Commercial 

Airplanes MD80

Service Bulletin

ALERT

Number: MD80-55A069

Original Issue: January 19, 2011

ATA System: 5511

SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Horizontal Stabilizer

Center Section Left and Right Rib Hinge Bearing Lugs

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

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

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

laws.

ECCN: 9E991

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Unpublished Work - All Rights Reserved

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BLANK PAGE
Table of Contents

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

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

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

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

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

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

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

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

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 19

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 22

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS . . . . . . . . . . . . . . 27

FIGURE 2: CRACK LENGTH MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 3: BLEND OUT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 4: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS . . . . . . . . . . . . . . 44

APPENDIX A: TEMPLATE/SHIELD SHOP AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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Commercial 

Airplanes MD80

Service Bulletin

ALERT

Summary Number: MD80-55A069

Original Issue: January 19, 2011

ATA System: 5511

SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Horizontal Stabilizer

Center Section Left and Right Rib Hinge Bearing Lugs

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

Boeing has received two reports of cracks being found on either the left or right MD-80 horizontal stabilizer

center section ribs. These cracks were found on the aft face of the horizontal stabilizer hinge bearing lugs.

Cracks were reported on MD-80 airplanes with between 23,700 and 41,963 flight-hours and 23,300 and 35,294

flight cycles. In addition, eleven cracks at the same location have been reported in either the left or right, or in

two cases, both of the MD-90 horizontal stabilizer center section ribs. Accordingly, MD-90 Alert Service Bulletin

MD90-55A016 has been issued. Investigation by Boeing has yet to establish the definitive cause of these cracks.

Performing an Eddy Current, High Frequency inspection of the affected area will determine the existence of any

crack. If not corrected, undetected cracks in the center section left and right rib hinge bearing lugs could spread

at the same time which would cause both hinge bearing lugs to fail, resulting in the horizontal stabilizer being

unable to sustain the required loads.

ACTION

This service bulletin gives instructions to do an Eddy Current, High Frequency inspection of the horizontal

stabilizer center section left and right rib hinge bearing lugs for cracks and does as follows:

CONDITION 1 (No Crack Found in Rib Hinge Bearing Lug)

1. Repeats the Eddy Current, High Frequency inspection at defined intervals.

CONDITION 2 (Crack Found in Rib Hinge Bearing Lug)

1. Measures the crack length and does as follows:

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CONDITION 2A (Crack Length Between Points 'A' and 'B' is Less Than or Equal to 0.15 Inch, and

Crack Length Between Points 'C' and 'D' is Less Than or Equal to 0.05 Inch)

a. Does blend out repair to remove crack.

b. Repetitively inspects blend out area for cracks, using Eddy Current, High Frequency inspection.

CONDITION 2B (Crack Length Between Points 'A' and 'B' is Greater Than 0.15 Inch, or Crack Length

Between Points 'C' and 'D' is Greater Than 0.05 Inch)

a. Replaces horizontal stabilizer center section rib.

b. Does Eddy Current, High Frequency inspections at a defined threshold.

EFFECTIVITY

DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 Airplanes. Refer to Paragraph

1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection and/or repair procedures 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.

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Commercial 

Airplanes MD80

Service Bulletin

ALERT

Number: MD80-55A069

Original Issue: January 19, 2011

ATA System: 5511

SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Repair/Replace Horizontal Stabilizer

Center Section Left and Right Rib Hinge Bearing Lugs

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

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

MD-80 airplanes with horizontal stabilizer rib(s) made from

7075-T7351 material.

1 -

MD-80 airplanes with horizontal stabilizer rib(s) made from

7050-T7451 material.

