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.

ECCN: 9E991

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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Unpublished Work - All Rights Reserved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

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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

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Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

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7.0
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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

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BLANK PAGE
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.

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9. 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

Original Issue: May 08, 2009

Revision 1: January 07, 2011

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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

Flight-Hours Landing Cycles

51,193 to 69,453 35,286 to 39,338

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.

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INDUSTRY SUPPORT INFORMATION

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

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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BLANK PAGE
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

GROUP CONFIGURATION DESCRIPTION

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

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Fuselage Num- Group

ber

938 1

941 1

944 1

948 1

950 1

952 - 953 1

957 1

962 1

966 - 967 1

969 - 971 1

973 1

978 1

981 1

986 1

988 1

992 1

994 - 995 1

999 - 1001 1

1004 - 1006 1

1011 - 1012 1

1016 1

1018 - 1019 1

1028 1

1031 1

1034 1

1043 1

1045 1

1047 1

1049 1

1051 1

1053 1

1055 1

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Fuselage Num- Group

ber

1057 1

1059 - 1060 1

1063 - 1071 1

1073 1

1075 - 1080 1

1082 1

1085 1

1087 - 1092 1

1095 - 1103 1

1105 - 1110 1

1112 - 1117 1

1119 - 1128 1

1130 1

1133 - 1145 1

1147 - 1172 1

1174 - 1181 1

1183 - 1203 1

1205 - 1206 1

1208 - 1223 1

1225 - 1260 1

1262 - 1290 1

1292 1

1294 - 1314 1

1316 - 1323 1

1325 1

1327 - 1334 1

1336 - 1342 1

1344 - 1350 1

1352 - 1395 1

1397 - 1451 1

1453 - 1469 1

1470 - 1477 2

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Fuselage Num- Group

ber

1479 - 1481 2

1482 3

1483 - 1503 2

1505 - 1513 2

1514 3

1515 2

1516 - 2007 3

2009 - 2016 3

2019 - 2034 3

2036 - 2069 3

2071 - 2093 3

2101 - 2114 3

2116 3

2118 - 2119 3

2121 3

2124 3

2127 3

2130 3

2132 3

2134 - 2135 3

2137 3

2139 3

2145 3

2148 3

2151 - 2152 3

2155 3

2167 3

2174 3

2176 3

2178 3

2180 3

2183 3

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Fuselage Num- Group

ber

2185 3

2187 3

2189 3

2192 3

2196 3

2199 3

2201 3

2204 3

2206 3

2208 3

2214 3

2218 4

2234 4

2239 4

2241 4

2244 4

2247 4

2249 4

2252 4

2254 4

2264 - 2287 4

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.

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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

Flight-Hours Landing Cycles

66,260 to 69,453 35,286 to 37,006

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.

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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):

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(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

Model Zone

DC-9-81 (MD-81), DC-9-82 13, 14, 15, 16

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

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ALERT ALERT
Group 4:

Affected Maintenance Zones

Model Zone

DC-9-83 (MD-83) 13, 14, 15, 16

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 Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,360 -

flight cycles after

the original issue

date 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 flight

cycles 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 upper

cap 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

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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 Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further - -

flight.

Option 1:

Do doubler repair of rear spar lower

cap in accordance with Accomplishment Instructions 3.B.

Condition 2a

No Crack in Rear Upper Spar Cap.

AND

Within

7,000 flight

cycles 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 flight

cycles after doing

the ETLF

and 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.

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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 Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

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 flight

cycles 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 and

lower 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 flight

cycles after doing

the ETLF

and UT inspection.

Within 22,000 -

flight cycles after

splice repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instructions 3.B.

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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 Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further - -

flight.

Option 1:

Do splice repair of rear spar upper

cap and doubler repair of rear spar

lower 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 Radius AND

Within

7,000 flight

cycles 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 flight

cycles after doing

the ETLF

and UT inspection.

Within 22,000 -

flight cycles after

splice repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instructions 3.B.

Before further - -

flight.

Do ETHF inspection of the left

and/or right wing rear spar upper

cap 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.

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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 Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further -

flight.

Do splice repair of rear spar lower

cap in accordance with Accomplishment Instructions 3.B.

Condition 3a:

No crack in rear spar

upper cap.

AND

Within

2,900 flight

cycles after doing

the ETLF

and UT inspection.

Within 22,000

flight cycles after

splice repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instructions 3.B.

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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 Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further - -

flight.

Option 1:

Do doubler repair of rear spar upper

cap and splice repair of rear spar

lower 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 Radius AND

Within

7,000 flight

cycles 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 flight

cycles after doing

the ETLF

and UT inspection.

Within 22,000 -

flight cycles after

splice repair.

Do ETLF and UT inspections 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 flight

cycles after doing

the ETLF

and UT inspection.

Within 22,000 -

flight cycles after

splice repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instructions 3.B.

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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 Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

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 Radius

AND

Within

2,900 flight

cycles after doing

the ETLF

and UT inspection.

Within 22,000 -

flight cycles after

splice repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap 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

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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

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 2 1.0 0.5

Inspect 2 4.0 2.0

Close Access 2 1.0 0.5

TOTAL FOR EACH WING 6.0 3.0

TABLE 2: DOUBLER REPAIR

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 2 1.0 0.5

Inspect 2 4.0 2.0

Open Access to 2 1.0 0.5

tanks.

Defuel 1 4.0 4.0

Purge 1 8.0 8.0

Repair 2 200.0* 100.0*

Close Access 2 1.0 0.5

Test 2 4.0 2.0

TOTAL FOR EACH WING 223.0* 117.5*

* Actual task hours and elapsed hours for repair are contingent upon inspection

results.

TABLE 3: SPLICE REPAIR

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 2 1.0 0.5

Inspect 2 4.0 2.0

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
TABLE 3: SPLICE REPAIR

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access to 2 1.0 0.5

tanks

Defuel 1 4.0 4.0

Purge 1 8.0 8.0

Repair 2 400.0* 200.0*

Close Access 2 1.0 0.5

Test 2 4.0 2.0

TOTAL FOR EACH WING 423.0* 317.5*

* 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:

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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:

Drawing No Title Sheet DCN/REV ADCN

EDDY CURRENT INSPECTION - WING DWG C -

REAR SPAR TEMPORARY REPAIR STA

Xrs=164

3668XXX

SERVICE REWORK - WING REAR SPAR AEO U Y

CAP SPLICE SERVICE REWORK DWG

J060165

AEO U Z

AEO U V

AEO U W

DWG U AA

SERVICE REWORK - TEMP REPAIR, DWG T U

WING REAR SPAR XRS=164.000

J060271

INSPECTION - REAR SPAR AFT TANG DWG - -

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.

