Commercial 

Airplanes MD80

Service Bulletin

ALERT

Number: MD80-55A067

Original Issue: June 24, 2010

ATA System: 5531

SUBJECT: STABILIZERS - Vertical Stabilizer - Inspect/Repair Fixed Leading Edge Skin and Front

Spar Cap at Station Zfs=52.267

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ECCN: 9E991

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Unpublished Work - All Rights Reserved

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

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

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

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BLANK PAGE
Table of Contents

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 27

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 29

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 29

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE INSPECTION . . . . . . . . . . 43

APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267 . 46

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Commercial 

Airplanes MD80

Service Bulletin

ALERT

Summary Number: MD80-55A067

Original Issue: June 24, 2010

ATA System: 5531

SUBJECT: STABILIZERS - Vertical Stabilizer - Inspect/Repair Fixed Leading Edge Skin and Front

Spar Cap at Station Zfs=52.267

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

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

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

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Two operators reported finding a cracked vertical stabilizer skin at Station Zfs=52.267. Subsequent inspection

revealed a severed front spar cap and a cracked front spar web. Cracks were also found on several other MD-80

airplanes, in the vertical stabilizer front spar cap bolt holes. The affected MD-80 airplanes had accrued between

39,749 through 56,212 flight-hours and 32,176 through 44,001 landing cycles when the cracks/anomalies were

found. Boeing investigation determined that the skin cracks are due to high loading occurrences, such as, but

not limited to, in-flight turbulence. Inspection will determine condition of the vertical stabilizer skin. Incorporation

of the leading edge repair will minimize the possibility of crack growth. If not corrected, cracks in the vertical

stabilizer leading edge and front spar cap may result in the structure unable to support limit load, and may lead

to the loss of the vertical stabilizer.

ACTION

Refer to Paragraph 1.D., Description.

EFFECTIVITY

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

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

COMPLIANCE

Refer to Paragraph 1.E., Compliance.

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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MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BLANK PAGE
Commercial 

Airplanes MD80

Service Bulletin

ALERT

Number: MD80-55A067

Original Issue: June 24, 2010

ATA System: 5531

SUBJECT: STABILIZERS - Vertical Stabilizer - Inspect/Repair Fixed Leading Edge Skin and Front

Spar Cap at Station Zfs=52.267

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

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

(MD-87), MD-88 Airplanes

1 -

Airplane Models:

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

Fuselage Num- Group

ber

1000 - 1001 1

1004 - 1006 1

1008 - 1013 1

1016 1

1018 - 1019 1

1022 1

1025 1

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Fuselage Num- Group

ber

1031 1

1034 - 1035 1

1043 1

1045 1

1049 1

1051 1

1053 1

1055 1

1057 1

1059 - 1060 1

1063 - 1080 1

1082 - 1083 1

1085 1

1087 - 1093 1

1095 - 1110 1

1112 - 1128 1

1130 - 1158 1

1160 - 1179 1

1181 1

1183 - 1223 1

1225 - 1241 1

1243 - 1273 1

1275 - 1290 1

1292 - 1323 1

1325 - 1334 1

1336 - 1350 1

1352 - 1451 1

1453 - 1477 1

1479 - 1503 1

1505 - 1666 1

1668 - 1701 1

1703 - 1771 1

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Fuselage Num- Group

ber

1773 - 1777 1

1779 - 1843 1

1845 - 1915 1

1917 - 1924 1

1926 - 1994 1

1996 - 2007 1

2009 - 2016 1

2019 - 2029 1

2031 - 2034 1

2036 - 2069 1

2071 - 2093 1

2101 - 2114 1

2116 1

2118 - 2119 1

2121 1

2124 1

2127 1

2130 1

2132 1

2134 - 2135 1

2137 1

2139 1

2145 1

2148 1

2151 - 2152 1

2167 1

2174 1

2176 1

2178 1

2180 1

2183 1

2185 1

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Fuselage Num- Group

ber

2187 1

2189 1

2192 1

2196 1

2199 1

2201 1

2204 1

2206 1

2208 1

2214 1

2218 1

2234 1

2239 1

2241 1

2244 1

2247 1

2249 1

2252 1

2254 1

2264 - 2287 1

924 1

938 1

941 1

944 1

946 1

948 1

950 1

952 - 953 1

955 1

957 - 958 1

960 1

962 1

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Fuselage Num- Group

ber

965 - 967 1

969 - 971 1

973 - 975 1

977 - 979 1

981 1

983 1

986 1

988 1

991 - 992 1

994 - 995 1

997 1

999 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Two operators reported finding a cracked vertical stabilizer skin at Station Zfs=52.267. Subsequent

