Commercial 

Airplanes MD80

Service Bulletin

ALERT

Number: MD80-55A068

Original Issue: July 16, 2010

ATA System: 5510

SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Center Skin Panels

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

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

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laws.

ECCN: 9E991

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Copyright © 2010 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

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2.0
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BLANK PAGE
Table of Contents

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

1. PLANNING INFORMATION ........................................ 7

A. Effectivity ................................................ 7

1. Airplanes ............................................. 7

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

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

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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

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

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 27

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FIGURE 1: HORIZONTAL STABILIZER LEFT AND RIGHT UPPER CENTER SKIN PANELS - EDDY

CURRENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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BLANK PAGE
Commercial 

Airplanes MD80

Service Bulletin

ALERT

Summary Number: MD80-55A068

Original Issue: July 16, 2010

ATA System: 5510

SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Center Skin Panels

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 inspection of the horizontal stabilizer upper aft skin panel in accordance with Service Bulletin

MD80-55A065, one operator reported finding a crack in the right horizontal stabilizer upper center skin panel at

the aft inboard corner. The airplane had accumulated 47,146 flight-hours and 26,490 flight cycles when the

crack was found. The cause of the horizontal stabilizer upper center skin panel cracking is suspected to be

fatigue. If undetected, a crack in the upper center skin panel may transfer load to the upper aft skin panel. This

may result in the upper aft skin panel cracking faster than the existing inspection intervals, defined in Service

Bulletin MD80-55A065, will detect. Inspection of the affected areas will determine the condition of the horizontal

stabilizer upper center skin panels. If not corrected, undetected cracks may ultimately lead to the loss of overall

structural integrity of the horizontal stabilizer.

ACTION

Refer to Paragraph 1.D., Description.

EFFECTIVITY

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

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

COMPLIANCE

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

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

mandatory.

Refer to Paragraph 1.E., Compliance.

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INDUSTRY SUPPORT INFORMATION

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

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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ALERT ALERT
Commercial 

Airplanes MD80

Service Bulletin

ALERT

Number: MD80-55A068

Original Issue: July 16, 2010

ATA System: 5510

SUBJECT: STABILIZERS - Horizontal Stabilizer - Inspect/Replace Upper Center Skin Panels

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

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

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

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - MD-80 Series Airplanes (Fuselage Numbers 909 Thru 1614)

2 - MD-80 Series Airplanes (Fuselage Numbers 1615 Thru 2287)

Airplane Models:

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

Fuselage Num- Group

ber

909 1

917 1

924 1

938 1

941 1

944 1

946 1

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Fuselage Num- Group

ber

948 1

950 1

952 - 953 1

955 1

957 - 958 1

960 1

962 - 963 1

965 - 967 1

969 - 971 1

973 - 975 1

977 - 979 1

981 1

983 1

985 - 986 1

988 - 989 1

991 - 992 1

994 - 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

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Fuselage Num- Group

ber

1055 1

1057 1

1059 - 1080 1

1082 - 1083 1

1085 - 1614 1

1615 - 2007 2

2009 - 2016 2

2019 - 2034 2

2036 - 2069 2

2071 - 2093 2

2101 - 2114 2

2116 2

2118 - 2119 2

2121 2

2124 2

2127 - 2128 2

2130 2

2132 2

2134 - 2135 2

2137 2

2139 2

2145 2

2148 2

2151 - 2152 2

2155 2

2167 2

2174 2

2176 2

2178 2

2180 2

2183 2

2185 2

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Fuselage Num- Group

ber

2187 2

2189 2

2192 2

2196 2

2199 2

2201 2

2204 2

2206 2

2208 2

2214 2

2218 2

2234 2

2239 2

2241 2

2244 2

2247 2

2249 2

2252 2

2254 2

2264 - 2287 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

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BOEING SERVICE BULLETIN MD80-55A068

ALERT ALERT
C. Reason

During inspection of the horizontal stabilizer upper aft skin panel in accordance with Service Bulletin

