### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Number: MD80-55A070**  Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 **SUBJECT:**STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes 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.9E991 ECCN: 

## 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 Unpublished Work.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 Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 1 of 53 3.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 2 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 26 4. Process Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 26 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1. Kits/Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 36 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 37 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 FIGURE 1: REMOVE SKIN FILLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 FIGURE 2: INSPECTION SURFACE AREA - PREPARATION. . . . . . . . . . . . . . . . . . . . . . 48 FIGURE 3: HIGH FREQUENCY EDDY CURRENT INSPECTION. . . . . . . . . . . . . . . . . . . . 51

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 3 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 4 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: MD80-55A070** Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 **SUBJECT:**STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** 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. No more work is necessary on the airplane(s) changed or inspected in accordance with the original issue of this service bulletin. **REASON FOR REVISION** Revision 1 is sent to correct Paragraph 1.E., Compliance Tables 1 and 2 group configuration headings and Table 1 initial inspections thresholds. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. These sections were changed: 1. In Paragraph 1.E., Compliance, changed Table 1 and Table 2 group configuration headings and Table 1 initial inspection thresholds. 2. Figure 2, changed art and split footnote (a) into footnote (a) and (b). 3. Figure 3, changed art and footnoe (c). Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes. Pages with no vertical lines have no changes. **REVISION HISTORY** May 22, 2013 Original Issue:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 5 of 53December 17, 2013 Revision 1:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 6 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**

### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Summary**  **Number: MD80-55A070** Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 **SUBJECT:**STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes 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** During the inspections called for in Service Bulletin MD80-55A065, two operators reported finding cracks emanating from the left and right upper rear spar cap aft-most barrel nut holes of the horizontal stabilizer. One airplane had accumulated 40,144 flight hours and 32,253 landing cycles, while the other airplane had accumulated 58,296 flight hours and 43,512 landing cycles. In both cases, the affected part was removed from the airplane and submitted to Boeing for evaluation. Investigation by Boeing has determined that the cracks are caused by fatigue. In both cases, the cracks originated inside the barrel nut holes, and radiated vertically and in the aft direction from the barrel nut holes. If not corrected, these cracks may propagate until it severs the upper rear spar cap which may result in the failure of the horizontal stabilizer upper center or aft skin panel, adversely affecting the structural integrity of the airplane. Boeing Fleet Team Digest (FTD) MD-80 FTD 55-12002 is related to this service bulletin. **ACTION** This service bulletin provides instructions to perform a High Frequency Eddy Current (ETHF) inspection on the left and right upper rear spar cap aft-most barrel nut holes for crack(s), and does as follows: **Group 1, Configuration 1, 3:** Condition 1 - No Crack Found Repeats ETHF inspection at defined intervals. Condition 2 - Any Crack Found

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 7 of 53**NOTE:**Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with Federal Aviation Administration Airworthiness Directive AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option. Option 1 1) Does a splice repair of the horizontal stabilizer upper rear spar cap. 2) Repeats ETHF inspection at defined intervals until replacement of upper rear spar cap. Option 2 1) Replaces the horizontal stabilizer upper rear spar cap. 2) Repeats ETHF inspection at defined intervals. **Group 1, Configuration 2, 4:** Condition 1 - No Crack Found Repeats ETHF inspection at defined intervals. Condition 2 - Any Crack Found **NOTE:**Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with FAA AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option. Option 1 1) Does a splice repair of the horizontal stabilizer upper rear spar cap. 2) Installs new Forcemate bushing 3) Repeats ETHF inspection at defined intervals until replacement of upper rear spar cap. Option 2 1) Replaces the horizontal stabilizer upper rear spar cap. 2) Installs new Forcemate bushing 3) Repeats ETHF inspection at defined intervals.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 8 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT EFFECTIVITY**  All DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s). **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 9 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 10 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**

### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Number: MD80-55A070**  Original Issue: May 22, 2013 Revision 1: December 17, 2013 ATA System: 5510 **SUBJECT:**STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Rear Spar Cap at Aft Barrel Nut Holes 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 11 of 53**DESCRIPTION CONFIGURATION**  **GROUP** All Airplanes - 1 Airplanes Not Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement in Accordance With Service Bulletin MD80-55A065 or other service action 1
Airplanes Not Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement And Having Forcemate Bushings Installed in Spar Web in Accordance With Service Bulletin MD80-55A065 Revision 1 or other service action 2

Airplanes Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement in Accordance With Service Bulletin MD80-55A065 or other service action 3
Airplanes Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement And Having Forcemate Bushings Installed in Spar Web in Accordance With Service Bulletin MD80-55A065 Revision 1 or other service action 4

Airplane Models: DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88 **Group Fuselage Num-**  **ber** 1 909 1 917 1 924 1 938 1 941 1 944 1 946 1 948 1 950 1 952 - 953 1 955 1 957 - 958 1 960 1 962 - 963

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 12 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 965 - 967 1 969 1 970 - 971 1 973 - 975 1 977 - 979 1 981 1 983 1 985 - 986 1 988 - 989 1 991 - 992 1 994 - 999 1 1000 - 1013 1 1015 - 1016 1 1018 - 1020 1 1022 - 1023 1 1025 - 1026 1 1028 - 1029 1 1031 - 1032 1 1034 - 1035 1 1037 - 1038 1 1040 - 1041 1 1043 1 1045 1 1047 1 1049 1 1051 1 1053 1 1055 1 1057 1 1059 - 1080 1 1082 - 1083 1 1085 - 1099

