### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Number: MD80-57A242**  Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 1 of 71 7.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 2 of 71 **BOEING SERVICE BULLETIN MD80-57A242 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 28 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 54 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 55 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH FREQUENCY INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 3 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 4 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: MD80-57A242** Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000 This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-11-07 is related to this service bulletin. **REASON FOR REVISION** This revision is sent to incorporate engineering released subsequent to original release of this service bulletin, which incorporates an option to do a splice repair of the upper and/or lower rear spar caps. The information provided in Information Notices MD80-57A242 IN 01 and MD80-57A242 IN 02 are included in this revision. These sections were changed: 1. In Paragraph 1.A.1., Airplanes, added Groups 3 and 4. 2. In Paragraph 1.C., Reason, added spar splice option. 3. In Paragraph 1.D., Description, added Condition titles, Option 1 heading and Option 2 splice repair, and added repair options for Condition 3. 4. In Paragraph 1.E., Compliance, added calender time information, Option 1 heading, Option 2 splice repair, repair options for Condition 3, and Federal Aviation Administration (FAA) Airworthiness Directive information. 5. In Paragraph 1.F., Approval, added Alternative Method of Compliance statement. 6. In Paragraph 1.G., Manpower, added Groups 3 and 4 and a table for splice repair hours. 7. In Paragraph 1.J.1., Existing Data, changed Aircraft Maintenance Manual (AMM) references to reflect correct chapter references. 8. In Paragraph 1.J.2., Data supplied with this Service Bulletin, added drawings and updated DCN/REV column.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 5 of 719. In Paragraph 1.K., Publications Affected, added Damage Tolerance Based Structural Inspection information. 10. In Paragraph 2.A., Material - Price and Availability, added Service Kits, expiration date, and unit price. 11. In Paragraph 2.C.1., Kits/Parts, changed Service Kit applicability table to add new kits, changed kit descriptions, and added new kit parts list. 12. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, changed supplier address. 13. In Paragraph 2.C.3., Parts Modified and Reidentified, added parts changed based on repair configuration. 14. In Paragraph 3.A., General Information, added notes. 15. In Paragraph 3.B., Work Instructions, added Groups 3 and 4, Option 1 heading, Option 2 splice repair, and repair options for Condition 3, removed one work step, resequenced work steps, and corrected Aircraft Maintenance Manual Chapter references. 16. Changed note and scope of inspection in Figure 1 for clarity of work required. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** May 08, 2009 Original Issue: January 07, 2011 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 6 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**

### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Summary**  **Number: MD80-57A242** Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000 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** Two operators, while doing an investigation for fuel leaks, reported four instances of cracking of the wing rear spar lower cap at the outboard flap, inboard drive hinge at station Xrs=164.000. Boeing has determined that cracks are the result of material fatigue from normal flap operating loads. Inspecting this area for cracks will stop any crack migration and ensure repairs are done before additional damage occurs. Installation of doublers or doing a spar lower cap splice will help insure the structural integrity of the rear spar. If not corrected, fuel leaks and damage to the wing skin or other structure may occur, resulting in flight disruptions and possible loss of the structural integrity of the wing.**Service History Landing Cycles**  **Flight-Hours**35,286 to 39,338 51,193 to 69,453 **ACTION** Refer to Paragraph 1.D., for Description. **EFFECTIVITY** DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87) and MD-88 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. **COMPLIANCE** Refer to Paragraph 1.E., Compliance.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 7 of 71**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 8 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 9 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 10 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# MD80 Service Bulletin **ALERT Number: MD80-57A242**  Original Issue: May 08, 2009 Revision 1: January 07, 2011 ATA System: 5710 **SUBJECT:**WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station Xrs=164.000 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
**DESCRIPTION CONFIGURATION**  **GROUP** Airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 and affected by Service Bulletin MD80-57-184. - 1 Airplanes that accomplished Service Bulletin MD80-57-184 temporary repair. 1 Airplanes that did not accomplish Service Bulletin MD80-57-184 temporary repair. 2 Airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 and not affected by Service Bulletin MD80-57-184. - 2 Airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 and not affected by Service Bulletin MD80-57-184. - 3
Airplanes with a machined bulkhead at wing station Xrs=137.750 and not affected by Service Bulletin MD80-57-184. - 4
Airplane Models: DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), DC-9-87 (MD-87), MD-88

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 11 of 71**Group Fuselage Num-**  **ber**1 938 1 941 1 944 1 948 1 950 1 952 - 9531 957 1 962 1 966 - 9671 969 - 9711 973 1 978 1 981 1 986 1 988 1 992 1 994 - 9951 999 - 10011 1004 - 10061 1011 - 10121 1016 1 1018 - 10191 1028 1 1031 1 1034 1 1043 1 1045 1 1047 1 1049 1 1051 1 1053 1 1055

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 12 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group**  **Fuselage Num- ber** 1 1057 1 1059 - 10601 1063 - 10711 1073 1 1075 - 10801 1082 1 1085 1 1087 - 10921 1095 - 11031 1105 - 11101 1112 - 11171 1119 - 11281 1130 1 1133 - 11451 1147 - 11721 1174 - 11811 1183 - 12031 1205 - 12061 1208 - 12231 1225 - 12601 1262 - 12901 1292 1 1294 - 13141 1316 - 13231 1325 1 1327 - 13341 1336 - 13421 1344 - 13501 1352 - 13951 1397 - 14511 1453 - 14692 1470 - 1477

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 13 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group**  **Fuselage Num- ber** 2 1479 - 14813 1482 2 1483 - 15032 1505 - 15133 1514 2 1515 3 1516 - 20073 2009 - 20163 2019 - 20343 2036 - 20693 2071 - 20933 2101 - 21143 2116 3 2118 - 21193 2121 3 2124 3 2127 3 2130 3 2132 3 2134 - 21353 2137 3 2139 3 2145 3 2148 3 2151 - 21523 2155 3 2167 3 2174 3 2176 3 2178 3 2180 3 2183

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 14 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group**  **Fuselage Num- ber** 3 2185 3 2187 3 2189 3 2192 3 2196 3 2199 3 2201 3 2204 3 2206 3 2208 3 2214 4 2218 4 2234 4 2239 4 2241 4 2244 4 2247 4 2249 4 2252 4 2254 4 2264 - 2287 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** Two operators, while doing an investigation for fuel leaks, reported four instances of cracking of the wing rear spar lower cap at the outboard flap, inboard drive hinge at station Xrs=164.000. Boeing has determined that cracks are the result of material fatigue from normal flap operating loads. Inspecting this area for cracks will stop any crack migration and ensure repairs are done before additional damage occurs. Installation of doublers or doing a spar lower cap splice will help insure the structural integrity of the rear spar. If not corrected, fuel leaks and damage to the wing skin or other structure may occur, resulting in flight disruptions and possible loss of the structural integrity of the wing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 15 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**Revision 1 is sent to incorporate engineering released subsequent to original release of this service bulletin, which incorporates an option to do a splice repair of the upper and/or lower rear spar caps. The information provided in Information Notices MD80-57A242 IN 01 and MD80-57A242 IN 02 are included in this revision. **Service History Landing Cycles**  **Flight-Hours**35,286 to 37,006 66,260 to 69,453 **D. Description Group 1, Configuration 1:**  1. Continues repeat inspections in accordance with Service Bulletin MD80-57-184, Paragraph 1.D.(5), Compliance. **Group 1, Configuration 2; Group 2-4:** 1. Does Eddy Current, High Frequency inspection (ETHF) on the aft side of the left and right wing rear spar lower caps at station Xrs=164.000 for cracks and based on inspection results does as follows: a. Condition 1 (No Crack) Does repeat ETHF inspections. b. Condition 2 (Lower Spar Cap has a Crack 2.0 Inches or Less in Length and Not in the Rear Spar Cap Forward Horizontal Leg Radius) Does ETHF on the aft side of the left and/or right wing rear spar upper cap at station Xrs=164.000 for cracks and based on inspection results does as follows: (1) Condition 2a (No Crack in Rear Spar Upper Cap): **Option 1** (a) Does doubler repair to rear spar lower cap in accordance with Service Rework Drawing J060271. (b) Does repeat ETHF inspections.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 16 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Option 2**  (a) Does splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165. (b) Does Eddy Current, Low Frequency (ETLF) and Ultrasonic (UT) inspections of rear spar lower cap splice repair. (2) Condition 2b (Upper Spar Cap has a Crack 2.0 Inches or Less in Length and Not in the Rear Spar Cap Forward Horizontal Leg Radius): **NOTE:**Operators can do Option 1 or Option 2 or any combination of Options 1 and 2. **Option 1** (a) Does doubler repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060271. (b) Does ETHF inspections of rear spar upper and lower cap doubler repairs. **Option 2** (a) Does splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165. (b) Does ETLF and UT inspections of rear spar lower cap splice repair. (3) Condition 2c (Upper Spar Cap Has a Crack Longer than 2.0 Inches in Length or Crack in the Rear Spar Cap Forward Horizontal Leg Radius): **Option 1** (a) Does splice repair to rear spar upper cap in accordance with Service Rework Drawing J060165 and doubler repair to rear spar lower cap in accordance with Service Rework Drawing J060271. (b) Does ETHF inspections of rear spar lower cap doubler repair. **Option 2** (a) Does splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165. (b) Does ETLF and UT inspections of rear spar lower cap repair. c. Condition 3 (Lower Spar Cap has a Crack Longer than 2.0 Inches in Length or Crack in Rear Spar Cap Forward Horizontal Leg Radius) Does ETHF inspection on the aft side of the left and/or right wing rear spar upper cap at station Xrs=164.000 for cracks and based on inspection results does as follows: (1) Condition 3a (No Crack in Rear Spar Upper Cap):

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 17 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**(a) Does splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165. (b) Does ETLF and UT inspections of rear spar lower cap splice repair. (2) Condition 3b (Crack 2.0 Inches or Less in Length in Rear Spar Upper Cap and Not in the Rear Spar Upper Cap Forward Horizontal Leg Radius): **Option 1** (a) Does doubler repair to rear spar upper cap in accordance with Service Rework Drawing J060271 and splice repair to rear spar lower cap in accordance with Drawing J060165. (b) Does ETHF inspection of rear spar upper cap doubler repair. (c) Does ETLF and UT inspections of rear spar lower cap splice repair. **Option 2** (a) Does splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165. (b) Does ETLF and UT inspections of rear spar lower cap splice repair. (3) Condition 3c (Crack Longer than 2.0 Inches in Length in Rear Spar Upper Cap or Crack in the Rear Spar Upper Cap Forward Horizontal Leg Radius): (a) Does splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165. (b) Does ETLF and UT inspections of rear spar lower cap splice repair. 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 1-3: Affected Maintenance Zones** **Zone Model**  13, 14, 15, 16 DC-9-81 (MD-81), DC-9-82(MD-82), DC-9-83 (MD-83), DC9-87 (MD-87), MD-88

