Commercial 

Airplanes 727

Service Bulletin

ALERT

Number: 727-57A0135

Original Issue: February 07, 1975

Revision 4: September 26, 2012

ATA System: 5742

SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And

Adjustment

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

CFR 300-774). 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 © 1989 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

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

BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing

liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection

with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management

Company.

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Revision 4: September 26, 2012 727-57A0135

1 of 37

4.0
Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 24

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

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

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

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 25

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 1: INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FIGURE 2: CHECK FOR CLEARANCE / INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . 32

FIGURE 3: REWORK OF LUG ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 4: CARRIAGE FITTING INSTALLATION FOR OUTBOARD FORE FLAP WBL 348 - DEVIATION

FROM OVERHAUL MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 727

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 727-57A0135

Original Issue: February 07, 1975

Revision 4: September 26, 2012

ATA System: 5742

SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And

Adjustment

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on the airplanes changed in accordance with Revision 3 of this service bulletin. For the

outboard foreflap, replace the production carriage attach fittings with the new improved carriage attach fittings

at the time given in Paragraph 1.E., Compliance. Continue to inspect the carriage attach fittings at the interval

given in Paragraph 1.E., Compliance. Do general visual inspections and functionality check of the outboard

foreflap installation for damage and incorrect operation at the interval given in Paragraph 1.E., Compliance.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 is related to this service bulletin.

REASON FOR REVISION

This revision is sent to increase the frequency of the repeat High Frequency Eddy Current (HFEC) inspection

of production outboard foreflap carriage attach fittings, make compulsory the installation of the improved outboard

foreflap carriage attach fittings, make incorporation of the concurrent service bulletins compulsory, add a general

visual inspection and functionality check of the outboard foreflap and to require repeat inspections of the improved

outboard foreflap carriage attach fittings.

Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph

3.A., General Information - Notes.

These sections are changed:

1. Summary Background - Reference to a new Boeing Service Related Problem (SRP) and new service

history is added. A Summary Evaluation table is added.

2. The Summary Action is updated.

3. Summary Compliance - Reference to FAA AD 2005-14-07 is added.

4. Paragraph 1.C., Reason - Reference to a new Boeing SRP is added.

5. Paragraph 1.A.1., Airplanes - A Group Configuration Table is added.

Export Controlled ECCN: 9E991 - BOEING

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5 of 37
6. Paragraph 1.C., Reason - Reference to a new Boeing Service Related Problem (SRP) and new service

history is added. A Summary Evaluation table is added.

7. Paragraph 1.D., Description - Affected maintenance zones are added.

8. Paragraph 1.E., Compliance - Reference to FAA AD 2005-14-07 is added and the compliance information

is updated.

9. Paragraph 1.F., Approval - The approval statement is updated.

10. Paragraph 1.G., Manpower - Manpower information for general visual inspection and functionality

check is added.

11. Paragraph 1.J.1., Existing Data - References to FAA AD 2005-14-07, a new SRP and Service Bulletin

Index are added.

12. Paragraph 1.K., Publications Affected - A Damage Tolerance Inspection (DTI) statement is added.

13. Paragraph 1.M., Software Accomplishment Summary - Section is added.

14. Paragraph 3.A., Accomplishment Instructions - General Note 1 regarding the sequencing of steps is

deleted. A caution and 8 general notes are added.

15. Paragraph 3.B., Work Instructions - Instructions to do a general visual inspection and functionality

check are added.

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: February 07, 1975

Revision 1: August 29, 1975

Revision 2: October 29, 1998

Revision 3: June 27, 2002

Revision 4: September 26, 2012

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Commercial 

Airplanes 727

Service Bulletin

ALERT

Summary Number: 727-57A0135

Original Issue: February 07, 1975

Revision 4: September 26, 2012

ATA System: 5742

SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And

Adjustment

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

Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND

This service bulletin gives instructions to inspect the carriage attach fitting of the inboard and outboard foreflaps

for any crack or damage. Fleet service information and analysis show that repeat inspections or replacement

of the carriage attach fitting decrease the risk of partial or complete foreflap loss caused by fatigue. Inspection

and adjustment, if necessary, of the gap between the foreflap carriage attach fitting and the carriage lug on the

inboard and outboard foreflap assemblies will decrease the possibility of fatigue failure of the carriage attach

fitting from excessive clamp-up. The fatigue life of the new replacement fitting increased with the design of

thicker flanges, and a material change to Corrosion Resistant Steel. If the work in this service bulletin is not

done, breakage of the carriage attach fitting could result in the loss of the foreflap and damage to adjacent

structures which could lead to loss of controllability of the airplane during take-off and landing.

Sixteen operators sent reports of twenty-eight damaged or failed outboard Foreflaps with the carriage attach

fitting of the Foreflap Sequencing Carriage cracked or failed. Recent Boeing examination of a failed fitting

indicates fatigue breakage of the fitting is possible as a result of high fit-up stress combined with airloads.

Revision 3 changes this service bulletin to Alert status. It also provides specific inspection intervals for the

carriage attach fitting.

Since the release of Revision 3, one operator has reported that during a scheduled inspection per Federal

Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 , both inboard and outboard Foreflap

Carriage Fittings were found broken. The event occurred at 47,125 Flight Cycles. Metallurgical analysis determined

that the cause of the broken fittings is a suspected static overload condition.

