Commercial 

Airplanes 707

Service Bulletin

ALERT

Number: A3515

Original Issue: December 19, 2007

Revision 1: October 10, 2014

ATA System: 5510

SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection

and Repair

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

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

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2007 Boeing.

Unpublished Work. All Rights Reserved.

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10.0
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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

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

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

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

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

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 22

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 24

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUTBOARD

- CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 -

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 3: HORIZONTAL STABILIZER - REAR SPAR - UPPER INBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
FIGURE 4: HORIZONTAL STABILIZER - REAR SPAR - LOWER OUTBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 5: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FIGURE 6: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION -13.179 TO STABILIZER STATION 92.55 - INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Appendix A: CONFIGURATION VERIFICATION - INSPECTION RESULTS FORM - MATERIAL DATA . 38

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
Commercial 

Airplanes 707

Service Bulletin

ALERT

Revision Transmittal Sheet Number: A3515

Original Issue: December 19, 2007

Revision 1: October 10, 2014

ATA System: 5510

SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection

and Repair

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1 are related

to this service bulletin.

No more work is necessary on the airplane(s) changed in accordance with the original issue of this service

bulletin.

REASON FOR REVISION

This revision is sent to updated compliance table and wording to clarify requirements, provide clarifying information

for the Compliance requirements for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords,

to clarify Parts 3, 4 & 5 by removing unnecessary redundant wording, and to add reference to Federal Aviation

Administration (FAA) Airworthiness Directive AD 2012-17-13.

These sections were changed:

1. Summary, Background, added clarifying information for the Part 6 7079 aluminum chord replacement

with 7075 aluminum chords.

2. Summary, Compliance, added FAA Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1.

3. Paragraph 1.C., Reason, added clarifying information for the Part 6 7079 aluminum chord replacement

with 7075 aluminum chords.

4. Paragraph 1.E., Compliance, updated compliance table to clarify requirements, added clarifying

information for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords and added

FAA Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1.

5. Paragraph 1.F., Approval, added FAA Airworthiness Directive AD 2012-17-13.

6. Paragraph 1.J., References, added FAA Airworthiness Directives AD 85-12-01 R1 and AD 2012-17-13.

7. Paragraph 2.C.2., Parts and Materials Supplied by the Operator, removed footnote (c) and added parts

65-95600-703 and 65-95600-704 and footnotes (j) and (k).

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8. Paragraph 3.B.3., Work Instructions, removed unnecessary redundant wording.

9. Paragraph 3.B.4., Work Instructions, removed unnecessary redundant wording.

10. Paragraph 3.B.5., Work Instructions, removed unnecessary redundant wording.

11. Paragraph 3.B.6., Work Instructions, added clarifying information for the Part 6 7079 aluminum chord

replacement with 7075 aluminum chords.

12. Paragraph 3.B., Work Instructions, Figures 1 through 6 and Appendix A, changed all NDT callouts to

"in accordance with".

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 important changes.

REVISION HISTORY

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
Commercial 

Airplanes 707

Service Bulletin

ALERT

Summary Number: A3515

Original Issue: December 19, 2007

Revision 1: October 10, 2014

ATA System: 5510

SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection

and Repair

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 Service Related Problem (SRP) 707-SRP-55-0033 is related to this service bulletin.

1. ISSUE 1 - Stress Corrosion Cracking in Chords Made from 7079 Aluminum in the Horizontal Stabilizer

Rear Spar

Boeing has received numerous reports of stress corrosion cracking in the chord segments made from

7079 aluminum in the 707 horizontal stabilizer rear spar This is a material that is known to be susceptible

to stress corrosion cracking. Early reports led to Boeing Service Bulletins 707-3356 and 707-3381.

Incorporation of the modifications in those service bulletins has helped to slow the development of

stress corrosion cracks. Boeing Service Bulletin 707-A3515 continues the inspections of 707-3356 and

707-3381, but at shorter intervals, and in concurrence with the necessary actions that are the subject

of Issue 2 below, until the 7079 aluminum chord segments are replaced by ones made from 7075. The

actions of this service bulletin addressing Issue 1 are necessary to adequately detect development of

stress corrosion cracking in 7079 aluminum chords.

2. ISSUE 2 - Early Fatigue Cracking in the Inboard Segment of the Upper Chord in the Horizontal Stabilizer

Rear Spar

Boeing has received three reports of fatigue cracking in the upper chord of the horizontal stabilizer rear

spar at a location near the side of the body. In all cases the fatigue prevention and fail safety

improvement modifications of Boeing Service Bulletin 707-A3313 had been incorporated. The fatigue

cracking is considered to be early in the life of the modified structure. The fatigue cracks are generated

by frequent use of the airplanes for training flights that include multiple Touch and Goes. This frequent

use of the airplane for this type of training has been most prevalent with military operators of commercial

model 707 and 720 airplanes. The actions of this service bulletin are necessary to adequately detect

early fatigue cracking.

