE 2 inspection

is optional to FIGURE 1 inspection. FIGURE 2 estimates are not included in the total.

(b) If required. Not included in total. Estimate is for inspection of one frame. Multiply the

estimate by the number of frames that need to be inspected.

REPLACEMENT

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 15.00 3.75

PART 5 - TENSION TIE RE- 4 336.00 84.00

PLACEMENT (a)

Restoration 4 15.00 3.75

TOTAL FOR EACH AIRPLANE 366.00 91.50

(a) Does not include time for repairs if frames are found cracked during tension tie replacement. If frames are found cracked, more time will be necessary.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Boeing Service Bulletin 747-53A2507, 747-53A2559

b. Boeing Service Letter 747-SL-51-048, 747-SL-53-088

c. Boeing Service Related Problem (SRP) 747-SRP-53-0435

d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1

e. Service Bulletin Index D6-30300

f. Standard Overhaul Practices Manual (SOPM) 20-41-05, 20-43-03, 20-50-01

g. 747 Fleet Team Digest (FTD) 53-13006

h. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00

i. 747-100/200/300 Aircraft Maintenance Manual (AMM) 24-22-00, 25-59-01, 25-59-05

j. 747-100/200/300 Structural Repair Manual (SRM) 51-30-09, 51-50-01

k. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 25-59-01, 25-59-05

l. 747-400SF Structural Repair Manual (SRM) 51-40-09, 51-50-02, 53-20-30, 53-40-30

2. Data Supplied with this Service Bulletin:

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

TENSION TIE INSTL - STA 880 - STA 1 B -

1220, MOD

657U7304

2 D -

3 D -

4 C -

5 C -

6 C -

PL K -

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

TENSION TIE INSTL - STA 880 - STA PSDL A -

1220, MOD

657U7304#DL

TENSION TIE DETAILS, STA 880 -STA 1 C -

1220, MOD

657U7314

2 C -

3 C -

4 C -

5 C -

6 B -

7 - -

8 - -

9 - -

PL G -

TENSION TIE DETAILS, STA 880 -STA PSDL - -

1220, MOD

657U7314#DL

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

TENSION TIE REWORK INSTL STA 880 11 - -

THRU STA 1220 MOD

814B9001

12 A -

13 A -

14 A -

15 - -

16 - -

17 - -

18 - -

19 - -

20 - -

21 A -

22 - -

23 - -

24 B -

25 A -

26 B -

27 - -

28 - -

29 - -

30 - -

31 - -

32 B -

33 - -

34 - -

35 - -

36 - -

37 B -

38 - -

39 - -

40 - -

41 A -

42 - -

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

TENSION TIE REWORK INSTL STA 880 PSDL F -

THRU STA 1220 MOD

814B9001#DL

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.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary

Not affected.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection or modification procedures given in this

service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

Part Number / Speci- QTY Name Notes

fication

Alodine as required Chemical Conversion Coating (a) (b) (c)

BMS 10-11, Type I as required Primer (b) (c)

BMS 3-23, Type II as required Corrosion Inhibiting Compound (b) (c)

BMS 5-95 as required Sealant (b) (c)

(a) Refer to SOPM 20-43-03 for material alternatives.

(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(c) This material could be necessary for tension tie repairs. More parts will be necessary if tension

tie replacement is required. If necessary, contact Boeing for the engineering drawing information

to determine the required parts if tension tie replacement will be accomplished.

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
E. Special Tooling - Price and Availability

The 747 Structural Repair Manual Subject 747-100/200/300 SRM 51-30-09 or 747-400SF SRM 51-40-09

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

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

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

NOTE: Special tools are not necessary to do the change in this service bulletin. However, standard

cold working tools are necessary for cold working of the holes at the ends of the tension ties

if the tension ties are replaced in accordance with this service bulletin.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

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

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 747 Structural Repair Manual,

Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 747

Airplane Maintenance Manual (AMM).

— Non-standard torque values for maintenance tasks are included in the

applicable installation step.

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

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate

full threaded fasteners (screws) needed for installation in this service bulletin.

6. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

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ALERT ALERT
7. 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.

8. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

9. 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.

10. 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.

11. 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.

12. If shading is used, shaded areas in Figures are to separate the non-critical and

non-authoritative information from the critical and authoritative information.

13. When more than one OPTION is given for a CONDITION, do only one of the OPTION

numbers. When more than one ACTION is given for a CONDITION number or an

OPTION number, do all of the ACTION numbers for that CONDITION number or

OPTION number.

14. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

15. Some steps in the Work Instructions are identified as Required for Compliance (RC).

If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps

identified as RC must be done to comply with the AD. Alternative procedures for

steps not identified with RC can be used if the RC steps can still be done as specified,

and the airplane can be put back in a serviceable condition. An Alternative Method

of Compliance (AMOC) is not necessary for deviations to steps that are not identified

as RC.

16. For 747-100/200/300 airplanes that have been modified by Boeing to Special Freighter

(SF) configuration, the 747-100/200/300 SRM does not include repairs for tension

ties from STA 880 to STA 1100 that were installed during conversion. It is acceptable

to use 747-400SF SRM 53-20-30 or 747-400SF SRM 53-40-30, as applicable, for

repair of STA 880 - STA 1100 tension ties on 747-100/200/300 airplanes.

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ALERT ALERT
17. Refer to APPENDIX A for Logic Diagram 1 related to the tension tie initial inspection,

repair, and replacement requirements. Refer to APPENDIX B for Logic Diagram 2

related to the post-replacement inspection and repair requirements. Logic diagrams

are provided as an aid only. Information contained in Paragraph 1.E., Compliance

is the primary source for compliance times. Information in Paragraph 3.B., Work

Instructions is the primary source for tasks required for compliance.

18. Replacement of tension tie channels with original SF or BCF modification parts in

accordance with Paragraph 3.B., Work Instructions, PART 5 on airplanes RS762

and RT456 would cancel the effect of the modification performed by Service Bulletin

747-53A2610. Therefore, PART 5 instructions include a requirement to concurrently

incorporate Service Bulletin 747-53A2610 modification on any aft tension tie channels

being installed as replacements.

B. WORK INSTRUCTIONS

Group 1, Configuration 1:

No action is required for airplanes that have not been converted by Boeing to Special Freighter (SF)

or Boeing Converted Freighter (BCF) configuration.

Group 1, Configuration 2; Group 2:

Tension Tie Inspection, Repair, and Replacement

1. Do PART 1: TENSION TIE DETAILED INSPECTION for cracks, or Do PART 2: TENSION TIE

DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.

CONDITION 1: NO TENSION TIE CRACK FOUND

a. Do one of the following:

(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.

(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY

EDDY CURRENT INSPECTION for cracks.

(3) OPTION 3: Do PART 5: TENSION TIE REPLACEMENT.

CONDITION 2: TENSION TIE CRACK FOUND

a. Do PART 3: FRAME DETAILED INSPECTION for cracks.

CONDITION 3: FRAME CRACK FOUND

(1) ACTION 1: Contact Boeing for repair instructions and do the repair.

(2) ACTION 2: Do PART 4: TENSION TIE REPAIR.

CONDITION 4: NO FRAME CRACK FOUND

(1) Do PART 4: TENSION TIE REPAIR.

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ALERT ALERT
CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED

a. Do one of the following:

(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.

(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY

EDDY CURRENT INSPECTION for cracks.

(3) OPTION 3: Do PART 5: TENSION TIE REPLACEMENT.

2. Do PART 5: TENSION TIE REPLACEMENT.

Group 1, Configuration 2; Group 2:

Post-Replacement Tension Tie Inspection and Repair

1. Do PART 1: TENSION TIE DETAILED INSPECTION for cracks, or Do PART 2: TENSION TIE

DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.

CONDITION 1: NO TENSION TIE CRACK FOUND

a. Do one of the following:

(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.

(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY

EDDY CURRENT INSPECTION for cracks.

CONDITION 2: TENSION TIE CRACK FOUND

a. Do PART 3: FRAME DETAILED INSPECTION for cracks.

CONDITION 3: FRAME CRACK FOUND

(1) ACTION 1: Contact Boeing for repair instructions and do the repair.

(2) ACTION 2: Do PART 4: TENSION TIE REPAIR.

CONDITION 4: NO FRAME CRACK FOUND

(1) Do PART 4: TENSION TIE REPAIR.

CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED

a. Do one of the following:

(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.

(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY

EDDY CURRENT INSPECTION for cracks.

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ALERT ALERT
Group 1, Configuration 2; Group 2:

PART 1: TENSION TIE DETAILED INSPECTION

1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or

747-400 AMM 24-22-00 as accepted procedures.

2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation

as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01

or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300

AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation.

3. RC - At each tension tie station from 880 to 1100, do a detailed inspection for cracks in the tension

tie structure in accordance with FIGURE 1.

4. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05

or 747-400 AMM 25-59-05 as an accepted procedure.

5. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01

or 747-400 AMM 25-59-01 as an accepted procedure.

6. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM

24-22-00 as an accepted procedure.