Boeing Service Related Problem (SRP) 727-SRP-57-0128 and 727-SRP-57-0243 are related to this service

bulletin.

Export Controlled ECCN: 9E991 - BOEING

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This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected Yes Paragraph 1.A.2., Spares Affected

AD Related Yes Paragraph 1.E., Compliance

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected Yes Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected Yes Paragraph 1.K., Publications Affected

(Flight Crew Operations Manual and/or

FAA Approved Airplane Flight Manual)

Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION (PRR 23907, PRR 24826-R)

Do a detailed and High Frequency Eddy Current (HFEC) inspection of the foreflap carriage attach fittings for

any crack or damage. If any crack or damage is found, replace the carriage attach fitting. If no crack or damage

is found, do the repeat inspections at the interval given in Paragraph 1.E., Compliance .

Incorporate the service bulletins listed in Paragraph 1.B., Concurrent Requirements .

– For the inboard foreflap, installation of the improved carriage attach fittings and incorporation of the service

bulletins listed in Paragraph 1.B., Concurrent Requirements terminates the repeat inspections.

– For the outboard foreflap, installation of the improved carriage attach fittings and incorporation of the service

bulletins listed in Paragraph 1.B., Concurrent Requirements decreases the frequency of the repeat

inspections.

Do a one-time clearance/interference check of the carriage attach fitting. Shim if required. If interference is found,

rework the carriage attach lug.

On airplanes with the production carriage attach fitting, replace the production carriage attach fitting with the

improved carriage attach fitting and incorporate the service bulletins listed in Paragraph 1.B., Concurrent

Requirements . For the outboard foreflap the installation of the improved carriage attach fittings and the

incorporation of the service bulletins listed in Paragraph 1.B., Concurrent Requirements , is not a terminating

action.

For the outboard foreflap, do general visual inspections and functionality check of the outboard foreflap installation

for damage and incorrect operation.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
EFFECTIVITY

All 727, 727-100, 727-100C, 727-200, 727-200F, 727C Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the

list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 is related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes, 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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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Commercial 

Airplanes 727

Service Bulletin

ALERT

Number: 727-57A0135

Original Issue: February 07, 1975

Revision 4: September 26, 2012

ATA System: 5742

SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And

Adjustment

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

Refer to Service Bulletin Index D6-9825 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

GROUP CONFIGURATION DESCRIPTION

727, 727-100, 100C, 200, 200F, 727C airplanes line numbers 1 thru

1832.

1 -

Airplane Models:

727, 727-100, 727-100C, 727-200, 727-200F, 727C

Variable Number Group

E0001 - E0042 1

E0101 - E0140 1

E0201 - E0216 1

E0301 - E0351 1

E0401 - E0423 1

E3001 - E3006 1

E3011 - E3014 1

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Variable Number Group

E3021 - E3040 1

E3059 1

E3061 - E3077 1

E3101 - E3103 1

E3111 - E3118 1

E3141 - E3152 1

E3171 - E3177 1

E3201 - E3206 1

E3221 - E3224 1

E3241 - E3290 1

E3341 - E3350 1

E3401 - E3421 1

E3451 - E3452 1

E3471 - E3474 1

E3501 - E3513 1

E3516 - E3523 1

E3551 - E3553 1

E3571 - E3578 1

E3601 - E3604 1

E3621 - E3622 1

E3651 - E3655 1

E3677 1

E3681 - E3684 1

E3701 - E3704 1

E3751 - E3755 1

E3781 - E3784 1

E5001 - E5011 1

E5031 - E5068 1

E5101 - E5116 1

E5141 - E5143 1

E5161 - E5164 1

E5201 - E5203 1

E5221 - E5245 1

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Variable Number Group

E5251 - E5252 1

E5271 - E5281 1

E5301 - E5306 1

E5351 - E5353 1

E5381 - E5382 1

E5401 - E5424 1

E5426 - E5429 1

E5433 1

E5435 1

E5451 - E5455 1

E5481 - E5483 1

E5501 - E5502 1

QA001 - QA046 1

QA051 - QA099 1

QA101 - QA199 1

QA201 - QA225 1

QA301 - QA349 1

QA351 - QA376 1

QA378 1

QA401 - QA499 1

QA501 - QA537 1

QA551 - QA579 1

QA581 - QA585 1

QA601 - QA688 1

QA701 - QA753 1

QA801 - QA805 1

QA851 - QA899 1

QA901 - QA946 1

QA949 1

QB001 - QB002 1

QB031 - QB049 1

QB051 - QB068 1

QB101 - QB110 1

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Variable Number Group

QB114 - QB119 1

QB121 - QB149 1

QB151 - QB158 1

QB201 - QB220 1

QB301 - QB316 1

QB351 - QB352 1

QB401 - QB407 1

QB451 - QB458 1

QB501 - QB575 1

QB601 - QB629 1

QB651 1

QB701 - QB705 1

QB801 - QB810 1

QB901 - QB904 1

QD001 - QD012 1

QD031 - QD046 1

QD085 - QD088 1

QD101 - QD105 1

QD121 - QD127 1

QD141 - QD149 1

QD161 - QD164 1

QD191 - QD192 1

QD201 - QD239 1

QD281 - QD284 1

QD301 - QD305 1

QD321 - QD330 1

QD351 1

QD401 - QD403 1

QD407 1

QD410 1

QD421 - QD427 1

QD441 - QD453 1

QD471 - QD475 1

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Variable Number Group

QD501 - QD518 1

QD551 - QD558 1

QD571 - QD572 1

QD581 - QD583 1

QD601 - QD607 1

QD621 - QD624 1

QD641 1

QD661 - QD663 1

QD681 - QD685 1

QD691 - QD692 1

QD701 - QD702 1

QD711 - QD717 1

QD741 1

QD761 - QD769 1

QD781 - QD782 1

QD791 1

QD801 - QD804 1

QD821 - QD828 1

QD901 - QD910 1

QD931 - QD932 1

QD951 - QD954 1

QD971 - QD973 1

QD991 - QD992 1

QE001 - QE002 1

QL001 - QL008 1

QL031 - QL032 1

QL081 1

QL501 - QL515 1

2. Spares Affected

Examine your spares supply for the parts or components identified below. If any parts or components

are found, refer to Accomplishment Instructions paragraph 3.B.2.b. for the recommended action.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Part Number

69-26255-3

69-26255-4

69-26256-1

69-26256-2

69-26257-1

69-26257-2

B. Concurrent Requirements

The service bulletins listed below must be done before or at the same time as this service bulletin:

Company Service Bulletin Description

Outboard Trailing Edge Foreflap Track Guide

Block Installation.

Boeing 727-57-0059 Revision 01.

Boeing 727-57-0072 Original issue. Foreflap Track Modification.

Outboard Trailing Edge Foreflap Rigging and

Jackscrew Modification at 40 Degrees Position.

Boeing 727-27-0133 Revision 01.

NOTE: The components in the concurrent service bulletins are interchangeable between 727 airplanes.

As such, Boeing recommends the inspection of each component, as given in the applicable

service bulletin (for all 727 airplanes and spares inventory), to decide if it has been modified.

C. Reason

This service bulletin gives instructions to inspect the carriage attach fittings of the inboard and outboard

foreflaps for any crack or damage. Fleet service information and analysis show that repeat inspections

or replacement of the carriage attach fittings decrease the risk of partial or complete foreflap loss caused

by fatigue. Inspection and adjustment, if necessary, of the gap between the foreflap carriage attach

fitting and the carriage lug on the inboard and outboard foreflap assemblies will decrease the possibility

of fatigue failure of the carriage attach fittings from excessive clamp-up. The fatigue life of the new

replacement fittings increased with the design of thicker flanges, and a material change to Corrosion

Resistant Steel. If the work in this service bulletin is not done, breakage of the carriage attach fittings

can result in the loss of the foreflap and damage to adjacent structures which could lead to loss of

controllability of the airplane during take-off and landing.

Sixteen operators reported twenty-eight failed or damaged outboard foreflaps with the attach fitting of

the Foreflap Sequencing Carriage cracked or failed. In the first fourteen instances the foreflap failures

were attributed to a flap overextension condition. Service bulletins 727-57-0059, 727-57-0072 and

727-27-0133 were issued to correct this and other related conditions.

A recent failure could not be attributed to the overextension condition. Analysis indicated that the fitting

had failed in fatigue. A review of the dimensional tolerances at the carriage attach lug and the carriage

attach fitting showed that very high clamp-up stresses are possible under the most adverse tolerance

conditions. High clamp-up stresses combined with airloads can cause fatigue cracks.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
As a result of the findings, it is suggested that operators inspect, and if necessary, reduce the clamp-up

of the attach fitting in addition to correcting foreflap overextension and related condition given in the

earlier service bulletins.

Subsequent to release of the original issue of the service bulletin, a review of manufacturing records

show that the full intent of the service bulletin was incorporated on a number of Group II airplanes in

production. On other Group II airplanes, however, the intent of the service bulletin was accomplished

on the inboard foreflap instead of the outboard foreflap or had been accomplished on neither.

It has also been noted that reverse dimensional tolerance at the carriage attach lug and carriage attach

fitting could result in interference, as opposed to excessive gap and clamp-up.

Boeing Service Related Problem (SRP) 727-SRP-57-0128 and 727-SRP-57-0243 are related to this

service bulletin.

Revision 1 was issued to advise inspection for interference in addition to inspection for clamp-up, to

delete a number of Group II airplanes from the effectivity, to transfer a number of airplanes from Group

II to Group I, and to advise inspections of the outboard foreflaps instead of the inboard foreflaps on the

remaining Group II airplanes.

Revision 2 changed the penetrant inspection to magnetic particle inspection and added an examination

of the carriage attach fitting clevis. Revision 2 also added all remaining 727 airplanes to the effectivity

because of interchangeability of flaps among airplanes. Because of flap interchangeability, airplanes

are no longer in two groups as given in previous issues of this service bulletin.

Revision 3 changed this service bulletin to Alert status. This revision also provides specific inspection

intervals for the carriage attach fittings. The added inspections make it easier to find cracks that start

at the bore of the upper bolt hole or the forward edge of the lug. High-Frequency Eddy Current (HFEC)

Inspections replace the Penetrant Inspection used in Revision 2. As a result of these changes, the

layout of the service bulletin is different. That is, Figures 2 and 3 and 4 are added to the Accomplishment

Instructions. Figure 2 contains the clearance and/or interference checks, and Figure 3 is the rework of

the carriage attach lug. Figure 4 provides installation for the improved fitting for the Outboard Foreflap

at WBL 348 since a new bolt type is used than what is shown in the Overhaul Manual for that location.