MD80-55A065, one operator reported finding a crack in the right horizontal stabilizer upper center skin

panel at the aft inboard corner. The airplane had accumulated 47,146 flight-hours and 26,490 flight

cycles when the crack was found. The cause of the horizontal stabilizer upper center skin panel cracking

is suspected to be fatigue. If undetected, a crack in the upper center skin panel may transfer load to

the upper aft skin panel. This may result in the upper aft skin panel cracking faster than the existing

inspection intervals, defined in Service Bulletin MD80-55A065, will detect. Inspection of the affected

areas will determine the condition of the horizontal stabilizer upper center skin panels. If not corrected,

undetected cracks may ultimately lead to the loss of overall structural integrity of the horizontal stabilizer.

D. Description

This service bulletin provides instructions to do an eddy current inspection of the horizontal stabilizer

left and right upper center skin panels for cracks, and based on inspection results for each panel, does

as follows:

Condition 1 (No Crack Found)

1. Does repetitive eddy current inspections of the horizontal stabilizer upper center skin panel.

Condition 2 (Crack Found)

1. OPTION 1:

a. Replaces the cracked horizontal stabilizer upper center skin panel.

b. Does repetitive eddy current inspection of the replacement horizontal stabilizer upper center

skin panel.

2. OPTION 2:

a. Contacts Boeing for possible temporary repair of crack and does the repair in accordance

with Boeing's instructions.

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

Affected Maintenance Zones

Model Zone

DC-9-81 (MD-81), DC-9-82 33, 34

(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.

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ALERT ALERT
Table 1: Inspect Horizontal Stabilizer Left and Right Upper Center Skin Panels for Cracks

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,379 -

flight cycles after the original

issue date on

this service bulletin.

Before the accumulation of

20,000 total

flight cycles.

Do initial eddy current inspection of the horizontal

stabilizer left and right

upper center skin panels

in accordance with Paragraph 3.B., Work Instructions, using one of the

options as follows:

All Airplanes

OPTION 1:

Scan 1 - Eddy Current,

High Frequency (ETHF)

Scan 2 - Eddy Current,

High Frequency (ETHF)

Scan 3 - Eddy Current,

Low Frequency (ETLF)

OR

OPTION 2:

Scan 1 - Eddy Current,

High Frequency (ETHF)

Scan 2 - Eddy Current,

High Frequency (ETHF)

Scan 3 - Eddy Current,

High Frequency (ETHF)

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ALERT ALERT
Table 1: Inspect Horizontal Stabilizer Left and Right Upper Center Skin Panels for Cracks

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Do repetitive eddy current - - -

inspection of the horizontal stabilizer left and right

upper center skin panels

in accordance with Paragraph 3.B., Work Instructions, using one of the

options as follows:

Condition 1

(No Crack Found)

Within 5,200 - 5,200 flight cycles

flight cycles after doing the initial eddy current

inspection.

OPTION 1:

Scan 1 - Eddy Current,

High Frequency (ETHF)

Scan 2 - Eddy Current,

High Frequency (ETHF)

(a)

Scan 3 - Eddy Current, (a)

Low Frequency (ETLF)

OR

Within 2,500 - 2,500 flight cycles

flight cycles after doing the initial eddy current

inspection.

OPTION 2:

Scan 1 - Eddy Current,

High Frequency (ETHF)

Scan 2 - Eddy Current,

High Frequency (ETHF)

(a)

Scan 3 - Eddy Current, (a)

High Frequency (ETHF)

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BOEING SERVICE BULLETIN MD80-55A068

ALERT ALERT
Table 1: Inspect Horizontal Stabilizer Left and Right Upper Center Skin Panels for Cracks

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

OPTION 1: Do items (1), - - -

(2), and (3) as follows:

Condition 2

(Crack Found)

Before further - -

flight

(1) Replace the cracked

horizontal stabilizer upper

center skin panel in accordance with Paragraph

3.B., Work Instructions

AND

Within 20,000 - -

flight cycles after installation of

the replacement

horizontal stabilizer upper center skin panel.