2 -

Airplane Models:

DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88

Fuselage Num- Group

ber

924 1

938 1

941 1

944 1

946 1

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Fuselage Num- Group

ber

948 1

950 1

952 - 953 1

955 1

957 1

960 1

962 1

965 - 967 1

969 - 971 1

973 1

975 1

977 - 979 1

981 1

983 1

985 - 986 1

988 1

991 - 992 1

994 - 995 1

997 1

999 - 1006 1

1008 - 1013 1

1016 1

1018 - 1019 1

1022 1

1025 1

1028 1

1031 1

1034 - 1035 1

1043 1

1045 1

1049 1

1051 1

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Fuselage Num- Group

ber

1053 1

1055 1

1057 1

1059 - 1060 1

1063 - 1080 1

1082 - 1083 1

1085 1

1088 - 1093 1

1095 - 1110 1

1112 - 1128 1

1130 - 1181 1

1183 - 1223 1

1225 - 1290 1

1292 - 1323 1

1325 - 1334 1

1336 - 1337 1

1339 - 1340 1

1342 - 1343 1

1345 - 1350 1

1352 - 1450 1

1451 2

1453 - 1477 2

1479 - 1503 2

1505 - 1666 2

1668 - 1701 2

1703 - 1771 2

1773 - 1787 2

1789 - 1843 2

1845 - 1915 2

1917 - 1924 2

1926 - 1994 2

1996 - 2007 2

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Fuselage Num- Group

ber

2009 - 2016 2

2019 - 2029 2

2031 - 2034 2

2036 - 2069 2

2071 - 2089 2

2091 - 2093 2

2101 - 2114 2

2116 2

2118 - 2119 2

2121 2

2124 2

2127 2

2130 2

2132 2

2134 - 2135 2

2137 2

2139 2

2145 2

2148 2

2151 - 2152 2

2155 2

2167 2

2174 2

2176 2

2178 2

2180 2

2183 2

2185 2

2187 2

2189 2

2192 2

2196 2

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Fuselage Num- Group

ber

2199 2

2201 2

2204 2

2206 2

2208 2

2214 2

2218 2

2234 2

2239 2

2241 2

2244 2

2247 2

2249 2

2252 2

2254 2

2264 - 2287 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Boeing has received two reports of cracks being found on either the left or right MD-80 horizontal

stabilizer center section ribs. These cracks were found on the aft face of the horizontal stabilizer hinge

bearing lugs. Cracks were reported on MD-80 airplanes with between 23,700 and 41,963 flight-hours

and 23,300 and 35,294 flight cycles. In addition, eleven cracks at the same location have been reported

in either the left or right, or in two cases, both of the MD-90 horizontal stabilizer center section ribs.

Accordingly, MD-90 Alert Service Bulletin MD90-55A016 has been issued. Investigation by Boeing has

yet to establish the definitive cause of these cracks. Performing an Eddy Current, High Frequency

inspection of the affected area will determine the existence of any crack. If not corrected, undetected

cracks in the center section left and right rib hinge bearing lugs could spread at the same time which

would cause both hinge bearing lugs to fail, resulting in the horizontal stabilizer being unable to sustain

the required loads.

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D. Description

This service bulletin gives instructions to do an Eddy Current, High Frequency inspection of the horizontal

stabilizer center section left and right rib hinge bearing lugs for cracks and does as follows:

CONDITION 1 (No Crack Found in Rib Hinge Bearing Lug)

1. Repeats the Eddy Current, High Frequency inspection at defined intervals.

CONDITION 2 (Crack Found in Rib Hinge Bearing Lug)

1. Measures the crack length and does as follows:

CONDITION 2A (Crack Length Between Points 'A' and 'B' is Less Than or Equal to 0.15 Inch,

and Crack Length Between Points 'C' and 'D' is Less Than or Equal to 0.05 Inch)

a. Does blend out repair to remove crack.

b. Repetitively inspects blend out area for cracks, using Eddy Current, High Frequency inspection.

CONDITION 2B (Crack Length Between Points 'A' and 'B' is Greater Than 0.15 Inch, or Crack

Length Between Points 'C' and 'D' is Greater Than 0.05 Inch)

a. Replaces horizontal stabilizer center section rib.

b. Does Eddy Current, High Frequency inspections at a defined threshold.