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3. CONFIGURATION

The ability to move the horizontal stabilizer to a different airplane is of significance to Issue 1 and Issue

2. Parts made from 7079 have been discovered on airplanes not originally delivered with those parts.

Therefore, to adequately address Issue 1, it is necessary to determine the horizontal stabilizer rear

spar chord configuration on the airplane. It is also necessary to carefully maintain a record of that

configuration until all 7079 horizontal stabilizer rear spar chord segments have been removed from the

fleet. Regarding Issue 2, since horizontal stabilizers can be moved to different airplanes, it is necessary

to implement the inspections for early fatigue cracking on all effective airplanes at the time stated in

the 1.E Compliance section, regardless of the current usage of the airplane.

ACTION (PRR 18101-2RS)

Cycle Definition: To adequately account for in-flight training maneuvers, incorporate the cycle counting procedure

defined in this service bulletin.

Configuration Check: To Maintain configuration identity, determine the material for each horizontal stabilizer

rear spar chord segment addressed by this service bulletin. Maintain the configuration identity indefinitely.

Inspections: Complete the inspections for stress corrosion cracking and fatigue cracking in accordance with the

methods and times stated in this service bulletin.

Repair: Contact Boeing for repair instructions or replace the cracked part with a spare part made from 7075

aluminum.

EFFECTIVITY

All 707-300, 707-300B, 707-300C and 707-400 Airplanes. See Paragraph 1.A.1 for effectivity.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1 are related

to this service bulletin.

See Service Bulletin Paragraph 1.E. for compliance information.

INDUSTRY SUPPORT INFORMATION

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

bulletin.

MANPOWER

See Service Bulletin Paragraph 1.G. for manpower information.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 707

Service Bulletin

ALERT

Number: A3515

Original Issue: December 19, 2007

Revision 1: October 10, 2014

ATA System: 5510

SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection

and Repair

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. An equivalent change is on subsequent

production airplanes. Refer to PRR 18101-2RS for data about this change.

Refer to Service Bulletin Index Document D6-1647 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

GROUP CONFIGURATION DESCRIPTION

1 - All horizontal stabilizer rear spar chords made from 7079-T6.

Horizontal stabilizer rear spar upper inboard and upper outboard

chords made of 7079-T6.

2 -

Left side horizontal stabilizer rear spar upper inboard chords made

from 7079-T6.

3 -

4 - All horizontal stabilizer rear spar chords made from 7075-T73511.

Airplane Models:

707-300, 707-300B, 707-300C, 707-400

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Variable Number Group

02001 - 02020 1

02101 - 02121 1

02201 - 02207 1

02301 - 02303 1

02401 - 02418 1

04001 - 04005 1

04020 - 04022 1

04101 - 04106 1

04201 - 04218 1

04271 - 04272 1

04301 - 04303 1

05001 - 05060 1

05101 - 05138 1

05201 - 05208 1

05301 - 05312 1

05401 1

05601 - 05605 1

05631 - 05635 1

05701 - 05703 1

05801 - 05802 1

05821 - 05827 1

05831 - 05833 1

05851 - 05854 1

05891 - 05892 1

05921 - 05923 1

05941 - 05942 1

05961 - 05970 1

06001 - 06002 1

06101 1

06401 - 06404 1

06451 4

06461 4

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
Variable Number Group

07001 - 07017 1

07041 - 07059 1

07071 - 07081 1

07101 - 07109 1

07181 1

07191 1

07201 - 07208 1

07210 1

07212 - 07215 1

07251 - 07271 1

07401 - 07407 1

07451 - 07458 1

07501 - 07504 1

07601 - 07626 1

07661 - 07662 1

07681 - 07684 1

07701 - 07702 1

07801 - 07821 1

07901 - 07907 1

08001 - 08008 1

08021 1

08051 - 08056 1

08071 - 08077 1

08101 - 08104 1

08121 - 08129 1

08141 - 08144 1

08151 - 08153 1

08171 - 08173 1

08191 - 08192 1

08201 - 08208 1

08209 - 08210 3

08221 - 08224 1

08241 - 08244 1

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
Variable Number Group

08251 1

08261 1

08271 1

08301 - 08320 1

08324 - 08330 1

08333 1

08401 - 08410 1

08451 - 08452 1

08471 - 08475 1

08501 - 08502 1

08551 - 08553 1

08581 - 08582 1

09001 - 09006 1

09101 - 09102 1

09103 - 09105 3

09106 - 09107 4

09161 - 09167 4

09201 - 09202 1

09203 2

09204 4

09221 - 09223 3

09227 4

09231 2

09232 3

09251 4

09271 4

09281 4

09286 - 09290 4

09411 4

09421 4

09438 4

09441 4

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Boeing Service Related Problem (SRP) 707-SRP-55-0033 is related to this service bulletin.