(2) Do initial eddy current

inspection of the replacement horizontal stabilizer

upper center skin panel

in accordance with Paragraph 3.B., Work Instructions, using one of the

options as follows:

OPTION 1:

Scan 1 - Eddy Current,

High Frequency (ETHF)

Scan 2 - Eddy Current,

High Frequency (ETHF)

Scan 3 - Eddy Current,

Low Frequency (ETLF)

OR

OPTION 2:

Scan 1 - Eddy Current,

High Frequency (ETHF)

Scan 2 - Eddy Current,

High Frequency (ETHF)

Scan 3 - Eddy Current,

High Frequency (ETHF)

AND

(3) Do repetitive eddy - - -

current inspection of the

horizontal stabilizer left

and right upper center

skin panels in accordance

with Paragraph 3.B.,

Work Instructions, using

one of the options as follows:

OPTION 1: - 5,200 flight cycles

(a)

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BOEING SERVICE BULLETIN MD80-55A068

ALERT ALERT
Table 1: Inspect Horizontal Stabilizer Left and Right Upper Center Skin Panels for Cracks

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Scan 1 - Eddy Current,

High Frequency (ETHF)

Within 5,200

flight cycles after doing the eddy current inspection.

Scan 2 - Eddy Current,

High Frequency (ETHF)

Scan 3 - Eddy Current,

Low Frequency (ETLF) (a)

OR

Within 2,500 - 2,500 flight cycles

flight cycles after doing the eddy current inspection.

OPTION 2:

Scan 1 - Eddy Current,

High Frequency (ETHF)

Scan 2 - Eddy Current,

High Frequency (ETHF)

(a)

Scan 3 - Eddy Current, (a)

High Frequency (ETHF)

OR

Before further - -

flight

OPTION 2:

Contact Boeing for possible temporary repair of

crack and do the repair in

accordance with Boeing's

instructions.

Condition 2

(Crack Found)

(a) It is acceptable to change inspection procedures from Option 1 to Option 2 or from Option 2 to Option 1

if you do as follows:

1. If the inspection procedure is being changed from Option 1 to Option 2, the first Option 2 inspection must

be done within 5,200 flight cycles after the Option 1 inspection. The Option 2 inspections that follows must

be done within 2,500 flight cycle repeat intervals

2. If the inspection procedure is being changed from Option 2 to Option 1, the first Option 1 inspection must

be done within 2,500 flight cycles after the Option 2 inspection. The Option 1 inspections that follows must

be done within 5,200 flight cycle repeat intervals

F. Approval

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

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

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

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

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

changes.

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

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

before incorporating this service bulletin.

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ALERT ALERT
G. Manpower

The table below shows an estimate of the task hours necessary to do the inspection and/or configuration

changes for each horizontal stabilizer upper center skin panel. 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.

All Airplanes: Horizontal Stabilizer Upper Center Skin Panel Initial Inspection

Task Number of Persons Task Hours Elapsed Hours

Figure 1 - Inspection 2 4.0 2.0

TOTAL FOR EACH UPPER CENTER SKIN 4.0 2.0

PANEL

Condition 1: Horizontal Stabilizer Upper Center Skin Panel Repetitive Inspection

Task Number of Persons Task Hours Elapsed Hours

Figure 1 - Inspection 2 4.0 2.0

TOTAL FOR EACH UPPER CENTER SKIN 4.0 2.0

PANEL

Condition 2, Option 1: Horizontal Stabilizer Upper Center Skin Panel Replacement

Task Number of Persons Task Hours Elapsed Hours

Remove Horizontal 6 48.0 8.0

Stabilizer

Remove Leading 2 24.0 12.0

Edge and Upper Forward Skin Panel

Replace Horizontal 3 504.0 168.0

Stabilizer Upper

Center Skin Panel

Install Leading Edge 2 24.0 12.0

and Upper Forward

Skin Panel

Install Horizontal 6 48.0 8.0

Stabilizer

TOTAL FOR EACH UPPER CENTER SKIN 648.0 208.0

PANEL

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ALERT ALERT
H. Weight and Balance Changes

Group 1:

Condition 1:

1. None

Group 1:

Condition 2, Option 1:

1. Replacement of 5922577-501 or 5922577-502 Upper Center Skin Panel

a. DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), and MD-88 Airplanes

Moment Change

(MEW) IN.-LBS

Mfr's Empty

Weight (MEW)

LBS

Approximate Station (Inches)SR09550033 Configuration

SR09550033-7005 + 1640.5 + 1.9 3117.0

SR09550033-7006

SR09550033-7007 + 1640.5 + 1.9 3117.0

SR09550033-7008

b. DC-9-87 (MD-87) Airplanes

Moment Change

(MEW) IN.-LBS

Mfr's Empty

Weight (MEW)

LBS

Approximate Station (Inches)SR09550033 Configuration

SR09550033-7005 + 1431.5 + 1.9 2719.9

SR09550033-7006

SR09550033-7007 + 1431.5 + 1.9 2719.9

SR09550033-7008

2. Replacement of 5922577-507 or 5922577-508 Upper Center Skin Panel

a. DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), and MD-88 Airplanes

Moment Change

(MEW) IN.-LBS

Mfr's Empty

Weight (MEW)

LBS

Approximate Station (Inches)SR09550033 Configuration

SR09550033-7005 + 1640.5 + 1.1 1804.6

SR09550033-7006

SR09550033-7007 + 1640.5 + 1.1 1804.6

SR09550033-7008

b. DC-9-87 (MD-87) Airplanes

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Moment Change

(MEW) IN.-LBS

Mfr's Empty

Weight (MEW)

LBS

Approximate Station (Inches)SR09550033 Configuration

SR09550033-7005 + 1431.5 + 1.1 1574.7

SR09550033-7006

SR09550033-7007 + 1431.5 + 1.1 1574.7

SR09550033-7008

Group 2:

Condition 1:

1. None

Group 2:

Condition 2, Option 1:

1. Replacement of 5922577-507 or 5922577-508 Upper Center Skin Panel

a. DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), and MD-88 Airplanes

Moment Change

(MEW) IN.-LBS

Mfr's Empty

Weight (MEW)

LBS

Approximate Station (Inches)SR09550033 Configuration

SR09550033-7001 + 1640.5 + 1.1 1804.6

SR09550033-7002

SR09550033-7003 + 1640.5 + 1.1 1804.6

SR09550033-7004

b. DC-9-87 (MD-87) Airplanes

Moment Change

(MEW) IN.-LBS

Mfr's Empty

Weight (MEW)

LBS

Approximate Station (Inches)SR09550033 Configuration

SR09550033-7001 + 1431.5 + 1.1 1574.7

SR09550033-7002

SR09550033-7003 + 1431.5 + 1.1 1574.7

SR09550033-7004

I. Electrical Load Data

Not changed.

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ALERT ALERT
J. References

1. Existing Data:

a. Non-Destructive Test Standard Practices Manual (NDTSPM) 06-00-07, 06-10-01.001,

06-10-02.005.

b. MD80 Aircraft Maintenance Manual (AMM) 55-10-00, 55-10-01.

2. Data supplied with this Service Bulletin:

No data is supplied with this service bulletin. To obtain the data necessary to support this service

bulletin submit a data request to:

Data and Services Management

MS D800-0019

3855 Lakewood Boulevard

Long Beach, California 90846

Phone: (562) 593-6996

Fax: (562) 593-2001

E-mail: dse.boecom@boeing.com

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

PANEL INSTL-UPPER & LOWER CTR DWG - -

PANEL, HORIZONTAL STABILIZER

SR09550033

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

Document Number Title Change

PANEL-SKIN AND STGR, HORIZ T

STAB, CTR

5922577

STRUCT ASSEM-HORIZ STAB DA

OUTER PANEL FRONT TO REAR

SPAR

5922575

STABILIZER ASSY-COMPLETE BF

HORIZONTAL

5930603

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

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ALERT ALERT
None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected

are contained in Paragraph 1.E., Compliance of this service bulletin.