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

Affected Maintenance Zones

Model Zone

DC-9-81 (MD-81), DC-9-82 37, 38

(MD-82), DC-9-83 (MD-83), DC9-87 (MD-87), MD-88

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ALERT ALERT
E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Group 1:

Table 1 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before the accumulation of 23,000 total flight cycles, or

within 4383 flight

cycles after the

original issue date

on this service bulletin, whichever occurs later.

Do an Eddy Current, High

Frequency inspection of the

aft face of the horizontal

stabilizer center section left

and right rib hinge lugs in

accordance with Accomplishment Instructions,

Paragraph 3.B.2.

All Airplanes

Within 8200 flight

cycles from last inspection.

Within 8200 flight

cycles from last inspection.

Do an Eddy Current, High

Frequency inspection of the

aft face of the uncracked

horizontal stabilizer center

section rib hinge lugs in accordance with Accomplishment Instructions, Paragraph 3.B.2.

CONDITION 1

(No Crack Found in Rib

Hinge Bearing Lug)

(a)

Before further

flight.

Measure crack length in accordance with Accomplishment Instructions, Paragraph 3.B.2.CONDITION 2

(Crack Found In Rib Hinge

Bearing Lug)

Before further

flight.

Blend out crack in accordance with Accomplishment

Instructions, Paragraph

3.B.2.

CONDITION 2A

(Crack Length Between

Points 'A' and 'B' is Less

Than or Equal to 0.15 Inch,

and Crack Length Between

Points 'C' and 'D' is Less

Than or Equal to 0.05 Inch.)

AND

Within 3900 flight

cycles.

Within 15,600 flight

cycles after blend

out.

Do an Eddy Current, High

Frequency inspection of the

blend out on the center

section rib hinge bearing lug

in accordance with Accomplishment Instructions,

Paragraph 3.B.2.

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ALERT ALERT
Group 1:

Table 1 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further

flight.

Replace horizontal stabilizer

center section rib.

CONDITION 2B

(Crack Length Between

Points 'A' and 'B' is Greater

Than 0.15 Inch, OR Crack

Length Between Points 'C'

and 'D' is Greater Than 0.05

Inch.)

AND

Within 11,300 flight

cycles from last inspection.

Before the accumulation of 23,000 total flight cycles after the installation

of the new rib.

Do an Eddy Current, High

Frequency inspection of the

aft face of the replaced horizontal stabilizer center

section rib hinge lug in accordance with Accomplishment Instructions, Paragraph 3.B.2.

(a)

(a) For MD-80 operators to take advantage of the rib material change to 7050-T7451 and the

associated repeat inspection cycles, they must have all horizontal stabilizer records in accordance with fuselage number if they relocated the horizontal stabilizer to a different fuselage

number after production delivery. Otherwise they must use the lower (8200 flight cycles) repeat

inspection interval.

Group 2:

Table 2 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before the accumulation of 23,000 total flight cycles, or

within 4383 flight

cycles after the

original issue date

on this service bulletin, whichever occurs later.

Do an Eddy Current, High

Frequency inspection of the

aft face of the horizontal

stabilizer center section left

and right rib hinge lugs in

accordance with Accomplishment Instructions,

Paragraph 3.B.2.

All Airplanes

Within 11,300 flight

cycles from last inspection.

Within 11,300 flight

cycles from last inspection.

Do an Eddy Current, High

Frequency inspection of the

aft face of the uncracked

horizontal stabilizer center

section rib hinge lugs in accordance with Accomplishment Instructions, Paragraph 3.B.2.

CONDITION 1

(No Crack Found in Rib

Hinge Bearing Lug)

(a)

Before further

flight.

Measure crack length in accordance with Accomplishment Instructions, Paragraph 3.B.2.

CONDITION 2

(Crack Found In Rib Hinge

Bearing Lug)

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ALERT ALERT
Group 2:

Table 2 - Inspect Horizontal Stabilizer Center Section Left and Right Rib Hinge Lug for Cracks:

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further

flight.

Blend out crack in accordance with Accomplishment

Instructions, Paragraph

3.B.2.

CONDITION 2A

(Crack Length Between

Points 'A' and 'B' is Less

Than or Equal to 0.15 Inch,

and Crack Length Between

Points 'C' and 'D' is Less

Than or Equal to 0.05 Inch.)

