Commercial McDonnell Douglas

Airplanes MD90

Service Bulletin

ALERT

Number: MD90-53A031

Original Issue: April 10, 2009

ATA System: 5310

SUBJECT: FUSELAGE - Fuselage Main Frame - Inspect Overwing Frames for Cracks

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

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Unpublished Work - All Rights Reserved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, 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.

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2.0
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BLANK PAGE
Table of Contents

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

1. PLANNING INFORMATION ......................................... 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 15

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

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

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

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

FIGURE 1: DETAILED VISUAL INSPECTION - OVERWING FRAMES . . . . . . . . . . . . . . . . . 29

FIGURE 2: EDDY CURRENT, HIGH FREQUENCY INSPECTION - OVERWING FRAMES . . . . . . 31

FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS . . . . . . . . . . . . . . . . . . . . 33

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BLANK PAGE
Commercial McDonnell Douglas

Airplanes MD90

Service Bulletin

ALERT

Summary Number: MD90-53A031

Original Issue: April 10, 2009

ATA System: 5310

SUBJECT: FUSELAGE - Fuselage Main Frame - Inspect Overwing Frames for Cracks

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

There have been over forty reports of overwing frames cracking on MD-80 airplanes having logged between

19,876 and 41,166 flight cycles. There is no report of a cracked overwing frame on an MD-90 airplane but due

to similarity in frame design, the MD-90's are susceptible to cracks. The cracks, which originate in the upper

radius of the frame inboard tab just below the floor, were caused by fatigue. Boeing has determined that MD-90

overwing frames at Stations 883, 902, 924, 943 and 962 are also susceptible to this type of failure. All the noted

frames are a part of MD-90 Principal Structural Element (PSE) 53.12.09.1 Inspection of the overwing frames

from Station 883 to 962 on left and right sides will determine if cracks exist. If not corrected, an undetected crack

may sever the frame, which may increase the loading of adjacent frames and result in damage to adjacent

structure and extensive repair, or ultimately could lead to the loss of overall structural integrity of the airplane.

ACTION

This service bulletin provides instructions to do a general visual inspection and a high frequency eddy current

inspection of the overwing frames at Stations 883, 902, 924, 943 and 962 on left and right sides. The purpose

of these inspections is to detect fatigue cracks in the upper radius of the frame tab. Based on inspection results,

do as follows:

Condition 1 (No Crack)

1. Does repetitive inspections of the overwing frames for cracks.

Condition 2 (Crack Less than 0.125 Inch in Depth)

1. Does a blend-out repair of the crack.

2. Does repetitive inspections of the overwing frames for cracks.

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Condition 3 (Crack is Equal To or Greater Than 0.125 Inch in Depth)

1. Replaces the cracked overwing frame.

2. Does repetitive inspections of the overwing frames for cracks.

EFFECTIVITY

All MD-90-30 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE

Refer to Paragraph 1.E., Compliance.

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

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

mandatory.

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 McDonnell Douglas

Airplanes MD90

Service Bulletin

ALERT

Number: MD90-53A031

Original Issue: April 10, 2009

ATA System: 5310

SUBJECT: FUSELAGE - Fuselage Main Frame - Inspect Overwing Frames for Cracks

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

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

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

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - All MD-90 Airplanes

Airplane Models:

MD-90-30

Fuselage Num- Group

ber

2094 - 2100 1

2115 1

2117 1

2120 1

2122 - 2123 1

2125 - 2126 1

2129 1

2131 1

2133 1

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Fuselage Num- Group

ber

2136 1

2138 1

2140 - 2144 1

2146 - 2147 1

2149 - 2150 1

2153 - 2154 1

2156 - 2159 1

2161 - 2166 1

2169 - 2171 1

2173 1

2175 1

2177 1

2179 1

2181 - 2182 1

2184 1

2186 1

2190 - 2191 1

2193 - 2195 1

2197 - 2198 1

2200 1

2202 - 2203 1

2205 1

2207 1

2209 - 2213 1

2215 - 2217 1

2219 - 2233 1

2235 - 2237 1

2240 1

2243 1

2245 1

2248 1

2250 - 2251 1

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Fuselage Num- Group

ber

2253 1

2255 - 2263 1

2288 - 2290 1

4001 - 4002 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

There have been over forty reports of overwing frames cracking on MD-80 airplanes having logged

between 19,876 and 41,166 flight cycles. There is no report of a cracked overwing frame on an MD-90

airplane but due to similarity in frame design, the MD-90's are susceptible to cracks.The cracks, which

originate in the upper radius of the frame inboard tab just below the floor, were caused by fatigue.