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 13 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 1100 - 1199 1 1200 - 1299 1 1300 - 1399 1 1400 - 1499 1 1500 - 1599 1 1600 - 1699 1 1700 - 1799 1 1800 - 1899 1 1900 - 1999 1 2000 - 2007 1 2009 - 2016 1 2019 - 2034 1 2036 - 2069 1 2071 - 2093 1 2101 - 2114 1 2116 1 2118 - 2119 1 2121 1 2124 1 2127 - 2128 1 2130 1 2132 1 2134 - 2135 1 2137 1 2139 1 2145 1 2148 1 2151 - 2152 1 2155 1 2167 1 2174 1 2176

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 14 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 2178 1 2180 1 2183 1 2185 1 2187 1 2189 1 2192 1 2196 1 2199 1 2201 1 2204 1 2206 1 2208 1 2214 1 2218 1 2234 1 2239 1 2241 1 2244 1 2247 1 2249 1 2252 1 2254 1 2264 - 2287 2. Spares Affected Examine your spares supply for the parts or components identified below. If any parts or components are found, refer to Paragraph 3.B., Work Instructions for the recommended action. **Part Number** 5930603-(xxx) Stabilizer Assembly, Complete (xxx) denotes any configuration.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 15 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT B. Concurrent Requirements**  None. **C. Reason** During the inspections called for in Service Bulletin MD80-55A065, two operators reported finding cracks emanating from the two upper rear spar cap aft-most barrel nut holes of the horizontal stabilizer. One airplane had accumulated 40,144 flight hours and 32,253 landing cycles, while the other airplane had accumulated 58,296 flight hours and 43,512 landing cycles. In both cases, the affected part was removed from the airplane and submitted to Boeing for evaluation. Investigation by Boeing has determined that the cracks are caused by fatigue. In both cases, the cracks originated inside the barrel nut holes, and radiated vertically and in the aft direction from the barrel nut holes. If not corrected, these cracks may propagate until it severs the upper rear spar cap which may result in the failure of the horizontal stabilizer upper center or aft skin panel, adversely affecting the structural integrity of the airplane. Boeing Fleet Team Digest (FTD) MD-80 FTD 55-12002 is related to this service bulletin. Revision 1 is sent to correct Paragraph 1.E., Compliance Tables 1 and 2 group configuration headings and Table 1 initial inspections thresholds. **D. Description** This service bulletin provides instructions to perform a High Frequency Eddy Current (ETHF) inspection on the left and right upper rear spar cap aft-most barrel nut holes for crack(s), and does as follows: **Group 1, Configuration 1, 3:** Condition 1 - No Crack Found Repeats ETHF inspection at defined intervals. Condition 2 - Any Crack Found **NOTE:**Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with Federal Aviation Administration Airworthiness Directive AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option. Option 1 1) Does a splice repair of the horizontal stabilizer upper rear spar cap. 2) Repeats ETHF inspection at defined intervals until replacement of upper rear spar cap. Option 2 1) Replaces the horizontal stabilizer upper rear spar cap. 2) Repeats ETHF inspection at defined intervals. **Group 1, Configuration 2, 4:** Condition 1 - No Crack Found

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 16 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**Repeats ETHF inspections at defined intervals. Condition 2 - Any Crack Found **NOTE:**Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with FAA AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option. Option 1 1) Does a splice repair of the horizontal stabilizer upper rear spar cap. 2) Installs new Forcemate bushing 3) Repeats ETHF inspection at defined intervals until replacement of upper rear spar cap. Option 2 1) Replaces the horizontal stabilizer upper rear spar cap. 2) Installs new Forcemate bushing 3) Repeats ETHF inspection at defined intervals. No more work is necessary on the airplane(s) changed or inspected in accordance with the original issue of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. **Affected Maintenance Zones Zone**  **Model** 33, 34 DC-9-81 (MD-81), DC-9-82(MD-82), DC-9-83 (MD-83), DC9-87 (MD-87), MD-88 **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. 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. Accomplish the required action(s), based on the applicable condition(s), in Tables 1 or 2, in accordance with Paragraph 3. Accomplishment Instructions.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 17 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 1-2:**  **Table 1: Airplanes Not Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement Barrel Nut Hole Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- Within 2,768flight cycles after the original issue date ofthis service bulletin. Before 22,000total flight cycles. Do Eddy Current, HighFrequency (ETHF) inspection of left and right upper rear spar caps at the two aft-most barrel nut holes and do the work of the applicable condition that follows: All Airplanes not having accomplished an upper rear spar cap splice repairor upper rear spar cap replaced in accordance with Service Bulletin MD80- 55A065 or other service action 4,500 flight cycles. - - Do Eddy Current, HighFrequency (ETHF) inspection of left and right upper rear spar caps at the two aft-most barrel nut holes Condition 1 (No Crack Found) (a) (b)
(a) (b)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 18 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 1-2:**  **Table 1: Airplanes Not Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement Barrel Nut Hole Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- - Before further flight. Option 1 Splice repair the affected upper aft spar cap. Condition 2 (Any Crack Found)

- - - AND 4,500 flight cycles. - Before 22,000flight cycles after repair. Do Eddy Current, HighFrequency (ETHF) inspection of the splice repaired upper rear spar cap at the two aft-most barrel nut holes (a) (b)

(a) (b)

- - - AND

- - Before 97,000flight cycles after repair.Replace the spliced repaired horizontal stabilizer upper rear spar cap.

- - - AND 4,500 flight cycles. - Before 22,000flight cycles after replacement. Do Eddy Current, HighFrequency (ETHF) inspection of the replaced upper rear spar cap at the two aft-most barrel nut holes (a) (b)
(a) (b) OR

- - Before further flight. Option 2 Replace the horizontal stabilizer upper rear spar cap.