1. ISSUE 1 - Stress Corrosion Cracking in Chords made from 7079 Aluminum in the Horizontal

Stabilizer Rear Spar

Boeing has received numerous reports of stress corrosion cracking in the chord segments made

from 7079 aluminum in the 707 horizontal stabilizer rear spar. This is a material that is known to

be susceptible to stress corrosion cracking. Early reports led to Boeing Service Bulletins 707-3356

and 707-3381. Incorporation of the modifications in those service bulletins has helped to slow the

development of stress corrosion cracks. Boeing Service Bulletin 707-A3515 continues the

inspections of 707-3356 and 707-3381, but at shorter intervals, and in concurrence with the

necessary actions that are the subject of Issue 2 below, until the 7079 aluminum chord segments

are replaced by ones made from 7075. The actions of this service bulletin addressing Issue 1 are

necessary to adequately detect development of stress corrosion cracking in 7079 aluminum chords.

2. ISSUE 2 - Early Fatigue Cracking in the Inboard Segment of the Upper Chord in the Horizontal

Stabilizer Rear Spar

Boeing has received three reports of fatigue cracking in the upper chord of the horizontal stabilizer

rear spar at a location near the side of the body. In all cases the fatigue prevention and fail safety

improvement modifications of Boeing Service Bulletin 707-A3313 had been incorporated. The

fatigue cracking is considered to be early in the life of the modified structure. The fatigue cracks

are generated by frequent use of the airplanes for training flights that include multiple Touch and

Goes. This frequent use of the airplane for this type of training has been most prevalent with military

operators of commercial model 707 and 720 airplanes.

The actions of this service bulletin are necessary to adequately detect early fatigue cracking.

3. CONFIGURATION

The ability to move the horizontal stabilizer to a different airplane is of significance to Issue 1 and

Issue 2. Parts made from 7079 have been discovered on airplanes not originally delivered with

those parts. Therefore, to adequately address Issue 1, it is necessary to determine the horizontal

stabilizer rear spar chord configuration on the airplane. It is also necessary to carefully maintain

a record of that configuration until all 7079 horizontal stabilizer rear spar chord segments have

been removed from the fleet. Regarding Issue 2, since horizontal stabilizers can be moved to

different airplanes, it is necessary to implement the inspections for early fatigue cracking on all

effective airplanes at the time stated in the 1.E Compliance section, regardless of the current usage

of the airplane.

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
Revision 1 is sent to updated compliance table and wording to clarify requirements, provide clarifying

information for the Compliance requirements for the Part 6 7079 aluminum chord replacement with

7075 aluminum chords, to clarify Parts 3, 4 & 5 by removing unnecessary redundant wording, and to

add reference to Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-17-13.

D. Description

Cycle Definition: To adequately account for in-flight training maneuvers, incorporate the cycle counting

procedure defined in this service bulletin.

Configuration Check: To Maintain configuration identity, determine the material for each horizontal

stabilizer rear spar chord segment addressed by this service bulletin. Maintain the configuration identity

indefinitely.

Inspections: Complete the inspections for stress corrosion cracking and fatigue cracking in accordance

with the methods and times stated in this service bulletin.

Repair: Contact Boeing for repair instructions or replace the cracked part with a spare part made from

7075 aluminum.

Revision 1 - No more work is necessary on airplanes changed 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.

Group 1:

Affected Maintenance Zones

Model Zone

707-300, 707-300B, 707-300C, 3-93, 3-94

707-400

Group 2-3:

Affected Maintenance Zones

Model Zone

707-300C 3-93, 3-94

Group 4:

Affected Maintenance Zones

Model Zone

707-300B, 707-300C 3-93, 3-94

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1

are related to this service bulletin.

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BOEING SERVICE BULLETIN A3515

ALERT ALERT
Boeing recommends the following:

Applicable to all rear spar chord segments (upper inboard, upper outboard, lower inboard, lower outboard

and center) made from 7079, do the Part 6 - Chord Replacement within 48 months after the Revision

1 date of this service bulletin.

Table 1: Determine Flight Cycles and Material of Horizontal Stabilizer Rear Spar Chord Segments

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

At time of original service bulletin -

release.

Determine flight cycles as given

in Accomplishment Instructions

paragraph 3.B.1. Part 1.

All airplanes

180 calendar

days or 250 flight

cycles, whichever

occurs first. (a)

Within 180 calendar days after the

original release date of this service

bulletin.

Determine material of the left and

right side horizontal stabilizer rear

spar chord segments as given in

Accomplishment Instructions

Paragraph 3.B.2. Part 2. (c)

All airplanes

Before further flight following the N/A

horizontal stabilizer replacement.

Airplanes on which

the horizontal stabilizer is being replaced

with a different horizontal stabilizer.

Inspect and repair the horizontal - -

stabilizer rear spar chord segments made from 7075 as given

in Table 2. (b) (c)

Airplanes with horizontal stabilizer rear

spar chord segments

made from 7075 as

found in the Accomplishment Instructions Paragraph

3.B.2 Part 2. (c)

Inspect and repair the horizontal - -

stabilizer rear spar chord segments made from 7079 as given

in Table 3. (b) (c)

Airplanes with horizontal stabilizer rear

spar chord segments

made from 7079 as

found in the Accomplishment Instructions Paragraph

3.B.2 Part 2. (c)

(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."