AND

Within 5800 flight

cycles.

Within 15,600 flight

cycles after blend

out.

Do an Eddy Current, High

Frequency inspection of the

blend out on the center

section rib hinge bearing lug

in accordance with Accomplishment Instructions,

Paragraph 3.B.2.

Before further

flight.

Replace horizontal stabilizer

center section rib.

CONDITION 2B

(Crack Length Between

Points 'A' and 'B' is Greater

Than 0.15 Inch, OR Crack

Length Between Points 'C'

and 'D' is Greater Than 0.05

Inch.)

AND

Within 11,300 flight

cycles from last inspection.

Before the accumulation of 23,000 total flight cycles after the installation

of the new rib.

Do an Eddy Current, High

Frequency inspection of the

aft face of the replaced horizontal stabilizer center

section rib hinge lug in accordance with Accomplishment Instructions, Paragraph 3.B.2.

(a)

(a) For MD-80 operators to take advantage of the rib material change to 7050-T7451 and the

associated repeat inspection cycles, they must have all horizontal stabilizer records in accordance with fuselage number if they relocated the horizontal stabilizer to a different fuselage

number after production delivery. Otherwise they must use the lower (8200 flight cycles) repeat

inspection interval.

F. Approval

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

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

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

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

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

changes.

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

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

before incorporating this service bulletin.

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ALERT ALERT
G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 2.0 1.0

Inspect 1 2.0 2.0

Close Access 2 2.0 1.0

TOTAL FOR EACH AIRPLANE 6.0 4.0

NOTE: The Manpower totals listed do not include the hours required to accomplish any blend out

repair(s) or replacement of center section rib(s), if required. Operators are to estimate the task

hours required based on inspection results.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Boeing Service Bulletin MD90-55A016.

b. Non-Destructive Test Standard Practice Manual (NDTSPM) 06-10-01.001.

c. MD-80 Aircraft Maintenance Manual (AMM) 06-23-00.

d. MD-80 Structural Repair Manual (SRM) 51-10-3.

2. Data supplied with this Service Bulletin

None.

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

Document Number Title Change

RIB CRACK REPAIR - HORIZ STAB, B Memo 1

STA XH=6.625

SR90550001

This drawing was used to prepare this service bulletin. This drawing is not necessary to make the

specified changes, and is not supplied with this service bulletin. This drawing may not be applicable

to all airplane configurations or operators.

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.

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ALERT ALERT

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

NOTE: Parts are only required for Condition 2B.

Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary for Each Airplane if needed,

as shown below. If there is a limit to the quantity of available parts, a supply sequence is given by

Spares. More parts become available as shown in the Reorder Lead Time (ROLT). Operators are

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

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 (US

Dollars)

ROLT (Calendar

Days)

Part Number Name

RIB CRACK REPAIR - HORIZ STAB, STA- TBD $14,500.00

TION XH=6.625 - LEFT

9911846-509

RIB CRACK REPAIR - HORIZ STAB, STA- TBD 14,500.00

TION XH=6.625 - RIGHT

9911846-510

The parts 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

B. Industry Support Information

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts

NOTE: Parts are only required for Condition 2B.

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

Group 1:

Existing Part

Number

New Part Number QTY Name

RIB CRACK REPAIR - HORIZ 9911846-505 or

STAB, STATION XH=6.625 -

LEFT

9911846-509 1

9911846-507 or

9911846-509

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ALERT ALERT
Group 1:

Existing Part

Number

New Part Number QTY Name

RIB CRACK REPAIR - HORIZ 9911846-506 or

STAB, STATION XH=6.625 -

RIGHT

9911846-510 1

9911846-508 or

9911846-510

Group 2:

Existing Part

Number

New Part Number QTY Name

RIB CRACK REPAIR - HORIZ 9911846-509

STAB, STATION XH=6.625 -

LEFT

9911846-509 1

RIB CRACK REPAIR - HORIZ 9911846-510

STAB, STATION XH=6.625 -

RIGHT

9911846-510 1

2. Parts and Materials Supplied by the Operator

None.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this

Service Bulletin. Tool price and supply data are not given.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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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.