L. Interchangeability and Intermixability of Parts

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

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown below which contain the parts listed 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

Group 1:

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

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name

SA09550068-3 Service Kit - Upper Center 120 $36,405.00

Skin Panel (Left)

SA09550068-5 Service Kit - Upper Center 120 $36,405.00

Skin Panel (Right)

Group 2:

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

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name

SA09550068-7 Service Kit - Upper Center 120 $54,071.00

Skin Panel (Left)

SA09550068-9 Service Kit - Upper Center 120 $54,071.00

Skin Panel (Right)

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ALERT ALERT
Boeing can supply the parts shown below as end item spares. Operators are encouraged to share

schedule requirements with Boeing for incorporation of the service bulletin. The parts are subject to

the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United

States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

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

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Part Number Name

SE09550017-6 (a) Upper Center Skin Panel (Left) 120 $23,995.00

(5922577-508)

SE09550017-5 (a) Upper Center Skin Panel (Right) 120 $23,995.00

(5922577-507)

(a) A limited quantity of parts are available. Please contact spares for parts availability. Once the supply is

exhausted this part will no longer be available.

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.

NOTE: One top kit per panel location (left or right) and the items shown in Paragraph 2.C.2.,

Parts and Materials Supplied by the Operator, are necessary for each airplane.

Group 1:

SERVICE KIT APPLICABILITY

SA Kit Number Name SR Drawing Configuration

SA09550068-3 Service Kit - Upper Center SR09550033-7005

Skin Panel (Left)

SA09550068-5 Service Kit - Upper Center SR09550033-7007

Skin Panel (Right)

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ALERT ALERT
Group 2:

SERVICE KIT APPLICABILITY

SA Kit Number Name SR Drawing Configuration

SA09550068-7 Service Kit - Upper Center SR09550033-7001

Skin Panel (Left)

SA09550068-9 Service Kit - Upper Center SR09550033-7003

Skin Panel (Right)

Group 1:

Kit SA09550068

Existing Part Notes

Number

New Part Number QTY Name

-3 -5

SA09550068-3 - . (a)

SA09550068-5 . - (a)

117LH7940T-054 7 7 NUT BARREL

3964835-511 14 14 FILLER 5930603-9 (b)

3D0006-3 1 1 NUT ASSEMBLY

3D0006-4 1 1 NUT ASSEMBLY

3D0031-5-22 6 6 BOLT

3D0031-5-24 1 1 BOLT

UPPER PANEL 5922577-501 (c)

(RIGHT)

5922577-511 . 1

or

5922577-507

UPPER PANEL 5922577-502 (d)

(LEFT)

5922577-512 1 .

or

5922577-508

73232-5-8.1 7 7 WASHER

HLT435-6-3 14 14 PIN

HLT435-6-4 27 27 PIN

HLT435-6-5 7 7 PIN

HLT435-6-6 5 5 PIN

HLT435-6-8 2 2 PIN

HLT435-8-3 15 15 PIN

HLT435-8-4 43 43 PIN

HLT435-8-5 1 1 PIN

HLT439-8-3 58 58 PIN

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Group 1:

Kit SA09550068

Existing Part Notes

Number

New Part Number QTY Name

-3 -5

MS20426AD5-6D 12 12 RIVET

MS20426AD5-7D 44 44 RIVET

MS20426AD5-8D 6 6 RIVET

MS20426AD6-8D 8 8 RIVET

MS20426E8-12D 7 7 RIVET

MS20426E8-9D 37 37 RIVET

MS20470AD6-7D 16 16 RIVET

MS20470AD6-8D 22 22 RIVET

MS21042L3 58 58 NUT

MS21042L4 116 116 NUT

NAS1097KE8-10D 54 54 RIVET

NAS1097KE8-11D 2 2 RIVET

NAS1097KE8-12D 11 11 RIVET

NAS1097KE8-9D 110 110 RIVET

NAS1252-10L 58 58 WASHER

NAS1252-416L 116 116 WASHER

S4931919-6-5 4 4 PIN

(a) If grip length shown is not available at Boeing, fasteners supplied in kits may

be one grip length longer than indicated. Also, if any fasteners part numbers

listed are not available or have been superseded, substitute fasteners may be

supplied in kits.