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 18 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 4:**  **Affected Maintenance Zones Zone**  **Model** 13, 14, 15, 16 DC-9-83 (MD-83) **E. Compliance** Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-11-07 is related to this service bulletin. **Group 1, Configuration 1:** 1. No action is necessary for this service bulletin. **NOTE:**Repeat inspections in accordance with Service Bulletin MD80-57-184, Paragraph 1.D.(5), Compliance, are still required. **Group 1, Configuration 2; Group 2-4: Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000** **Repeat In terval** **(Not to Ex ceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 

- Within 3,360 flight cycles after the original issuedate on this service bulletin.Before the accumulation of 30,000 total flight cycles. Do Eddy Current, High Frequency (ETHF) inspection of the left and right wing rear spar lower cap at station Xrs=164.000 in accordance with Accomplishment Instructions 3.B. All airplanes

Within 2,650 flightcycles after doing the ETHF inspection. - - Do ETHF inspection of the left and right wing rear spar lower caps at station Xrs=164.000 in accordance with Accomplishment Instructions 3.B. Condition 1: No Crack

Before further flight. Do ETHF inspection of the left and/or right wing rear spar uppercap at station Xrs=164.000 in accordance with Accomplishment Instructions 3.B. Condition 2: Lower Spar Cap has a Crack 2.0 Inches or Less in Length and Not in the Rear Spar Cap Forward Horizontal Leg Radius

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 19 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2-4:**  **Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000 Repeat In**  **terval (Not to Ex**  **ceed) Compliance Time**  **(Whichever Occurs Later) Action**  **Condition**

- - Before further flight. Option 1: Do doubler repair of rear spar lowercap in accordance with Accomplishment Instructions 3.B. Condition 2aNo Crack in Rear Upper Spar Cap.AND Within 7,000 flightcycles after doing the ETHF inspection. - Within 11,000 flight cycles after doubler repair. Do ETHF inspection in the repaired area of the rear spar lower cap in accordance with Accomplishment Instructions 3.B.
OR

- - Before further flight. Option 2: Do splice repair in accordance with Accomplishment Instructions 3.B. AND Within 2,900 flightcycles after doing the ETLFand UT inspection. - Within 22,000 flight cycles after splice repair. Do Eddy Current, Low Frequency(ETLF) and Ultrasonic (UT) inspections in the repaired area of the rear spar lower cap in accordance with Accomplishment Instructions 3.B.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 20 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2-4:**  **Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000 Repeat In**  **terval (Not to Ex**  **ceed) Compliance Time**  **(Whichever Occurs Later) Action**  **Condition**

- - Before further flight. Option 1: Do doubler repair of rear spar upper and lower caps in accordance with Accomplishment Instructions 3.B. Condition 2b: Upper Spar Cap has a Crack 2.0 Inches or Less in Length and Not in the Rear Spar Cap Forward Horizontal Leg Radius AND Within 7,000 flightcycles after doing the ETHF inspection. - Within 11,000 flight cycles after doubler repair. Do ETHF inspection in the repaired area of the rear spar upper andlower caps in accordance with Accomplishment Instructions 3.B.
OR

- - Before further flight. Option 2: Do splice repair of rear spar upper and lower caps in accordance with Accomplishment Instructions 3.B. AND Within 2,900 flightcycles after doing the ETLFand UT inspection. - Within 22,000 flight cycles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lowercap in accordance with Accomplishment Instructions 3.B.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 21 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2-4:**  **Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000 Repeat In**  **terval (Not to Ex**  **ceed) Compliance Time**  **(Whichever Occurs Later) Action**  **Condition**

- - Before further flight. Option 1: Do splice repair of rear spar upper cap and doubler repair of rear sparlower cap in accordance with Accomplishment Instructions 3.B. Condition 2c: Upper Spar Cap Has a Crack Longer than 2.0 Inches in Length or Crack the Rear Spar Cap Forward Horizontal Leg RadiusAND Within 7,000 flightcycles after doing the ETHF inspection. - Within 11,000 flight cycles after doubler repair. Do ETHF inspection in the repaired area of the rear spar lower cap in accordance with Accomplishment Instructions 3.B.
OR

- - Before further flight. Option 2: Do splice repair of rear spar upper and lower caps in accordance with Accomplishment Instructions 3.B. AND Within 2,900 flightcycles after doing the ETLFand UT inspection. - Within 22,000 flight cycles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lowercap in accordance with Accomplishment Instructions 3.B.

- - Before further flight. Do ETHF inspection of the left and/or right wing rear spar uppercap at station Xrs=164.000 in accordance with Accomplishment Instructions 3.B. Condition 3: Lower Spar Cap has a Crack Longer than 2.0 Inches in Length or Crack in the Rear Spar Cap Forward Horizontal Leg Radius.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 22 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2-4:**  **Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000 Repeat In**  **terval (Not to Ex**  **ceed) Compliance Time**  **(Whichever Occurs Later) Action**  **Condition**

- Before further flight. Do splice repair of rear spar lowercap in accordance with Accomplishment Instructions 3.B. Condition 3a: No crack in rear spar upper cap.AND Within 2,900 flightcycles after doing the ETLFand UT inspection. Within 22,000 flight cycles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lowercap in accordance with Accomplishment Instructions 3.B.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 23 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2-4:**  **Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000 Repeat In**  **terval (Not to Ex**  **ceed) Compliance Time**  **(Whichever Occurs Later) Action**  **Condition**

- - Before further flight. Option 1: Do doubler repair of rear spar upper cap and splice repair of rear sparlower cap in accordance with Accomplishment Instructions 3.B. Condition 3b: Crack 2.0 Inches or Less in Length in Rear Spar Upper Cap and Not in the Rear Spar Upper Cap Forward Horizontal Leg RadiusAND Within 7,000 flightcycles after doing the ETHF inspection. - Within 11,000 flight cycles after doubler repair. Do ETHF inspection in the repaired area of the rear spar upper cap in accordance with Accomplishment Instructions 3.B.
AND Within 2,900 flightcycles after doing the ETLFand UT inspection. - Within 22,000 flight cycles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lowercap in accordance with Accomplishment Instructions 3.B.

OR

- - Before further flight. Option 2: Do splice repair of rear spar upper and lower caps in accordance with Accomplishment Instructions 3.B. AND Within 2,900 flightcycles after doing the ETLFand UT inspection. - Within 22,000 flight cycles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lowercap in accordance with Accomplishment Instructions 3.B.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 24 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2-4:**  **Table 1: Inspect Left and Right Wing Upper and Lower Rear Spar Caps for Cracks at Station Xrs = 164.000 Repeat In**  **terval (Not to Ex**  **ceed) Compliance Time**  **(Whichever Occurs Later) Action**  **Condition**

- - Before further flight. Do splice repair of rear spar upper and lower caps in accordance with Accomplishment Instructions 3.B. Condition 3c: Crack Longer than 2.0 Inches in Length in Rear Spar Upper Cap or Crack in Rear Spar Upper Cap Forward Horizontal Leg RadiusAND Within 2,900 flightcycles after doing the ETLFand UT inspection. - Within 22,000 flight cycles after splice repair. Do ETLF and UT inspections in the repaired area of the rear spar lowercap in accordance with Accomplishment Instructions 3.B.

**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. In addition, the repair and inspections described in Paragraph 1.D has been shown to comply with the applicable Federal Aviation Regulations and is approved by the Manager, Los Angeles Aircraft Certification Office, FAA Northwest Mountain Region and is approved as an alternative method of compliance with Paragraph (b) and (c) of Airworthiness Directive 2004-11-07 as it applies to repaired structure. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. **G. Manpower** The table below shows an estimate of the task hours necessary to do the inspection/change/repair 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 25 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**— Time to make the parts — Time to find the tools. — Time to make reference standards. 1.**Group 1, Configuration 1:** Manpower is in accordance with Service Bulletin MD80-57-184, Paragraph 1.F., Manpower. 2.**Group 1, Configuration 2; Group 2-4:** Use applicable table for Manpower as follows: **TABLE 1: NO CRACKS Elapsed Hours**  **Task Hours Number of Per-**  **sons Task**  0.5 1.0 2 Open Access 2.0 4.0 2 Inspect 0.5 1.0 2 Close Access 3.0 6.0 TOTAL FOR EACH WING **TABLE 2: DOUBLER REPAIR Elapsed Hours**  **Task Hours Number of Per-**  **sons Task**  0.5 1.0 2 Open Access 2.0 4.0 2 Inspect 0.5 1.0 2 Open Access to tanks. 4.0 4.0 1 Defuel 8.0 8.0 1 Purge 100.0* 200.0* 2 Repair 0.5 1.0 2 Close Access 2.0 4.0 2 Test 117.5* 223.0* TOTAL FOR EACH WING * Actual task hours and elapsed hours for repair are contingent upon inspection results. **TABLE 3: SPLICE REPAIR Elapsed Hours**  **Task Hours Number of Per-**  **sons Task**  0.5 1.0 2 Open Access 2.0 4.0 2 Inspect

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 26 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT TABLE 3: SPLICE REPAIR**  **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task** 0.5 1.0 2 Open Access to tanks 4.0 4.0 1 Defuel 8.0 8.0 1 Purge 200.0* 400.0* 2 Repair 0.5 1.0 2 Close Access 2.0 4.0 2 Test 317.5* 423.0* TOTAL FOR EACH WING * Actual task hours and elapsed hours for repair are contingent upon inspection results. **H. Weight and Balance Changes** Weight and balance changes affected by incorporation of this service bulletin are contingent upon the changes to each particular airplane. Weight data is to be computed by the operator by weighing parts removed and parts installed during this change. Necessary revisions should be made to the appropriate airplane weight and balance report. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Boeing Service Bulletin MD80-57-184. b. Non-Destructive Test Standard Practices Manual (NDTSPM) 01-00-01, 06-00-01, 06-10-01.001. Part 06, 06-20-01. c. MD80 Aircraft Maintenance Manual (AMM) 06-21-00, 27-10-00, 27-51-01, 27-60-00, 28-00-00, 28-10-01, 29-00-00, 32-10-0, 32-10-00, 57-20-03, 57-40-01. d. MD80 Structural Repair Manual (SRM) 51-10-03, 51-10-04, 51-20-00, 51-30-01, 51-30-02, 51-30-03, 51-30-05, 51-30-09, 51-30-11, 51-30-60. e. MD80 Supplemental Inspection Document (SID) Volume II, L26-022, Section 57.80.012, Sequence 1, Method 1. 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:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 27 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**Data and Services Management MS D800-0019 3855 Lakewood Boulevard Long Beach, California 90846 Phone: (562) 593-6996 Fax: (562) 593-2001 E-mail: dse.boecom@boeing.com a. Drawings: **ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- C DWG EDDY CURRENT INSPECTION - WING REAR SPAR TEMPORARY REPAIR STA Xrs=164 3668XXX
Y U AEO SERVICE REWORK - WING REAR SPAR CAP SPLICE SERVICE REWORK DWG J060165 Z U AEO V U AEO W U AEO AA U DWG U T DWG SERVICE REWORK - TEMP REPAIR, WING REAR SPAR XRS=164.000 J060271