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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 Bulletin (Calendar Days)

Kit Number Name

SA09570242-3 Service Kit 17 43,417.00

SA09570242-5 Service Kit 17 43,517.00

SA09570242-7 Service Kit 17 40,435.00

SA09570242-9 Service Kit 17 40,435.00

SA09570242-11 Service Kit 17 74,903.00

SA09570242-13 Service Kit 17 76,744.00

SA09570242-15 Service Kit 17 80,082.00

SA09570242-17 Service Kit 17 77,920.00

SA09570242-19 Service Kit 17 140,805.00

SA09570242-21 Service Kit 17 140,805.00

SA09570242-23 Service Kit 17 205,700.00

SA09570242-25 Service Kit 17 205,700.00

SA09570242-27 Service Kit 17 140,118.00

SA09570242-29 Service Kit 17 138,473.00

SA09570242-31 Service Kit 17 70,974.00

SA09570242-33 Service Kit 17 76,359.00

SA09570242-35 Service Kit 17 205,257.00

SA09570242-37 Service Kit 17 203,095.00

SA09570242-39 Service Kit 17 140,127.00

SA09570242-41 Service Kit 17 140,127.00

SA09570242-43 Service Kit 17 76,924.00

SA09570242-45 Service Kit 17 74,762.00

SA09570242-47 Service Kit 17 202,352.00

SA09570242-49 Service Kit 17 203,095.00

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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

Service Kit Drawing Configuration Description

Doubler Repair for Cracks in Rear Spar Lower Cap (Left

Wing)

SA09570242-3 J060271-509

Doubler Repair for Cracks in Rear Spar Lower Cap (Right

Wing)

SA09570242-5 J060271-510

Doubler Repair for Cracks in Rear Spar Upper Cap (Left

Wing)

SA09570242-7 J060271-511

Doubler Repair for Cracks in Rear Spar Upper Cap (Right

Wing)

SA09570242-9 J060271-512

Doubler Repair for Cracks in Rear Spar Upper and Lower

Cap (Left Wing)

SA09570242-11 J060271-513

Doubler Repair for Cracks in Rear Spar Upper and Lower

Cap (Right Wing)

SA09570242-13 J060271-514

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Table 1: Service Kit Applicability

Service Kit Drawing Configuration Description

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)

SA09570242-15 J060165-511

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)

SA09570242-17 J060165-512

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)

SA09570242-19 J060165-513

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)

SA09570242-21 J060165-514

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)

SA09570242-23 J060165-515

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)

SA09570242-25 J060165-516

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)

SA09570242-27 J060165-517

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)

SA09570242-29 J060165-518

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)

SA09570242-31 J060165-519

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)

SA09570242-33 J060165-520

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)

SA09570242-35 J060165-521

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)

SA09570242-37 J060165-522

Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a machined bulkhead at wing station

Xrs=137.750 (Left Wing)

SA09570242-39 J060165-523

Splice Repair for Cracks in Rear Spar Upper Cap on airplanes with a machined bulkhead at wing station

Xrs=137.750 (Right Wing)

SA09570242-41 J060165-524

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31 of 71

BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Table 1: Service Kit Applicability

Service Kit Drawing Configuration Description

Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a machined bulkhead at wing station

Xrs=137.750 (Left Wing)

SA09570242-43 J060165-525

Splice Repair for Cracks in Rear Spar Lower Cap on airplanes with a machined bulkhead at wing station

Xrs=137.750 (Right Wing)

SA09570242-45 J060165-526

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)

SA09570242-47 J060165-527

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)