- - - AND 4,500 flight cycles. - Before 22,000flight cycles after replacement. Do Eddy Current, HighFrequency (ETHF) inspection of the replaced upper rear spar cap at the two aft-most barrel nut holes (a) (b)
(a) (b) (a) If any crack is found, do Option 1 or Option 2 before further flight. (b) If no crack is found, repeat inspect upper aft spar caps at noted interval.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 19 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 3-4:**  **Table 2: Airplanes Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement Barrel Nut Hole Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- - Before 22,000 total flight cycles after repair or replacement. Do Eddy Current, HighFrequency (ETHF) inspection of original upper rearspar cap at the two aftmost barrel nut holes anddo the work of the applicable condition that follows:All Airplanes having accomplished an upper rear spar cap splice repair or upper rear spar cap replaced in accordance with Service Bulletin MD80-55A065 or other service action 4,500 flight cycles. - - Do Eddy Current, HighFrequency (ETHF) inspection of left and right upper rear spar cap at the two aft-most barrel nut holes Condition 1 (No Crack Found) (a) (b)
(a) (b)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 20 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 3-4:**  **Table 2: Airplanes Having Accomplished an Upper Rear Spar Cap Splice Repair or Upper Rear Spar Cap Replacement Barrel Nut Hole Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- - Before further flight. Option 1 Splice repair the affected upper aft spar cap. Condition 2 (Any Crack Found)

- - - AND 4,500 flight cycles. - Before 22,000flight cycles after splice repair. Do Eddy Current, HighFrequency (ETHF) inspection splice repaired upper rear spar cap at the two aft-most barrel nut holes (a) (b)
(a) (b)

- - - AND

- - Before 97,000flight cycles after repair.Replace the splice repaired horizontal stabilizer upper rear spar cap.

- - - AND 4,500 flight cycles. - Before 22,000flight cycles after replacement. Do Eddy Current, HighFrequency (ETHF) inspection of the replaced upper rear spar cap at the two aft-most barrel nut holes (a) (b)
(a) (b) OR

- - Before further flight. Option 2Replace the affected horizontal stabilizer upper rear spar cap.

- - - AND 4,500 flight cycles. - Before 22,000flight cycles after replacement. Do ETHF inspection of the replaced upper rearspar cap at the two aftmost barrel nut holes (a) (b) (a) (b) (a) If any crack is found, do Option 1 or Option 2 before further flight. (b) If no crack is found, repeat inspect upper aft spar caps at noted interval.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 21 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT 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. **G. Manpower** The table below shows an estimate of the task hours necessary to do this inspection (and repair, if required) 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. **Inspect Upper Rear Spar Aft Spar Cap Barrel Nut Holes Elapsed Hours**  **Task Hours Number of Persons**  **Task** 1.5 1.5 1 Open Access (FIG- URE 1) 1.5 1.5 1 FIGURE 2 FIGURE 3 1.5 1.5 1 Close Access 4.5 4.5 TOTAL FOR EACH SPAR CAP **Group 1, Configuration 1, 3: Option 1 - Upper Spar Cap Splice Repair**  **Elapsed Hours Task Hours**  **Number of Persons Task**  8.0 48.0 6 Remove - Horizon- tal Stabilizer 8.0 16.0 2 Remove - Elevators 6.0 12.0 2 Remove - Leading Edge

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 22 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 1, 3:**  **Option 1 - Upper Spar Cap Splice Repair Elapsed Hours**  **Task Hours Number of Persons**  **Task** 72.0 216.0 3 Install Horizontal Stabilizer Rear Spar Upper Cap Splice 6.0 12.0 2 Install - Leading Edge 8.0 16.0 2 Install - Elevators 8.0 48.0 6 Install - Horizontal Stabilizer 116.0 368.0 TOTAL FOR EACH SPAR CAP **Group 1, Configuration 2, 4: Option 1 - Upper Spar Cap Splice Repair**  **Elapsed Hours Task Hours**  **Number of Persons Task**  8.0 48.0 6 Remove - Horizon- tal Stabilizer 8.0 16.0 2 Remove - Elevators 6.0 12.0 2 Remove - Leading Edge 72.0 216.0 3 Install Horizontal Stabilizer Rear Spar Upper Cap Splice 13.0 26.0 2 Install Bushing/Cold Work Hole 6.0 12.0 2 Install - Leading Edge 8.0 16.0 2 Install - Elevators 8.0 48.0 6 Install - Horizontal Stabilizer 129.0 394.0 TOTAL FOR EACH SPAR CAP **Group 1, Configuration 1, 3: Option 2 - Upper Spar Cap Replacement**  **Elapsed Hours Task Hours**  **Number of Persons Task**  8.0 48.0 6 Remove - Horizon- tal Stabilizer

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 23 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 1, 3:**  **Option 2 - Upper Spar Cap Replacement Elapsed Hours**  **Task Hours Number of Persons**  **Task** 8.0 16.0 2 Remove - Elevators 6.0 12.0 2 Remove - Leading Edge 72.0 216.0 3 Replace Horizontal Stabilizer Rear Spar Upper Cap 6.0 12.0 2 Install - Leading Edge 8.0 16.0 2 Install - Elevators 8.0 48.0 6 Install - Horizontal Stabilizer 116.0 368.0 TOTAL FOR EACH SPAR CAP **Group 1, Configuration 2, 4: Option 2 - Upper Spar Cap Replacement**  **Elapsed Hours Task Hours**  **Number of Persons Task**  8.0 48.0 6 Remove - Horizon- tal Stabilizer 8.0 16.0 2 Remove - Elevators 6.0 12.0 2 Remove - Leading Edge 72.0 216.0 3 Replace Horizontal Stabilizer Rear Spar Upper Cap 13.0 26.0 2 Install Bushing/Cold Work Hole 6.0 12.0 2 Install - Leading Edge 8.0 16.0 2 Install - Elevators 8.0 48.0 6 Install - Horizontal Stabilizer 129 394.0 TOTAL FOR EACH SPAR CAP