Boeing has determined that MD-90 overwing frames at Stations 883, 902, 924, 943 and 962 are also

susceptible to this type of failure. All the noted frames are a part of MD-90 Principal Structural Element

(PSE) 53.12.09.1 Inspection of the overwing frames from Station 883 to 962 on left and right sides will

determine if cracks exist. If not corrected, an undetected crack may sever the frame, which may increase

the loading of adjacent frames and result in damage to adjacent structure and extensive repair, or

ultimately could lead to the loss of overall structural integrity of the airplane.

D. Description

This service bulletin provides instructions to do a general visual inspection and a high frequency eddy

current inspection of the overwing frames at Stations 883, 902, 924, 943 and 962 on left and right sides.

The purpose of these inspections is to detect fatigue cracks in the upper radius of the frame tab. Based

on inspection results, does as follows:

Condition 1 (No Crack)

1. Does repetitive inspections of the overwing frames for cracks.

Condition 2 (Crack Less than 0.125 Inch in Depth)

1. Does a blend-out repair of the crack.

2. Does repetitive inspections of the overwing frames for cracks.

Condition 3 (Crack is Equal To or Greater Than 0.125 Inch in Depth)

1. Replaces the cracked overwing frame.

2. Does repetitive inspections of the overwing frames for cracks.

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

Affected Maintenance Zones

Model Zone

MD-90-30 151, 161

E. Compliance

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

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

service bulletin mandatory.

Table 1: Inspect Left and Right Side Overwing Frames for Cracks from Station 883 to 962

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Within 60 months -

after the original issue date on this

service bulletin.

Before the accumulation of 20,000 total flight cycles.Do a general visual inspection and a high frequency

eddy current inspection of

the overwing frames in accordance with Accomplishment Instructions 3.B.

All Airplanes

Do repeat general visual in- - - 5,900 flight cycles.

spection and high frequency

eddy current inspection of

the overwing frames in accordance with Accomplishment Instructions 3.B.

Condition 1

(No Crack Found)

Before further - -

flight.

Repair the cracked overwing frame in accordance

with Accomplishment Instructions 3.B.

Condition 2

(Crack Found is

Less Than 0.125

Inch in Depth)

AND

Do a general visual inspec- - - 5,900 flight cycles.

tion and high frequency eddy current inspection of the

repaired overwing frame in

accordance with Accomplishment Instructions 3.B.

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ALERT ALERT
Table 1: Inspect Left and Right Side Overwing Frames for Cracks from Station 883 to 962

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Before further - -

flight.

Replace the cracked overwing frame in accordance

with Accomplishment Instructions 3.B.

Condition 3

(Crack Found is

Equal To

OR

Greater Than 0.125

Inch in Depth) AND

Within 20,000 flight - 5,900 flight cycles.

cycles after replacement.

Do a general visual inspection and high frequency eddy current inspection of the

replacement overwing

frame in accordance with

Accomplishment Instructions 3.B.

F. Approval

The resultant modification 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.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Condition 1

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 32.0 8.0

Visual Inspect 1 5.0 5.0

ETHF Inspect 1 5.0 5.0

Close Access 4 32.0 8.0

TOTAL FOR EACH AIRPLANE 74.0 26.0

NOTE: Maximum total task hours and elapsed hours are given for inspection per airplane.

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Condition 2

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 32.0 8.0

Visual Inspect 1 5.0 5.0

ETHF Inspect 1 5.0 5.0

Remove Cusp 1 8.0 8.0

Membrane

Blendout Repair 1 2.0 2.0

Install Cusp Mem- 1 8.0 8.0

brane

Close Access 4 32.0 8.0

TOTAL FOR EACH AIRPLANE 92.0 44.0

NOTE: Maximum total task hours and elapsed hours are given for the blendout repair of one frame.