SA09570242-49 J060165-528

Service Kit SA09570242

New Part Number QTY Name Notes

-3 -5 -7 -9 -11 -13

2917053-501 1 1 . . 1 1 WASHER

2917053-509 1 1 . . 1 1 WASHER

3D0006-4 19 19 27 27 46 46 NUT ASSY

SPACER CONICAL4894213-1 . . 26 26 26 26

SPACER CONICAL4894213-501 18 18 . . 18 18

4894213-503 47 47 50 50 97 97 SPACER

CONICAL SPACER4894213-505 7 7 . . 7 7

CONICAL SPACER4894213-547 4 4 4 4 8 8

9910010-39 1 1 1 1 1 1 STIFFENER

9924775-27 . . 1 . . . CLIP

9924775-28 . . . 1 . . CLIP

HL328-6-10 4 4 . . 4 4 PIN

HL328-6-18 4 4 . . 4 4 PIN

HL328-6-8 . . 6 6 6 6 PIN

HL328-8-10 6 6 14 14 20 20 PIN

HL328-8-6 3 3 . . 3 3 PIN

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-3 -5 -7 -9 -11 -13

HL328-8-8 5 5 . . 5 5 PIN

HL329-6-14 3 3 . . 3 3 PIN

HL329-6-16 2 2 . . 2 2 PIN

HL329-6-5 15 15 . . 15 15 PIN

HL329-6-6 . . 16 16 16 16 PIN

HLT1001PB-6-10 4 4 . . . . PIN, OVERSIZE

HLT1001PB-6-12 2 2 26 26 28 28 PIN, OVERSIZE

HLT1001PB-6-14 8 8 7 7 15 15 PIN, OVERSIZE

HLT1001PB-6-16 8 8 . . 8 8 PIN, OVERSIZE

HLT1001PB-6-18 2 2 . . 2 2 PIN, OVERSIZE

HLT1001PB-8-10 2 2 . . 2 2 PIN, OVERSIZE

HLT1001PB-8-12 10 10 2 2 12 12 PIN, OVERSIZE

HLT1001PB-8-14 19 19 29 29 48 48 PIN, OVERSIZE

HLT1001PB-8-16 6 6 1 1 7 7 PIN, OVERSIZE

HLT1001PB-8-18 11 11 18 18 29 29 PIN, OVERSIZE

HLT428-6-8 5 5 6 6 11 11 PIN

HLT428-8-10 13 13 13 13 26 26 PIN

HLT428-8-12 20 20 32 32 52 52 PIN

HLT428-8-8 2 2 . . 2 2 PIN

HLT629-8-6 . . 1 1 1 1 PIN, OVERSIZE

HLT629-8-7 2 2 . . 2 2 PIN, OVERSIZE

J060271-13 . . . . 1 1 SHIM

J060271-17 . . . . 1 1 SHIM

J060271-19 1 1 1 1 . . SHIM

J060271-21 1 1 1 1 . . SHIM

J060271-27 . . 1 . 1 . DOUBLER

J060271-28 . . . 1 . 1 DOUBLER

J060271-31 1 1 . . 1 1 FILLER

J060271-33 1 . . . 1 . CLIP

J060271-34 . 1 . . . 1 CLIP

J060271-35 1 . . . 1 . CLIP

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-3 -5 -7 -9 -11 -13

J060271-36 . 1 . . . 1 CLIP

J060271-37 2 2 . . 2 2 SPACER

J060271-39 . . 1 . 1 . DOUBLER

J060271-40 . . . 1 . 1 DOUBLER

J060271-41 . . 1 . 1 . DOUBLER

J060271-42 . . . 1 . 1 DOUBLER

J060271-43 1 . . . 1 . DOUBLER

J060271-44 . 1 . . . 1 DOUBLER

J060271-45 1 . . . 1 . DOUBLER

J060271-46 . 1 . . . 1 DOUBLER

J060271-47 1 . . . 1 . DOUBLER

J060271-48 . 1 . . . 1 DOUBLER

J060271-49 1 1 . . 1 1 FILLER

J060271-51 1 1 . . 1 1 FILLER

J060271-53 1 1 . . 1 1 SHIM

J060271-57 1 1 1 1 1 1 STIFFENER

J060271-65 1 . . . 1 . TEE

J060271-66 . 1 . . . 1 TEE

J060271-67 1 . . . 1 . RADIUS BLOCK

J060271-68 . 1 . . . 1 RADIUS BLOCK

MS20470AD6-10D 2 2 2 2 2 2 RIVET

MS20470AD6-8D . . 2 2 2 2 RIVET

MS20470AD6-9D 3 3 3 3 3 3 RIVET

MS20470AD8-12D 16 16 16 16 16 16 RIVET

MS21042L3 48 48 57 57 105 105 NUT

MS21042L4 89 89 107 107 196 196 NUT

MS21059L3 2 2 . . 2 2 NUTPLATE

NAS1252-10H 28 28 22 22 50 50 WASHER

NAS1252-416H 14 14 14 14 28 28 WASHER

NAS1401-3D3 . . 24 24 24 24 WASHER

PIC239-3-10 4 4 . . 4 4 BOLT

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-3 -5 -7 -9 -11 -13

PIC239-3-15 3 3 . . 3 3 BOLT

PIC239-3-17 . . 3 3 . . BOLT

PIC239-3-6 2 2 . . 2 2 BOLT

S2931983-30A06 20 20 35 35 55 55 WASHER

S2931983-40A06 85 85 95 95 180 180 WASHER

Service Kit SA09570242

New Part Number QTY Name Notes

-15 -17 -19 -21 -23 -25

3D0006-3 15 15 22 22 22 22 NUT ASSY

3D0006-4 61 61 155 155 216 216 NUT ASSY

3D0006-5 17 17 40 40 57 57 NUT ASSY

3D0097-10X12 . . 4 4 4 4 PIN

3D0097-10X13 . . 4 4 4 4 PIN

3D0097-10X17 . . 12 12 12 12 PIN

3D0097-10X18 . . 16 16 16 16 PIN

3D0097-10X20 . . 4 4 4 4 PIN

3D0097-8X10 . . 21 21 21 21 PIN

3D0097-8X11 . . 11 11 11 11 PIN

3D0097-8X12 . . 1 1 1 1 PIN

3D0097-8X13 . . 3 3 3 3 PIN

3D0097-8X14 . . 4 4 4 4 PIN

3D0097-8X15 . . 12 12 12 12 PIN

3D0097-8X16 . . 12 12 12 12 PIN

3D0097-10X14 17 17 . . 17 17 PIN

3D0097-6-7 . . 2 2 2 2 PIN

HL325-6-10 3 3 4 4 7 7 PIN

HL325-6-11 . . 2 2 2 2 PIN

HL325-6-12 5 5 2 2 7 7 PIN

HL325-6-13 . . 15 15 15 15 PIN

HL325-6-14 2 2 . . 2 2 PIN

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-15 -17 -19 -21 -23 -25

HL325-6-8 1 1 . . 1 1 PIN

HL325-6-9 5 5 . . . . PIN

HL325-8-5 7 7 . . . . PIN

HL325-8-6 23 23 . . 23 23 PIN

HL325-8-7 2 2 . . . . PIN

HL325-8-8 8 8 . . . . PIN

HLT1001PB-6-6 7 7 . . 7 7 PIN, OVERSIZE

HLT425-6-13 . . 4 4 4 4 PIN

HLT425-8-10 7 7 . . . . PIN

HLT425-8-11 17 17 . . . . PIN

HLT425-8-9 31 31 . . . . PIN

HLT426-10-18 4 4 10 10 10 10 PIN

HLT426-6-10 35 35 56 56 44 44 PIN

HLT426-6-12 18 18 24 24 24 24 PIN

HLT426-6-13 . . 4 4 4 4 PIN

HLT426-6-14 18 18 2 2 2 2 PIN

HLT426-6-15 2 2 4 4 6 6 PIN

HLT426-6-16 4 4 4 4 8 8 PIN

HLT426-6-17 2 2 . . . . PIN

HLT426-6-3 3 3 . . . . PIN

HLT426-6-4 9 9 9 9 11 11 PIN

HLT426-6-5 22 22 . . 23 23 PIN

HLT426-6-6 74 74 41 41 57 57 PIN

HLT426-6-7 22 22 30 30 50 50 PIN

HLT426-6-8 8 8 9 9 7 7 PIN

HLT426-8-10 98 98 77 77 90 90 PIN

HLT426-8-11 10 10 9 9 9 9 PIN

HLT426-8-12 99 99 105 105 104 104 PIN

HLT426-8-13 16 16 3 3 19 19 PIN