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 24 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT H. Weight and Balance Changes**  **Condition 2, Option 1 Only Moment**  **Change (MEW) IN.-LBS**  **Mfr's Empty Weight (MEW)**  **LBS Approximate** **Station (Inch es)**  **Airplane Configuration** 

+5312.3 +3.2 1660.1 DC-9-81 (MD-81) DC-9-82 (MD-82) DC-9-83 (MD-83) MD-88 SR09550027-7001 or SR09550027-7003 or SR09550027-7013 or SR09550027-7015 +4643.5 +3.2 1451.1 DC-9-87 (MD-87) SR09550027-7001 or SR09550027-7003 or SR09550027-7013 or SR09550027-7015 Condition 2, Option 2 Only None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Boeing Service Bulletin MD80-55A065. b. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2007-10-04. c. Non-Destructive Test Standard Practices Manual (NDTSPM) 06-00-02, 06-10-01.001. d. MD-80 Aircraft Maintenance Manual (AMM) 20-20-01, 27-30-02, 55-10-00, 55-10-01. e. MD-80 Fleet Team Digest (FTD) 55-12002 f. MD-80 Structural Repair Manual (SRM) 51, 51-10-02, 51-10-03, 51-10-04, 51-20-00, 51-30-01, 51-30-02, 51-30-03, 51-30-05, 51-30-09, 51-30-11, 51-70-02. 2. Data Supplied with this Service Bulletin: No data is supplied with this service bulletin. To obtain the data necessary to support this service bulletin submit a data request to:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 25 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**Data and Services Management MS D800-0019 3855 Lakewood Boulevard Long Beach, California 90846 Phone: (562) 593-6996 Fax: (562) 593-2001 E-mail: dse.boecom@boeing.com a. Drawings: **ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- E DWG Rear Spar Repair - Inboard Upper SR09550027

- C DWG Rear Spar Replacement Horizontal SR09550030

- B DWG Fatigue Life Enhancement - Upper Rear SR09550032 3. Installation Drawings Used in the Preparation of this Service Bulletin: **Change Title**  **Drawing Number** DD Structural Assembly - Horizontal Stabilizer Outer Panel, Front Spar to Rear Spar 5922575 BJ Stabilizer Assembly - Complete Horizontal 5930603 DC Spar Assembly - Horizontal Stabilizer, Rear 9918401

4. Process Data: Douglas Process Specifications referred to on the drawings are not given in this service bulletin since these procedures are frequently used as standard shop practices. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 26 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 **REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION**  **Unit Price as of the Original Issue** 

**of this Service Bulletin (US Dol**  **lars) ROLT as of the**  **Original Issue of this Service Bul** 

**letin (Calendar Days)**  **QTY Date**  **Name Kit Number** 

$3,014.00 90 1 June 15, 2013 SERVICE KIT SA09550070-3 $32,440.00 90 1 June 15, 2013 FULL SPAR SPLICE KIT - UPPER LEFT SA09550065-3 $29,304.00 90 1 June 15, 2013 FULL SPAR SPLICE KIT - UPPER RIGHT SA09550065-5 $60,222.00 90 1 June 15, 2013 FULL SPAR CAP RE- PLACEMENT KIT - UPPER LEFT SA09550065-53 $60,074.00 90 1 June 15, 2013 FULL SPAR CAP RE- PLACEMENT KIT - UPPER RIGHT SA09550065-55 $1,269.00 90 1 June 15, 2013 FORCEMATE BUSH- ING KIT- NOMINAL SA09550065-61
**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 To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 27 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT NOTE:** One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary based on inspection results and operators choice of the required change. **Parts Kits Required Configuration and Option**  SA09550070-3 All Configurations, All Conditions SA09550065-3 (Left Side) Configurations 1 and 3, Condition 2, Option 1 SA09550065-5 (Right Side) SA09550065-3 and SA09550065-61 (Left Side) Configurations 2 and 4, Condition 2, Option 1 SA09550065-5 and SA09550065-61 (Right Side) SA09550065-53 (Left Side) Configurations 1 and 3, Condition 2, Option 2 SA09550065-55 (Right Side) SA09550065-53 and SA09550065-61 (Left Side) Configurations 2 and 4, Condition 2, Option 2 SA09550065-55 and SA09550065-61 (Right Side) **Group 1, Configuration 1, 3: Condition 2, Option 1:**  **Kit SA09550065 Notes**  **Name QTY**  **New Part Number -5**  **-3** (a) SPAR SPLICE KIT-LH
- 1 SA09550065-7 (b) SPAR SPLICE KIT-RH 1 - SA09550065-9 (c) SPAR CAP (STUB)
- 1 SR09550027-13 (d) SPAR CAP (STUB) 1 - SR09550027-14 (a) SA09550065-7 is a sub kit of SA09550065-3. (b) SA09550065-9 is a sub kit of SA09550065-5. (c) May be made from 5918000-526. (d) May be made from 5918000-525.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 28 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 2, 4:**  **Condition 2, Option 1: Kit SA09550065**  **Notes Name**  **QTY New Part Number**  **-61 -5**  **-3**

- BUSHING 2 - - 7090-040

- BUSHING 2 - - 7090-043

- HILOK 1 - - HLT434-8-13

- PIN 1 - - HLT634-8-13

- NUT 1 - - MS21042L4

- WASHER 1 - - NAS1252-416L

- WASHER 2 - - NAS620-416L

- BOLT 2 - - NAS6204-13

- NUT 2 - - NAS679A4 (a) SPAR SPLICE KIT-LH
- - 1 SA09550065-7 (b) SPAR SPLICE KIT-RH
- 1 - SA09550065-9 (c) SPAR CAP (STUB)
- - 1 SR09550027-13 (d) SPAR CAP (STUB)
- 1 - SR09550027-14 (a) SA09550065-7 is a sub kit of SA09550065-3. (b) SA09550065-9 is a sub kit of SA09550065-5. (c) May be made from 5918000-526. (d) May be made from 5918000-525. **Group 1, Configuration 1, 3: Condition 2, Option 2:**  **Kit SA09550065 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -55**  **-53**