inspection revealed a severed front spar cap and a cracked front spar web. Cracks were also found

on several other MD-80 airplanes, in the vertical stabilizer front spar cap bolt holes. The affected MD-80

airplanes had accrued between 39,749 through 56,212 flight-hours and 32,176 through 44,001 landing

cycles when the cracks/anomalies were found. Boeing investigation determined that the skin cracks

are due to high loading occurrences, such as, but not limited to, in-flight turbulence. Inspection will

determine condition of the vertical stabilizer skin. Incorporation of the leading edge repair will minimize

the possibility of crack growth. If not corrected, cracks in the vertical stabilizer leading edge and front

spar cap may result in the structure unable to support limit load, and may lead to the loss of the vertical

stabilizer.

D. Description

This service bulletin provides instructions to do an initial inspection and repetitive inspections of the

vertical stabilizer leading edge structure at the splice at Station Zfs=52.267, and the vertical stabilizer

front spar cap forward flanges and either the aft flanges or side skins, as follows:

NOTE: Refer to APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE INSPECTION,

as a supplement to Paragraph 1.D., Description.

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PART A - INITIAL INSPECTION:

1. Removes two rows of fasteners above the splice and two rows of fasteners below the splice at

Station Zfs=52.267.

2. Does a detailed inspection for "distress" in, and "existing repairs" to, the vertical stabilizer leading

edge structure at the splice at Station Zfs=52.267.

NOTE: "Distress" is defined as deformed holes, elongated holes, oversized holes or cracks in

the leading edge skin and splice.

"Existing Repairs" are bushings, washers or reinforcing repairs to the leading edge.

3. Based on inspection results, does as follows:

CONDITION 1 (Leading Edge is Not Distressed and No Existing Repair Found)

a. Does an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267.

b. Based on inspection results, does as follows:

CONDITION 1A (No Crack Found)

(1) Puts the airplane back to a serviceable condition.

CONDITION 1B (Any Crack Found)

(1) Does an evaluation/verification to confirm all crack indications.

(2) Contacts Boeing for repair of all cracking and does the repair in accordance with Boeing's

instructions.

(3) Puts the airplane back to a serviceable condition.

CONDITION 2 (Leading Edge is Distressed)

a. Does an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267.

b. Based on inspection results, does as follows:

CONDITION 2A (No Crack Found)

(1) Does leading edge repair.

(2) Puts the airplane back to a serviceable condition.

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CONDITION 2B (Any Crack Found)

(1) Does leading edge repair.

(2) Does an evaluation/verification to confirm all crack indications.

(3) Contacts Boeing for repair of all cracking and does the repair in accordance with Boeing's

instructions.

(4) Puts the airplane back to a serviceable condition.

CONDITION 3 (Leading Edge Existing Repair Found)

a. Does an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267.

b. Based on inspection results, does as follows:

CONDITION 3A (No Crack Found)

(1) Puts the airplane back to a serviceable condition.

CONDITION 3B (Any Crack Found)

(1) Does an evaluation/verification to confirm all crack indications.

(2) Contacts Boeing for repair of all cracking and does the repair in accordance with Boeing's

instructions.

(3) Puts the airplane back to a serviceable condition.

PART B - REPETITIVE INSPECTION:

1. Inspection - Vertical Stabilizer Leading Edge:

a. Does a detailed inspection of the vertical stabilizer leading edge at the splice at Station

Zfs=52.267 (fasteners not removed) for indications of loose fasteners and missing fasteners.

b. Based on inspection results, does as follows:

CONDITION 4 (No Loose Leading Edge Fasteners and No Missing Leading Edge

Fasteners)

(1) Does repetitive detailed inspection of the vertical stabilizer leading edge at the splice at

Station Zfs=52.267 (fasteners not removed) for indications of loose fasteners and missing

fasteners.

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ALERT ALERT
CONDITION 5 (Loose Leading Edge Fasteners or Missing Leading Edge Fasteners)

(1) Does leading edge repair.

(2) Does repetitive detailed inspection of the vertical stabilizer leading edge at the splice at

Station Zfs=52.267 (fasteners not removed) for indications of loose fasteners and missing

fasteners.

2. Inspection - Vertical Stabilizer Front Spar Cap Forward Flanges and either the Aft Flanges or Side

Skins:

a. Does an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267.

b. Based on inspection results, does as follows:

CONDITION 6 (No Crack Found)

(1) Does repetitive inspection for cracks on the left and right vertical stabilizer front spar cap

forward flanges and either the aft flanges or side skins at Station Zfs=52.267.

CONDITION 7 (Any Crack Found)

(1) Does an evaluation/verification to confirm all crack indications.