The improved fittings have the same foot print as the existing fittings; however, the clevis lugs are

thicker and material is now Corrosion Resistant Steel.

Revision 4 is sent to increase the frequency of the repeat High Frequency Eddy Current (HFEC)

inspection of production outboard foreflap carriage attach fittings, make compulsory the installation of

the improved outboard foreflap carriage attach fittings, make incorporation of the concurrent service

bulletins compulsory, add a general visual inspection and functionality check of the outboard foreflap

and to require repeat inspections of the improved outboard foreflap carriage attach fittings.

Since the release of Revision 2, Boeing received 5 reports of foreflap loss from 3 operators. In early

revisions of this service bulletin, the total number of reports included all occurrences related to foreflap

overextension and the carriage attach fitting. This service bulletin is only applicable to the carriage

attach fitting. The service bulletins given in Paragraph 1.B., Concurrent Requirements, are applicable

to foreflap also.

Since the release of Revision 3, one operator has reported that during a scheduled inspection per

Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 , both inboard and

outboard Foreflap Carriage Fittings were found broken. The event occurred at 47,125 Flight Cycles.

Metallurgical analysis determined that the cause of the broken fittings is a suspected static overload

condition.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
D. Description

Revision 4 - More work is necessary on the airplanes changed in accordance with Revision 3 of this

service bulletin. For the outboard foreflap, replace the production carriage attach fittings with the new

improved carriage attach fittings at the time given in Paragraph 1.E., Compliance . Continue to inspect

the carriage attach fittings at the interval given in Paragraph 1.E., Compliance .

Revision 3 - more work is necessary on airplanes changed by Revision 2 because there are more

frequent inspections of the carriage attach fitting.

Revision 2 - more work was necessary on airplanes changed as shown in Revision 1 or the original

release of this service bulletin because of flap interchangeability among airplanes. Revision 2

recommended the inspection of the inboard and outboard foreflaps on all 727 airplanes.

Do a detailed and High Frequency Eddy Current (HFEC) inspection of the foreflap carriage attach

fittings for any crack or damage. If any crack or damage is found, replace the carriage attach fitting. If

no crack or damage is found, do the repeat inspections at the interval given in Paragraph 1.E.,

Compliance .

Incorporate the service bulletins listed in Paragraph 1.B., Concurrent Requirements .

– For the inboard foreflap, installation of the improved carriage attach fittings and incorporation of

the service bulletins listed in Paragraph 1.B., Concurrent Requirements terminates the repeat

inspections.

– For the outboard foreflap, installation of the improved carriage attach fittings and incorporation of

the service bulletins listed in Paragraph 1.B., Concurrent Requirements decreases the frequency

of the repeat inspections.

Do a one-time clearance/interference check of the carriage attach fitting. Shim if required. If interference

is found, rework the carriage attach lug.

On airplanes with the production carriage attach fitting, replace the production carriage attach fittings

with the improved carriage attach fittings and incorporate the service bulletins listed in Paragraph 1.B.,

Concurrent Requirements. For the outboard foreflap the installation of the improved carriage attach

fittings and the incorporation of the service bulletins listed in Paragraph 1.B., Concurrent Requirements,

is not a terminating action.

For the outboard foreflap, do general visual inspections and functionality check of the outboard foreflap

installation for damage and incorrect operation.

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

Affected Maintenance Zones

Model Zone

727, 727-100, 727-100C, 727- 5-82, 5-84, 6-85, 6-87

200, 727-200F, 727C

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 is related to this service

bulletin.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Boeing recommends that you do the inspection in Figure 1 within 1,000 flight cycles after the Revision

3 date of this service bulletin or within 6 months from the Revision 4 date of this service bulletin,

whichever occurs first. If any crack or damage is found in the carriage attach fitting, replace the carriage

attach fitting in accordance with Accomplishment Instructions paragraph 3.B.2.b. before further flight.

Boeing also recommends that you do the one-time check in Figure 2 and the service bulletins listed in

Paragraph 1.B., Concurrent Requirements within 3,500 flight cycles after the Revision 3 date of this

service bulletin.

For the inboard foreflap, continue to do the inspections in accordance with Figure 1 at intervals not to

exceed 1,000 flight cycles. If any crack or damage is found in the carriage attach fitting, replace the

carriage attach fitting in accordance with Accomplishment Instructions paragraph 3.B.2.b. before further

flight. Do the repeat inspections until the carriage attach fitting is replaced as provided below:

– If a new carriage attach fitting, of the old configuration, from Boeing Spares is installed (never been

in service), as provided in Revision 3 and subsequent revisions of this service bulletin, and the

service bulletins listed in Paragraph 1.B., Concurrent Requirements are incorporated, inspect the

carriage attach fitting again in accordance with Figure 1 within 10,000 flight cycles. Thereafter,

continue to do the inspections in accordance with Figure 1 at intervals not to exceed 1,000 flight

cycles.