- - DWG INSPECTION - REAR SPAR AFT TANG SERVICE NDI DRAWING SN90570006 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. **K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 28 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. **Unit Price as of the Revision 01 date of**  **this Service Bulletin (US Dollars)**  **ROLT as of the Revision**  **01 date of this Service Bul** **letin (Calen dar Days)**  **Name Kit Number** 

43,417.00 17 Service Kit SA09570242-3 43,517.00 17 Service Kit SA09570242-5 40,435.00 17 Service Kit SA09570242-7 40,435.00 17 Service Kit SA09570242-9 74,903.00 17 Service Kit SA09570242-11 76,744.00 17 Service Kit SA09570242-13 80,082.00 17 Service Kit SA09570242-15 77,920.00 17 Service Kit SA09570242-17 140,805.00 17 Service Kit SA09570242-19 140,805.00 17 Service Kit SA09570242-21 205,700.00 17 Service Kit SA09570242-23 205,700.00 17 Service Kit SA09570242-25 140,118.00 17 Service Kit SA09570242-27 138,473.00 17 Service Kit SA09570242-29 70,974.00 17 Service Kit SA09570242-31 76,359.00 17 Service Kit SA09570242-33 205,257.00 17 Service Kit SA09570242-35 203,095.00 17 Service Kit SA09570242-37 140,127.00 17 Service Kit SA09570242-39 140,127.00 17 Service Kit SA09570242-41 76,924.00 17 Service Kit SA09570242-43 74,762.00 17 Service Kit SA09570242-45 202,352.00 17 Service Kit SA09570242-47 203,095.00 17 Service Kit SA09570242-49

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 29 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Mail to: Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **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 and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. **Table 1: Service Kit Applicability Description**  **Drawing Configuration Service Kit**  Doubler Repair for Cracks in Rear Spar Lower Cap (Left Wing) J060271-509 SA09570242-3 Doubler Repair for Cracks in Rear Spar Lower Cap (Right Wing) J060271-510 SA09570242-5 Doubler Repair for Cracks in Rear Spar Upper Cap (Left Wing) J060271-511 SA09570242-7 Doubler Repair for Cracks in Rear Spar Upper Cap (Right Wing) J060271-512 SA09570242-9 Doubler Repair for Cracks in Rear Spar Upper and Lower Cap (Left Wing) J060271-513 SA09570242-11 Doubler Repair for Cracks in Rear Spar Upper and Lower Cap (Right Wing) J060271-514 SA09570242-13

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 30 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Table 1: Service Kit Applicability**  **Description Drawing Configuration**  **Service Kit** Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 (Left Wing) J060165-511 SA09570242-15 Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 (Right Wing) J060165-512 SA09570242-17 Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 (Left Wing) J060165-513 SA09570242-19 Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 (Right Wing) J060165-514 SA09570242-21 Splice Repair for Cracks in Rear Spar Upper and Lower Caps on airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 (Left Wing) J060165-515 SA09570242-23 Splice Repair for Cracks in Rear Spar Upper and Lower Caps on airplanes with a multi-component bulkhead with bolts at wing station Xrs=137.750 (Right Wing) J060165-516 SA09570242-25 Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Left Wing) J060165-517 SA09570242-27 Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Right Wing) J060165-518 SA09570242-29 Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Left Wing) J060165-519 SA09570242-31 Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Right Wing) J060165-520 SA09570242-33 Splice Repair for Cracks in Rear Spar Upper and Lower Caps on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Left Wing) J060165-521 SA09570242-35 Splice Repair for Cracks in Rear Spar Upper and Lower Caps on airplanes with a multi-component bulkhead without bolts at wing station Xrs=137.750 (Right Wing) J060165-522 SA09570242-37 Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Left Wing) J060165-523 SA09570242-39 Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Right Wing) J060165-524 SA09570242-41

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 31 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Table 1: Service Kit Applicability**  **Description Drawing Configuration**  **Service Kit** Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Left Wing) J060165-525 SA09570242-43 Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a machined bulkhead at wing station Xrs=137.750 (Right Wing) J060165-526 SA09570242-45 Splice Repair for Cracks in Rear Spar Upper and Lower Caps on airplanes with a machined bulkhead at wing station Xrs=137.750 (Left Wing) J060165-527 SA09570242-47 Splice Repair for Cracks in Rear Spar Upper and Lower Caps on airplanes with a machined bulkhead at wing station Xrs=137.750 (Right Wing) J060165-528 SA09570242-49

**Service Kit SA09570242 Notes**  **Name QTY**  **New Part Number -13**  **-11 -9**  **-7 -5**  **-3** WASHER 1 1
. . 1 1 2917053-501 WASHER 1 1
. . 1 1 2917053-509 NUT ASSY 46 46 27 27 19 19 3D0006-4 SPACER CONICAL 26 26 26 26
. . 4894213-1 SPACER CONICAL 18 18
. . 18 18 4894213-501 SPACER 97 97 50 50 47 47 4894213-503 CONICAL SPACER 7 7
. . 7 7 4894213-505 CONICAL SPACER 8 8 4 4 4 4 4894213-547 STIFFENER 1 1 1 1 1 1 9910010-39 CLIP
. . . 1
. . 9924775-27 CLIP
. . 1
. . . 9924775-28 PIN 4 4
. . 4 4 HL328-6-10 PIN 4 4
. . 4 4 HL328-6-18 PIN 6 6 6 6
. . HL328-6-8 PIN 20 20 14 14 6 6 HL328-8-10 PIN 3 3
. . 3 3 HL328-8-6

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 32 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-13 -11**  **-9 -7**  **-5 -3**  PIN 5 5
. . 5 5 HL328-8-8 PIN 3 3
. . 3 3 HL329-6-14 PIN 2 2
. . 2 2 HL329-6-16 PIN 15 15
. . 15 15 HL329-6-5 PIN 16 16 16 16
. . HL329-6-6 PIN, OVERSIZE
. . . . 4 4 HLT1001PB-6-10 PIN, OVERSIZE 28 28 26 26 2 2 HLT1001PB-6-12 PIN, OVERSIZE 15 15 7 7 8 8 HLT1001PB-6-14 PIN, OVERSIZE 8 8
. . 8 8 HLT1001PB-6-16 PIN, OVERSIZE 2 2
. . 2 2 HLT1001PB-6-18 PIN, OVERSIZE 2 2
. . 2 2 HLT1001PB-8-10 PIN, OVERSIZE 12 12 2 2 10 10 HLT1001PB-8-12 PIN, OVERSIZE 48 48 29 29 19 19 HLT1001PB-8-14 PIN, OVERSIZE 7 7 1 1 6 6 HLT1001PB-8-16 PIN, OVERSIZE 29 29 18 18 11 11 HLT1001PB-8-18 PIN 11 11 6 6 5 5 HLT428-6-8 PIN 26 26 13 13 13 13 HLT428-8-10 PIN 52 52 32 32 20 20 HLT428-8-12 PIN 2 2
. . 2 2 HLT428-8-8 PIN, OVERSIZE 1 1 1 1
. . HLT629-8-6 PIN, OVERSIZE 2 2
. . 2 2 HLT629-8-7 SHIM 1 1
. . . . J060271-13 SHIM 1 1
. . . . J060271-17 SHIM
. . 1 1 1 1 J060271-19 SHIM
. . 1 1 1 1 J060271-21 DOUBLER
. 1
. 1
. . J060271-27 DOUBLER 1
. 1
. . . J060271-28 FILLER 1 1
. . 1 1 J060271-31 CLIP
. 1
. . . 1 J060271-33 CLIP 1
. . . 1
. J060271-34 CLIP
. 1
. . . 1 J060271-35

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 33 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-13 -11**  **-9 -7**  **-5 -3**  CLIP 1
. . . 1
. J060271-36 SPACER 2 2
. . 2 2 J060271-37 DOUBLER
. 1
. 1
. . J060271-39 DOUBLER 1
. 1
. . . J060271-40 DOUBLER
. 1
. 1
. . J060271-41 DOUBLER 1
. 1
. . . J060271-42 DOUBLER
. 1
. . . 1 J060271-43 DOUBLER 1
. . . 1
. J060271-44 DOUBLER
. 1
. . . 1 J060271-45 DOUBLER 1
. . . 1
. J060271-46 DOUBLER
. 1
. . . 1 J060271-47 DOUBLER 1
. . . 1
. J060271-48 FILLER 1 1
. . 1 1 J060271-49 FILLER 1 1
. . 1 1 J060271-51 SHIM 1 1
. . 1 1 J060271-53 STIFFENER 1 1 1 1 1 1 J060271-57 TEE
. 1
. . . 1 J060271-65 TEE 1
. . . 1
. J060271-66 RADIUS BLOCK
. 1
. . . 1 J060271-67 RADIUS BLOCK 1
. . . 1
. J060271-68 RIVET 2 2 2 2 2 2 MS20470AD6-10D RIVET 2 2 2 2
. . MS20470AD6-8D RIVET 3 3 3 3 3 3 MS20470AD6-9D RIVET 16 16 16 16 16 16 MS20470AD8-12D NUT 105 105 57 57 48 48 MS21042L3 NUT 196 196 107 107 89 89 MS21042L4 NUTPLATE 2 2
. . 2 2 MS21059L3 WASHER 50 50 22 22 28 28 NAS1252-10H WASHER 28 28 14 14 14 14 NAS1252-416H WASHER 24 24 24 24
. . NAS1401-3D3 BOLT 4 4
. . 4 4 PIC239-3-10