(2) Contacts Boeing for repair of all cracking and does the repair in accordance with Boeing's

instructions.

3. Puts the airplane back to a serviceable condition.

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

Affected Maintenance Zones

Model Zone

DC-9-81 (MD-81), DC-9-82 63, 64

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

E. Compliance

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

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

service bulletin mandatory.

NOTE: Refer to APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE INSPECTION,

as a supplement to Paragraph 1.E., Compliance.

NOTE: "Distress" is defined as deformed holes, elongated holes, oversized holes or cracks in the

leading edge skin and splice.

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"Existing Repairs" are bushings, washers or reinforcing repairs to the leading edge.

Table 1: PART A - Initial Inspection: Fixed Leading Edge Skin and Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 4,500 flight -

cycles after the

original issue date

on this service bulletin.

Do a detailed inspection for "distress" in, and

"existing repairs" to, the vertical stabilizer

leading edge structure at the splice at Station

Zfs=52.267 in accordance with Paragraph

3.B., Work Instructions.

All Airplanes

Before further -

flight.

Do an inspection for cracking on the left and

right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267, using one of the

options as follows:

CONDITION 1

(Leading Edge is Not

Distressed and No Existing Repair Found)

OPTION 1: - -

Do an open hole Eddy Current, High Frequency (ETHF) inspection of the left and

right vertical stabilizer front spar cap forward

flanges in accordance with Paragraph 3.B.,

Work Instructions.

AND

Do a Radiographic Testing (RT) inspection

of the left and right vertical stabilizer front

spar cap aft flanges in accordance with

Paragraph 3.B., Work Instructions.

OR

OPTION 2: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an ETHF surface inspection of the left

and right side skins at the vertical stabilizer

front spar cap aft flanges in accordance with

Paragraph 3.B., Work Instructions.

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ALERT ALERT
Table 1: PART A - Initial Inspection: Fixed Leading Edge Skin and Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

In Accordance With -

Table 2: PART B -

Repetitive Inspection: Fixed Leading

Edge Skin at Station Zfs=52.267

Do repetitive inspections of the vertical stabilizer leading edge structure at the splice at

Station Zfs=52.267 in accordance with

Paragraph 3.B., Work Instructions.

CONDITION 1A

(No Crack Found during either Option 1 or

Option 2 Inspection)

AND

In Accordance With -

Table 3: PART B -

Repetitive Inspection: Front Spar

Cap at Station

Zfs=52.267

Do repetitive inspections of the left and right

vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267 in accordance

with Paragraph 3.B., Work Instructions.

Before further -

flight.

Do an evaluation/verification to confirm all

crack indications in accordance with Paragraph 3.B., Work Instructions.

CONDITION 1B

(Any Crack Found during either Option 1 or

Option 2 Inspection)

Before further -

flight.

Contact Boeing for repair of all cracking and

do the repair in accordance with Boeing's

instructions.

CONDITION 1B

(Any confirmed crack

indication)

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ALERT ALERT
Table 1: PART A - Initial Inspection: Fixed Leading Edge Skin and Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do an inspection for cracking on the left and

right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267, using one of the

options as follows:

CONDITION 2

(Leading Edge is Distressed)

OPTION 1: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an RT inspection of the left and right

vertical stabilizer front spar cap aft flanges

in accordance with Paragraph 3.B., Work

Instructions.

OR

OPTION 2: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an ETHF surface inspection of the left

and right side skins at the vertical stabilizer

front spar cap aft flanges in accordance with

Paragraph 3.B., Work Instructions.

Before further -

flight.

Do leading edge repair in accordance with

Paragraph 3.B., Work Instructions.

CONDITION 2A

(No Crack Found during either Option 1 or

Option 2 Inspection) AND

In Accordance With -

Table 2: PART B -

Repetitive Inspection: Fixed Leading

Edge Skin at Station Zfs=52.267

Do repetitive inspections of the vertical stabilizer leading edge structure at the splice at

Station Zfs=52.267 in accordance with

Paragraph 3.B., Work Instructions.

AND

In Accordance With -

Table 3: PART B -

Repetitive Inspection: Front Spar

Cap at Station

Zfs=52.267

Do repetitive inspections of the left and right

vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267 in accordance

with Paragraph 3.B., Work Instructions.

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ALERT ALERT
Table 1: PART A - Initial Inspection: Fixed Leading Edge Skin and Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do leading edge repair in accordance with

Paragraph 3.B., Work Instructions.

CONDITION 2B

(Any Crack Found during either Option 1 or

Option 2 Inspection) AND

Before further -

flight.

Do an evaluation/verification to confirm all

crack indications in accordance with Paragraph 3.B., Work Instructions.