- - NUT 3 3 113LH7940T064

- - NUT 4 4 113LH7940T070

- - BARREL NUT 1 1 113LH7940T080

- - NUT BARREL 2 2 117LH7940T-098

- - NUT ASSY 99 99 3D0006-3

- - NUT ASSY 5 5 3D0006-4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 29 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 1, 3:**  **Condition 2, Option 2: Kit SA09550065**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-55 -53**  (a) - BARREL NUT SUB SUB 3D0011-9

- RETAINER SUB SUB 3D0012-9

- - BOLT 2 2 3D0031-9-34

- 5918000-525 SPAR CAP 1 - 5918000-525 5918000-529

- 5918000-526 SPAR CAP
- 1 5918000-526 5918000-530

- - WASHER 2 2 73232-9-28.7

- - PIN 5 5 HLT434-6-3

- - PIN 72 72 HLT434-6-4

- - PIN 32 32 HLT434-6-5

- - PIN 18 18 HLT434-6-6

- - PIN 18 18 HLT434-6-7

- - PIN 25 25 HLT434-6-8

- - PIN 2 2 HLT434-6-9

- - PIN 5 5 HLT434-6-11

- - HILOK 1 1 HLT434-8-8

- - HILOK 3 3 HLT434-8-13

- - HILOK 2 2 HLT434-8-16

- - PIN 84 84 HLT435-6-4

- - PIN 77 77 HLT435-6-5

- - PIN 9 9 HLT435-6-6

- - PIN 13 13 HLT435-6-7

- - PIN 4 4 HLT435-6-8

- - WASHER 2 2 MS20002-5

- - WASHER 1 1 MS20002-6

- - WASHER 1 1 MS20002-7

- - WASHER 2 2 MS20002C5

- - WASHER 3 3 MS20002C6

- - WASHER 4 4 MS20002C7

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 30 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 1, 3:**  **Condition 2, Option 2: Kit SA09550065**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-55 -53** 

- - WASHER 1 1 MS20002C8

- - RIVET 6 6 MS20426AD3-4D

- - RIVET 1 1 MS20426AD5-8D

- - RIVET 45 45 MS20426AD5-9D

- - RIVET 95 95 MS20426AD6-8D

- - RIVET 57 57 MS20426AD6-9D

- - RIVET 4 4 MS20426AD6-10D

- - RIVET 20 20 MS20470AD5-8D

- - RIVET 106 106 MS20470E5-6D

- - RIVET 20 20 MS20470E5-7D

- - RIVET 52 52 MS20470E6-7D

- - RIVET 26 26 MS20470E6-8D

- - NUT 291 291 MS21042L3

- - NUTPLATE 5 5 MS21075L3

- - BOLT 2 2 MS21250-05018

- - BOLT 1 1 MS21250-06020

- - BOLT 1 1 MS21250-06022

- - BOLT 1 1 MS21250-06024

- - BOLT 1 1 MS21250-07020

- - BOLT 1 1 MS21250-07024

- - BOLT 1 1 MS21250-07026

- - BOLT 1 1 MS21250-08028

- - BOLT

. 1 MS21250H07060

- - RIVET 8 8 NAS1097KE5-8D

- - RIVET 7 7 NAS1097KE5-9D

- - RIVET 44 44 NAS1097KE6-8D

- - RIVET 59 59 NAS1097KE6-9D

- - RIVET 4 4 NAS1097KE6-11D

- - WASHER 78 78 NAS1149F0332P

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 31 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 1, 3:**  **Condition 2, Option 2: Kit SA09550065**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-55 -53** 

- - WASHER 24 24 NAS1149F0463P

- - WASHER 14 14 NAS1149FN816P

- - WASHER 316 316 NAS1252-10L

- - SCREW 14 14 NAS1403-2

- - SCREW 20 20 NAS1403-4

- - SCREW 30 30 NAS1403-5

- - SCREW 4 4 NAS1403-8

- - WASHER 23 23 NAS1587A3C

- - SCREW 1 1 NAS333CPA4-5

- - RETAINER 3 3 NAS578-6B

- - RETAINER 4 4 NAS578-7B

- - RETAINER 1 1 NAS578-8B

- - SCREW 24 24 NAS602-7P

- - WASHER 6 6 NAS620-416L

- - BOLT 6 6 NAS6203-10

- - BOLT 8 8 NAS6203-6

- - BOLT 6 6 NAS6204-13

- - BOLT 24 24 NAS6204-4

- - NUT 31 31 NAS679A3

- - NUT 7 7 NAS679A4

- - BOLT 1 1 PIC239-3-4

- - BOLT 2 2 PIC239-4-4

- - PIN 4 4 S4931919-6-5

- - PIN 8 8 S4931920-6-4

- - PIN 10 10 S4931920-6-5

- - PIN 14 14 S4931920-6-6

- - PIN 4 4 S4931920-6-7

- - PIN 6 6 S4931920-6-8 (a) May be substituted for 117LH7940T-098 barrel nut assembly.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 32 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 2, 4:**  **Condition 2, Option 2: Kit SA09550065**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-61 -55**  **-53**