(b) If you have a mixture of 7075 chord segments and 7079 chord segments, use Tables 2 and 3.

(c) Spar chord segments are as defined in APPENDIX A.

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ALERT ALERT
Table 2: Inspect and Repair Horizontal Stabilizer Rear Spar Upper Inboard Chord Segments Made From

7075 Material

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

500 flight cycles.

(a)

Within 180 calendar days or 500

flight cycles after the original release date of this service bulletin,

whichever occurs first. (a) (c)

Inspect and repair the upper inboard chord segment from stabilizer station -13.179 to 92.55 as

given in Accomplishment Instructions Paragraph 3.B.3. Part 3. (d)

Airplanes with horizontal stabilizer rear

spar upper inboard

chord segment made

from 7075. (d)

Before further flight following the N/A

horizontal stabilizer replacement.

(c)

Airplanes on which

the horizontal stabilizer is being replaced

with a different horizontal stabilizer having the upper inboard

chord segment made

from 7075. (d)

500 flight cycles.

(a)

Within 4000 flight cycles after the

date of upper chord inboard segment replacement. (a) (d)

Inspect and repair the upper inboard chord segment from stabilizer station -13.179 to 92.55 as

given in Accomplishment Instructions Paragraph 3.B.3. Part 3. (b)

(d)

Airplanes on which

the horizontal stabilizer rear spar upper inboard chord segment

is replaced as given

in Accomplishment

Instructions Paragraph 3.B.6 Part 6.

(d)

(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."

(b) Continued inspections are only necessary for rear spar upper inboard chord segments made from 7075.

Continued inspections are not necessary for other spar chord segments replaced with 7075 parts.

(c) When you replace the rear spar upper inboard chord segment as given in Accomplishment Instructions

Paragraph 3.B.6 Part 6, you can defer that chord segment inspection given in Accomplishment Instructions

Paragraph 3.B.3. Part 3 for a maximum of 4,000 flight cycles.

(d) Spar chord segments are as defined in APPENDIX A.

Table 3: Inspect and Repair Horizontal Stabilizer Rear Spar Upper and Lower Chord Segments Made

From 7079 Material

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

180 calendar

days or 250 flight

cycles, whichever

occurs first. (a)

Within 180 calendar days or 250

flight cycles after the original release date of this service bulletin,

whichever occurs first. (a)

Inspect and repair the upper inboard chord segment from stabilizer station -13.179 to 92.55 as

given in Accomplishment Instructions Paragraph 3.B.3. Part 3. (c)

Airplanes with horizontal stabilizer rear

spar upper inboard

chord segment made

from 7079. (c)

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ALERT ALERT
Table 3: Inspect and Repair Horizontal Stabilizer Rear Spar Upper and Lower Chord Segments Made

From 7079 Material

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

180 calendar

days or 1000

flight cycles,

whichever occurs

first. (a)

Within 180 calendar days or 1000

flight cycles after the original release date of this service bulletin,

whichever occurs first. (a)

Inspect and repair the web

flanges of the rear spar upper and

lower chord segments made from

7079, from stabilizer station 92.55

to 272.55 as given in Accomplishment Instructions Paragraph

3.B.4. Part 4. (b) (c)

Airplanes with any of

the following horizontal stabilizer rear spar

chord segments

made from 7079:

upper inboard, upper

outboard, lower inboard, lower outboard. (c) Inspect and repair the forward

skin flanges of the rear spar upper and lower chord segments

made from 7079, from stabilizer

station -13.179 to 272.55 as given

in Accomplishment Instructions

Paragraph 3.B.5. Part 5. (b) (c)

Before further flight following the N/A

horizontal stabilizer replacement.

(c)

Do the Part 6 - Chord Replacement, for all rear spar chord segments made from 7079. (c)

Airplanes on which

the horizontal stabilizer is being replaced

with a different horizontal stabilizer having rear spar chord

segments made from

7079. (c)

Do Boeing service bulletin 707- Before further flight. -

3381 Part II - Preventative Modification as given in Accomplishment Instructions Paragraphs

3.B.4 Part 4 and 3.B.5 Part 5 or

replace the chord as given in Accomplishment Instructions Paragraph 3.B.6 Part 6.

Airplanes with horizontal stabilizers that

have rear spar chord

segments made from

7079 for which the

Service Bulletin 707-

3381 Part II - Preventative Modification is

not completed. (c)

(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."

(b) Only those chord segments made from 7079 material require the inspection and repair given in the Accomplishment Instructions Paragraphs 3.B.4. Part 4 and 3.B.5. Part 5. Chord segments made from 7075

material do not require the inspection and repair given in the Accomplishment Instructions Paragraphs

3.B.4. Part 4 and 3.B.5. Part 5.

(c) Spar chord segments are as defined in APPENDIX A.

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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.