Additional task hours and elapsed hours for the repair of other cracked frames are contingent

upon inspection results and are to be estimated by the operator.

Condition 3

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 32.0 8.0

Visual Inspect 1 5.0 5.0

ETHF Inspect 1 5.0 5.0

Remove Cusp 1 8.0 8.0

Membrane

Remove Frame 2 20.0 10.0

Install Frame 2 48.0 24.0

Install Cusp Mem- 1 8.0 8.0

brane

Close Access 4 32.0 8.0

TOTAL FOR EACH AIRPLANE 158.0 76.0

NOTE: Maximum total task hours and elapsed hours are given for the replacement of one frame.

Additional task hours and elapsed hours for the replacement of other cracked frames, are

contingent upon inspection results and are to be estimated by the operator.

H. Weight and Balance Changes

None.

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I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Non-Destructive Test Standard Practices Manual (NDTSPM) 06-10-01.001, 09-00-04 and

09-00-06.

b. Standard Overhaul Practices Manual (SOPM) 20-10-10.

c. MD90 Aircraft Maintenance Manual (AMM) 06-31-00, 07-10-00, 07-20-00, 08-10-00, 12-11-10,

20-20-03, 25-21-00, 25-21-03, 25-23-00, 25-27-00, 52-21-00 and 53-21-01.

d. MD90 Structural Repair Manual (SRM), Volume 2, 51-10-03, 51-10-05, 51-20-00, 51-30-01,

51-30-02, 51-30-03, 51-30-05 and 51-40-00.

2. Data supplied with this Service Bulletin

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

bulletin submit a data request to:

Data and Services Management

MS D800-0019

3855 Lakewood Boulevard

Long Beach, California 90846

Phone: (562) 593-6996

Fax: (562) 593-2001

E-mail: dse.boecom@boeing.com

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

FRAME INSTALLATION - OVERWING DWG - -

REPLACEMENT

SR90530027

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

None.

K. Publications Affected

1. Publications:

Publication Chapter-Section

Maintenance Planning Document

2. Damage Tolerance Based Structural Inspections:

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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 but no new DTIs are necessary.

L. Interchangeability and Intermixability of Parts

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

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the Kits shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown

below. Kit availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date

Boeing gets the purchase order.

A limited quantity of kits are available. Once consumed, refer to the standard ROLT listed below.

Unit Price thru

December 31, 2009

Number Name ROLT (Weeks)

SA90530031-3 Service Kit 17 $32,200.00

SA90530031-5 Service Kit 17 32,200.00

SA90530031-7 Service Kit 17 33,157.00

SA90530031-9 Service Kit 17 33,156.00

SA90530031-11 Service Kit 17 33,192.00

SA90530031-13 Service Kit 17 33,192.00

SA90530031-15 Service Kit 17 37,096.00

SA90530031-17 Service Kit 17 37,096.00

SA90530031-19 Service Kit 17 36,851.00

SA90530031-21 Service Kit 17 36,851.00

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.

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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.