– When an improved carriage attach fitting is installed, in accordance with Revision 3 and subsequent

revisions of this service bulletin, and the service bulletins listed in Paragraph 1.B., Concurrent

Requirements are incorporated, no more inspections of the inboard foreflap carriage attach fittings

by this service bulletin are necessary.

For the outboard foreflap, continue to do the inspections in accordance with Figure 1 at intervals not

to exceed 200 flight cycles, until the carriage attach fitting is replaced as provided below:

– On airplanes with the production carriage attach fitting, replace the production carriage attach

fitting with an improved carriage attach fitting in accordance with Accomplishment Instructions

paragraph 3.B.2.b. and incorporate the service bulletins listed in Paragraph 1.B., Concurrent

Requirements, within 3,000 flight cycles or three years after the Revision 4 date of this service

bulletin, whichever comes first.

– If a new carriage attach fitting, of the old configuration, from Boeing Spares is installed (never been

in service), in accordance with Revision 3 and subsequent revisions of this service bulletin, and

the service bulletins listed in Paragraph 1.B., Concurrent Requirements are incorporated, inspect

the carriage attach fitting again in accordance with Figure 1 within 1,000 flight cycles after the

Revision 4 date of this service bulletin. Thereafter continue to do the inspections in accordance

with Figure 1 at intervals not to exceed 200 flight cycles. Replace the carriage attach fitting with

an improved carriage attach fitting in accordance with Accomplishment Instructions paragraph

3.B.2.b. and incorporate the service bulletins listed in Paragraph 1.B., Concurrent Requirements,

within 3,000 flight cycles or three years after the Revision 4 date of this service bulletin, whichever

comes first.

– When an improved carriage attach fitting is installed, as provided in Revision 3 and subsequent

revisions of this service bulletin, inspect the carriage attach fitting in accordance with Figure 1

within 20,000 flight cycles after installation of the improved carriage attach fitting. Thereafter

continue to do the inspections in accordance with Figure 1 at intervals not to exceed 1,400 flight

cycles. Note that installation of the improved carriage attach fittings on the outboard flap and the

incorporation of the service bulletins in Paragraph 1.B., Concurrent Requirements, is not terminating

action.

– If any crack or damage is found in the carriage attach fitting when doing a repeat inspection, replace

the carriage attach fitting in accordance with Accomplishment Instructions paragraph 3.B.2.b.

before further flight.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
If a component in Boeing Service Bulletin 727-57-0059, 727-57-0072 or 727-27-0133 is removed from

the airplane and replaced with a different component (new or overhauled), make sure it agrees with

the approved conditions in that applicable service bulletin.

NOTE: An improved carriage attach fitting is specified by the part numbers given in Paragraph 2.C.,

Parts Necessary for Each Airplane.

For the outboard foreflap only, do a general visual inspection and functionality check of the outboard

foreflap installation for damage and incorrect operation in accordance with Accomplishment Instructions

paragraph 3.B.4. within 200 flight cycles or 6 months after the Revision 4 date of this service bulletin,

whichever occurs first. If any damage or incorrect operation is found, replace the sequence carriage

slider and/or sidewall rubstrips in accordance with Accomplishment Instructions paragraph 3.B.4.a.

Repeat the general visual inspection and functionality check at intervals not to exceed 500 flight cycles.

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.

The Manager of the FAA Seattle Aircraft Certification Office approves the inspections, repair/modification

and replacement of the foreflap carriage attachment fittings, defined in SB 727-57A0135, Revision 4,

as an alternative method of compliance to the inspections, repair/modification and replacement of the

foreflap carriage attachment fittings, defined in SB 727-57A0135, Revision 3, dated June 27, 2002,

and required by paragraphs (f), (g), (h), (i), (n) and (o) of AD 2005-14-07. When this service bulletin

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

in accordance with paragraph (i) of the AD. All provisions of AD 2005-14-07 that are not specifically

referenced in the above statement remain fully applicable and must be complied with accordingly.

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 this 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.

NOTE: This estimate does not include the man-hour data for work done in service bulletins

727-57-0059, 727-57-0072 or 727-27-0133.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 1 0.50 0.50

Visual / HFEC Inspection 2 4.00 2.00 (a)

Fitting Replacement 1 0.75 0.75 (b)

Fit / Trim 2 2.00 1.00 (c)

Close Access 1 0.50 0.50

General Visual Inspection and 1 1.00 1.00

Functionality Check

Test (operational) 2 1.00 0.50

TOTAL FOR EACH AIRPLANE 9.75 6.75

(a) All fittings.

(b) Each Fitting.

(c) Each foreflap.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 23907, PRR 24826-R.

b. Boeing Service Bulletin 727-27-0133, 727-57-0059, 727-57-0072.

c. Boeing Service Related Problem (SRP) 727-SRP-57-0128, 727-SRP-57-0243 .

d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-14-07.

e. Overhaul Manual (OHM) 57-52-01, 57-52-11.

f. Service Bulletin Index D6-9825.

g. Standard Overhaul Practices Manual (SOPM) 20-10-02, 20-10-03, 20-20-01, 20-30-03,

20-41-02, 20-42-10.

h. 727 Aircraft Maintenance Manual (AMM) 727 AMM 27-51-00, 27-51-04, 27-51-14.

i. 727 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Figure 2 and Part 6, 57-40-27,

Figure 3.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

65-21631, Sht 4 Fore Flap - Outboard Flap, Assy of

The table above lists applicable drawings used to prepare this service bulletin. The drawings are

not necessary to make the specified changes, and are not supplied with this service bulletin. The

drawings may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

Publication Chapter-Section

727 Operations Manual 57-52

727 Illustrated Parts Catalog 57-53

727 Component Maintenance Manual 57-52

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 and new DTI requirements for the structure

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

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability

information.