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. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

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

definition of the acronyms.

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

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

Structural Repair Manual (SRM) 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.

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

– Angular tolerance is plus or minus 2 degrees

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

8. 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 access procedures may be required.

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ALERT ALERT
9. 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.

10. 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.

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. 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.

13. 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.

The removed part can be discarded if a new or serviceable part is installed.

14. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

B. WORK INSTRUCTIONS

1. Remove and keep access panels. Refer to MD-80 AMM 06-23-00.

Access Panel Location

3703A Left side lower horizontal stabilizer fairing

3804A Right side lower horizontal stabilizer fairing

2. Do the Eddy Current, High Frequency (ETHF) inspection of the aft face of the center section left

and right rib hinge bearing lugs for cracks in accordance with FIGURE 1 and do as follows:

CONDITION 1 (NO CRACK FOUND IN RIB HINGE BEARING LUG)

a. Install kept access panels. Refer to MD-80 AMM 06-23-00.

Access Panel Location

3703A Left side lower horizontal stabilizer fairing

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ALERT ALERT
Access Panel Location

3804A Right side lower horizontal stabilizer fairing

b. Put the airplane back to a serviceable condition.

c. Report inspection results, both positive and negative, fuselage number, and cycles and flight

hours of affected airplane, through your local field service representative or by one of the

methods that follow:

— Mail: Boeing - Long Beach Division

P.O. Box 1771

Long Beach, California 90801

Attn: Senior Manager Technical and Fleet Support

Structures/Payloads & Repair Design

ATA CODE: 5511

Service Engineering D800-0032

(Service Bulletin MD80-55A069)

— Email: dse.boecom@boeing.com

ATA CODE: 5511

— Fax: Long Beach Service Engineering

FAX: (206) 766-5683

ATA CODE: 5511

d. Repeat the ETHF inspection of any uncracked horizontal stabilizer hinge bearing lugs in

accordance with FIGURE 1, at intervals defined in Paragraph 1.E., Compliance Table 1 or

Table 2.

CONDITION 2 (CRACK FOUND IN RIB HINGE BEARING LUG)

a. Measure the length of the crack in accordance with FIGURE 2 and do as follows:

CONDITION 2A (CRACK LENGTH BETWEEN POINTS 'A' AND 'B' IS LESS THAN OR

EQUAL TO 0.15 INCH AND CRACK LENGTH BETWEEN POINTS 'C' AND 'D' IS LESS

THAN OR EQUAL TO 0.05 INCH)

(1) Report inspection results, both positive and negative, fuselage number, and cycles and

flight hours of affected airplane, through your local field service representative or by one

of the methods that follow:

— Mail: Boeing - Long Beach Division

P.O. Box 1771

Long Beach, California 90801

Attn: Senior Manager Technical and Fleet Support

Structures/Payloads & Repair Design

ATA CODE: 5511

Service Engineering D800-0032

(Service Bulletin MD80-55A069)

— Email: dse.boecom@boeing.com

ATA CODE: 5511

— Fax: Long Beach Service Engineering

FAX: (206) 766-5683

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ALERT ALERT
ATA CODE: 5511

(2) Do blend out repair in accordance with FIGURE 3.

NOTE: Drawings for a locally manufactured template/shield shop aid that can be used

to help define the blend out area are available in APPENDIX A.

(3) Install kept access panels. Refer to MD-80 AMM 06-23-00.

Access Panel Location

3703A Left side lower horizontal stabilizer fairing

3804A Right side lower horizontal stabilizer fairing

(4) Put the airplane back to a serviceable condition.

(5) Inspect blend out area for cracks in accordance with FIGURE 4 at intervals defined in

Paragraph 1.E., Compliance Table 1 or Table 2.

CONDITION 2B (CRACK LENGTH BETWEEN POINTS 'A' AND 'B' IS GREATER THAN

0.15 INCH OR CRACK LENGTH BETWEEN POINTS 'C' AND 'D' IS GREATER THAN 0.05

INCH)

(1) Replace horizontal stabilizer center section rib.