- - NUT - 3 3 113LH7940T064

- - NUT - 4 4 113LH7940T070

- - BARREL NUT - 1 1 113LH7940T080

- - NUT BARREL - 2 2 117LH7940T-098

- - NUT ASSY
- 99 99 3D0006-3

- - NUT ASSY
- 5 5 3D0006-4 (a) - BARREL NUT - SUB SUB 3D0011-9

- RETAINER - SUB SUB 3D0012-9

- - BOLT
- 2 2 3D0031-9-34

- 5918000-525 SPAR CAP
- 1 - 5918000-525 5918000-529

- 5918000-526 SPAR CAP
- - 1 5918000-526 5918000-530

- - WASHER
- 2 2 73232-9-28.7

- - BUSHING 2 - - 7090-040

- - BUSHING 2 - - 7090-043

- - PIN - 5 5 HLT434-6-3

- - PIN - 72 72 HLT434-6-4

- - PIN - 32 32 HLT434-6-5

- - PIN - 18 18 HLT434-6-6

- - PIN - 18 18 HLT434-6-7

- - PIN - 25 25 HLT434-6-8

- - PIN - 2 2 HLT434-6-9

- - PIN - 5 5 HLT434-6-11

- - HILOK
- 1 1 HLT434-8-8

- - HILOK 1 3 3 HLT434-8-13

- - HILOK
- 2 2 HLT434-8-16

- - PIN - 84 84 HLT435-6-4

- - PIN - 77 77 HLT435-6-5

- - PIN - 9 9 HLT435-6-6

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 33 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 2, 4:**  **Condition 2, Option 2: Kit SA09550065**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-61 -55**  **-53**

- - PIN - 13 13 HLT435-6-7

- - PIN - 4 4 HLT435-6-8

- - PIN 1 - - HLT634-8-13

- - WASHER
- 2 2 MS20002-5

- - WASHER
- 1 1 MS20002-6

- - WASHER
- 1 1 MS20002-7

- - WASHER
- 2 2 MS20002C5

- - WASHER
- 3 3 MS20002C6

- - WASHER
- 4 4 MS20002C7

- - WASHER
- 1 1 MS20002C8

- - RIVET - 6 6 MS20426AD3-4D

- - RIVET - 1 1 MS20426AD5-8D

- - RIVET - 45 45 MS20426AD5-9D

- - RIVET - 95 95 MS20426AD6-8D

- - RIVET - 57 57 MS20426AD6-9D

- - RIVET - 4 4 MS20426AD6-10D

- - RIVET - 20 20 MS20470AD5-8D

- - RIVET - 106 106 MS20470E5-6D

- - RIVET - 20 20 MS20470E5-7D

- - RIVET - 52 52 MS20470E6-7D

- - RIVET - 26 26 MS20470E6-8D

- - NUT - 291 291 MS21042L3

- - NUT 1 - - MS21042L4

- - NUTPLATE - 5 5 MS21075L3

- - BOLT
- 2 2 MS21250-05018

- - BOLT
- 1 1 MS21250-06020

- - BOLT
- 1 1 MS21250-06022

- - BOLT
- 1 1 MS21250-06024

- - BOLT
- 1 1 MS21250-07020

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 34 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 2, 4:**  **Condition 2, Option 2: Kit SA09550065**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-61 -55**  **-53**

- - BOLT
- 1 1 MS21250-07024

- - BOLT
- 1 1 MS21250-07026

- - BOLT
- 1 1 MS21250-08028

- - BOLT
- . 1 MS21250H07060

- - RIVET - 8 8 NAS1097KE5-8D

- - RIVET - 7 7 NAS1097KE5-9D

- - RIVET - 44 44 NAS1097KE6-8D

- - RIVET - 59 59 NAS1097KE6-9D

- - RIVET - 4 4 NAS1097KE6-11D

- - WASHER
- 78 78 NAS1149F0332P

- - WASHER
- 24 24 NAS1149F0463P

- - WASHER
- 14 14 NAS1149FN816P

- - WASHER
- 316 316 NAS1252-10L

- - WASHER 1 - - NAS1252-416L

- - SCREW
- 14 14 NAS1403-2

- - SCREW
- 20 20 NAS1403-4

- - SCREW
- 30 30 NAS1403-5

- - SCREW
- 4 4 NAS1403-8

- - WASHER
- 23 23 NAS1587A3C

- - SCREW
- 1 1 NAS333CPA4-5

- - RETAINER - 3 3 NAS578-6B

- - RETAINER - 4 4 NAS578-7B

- - RETAINER - 1 1 NAS578-8B

- - SCREW
- 24 24 NAS602-7P

- - WASHER 2 6 6 NAS620-416L

- - BOLT
- 6 6 NAS6203-10

- - BOLT
- 8 8 NAS6203-6

- - BOLT 2 6 6 NAS6204-13

- - BOLT
- 24 24 NAS6204-4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 35 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Group 1, Configuration 2, 4:**  **Condition 2, Option 2: Kit SA09550065**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-61 -55**  **-53**

- - NUT - 31 31 NAS679A3

- - NUT 2 7 7 NAS679A4

- - BOLT
- 1 1 PIC239-3-4

- - BOLT
- 2 2 PIC239-4-4

- - PIN - 4 4 S4931919-6-5

- - PIN - 8 8 S4931920-6-4

- - PIN - 10 10 S4931920-6-5

- - PIN - 14 14 S4931920-6-6

- - PIN - 4 4 S4931920-6-7

- - PIN - 6 6 S4931920-6-8 (a) May be substituted for 117LH7940T-098 barrel nut assembly.