AND

Before further -

flight.

Contact Boeing for repair of all cracking and

do the repair in accordance with Boeing's

instructions.

CONDITION 2B

(Any confirmed crack

indication)

Before further -

flight.

Do an inspection for cracking on the left and

right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267, using one of the

options as follows:

CONDITION 3

(Leading Edge Existing

Repair Found)

OPTION 1: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an RT inspection of the left and right

vertical stabilizer front spar cap aft flanges

in accordance with Paragraph 3.B., Work

Instructions.

OR

OPTION 2: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an ETHF surface inspection of the left

and right side skins at the vertical stabilizer

front spar cap aft flanges in accordance with

Paragraph 3.B., Work Instructions.

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ALERT ALERT
Table 1: PART A - Initial Inspection: Fixed Leading Edge Skin and Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

In Accordance With -

Table 2: PART B -

Repetitive Inspection: Fixed Leading

Edge Skin at Station Zfs=52.267

Do repetitive inspections of the vertical stabilizer leading edge structure at the splice at

Station Zfs=52.267 in accordance with

Paragraph 3.B., Work Instructions.

CONDITION 3A

(No Crack Found during either Option 1 or

Option 2 Inspection)

AND

In Accordance With -

Table 3: PART B -

Repetitive Inspection: Front Spar

Cap at Station

Zfs=52.267

Do repetitive inspections of the left and right

vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267 in accordance

with Paragraph 3.B., Work Instructions.

Before further -

flight.

Do an evaluation/verification to confirm all

crack indications in accordance with Paragraph 3.B., Work Instructions.

CONDITION 3B

(Any Crack Found during either Option 1 or

Option 2 Inspection)

Before further -

flight.

Contact Boeing for repair of all cracking and

do the repair in accordance with Boeing's

instructions.

CONDITION 3B

(Any confirmed crack

indication)

Table 2: PART B - Repetitive Inspection: Fixed Leading Edge Skin at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 4,400 flight -

cycles after doing

the initial inspection.

Do a detailed inspection of the vertical stabilizer leading edge structure at the splice at

Station Zfs=52.267 for indications of loose

fasteners and missing fasteners in accordance with Paragraph 3.B., Work Instructions.

Airplanes from CONDITION 1A or 2A or 3A of

Table 1: PART A - Initial Inspection on which

the OPTION 1 inspections were done.

Within 3,000 flight -

cycles after doing

the initial inspection.

Do a detailed inspection of the vertical stabilizer leading edge structure at the splice at

Station Zfs=52.267 for indications of loose

fasteners and missing fasteners in accordance with Paragraph 3.B., Work Instructions.

Airplanes from CONDITION 1A or 2A or 3A of

Table 1: PART A - Initial Inspection on which

the OPTION 2 inspections were done.

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ALERT ALERT
Table 2: PART B - Repetitive Inspection: Fixed Leading Edge Skin at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

4,400 flight cycles

(a)

Within 4,400 flight

cycles after doing

the detailed inspection.

Do repetitive detailed inspection of the vertical stabilizer leading edge structure at the

splice at Station Zfs=52.267 for indications

of loose fasteners and missing fasteners in

accordance with Paragraph 3.B., Work Instructions.

CONDITION 4

(No Loose Leading

Edge Fasteners and No

Missing Leading Edge

Fasteners) for airplanes

on which the prior inspection of the front

spar cap was done using OPTION 1.

3,000 flight cycles

(a)

Within 3,000 flight

cycles after doing

the detailed inspection.

Do repetitive detailed inspection of the vertical stabilizer leading edge structure at the

splice at Station Zfs=52.267 for indications

of loose fasteners and missing fasteners in

accordance with Paragraph 3.B., Work Instructions.

CONDITION 4

(No Loose Leading

Edge Fasteners and No

Missing Leading Edge

Fasteners) for airplanes

on which the prior inspection of the front

spar cap was done using OPTION 2.

Before further -

flight.

Do leading edge repair in accordance with

Paragraph 3.B., Work Instructions.

CONDITION 5

(Loose Leading Edge

Fasteners or Missing

Leading Edge Fasteners) for airplanes on

which the prior inspection of the front spar

cap was done using

OPTION 1.

AND

4,400 flight cycles

(a)

Within 4,400 flight

cycles after doing

the detailed inspection.

Do repetitive detailed inspection of the vertical stabilizer leading edge structure at the

splice at Station Zfs=52.267 for indications

of loose fasteners and missing fasteners in

accordance with Paragraph 3.B., Work Instructions.

Before further -

flight.

Do leading edge repair in accordance with

Paragraph 3.B., Work Instructions.