The Part 3 inspections of this service bulletin supersede and replace the 707 Supplemental Structural

Inspection Document (SSID) inspections 55-A25-03, 55-A35-03 and 55-A45-03 mandated by Paragraph

A of AD 85-12-01 R1. The inspections contained in this service bulletin have been reviewed and

approved by the Manager of the FAA Seattle Aircraft Certification Office as an alternative method of

compliance to the requirements of Paragraph A of AD 85-12-01 R1 for SSID items 55-A25-03, 55-A35-03

and 55-A45-03 covered by this service bulletin. All other provisions of AD 85-12-01 R1 that are not

specifically referenced above remain fully applicable and must be complied with.

In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the flight cycle counting

procedures, inspections or modifications defined in this service bulletin as an alternative method of

compliance to the requirements of paragraphs (g), (h), (i), (j), (k), (l), and (m) of AD 2012-17-13 pertaining

to Boeing Alert Service Bulletin 707 A3515, dated December 19, 2007. When the service bulletin

specifies contacting Boeing for repair instructions, the repair must be approved by the FAA in accordance

with paragraph (n) of the AD. All provisions of AD 2012-17-13 that are not specifically referenced in

this paragraph remain fully applicable and must be complied with accordingly.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this service bulletin 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 examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 2 1.0 0.5

Part 1 - (a) (a)

Part 2 2 1.0(b) 0.5(b)

Part 3 4 26.0 6.5

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ALERT ALERT
Number of Per- Task Hours Elapsed Hours

sons

Task

Part 4 4 32.0 8.0

Part 5 4 24.0 6.0

Part 6 (c) (c) (c)

Close Access 2 1.0 0.5

TOTAL FOR EACH AIRPLANE (d) (d)

(a) Considered Lost Time. Not able to estimate.

(b) Covers conductivity test only, does not include maintenance record review.

(c) No estimate is available.

(d) No total is given because of the variability in time required for Part 1, Part 2

and Part 6 activities.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 18101-2RS

b. Boeing Service Bulletin 707-3356, 707-3381

c. Service Related Problem (SRP) 707-SRP-55-0033.

d. 707 Supplemental Structural Inspection Document (SSID) D6-44860, Revision P, Item

55-A25-03, 55-A35-03 and 55-A45-03.

e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2012-17-13, 85-12-01 R1

f. Standard Overhaul Practices Manual (SOPM) 20-41-05

g. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-12, 20-10-19

h. 707, 720 Non-Destructive Testing (NDT) Manual Part 1, 51-01-00, Part 6, 51-00-00, Part 6,

55-10-07

i. 707 Aircraft Maintenance Manual (AMM) 27-07-31

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ALERT ALERT
2. Data Supplied with this Service Bulletin:

None.

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

None.

K. Publications Affected

None.

L. Interchangeability and Intermixability of Parts

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

M. Software Accomplishment Summary

Not affected.

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection procedures given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

Part Number / Specification QTY Name Notes

65-95600-887 1 Upper Chord, Inboard, Left Side (a) (d)

65-95600-888 1 Upper Chord, Inboard, Right Side (a) (e)

65-95600-701 1 Lower Chord, Inboard, Left Side (a) (f)

65-95600-702 1 Lower Chord, Inboard, Right Side (a) (g)

65-95600-703 1 Center Rear Spar, Left Side (a) (j)

65-95600-704 1 Center Rear Spar, Right Side (a) (k)

65C80665-165 1 Upper Chord, Outboard, Left Side (a) (h)

65C80665-165 1 Lower Chord, Outboard, Right Side (a) (h)

65C80665-166 1 Lower Chord, Outboard, Left Side (a) (i)

65C80665-166 1 Upper Chord, Outboard, Right Side (a) (i)

BMS 3-23 Type II 1 Pint Corrosion Inhibiting compound (b)

(a) Discard the existing part.

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

(c) This note has been deleted.

(d) 65-95600-887 is the same as 65-3321-27 plus two 66-11433-4 bushings.

(e) 65-95600-888 is the same as 65-3321-28 plus two 66-11433-4 bushings.

(f) 65-95600-701 is the same as 65-3322-15 plus two 69-38158-1 bushings plus two 69-38158-2 bushings.

(g) 65-95600-702 is the same as 65-3322-16 plus two 69-38158-1 bushings plus two 69-38158-2 bushings.

(h) 65C80665-165 is the same as 65-05201-3.

(i) 65C80665-166 is the same as 65-05201-4.

(j) 65-95600-703 is the same as 65-3323-27 plus two 66-11433-2 bushings.

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ALERT ALERT
Part Number / Specification QTY Name Notes

(k) 65-95600-704 is the same as 65-3323-28 plus two 66-11433-2 bushings.

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

See 707, 720 NDT Manual Part 1, 51-01-00.

– 8MIT65-6088

– 9MIT65-6088

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ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

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

– Linear dimensions are in inches

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

or minus 0.03 inch

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

– Angular tolerance is plus or minus 2 degrees

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

Manual (SRM) Chapter 51

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

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

SRM Chapter 51. Alternate fasteners are listed in SRM Chapter 51.