(b) 5930603-9 Filler may be used in lieu of 3964835-511 Filler.

(c) 5922577-507 Upper Center Skin Panel may be used in lieu of 5922577-511

Upper Center Skin Panel.

(d) 5922577-508 Upper Center Skin Panel may be used in lieu of 5922577-512

Upper Center Skin Panel.

Group 2:

Kit SA09550068

Existing Part Notes

Number

New Part Number QTY Name

-7 -9

SA09550068-7 - . (a)

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ALERT ALERT
Group 2:

Kit SA09550068

Existing Part Notes

Number

New Part Number QTY Name

-7 -9

SA09550068-9 . - (a)

117LH7940T-054 7 7 NUT BARREL

3964835-511 14 14 FILLER 5930603-9 (b)

3D0006-3 1 1 NUT ASSEMBLY

3D0031-5-22 6 6 BOLT

3D0031-5-24 1 1 BOLT

UPPER PANEL 5922577-507 (c)

(RIGHT)

5922577-511 . 1

UPPER PANEL 5922577-508 (d)

(LEFT)

5922577-512 1 .

73232-5-8.1 7 7 WASHER

HLT435-6-3 14 14 PIN

HLT435-6-4 27 27 PIN

HLT435-6-5 7 7 PIN

HLT435-6-6 5 5 PIN

HLT435-6-8 2 2 PIN

HLT435-8-3 73 73 PIN

HLT435-8-4 43 43 PIN

MS20426AD5-6D 12 12 RIVET

MS20426AD5-7D 44 44 RIVET

MS20426AD5-8D 6 6 RIVET

MS20426AD6-8D 8 8 RIVET

MS20470AD6-7D 16 16 RIVET

MS20470AD6-8D 22 22 RIVET

MS21042L3 58 58 NUT

MS21042L4 116 116 NUT

NAS1097KE8-10D 54 54 RIVET

NAS1097KE8-11D 2 2 RIVET

NAS1097KE8-12D 18 18 RIVET

NAS1097KE8-9D 147 147 RIVET

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ALERT ALERT
Group 2:

Kit SA09550068

Existing Part Notes

Number

New Part Number QTY Name

-7 -9

NAS1252-10L 58 58 WASHER

NAS1252-416L 116 116 WASHER

S4931919-6-5 4 4 PIN

(a) If grip length shown is not available at Boeing, fasteners supplied in kits may

be one grip length longer than indicated. Also, if any fasteners part numbers

listed are not available or have been superseded, substitute fasteners may be

supplied in kits.

(b) 5930603-9 Filler may be used in lieu of 3964835-511 Filler.

(c) 5922577-507 Upper Center Skin Panel may be used in lieu of 5922577-511

Upper Center Skin Panel.

(d) 5922577-508 Upper Center Skin Panel may be used in lieu of 5922577-512

Upper Center Skin Panel.

2. Parts and Materials Supplied by the Operator:

Part Number/Specification Name QTY Notes

PR-1422 B-2 Sealant As Required (a)

(DMS 2082)

or

Equivalent

Supplier CAGE

(a) Can be purchased from: PRC - DeSoto International, Incorporated 83574

24811 Avenue Rockefeller

Valencia, California 91355 -3468

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

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BOEING SERVICE BULLETIN MD80-55A068

ALERT ALERT
E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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ALERT ALERT

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

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

bulletin can be changed.

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

definition of the acronyms.

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

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

accordance with MD-80 Structural Repair Manual (SRM) 51.

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

installation standards in MD-80 SRM 51, then a fastener of the same specification,

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

MD-80 SRM 51 may be used.

6. 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.

7. 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.

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BOEING SERVICE BULLETIN MD80-55A068

ALERT ALERT
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.

B. WORK INSTRUCTIONS

GROUP 1:

1. Do an eddy current inspection of the horizontal stabilizer left and right upper center skin panels in

accordance with FIGURE 1 and based on inspection results for each panel, do as follows:

Condition 1 (No Crack Found)

a. Do repetitive eddy current inspections of the horizontal stabilizer upper center skin panel in

accordance with FIGURE 1, at intervals specified in Paragraph 1.E., Compliance.