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 34 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-13 -11**  **-9 -7**  **-5 -3**  BOLT 3 3
. . 3 3 PIC239-3-15 BOLT
. . 3 3
. . PIC239-3-17 BOLT 2 2
. . 2 2 PIC239-3-6 WASHER 55 55 35 35 20 20 S2931983-30A06 WASHER 180 180 95 95 85 85 S2931983-40A06 **Service Kit SA09570242 Notes**  **Name QTY**  **New Part Number -25**  **-23 -21**  **-19 -17**  **-15** NUT ASSY 22 22 22 22 15 15 3D0006-3 NUT ASSY 216 216 155 155 61 61 3D0006-4 NUT ASSY 57 57 40 40 17 17 3D0006-5 PIN 4 4 4 4
. . 3D0097-10X12 PIN 4 4 4 4
. . 3D0097-10X13 PIN 12 12 12 12
. . 3D0097-10X17 PIN 16 16 16 16
. . 3D0097-10X18 PIN 4 4 4 4
. . 3D0097-10X20 PIN 21 21 21 21
. . 3D0097-8X10 PIN 11 11 11 11
. . 3D0097-8X11 PIN 1 1 1 1
. . 3D0097-8X12 PIN 3 3 3 3
. . 3D0097-8X13 PIN 4 4 4 4
. . 3D0097-8X14 PIN 12 12 12 12
. . 3D0097-8X15 PIN 12 12 12 12
. . 3D0097-8X16 PIN 17 17
. . 17 17 3D0097-10X14 PIN 2 2 2 2
. . 3D0097-6-7 PIN 7 7 4 4 3 3 HL325-6-10 PIN 2 2 2 2
. . HL325-6-11 PIN 7 7 2 2 5 5 HL325-6-12 PIN 15 15 15 15
. . HL325-6-13 PIN 2 2
. . 2 2 HL325-6-14

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 35 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-25 -23**  **-21 -19**  **-17 -15**  PIN 1 1
. . 1 1 HL325-6-8 PIN
. . . . 5 5 HL325-6-9 PIN
. . . . 7 7 HL325-8-5 PIN 23 23
. . 23 23 HL325-8-6 PIN
. . . . 2 2 HL325-8-7 PIN
. . . . 8 8 HL325-8-8 PIN, OVERSIZE 7 7
. . 7 7 HLT1001PB-6-6 PIN 4 4 4 4
. . HLT425-6-13 PIN
. . . . 7 7 HLT425-8-10 PIN
. . . . 17 17 HLT425-8-11 PIN
. . . . 31 31 HLT425-8-9 PIN 10 10 10 10 4 4 HLT426-10-18 PIN 44 44 56 56 35 35 HLT426-6-10 PIN 24 24 24 24 18 18 HLT426-6-12 PIN 4 4 4 4
. . HLT426-6-13 PIN 2 2 2 2 18 18 HLT426-6-14 PIN 6 6 4 4 2 2 HLT426-6-15 PIN 8 8 4 4 4 4 HLT426-6-16 PIN
. . . . 2 2 HLT426-6-17 PIN
. . . . 3 3 HLT426-6-3 PIN 11 11 9 9 9 9 HLT426-6-4 PIN 23 23
. . 22 22 HLT426-6-5 PIN 57 57 41 41 74 74 HLT426-6-6 PIN 50 50 30 30 22 22 HLT426-6-7 PIN 7 7 9 9 8 8 HLT426-6-8 PIN 90 90 77 77 98 98 HLT426-8-10 PIN 9 9 9 9 10 10 HLT426-8-11 PIN 104 104 105 105 99 99 HLT426-8-12 PIN 19 19 3 3 16 16 HLT426-8-13 PIN 10 10 20 20 10 10 HLT426-8-14 PIN
. . . . 31 31 HLT426-8-15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 36 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-25 -23**  **-21 -19**  **-17 -15**  PIN 7 7 12 12 1 1 HLT426-8-16 PIN
. . . . 58 58 HLT426-8-17 PIN
. . . . 18 18 HLT426-8-18 PIN
. . . . 24 24 HLT426-8-19 PIN
. . . . 16 16 HLT426-8-22 PIN
. . . . 10 10 HLT426-8-24 PIN 32 32 32 32 28 28 HLT426-8-4 PIN 23 23 20 20 22 22 HLT426-8-5 PIN 28 28 28 28 26 26 HLT426-8-6 PIN 4 4 1 1 16 16 HLT426-8-7 PIN 83 83 74 74 83 83 HLT426-8-8 PIN 2 2 2 2
. . HLT426-8-9 6 6
. . 6 6 HLT426-10-7 PIN 9 9
. . 9 9 HLT427-10-18 PIN 12 12
. . 12 12 HLT427-10-20 PIN 35 35
. . 35 35 HLT427-10-22 PIN 6 6
. . 6 6 HLT427-10-24 PIN 2 2
. . 2 2 HLT427-10-26 PIN 5 5
. . 5 5 HLT427-6-10 PIN 2 2 2 2 12 12 HLT427-6-11 PIN 10 10 10 10 10 10 HLT427-6-12 PIN 6 6
. . 6 6 HLT427-6-14 PIN 2 2 2 2
. . HLT427-6-7 PIN 1 1
. . 2 2 HLT427-6-8 PIN
. . . . 6 6 HLT427-6-9 PIN 43 43 9 9 34 34 HLT427-8-10 PIN
. . . . 19 19 HLT427-8-11 PIN 49 49
. . 49 49 HLT427-8-12 PIN 2 2 2 2
. . HLT427-8-13 PIN 24 24 2 2 22 22 HLT427-8-14 PIN 5 5 4 4 1 1 HLT427-8-15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 37 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-25 -23**  **-21 -19**  **-17 -15**  PIN 36 36 2 2 36 36 HLT427-8-16 PIN 2 2 2 2 56 56 HLT427-8-17 PIN 20 20 20 20 15 15 HLT427-8-18 PIN 21 21 21 21 2 2 HLT427-8-19 PIN 6 6 2 2 4 4 HLT427-8-20 PIN 3 3 2 2 1 1 HLT427-8-21 PIN 2 2
. . 2 2 HLT427-8-22 PIN 2 2 2 2 2 2 HLT427-8-23 PIN 13 13
. . 13 13 HLT427-8-24 PIN 2 2 2 2
. . HLT427-8-25 PIN 2 2 2 2
. . HLT427-8-26 PIN 11 11 11 11
. . HLT427-8-27 PIN
. . . . 10 10 HLT427-8-28 PIN 13 13
. . 13 13 HLT427-8-6 PIN 1 1 1 1 4 4 HLT427-8-8 PIN 5 5 5 5 5 5 HLT427-8-9 PIN 5 5 5 5
. . HLT437-6-6 PIN 2 2 2 2
. . HLT437-6-7 ANGLE 1
. . . 1
. J060165-10 FILLER
. 1
. . . 1 J060165-13 FILLER 1
. . . 1
. J060165-14 FILLER 1 1
. . 1 1 J060165-15 FILLER 1 1
. . 1 1 J060165-17 FILLER 1 1
. . 1 1 J060165-19 TEE
. . . . 1 1 J060165-21 STIFFENER 1 1
. . 1 1 J060165-23 PLATE
. . . . . . J060165-25 PLATE 1 1
. . . . J060165-27 ANGLE
. 1
. 1
. . J060165-31 ANGLE 1
. 1
. . . J060165-32 FILLER
. 1
. 1
. . J060165-33

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 38 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-25 -23**  **-21 -19**  **-17 -15**  FILLER 1
. 1
. . . J060165-34 FILLER
. 1
. 1
. . J060165-35 FILLER 1
. 1
. . . J060165-36 ANGLE
. 1
. 1
. . J060165-37 ANGLE 1
. 1
. . . J060165-38 DOUBLER
. 1
. 1
. . J060165-39 DOUBLER 1
. 1
. . . J060165-40 FILLER 1 1 1 1
. . J060165-41 FILLER 1 1 1 1
. . J060165-43 FILLER 1 1 1 1
. . J060165-45 FILLER 1 1 1 1
. . J060165-47 FILLER 1 1 1 1
. . J060165-49 ANGLE
. 1
. . . 1 J060165-5 TEE 1 1
. . . . J060165-51 STIFFENER 1 1 1 1 1 1 J060165-53 SPLICE 1 1 1 1 1 1 J060165-55 SPACER 1 1
. . 1 1 J060165-57 SPACER 1 1
. . 1 1 J060165-59 ANGLE 1
. . . 1
. J060165-6 DOUBLER
. 1
. . . 1 J060165-61 DOUBLER 1
. . . 1
. J060165-62 SPAR CAP
. 1
. . . 1 J060165-63 SPAR CAP 1
. . . 1
. J060165-64 SPLICE 1 1 1 1 1 1 J060165-65 BUSHING 7 7
. . 7 7 J060165-67 SPAR CAP
. 1
. 1
. . J060165-69 FILLER
. 1
. . . 1 J060165-7 SPAR CAP 1
. 1
. . . J060165-70 FILLER 1
. . . 1
. J060165-8 ANGLE
. 1
. . . 1 J060165-9 RIVET 3 3 3 3
. . MS20426AD6-12D

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 39 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-25 -23**  **-21 -19**  **-17 -15**  RIVET
. . . . 2 2 MS20426AD6-8D RIVET
. . . . 5 5 MS20470AD4-6D RIVET
. . . . 10 10 MS20470AD5-7D RIVET
. . . . 2 2 MS20470AD5-9D RIVET 63 63 63 63 71 71 MS20470AD6-10D RIVET 10 10 10 10 10 10 MS20470AD6-11D RIVET 22 22 22 22 29 29 MS20470AD6-12D RIVET 4 4 4 4 4 4 MS20470AD6-14D RIVET
. . . . 4 4 MS20470AD6-15D RIVET
. . . . 4 4 MS20470AD6-16D RIVET 48 48 48 48 58 58 MS20470AD6-8D RIVET 2 2 2 2
. . MS20470AD6-9D RIVET 58 58 58 58 50 50 MS20470AD8-10D RIVET
. . . . 4 4 MS20470AD8-11D RIVET 33 33 33 33 33 33 MS20470AD8-12D RIVET
. . . . 28 28 MS20470AD8-13D RIVET 36 36 36 36 36 36 MS20470AD8-14D RIVET
. . . . 4 4 MS20470AD8-16D RIVET
. . . . 1 1 MS20470AD8-17D RIVET
. . . . 6 6 MS20470AD8-18D RIVET
. . . . 1 1 MS20470AD8-19D RIVET
. . . . 5 5 MS20470AD8-7D RIVET
. . . . 18 18 MS20470AD8-9D NUT 273 273 218 218 180 180 MS21042L3 NUT 549 549 549 549 536 536 MS21042L4 NUT 84 84 10 10 84 84 MS21042L5 NUT 2 2 2 2 2 2 MS21042L6 CHANNEL
. . . . 1 1 MS21064L5-11-4 BOLT 2 2
. . 2 2 NAS1203-4 BOLT 7 7
. . 7 7 NAS1203-8 BOLT
. . . . 8 8 NAS1204-12