HLT426-8-14 10 10 20 20 10 10 PIN

HLT426-8-15 31 31 . . . . PIN

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-15 -17 -19 -21 -23 -25

HLT426-8-16 1 1 12 12 7 7 PIN

HLT426-8-17 58 58 . . . . PIN

HLT426-8-18 18 18 . . . . PIN

HLT426-8-19 24 24 . . . . PIN

HLT426-8-22 16 16 . . . . PIN

HLT426-8-24 10 10 . . . . PIN

HLT426-8-4 28 28 32 32 32 32 PIN

HLT426-8-5 22 22 20 20 23 23 PIN

HLT426-8-6 26 26 28 28 28 28 PIN

HLT426-8-7 16 16 1 1 4 4 PIN

HLT426-8-8 83 83 74 74 83 83 PIN

HLT426-8-9 . . 2 2 2 2 PIN

HLT426-10-7 6 6 . . 6 6

HLT427-10-18 9 9 . . 9 9 PIN

HLT427-10-20 12 12 . . 12 12 PIN

HLT427-10-22 35 35 . . 35 35 PIN

HLT427-10-24 6 6 . . 6 6 PIN

HLT427-10-26 2 2 . . 2 2 PIN

HLT427-6-10 5 5 . . 5 5 PIN

HLT427-6-11 12 12 2 2 2 2 PIN

HLT427-6-12 10 10 10 10 10 10 PIN

HLT427-6-14 6 6 . . 6 6 PIN

HLT427-6-7 . . 2 2 2 2 PIN

HLT427-6-8 2 2 . . 1 1 PIN

HLT427-6-9 6 6 . . . . PIN

HLT427-8-10 34 34 9 9 43 43 PIN

HLT427-8-11 19 19 . . . . PIN

HLT427-8-12 49 49 . . 49 49 PIN

HLT427-8-13 . . 2 2 2 2 PIN

HLT427-8-14 22 22 2 2 24 24 PIN

HLT427-8-15 1 1 4 4 5 5 PIN

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-15 -17 -19 -21 -23 -25

HLT427-8-16 36 36 2 2 36 36 PIN

HLT427-8-17 56 56 2 2 2 2 PIN

HLT427-8-18 15 15 20 20 20 20 PIN

HLT427-8-19 2 2 21 21 21 21 PIN

HLT427-8-20 4 4 2 2 6 6 PIN

HLT427-8-21 1 1 2 2 3 3 PIN

HLT427-8-22 2 2 . . 2 2 PIN

HLT427-8-23 2 2 2 2 2 2 PIN

HLT427-8-24 13 13 . . 13 13 PIN

HLT427-8-25 . . 2 2 2 2 PIN

HLT427-8-26 . . 2 2 2 2 PIN

HLT427-8-27 . . 11 11 11 11 PIN

HLT427-8-28 10 10 . . . . PIN

HLT427-8-6 13 13 . . 13 13 PIN

HLT427-8-8 4 4 1 1 1 1 PIN

HLT427-8-9 5 5 5 5 5 5 PIN

HLT437-6-6 . . 5 5 5 5 PIN

HLT437-6-7 . . 2 2 2 2 PIN

J060165-10 . 1 . . . 1 ANGLE

J060165-13 1 . . . 1 . FILLER

J060165-14 . 1 . . . 1 FILLER

J060165-15 1 1 . . 1 1 FILLER

J060165-17 1 1 . . 1 1 FILLER

J060165-19 1 1 . . 1 1 FILLER

J060165-21 1 1 . . . . TEE

J060165-23 1 1 . . 1 1 STIFFENER

J060165-25 . . . . . . PLATE

J060165-27 . . . . 1 1 PLATE

J060165-31 . . 1 . 1 . ANGLE

J060165-32 . . . 1 . 1 ANGLE

J060165-33 . . 1 . 1 . FILLER

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Service Kit SA09570242

New Part Number QTY Name Notes

-15 -17 -19 -21 -23 -25

J060165-34 . . . 1 . 1 FILLER

J060165-35 . . 1 . 1 . FILLER

J060165-36 . . . 1 . 1 FILLER

J060165-37 . . 1 . 1 . ANGLE

J060165-38 . . . 1 . 1 ANGLE

J060165-39 . . 1 . 1 . DOUBLER

J060165-40 . . . 1 . 1 DOUBLER

J060165-41 . . 1 1 1 1 FILLER

J060165-43 . . 1 1 1 1 FILLER

J060165-45 . . 1 1 1 1 FILLER

J060165-47 . . 1 1 1 1 FILLER

J060165-49 . . 1 1 1 1 FILLER

J060165-5 1 . . . 1 . ANGLE

J060165-51 . . . . 1 1 TEE

J060165-53 1 1 1 1 1 1 STIFFENER

J060165-55 1 1 1 1 1 1 SPLICE

J060165-57 1 1 . . 1 1 SPACER

J060165-59 1 1 . . 1 1 SPACER

J060165-6 . 1 . . . 1 ANGLE

J060165-61 1 . . . 1 . DOUBLER

J060165-62 . 1 . . . 1 DOUBLER

J060165-63 1 . . . 1 . SPAR CAP

J060165-64 . 1 . . . 1 SPAR CAP

J060165-65 1 1 1 1 1 1 SPLICE

J060165-67 7 7 . . 7 7 BUSHING

J060165-69 . . 1 . 1 . SPAR CAP

J060165-7 1 . . . 1 . FILLER

J060165-70 . . . 1 . 1 SPAR CAP

J060165-8 . 1 . . . 1 FILLER

J060165-9 1 . . . 1 . ANGLE

MS20426AD6-12D . . 3 3 3 3 RIVET

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Service Kit SA09570242

New Part Number QTY Name Notes

-15 -17 -19 -21 -23 -25

MS20426AD6-8D 2 2 . . . . RIVET

MS20470AD4-6D 5 5 . . . . RIVET

MS20470AD5-7D 10 10 . . . . RIVET

MS20470AD5-9D 2 2 . . . . RIVET

MS20470AD6-10D 71 71 63 63 63 63 RIVET

MS20470AD6-11D 10 10 10 10 10 10 RIVET

MS20470AD6-12D 29 29 22 22 22 22 RIVET

MS20470AD6-14D 4 4 4 4 4 4 RIVET

MS20470AD6-15D 4 4 . . . . RIVET

MS20470AD6-16D 4 4 . . . . RIVET

MS20470AD6-8D 58 58 48 48 48 48 RIVET

MS20470AD6-9D . . 2 2 2 2 RIVET

MS20470AD8-10D 50 50 58 58 58 58 RIVET

MS20470AD8-11D 4 4 . . . . RIVET

MS20470AD8-12D 33 33 33 33 33 33 RIVET

MS20470AD8-13D 28 28 . . . . RIVET

MS20470AD8-14D 36 36 36 36 36 36 RIVET

MS20470AD8-16D 4 4 . . . . RIVET

MS20470AD8-17D 1 1 . . . . RIVET

MS20470AD8-18D 6 6 . . . . RIVET

MS20470AD8-19D 1 1 . . . . RIVET

MS20470AD8-7D 5 5 . . . . RIVET

MS20470AD8-9D 18 18 . . . . RIVET

MS21042L3 180 180 218 218 273 273 NUT

MS21042L4 536 536 549 549 549 549 NUT

MS21042L5 84 84 10 10 84 84 NUT

MS21042L6 2 2 2 2 2 2 NUT

MS21064L5-11-4 1 1 . . . . CHANNEL

NAS1203-4 2 2 . . 2 2 BOLT

NAS1203-8 7 7 . . 7 7 BOLT

NAS1204-12 8 8 . . . . BOLT

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-15 -17 -19 -21 -23 -25

NAS1204-13 4 4 . . . . BOLT

NAS1204-14 1 1 . . . . BOLT

NAS1205-15 7 7 . . . . BOLT

NAS1252-10H 180 180 228 228 273 273 WASHER

NAS1252-416H 542 542 542 542 542 542 WASHER

NAS1252-516H 81 81 10 10 91 91 WASHER

NAS1252-616H 12 12 12 12 12 12 WASHER

NAS1704-8 1 1 . . . . BOLT

NAS6205-10 22 22 . . . . BOLT

NAS6205-16 8 8 . . . . BOLT

NAS6205-26 8 8 . . . . BOLT