Condition 2 (Crack Found)

a. OPTION 1:

(1) Remove and keep horizontal stabilizer. Refer to MD80 AMM 55-10-00.

(2) Remove and keep horizontal stabilizer leading edge. Refer to MD80 AMM 55-10-01.

(3) Remove and keep horizontal stabilizer upper forward skin panel to gain access to the

cracked horizontal stabilizer upper center skin panel. Refer to drawing 5922575.

(4) Remove and replace the cracked horizontal stabilizer upper center skin panel in

accordance with the applicable configuration of Service Rework Drawing SR09550033

using the applicable kit as follows:

KIT

SA09550068

CENTER SKIN

PANEL LOCATION

DRAWING

SR09550033

-7005 UPPER LEFT -3

-7007 UPPER RIGHT -5

(5) Install kept horizontal stabilizer upper forward skin panel. Refer to drawing 5922575 and

MD80 SRM 51.

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ALERT ALERT
(6) Install kept horizontal stabilizer leading edge. Refer to MD80 AMM 55-10-01.

(7) Install kept horizontal stabilizer. Refer to MD80 AMM 55-10-00.

(8) Do repeat eddy current inspection of the replacement horizontal stabilizer upper center

skin panel in accordance with FIGURE 1, at intervals specified in Paragraph 1.E.,

Compliance.

b. OPTION 2:

(1) Contact Boeing for possible temporary repair of crack and do the repair in accordance

with Boeing's instructions.

2. Put the airplane back to serviceable condition.

GROUP 2:

1. Do an eddy current inspection of the horizontal stabilizer left and right upper center skin panels in

accordance with FIGURE 1 and based on inspection results for each panel, do as follows:

Condition 1 (No Crack Found)

a. Do repeat eddy current inspections of the horizontal stabilizer upper center skin panel in

accordance with FIGURE 1, at intervals specified in Paragraph 1.E., Compliance.

Condition 2 (Crack Found)

a. OPTION 1:

(1) Remove and keep horizontal stabilizer. Refer to MD80 AMM 55-10-00.

(2) Remove and keep horizontal stabilizer leading edge. Refer to MD80 AMM 55-10-01.

(3) Remove and keep horizontal stabilizer upper forward skin panel to gain access to the

cracked horizontal stabilizer upper center skin panel. Refer to drawing 5922575.

(4) Remove and replace the cracked horizontal stabilizer upper center skin panel in

accordance with the applicable configuration of Service Rework Drawing SR09550033

using the applicable kit as follows:

KIT

SA09550068

CENTER SKIN

PANEL LOCATION

DRAWING

SR09550033

-7001 UPPER LEFT -7

-7003 UPPER RIGHT -9

(5) Install kept horizontal stabilizer upper forward skin panel. Refer to drawing 5922575 and

MD80 SRM 51.

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ALERT ALERT
(6) Install kept horizontal stabilizer leading edge. Refer to MD80 AMM 55-10-01.

(7) Install kept horizontal stabilizer. Refer to MD80 AMM 55-10-00.

(8) Do repeat eddy current inspection of the replacement horizontal stabilizer upper center

skin panel in accordance with FIGURE 1, at intervals specified in Paragraph 1.E.,

Compliance.

b. OPTION 2:

(1) Contact Boeing for possible temporary repair of crack and do the repair in accordance

with Boeing's instructions.