5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

6. The necessary conditions for selection of clamp type and size are included in SWPM

20-10-12. If any wire bundle support clamp specified in this service bulletin does not

make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted

procedure to select a clamp that fits correctly.

7. 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.

8. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

9. Boeing Service Letter 707-SL-51-029 Damage Reporting and Repair Plan/Design

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

additional structural repair instructions. The Service Letter describes what information

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

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ALERT ALERT
10. Refer to APPENDIX A, for configuration verification, inspection, material data results

form..

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.

15. Some Boeing parts are supplied in a temporary configuration. Those parts are

identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is

permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'

(dash) part number. Boeing Drawing 005W0900 contains more data.

B. WORK INSTRUCTIONS

1. Part 1 - Cycle Counting Procedure

a. Determine flight cycles.

NOTE: The term "flight cycle" wherever stated in this bulletin is defined as any one of the

following:

1. A complete flight cycle (takeoff and full stop landing).

2. Any touch-and-go cycle within a flight cycle for which the airplane makes

a runway approach, with or without runway contact.

2. Part 2 - Configuration Records Inspection

a. Refer to APPENDIX A for definition of the inboard and outboard segments of the left and right

horizontal stabilizer rear spar upper and lower chords. Determine the material of all of the

spar chord segments listed in APPENDIX A using one of the following methods.

(1) Review the airplanes maintenance records or the previously completed APPENDIX A

data sheet to identify the location of the upper and lower chords on the horizontal stabilizer

rear spar that are made from 7079. If the material cannot be conclusively determined, do

step (2).

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(2) Do a conductivity test to determine whether each upper chord and lower chord segment

on the horizontal stabilizer rear spar listed in APPENDIX A is made from 7079-T6 or

7075-T73511 material in accordance with 707, 720 NDT, Part 6, 51-00-00, Figure 20,

dated April 5, 2004.

b. Optional.

(1) Record the material of each upper chord and lower chord segment on the APPENDIX A

data sheet. Describe any existing repairs in the "Comments" field.

(2) Retain the APPENDIX A data sheet with the airplane records.

3. Part 3 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Inboard - Upper Chord - Stabilizer

Station -13.179 to 92.55.

Upper Chords, Horizontal Stabilizer Rear Spar, Inboard Segment, Made From 7075 and 7079

a. Do a special detailed inspection of the upper chord.

(1) Inspect for cracks in the forward flange of the chord along the fasteners common to the

skin. Inspect from the inboard edge of the inspar skin to 25.5 inches outboard in

accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 1.

(2) Inspect for cracks in the space between the inspar skin and the forward edge of the

exposed upper surface of the chord. Inspect from the side of the body outboard to Stabilizer

Station 92.55 in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 2.

(3) Inspect for cracks in the space between the trailing edge skin and the aft edge of the

exposed upper surface of the chord. Inspect from the side of the body outboard to Stabilizer

Station 92.55 in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 2.

(4) Inspect for cracks in the aft flange of the chord along the fasteners common to the skin.

Inspect from the inboard edge of the trailing edge skin to 25.5 inches outboard in

accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 3.

(5) Inspect for cracks along the forward and aft edges of the exposed upper surface of the

chord. Inspect from the side of the body outboard to Stabilizer Station 92.55 in accordance

with 707, 720 NDT Manual Part 6, 55-10-07, Figure 7.

b. If a crack is found:

(1) Contact Boeing for repair instructions or

(2) Replace the spar chord as given in Accomplishment Instructions Paragraph 3.B.6. Part

6.

c. Apply corrosion inhibiting compound BMS 3-23 or equivalent to the exposed area of the chord.

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

d. Put the airplane back to a serviceable condition.

4. Part 4 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Upper and Lower Chord - Web

Flange - Stabilizer Station 92.55 to 272.55

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ALERT ALERT
Upper and Lower Chords, Horizontal Stabilizer Rear Spar, Made From 7079

a. Remove and keep the elevator balance bay number 2 through number 5 panels. Refer to 707

AMM 27-07-31 as an accepted procedure.

b. Remove and keep the cove shells and supporting structures as required to get access to the

aft surface of the vertical flanges of the upper and lower chords.

c. Do a High Frequency Eddy Current (HFEC) inspection of the web flanges of the upper and

lower chords between stabilizer station 92.55 and 272.55 for cracks as given in FIGURE 1.

d. If a crack is found:

(1) Replace the spar chord as given in Accomplishment Instructions Paragraph 3.B.6. Part

6 or

(2) Complete steps (a) and (b) that follow:

(a) Determine if the crack meets the limits defined in Boeing Service Bulletin 707-3356

and has been repaired according to Boeing Service Bulletin 707-3356.

1) For each crack that meets the limits of Boeing Service Bulletin 707-3356, Part

III - Repair, Notes (a) and (b), contact Boeing for new repair instructions.