CONDITION 5

(Loose Leading Edge

Fasteners or Missing

Leading Edge Fasteners) for airplanes on

which the prior inspection of the front spar

cap was done using

OPTION 2.

AND

3,000 flight cycles

(a)

Within 3,000 flight

cycles after doing

the detailed inspection.

Do repetitive detailed inspection of the vertical stabilizer leading edge structure at the

splice at Station Zfs=52.267 for indications

of loose fasteners and missing fasteners in

accordance with Paragraph 3.B., Work Instructions.

(a) Changing from one inspection option to another option is acceptable, provided the repeat interval requirement is first complied with, before changing options.

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ALERT ALERT
Table 3: PART B - Repetitive Inspection: Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 4,400 flight -

cycles after doing

the initial inspection.

Do an inspection for cracking on the left and

right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267, using one of the

options as follows:

Airplanes from CONDITION 1A or 2A or 3A of

Table 1: PART A - Initial Inspection on which

the OPTION 1 inspections were done. OPTION 1: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an RT inspection of the left and right

vertical stabilizer front spar cap aft flanges

in accordance with Paragraph 3.B., Work

Instructions.

OR

OPTION 2: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an ETHF surface inspection of the left

and right side skins at the vertical stabilizer

front spar cap aft flanges in accordance with

Paragraph 3.B., Work Instructions.

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ALERT ALERT
Table 3: PART B - Repetitive Inspection: Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 3,000 flight -

cycles after doing

the initial inspection.

Do an inspection for cracking on the left and

right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267, using one of the

options as follows:

Airplanes from CONDITION 1A or 2A or 3A of

Table 1: PART A - Initial Inspection on which

the OPTION 2 inspections were done. OPTION 1: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an RT inspection of the left and right

vertical stabilizer front spar cap aft flanges

in accordance with Paragraph 3.B., Work

Instructions.

OR

OPTION 2: - -

Do an open hole ETHF inspection of the left

and right vertical stabilizer front spar cap

forward flanges in accordance with Paragraph 3.B., Work Instructions.

AND

Do an ETHF surface inspection of the left

and right side skins at the vertical stabilizer

front spar cap aft flanges in accordance with

Paragraph 3.B., Work Instructions.

4,400 flight cycles

(a)

Within 4,400 flight

cycles after doing

the inspection.

Do repetitive inspections of the left and right

vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267 in accordance

with Paragraph 3.B., Work Instructions.

CONDITION 6

(No Crack Found) for

airplanes on which the

prior inspection of the

front spar cap was

done using OPTION 1.

3,000 flight cycles

(a)

Within 3,000 flight

cycles after doing

the inspection.

Do repetitive inspections of the left and right

vertical stabilizer front spar cap forward

flanges and either the aft flanges or side

skins at Station Zfs=52.267 in accordance

with Paragraph 3.B., Work Instructions.

CONDITION 6

(No Crack Found) for

airplanes on which the

prior inspection of the

front spar cap was

done using OPTION 2.

Before further -

flight.

Do an evaluation/verification to confirm all

crack indications in accordance with Paragraph 3.B., Work Instructions.

CONDITION 7

(Any Crack Found during either Option 1 or

Option 2 Inspection)

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ALERT ALERT
Table 3: PART B - Repetitive Inspection: Front Spar Cap at Station Zfs=52.267

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Contact Boeing for repair of all cracking and

do the repair in accordance with Boeing's

instructions.

CONDITION 7

(Any confirmed crack

indication)

(a) Changing from one inspection option to another option is acceptable, provided the repeat interval requirement is first complied with, before changing options.

F. Approval

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

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

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

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

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

changes.

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

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

before incorporating this service bulletin.

G. Manpower

The table below shows an estimate of the task hours necessary to do the inspection/change/repair for

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

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

examples of lost time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Table 1: PART A - Initial Inspection: Fixed Leading Edge Skin and Front Spar Cap at Station

Zfs=52.267

Task Number of Persons Task Hours Elapsed Hours

Remove Fasteners - 1 1.5 1.5

Fixed Leading Edge

Inspect - Fixed Lead- 1 1.0 1.0

ing Edge

Remove Fasteners - 1 1.0 1.0

Front Spar Cap Forward Flange

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ALERT ALERT
Table 1: PART A - Initial Inspection: Fixed Leading Edge Skin and Front Spar Cap at Station

Zfs=52.267

Task Number of Persons Task Hours Elapsed Hours

Inspect - Front Spar 1 1.0 1.0

Cap Forward Flange

Install Fasteners - 1 1.5 1.5

Front Spar Cap Forward Flange

Inspect - Front Spar 1 2.0 2.0

Cap Aft Flange

Install Fasteners - 1 2.0 2.0

Fixed Leading Edge

TOTAL FOR EACH AIRPLANE 10.0 10.0

(a) (b)

(a) Inspection hours given are for each airplane.