Service Kit Matrix

Service Kit Drawing Configuration Position Station Location

SA90530031-3 SR90530027-7001 Left Y= 883.000

SA90530031-5 SR90530027-7003 Right

SA90530031-7 SR90530027-7005 Left Y= 902.000

SA90530031-9 SR90530027-7007 Right

SA90530031-11 SR90530027-7009 Left Y= 924.000

SA90530031-13 SR90530027-7011 Right

SA90530031-15 SR90530027-7013 Left Y= 943.000

SA90530031-17 SR90530027-7015 Right

SA90530031-19 SR90530027-7017 Left Y= 962.000

SA90530031-21 SR90530027-7019 Right

Kit SA90530031

Existing Part Notes

Number

New Part Number QTY Name

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

2913797-1 . . 1 1 . . CLIP

2913870-1 . . 1 1 1 1 CLIP

2920753-1 . . . . 1 1 CLIP

2920754-1 . . 1 1 . . CLIP

2920756-1 . . . 1 . 1 CLIP

2920756-2 . . 1 . 1 . CLIP

3D0006-3 24 24 58 58 58 58 NUT ASSY

3D0006-4 2 2 . . . . NUT ASSY

3D0010-6-6 . . 1 1 . . PIN

3D0010-6-7 . . 14 14 12 12 PIN

3D0010-6-8 . . 5 5 13 13 PIN

3D0010-6-9 . . 6 6 1 1 PIN

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Kit SA90530031

Existing Part Notes

Number

New Part Number QTY Name

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

9919669-17 . . 1 . . . CLIP

9919669-18 . . . 1 . . CLIP

9923405-505 . . 1 . . . FRAME

9923405-506 . . . 1 . . FRAME

9923405-507 . . . . . 1 FRAME

9923405-508 . . . . 1 . FRAME

9935997-7 4 4 . . . . CLIP

9936471-501 1 . . . . . FRAME

9936471-502 . 1 . . . . FRAME

9957901-9 1 1 . . . . CLIP

9964454-17 . . . . . 1 CLIP

9964454-18 . . . . 1 . CLIP

9964454-19 . . . . 1 1 CLIP

9964454-21 . . . . 1 1 CLIP

HL329-6-11 . . 1 1 1 1 PIN

HLT425-6-5 . . 1 1 1 1 PIN

HLT425-6-6 . . 1 1 1 1 PIN

HLT425-6-7 . . 4 4 4 4 PIN

HLT426-10-10 1 1 1 1 1 1 PIN

HLT426-12-11 2 2 . . . . O/S FASTENER

HLT426-12-13 . . . . 2 2 O/S FASTENER

HLT426-12-9 . . 2 2 . . PIN

HLT426-6-10 . . 1 1 1 1 PIN

HLT426-6-3 . . 8 8 19 19 PIN

HLT426-6-4 2 2 20 20 13 13 PIN

HLT426-6-5 22 22 11 11 11 11 PIN

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

HLT426-6-7 1 1 . . . . PIN

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

HLT426-6-9 . . 1 1 1 1 PIN

HLT426-8-10 3 3 3 3 3 3 PIN

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MD90-53A031

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
Kit SA90530031

Existing Part Notes

Number

New Part Number QTY Name

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

HLT426-8-7 . . 1 1 1 1 PIN

HLT426-8-8 1 1 . . . . PIN

HLT426-8-9 2 2 3 3 3 3 PIN

HLT435-6-10 1 1 1 1 1 1 PIN

HLT435-6-11 1 1 . . . . PIN

HLT435-6-6 18 18 2 2 2 2 PIN

HLT435-6-7 27 27 58 58 58 58 PIN

HLT435-6-8 6 6 1 1 1 1 PIN

HLT435-6-9 1 1 . . . . PIN

MS20470AD5-10D 3 3 20 10 10 10 RIVET

MS20470AD5-11D 3 3 1 1 21 21 RIVET

MS20470AD5-12D . . 20 20 1 1 RIVET

MS20470AD5-6D 24 24 . . . . RIVET

MS20470AD5-7D 6 6 . . . . RIVET

MS20470AD5-8D 3 3 . . . . RIVET

MS20470AD5-9D . . 1 1 . . RIVET

MS20470AD6-12D . . . . 1 1 RIVET

MS20470AD6-14D . . 1 1 . . RIVET

MS21042L3 73 73 97 97 101 101 NUT

MS21042L4 2 2 7 7 7 7 NUT

MS21042L5 1 1 1 1 1 1 NUT

MS21042L6 2 2 2 2 2 2 NUT

NAS1252-10H 41 41 93 93 97 97 WASHER

NAS1252-10L 32 32 5 5 5 5 WASHER

NAS1252-416H 2 2 7 7 7 7 WASHER

NAS1252-516H 1 1 1 1 1 1 WASHER

NAS1252-616H 2 2 2 2 2 2 WASHER

NAS679A3 . . 1 1 1 1 NUT