M. Software Accomplishment Summary

Not affected.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each

Airplane and Paragraph 2.D., Parts Necessary to Change Spares. As an alternative, operators can

purchase the parts from Boeing Spares. This service bulletin does not show the Boeing price and

supply data.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair

procedures given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

QTY Part NUmber Name

BACS40R007U015 (or Shim Laminated

equivalent)

As Necessary

Outboard Foreflap Carriage Attach

Fitting - WBL 348

1 69-26255-5 Left Wing

Outboard Foreflap Carriage Attach

Fitting - WBL 348

69-26255-6 Right Wing, opposite1

Outboard Foreflap Carriage Attach

Fitting - WBL 442

1 69-26256-3 Left Wing

Outboard Foreflap Carriage Attach

Fitting - WBL 442

69-26256-4 Right Wing, opposite1

Inboard Foreflap Carriage Attach

Fitting - WBL 124 & 224

2 69-26257-3 Left Wing

Inboard Foreflap Carriage Attach

Fitting - WBL 124 & 224

69-26257-4 Right Wing, opposite2

Bolt for Outboard fitting - WBL 348

(Figure 4)

2 BACB30VF4K6

4 BACB30ZB4-8 Bolt - Lug/Clevis

4 BACB30ZB5-8 Bolt - Lug/Clevis

8 BACB30ZB4-8 Bolt - Lug/Clevis

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
2. Parts and Materials Supplied by the Operator

Part Number / Speci- QTY Name Notes

fication

BACS40R007U015 As Necessary Shim laminated -

(or equivalent)

BMS 10-11, Type 1 As Necessary Primer -

BMS 10-11, Type 2 As Necessary Gray Enamel -

3. Parts Modified and Reidentified

Existing Part QTY Name New Part Number Notes

Number

Outboard Foreflap, 69-26255-5 (a) (b) (c)

Carriage Fitting, Left

Wing (BL348)

69-26255-3 1

Outboard Foreflap, 69-26255-6 (a) (b) (c)

Carriage Fitting, Right

Wing (BL348)

69-26255-4 1

Outboard Foreflap, 69-26256-3 (a) (b) (c)

Carriage Fitting, Left

Wing (BL442)

69-26256-1 1

Outboard Foreflap, 69-26256-4 (a) (b) (c)

Carriage Fitting, Right

Wing (BL442)

69-26256-2 1

Inboard Foreflap, Car- 69-26257-3 (a) (b) (c)

riage Fitting, Left Wing

(BL 124 & 224)

69-26257-1 2

Inboard Foreflap, Car- 69-26257-4 (a) (b) (c)

riage Fitting, Right Wing

(BL 124 & 224)

69-26257-2 2

(a) Discard the existing part (after hole transfer location is made to the new part).

(b) This is the part number for the new equivalent or replacement part. To get a new part, use

this part number in your order.

(c) Do not use the existing part to replace the new or changed part.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
QTY Part Number Name

BACS40R007U015 (or Shim Laminated

equivalent)

As Necessary

Outboard Foreflap Carriage Attach

Fitting - WBL 348

1 69-26255-5 Left Wing

Outboard Foreflap Carriage Attach

Fitting - WBL 348

69-26255-6 Right Wing, opposite1

Outboard Foreflap Carriage Attach

Fitting - WBL 442

1 69-26256-3 Left Wing

Outboard Foreflap Carriage Attach

Fitting - WBL 442

69-26256-4 Right Wing, opposite1

Inboard Foreflap Carriage Attach

Fitting - WBL 124 & 224

2 69-26257-3 Left Wing

Inboard Foreflap Carriage Attach

Fitting - WBL 124 & 224

69-26257-4 Right Wing, opposite2

Bolt for Outboard fitting - WBL 348

(Figure 4)

2 BACB30VF4K6

4 BACB30ZB4-8 Bolt - Lug/Clevis

4 BACB30ZB5-8 Bolt - Lug/Clevis

8 BACB30ZB4-8 Bolt - Lug/Clevis

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
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ALERT ALERT

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

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

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

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

SRM Chapter 51.

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

standards given in SRM Chapter 51, then a fastener of the same specification, or

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

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

6. 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.

7. 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 enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally 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.

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

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

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

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

must be used.

9. Boeing Service Letter 727-SL-51-041, Damage Reporting and Repair Plan/Design

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

additional structural repair instructions. The Service Letter describes what information

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

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ALERT ALERT
10. 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.

11. 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.

12. 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

1. Provide system A hydraulic power (reference 727 AMM 27-51-00 ) and extend the inboard and

outboard trailing edge flaps. Then, remove system A hydraulic power. Refer to 727 AMM 27-51-00

as an accepted procedure. At the P6 circuit breaker panel, OPEN the FLAP breaker and place a

"Do-Not-Disturb" placard at this breaker. Support the Foreflap in its extended position.