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 40 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-25 -23**  **-21 -19**  **-17 -15**  BOLT
. . . . 4 4 NAS1204-13 BOLT
. . . . 1 1 NAS1204-14 BOLT
. . . . 7 7 NAS1205-15 WASHER 273 273 228 228 180 180 NAS1252-10H WASHER 542 542 542 542 542 542 NAS1252-416H WASHER 91 91 10 10 81 81 NAS1252-516H WASHER 12 12 12 12 12 12 NAS1252-616H BOLT
. . . . 1 1 NAS1704-8 BOLT
. . . . 22 22 NAS6205-10 BOLT
. . . . 8 8 NAS6205-16 BOLT
. . . . 8 8 NAS6205-26 BOLT 2 2
. . 2 2 NAS6206-10 BOLT 2 2 2 2
. . NAS6206-12 NUT 17 17
. . 17 17 NAS679A5 BOLT 4 4
. . 4 4 PIC239-3-10 BOLT 3 3
. . 3 3 PIC239-3-15 PIN 6 6 6 6
. . S4931917-8X10 PIN 6 6 6 6
. . S4931917-8X11 PIN 1 1 1 1
. . S4931917-8X13 PIN 1 1 1 1
. . S4931917-8X16 PIN 1 1 1 1
. . S4931917-8X9 **Service Kit SA09570242 Notes**  **Name QTY**  **New Part Number -37**  **-35 -33**  **-31 -29**  **-27** NUT ASSY 22 22 15 15 22 22 3D0006-3 NUT ASSY 216 216 74 74 155 155 3D0006-4 NUT ASSY 57 57 17 17 40 40 3D0006-5 PIN 4 4
. . 4 4 3D0097-10X12 PIN 4 4
. . 4 4 3D0097-10X13 PIN 12 12
. . 12 12 3D0097-10X17

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 41 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-37 -35**  **-33 -31**  **-29 -27**  PIN 16 16
. . 16 16 3D0097-10X18 PIN 4 4
. . 4 4 3D0097-10X20 PIN 17 17 17 17
. . 3D0097-10X14 PIN 2 2
. . 2 2 3D0097-6-7 PIN 21 21
. . 21 21 3D0097-8X10 PIN 11 11
. . 11 11 3D0097-8X11 PIN 1 1
. . 1 1 3D0097-8X12 PIN 3 3
. . 3 3 3D0097-8X13 PIN 4 4
. . 4 4 3D0097-8X14 PIN 12 12
. . 12 12 3D0097-8X15 PIN 12 12
. . 12 12 3D0097-8X16 PIN 7 7 3 3 4 4 HL325-6-10 PIN 2 2
. . 2 2 HL325-6-11 PIN 7 7 5 5 2 2 HL325-6-12 PIN 15 15
. . 15 15 HL325-6-13 PIN 2 2 2 2
. . HL325-6-14 PIN 1 1 1 1
. . HL325-6-8 PIN 5 5 5 5
. . HL325-6-9 PIN 23 23 23 23
. . HL325-8-6 PIN 2 2 2 2
. . HL325-8-7 PIN 8 8 8 8
. . HL325-8-8 PIN, OVERSIZE 7 7 7 7
. . HLT1001PB-6-6 PIN 4 4
. . 4 4 HLT425-6-13 PIN 7 7 7 7
. . HLT425-8-10 PIN 17 17 17 17
. . HLT425-8-11 PIN 31 31 31 31
. . HLT425-8-9 PIN 6 6 6 6
. . HLT426-10-7 PIN 4 4 4 4 10 10 HLT426-10-18 PIN 44 44 35 35 56 56 HLT426-6-10 PIN 24 24 18 18 24 24 HLT426-6-12 PIN 4 4
. . 4 4 HLT426-6-13

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 42 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-37 -35**  **-33 -31**  **-29 -27**  PIN 18 18 18 18 2 2 HLT426-6-14 PIN 6 6 2 2 4 4 HLT426-6-15 PIN 8 8 4 4 4 4 HLT426-6-16 PIN 2 2 2 2
. . HLT426-6-17 PIN 3 3 3 3
. . HLT426-6-3 PIN 11 11 9 9 9 9 HLT426-6-4 PIN 22 22 22 22
. . HLT426-6-5 PIN 74 74 74 74 41 41 HLT426-6-6 PIN 50 50 22 22 30 30 HLT426-6-7 PIN 8 8 8 8 9 9 HLT426-6-8 PIN 98 98 98 98 85 85 HLT426-8-10 PIN 10 10 10 10 9 9 HLT426-8-11 PIN 108 108 108 108 109 109 HLT426-8-12 PIN 19 19 16 16 3 3 HLT426-8-13 PIN 14 14 14 14 24 24 HLT426-8-14 PIN 31 31 31 31
. . HLT426-8-15 PIN 7 7 1 1 12 12 HLT426-8-16 PIN 58 58 58 58
. . HLT426-8-17 PIN 18 18 18 18
. . HLT426-8-18 PIN 24 24 24 24
. . HLT426-8-19 PIN 16 16 16 16
. . HLT426-8-22 PIN 10 10 10 10
. . HLT426-8-24 PIN 32 32 28 28 32 32 HLT426-8-4 PIN 23 23 22 22 20 20 HLT426-8-5 PIN 28 28 26 26 28 28 HLT426-8-6 PIN 16 16 16 16 1 1 HLT426-8-7 PIN 83 83 83 83 74 74 HLT426-8-8 PIN 2 2
. . 2 2 HLT426-8-9 PIN 9 9 9 9
. . HLT427-10-18 PIN 12 12 12 12
. . HLT427-10-20 PIN 35 35 35 35
. . HLT427-10-22

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 43 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-37 -35**  **-33 -31**  **-29 -27**  PIN 6 6 6 6
. . HLT427-10-24 PIN 2 2 2 2
. . HLT427-10-26 PIN 5 5 5 5
. . HLT427-6-10 PIN 12 12 12 12 2 2 HLT427-6-11 PIN 10 10 10 10 10 10 HLT427-6-12 PIN 6 6 6 6
. . HLT427-6-14 PIN 2 2
. . 2 2 HLT427-6-7 PIN 2 2 2 2
. . HLT427-6-8 PIN 6 6 6 6
. . HLT427-6-9 PIN 43 43 34 34 9 9 HLT427-8-10 PIN 19 19 19 19
. . HLT427-8-11 PIN 49 49 49 49
. . HLT427-8-12 PIN 2 2
. . 2 2 HLT427-8-13 PIN 24 24 22 22 2 2 HLT427-8-14 PIN 5 5 1 1 4 4 HLT427-8-15 PIN 36 36 36 36 2 2 HLT427-8-16 PIN 56 56 56 56 2 2 HLT427-8-17 PIN 20 20 15 15 20 20 HLT427-8-18 PIN 21 21 2 2 21 21 HLT427-8-19 PIN 6 6 4 4 2 2 HLT427-8-20 PIN 3 3 1 1 2 2 HLT427-8-21 PIN 2 2 2 2
. . HLT427-8-22 PIN 2 2 2 2 2 2 HLT427-8-23 PIN 13 13 13 13
. . HLT427-8-24 PIN 2 2
. . 2 2 HLT427-8-25 PIN 2 2
. . 2 2 HLT427-8-26 PIN 11 11
. . 11 11 HLT427-8-27 PIN 10 10 10 10
. . HLT427-8-28 PIN 13 13 13 13
. . HLT427-8-6 PIN 4 4 4 4 1 1 HLT427-8-8 PIN 5 5 5 5 5 5 HLT427-8-9

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 44 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-37 -35**  **-33 -31**  **-29 -27**  PIN 5 5
. . 5 5 HLT437-6-6 ANGLE 1
. 1
. . . J060165-10 FILLER
. 1
. 1
. . J060165-13 FILLER 1
. 1
. . . J060165-14 FILLER 1 1 1 1
. . J060165-15 FILLER 1 1 1 1
. . J060165-17 FILLER 1 1 1 1
. . J060165-19 TEE
. . 1 1 1 1 J060165-21 STIFFENER 1 1 1 1
. . J060165-23 PLATE 1 1 1 1
. . J060165-27 ANGLE
. 1
. . . 1 J060165-31 ANGLE 1
. . . 1
. J060165-32 FILLER
. 1
. . . 1 J060165-33 FILLER 1
. . . 1
. J060165-34 FILLER
. 1
. 1
. 1 J060165-35 FILLER 1
. 1
. 1
. J060165-36 ANGLE
. 1
. . . 1 J060165-37 ANGLE 1
. . . 1
. J060165-38 DOUBLER
. 1
. . . 1 J060165-39 DOUBLER 1
. . . 1
. J060165-40 FILLER 1 1
. . 1 1 J060165-41 FILLER 1 1
. . 1 1 J060165-43 FILLER 1 1
. . 1 1 J060165-45 FILLER 1 1
. . 1 1 J060165-47 FILLER 1 1
. . 1 1 J060165-49 ANGLE
. 1
. 1
. . J060165-5 TEE 1 1
. . . . J060165-51 STIFFENER 1 1 1 1 1 1 J060165-53 SPLICE 1 1 1 1 1 1 J060165-55 SPACER 1 1 1 1
. . J060165-57 SPACER 1 1 1 1
. . J060165-59

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 45 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-37 -35**  **-33 -31**  **-29 -27**  ANGLE 1
. 1
. . . J060165-6 DOUBLER
. 1
. 1
. . J060165-61 DOUBLER 1
. 1
. . . J060165-62 SPAR CAP
. 1
. 1
. . J060165-63 SPAR CAP 1
. 1
. . . J060165-64 SPLICE 1 1 1 1 1 1 J060165-65 BUSHING 7 7 7 7
. . J060165-67 SPAR CAP
. 1
. . . 1 J060165-69 FILLER
. 1
. 1
. . J060165-7 SPAR CAP 1
. . . 1
. J060165-70 FILLER 1
. 1
. . . J060165-8 ANGLE
. 1
. 1
. . J060165-9 RIVET 3 3
. . 3 3 MS20426AD6-12D RIVET 18 18 18 18 4 4 MS20426AD6-14D RIVET 2 2 2 2
. . MS20426AD6-8D RIVET 5 5 5 5
. . MS20470AD4-6D RIVET 2 2 2 2
. . MS20470AD5-9D RIVET 63 63 71 71 63 63 MS20470AD6-10D RIVET 10 10 10 10 10 10 MS20470AD6-11D RIVET 22 22 29 29 22 22 MS20470AD6-12D RIVET 4 4 4 4 4 4 MS20470AD6-14D RIVET 4 4 4 4
. . MS20470AD6-15D RIVET 4 4 4 4
. . MS20470AD6-16D RIVET 48 48 58 58 48 48 MS20470AD6-8D RIVET 2 2
. . 2 2 MS20470AD6-9D RIVET 58 58 50 50 58 58 MS20470AD8-10D RIVET 4 4 4 4
. . MS20470AD8-11D RIVET 33 33 33 33 33 33 MS20470AD8-12D RIVET 28 28 28 28
. . MS20470AD8-13D RIVET 42 42 42 42 42 42 MS20470AD8-14D RIVET 4 4 4 4
. . MS20470AD8-16D