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
Kit SA90530031

Existing Part Notes

Number

New Part Number QTY Name

-15 -17 -19 -21

2913870-1 1 1 1 1 CLIP

2920753-1 1 1 1 1 CLIP

2920756-1 1 . . 1 CLIP

2920756-2 . 1 1 . CLIP

3D0006-3 64 64 65 65 NUT ASSY

3D0010-6-5 . . 1 1 PIN

3D0010-6-6 . . 9 9 PIN

3D0010-6-7 . . 6 6 PIN

3D0010-6-8 . . 10 10 PIN

9919671-17 . 1 1 . CLIP

9919671-18 1 . . 1 CLIP

9919671-19 1 1 1 1 CLIP

9919671-21 1 1 1 1 CLIP

9923406-503 1 . . . FRAME

9923406-504 . 1 . . FRAME

9923407-503 . . 1 . FRAME

9923407-504 . . . 1 FRAME

HL329-6-10 . . 1 1 PIN

HLT426-12-10 2 2 2 2 PIN, OVERSIZE

HLT426-6-10 1 1 . . PIN

HLT426-6-3 15 15 15 15 PIN

HLT426-6-4 14 14 14 14 PIN

HLT426-6-5 13 13 12 12 PIN

HLT426-6-6 21 21 16 16 PIN

HLT426-6-7 2 2 10 10 PIN

HLT426-6-8 7 7 1 1 PIN

HLT426-6-9 1 1 1 1 PIN

HLT426-8-10 4 4 4 4 PIN

HLT426-8-8 . . 1 1 PIN

HLT426-8-9 4 4 3 3 PIN

HLT435-6-10 1 1 . . PIN

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
Kit SA90530031

Existing Part Notes

Number

New Part Number QTY Name

-15 -17 -19 -21

HLT435-6-6 32 32 2 2 PIN

HLT435-6-7 28 28 57 57 PIN

HLT435-6-8 3 3 5 5 PIN

HLT435-6-9 . . 1 1 PIN

MS20470AD5-10D 3 3 . . RIVET

MS20470AD5-11D 3 3 18 18 RIVET

MS20470AD5-12D . . 2 2 RIVET

MS20470AD5-6D 36 36 . . RIVET

MS20470AD5-7D 12 12 . . RIVET

MS20470AD5-8D . . 10 10 RIVET

MS20470AD5-9D . . 2 2 RIVET

MS20470AD6-13D . . 1 1 RIVET

MS21042L3 74 74 95 95 NUT

MS21042L4 8 8 8 8 NUT

MS21042L6 2 2 2 2 NUT

NAS1252-10H 74 74 95 95 WASHER

NAS1252-10L . . 1 1 WASHER

NAS1252-416H 8 8 8 8 WASHER

NAS1252-616H 2 2 2 2 WASHER

NAS679A3 . . 1 1 NUT

2. Parts and Materials Supplied by the Operator

NOTE: Refer to Non-Destructive Testing Standard Practice Manual (NDTSPM) Part 06 and Part

09 for the required materials to be used in the inspections.

Part Number / Specification QTY Name Notes

PC21F 1 Roll Tape, Cloth Coated (a)

(DMS 1968 Type 2)

OR

Polyken 225 1 Roll Tape, Cloth Coated (b)

(DMS 1968 Type 2)

OR

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
Part Number / Specification QTY Name Notes

770-3 FRD 1 Roll Tape, Adhesive (c)

(DMS 1984 Type 6 Class 2)

OR

OT-16A 1 Roll Tape, Adhesive (d)

(DMS 1984 Type 6 Class 2)

PR-1422 Class B-2 1 Quart Sealing Compound (e)

(DMS 2082)

OR

Equivalent

(a) May be purchased from: Shurtape Technologies, LLC CAGE

1506 Highland Avenue 4L0S0

Hickory, North Carolina 28601

(b) May be purchased from: Covalence Specialty Adhesives 80769

2320 Bowling Green Road

Franklin, Massachusetts 02038

(c) May be purchased from: Annitti Enterprises Incorporated 9U930

138 Grand Street

Paterson, New Jersey 07501

(d) May be purchased from: Orcon Corporation 23788

251 rope Mill Parkway STE 1

Woodstock, Georgia 30188

(e) May be purchased from: PRC-DeSoto International, Incorporated 92108

5454 San Fernando Road

Glendale, California 91203

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None

E. Special Tooling - Price and Availability

General visual inspection equipment and high frequency eddy current inspection equipment required

to accomplish this service bulletin are listed in the Non-Destructive Testing Standard Practice Manual

(NDTSPM) and are to be procured from operator’s stock or sources indicated.