2. Inspect the two carriage attach fittings on the inboard and outboard Foreflaps, of each wing, in

accordance with Figure 1.

a. If no cracking is found, continue on with Paragraph 3 (note compliance time for this

requirement).

b. If any crack is found, remove the carriage attach fitting from the Foreflap. The Foreflap

Sequencing Carriage will first have to be removed. Refer to 727 AMM 27-51-04 (Inboard

Flap) and 727 AMM 27-51-14 (Outboard Flap) as an accepted procedure for carriage removal.

Then remove the carriage attach fitting. Refer to OHM 57-52-11 (Outboard T.E. Flap) and

OHM 57-52-01 (Inboard T.E. Flap) as an accepted procedure. Transfer the mounting holes

from the removed carriage attach fitting to its replacement carriage attach fitting (The fittings

are unique to their location.).

(1) If you install an existing part number carriage attach fitting on the inboard and/or outboard

Foreflaps, refer to OHM 57-52-11 (Outboard T.E. Flap) and OHM 57-52-01 (Inboard T.E.

Flap) as an accepted procedure for installation. Refer to Paragraph 1.E., Compliance for

continued inspections of the old fitting until the improved fitting is installed on the Foreflap.

(2) If you install an improved carriage attach fitting (reference Existing Parts Accountability),

install as follows:

(a) For the two locations on the inboard (WBL 124 / WBL 224) Foreflap, refer to OHM

57-52-01 (Inboard T.E. Flap) as an accepted procedure for installation. When

attaching the carriage lug to the improved fitting, remember that due to the increase

flange thicknesses of the clevis, install a longer bolt when you attach the lug to the

clevis as follows:

– Upper clevis hole: NAS1104-8 or BACB30ZB4-8.

– Lower clevis hole: NAS1105-8 or BACB30ZB5-8.

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ALERT ALERT
(b) For the WBL 442 outboard location on the outboard Foreflap, refer to OHM 57-52-11

(Outboard T.E. Flap) as an accepted procedure for installation. When attaching the

carriage lug to the improved fitting, remember that due to the increase flange

thicknesses of the clevis, install a longer bolt when you attach the lug to the clevis.

Use bolt NAS1104-8 or BACB30ZB4-8 at the upper and lower clevis hole locations.

(c) For the WBL 348 (most inboard) location on the outboard Foreflap, refer to OHM

57-52-11 (Outboard T.E. Flap) as an accepted procedure for installation, except for

one bolt location (aft outboard) install in accordance with Figure 4.

When attaching the carriage lug to the improved fitting, remember that due to the

increase flange thicknesses of the clevis, install a longer bolt when you attach the

lug to the clevis. Use bolt NAS1104-8 or BACB30ZB4-8 at the upper and lower clevis

hole locations.

c. Reinstall the Foreflap Sequencing Carriage. Refer to 727 AMM 27-51-04 (Inboard Flap) and

727 AMM 27-51-14 (Outboard Flap) as an accepted procedure. Then continue on with

Paragraph 3.

3. Measure the distance between the carriage attach fitting and the carriage lug fitting in accordance

with Figure 2.

a. If the clearance is between 0.000 inch and 0.003 inch, no more work is necessary. Install the

bolt.

b. If the clearance is more than 0.003 inch, add a shim. Install BACS40R007U015. Remove

laminations, as necessary. Apply 2 layers of Primer (BMS 10-11, Type 1) and 1 layer of Enamel

(BMS 10-11, Type 2). Refer to SOPM 20-41-02 as an accepted procedure.

c. If interference is found, rework the carriage attach lug in accordance with Figure 3.

4. For the outboard foreflap only, do a general visual inspection and functionality check of the outbd

foreflap installation for damage and incorrect operation. Refer to 727 AMM 27-51-14 as an accepted

procedure.

a. If any damage or incorrect operation is found, replace the sequence carriage slider and/or

sidewall rubstrips as required. Refer to 727 AMM 27-51-14 as an accepted procedure.

b. If no damage is found and the flap operates correctly, repeat the general visual inspection

and functionality check of the flap system at the interval given in Paragraph 1.E., Compliance.

5. Put the airplane back to a condition that is approved for service.

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
FIGURE 1: INSPECTION

(SHEET 1 OF 2)

Export Controlled ECCN: 9E991 - BOEING

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30 of 37

BOEING SERVICE BULLETIN 727-57A0135

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

numbers shown below are the numbers of parts necessary for one fitting.

STEP TASK NAME PROCEDURE NOTES

Keep the parts to use

again if they are in

an approved condition for service.

1 Remove / Keep Bolt, Washer, Nut -

Look for any crack or

surface deviation on

all edges, surfaces

and holes. (a)

Hole, Base Radius, Detailed Inspection

Lug Face, forward

edge

2 Inspect

Look for any crack in

accordance with 727

NDT Part 6, 51-00-

00, Figure 2.

High Frequency Eddy Current3 Inspect Hole

Look for any crack in

accordance with 727

NDT Part 6, 57-40-

27, Figure 3.

High Frequency Eddy CurrentHole, Base Radius,

Lug Face, forward

edge

4 Inspect

If there is no crack, reinstall the bolt, washer and nut.