(b) Task hours required for repairs are not included and are to be determined by

the operator based on inspection results.

Table 2: PART B - Repetitive Inspection: Fixed Leading Edge Skin and Front Spar Cap at

Station Zfs=52.267

Task Number of Persons Task Hours Elapsed Hours

Inspect - Fixed Lead- 1 1.0 1.0

ing Edge

Remove Fasteners - 1 1.0 1.0

Front Spar Cap Forward Flange

Inspect - Front Spar 1 1.0 1.0

Cap Forward Flange

Install Fasteners - 1 1.5 1.5

Front Spar Cap Forward Flange

Inspect - Front Spar 1 2.0 2.0

Cap Aft Flange

TOTAL FOR EACH AIRPLANE 6.5 6.5

(a) (b)

(a) Inspection hours given are for each airplane.

(b) Task hours required for repairs are not included and are to be determined by

the operator based on inspection results.

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ALERT ALERT
H. Weight and Balance Changes

Weight and balance changes affected by incorporation of this service bulletin are contingent upon the

changes to each particular airplane. Weight data is to be computed by the operator by weighing parts

removed and parts installed during this change. Necessary revisions should be made to the appropriate

airplane weight and balance report.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Non-Destructive Test Standard Practices Manual (NDTSPM), 02-00-07, 06-00-07,

06-10-01.001, 06-10-01.003, Part 01-00-03, Part 02-00-03, Part 02-00-04, Part 06-00-03,

Part 06-00-04.

b. MD80 Structural Repair Manual (SRM) 55-03 Figure 29, Figure 30, and Figure 31, dated

March 15, 2010.

2. Data supplied with this Service Bulletin

None.

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

Document Number Title Change

REPAIR-FIXED LEADING EDGE A

SKIN, ZFS=52.267, VERTICAL STABILIZER

SG09550004

5912123 STRUCTURE ASSY-VERT STAB DA

LEADING EDGE INSTL-VERTICAL Y

STABILIZER

5930609

5911394 CAP-VERT STAB FRONT SPAR F

9911833 SPAR ASSY-VERT STAB, FRONT AD

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

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

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

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ALERT ALERT
Publication Chapter-Section

Structural Repair Manual MD80 SRM 55-03

2. Damage Tolerance Based Structural Inspections:

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

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

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

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

L. Interchangeability and Intermixability of Parts

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

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

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

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts

Based on inspection results, refer to Figure 29 or Figure 30 or Figure 31 of MD80 SRM 55-03,

dated March 15, 2010, for repair parts necessary for each airplane.

2. Parts and Materials Supplied by the Operator

Based on inspection results, refer to Figure 29 or Figure 30 or Figure 31 of MD80 SRM 55-03,

dated March 15, 2010, for operator supplied parts and materials necessary to do the required

repairs.

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

Inspection equipment required to accomplish this service bulletin are listed in APPENDIX B and in the

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

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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ALERT ALERT

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

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

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

CAN OCCUR.

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

TO THE AIRPLANE OR EQUIPMENT.

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

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

bulletin can be changed.

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

definition of the acronyms.

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

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

accordance with MD80 SRM 51.

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

6. The inspection area of the vertical stabilizer leading edge structure is two rows of

fasteners above the splice and two rows of fasteners below the splice at Station

Zfs=52.267.

7. "Distress" in the vertical stabilizer leading edge structure at the splice at Station

Zfs=52.267 is defined as deformed holes, elongated holes, oversized holes or cracks

in the leading edge skin and splice.

8. "Existing Repairs" to the vertical stabilizer leading edge structure at the splice at

Station Zfs=52.267 are bushings, washers or reinforcing repairs to the leading edge.

9. "Breakaway torque" is defined as the torque required to overcome static friction when

100 percent of the locking feature is engaged and the fastener is unseated. Breakaway

torque can be prefixed with a "maximum" or "minimum", and can be measured in

either a loosening or tightening direction. Check for proper minimum breakaway

torque. The minimum breakaway torque value for 1/4 inch diameter fasteners is 5.0

inch-pounds. The minimum breakaway torque value for 5/16 inch diameter fasteners

is 7.0 inch-pounds.

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10. The inspection area of the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins is defined as 12.50 inches +/- 0.25

inch above the leading edge skin splice and 12.50 inches +/- 0.25 inch below the

leading edge skin splice at Station Zfs=52.267.

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 same part.

The removed part can be discarded if a new part or serviceable part is installed.