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
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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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

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

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

CAN OCCUR.

CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE

TO THE AIRPLANE OR EQUIPMENT.

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s)

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

bulletin can be changed.

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

definition of the acronyms.

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

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

MD90 SRM, Chapter 51, Volume 2.

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

installation standards in MD90 SRM Chapter 51, then a fastener of the same

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

standards in MD90 SRM Chapter 51, Volume 2, 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. Oversize fasteners must be used when the hole diameter exceeds the maximum

diameter specified.

8. Refer to the manuals that follow as an accepted procedure:

Accepted Procedure Operation

MD90 AMM 20-20-03 Sealant Application

MD90 SRM 51-10-03 Corrosion/Erosion Control and Prevention

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ALERT ALERT
Accepted Procedure Operation

MD90 SRM 51-10-05 Drilling and Countersinking

MD90 SRM 51-20-00 Repair Sealing

MD90 SRM 51-30-01 Installing Bolts, Screws, and Washers

MD90 SRM 51-30-02 Installing and Removing Rivets

MD90 SRM 51-30-03 Installing and Removing Lockbolts

MD90 SRM 51-30-05 Installing and Removing Hi-Lok Attachments

MD90 SRM 51-40-00 Substitution and Interchangeability

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

10. 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.

11. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to ensure visual access to all surfaces in the

inspection area. This level of inspection is made under normal available lighting

conditions such as daylight, hangar lighting, flashlight or drop-light and may require

removal or opening of access panels or doors. Stands, ladders or platforms may be

required to gain proximity to the area being checked.

12. 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.

B. WORK INSTRUCTIONS

1. Remove and keep the following items and attaching parts, as applicable, to get access to the left

and right side overwing frames at Stations 883, 902, 924, 943 and 962.

Item Accepted Procedure

Passenger Seats MD90 AMM 25-23-00

Passenger Compartment Lining MD90 AMM 25-21-00

Passenger Compartment Insulation MD90 AMM 25-21-03

Passenger Compartment Floor Covering MD90 AMM 25-27-00

Passenger Compartment Floor Panels MD90 AMM 53-21-01

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
Item Accepted Procedure

Overwing Emergency Exit Doors MD90 AMM 52-21-00

2. Remove tape from the cutout between the cusp membrane and frame to get access to the frame

inspection area.

3. Remove and keep the cusp membrane, as necessary, to get access to the frame inspection area.

4. Do a General Visual inspection and an Eddy Current, High Frequency (ETHF) inspection of the

upper radius of the frame tab of the overwing frames in accordance with Figures 1 and 2. Based

on findings do as follows:

Condition 1 (No Crack)

a. Install kept cusp membrane if it was removed to get access to the frame inspection area.

b. Install tape to seal along the cutout between the cusp membrane and frame.

c. Do repeat inspections of the overwing frames.

Condition 2 (Crack less than 0.125 Inch in Depth)

a. If installed, remove and keep the cusp membrane to get access to the cracked frame.

b. Do a blend-out repair of the crack in accordance with Figure 3.

c. Install kept cusp membrane.

d. Install tape to seal along the cutout between the cusp membrane and frame.

e. Do repeat inspections of the overwing frames.

Condition 3 ( Crack 0.125 Inch in Depth or Greater)

a. Defuel the airplane. Refer to MD90 AMM 12-11-10 as an accepted procedure.

b. Raise and level the airplane. Refer to MD90 AMM 07-10-00 and MD90 AMM 08-10-00 as an

accepted procedure.

NOTE: Boeing recommends each frame be replaced separately. If two or more frames are

replaced at the same time, shoring the airplane is recommended. Refer to MD90

AMM 07-20-00 as an accepted procedure.

c. If installed, remove and keep the cusp membrane to get access to the cracked frame.

d. Remove and keep the applicable wing to fuselage fillet panels 150CL, 150FL and 150ML on

the left side and 160CR, 160FR and 160MR on the right side to get access to the cracked

frame. Refer to MD90 AMM 06-31-00 as an accepted procedure.

e. Replace cracked overwing frame in accordance with Service Rework Drawing SR90530027.