NAS6206-10 2 2 . . 2 2 BOLT

NAS6206-12 . . 2 2 2 2 BOLT

NAS679A5 17 17 . . 17 17 NUT

PIC239-3-10 4 4 . . 4 4 BOLT

PIC239-3-15 3 3 . . 3 3 BOLT

S4931917-8X10 . . 6 6 6 6 PIN

S4931917-8X11 . . 6 6 6 6 PIN

S4931917-8X13 . . 1 1 1 1 PIN

S4931917-8X16 . . 1 1 1 1 PIN

S4931917-8X9 . . 1 1 1 1 PIN

Service Kit SA09570242

New Part Number QTY Name Notes

-27 -29 -31 -33 -35 -37

3D0006-3 22 22 15 15 22 22 NUT ASSY

3D0006-4 155 155 74 74 216 216 NUT ASSY

3D0006-5 40 40 17 17 57 57 NUT ASSY

3D0097-10X12 4 4 . . 4 4 PIN

3D0097-10X13 4 4 . . 4 4 PIN

3D0097-10X17 12 12 . . 12 12 PIN

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-27 -29 -31 -33 -35 -37

3D0097-10X18 16 16 . . 16 16 PIN

3D0097-10X20 4 4 . . 4 4 PIN

3D0097-10X14 . . 17 17 17 17 PIN

3D0097-6-7 2 2 . . 2 2 PIN

3D0097-8X10 21 21 . . 21 21 PIN

3D0097-8X11 11 11 . . 11 11 PIN

3D0097-8X12 1 1 . . 1 1 PIN

3D0097-8X13 3 3 . . 3 3 PIN

3D0097-8X14 4 4 . . 4 4 PIN

3D0097-8X15 12 12 . . 12 12 PIN

3D0097-8X16 12 12 . . 12 12 PIN

HL325-6-10 4 4 3 3 7 7 PIN

HL325-6-11 2 2 . . 2 2 PIN

HL325-6-12 2 2 5 5 7 7 PIN

HL325-6-13 15 15 . . 15 15 PIN

HL325-6-14 . . 2 2 2 2 PIN

HL325-6-8 . . 1 1 1 1 PIN

HL325-6-9 . . 5 5 5 5 PIN

HL325-8-6 . . 23 23 23 23 PIN

HL325-8-7 . . 2 2 2 2 PIN

HL325-8-8 . . 8 8 8 8 PIN

HLT1001PB-6-6 . . 7 7 7 7 PIN, OVERSIZE

HLT425-6-13 4 4 . . 4 4 PIN

HLT425-8-10 . . 7 7 7 7 PIN

HLT425-8-11 . . 17 17 17 17 PIN

HLT425-8-9 . . 31 31 31 31 PIN

HLT426-10-7 . . 6 6 6 6 PIN

HLT426-10-18 10 10 4 4 4 4 PIN

HLT426-6-10 56 56 35 35 44 44 PIN

HLT426-6-12 24 24 18 18 24 24 PIN

HLT426-6-13 4 4 . . 4 4 PIN

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-27 -29 -31 -33 -35 -37

HLT426-6-14 2 2 18 18 18 18 PIN

HLT426-6-15 4 4 2 2 6 6 PIN

HLT426-6-16 4 4 4 4 8 8 PIN

HLT426-6-17 . . 2 2 2 2 PIN

HLT426-6-3 . . 3 3 3 3 PIN

HLT426-6-4 9 9 9 9 11 11 PIN

HLT426-6-5 . . 22 22 22 22 PIN

HLT426-6-6 41 41 74 74 74 74 PIN

HLT426-6-7 30 30 22 22 50 50 PIN

HLT426-6-8 9 9 8 8 8 8 PIN

HLT426-8-10 85 85 98 98 98 98 PIN

HLT426-8-11 9 9 10 10 10 10 PIN

HLT426-8-12 109 109 108 108 108 108 PIN

HLT426-8-13 3 3 16 16 19 19 PIN

HLT426-8-14 24 24 14 14 14 14 PIN

HLT426-8-15 . . 31 31 31 31 PIN

HLT426-8-16 12 12 1 1 7 7 PIN

HLT426-8-17 . . 58 58 58 58 PIN

HLT426-8-18 . . 18 18 18 18 PIN

HLT426-8-19 . . 24 24 24 24 PIN

HLT426-8-22 . . 16 16 16 16 PIN

HLT426-8-24 . . 10 10 10 10 PIN

HLT426-8-4 32 32 28 28 32 32 PIN

HLT426-8-5 20 20 22 22 23 23 PIN

HLT426-8-6 28 28 26 26 28 28 PIN

HLT426-8-7 1 1 16 16 16 16 PIN

HLT426-8-8 74 74 83 83 83 83 PIN

HLT426-8-9 2 2 . . 2 2 PIN

HLT427-10-18 . . 9 9 9 9 PIN

HLT427-10-20 . . 12 12 12 12 PIN

HLT427-10-22 . . 35 35 35 35 PIN

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-27 -29 -31 -33 -35 -37

HLT427-10-24 . . 6 6 6 6 PIN

HLT427-10-26 . . 2 2 2 2 PIN

HLT427-6-10 . . 5 5 5 5 PIN

HLT427-6-11 2 2 12 12 12 12 PIN

HLT427-6-12 10 10 10 10 10 10 PIN

HLT427-6-14 . . 6 6 6 6 PIN

HLT427-6-7 2 2 . . 2 2 PIN

HLT427-6-8 . . 2 2 2 2 PIN

HLT427-6-9 . . 6 6 6 6 PIN

HLT427-8-10 9 9 34 34 43 43 PIN

HLT427-8-11 . . 19 19 19 19 PIN

HLT427-8-12 . . 49 49 49 49 PIN

HLT427-8-13 2 2 . . 2 2 PIN

HLT427-8-14 2 2 22 22 24 24 PIN

HLT427-8-15 4 4 1 1 5 5 PIN

HLT427-8-16 2 2 36 36 36 36 PIN

HLT427-8-17 2 2 56 56 56 56 PIN

HLT427-8-18 20 20 15 15 20 20 PIN

HLT427-8-19 21 21 2 2 21 21 PIN

HLT427-8-20 2 2 4 4 6 6 PIN

HLT427-8-21 2 2 1 1 3 3 PIN

HLT427-8-22 . . 2 2 2 2 PIN

HLT427-8-23 2 2 2 2 2 2 PIN

HLT427-8-24 . . 13 13 13 13 PIN

HLT427-8-25 2 2 . . 2 2 PIN

HLT427-8-26 2 2 . . 2 2 PIN

HLT427-8-27 11 11 . . 11 11 PIN

HLT427-8-28 . . 10 10 10 10 PIN

HLT427-8-6 . . 13 13 13 13 PIN

HLT427-8-8 1 1 4 4 4 4 PIN

HLT427-8-9 5 5 5 5 5 5 PIN

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-27 -29 -31 -33 -35 -37

HLT437-6-6 5 5 . . 5 5 PIN

J060165-10 . . . 1 . 1 ANGLE

J060165-13 . . 1 . 1 . FILLER

J060165-14 . . . 1 . 1 FILLER

J060165-15 . . 1 1 1 1 FILLER

J060165-17 . . 1 1 1 1 FILLER

J060165-19 . . 1 1 1 1 FILLER

J060165-21 1 1 1 1 . . TEE

J060165-23 . . 1 1 1 1 STIFFENER

J060165-27 . . 1 1 1 1 PLATE

J060165-31 1 . . . 1 . ANGLE

J060165-32 . 1 . . . 1 ANGLE

J060165-33 1 . . . 1 . FILLER

J060165-34 . 1 . . . 1 FILLER

J060165-35 1 . 1 . 1 . FILLER

J060165-36 . 1 . 1 . 1 FILLER

J060165-37 1 . . . 1 . ANGLE

J060165-38 . 1 . . . 1 ANGLE

J060165-39 1 . . . 1 . DOUBLER

J060165-40 . 1 . . . 1 DOUBLER

J060165-41 1 1 . . 1 1 FILLER

J060165-43 1 1 . . 1 1 FILLER

J060165-45 1 1 . . 1 1 FILLER

J060165-47 1 1 . . 1 1 FILLER

J060165-49 1 1 . . 1 1 FILLER

J060165-5 . . 1 . 1 . ANGLE

J060165-51 . . . . 1 1 TEE

J060165-53 1 1 1 1 1 1 STIFFENER

J060165-55 1 1 1 1 1 1 SPLICE

J060165-57 . . 1 1 1 1 SPACER

J060165-59 . . 1 1 1 1 SPACER

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ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-27 -29 -31 -33 -35 -37