12. Refer to APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE

INSPECTION which describes the initial inspection and repetitive inspection

requirements and can be used as a supplement to Paragraph 3.B., Work Instructions.

13. Refer to APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR

CAP AT STATION ZFS=52.267, for the inspection procedures and requirements in

accordance with Paragraph 3.B., Work Instructions.

14. 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.

15. 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

PART A - INITIAL INSPECTION:

1. Do an initial inspection of the vertical stabilizer leading edge structure at the splice at Station

Zfs=52.267 as follows:

a. Remove and keep two rows of fasteners above the splice and two rows of fasteners below

the splice at Station Zfs=52.267.

NOTE: Remove fasteners one row at a time.

b. Do a detailed inspection for "distress" in, and "existing repairs" to, the vertical stabilizer leading

edge structure at the splice at Station Zfs=52.267.

NOTE: "Distress" is defined as deformed holes, elongated holes, oversized holes or cracks

in the leading edge skin and splice.

"Existing Repairs" are bushings, washers or reinforcing repairs to the leading edge.

2. Based on inspection results, do as follows:

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ALERT ALERT
CONDITION 1 (Leading Edge is Not Distressed and No Existing Repair Found)

a. Do an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267 in accordance with

APPENDIX B, using one of the options as follows:

NOTE: The inspection area is defined as 12.50 inches +/- 0.25 inch above the leading edge

skin splice and 12.50 inches +/- 0.25 inch below the leading edge skin splice at

Station Zfs=52.267.

OPTION 1:

(1) Do an Eddy Current, High Frequency (ETHF) inspection of the left and right vertical

stabilizer front spar cap forward flanges as follows:

(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do a Radiographic Testing (RT) inspection of the left and right vertical stabilizer front

spar cap aft flanges in accordance with the inspection procedure in APPENDIX B,

Inspection Sequence 2 - Option 1.

OPTION 2:

(1) Do an ETHF inspection of the left and right vertical stabilizer front spar cap forward flanges

as follows:

(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do an ETHF surface inspection of the side skin at the left and right vertical stabilizer front

spar cap aft flanges in accordance with the inspection procedure in APPENDIX B,

Inspection Sequence 2 - Option 2.

b. Based on inspection results, do as follows:

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ALERT ALERT
CONDITION 1A (No Crack Found during either Option 1 or Option 2 Inspection)

(1) Install kept fasteners common to the left and right vertical stabilizer front spar cap forward

flanges.

(2) Install kept leading edge fasteners.

CONDITION 1B (Any Crack Found during either Option 1 or Option 2 Inspection)

(1) Crack Found on the Vertical Stabilizer Front Spar Cap Forward Flange

(a) Remove and keep nut plate gang channel on the vertical stabilizer front spar cap

forward flange where the crack indication was found.

(b) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer front spar cap forward flange. Refer to NDTSPM 06-00-07 for applicable

Crack/Defect Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept nut plate gang channel on the vertical stabilizer front spar cap

forward flange.

b) Install kept fasteners common to the left and right vertical stabilizer front

spar cap forward flanges.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap forward

flange and do the repair in accordance with Boeing's instructions.

(2) Crack Found on the Vertical Stabilizer Side Skin or Front Spar Cap Aft Flange

(a) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer side skins. Refer to NDTSPM 06-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer side skins and do the

repair in accordance with Boeing's instructions.

(b) Do an evaluation/verification to confirm any crack indication found on the front spar

cap aft flange. Refer to NDTSPM 02-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

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a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap aft flange

and do the repair in accordance with Boeing's instructions.

CONDITION 2 (Leading Edge is Distressed)

a. Do an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267 in accordance with

APPENDIX B, using one of the options as follows:

NOTE: The inspection area is defined as 12.50 inches +/- 0.25 inch above the leading edge

skin splice and 12.50 inches +/- 0.25 inch below the leading edge skin splice at

Station Zfs=52.267.

OPTION 1:

(1) Do an ETHF inspection of the left and right vertical stabilizer front spar cap forward flanges

as follows:

(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do an RT inspection of the left and right vertical stabilizer front spar cap aft flanges in

accordance with the inspection procedure in APPENDIX B, Inspection Sequence 2 -

Option 1.

OPTION 2:

(1) Do an ETHF inspection of the left and right vertical stabilizer front spar cap forward flanges

as follows:

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(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do an ETHF surface inspection of the side skin at the left and right vertical stabilizer front

spar cap aft flanges in accordance with the inspection procedure in APPENDIX B,

Inspection Sequence 2 - Option 2.

b. Based on inspection results, do as follows:

CONDITION 2A (No Crack Found during either Option 1 or Option 2 Inspection)

(1) Do leading edge repair in accordance with Figure 29 or Figure 30 or Figure 31 of MD80

SRM 55-03, dated March 15, 2010, or Service General Repair Drawing SG09550004,

as applicable.