2) For each crack that has been repaired according to Boeing Service Bulletin

707-3356, Part III - Repair Paragraph C, determine if the crack still meets the

limits of Boeing Service Bulletin 707-3356, Part III - Repair Paragraph C, and

determine if the crack meets the following supplemental limits:

a) The crack path must be within the limits as given in FIGURE 1, View B-B.

b) The crack must terminate in an existing fastener hole.

c) There must be two or more fastener locations in the repair area as given

in FIGURE 1, View B-B that have no cracks indicated in the adjacent spaces.

d) A stiffener bay with a crack in the upper chord must not also have a crack

in the upper or lower chord of either of the adjacent stiffener bays.

e) A stiffener bay with a crack in the lower chord must not also have a crack

in the upper or lower chord of either of the adjacent stiffener bays.

3) For a crack that meets the limits of Boeing Service Bulletin 707-3356, Part III -

Repair Paragraph C, but is not repaired as given in Boeing Service Bulletin

707-3356, Part III - Repair Paragraph C, accomplish the repair as given in Boeing

Service Bulletin 707-3356, Part III - Repair Paragraph C. Obey the supplemental

limits that follow:

a) The crack path must be within the limits as given in FIGURE 1, View B-B.

b) The crack must terminate in an existing fastener hole.

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ALERT ALERT
c) There must be two or more fastener locations in the repair area as given

in FIGURE 1, View B-B that have no crack indicated in the adjacent spaces.

d) A stiffener bay with a crack in the upper chord must have no crack in the

upper or lower chord of either of the adjacent stiffener bays.

e) A stiffener bay with a crack in the lower chord must have no crack in the

upper or lower chord of either of the adjacent stiffener bays.

4) For a crack that meets the limits of Boeing Service Bulletin 707-3356, Part III -

Repair Paragraph D, accomplish the repair according to Boeing Service Bulletin

707-3356, Part III - Repair Paragraph D, unless already accomplished.

5) For a crack that does not meet the limits defined in the preceding paragraphs

1., 2., 3., & 4. above, contact Boeing for new repair instructions.

(b) Determine if all 7079 upper and lower chord segments installed on the horizontal

stabilizer have had Boeing Service Bulletin 707-3356 Part II, Group 1 Preventative

Modification done. If not yet accomplished, do the Boeing Service Bulletin 707-3356

Part II, Group 1 Preventative Modification on all 7079 chord segments still installed

on the horizontal stabilizer.

NOTE: Boeing Service Bulletin 707-3356 Part II, Group 1 Preventative Modification

is applicable to airplanes for which all chord segments (upper and lower

inboard, upper and lower outboard) are made from 7079. It is therefore

inclusive of all configurations where 7079 chord segments remain. Since

7079 chords may have been replaced with 7075 chords, it is only necessary

to do the modification where the 7079 chord segments are identified.

e. Apply corrosion inhibiting compound BMS 3-23 or equivalent to the exposed area of the

horizontal stabilizer rear spar chords. Refer to SOPM 20-41-05 as an accepted procedure.

f. Restore the airplane to a serviceable condition.

5. Part 5 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Upper and Lower Chord - Forward

Skin Flange - Stabilizer Station -13.179 to 272.55

Upper and Lower Chords of the Horizontal Stabilizer Rear Spar Made From 7079

a. Remove and keep the elevator balance bay number 0 through number 5 panels. Refer to 707

AMM 27-07-31 as an accepted procedure.

b. Do a Low Frequency Eddy Current (LFEC) inspection of the forward skin flange of the upper

chord between stabilizer station 182.55 and 272.55 for cracks as given in FIGURE 2.

c. Do a LFEC inspection of the forward skin flange of the upper chord between stabilizer station

92.55 and 182.55 for cracks as given in FIGURE 3.

d. Do a LFEC inspection of the forward skin flange of the lower chord between stabilizer station

182.55 and 272.55 for cracks as given in FIGURE 4.

e. Do a LFEC inspection of the forward skin flange of the lower chord between stabilizer station

92.55 and 182.55 for cracks as given in FIGURE 5.

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f. Do a LFEC inspection of the forward skin flange of the lower chord between stabilizer station

-13.179 and 92.55 for cracks as given in FIGURE 6.

g. If a crack is found:

(1) Replace the lower chord as given in Accomplishment Instructions Paragraph 3.B.6. Part

6 or

(2) Complete steps (a) and (b) that follow:

(a) Contact Boeing for repair instructions.

(b) Determine if all 7079 upper and lower chord segments installed on the horizontal

stabilizer have had Service Bulletin 707-3381 Part II - Preventative Modification

accomplished. If not yet accomplished, do the Service Bulletin 707-3381 Part II -

Preventative Modification on all 7079 chord segments still installed on the horizontal

stabilizer.

NOTE: Service Bulletin 707-3381 Part II - Preventative Modification is applicable

to airplanes for which all chord segments (upper and lower inboard, upper

and lower outboard) are made from 7079. It is therefore inclusive of all

configurations where 7079 chord segments remain. Since 7079 chords may

have been replaced with 7075 chords, it is only necessary to do the

modification where the 7079 chord segments are identified.

h. Apply corrosion inhibiting compound BMS 3-23 or equivalent to exposed area of the upper

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

i. Restore the airplane to a serviceable condition.