J060165-6 . . . 1 . 1 ANGLE

J060165-61 . . 1 . 1 . DOUBLER

J060165-62 . . . 1 . 1 DOUBLER

J060165-63 . . 1 . 1 . SPAR CAP

J060165-64 . . . 1 . 1 SPAR CAP

J060165-65 1 1 1 1 1 1 SPLICE

J060165-67 . . 7 7 7 7 BUSHING

J060165-69 1 . . . 1 . SPAR CAP

J060165-7 . . 1 . 1 . FILLER

J060165-70 . 1 . . . 1 SPAR CAP

J060165-8 . . . 1 . 1 FILLER

J060165-9 . . 1 . 1 . ANGLE

MS20426AD6-12D 3 3 . . 3 3 RIVET

MS20426AD6-14D 4 4 18 18 18 18 RIVET

MS20426AD6-8D . . 2 2 2 2 RIVET

MS20470AD4-6D . . 5 5 5 5 RIVET

MS20470AD5-9D . . 2 2 2 2 RIVET

MS20470AD6-10D 63 63 71 71 63 63 RIVET

MS20470AD6-11D 10 10 10 10 10 10 RIVET

MS20470AD6-12D 22 22 29 29 22 22 RIVET

MS20470AD6-14D 4 4 4 4 4 4 RIVET

MS20470AD6-15D . . 4 4 4 4 RIVET

MS20470AD6-16D . . 4 4 4 4 RIVET

MS20470AD6-8D 48 48 58 58 48 48 RIVET

MS20470AD6-9D 2 2 . . 2 2 RIVET

MS20470AD8-10D 58 58 50 50 58 58 RIVET

MS20470AD8-11D . . 4 4 4 4 RIVET

MS20470AD8-12D 33 33 33 33 33 33 RIVET

MS20470AD8-13D . . 28 28 28 28 RIVET

MS20470AD8-14D 42 42 42 42 42 42 RIVET

MS20470AD8-16D . . 4 4 4 4 RIVET

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Service Kit SA09570242

New Part Number QTY Name Notes

-27 -29 -31 -33 -35 -37

MS20470AD8-17D . . 1 1 1 1 RIVET

MS20470AD8-18D . . 6 6 6 6 RIVET

MS20470AD8-19D . . 1 1 1 1 RIVET

MS20470AD8-7D . . 5 5 5 5 RIVET

MS20470AD8-9D . . 18 18 18 18 RIVET

MS21042L3 218 218 191 191 273 273 NUT

MS21042L4 565 565 565 565 565 565 NUT

MS21042L5 10 10 84 84 84 84 NUT

NAS1203-4 . . 2 2 2 2 BOLT

NAS1203-8 . . 7 7 7 7 BOLT

NAS1204-12 . . 8 8 8 8 BOLT

NAS1204-13 . . 4 4 4 4 BOLT

NAS1204-14 . . 1 1 1 1 BOLT

NAS1205-15 . . 7 7 7 7 BOLT

NAS1252-10H 228 228 191 191 273 273 WASHER

NAS1252-416H 558 558 558 558 558 558 WASHER

NAS1252-516H 10 10 81 81 91 91 WASHER

NAS1252-616H 10 10 14 14 14 14 WASHER

NAS1704-8 . . 1 1 1 1 BOLT

NAS6205-10 . . 22 22 22 22 BOLT

NAS6205-16 . . 8 8 8 8 BOLT

NAS6205-26 . . 8 8 8 8 BOLT

NAS679A5 . . 17 17 17 17 NUT

PIC239-3-10 . . 4 4 4 4 BOLT

PIC239-3-15 . . 3 3 3 3 BOLT

S4931917-8X10 6 6 . . 6 6 PIN

S4931917-8X11 6 6 . . 6 6 PIN

S4931917-8X13 1 1 . . 1 1 PIN

S4931917-8X16 1 1 . . 1 1 PIN

S4931917-8X9 1 1 . . 1 1 PIN

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Service Kit SA09570242

New Part Number QTY Name Notes

-39 -41 -43 -45 -47 -49

3D0006-3 22 22 15 15 22 22 NUT ASSY

3D0006-4 155 155 74 74 216 216 NUT ASSY

3D0006-5 40 40 17 17 57 57 NUT ASSY

3D0097-10X12 4 4 . . 4 4 PIN

3D0097-10X13 4 4 . . 4 4 PIN

3D0097-10X17 12 12 . . 12 12 PIN

3D0097-10X18 16 16 . . 16 16 PIN

3D0097-10X20 4 4 . . 4 4 PIN

3D0097-10X14 . . 17 17 17 17 PIN

3D0097-6-7 2 2 . . 2 2 PIN

3D0097-8X10 21 21 . . 21 21 PIN

3D0097-8X11 11 11 . . 11 11 PIN

3D0097-8X12 1 1 . . 1 1 PIN

3D0097-8X13 3 3 . . 3 3 PIN

3D0097-8X14 4 4 . . 4 4 PIN

3D0097-8X15 12 12 . . 12 12 PIN

3D0097-8X16 12 12 . . 12 12 PIN

HL325-6-10 4 4 3 3 7 7 PIN

HL325-6-11 2 2 . . 2 2 PIN

HL325-6-12 2 2 5 5 7 7 PIN

HL325-6-13 15 15 . . 15 15 PIN

HL325-6-14 . . 2 2 2 2 PIN

HL325-6-8 . . 1 1 1 1 PIN

HL325-6-9 . . 5 5 5 5 PIN

HL325-8-6 . . 23 23 23 23 PIN

HL325-8-7 . . 2 2 2 2 PIN

HL325-8-8 . . 8 8 8 8 PIN

HLT1001PB-6-6 . . 7 7 7 7 PIN, OVERSIZE

HLT425-6-13 4 4 . . 4 4 PIN

HLT425-8-10 . . 7 7 7 7 PIN

HLT425-8-11 . . 17 17 17 17 PIN

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Service Kit SA09570242

New Part Number QTY Name Notes

-39 -41 -43 -45 -47 -49

HLT425-8-9 . . 31 31 31 31 PIN

HLT426-10-18 10 10 4 4 4 4 PIN

HLT426-6-10 56 56 35 35 44 44 PIN

HLT426-6-12 24 24 18 18 24 24 PIN

HLT426-6-13 4 4 . . 4 4 PIN

HLT426-6-14 2 2 18 18 18 18 PIN

HLT426-6-15 4 4 2 2 6 6 PIN

HLT426-6-16 4 4 4 4 8 8 PIN

HLT426-6-17 . . 2 2 2 2 PIN

HLT426-6-3 . . 3 3 3 3 PIN

HLT426-6-4 9 9 9 9 11 11 PIN

HLT426-6-5 . . 22 22 22 22 PIN

HLT426-6-6 41 41 74 74 74 74 PIN

HLT426-6-7 30 30 22 22 50 50 PIN

HLT426-6-8 9 9 8 8 8 8 PIN

HLT426-8-10 77 77 98 98 98 98 PIN

HLT426-8-11 9 9 10 10 10 10 PIN

HLT426-8-12 105 105 108 108 108 108 PIN

HLT426-8-13 3 3 16 16 19 19 PIN

HLT426-8-14 20 20 14 14 14 14 PIN

HLT426-8-15 . . 31 31 31 31 PIN

HLT426-8-16 12 12 1 1 7 7 PIN

HLT426-8-17 . . 58 58 58 58 PIN

HLT426-8-18 . . 18 18 18 18 PIN

HLT426-8-19 . . 24 24 24 24 PIN

HLT426-8-22 . . 16 16 16 16 PIN

HLT426-8-24 . . 10 10 10 10 PIN

HLT426-8-4 32 32 28 28 32 32 PIN

HLT426-8-5 20 20 22 22 23 23 PIN

HLT426-8-6 28 28 26 26 28 28 PIN

HLT426-8-7 1 1 16 16 16 16 PIN

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Service Kit SA09570242

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-39 -41 -43 -45 -47 -49

HLT426-8-8 74 74 83 83 83 83 PIN

HLT426-8-9 2 2 . . 2 2 PIN

HLT426-10-7 . . 6 6 6 6 PIN

HLT427-10-18 . . 9 9 9 9 PIN

HLT427-10-20 . . 12 12 12 12 PIN

HLT427-10-22 . . 35 35 35 35 PIN

HLT427-10-24 . . 6 6 6 6 PIN

HLT427-10-26 . . 2 2 2 2 PIN

HLT427-6-10 . . 2 2 5 5 PIN

HLT427-6-11 2 2 12 12 12 12 PIN

HLT427-6-12 10 10 10 10 10 10 PIN

HLT427-6-14 . . 6 6 6 6 PIN

HLT427-6-7 2 2 . . 2 2 PIN

HLT427-6-8 . . 2 2 2 2 PIN

HLT427-6-9 . . . . 6 6 PIN

HLT427-8-10 9 9 34 34 43 43 PIN

HLT427-8-11 . . 19 19 19 19 PIN

HLT427-8-12 . . 49 49 49 49 PIN

HLT427-8-13 2 2 . . 2 2 PIN

HLT427-8-14 2 2 22 22 24 24 PIN

HLT427-8-15 4 4 1 1 5 5 PIN

HLT427-8-16 2 2 36 36 36 36 PIN

HLT427-8-17 2 2 56 56 56 56 PIN