(a) Nicks, scratches or dents are NOT permitted on the forward surface or in the hole. If found, replace the

fitting. The lug surface finish must be 125 microinches or better.

FIGURE 1: INSPECTION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
FIGURE 2: CHECK FOR CLEARANCE / INTERFERENCE

(SHEET 1 OF 2)

Export Controlled ECCN: 9E991 - BOEING

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Work - See page 1 for details.

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BOEING SERVICE BULLETIN 727-57A0135

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

numbers shown below are the numbers of parts necessary for one fitting.

STEP TASK NAME PART NUMBER QTY NOTES

Minimum permitted thickness is

0.09 inch for existing fitting (nonimproved fitting) configuration.

Measure / Distance - 2

Record

1

Minimum permitted radius is 0.09

inch for existing fitting (non-improved fitting) configuration.

Measure / Radius - 2

Record

2

Maximum permitted finish is 125

micro inches. (a)

Inspect / Surface Finish - -

Record

3

Between the attach fitting clevis and

the carriage attach lug. (b)

4 Inspect Clearance / - -

Measure / Interference - -

Record

(a) Surface deformations, scratches and dents only can be blended out at a 10:1 taper ratio, and reworked.

Refer to OHM 57-52-11 (Outboard T.E. Flap) and OHM 57-52-01 (Inboard T.E. Flap) as an accepted

procedure. The minimum thickness after rework of the old configuration fitting is 0.090 inch. NOTE: Contact

Boeing if rework of the improved fitting is required.

(b) Minimum thickness of carriage attach lug is 0.14 inch.

FIGURE 2: CHECK FOR CLEARANCE / INTERFERENCE

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
FIGURE 3: REWORK OF LUG ASSEMBLY

(SHEET 1 OF 3)

Export Controlled ECCN: 9E991 - BOEING

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Work - See page 1 for details.

Original Issue: February 07, 1975

Revision 4 September 26, 2012 727-57A0135

34 of 37

BOEING SERVICE BULLETIN 727-57A0135

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

numbers shown below are the numbers of parts necessary for one fitting.

STEP TASK NAME PART NUMBER QTY NOTES

In accordance with OHM 57-52-11

(Outboard T.E. Flap) and OHM 57-

52-01 (Inboard T.E. Flap). (a)

Remove / Lug Assembly - -

Keep

1

Remove / Shim - -

Keep

In accordance with SOPM 20-30-

03.

2 Clean Lug face - -

As necessary for a maximum

clearance of 0.003 inch. Hold a

surface finish of 125 micro inches

or better in accordance with SOPM

20-10-02 and SOPM 20-10-03. (b)

Sand or Grind - -

Magnetic Particle Inspection in accordance with SOPM 20-20-01.Inspect Lug face - -

In accordance with SOPM 20-10-

03.

Flap Peen Lug face - -

To the lug face in accordance with

SOPM 20-42-10.

Cadmium Plate, - -

Stylus

Apply

Magnetic Particle Inspection in accordance with SOPM 20-20-01.Inspect Lug face - -

One layer of each on the lug face

in accordance with SOPM 20-41-

02.

BMS 10-11, Type -

1

Apply Primer

BMS 10-11, Type -

2

Apply Enamel

In accordance with OHM 57-52-11

(Outboard T.E. Flap) and OHM 57-

52-01 (Inboard T.E. Flap) for correct fasteners.

69-26258 (d) -or- 1

69-30160 (c)

Put / Hold / Lug Assembly

Align

3

Put / Hold / Shim BACS40R007U015 1 Locate to match the carriage lug.

Align

4

Match holes in shim to the carriage

lug.

Drill / Deburr 2

FIGURE 3: REWORK OF LUG ASSEMBLY

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

In accordance with OHM 57-52-11

(Outboard T.E. Flap) and OHM 57-

52-01 (Inboard T.E. Flap). Shim

equally both lug faces where material was removed, if necessary.

0.003 inch maximum gap prior to

torqueing.

5 Install / Kept Lug Assembly - 1

Install / Kept Shim - 1

In accordance with OHM 57-52-11

(Outboard T.E. Flap) and OHM 57-

52-01 (Inboard T.E. Flap).

6 Install / Kept Bolt - 2

Install / Kept Washer - 2

Install / Kept Nut - 2

(a) The Lug Assembly includes the carriage attach lug and the bearing. Do not remove the bearing. Use the

parts again if they are in an approved condition for service.

(b) Minimum lug thickness is 0.14 inch.

(c) Inboard Flap.

(d) Outboard Flap.

FIGURE 3: REWORK OF LUG ASSEMBLY

(SHEET 3 OF 3)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 727-57A0135

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

numbers shown below are the numbers of parts necessary for one fitting.

STEP TASK NAME PART NUMBER QTY NOTES

Aft outboard location for improved

fitting only. Hole is 0.250 - 0.254

inches dia. Counter Sink is 100

deg. X -.360-0.370 inch diameter..

1 Install Bolt BACB30VF4K6 1

For installation of all other mounting holes and fasteners refer to OHM 57-52-11 as an accepted procedure.

FIGURE 4: CARRIAGE FITTING INSTALLATION FOR OUTBOARD FORE FLAP WBL 348 - DEVIATION

FROM OVERHAUL MANUAL

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 727-57A0135

ALERT ALERT