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 46 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-37 -35**  **-33 -31**  **-29 -27**  RIVET 1 1 1 1
. . MS20470AD8-17D RIVET 6 6 6 6
. . MS20470AD8-18D RIVET 1 1 1 1
. . MS20470AD8-19D RIVET 5 5 5 5
. . MS20470AD8-7D RIVET 18 18 18 18
. . MS20470AD8-9D NUT 273 273 191 191 218 218 MS21042L3 NUT 565 565 565 565 565 565 MS21042L4 NUT 84 84 84 84 10 10 MS21042L5 BOLT 2 2 2 2
. . NAS1203-4 BOLT 7 7 7 7
. . NAS1203-8 BOLT 8 8 8 8
. . NAS1204-12 BOLT 4 4 4 4
. . NAS1204-13 BOLT 1 1 1 1
. . NAS1204-14 BOLT 7 7 7 7
. . NAS1205-15 WASHER 273 273 191 191 228 228 NAS1252-10H WASHER 558 558 558 558 558 558 NAS1252-416H WASHER 91 91 81 81 10 10 NAS1252-516H WASHER 14 14 14 14 10 10 NAS1252-616H BOLT 1 1 1 1
. . NAS1704-8 BOLT 22 22 22 22
. . NAS6205-10 BOLT 8 8 8 8
. . NAS6205-16 BOLT 8 8 8 8
. . NAS6205-26 NUT 17 17 17 17
. . NAS679A5 BOLT 4 4 4 4
. . PIC239-3-10 BOLT 3 3 3 3
. . PIC239-3-15 PIN 6 6
. . 6 6 S4931917-8X10 PIN 6 6
. . 6 6 S4931917-8X11 PIN 1 1
. . 1 1 S4931917-8X13 PIN 1 1
. . 1 1 S4931917-8X16 PIN 1 1
. . 1 1 S4931917-8X9

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 47 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-49 -47**  **-45 -43**  **-41 -39**  NUT ASSY 22 22 15 15 22 22 3D0006-3 NUT ASSY 216 216 74 74 155 155 3D0006-4 NUT ASSY 57 57 17 17 40 40 3D0006-5 PIN 4 4
. . 4 4 3D0097-10X12 PIN 4 4
. . 4 4 3D0097-10X13 PIN 12 12
. . 12 12 3D0097-10X17 PIN 16 16
. . 16 16 3D0097-10X18 PIN 4 4
. . 4 4 3D0097-10X20 PIN 17 17 17 17
. . 3D0097-10X14 PIN 2 2
. . 2 2 3D0097-6-7 PIN 21 21
. . 21 21 3D0097-8X10 PIN 11 11
. . 11 11 3D0097-8X11 PIN 1 1
. . 1 1 3D0097-8X12 PIN 3 3
. . 3 3 3D0097-8X13 PIN 4 4
. . 4 4 3D0097-8X14 PIN 12 12
. . 12 12 3D0097-8X15 PIN 12 12
. . 12 12 3D0097-8X16 PIN 7 7 3 3 4 4 HL325-6-10 PIN 2 2
. . 2 2 HL325-6-11 PIN 7 7 5 5 2 2 HL325-6-12 PIN 15 15
. . 15 15 HL325-6-13 PIN 2 2 2 2
. . HL325-6-14 PIN 1 1 1 1
. . HL325-6-8 PIN 5 5 5 5
. . HL325-6-9 PIN 23 23 23 23
. . HL325-8-6 PIN 2 2 2 2
. . HL325-8-7 PIN 8 8 8 8
. . HL325-8-8 PIN, OVERSIZE 7 7 7 7
. . HLT1001PB-6-6 PIN 4 4
. . 4 4 HLT425-6-13 PIN 7 7 7 7
. . HLT425-8-10 PIN 17 17 17 17
. . HLT425-8-11

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 48 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-49 -47**  **-45 -43**  **-41 -39**  PIN 31 31 31 31
. . HLT425-8-9 PIN 4 4 4 4 10 10 HLT426-10-18 PIN 44 44 35 35 56 56 HLT426-6-10 PIN 24 24 18 18 24 24 HLT426-6-12 PIN 4 4
. . 4 4 HLT426-6-13 PIN 18 18 18 18 2 2 HLT426-6-14 PIN 6 6 2 2 4 4 HLT426-6-15 PIN 8 8 4 4 4 4 HLT426-6-16 PIN 2 2 2 2
. . HLT426-6-17 PIN 3 3 3 3
. . HLT426-6-3 PIN 11 11 9 9 9 9 HLT426-6-4 PIN 22 22 22 22
. . HLT426-6-5 PIN 74 74 74 74 41 41 HLT426-6-6 PIN 50 50 22 22 30 30 HLT426-6-7 PIN 8 8 8 8 9 9 HLT426-6-8 PIN 98 98 98 98 77 77 HLT426-8-10 PIN 10 10 10 10 9 9 HLT426-8-11 PIN 108 108 108 108 105 105 HLT426-8-12 PIN 19 19 16 16 3 3 HLT426-8-13 PIN 14 14 14 14 20 20 HLT426-8-14 PIN 31 31 31 31
. . HLT426-8-15 PIN 7 7 1 1 12 12 HLT426-8-16 PIN 58 58 58 58
. . HLT426-8-17 PIN 18 18 18 18
. . HLT426-8-18 PIN 24 24 24 24
. . HLT426-8-19 PIN 16 16 16 16
. . HLT426-8-22 PIN 10 10 10 10
. . HLT426-8-24 PIN 32 32 28 28 32 32 HLT426-8-4 PIN 23 23 22 22 20 20 HLT426-8-5 PIN 28 28 26 26 28 28 HLT426-8-6 PIN 16 16 16 16 1 1 HLT426-8-7

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 49 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-49 -47**  **-45 -43**  **-41 -39**  PIN 83 83 83 83 74 74 HLT426-8-8 PIN 2 2
. . 2 2 HLT426-8-9 PIN 6 6 6 6
. . HLT426-10-7 PIN 9 9 9 9
. . HLT427-10-18 PIN 12 12 12 12
. . HLT427-10-20 PIN 35 35 35 35
. . HLT427-10-22 PIN 6 6 6 6
. . HLT427-10-24 PIN 2 2 2 2
. . HLT427-10-26 PIN 5 5 2 2
. . HLT427-6-10 PIN 12 12 12 12 2 2 HLT427-6-11 PIN 10 10 10 10 10 10 HLT427-6-12 PIN 6 6 6 6
. . HLT427-6-14 PIN 2 2
. . 2 2 HLT427-6-7 PIN 2 2 2 2
. . HLT427-6-8 PIN 6 6
. . . . HLT427-6-9 PIN 43 43 34 34 9 9 HLT427-8-10 PIN 19 19 19 19
. . HLT427-8-11 PIN 49 49 49 49
. . HLT427-8-12 PIN 2 2
. . 2 2 HLT427-8-13 PIN 24 24 22 22 2 2 HLT427-8-14 PIN 5 5 1 1 4 4 HLT427-8-15 PIN 36 36 36 36 2 2 HLT427-8-16 PIN 56 56 56 56 2 2 HLT427-8-17 PIN 20 20 15 15 20 20 HLT427-8-18 PIN 21 21 2 2 21 21 HLT427-8-19 PIN 6 6 4 4 2 2 HLT427-8-20 PIN 3 3 1 1 2 2 HLT427-8-21 PIN 2 2 2 2
. . HLT427-8-22 PIN 2 2 2 2 2 2 HLT427-8-23 PIN 13 13 13 13
. . HLT427-8-24 PIN 2 2
. . 2 2 HLT427-8-25

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 50 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-49 -47**  **-45 -43**  **-41 -39**  PIN 2 2
. . 2 2 HLT427-8-26 PIN 11 11
. . 11 11 HLT427-8-27 PIN 10 10 10 10
. . HLT427-8-28 PIN 13 13 13 13 13 13 HLT427-8-6 PIN 4 4 4 4 1 1 HLT427-8-8 PIN 5 5 5 5 5 5 HLT427-8-9 PIN 5 5
. . 5 5 HLT437-6-6 ANGLE 1
. 1
. . . J060165-10 FILLER
. 1
. 1
. . J060165-13 FILLER 1
. 1
. . . J060165-14 FILLER 1 1 1 1
. . J060165-15 FILLER 1 1 1 1
. . J060165-17 FILLER 1 1 1 1
. . J060165-19 TEE
. . 1 1 1 1 J060165-21 STIFFENER 1 1 1 1
. . J060165-23 PLATE 1 1 1 1
. . J060165-27 ANGLE
. 1
. . . 1 J060165-31 ANGLE 1
. . . 1
. J060165-32 FILLER
. 1
. . . 1 J060165-33 FILLER 1
. . . 1
. J060165-34 FILLER
. 1
. . . 1 J060165-35 FILLER 1
. . . 1
. J060165-36 ANGLE
. 1
. . . 1 J060165-37 ANGLE 1
. . . 1
. J060165-38 DOUBLER
. 1
. . . 1 J060165-39 DOUBLER 1
. . . 1
. J060165-40 FILLER 1 1
. . 1 1 J060165-41 FILLER 1 1
. . 1 1 J060165-43 FILLER 1 1
. . 1 1 J060165-45 FILLER 1 1
. . 1 1 J060165-47 FILLER 1 1
. . 1 1 J060165-49