HLT427-8-18 20 20 15 15 20 20 PIN

HLT427-8-19 21 21 2 2 21 21 PIN

HLT427-8-20 2 2 4 4 6 6 PIN

HLT427-8-21 2 2 1 1 3 3 PIN

HLT427-8-22 . . 2 2 2 2 PIN

HLT427-8-23 2 2 2 2 2 2 PIN

HLT427-8-24 . . 13 13 13 13 PIN

HLT427-8-25 2 2 . . 2 2 PIN

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Service Kit SA09570242

New Part Number QTY Name Notes

-39 -41 -43 -45 -47 -49

HLT427-8-26 2 2 . . 2 2 PIN

HLT427-8-27 11 11 . . 11 11 PIN

HLT427-8-28 . . 10 10 10 10 PIN

HLT427-8-6 13 13 13 13 13 13 PIN

HLT427-8-8 1 1 4 4 4 4 PIN

HLT427-8-9 5 5 5 5 5 5 PIN

HLT437-6-6 5 5 . . 5 5 PIN

J060165-10 . . . 1 . 1 ANGLE

J060165-13 . . 1 . 1 . FILLER

J060165-14 . . . 1 . 1 FILLER

J060165-15 . . 1 1 1 1 FILLER

J060165-17 . . 1 1 1 1 FILLER

J060165-19 . . 1 1 1 1 FILLER

J060165-21 1 1 1 1 . . TEE

J060165-23 . . 1 1 1 1 STIFFENER

J060165-27 . . 1 1 1 1 PLATE

J060165-31 1 . . . 1 . ANGLE

J060165-32 . 1 . . . 1 ANGLE

J060165-33 1 . . . 1 . FILLER

J060165-34 . 1 . . . 1 FILLER

J060165-35 1 . . . 1 . FILLER

J060165-36 . 1 . . . 1 FILLER

J060165-37 1 . . . 1 . ANGLE

J060165-38 . 1 . . . 1 ANGLE

J060165-39 1 . . . 1 . DOUBLER

J060165-40 . 1 . . . 1 DOUBLER

J060165-41 1 1 . . 1 1 FILLER

J060165-43 1 1 . . 1 1 FILLER

J060165-45 1 1 . . 1 1 FILLER

J060165-47 1 1 . . 1 1 FILLER

J060165-49 1 1 . . 1 1 FILLER

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Service Kit SA09570242

New Part Number QTY Name Notes

-39 -41 -43 -45 -47 -49

J060165-5 . . 1 . 1 . ANGLE

J060165-51 . . . . 1 1 TEE

J060165-53 1 1 1 1 1 1 STIFFENER

J060165-55 1 1 1 1 1 1 SPLICE

J060165-57 . . 1 1 1 1 SPACER

J060165-59 . . 1 1 1 1 SPACER

J060165-6 . . . 1 . 1 ANGLE

J060165-61 . . 1 . 1 . DOUBLER

J060165-62 . . . 1 . 1 DOUBLER

J060165-63 . . 1 . 1 . SPAR CAP

J060165-64 . . . 1 . 1 SPAR CAP

J060165-65 1 1 1 1 1 1 SPLICE

J060165-67 . . 7 7 7 7 BUSHING

J060165-69 1 . . . 1 . SPAR CAP

J060165-7 . . 1 . 1 . FILLER

J060165-70 . 1 . . . 1 SPAR CAP

J060165-8 . . . 1 . 1 FILLER

J060165-9 . . 1 . 1 . ANGLE

MS20426AD6-12D 3 3 . . 3 3 RIVET

MS20426AD6-14D 4 4 18 18 18 18 RIVET

MS20426AD6-8D . . 2 2 2 2 RIVET

MS20470AD4-6D . . 5 5 5 5 RIVET

MS20470AD5-9D . . 2 2 2 2 RIVET

MS20470AD6-10D 63 63 71 71 63 63 RIVET

MS20470AD6-11D 10 10 10 10 10 10 RIVET

MS20470AD6-12D 22 22 29 29 22 22 RIVET

MS20470AD6-14D 4 4 4 4 4 4 RIVET

MS20470AD6-15D . . 4 4 4 4 RIVET

MS20470AD6-16D . . 4 4 4 4 RIVET

MS20470AD6-8D 48 48 58 58 48 48 RIVET

MS20470AD6-9D 2 2 . . 2 2 RIVET

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Service Kit SA09570242

New Part Number QTY Name Notes

-39 -41 -43 -45 -47 -49

MS20470AD8-10D 58 58 50 50 58 58 RIVET

MS20470AD8-11D . . 4 4 4 4 RIVET

MS20470AD8-12D 33 33 33 33 33 33 RIVET

MS20470AD8-13D . . 28 28 28 28 RIVET

MS20470AD8-14D 36 36 42 42 42 42 RIVET

MS20470AD8-16D . . 4 4 4 4 RIVET

MS20470AD8-17D . . 1 1 1 1 RIVET

MS20470AD8-18D . . 6 6 6 6 RIVET

MS20470AD8-19D . . 1 1 1 1 RIVET

MS20470AD8-7D . . 5 5 5 5 RIVET

MS20470AD8-9D . . 18 18 18 18 RIVET

MS21042L3 218 218 191 191 273 273 NUT

MS21042L4 549 549 565 565 565 565 NUT

MS21042L5 10 10 84 84 84 84 NUT

NAS1203-4 . . 2 2 2 2 BOLT

NAS1203-8 . . 7 7 7 7 BOLT

NAS1204-12 . . 8 8 8 8 BOLT

NAS1204-13 . . 4 4 4 4 BOLT

NAS1204-14 . . 1 1 1 1 BOLT

NAS1205-15 . . 7 7 7 7 BOLT

NAS1252-10H 228 228 191 191 273 273 WASHER

NAS1252-416H 542 542 558 558 558 558 WASHER

NAS1252-516H 10 10 81 81 91 91 WASHER

NAS1252-616H 12 12 14 14 14 14 WASHER

NAS1704-8 . . 1 1 1 1 BOLT

NAS6205-10 . . 22 22 22 22 BOLT

NAS6205-16 . . 8 8 8 8 BOLT

NAS6205-26 . . 8 8 8 8 BOLT

NAS679A5 . . 17 17 17 17 NUT

PIC239-3-10 . . 4 4 4 4 BOLT

PIC239-3-15 . . 3 3 3 3 BOLT

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Service Kit SA09570242

New Part Number QTY Name Notes

-39 -41 -43 -45 -47 -49

S4931917-8X10 6 6 . . 6 6 PIN

S4931917-8X11 6 6 . . 6 6 PIN

S4931917-8X13 1 1 . . 1 1 PIN

S4931917-8X16 1 1 . . 1 1 PIN

S4931917-8X9 1 1 . . 1 1 PIN

2. Parts and Materials Supplied by the Operator:

Part Number/Specifi- QTY Supplier CAGE

cation

As Re- PRC-DeSoto International, Incorporated 92108

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.

Existing Part QTY Name New Part Number Notes

Number

9919474-1 1 CAP J060271-59 (a) (b) (c)

or

9919474-501

or

9919474-503

9919474-2 1 CAP J060271-60

or

9919474-502

or

9919474-504

9919472-23 1 ANGLE J060271-61

9919472-24 1 ANGLE J060271-62

(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.

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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.

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ALERT ALERT

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY

ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE

PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE

CAN OCCUR.

CAUTION: 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.

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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.

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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.

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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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060271-509 - SA09570242-3