**Kit SA09550070 Notes**  **Name QTY**  **New Part Number -3** 

- FILLER 2 5930603-17 2. Parts and Materials Supplied by the Operator **CAGE Supplier**  **QTY Part Number/Specification**  92108 PRC-DeSoto International, IncorporatedAs Required PR-1422 B-2 Sealant (DMS 2082 P.O. Box 1800 or Equivalent) Sylmar, California 91342 3. Parts Modified and Reidentified None 4. Parts Removed and Not Replaced None

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 36 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT D. Parts Necessary to Change Spares**  To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability. **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** To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available. **Notes CAGE**  **Supplier Name**  **Tool Number** (a) 81205 The Boeing Company Horizontal Stabiliz- er Hinge Alignment Tool C652-5922575 ATP3

81205 The Boeing Company Stress Coin Coun- tersink Die Tool C652-74956-165B-GT (a) Horizontal Stabilizer Hinge Alignment Tool is optional, not mandatory, and may be obtained from Boeing.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 37 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 38 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**

BLANK PAGE**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. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Equivalent parts are listed in the AEPL, Drawing 7595071. 3. Use the approved fastener and process material substitutions, in accordance with MD-80 SRM 51. 4. If the length of any fastener specified in this service bulletin does not meet installation standards given in Structural Repair Manual (SRM) Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 5. A 1/8-inch thick stack of the same type washers called for in this service bulletin is the maximum thickness which may be used under fastener head or nut to counteract accumulation of tolerances. EXCEPTION: When the available fastener length increments are greater than 1/16-inch, a 3/16-inch thick stack of the same type washers may be used. 6. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are in MD-80 SRM 51. – Torque limits to tighten nuts and bolts are in MD-80 SRM 51. 7. Refer to these chapters for the applicable operations as accepted procedures: – MD-80 SRM 51-10-02 - Forming, Heat Treatment, and Metal Handling – MD-80 SRM 51-10-03 - Corrosion and Dissimilar Metals Protection

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 39 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**– MD-80 SRM 51-10-04 - Drilling and Countersinking – MD-80 SRM 51-20-00 - Repair Sealing – MD-80 SRM 51-30-01 - Installing Bolts, Screws, and Washers – MD-80 SRM 51-30-02 - Removing and Installing Rivets – MD-80 SRM 51-30-03 - Removing and Installing Lockbolts – MD-80 SRM 51-30-05 - Installing Hi-Lok Attachments – MD-80 SRM 51-30-09 - Split Sleeve Cold Work – MD-80 SRM 51-30-11 - Conical Spacers (Countersink Washers) – MD-80 SRM 51-70-02 - Repair of Bonded Aluminum Assemblies – MD-80 AMM 20-20-01 - Cementing - Maintenance Practices 8. Obey all of the warnings and cautions given in the specified manual sections. 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. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U' or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U' or 'Y' as an alternative to the '-' (dash) number part. Boeing Drawing SE10000000, Sheets 5.0 and 6.0 contain more data. 11. 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. 12. 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. 13. 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. 14. Shaded areas in Figures are reference only. Shaded areas in Figures may look different than your airplane. 15. 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. 16. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. **B. WORK INSTRUCTIONS Group 1, Configuration 1, 3:**  1. Remove the left and right horizontal stabilizer skin filler. Refer to Figure 1 for location of skin fillers. **NOTE:**The skin fillers are bonded to the airplane structure with DMS 2082 adhesive.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 40 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**2. Prepare the surface area to be inspected in accordance with Figure 2. 3. Do a High Frequency Eddy Current (ETHF) inspection of the areas around the upper rear spar cap two aft-most barrel nut holes in accordance with Figure 3 and based on inspection results do the work of the applicable condition that follows:
**Condition 1 - No Crack Found** a. If required, fill area of forward barrel nut hole sealant removed for ETHF inspection in accordance with Figure 2 with DMS 2082 sealant. b. Install a new or serviceable 5930603-17 filler using DMS 2082 sealant. Refer to MD-80 AMM 20-20-01 as an acceptable procedure. c. Put the airplane back in serviceable condition. d. Repeat ETHF inspection at intervals specified in Paragraph 1.E., Compliance. **Condition 2 - Any Crack Found** a. Do Option 1 or Option 2 **NOTE:**Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with FAA AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option. **Option 1:** (1) Remove and keep horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure. (2) Remove and keep elevator from affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (3) Remove and keep horizontal stabilizer leading edge from affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure. (4) Splice horizontal stabilizer upper rear spar in accordance with Service Rework Drawing SR09550027-7001 (left side) or -7003 (right side). (5) Install kept horizontal stabilizer leading edge on affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure. (6) Install kept elevator on affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (7) Install a new or serviceable 5930603-17 filler using DMS 2082 sealant. Refer to MD-80 AMM 20-20-01 as an acceptable procedure. (8) Install kept horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 41 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**(9) Put the airplane back in serviceable condition. (10) Repeat ETHF inspection at intervals specified in Paragraph 1.E., Compliance. (11) Replace horizontal stabilizer upper rear spar cap in accordance with Service Rework Drawing SR09550030-7001 (left side) or -7005 (right side) as specified in Paragraph 1.E., Compliance. **Option 2:** (1) Remove and keep horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure. (2) Remove and keep elevator from affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (3) Remove and keep horizontal stabilizer leading edge from affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure. (4) Install new horizontal stabilizer upper rear spar cap in accordance with Service Rework Drawing SR09550030-7001 (left side) or -7005 (right side). (5) Install kept horizontal stabilizer leading edge on affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure. (6) Install kept elevator on affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (7) Install a new or serviceable 5930603-17 filler using DMS 2082 sealant. Refer to MD-80 AMM 20-20-01 as an acceptable procedure. (8) Install kept horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure. (9) Put the airplane back in serviceable condition. (10) Repeat ETHF inspection at intervals specified in Paragraph 1.E., Compliance. **Group 1, Configuration 2, 4:** 1. Remove the left and right horizontal stabilizer skin filler. Refer to Figure 1 for location of skin fillers. **NOTE:**The skin fillers are bonded to the airplane structure with DMS 2082 adhesive. 2. Prepare the surface area to be inspected in accordance with Figure 2. 3. Do a High Frequency Eddy Current (ETHF) inspection of the areas around the upper rear spar cap two aft-most barrel nut holes in accordance with Figure 3 and based on inspection results do the work of the applicable condition that follows:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 42 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT Condition 1 - No Crack Found**  a. If required, fill area of forward barrel nut hole sealant removed for ETHF inspection in accordance with Figure 2 with DMS 2082 sealant. b. Install a new or serviceable 5930603-17 filler using DMS 2082 sealant. Refer to MD-80 AMM 20-20-01 as an acceptable procedure. c. Put the airplane back in serviceable condition d. Repeat ETHF inspection at intervals specified in Paragraph 1.E., Compliance. **Condition 2 - Any Crack Found** a. Do Option 1 or Option 2 **NOTE:**Both Options affect the inspection requirements contained in Service Bulletin MD80-55A065, and will affect compliance with FAA AD 2007-10-04 as it relates to the upper rear spar cap. Operators are urged to consider both this service bulletin and Service Bulletin MD80-55A065 while choosing an option. **Option 1:** (1) Remove and keep horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure. (2) Remove and keep elevator from affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (3) Remove and keep horizontal stabilizer leading edge from affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure.. (4) Splice horizontal stabilizer upper rear spar cap in accordance with Service Rework Drawing SR09550027-7013 (left side) or -7015 (right side). (5) Install kept horizontal stabilizer leading edge on affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure. (6) Install kept elevator on affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (7) Install a new or serviceable 5930603-17 filler using DMS 2082 sealant. Refer to MD-80 AMM 20-20-01 as an acceptable procedure. (8) Install kept horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure. (9) Put the airplane back in serviceable condition. (10) Repeat ETHF inspection at intervals specified in Paragraph 1.E., Compliance.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 43 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**(11) Replace horizontal stabilizer upper rear spar cap in accordance with Service Rework Drawing SR09550030-7017 (left side) or -7019 (right side) as specified in Paragraph 1.E., Compliance. **Option 2:** (1) Remove and keep horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure. (2) Remove and keep elevator from affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (3) Remove and keep horizontal stabilizer leading edge from affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure. (4) Install new horizontal stabilizer upper rear spar cap in accordance with Service Rework Drawing SR09550030-7017 (left side) or -7019 (right side). (5) Install kept horizontal stabilizer leading edge on affected side. Refer to MD-80 AMM 55-10-01 as an acceptable procedure. (6) Install kept elevator on affected side. Refer to MD-80 AMM 27-30-02 as an acceptable procedure. (7) Install a new or serviceable 5930603-17 filler using DMS 2082 sealant. Refer to MD-80 AMM 20-20-01 as an acceptable procedure. (8) Install kept horizontal stabilizer. Refer to MD-80 AMM 55-10-00 as an acceptable procedure. (9) Put the airplane back in serviceable condition. (10) Repeat ETHF inspection at intervals specified in Paragraph 1.E., Compliance.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1: December 17, 2013 44 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT FIGURE 1: REMOVE SKIN FILLER**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 45 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT FIGURE 1: REMOVE SKIN FILLER**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 46 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) 2 5930603-17 Horizontal Stabiliz- er Upper Skin Filler Remove 1 (a) Filler is attached with DMS 2082 sealant.