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 51 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-49 -47**  **-45 -43**  **-41 -39**  ANGLE
. 1
. 1
. . J060165-5 TEE 1 1
. . . . J060165-51 STIFFENER 1 1 1 1 1 1 J060165-53 SPLICE 1 1 1 1 1 1 J060165-55 SPACER 1 1 1 1
. . J060165-57 SPACER 1 1 1 1
. . J060165-59 ANGLE 1
. 1
. . . J060165-6 DOUBLER
. 1
. 1
. . J060165-61 DOUBLER 1
. 1
. . . J060165-62 SPAR CAP
. 1
. 1
. . J060165-63 SPAR CAP 1
. 1
. . . J060165-64 SPLICE 1 1 1 1 1 1 J060165-65 BUSHING 7 7 7 7
. . J060165-67 SPAR CAP
. 1
. . . 1 J060165-69 FILLER
. 1
. 1
. . J060165-7 SPAR CAP 1
. . . 1
. J060165-70 FILLER 1
. 1
. . . J060165-8 ANGLE
. 1
. 1
. . J060165-9 RIVET 3 3
. . 3 3 MS20426AD6-12D RIVET 18 18 18 18 4 4 MS20426AD6-14D RIVET 2 2 2 2
. . MS20426AD6-8D RIVET 5 5 5 5
. . MS20470AD4-6D RIVET 2 2 2 2
. . MS20470AD5-9D RIVET 63 63 71 71 63 63 MS20470AD6-10D RIVET 10 10 10 10 10 10 MS20470AD6-11D RIVET 22 22 29 29 22 22 MS20470AD6-12D RIVET 4 4 4 4 4 4 MS20470AD6-14D RIVET 4 4 4 4
. . MS20470AD6-15D RIVET 4 4 4 4
. . MS20470AD6-16D RIVET 48 48 58 58 48 48 MS20470AD6-8D RIVET 2 2
. . 2 2 MS20470AD6-9D

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 52 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-49 -47**  **-45 -43**  **-41 -39**  RIVET 58 58 50 50 58 58 MS20470AD8-10D RIVET 4 4 4 4
. . MS20470AD8-11D RIVET 33 33 33 33 33 33 MS20470AD8-12D RIVET 28 28 28 28
. . MS20470AD8-13D RIVET 42 42 42 42 36 36 MS20470AD8-14D RIVET 4 4 4 4
. . MS20470AD8-16D RIVET 1 1 1 1
. . MS20470AD8-17D RIVET 6 6 6 6
. . MS20470AD8-18D RIVET 1 1 1 1
. . MS20470AD8-19D RIVET 5 5 5 5
. . MS20470AD8-7D RIVET 18 18 18 18
. . MS20470AD8-9D NUT 273 273 191 191 218 218 MS21042L3 NUT 565 565 565 565 549 549 MS21042L4 NUT 84 84 84 84 10 10 MS21042L5 BOLT 2 2 2 2
. . NAS1203-4 BOLT 7 7 7 7
. . NAS1203-8 BOLT 8 8 8 8
. . NAS1204-12 BOLT 4 4 4 4
. . NAS1204-13 BOLT 1 1 1 1
. . NAS1204-14 BOLT 7 7 7 7
. . NAS1205-15 WASHER 273 273 191 191 228 228 NAS1252-10H WASHER 558 558 558 558 542 542 NAS1252-416H WASHER 91 91 81 81 10 10 NAS1252-516H WASHER 14 14 14 14 12 12 NAS1252-616H BOLT 1 1 1 1
. . NAS1704-8 BOLT 22 22 22 22
. . NAS6205-10 BOLT 8 8 8 8
. . NAS6205-16 BOLT 8 8 8 8
. . NAS6205-26 NUT 17 17 17 17
. . NAS679A5 BOLT 4 4 4 4
. . PIC239-3-10 BOLT 3 3 3 3
. . PIC239-3-15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 53 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit SA09570242**  **Notes Name**  **QTY New Part Number**  **-49 -47**  **-45 -43**  **-41 -39**  PIN 6 6
. . 6 6 S4931917-8X10 PIN 6 6
. . 6 6 S4931917-8X11 PIN 1 1
. . 1 1 S4931917-8X13 PIN 1 1
. . 1 1 S4931917-8X16 PIN 1 1
. . 1 1 S4931917-8X9 2. Parts and Materials Supplied by the Operator: **CAGE Supplier**  **QTY Part Number/Specifi-**  **cation** 92108 PRC-DeSoto International, Incorporated As Re- quired PR-1422 B-2 Sealant (DMS 2082) P.O. Box 1800 or Sylmar, California 91342 Equivalent 3. Parts Modified and Reidentified: The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane. **NOTE:**Not all repair configurations require part modifications.**Notes New Part Number**  **Name QTY**  **Existing Part Number**  (a) (b) (c) J060271-59 CAP 1 9919474-1 or 9919474-501 or 9919474-503 J060271-60 CAP 1 9919474-2 or 9919474-502 or 9919474-504 J060271-61 ANGLE 1 9919472-23 J060271-62 ANGLE 1 9919472-24 (a) Make the change in accordance with in this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change done in accordance with this service bulletin was made. (c) This part is not used in production.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 54 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 55 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 56 of 71 **BOEING SERVICE BULLETIN MD80-57A242 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:**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. **CAUTION:**ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE TO THE AIRPLANE OR EQUIPMENT. **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 SRM, Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 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, Chapter 51. — Torque limits to tighten nuts and bolts are in MD-80 SRM,Chapter 51.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 57 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**8. Refer to the Standard Wiring Practices Manual 20-10-01 for the wire installation procedures. 9. Obey all of the warnings and cautions given in the specified manual sections and Service Rework Drawings. 10. Refer to the following MD-80 SRM Chapters as and accepted procedure for the applicable operation: MD80 SRM 51-10-03 - Corrosion and Dissimilar Metals Protection. MD80 SRM 51-10-04 - Drilling and Countersinking. MD80 SRM 51-20-00 - Sealing Methods. MD80 SRM 51-30-01 - Installing Bolts, Screws, and Washers. MD80 SRM 51-30-02 - Removing and Installing Rivets. MD80 SRM 51-30-03 - Removing and Installing Lockbolts. MD80 SRM 51-30-05 - Removing and Installing Hi-Loks. MD80 SRM 51-30-09 - Split Sleeve Cold Work. MD80 SRM 51-30-11 - Conical Spacers (Countersink Washers). MD80 SRM 51-30-60 - Substitution and Interchangeability 11. Follow applicable safety instructions and precautions in accordance with NDTSPM 01-00-01 and NDTSPM 06-00-01. 12. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 13. 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. 14. 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. 15. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 58 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**16. 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. 17. 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. 18. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. **B. WORK INSTRUCTIONS Group 1, Configuration 1:**  Continue repeat inspections in accordance with Service Bulletin MD80-57-184, Paragraph 2.AZ., Accomplishment Instructions. **Group 1, Configuration 2; Group 2-4:** 1. Fabricate DAC GSET AL.01 reference standard. Refer to NDTSPM Part 06, 06-20-01 as an accepted procedure. **WARNING:**BEFORE MOVING FLAP/SLAT HANDLE, MAKE CERTAIN THAT AREAS AROUND FLAPS AND SLATS ARE CLEAR OF PERSONNEL AND EQUIPMENT. 2. Extend wing flaps to full down position. Refer to MD80 AMM 27-51-01 as an accepted procedure. 3. Depressurize left and right hydraulic systems. Refer to MD80 AMM 29-00-00 as an accepted procedure. 4. Open main landing gear doors and install door keepers. Refer to MD80 AMM 32-10-00 as an accepted procedure. 5. Open or remove and retain inboard and center bent up trailing edge (BUTE) doors. Refer to MD80 AMM 57-20-03 as an accepted procedure to remove BUTE doors. 6. Open access door 1501C (left wing) and 1601C (right wing). Refer to MD80 AMM 06-21-00. 7. At operators option for ease of access, remove the fixed portion of the flap hinge fairing. 8. Clean area at top of flap hinge fitting and around and under flap hinge fitting and visually inspect for evidence of fuel leakage or if fuel tanks have been drained, visually inspect for cracks. 9. Do Eddy Current, High Frequency inspection (ETHF) on the aft side of the left and right wing rear spar lower caps at station Xrs=164.000 for cracks in accordance with Figure 1 and Drawing J060271, General Note 29, and based on findings do as follows: **CONDITION 1: NO CRACK** a. Do repeat inspect on the aft side of the left and right wing rear spar lower caps at station Xrs=164.000.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 59 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT CONDITION 2: LOWER SPAR CAP HAS A CRACK 2.0 INCHES OR LESS IN LENGTH AND**  **NOT IN THE REAR SPAR CAP FORWARD HORIZONTAL LEG RADIUS** a. Disconnect aileron control, aileron trim, aileron bus, and outboard spoiler mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides. Refer to MD80 AMM 27-10-00, MD80 AMM 27-51-01, and MD80 AMM 27-60-00 as accepted procedures. **NOTE:**Only cables which run through the lightening hole of flap hinge fitting at station Xrs=164.000 need to be disconnected. b. Defuel and purge left and right fuel tanks if/as required. Refer to MD80 AMM 28-00-00 and MD80 AMM 28-10-01 as accepted procedures. c. Remove and retain door number 1307 on the left wing main tank and door number 1410 on the right wing main tank and attaching parts. Refer to MD80 AMM 06-21-00. d. Prepare fuel tanks for entry and gain access to fuel tanks as required to reach attachments of flap hinge fitting at station Xrs=164.000. e. Remove and retain the inboard hinge fitting for the left and/or right wing outboard flap attaching parts (including any shims) at station Xrs=164.000. Refer to MD80 AMM 57-40-01 as an accepted procedure. f. Do ETHF inspection on the aft side of the left and/or right wing rear spar upper cap at station Xrs=164.000 for cracks in accordance with Figure 1 and Drawing J060271, General Note 29 and based on inspection results do as follows: **Condition 2a: No Crack in Rear Upper Spar Cap** (1) Repair the lower spar lower cap using Option 1 or Option 2 as follows: (a) Option 1: 1) Do doubler repair to rear spar lower cap in accordance with Service Rework Drawing J060271 using the applicable service kit as follows: **Service Kit Configuration**  **Rear Spar Cap Repair Right Wing**  **Left Wing** SA09570242-3 - J060271-509 Lower SA09570242-5 J060271-510 - Lower 2) Do ETHF inspections of rear spar lower cap repair in accordance with Service Sketch 3668XXX Revision C. (b) Option 2: 1) Do splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165 using the applicable service kit as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 60 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2:**  **Service Kit Configuration**  **Rear Spar Cap Repair Right Wing**  **Left Wing** SA09570242-19 - J060165-511 Lower SA09570242-21 J060165-512 - Lower **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-31 - J060165-519 Lower SA09570242-33 J060165-520 - Lower **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-43 - J060165-525 Lower SA09570242-45 J060165-526 - Lower 2) Do Eddy Current, Low Frequency (ETLF) and Ultrasonic (UT) inspections of rear spar lower cap splice repair in accordance with MD80 SID Volume II, Section 57.80.012, Sequence 1, Method 1 on forward side and SN90570006 on aft side. **Condition 2b: Upper Spar Cap has a Crack 2.0 Inches or Less in Length and Not in the Rear Spar Cap Forward Horizontal Leg Radius**  (1) Repair the upper and lower spar caps using Option 1 or Option 2. **NOTE:**Operators can do Option 1 or Option 2 or any combination of Options 1 and 2. (a) Option 1: 1) Do doubler repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060271 using the applicable service kit as follows: **Service Kit Configuration**  **Rear Spar Cap Repair Right Wing**  **Left Wing** SA09570242-11 - J060271-513 Upper and Lower