Lower - J060271-510 SA09570242-5

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:

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Group 1, Configuration 2; Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-511 - SA09570242-19

Lower - J060165-512 SA09570242-21

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-519 - SA09570242-31

Lower - J060165-520 SA09570242-33

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-525 - SA09570242-43

Lower - J060165-526 SA09570242-45

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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060271-513 - SA09570242-11

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Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower - J060271-514 SA09570242-13

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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-515 - SA09570242-23

Upper and Lower - J060165-516 SA09570242-25

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA09570242-35

Upper and Lower - J060165-522 SA09570242-37

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA09570242-47

Upper and Lower - J060165-528 SA09570242-49

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:

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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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060271-509 - SA09570242-3

Lower - J060271-510 SA09570242-5

Upper J060165-513 - SA09570242-15

Upper - J060165-514 SA09570242-17

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060271-509 - SA09570242-3

Lower - J060271-510 SA09570242-5

Upper J060165-517 - SA09570242-27

Upper - J060165-518 SA09570242-29

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060271-509 - SA09570242-3

Lower - J060271-510 SA09570242-5

Upper J060165-523 - SA09570242-39

Upper - J060165-524 SA09570242-41

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:

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ALERT ALERT
Group 1, Configuration 2; Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-515 - SA09570242-23

Upper and Lower - J060165-516 SA09570242-25

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA09570242-35

Upper and Lower - J060165-522 SA09570242-37

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA09570242-47

Upper and Lower - J060165-528 SA09570242-49

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.

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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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-511 - SA09570242-19

Lower - J060165-512 SA09570242-21

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-519 - SA09570242-31

Lower - J060165-520 SA09570242-33

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-525 - SA09570242-43

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ALERT ALERT
Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower - J060165-526 SA09570242-45

(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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper J060271-511 - SA09570242-7

Upper - J060271-512 SA09570242-9

Lower J060165-511 - SA09570242-19

Lower - J060165-512 SA09570242-21

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper J060271-511 - SA09570242-7

Upper - J060271-512 SA09570242-9

Lower J060165-519 - SA09570242-31

Lower - J060165-520 SA09570242-33

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper J060271-511 - SA09570242-7

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper - J060271-512 SA09570242-9

Lower J060165-525 - SA09570242-43

Lower - J060165-526 SA09570242-45

(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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-515 - SA09570242-23

Upper and Lower - J060165-516 SA09570242-25

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA09570242-35

Upper and Lower - J060165-522 SA09570242-37

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA09570242-47

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT
Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower - J060165-528 SA09570242-49

(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:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-515 - SA09570242-23

Upper and Lower - J060165-516 SA09570242-25

Group 3:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA09570242-35

Upper and Lower - J060165-522 SA09570242-37

Group 4:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA09570242-47

Upper and Lower - J060165-528 SA09570242-49

(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.

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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.

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ALERT ALERT
FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH

FREQUENCY INSPECTION

(SHEET 1 OF 2)

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

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Inspect (Scan 1) Eddy Lower Rear Spar Cap 5911301-XXX 1 (a) (b)

Current Testing High

Frequency (ETHF)

1

Inspect (Scan 2) Eddy Upper Rear Spar Cap 5911300-XXX 1 (a) (b)

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)

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BOEING SERVICE BULLETIN MD80-57A242

ALERT ALERT