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
NOTE: Apply PR-1422 sealant on all faying surfaces and wet install all fasteners during

frame replacement.

f. Install kept cusp membrane.

g. Install tape to seal along the cutout between the cusp membrane and frame.

h. Install kept applicable wing to fuselage fillet panels 150CL, 150FL and 150ML on the left side

and 160CR, 160FR and 160MR on the right side. Refer to MD90 AMM 06-31-00.

i. Remove any shoring and lower the airplane. Refer to MD90 AMM 07-10-00 and MD90 AMM

08-10-00 as an accepted procedure.

j. Do repeat inspections of the overwing frames.

5. Install all kept items and attaching parts, as applicable from Station 883.000 to 962.000.

Item Accepted Procedure

Passenger Seats MD90 AMM 25-23-00

Passenger Compartment Lining MD90 AMM 25-21-00

Passenger Compartment Insulation MD90 AMM 25-21-03

Passenger Compartment Floor Covering MD90 AMM 25-27-00

Passenger Compartment Floor Panels MD90 AMM 53-21-01

Overwing Emergency Exit Doors MD90 AMM 52-21-00

6. Put the airplane back to a serviceable condition.

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ALERT ALERT
FIGURE 1: DETAILED VISUAL INSPECTION - OVERWING FRAMES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN MD90-53A031

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

MORE

DATA

STATION LOCA- IDENTIFICATION

TION

STEP TASK PROCEDURE NAME

(a) (b)

(c)

1 Inspect Detailed Visual Frame Station 883 9936471-501/-502

Station 902 9923405-505/-506

Station 924 9923405-507/-508

Station 943 9923406-503/-504

Station 962 9923407-503/-504

(a) Do a Detailed inspection the frame in the shaded area at all accessible locations using remote visual devices

at Stations 883, 902, 924, 943 and 962 left and right sides.

(b) Utilize adjacent lightening holes for the remote visual inspection looking for cracks propagating inboard

and down from the upper radius of the frame tab.

(c) Refer to Non-Destructive Testing Standard Practice Manual NDTSPM 09-00-06 for remote visual device

usage and NDTSPM 09-00-04 for current supplier/vendor information.

FIGURE 1: DETAILED VISUAL INSPECTION - OVERWING FRAMES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
FIGURE 2: EDDY CURRENT, HIGH FREQUENCY INSPECTION - OVERWING FRAMES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN MD90-53A031

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

MORE

DATA

STATION LOCA- IDENTIFICATION

TION

STEP TASK PROCEDURE NAME

Eddy Current, High Frame Station 883 9936471-501/-502 (a) (b)

Frequency

1 Inspect

Station 902 9923405-505/-506

Station 924 9923405-507/-508

Station 943 9923406-503/-504

Station 962 9923407-503/-504

(a) Do a Detailed inspection the upper radius of the frame tab in the shaded area looking for cracks propagating

in the forward and aft direction. Refer to Non-Destructive Testing Standard Practice Manual NDTSPM 06-

10-01.001, Procedure 1, Calibration Method "G" and Scan Method "69".

(b) Any indication which exhibits the same relative phase angle and an amplitude of 50 percent or greater,

than the indication obtained from the calibration notch in the reference standard is considered a crack.

FIGURE 2: EDDY CURRENT, HIGH FREQUENCY INSPECTION - OVERWING FRAMES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN MD90-53A031

ALERT ALERT
FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN MD90-53A031

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Repair Frame - - (a) (b) (c) (d) (e)

(a) Repairable crack limit: blend-out not deeper than 0.125 inch with minimum 0.44R and verify

crack is removed.

(b) Radius corners 0.060 / 0.030.

(c) Surface finish 63 micro-inch finish or better.

(d) Glass bead peen or flap peen the frame tab surfaces. Refer to SOPM 20-10-10 as an accepted

procedure.

(e) Apply Alodine and FR Primer on all bare metal surfaces.

FIGURE 3: BLEND-OUT REPAIR - FRAME TAB UPPER RADIUS

(SHEET 3 OF 3)

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ALERT ALERT