(2) Inspect replaced rib hinge bearing lug for cracks in accordance with FIGURE 1 at intervals

defined in Paragraph 1.E., Compliance Table 1 or Table 2.

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ALERT ALERT
FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS

(SHEET 1 OF 4)

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FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS

(SHEET 2 OF 4)

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ALERT ALERT
FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS

(SHEET 3 OF 4)

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ALERT ALERT
The step number shown below agree with the number shown in the circle symbol in the figure.

Step Action

Perform an Eddy Current, High Frequency (ETHF) surface inspection of the rib at the hinge

bearing lug aft radius at approximately Stations Yh=76.000 and Xh=6.625. Scan the lug radius as

shown, looking for cracks propagating across the radius. Refer to NDTSPM 06-10-01.001 (ETHF

- Procedure 1). Use Calibration Method "G" and Scan Method "69".

1

Perform an Eddy Current, High Frequency surface inspection of the rib at the hinge bearing lug

aft radius at approximately Stations Yh=76.000 and Xh=6.625. Scan the lug radius as shown,

slightly above the scan done in Step 1, looking for cracks propagating in the vertical direction.

Refer to NDTSPM 06-10-01.001 (ETHF - Procedure 1). Use Calibration Method "C" and Scan

Method "62".

2

FIGURE 1: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 2: CRACK LENGTH MEASUREMENT

(SHEET 1 OF 3)

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FIGURE 2: CRACK LENGTH MEASUREMENT

(SHEET 2 OF 3)

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

Step Action

Measure the crack length from end point (Point A) to where crack intersects the chamfer (Point

B) on the outboard face of the hinge lug. Do not include the measurement of crack length in

chamfer. Record measurement.

1

Measure the crack length from end point (Point D) to where crack intersects the chamfer (Point

C) on the aft face of the hinge lug. Do not include measurement of crack length in the chamfer.

Record measurement.

2

FIGURE 2: CRACK LENGTH MEASUREMENT

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 1 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 2 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 3 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 4 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 5 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 6 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 7 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 8 OF 10)

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ALERT ALERT
FIGURE 3: BLEND OUT REPAIR

(SHEET 9 OF 10)

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

Step Action

Locate Point 1. Point 1 is identified as the intersecting point of a line offset from the horizontal stabilizer lower surface 0.050 inch, and the outboard edge of the chamfer on the hinge lug.1

Locate Point 2. Point 2 is identified as the point on a line offset from the horizontal stabilizer lower

surface 0.050 inch, and 0.58 inch forward of Point 1.

2

Locate Point 4. Point 4 is identified as the point located 1.59 inch measured normal to the horizontal

stabilizer lower surface at the aft edge of the hinge lug.

3

Locate Point 3. Point 3 is identified as the point located 0.19 inch from the inboard edge of the hinge

lug, and 0.50 inch from the horizontal stabilizer lower surface.

4

Blend out the crack. (Blend 'A') Do not exceed the limits of the area defined by points 1, 2, 3, and 4.

The blend out should form a "V" shape, with the deepest portion of the "V" being in the area of the

crack, and approximately 127 degrees between the legs of the "V". Maintain a 0.25 inch radius at the

bottom of the "V". The majority of the blend should be at approximately 45 degrees from the outboard

face of the lug. It is recommended that a 0.50 inch diameter ball grinder be used to do the blend out.

Remove only enough material to remove the crack. Do not remove more than 0.25 inch of material

total depth as measured from a line drawn between the points B and C that were established in Figure

2.

5

Do an Eddy Current, High Frequency (ETHF) inspections during material removal to verify crack has

been removed. Scan the blend out as shown, looking for cracks in the upper forward to lower aft direction. Scan the blend out and give more attention to the outside periphery. Refer to NDTSPM 06-

10-01.001 (ETHF - Procedure 1). Use Calibration Method "G" and Scan Method "69". If crack still is

not removed, repeat Steps 5 and 6.