6. Part 6 - Chord Replacement

a. Replace the applicable rear spar chord segment or segments according to standard procedures

and instructions supplied with the applicable parts kits and tooling. Reference assembly

drawing 65-3321, 65-3322 and 65-3323 for the rear spar upper, lower and center inboard

chords respectively.

b. Upon completion of chord replacement, revise the data on the APPENDIX A data sheet to

match the chord configuration currently on the airplane.

c. Retain the updated APPENDIX A data sheet with the airplane records

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FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUTBOARD

- CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 - INSPECTION

(SHEET 1 OF 2)

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Access Balance Bay Number 2, 3, 4 and 5 - -

2 Inspect Chord Web Flange - 2 See Table 1.(a)

(a) Do a High Frequency Eddy Current (HFEC) inspection of the left and right side horizontal stabilizer rear

spar upper and lower inboard and outboard chord web flange between stabilizer station 92.55 and 272.55 for

any cracking. Use a pencil probe to scan the aft surface of the chord vertical flange between fasteners and

along the tangent line of the flange fillet in accordance with 707, 720 NDT, Part 6, 51-00-00, Figure 4.

Table 1

7079 Chord Segment Balance Bay to Inspect

Upper Inboard 2,3

Lower Inboard 2,3

Upper Outboard 4,5

Lower Outboard 4,5

FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUTBOARD

- CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 - INSPECTION

(SHEET 2 OF 2)

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Forward Skin Flange - 2 (a)

(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear

spar upper outboard chord forward skin flange between stabilizer station 182.55 and 272.55 for any cracking

in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.

FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN A3515

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Forward Skin Flange - 2 (a)

(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear

spar upper inboard chord forward skin flange between stabilizer station 92.55 and 182.55 for any cracking

in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.

FIGURE 3: HORIZONTAL STABILIZER - REAR SPAR - UPPER INBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN A3515

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Forward Skin Flange - 2 (a)

(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear

spar lower outboard chord forward skin flange between stabilizer station 182.55 and 272.55 for any cracking

in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.

FIGURE 4: HORIZONTAL STABILIZER - REAR SPAR - LOWER OUTBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN A3515

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Forward Skin Flange - 2 (a) (b)

(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear

spar lower inboard chord forward skin flange between stabilizer station 92.55 and 182.55 for any cracking in

accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.

(b) Exclude inspection of areas not accessible due to interference with any vortex generators mounted on

the lower surface. However, if any cracks are found at any of the first six (6) inspectable fasteners on either

side of the vortex generator, remove the vortex generator and inspect all fastener locations.

FIGURE 5: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN A3515

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Forward Skin Flange - 2 (a) (b)

(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear

spar lower inboard chord forward skin flange between stabilizer station -13.179 and 92.55 for any cracking

in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.

(b) Exclude inspection of areas not accessible due to interference with any vortex generators mounted on the

lower surface. However, if any cracks are found at any of the first six (6) inspectable fasteners on either side

of the vortex generator, remove the vortex generator and inspect all fastener locations.

FIGURE 6: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN

FLANGE - STABILIZER STATION -13.179 TO STABILIZER STATION 92.55 - INSPECTION

(SHEET 1 OF 1)

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AIRPLANE REGISTRY: FLIGHT HOURS: FLIGHT CYCLES:

LEFT SIDE Horizontal Stabilizer

Stabilizer Part Number (a): Stabilizer Serial Number (a):

Spar Chord Material (b): (from Part 2 - Configuration

Check)

Spar Chord Seg- Location

ment

Upper Inboard Side of Body to SSTA 182.55

Lower Inboard Side of Body to SSTA 182.55

Upper Outboard SSTA 182.55 to Stabilizer Tip

Lower Outboard SSTA 182.55 to Stabilizer Tip

RIGHT SIDE Horizontal Stabilizer

Stabilizer Part Number (a): Stabilizer Serial Number (a):

Spar Chord Material (b) (from Part 2 - Configuration

Check)

Spar Chord Seg- Location

ment

Upper Inboard Side of Body to SSTA 182.55

Lower Inboard Side of Body to SSTA 182.55

Upper Outboard SSTA 182.55 to Stabilizer Tip

Lower Outboard SSTA 182.55 to Stabilizer Tip

Record the horizontal stabilizer part number and serial number as recorded on the data

plate.

(a)

Record spar chord material, 7079-T6 or 7075-T73511, as determined from maintenance

record review, or electrical conductivity test. Do the electrical conductivity test in accordance

with 707 Non-Destructive Testing (NDT) Manual D6-48023 Part 6, 51-00-00, Figure 20,

dated April 5, 2004, and Boeing Process Specification BAC5946, Table I, Page 12, Revision

(AA) dated July 9, 2001.

(b)

Comments:

.

.

.

.

.

.

Appendix A: CONFIGURATION VERIFICATION - INSPECTION RESULTS FORM - MATERIAL DATA

(SHEET 1 OF 1)

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ALERT ALERT