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 61 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-13 J060271-514 - Upper and Lower 2) Do ETHF inspections of rear spar upper and lower cap doubler repair in accordance with Service Sketch 3668XXX Revision C. (b) Option 2: 1) Do splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: **Group 1, Configuration 2; Group 2: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-23 - J060165-515 Upper and Lower SA09570242-25 J060165-516 - Upper and Lower **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-35 - J060165-521 Upper and Lower SA09570242-37 J060165-522 - Upper and Lower **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-47 - J060165-527 Upper and Lower SA09570242-49 J060165-528 - Upper and Lower 2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with MD80 SID Volume II, Section 57.80.012, Sequence 1, Method 1 on forward side and SN90570006 on aft side. **Condition 2c: Upper Spar Cap Has a Crack Longer than 2.0 Inches in Length or Crack in the Rear Spar Cap Forward Horizontal Leg Radius**  (1) Repair the upper and lower spar caps using Option 1 or Option 2. **NOTE:**Operators can do Option 1 or Option 2 or any combination of Options 1 and 2. (a) Option 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 62 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**1) Do doubler repair to rear spar lower cap in accordance with Service Rework Drawing J060271 and splice repair to rear spar upper cap in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: **Group 1, Configuration 2; Group 2: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-3 - J060271-509 Lower SA09570242-5 J060271-510 - Lower SA09570242-15 - J060165-513 Upper SA09570242-17 J060165-514 - Upper **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-3 - J060271-509 Lower SA09570242-5 J060271-510 - Lower SA09570242-27 - J060165-517 Upper SA09570242-29 J060165-518 - Upper **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-3 - J060271-509 Lower SA09570242-5 J060271-510 - Lower SA09570242-39 - J060165-523 Upper SA09570242-41 J060165-524 - Upper 2) Do ETHF inspections of rear spar lower cap doubler repair in accordance with Service Sketch 3668XXX Revision C. (b) Option 2: 1) Do splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165 using the applicable service kit as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 63 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 1, Configuration 2; Group 2:**  **Service Kit Configuration**  **Rear Spar Cap Repair Right Wing**  **Left Wing** SA09570242-23 - J060165-515 Upper and Lower SA09570242-25 J060165-516 - Upper and Lower **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-35 - J060165-521 Upper and Lower SA09570242-37 J060165-522 - Upper and Lower **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-47 - J060165-527 Upper and Lower SA09570242-49 J060165-528 - Upper and Lower 2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with MD80 SID Volume II, Section 57.80.012, Sequence 1, Method 1 on forward side and SN90570006 on aft side. g. Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD80 AMM 57-40-01 as an accepted procedure. h. Install door number 1307 on the left wing main tank and/or door number 1410 on the right wing main tank and attaching parts. Refer to MD80 AMM 06-21-00 . i. Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides. Refer to MD80 AMM 27-10-00, MD80 AMM 27-51-01, and MD80 AMM 27-60-00 as an accepted procedure. **CONDITION 3: LOWER SPAR CAP HAS A CRACK LONGER THAN 2.0 INCHES IN LENGTH OR CRACK IN THE REAR SPAR CAP FORWARD HORIZONTAL LEG RADIUS**  a. Disconnect aileron control, aileron trim, aileron bus, and outboard spoiler mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides. Refer to MD80 AMM 27-10-00, MD80 AMM 27-51-01, and MD80 AMM 27-60-00 as accepted procedures.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 64 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT NOTE:** Only cables which run through the lightening hole of flap hinge fitting at station Xrs=164.000 need to be disconnected. b. Defuel and purge left and right fuel tanks if/as required. Refer to MD80 AMM 28-00-00 and MD80 AMM 28-10-01 as accepted procedures. c. Remove and retain door number 1307 on the left wing main tank and door number 1410 on the right wing main tank and attaching parts. Refer to MD80 AMM 06-21-00. d. Prepare fuel tanks for entry and gain access to fuel tanks as required to reach attachments in vicinity of wing flap inboard hinge fitting. e. Remove and retain the inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD80 AMM 57-40-01 as an accepted procedure. f. Do eddy current testing high frequency inspection (ETHF) on the aft side of the left and/or right wing rear spar upper caps at station Xrs=164.000 for cracks in accordance with Figure 1 and Drawing J060271, General Note 29 and based on inspection results do as follows: **Condition 3a: No Crack in Rear Spar Upper Cap** (1) Do splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: **Group 1, Configuration 2; Group 2: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-19 - J060165-511 Lower SA09570242-21 J060165-512 - Lower **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-31 - J060165-519 Lower SA09570242-33 J060165-520 - Lower **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-43 - J060165-525 Lower

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 65 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 4:**  **Service Kit Configuration**  **Rear Spar Cap Repair Right Wing**  **Left Wing** SA09570242-45 J060165-526 - Lower (2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with MD80 SID Volume II, Section 57.80.012, Sequence 1, Method 1 on forward side and SN90570006 on aft side. **Condition 3b: Crack 2.0 Inches or Less in Length in Rear Spar Upper Cap and Not in the Rear Spar Upper Cap Forward Horizontal Leg Radius**  (1) Option 1: (a) Do doubler repair to rear spar upper cap in accordance with Service Rework Drawing J060271 and splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165. using the applicable service kit as follows: **Group 1, Configuration 2; Group 2: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-7 - J060271-511 Upper SA09570242-9 J060271-512 - Upper SA09570242-19 - J060165-511 Lower SA09570242-21 J060165-512 - Lower **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-7 - J060271-511 Upper SA09570242-9 J060271-512 - Upper SA09570242-31 - J060165-519 Lower SA09570242-33 J060165-520 - Lower **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-7 - J060271-511 Upper

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 66 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 4:**  **Service Kit Configuration**  **Rear Spar Cap Repair Right Wing**  **Left Wing** SA09570242-9 J060271-512 - Upper SA09570242-43 - J060165-525 Lower SA09570242-45 J060165-526 - Lower (b) Do ETHF inspections of rear spar upper cap doubler repair in accordance with Service Sketch 3668XXX Revision C. (c) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with MD80 SID Volume II, Section 57.80.012, Sequence 1, Method 1 on forward side and SN90570006 on aft side. (2) Option 2: (a) Do splice repair to rear spar upper and lower cap in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: **Group 1, Configuration 2; Group 2: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-23 - J060165-515 Upper and Lower SA09570242-25 J060165-516 - Upper and Lower **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-35 - J060165-521 Upper and Lower SA09570242-37 J060165-522 - Upper and Lower **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-47 - J060165-527 Upper and Lower

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 67 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT Group 4:**  **Service Kit Configuration**  **Rear Spar Cap Repair Right Wing**  **Left Wing** SA09570242-49 J060165-528 - Upper and Lower (b) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with MD80 SID Volume II, Section 57.80.012, Sequence 1, Method 1 on forward side and SN90570006 on aft side. **Condition 3c: Crack Longer than 2.0 Inches in Length in Rear Spar Upper Cap or Crack in Rear Spar Upper Cap Forward Horizontal Leg Radius**  (1) Do splice repair to rear spar upper and lower caps in accordance with Service Rework Drawing J060165 using the applicable service kit as follows: **Group 1, Configuration 2; Group 2: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-23 - J060165-515 Upper and Lower SA09570242-25 J060165-516 - Upper and Lower **Group 3: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-35 - J060165-521 Upper and Lower SA09570242-37 J060165-522 - Upper and Lower **Group 4: Service Kit**  **Configuration Rear Spar Cap Repair**  **Right Wing Left Wing**  SA09570242-47 - J060165-527 Upper and Lower SA09570242-49 J060165-528 - Upper and Lower (2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with MD80 SID Volume II, Section 57.80.012, Sequence 1, Method 1 on forward side and SN90570006 on aft side.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 68 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**g. Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching parts (including any shims) at station Xrs=164.000. Refer to MD80 AMM 57-40-01 as an accepted procedure. h. Install door number 1307 on the left wing main tank and/or door number 1410 on the right wing main tank and attaching parts. Refer to MD80 AMM 06-21-00 . i. Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides. Refer to MD80 AMM 27-10-00, MD80 AMM 27-51-01, and MD80 AMM 27-60-00 as accepted procedures. 10. Close or install retained inboard and center bent up trailing edge (BUTE) doors. Refer to MD80 AMM 57-20-03 as an accepted procedure for installation of BUTE doors. 11. If removed, install the fixed portion of the flap hinge fairing. 12. Remove door keepers and close main landing gear doors. Refer to MD80 AMM 32-10-0 as an accepted procedure. 13. Pressurize left and right hydraulic systems. Refer to MD80 AMM 29-00-00 as an accepted procedure. 14. Retract wing flaps to full up position. Refer to MD80 AMM 27-51-01 as an accepted procedure. 15. Put the airplane back to serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1: January 07, 2011 69 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH**  **FREQUENCY INSPECTION (SHEET 1 OF 2)** 
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1 January 07, 2011 70 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b) 1 5911301-XXX Lower Rear Spar Cap Inspect (Scan 1) Eddy Current Testing High Frequency (ETHF) 1 (a) (b) 1 5911300-XXX Upper Rear Spar Cap Inspect (Scan 2) Eddy Current Testing High Frequency (ETHF) 2 Note: Inspection not required when Lower Rear Spar Cap has no crack. (a) Use calibration scan method "R" and calibrate the N2 notch using DAC GSET AL.01 in accordance with NDTSPM 06-10-01.001, Procedure 1. Scan wing rear spar upper and lower caps with method 45. (b) The -XXX represents any dash number spar cap(s) that may exist on your airplane.

**FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH FREQUENCY INSPECTION**  **(SHEET 2 OF 2)**
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 08, 2009 MD80-57A242 Revision 1 January 07, 2011 71 of 71 **BOEING SERVICE BULLETIN MD80-57A242 ALERT**  **ALERT**