**FIGURE 1: REMOVE SKIN FILLER (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 47 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT FIGURE 2: INSPECTION SURFACE AREA - PREPARATION**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 48 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT FIGURE 2: INSPECTION SURFACE AREA - PREPARATION**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 49 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b) 1 5918000-525 5918000-526Horizontal Stabilizer Upper Spar Cap Prepare 1 (a) Make sure that the horizontal stabilizer skin does not interfere with the test probe in the areas that require inspection. The distance between the edge of the forward barrel nut hole and the skin at the closest point must be greater than the diameter of the probe coil plus 0.010 inch. (b) If the horizontal stabilizer skin interferes with the test probe, remove enough sealant from the forward face of the forward barrel nut hole to allow for the diameter of the probe plus 0.010 inch minimum in the inspection area.

**FIGURE 2: INSPECTION SURFACE AREA - PREPARATION (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 50 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT FIGURE 3: HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 51 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT FIGURE 3: HIGH FREQUENCY EDDY CURRENT INSPECTION**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 52 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b) (c) 1 5918000-525 5918000-526Horizontal Stabilizer Upper Spar CapInspect High Frequency Eddy Current (ETHF) 1
Make sure the surfaces to be inspected are clean. Refer to NDTSPM 06-00-02 as an acceptable procedure. (a)Perform a High Frequency Eddy Current surface inspection of the horizontal stabilizer rear spar upper cap adjacent to the two barrel nut holes at the inspection area. Scan around the barrel nut holes looking for cracks propagating in the forward and aft direction initiating at the barrel nut holes following the instructions found in the Nondestructive Testing Standard Practice Manual NDTSPM 06-10- 01.001 (ETHF - Procedure 1). Use Calibration Method "A" and Scan Method "79". (b)

If the horizontal stabilizer skin interferes with the test probe, inspect by scanning the forward face of the forward barrel nut holes following the instructions found in the Nondestructive Testing Standard Practice Manual NDTSPM 06-10-01.001 (ETHF - Procedure 1). Use calibration Method "A" and Scan Method "79". (c)

**FIGURE 3: HIGH FREQUENCY EDDY CURRENT INSPECTION (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 22, 2013 MD80-55A070 Revision 1 December 17, 2013 53 of 53 **BOEING SERVICE BULLETIN MD80-55A070 ALERT**  **ALERT**