7. Return the airplane to a serviceable condition.

Group 1, Configuration 2; Group 2:

PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION

1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or

747-400 AMM 24-22-00 as accepted procedures.

2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation

as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01

or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300

AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation.

3. RC - At each tension tie station from 880 to 1100, do detailed and HFEC inspections for cracks in

the tension tie structure in accordance with FIGURE 2.

4. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05

or 747-400 AMM 25-59-05 as an accepted procedure.

5. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01

or 747-400 AMM 25-59-01 as an accepted procedure.

6. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM

24-22-00 as an accepted procedure.

7. Return the airplane to a serviceable condition.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Group 1, Configuration 2; Group 2:

PART 3: FRAME DETAILED INSPECTION

1. At any station where a crack was found in a tension tie, remove the main deck cargo compartment

lining panels and insulation as necessary to get access to the frame structure between stringer 3

to stringer 12 on both sides of the airplane. Refer to 747-100/200/300 AMM 25-59-01 or 747-400

AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300 AMM 25-59-05

or 747-400 AMM 25-59-05 as an accepted procedure for insulation.

2. RC - At any station where a crack was found in a tension tie, do a detailed inspection of the frame

structure between stringer 3 and stringer 12 in accordance with FIGURE 3

Group 1, Configuration 2; Group 2:

PART 4: TENSION TIE REPAIR

CAUTION: MAKE SURE THAT THE AIRPLANE IS SUPPORTED IN THE JIGGED POSITION

BEFORE YOU DISASSEMBLE TWO ADJACENT FRAMES OR TENSION TIES. IF YOU

DO NOT, YOU WILL CAUSE DAMAGE TO THE STRUCTURE.

1. Put the airplane in a jigged position. Refer to 747-100/200/300 SRM 51-50-01 or 747-400SF SRM

51-50-02 as an accepted procedure. It is not necessary to put the airplane into a jigged position

if the airplane has the following conditions:

a. Only one tension tie or frame is disassembled.

b. There is a minimum of one tension tie and frame attached between those that are

disassembled.

2. RC - Repair any cracked tension tie in accordance with 747-400SF SRM 53-20-30 or 747-400SF

SRM 53-40-30 as applicable.

3. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05

or 747-400 AMM 25-59-05 as an accepted procedure.

4. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01

or 747-400 AMM 25-59-01 as an accepted procedure.

5. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM

24-22-00 as an accepted procedure.

6. Return the airplane to a serviceable condition.

Group 1, Configuration 2; Group 2:

PART 5: TENSION TIE REPLACEMENT

1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or

747-400 AMM 24-22-00 as accepted procedures.

2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation

as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01

or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300

AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
CAUTION: MAKE SURE THAT THE AIRPLANE IS SUPPORTED IN THE JIGGED POSITION

BEFORE YOU DISASSEMBLE TWO ADJACENT FRAMES OR TENSION TIES. IF YOU

DO NOT, YOU WILL CAUSE DAMAGE TO THE STRUCTURE.

3. Put the airplane in a jigged position. Refer to 747-100/200/300 SRM 51-50-01 or 747-400SF SRM

51-50-02 as an accepted procedure. It is not necessary to put the airplane into a jigged position

if the airplane has the following conditions:

a. Only one tension tie or frame is disassembled.

b. There is a minimum of one tension tie and frame attached between those that are

disassembled.

4. RC - At each station location from STA 880 to STA 1100, remove and discard the existing tension

tie channels. Also, remove and discard the existing steel plates, straps and fillers at the outboard

ends of the tension ties where the tension ties attach to the frames.

5. RC - After each tension tie is removed, do open hole HFEC inspection for cracks at all hole locations

where fasteners where removed from adjacent frame structure to remove the tension tie. Do the

inspection in accordance with 747 NDT Manual Part 6, 51-00-00, Procedure 1, 11, or 16. If any

crack is found, contact Boeing for repair instructions and do the repair.

6. RC - At each station location from STA 880 to STA 1100, temporarily install new tension tie

channels, steel plates, straps, and fillers which are the same as the original SF or BCF modification

parts that were removed. Install the new parts in accordance with the applicable SF or BCF

modification drawings specified in Paragraph 1.J.2., Data Supplied with this Service Bulletin, except

oversize any existing open fastener holes 1/32 inch. Maintain 2D minimum edge margin. Continue

with the following steps to install new tension ties.

7. RC - For airplanes that are included in the effectivity of Service Bulletin 747-53A2610, incorporate

the Service Bulletin 747-53A2610 modification on the new tension ties, concurrently with installation

of the new tension ties.