2. Put the airplane back to serviceable condition.

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ALERT ALERT
FIGURE 1: HORIZONTAL STABILIZER LEFT AND RIGHT UPPER CENTER SKIN PANELS - EDDY CURRENT

INSPECTION

(SHEET 1 OF 6)

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ALERT ALERT
FIGURE 1: HORIZONTAL STABILIZER LEFT AND RIGHT UPPER CENTER SKIN PANELS - EDDY CURRENT

INSPECTION

(SHEET 2 OF 6)

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ALERT ALERT
FIGURE 1: HORIZONTAL STABILIZER LEFT AND RIGHT UPPER CENTER SKIN PANELS - EDDY CURRENT

INSPECTION

(SHEET 3 OF 6)

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ALERT ALERT
FIGURE 1: HORIZONTAL STABILIZER LEFT AND RIGHT UPPER CENTER SKIN PANELS - EDDY CURRENT

INSPECTION

(SHEET 4 OF 6)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Upper Center Skin 5922577-501 1 (a) (e)

Panel - Right

Inspect - (Scan 1)

OPTION 1, 2:

1

or

Eddy Current, High

Frequency (ETHF)

5922577-507

or

5922577-511

or

SE09550017-5

Upper Center Skin 5922577-502

Panel - Left or

5922577-508

or

5922577-512

or

SE09550017-6

Upper Center Skin 5922577-501 1 (b) (e)

Panel - Right

Inspect - (Scan 2)

OPTION 1, 2:

2

or

Eddy Current, High

Frequency (ETHF)

5922577-507

or

5922577-511

or

SE09550017-5

Upper Center Skin 5922577-502

Panel - Left or

5922577-508

or

5922577-512

or

SE09550017-6

Upper Center Skin 5922577-501 1 (c) (e)

Panel - Right

Inspect - (Scan 3)

OPTION 1:

3

or

Eddy Current, Low

Frequency (ETLF)

5922577-507

or

5922577-511

or

SE09550017-5

Upper Center Skin 5922577-502

Panel - Left or

5922577-508

or

5922577-512

or

SE09550017-6

FIGURE 1: HORIZONTAL STABILIZER LEFT AND RIGHT UPPER CENTER SKIN PANELS - EDDY CURRENT

INSPECTION

(SHEET 5 OF 6)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Inspect - (Scan 3) (d) (e) Upper Center Skin 5922577-501 1

OPTION 2: Panel - Right or

Eddy Current, High 5922577-507

Frequency (ETHF) or

5922577-511

or

SE09550017-5

Upper Center Skin 5922577-502

Panel - Left or

5922577-508

or

5922577-512

or

SE09550017-6

Do an Eddy Current, High Frequency surface inspection of the horizontal stabilizer upper center

skin panels around the fastener in the inspection area. Scan around the fastener using a nonconductive circle template looking for cracks propagating from the fastener hole. Refer to NDTSPM 06-10-

01.001 (ETHF - Procedure 1). Use Calibration Method "P" and Scan Method "47".

(a)

Do an Eddy Current, High Frequency surface inspection of the horizontal stabilizer upper center

skin panels along the inboard portion of the aft edge as shown in the inspection area. Scan the edges

looking for cracks propagating from the panel edge. Refer to NDTSPM 06-10-01.001 (ETHF - Procedure 1). Use Calibration Method "A" and Scan Method "79".

(b)

Do an Eddy Current, Low Frequency sub-surface inspection of the horizontal stabilizer upper center

skin panels at all other areas in the rectangular shaped inspection area not inspected by Scan 1 or

2. Scan the noted area of the upper surface of the upper panels. Refer to NDTSPM 06-10-02.005

(ETLF - Procedure 5).

(c)

NOTE:

Space each scan approximately 1/2 probe coil diameter apart.

Do an Eddy Current, High Frequency surface inspection of the horizontal stabilizer upper center

skin panels at all other areas in the rectangular shaped inspection area not inspected by Scan 1 or

2. Scan the noted area of the upper surface of the upper panels. Refer to NDTSPM 06-10-01.001

(ETHF - Procedure 1).Use Calibration Method "C" and Scan Method "61".

(d)

NOTE:

Space each scan approximately 1/2 probe coil diameter apart.

(e) Evaluate and verify crack indications found during inspection. Refer to NDTSPM 06-00-07.

FIGURE 1: HORIZONTAL STABILIZER LEFT AND RIGHT UPPER CENTER SKIN PANELS - EDDY CURRENT

INSPECTION

(SHEET 6 OF 6)

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ALERT ALERT