6

Once the crack has been removed, remove an additional 0.050 inch of material to ensure that a crack

that is too small to detect has been removed. Finish blend out to a 63 micro-inch finish.

7

Do a taper of the outboard face of the lug. (Blend 'B') The taper begins at a line between Point 4 and

tangent to the radius on the aft portion of the bearing lug surface, and extends upward and aft to a

point 1.65 inches above Point 4. Finish blend out to a 63 micro-inch finish.

8

Break all reworked edges to a 0.12 inch radius. If adjacent structure prevents using a 0.12 inch radius,

use the largest radius possible in the area.

9

10 Apply FR Protection to the rework area. Refer to MD-80 SRM 51-10-3.

(Not

Shown)

FIGURE 3: BLEND OUT REPAIR

(SHEET 10 OF 10)

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ALERT ALERT
FIGURE 4: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS

(SHEET 1 OF 2)

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ALERT ALERT
The step number shown below agree with the number shown in the circle symbol in the figure.

Step Action

Perform an Eddy Current, High Frequency Surface inspection of Blend 'A' area at the hinge

bearing lug aft radius. Scan the blend out as shown, looking for cracks in the upper forward to

lower aft direction. Scan the blend out and give more attention to the outside periphery. Refer to

NDTSPM 06-10-01.001 (ETHF - Procedure 1). Use Calibration Method "G" and Scan Method "69".

1

FIGURE 4: INSPECT HORIZONTAL STABILIZER HINGE BEARING LUGS

(SHEET 2 OF 2)

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ALERT ALERT
This appendix provides instructions for the fabrication and usage of a template/shield shop aid to assist in

simplifying the identification of the extents of the blend out area, if required, identified in FIGURE 3.

This appendix provides instructions to build a template/shield for use on the left hand hinge bearing lug. A mirror

image template/shield is required for the right hand hinge bearing lug.

FABRICATION

1. Fabricate all parts from 0.050 Inch CRES Sheet, Type 321, per Aerospace Material Specification (AMS)

5510 or equivalent.

2. Identification of parts and assemblies at operator's option, and per operator's shop practice.

3. Fusion weld with Gas Tungsten Arc Welding (GTAW).

4. It is acceptable to fusion weld from opposite side than that specified by the welding symbol.

5. If surfaces on -3 and -9 parts are distorted by welding, straighten surfaces to within +/- .010 inch before

use.

6. Tack or continuous weld -11 to the sub assembly from sub-assembly step 3.

7. Trim -7 as shown.

8. Cut or grind radius on -7 as shown.

APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 1 OF 8)

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APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 2 OF 8)

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APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 3 OF 8)

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ALERT ALERT
APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 4 OF 8)

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ALERT ALERT
APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 5 OF 8)

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APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 6 OF 8)

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ALERT ALERT
DIRECTIONS FOR TEMPLATE/SHIELD SHOP AID USE

1. After identifying points 1, 2, 3, and 4 in accordance with the instructions in FIGURE 3, place template/shield

on lug. Push upper portion of template/shield against the lower surface of the horizontal stabilizer, and the

push the outer portion of the template/shield against the outboard surface of the lug.

2. Slide the template/shield fore and aft until the lower portion of the template is on Point 4, and check that

the template/shield is aligned with Point 2.

NOTE: The aft face of the template/shield may not be in contact with the aft face of the lug when the

template/shield is aligned with Points 2 and 4.

3. Using an appropriate marker, trace the template/shield shape on the aft face of the lug, and on the outboard

face of the lug, to visually define the shape of the blend out area. Do not exceed the limits of the blend out

area defined by Points 1, 2, 3, and 4 established in Figure 3 if they are different than the area defined by

the template/shield.

The template/shield may be secured to the lug and used as a shield to help while grinding the crack out in

accordance with FIGURE 3.

APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 7 OF 8)

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APPENDIX A: TEMPLATE/SHIELD SHOP AID

(SHEET 8 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 19, 2011

MD80-55A069

53 of 53

BOEING SERVICE BULLETIN MD80-55A069

ALERT ALERT