8. RC - At each station location from STA 880 to STA 1100, cold work the entire stack-up at all

fastener holes where the tension tie attaches to the frame. Also, cold work the entire stack-up at

all fastener holes that are common to the steel plates/straps, plus three fastener pairs inboard of

the ends of the steel plates. Do the cold working at both ends of the tension tie (both sides of the

airplane). Use the "high interference" cold work process in accordance with 747-100/200/300 SRM

51-30-09 or 747-400SF SRM 51-40-09, as applicable.

9. RC - After cold working, at each station location from STA 880 to STA 1100, permanently install

new tension tie channels, steel plates, straps, and fillers which are the same as the original SF or

BCF modification parts that were removed. Install the new structure in accordance with the

applicable SF or BCF modification drawings specified in Paragraph 1.J.2., Data Supplied with this

Service Bulletin, except install oversize fasteners at existing open fastener holes.

10. RC - Apply BMS 3-23, Type II, or equivalent, Corrosion Inhibiting Compound to the modified areas.

Refer to SOPM 20-41-05 as an accepted procedure.

11. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05

or 747-400 AMM 25-59-05 as an accepted procedure.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
12. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01

or 747-400 AMM 25-59-01 as an accepted procedure.

13. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM

24-22-00 as an accepted procedure.

14. Return the airplane to a serviceable condition.

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
This Figure applies only to: Group 1, Configuration 2; Group 2.

FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100)

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100)

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

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

Step Task Name Identification Qty More Data

Forward and Aft Ten- 657U7314-( ) - (a)

sion Tie Channels

1 Inspect

(a) Do a detailed inspection for cracks in the forward and aft tension tie channels in the inspection area shown.

Station 880 is shown. Other stations are similar. Do the inspection at all stations from Station 880 to

Station 1100. Inspect Qty 2 tension tie channels (one forward and one aft) at each station location. Total

quantity of tension tie channels to be inspected = 24.

FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100)

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
This Figure applies only to: Group 1, Configuration 2; Group 2.

FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA

880 - STA 1100)

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA

880 - STA 1100)

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

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

Step Task Name Identification Qty More Data

Forward and Aft Ten- 657U7314-( ) - (a) (c)

sion Tie Channels

1 Inspect

Forward and Aft Ten- 657U7314-( ) - (b) (c)

sion Tie Channels

2 Inspect

(a) Do a detailed inspection for cracks in the forward and aft tension tie channels in the inspection area shown.

(b) Do surface HFEC inspection for cracks around fasteners in the tension tie channels. Inspect from both

sides of the tension tie in order to inspect both the forward and aft channels. It is not necessary to do the

inspection where the tension tie channels are covered by straps, fittings, or other structure. Do the inspection in accordance with 747 NDT Manual Part 6, 51-00-00, Procedure 4 or 23.

(c) Station 880 is shown. Other stations are similar. Do the inspection at all stations from Station 880 to

Station 1100. Inspect Qty 2 tension tie channels (one forward and one aft) at each station location. Total

quantity of tension tie channels to be inspected = 24.

FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA

880 - STA 1100)

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
This Figure applies only to: Group 1, Configuration 2; Group 2.

FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100)

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100)

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

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

Step Task Name Identification Qty More Data

1 Inspect Frame - Left Side - - (a) (c)

2 Inspect Frame - Right Side - - (b) (c)

(a) Do a detailed inspection for cracks in the left side of the frame between stringer 3L and stringer 12L as

shown. Inspect the frame at each station location from STA 880 to STA 1100. Total quantity of frames to

be inspected = 12.

(b) Do a detailed inspection for cracks in the right side of the frame between stringer 3R and stringer 12R as

shown. Inspect the frame at each station location from STA 880 to STA 1100. Total quantity of frames to

be inspected = 12.

(c) Station 880 is shown. Other stations are similar. Do the inspection at all stations where a crack was found

in a tension tie.

FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100)

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
This Appendix applies only to: Group 1, Configuration 2; Group 2.

APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
Do PART 5 - TENSION TIE REPLACEMENT before the compliance time for replacement

specified in Paragraph 1.E., Compliance, Table 1. After replacement, do inspections as

specified in Paragraph 1.E., Compliance, Table 2, and refer to LOGIC DIAGRAM 2.

FLAG NOTE 1:

APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53A2866

ALERT ALERT
This Appendix applies only to: Group 1, Configuration 2; Group 2.

APPENDIX B: LOGIC DIAGRAM 2 - POST-REPLACEMENT TENSION TIE INSPECTION AND REPAIR

(SHEET 1 OF 1)

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ALERT ALERT