NOTE: At operator's discretion, replace 9911813-503 vertical stabilizer leading edge

splice band or repair in accordance with Figure 29 of MD80 SRM 55-03, dated

March 15, 2010, or Service General Repair Drawing SG09550004, as applicable.

(2) Install kept fasteners common to the left and right vertical stabilizer front spar cap forward

flanges.

(3) Install kept leading edge fasteners.

CONDITION 2B (Any Crack Found during either Option 1 or Option 2 Inspection)

(1) Do leading edge repair in accordance with Figure 29 or Figure 30 or Figure 31 of MD80

SRM 55-03, dated March 15, 2010, or Service General Repair Drawing SG09550004,

as applicable.

NOTE: At operator's discretion, replace 9911813-503 vertical stabilizer leading edge

splice band or repair in accordance with Figure 29 of MD80 SRM 55-03, dated

March 15, 2010, or Service General Repair Drawing SG09550004, as applicable.

(2) Crack Found on the Vertical Stabilizer Front Spar Cap Forward Flange

(a) Remove and keep nut plate gang channel on the vertical stabilizer front spar cap

forward flange where the crack indication was found.

(b) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer front spar cap forward flange. Refer to NDTSPM 06-00-07 for applicable

Crack/Defect Evaluation/Verification.

1) Crack Indication Not Confirmed

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ALERT ALERT
a) Install kept nut plate gang channel on the vertical stabilizer front spar cap

forward flange.

b) Install kept fasteners common to the left and right vertical stabilizer front

spar cap forward flanges.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap forward

flange and do the repair in accordance with Boeing's instructions.

(3) Crack Found on the Vertical Stabilizer Side Skin or Front Spar Cap Aft Flange

(a) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer side skins. Refer to NDTSPM 06-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer side skins and do the

repair in accordance with Boeing's instructions.

(b) Do an evaluation/verification to confirm any crack indication found on the front spar

cap aft flange. Refer to NDTSPM 02-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap aft flange

and do the repair in accordance with Boeing's instructions.

CONDITION 3 (Leading Edge Existing Repair Found)

a. Do an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267 in accordance with

APPENDIX B, using one of the options as follows:

NOTE: The inspection area is defined as 12.50 inches +/- 0.25 inch above the leading edge

skin splice and 12.50 inches +/- 0.25 inch below the leading edge skin splice at

Station Zfs=52.267.

OPTION 1:

(1) Do an ETHF inspection of the left and right vertical stabilizer front spar cap forward flanges

as follows:

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(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do an RT inspection of the left and right vertical stabilizer front spar cap aft flanges in

accordance with the inspection procedure in APPENDIX B, Inspection Sequence 2 -

Option 1.

OPTION 2:

(1) Do an ETHF inspection of the left and right vertical stabilizer front spar cap forward flanges

as follows:

(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do an ETHF surface inspection of the side skin at the left and right vertical stabilizer front

spar cap aft flanges in accordance with the inspection procedure in APPENDIX B,

Inspection Sequence 2 - Option 2.

b. Based on inspection results, do as follows:

CONDITION 3A (No Crack Found during either Option 1 or Option 2 Inspection)

(1) Install kept fasteners common to the left and right vertical stabilizer front spar cap forward

flanges.

(2) Install kept leading edge fasteners.

CONDITION 3B (Any Crack Found during either Option 1 or Option 2 Inspection)

(1) Crack Found on the Vertical Stabilizer Front Spar Cap Forward Flange

(a) Remove and keep nut plate gang channel on the vertical stabilizer front spar cap

forward flange where the crack indication was found.

(b) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer front spar cap forward flange. Refer to NDTSPM 06-00-07 for applicable

Crack/Defect Evaluation/Verification.

1) Crack Indication Not Confirmed

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ALERT ALERT
a) Install kept nut plate gang channel on the vertical stabilizer front spar cap

forward flange.

b) Install kept fasteners common to the left and right vertical stabilizer front

spar cap forward flanges.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap forward

flange and do the repair in accordance with Boeing's instructions.

(2) Crack Found on the Vertical Stabilizer Side Skin or Front Spar Cap Aft Flange

(a) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer side skins. Refer to NDTSPM 06-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer side skins and do the

repair in accordance with Boeing's instructions.

(b) Do an evaluation/verification to confirm any crack indication found on the front spar

cap aft flange. Refer to NDTSPM 02-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap aft flange

and do the repair in accordance with Boeing's instructions.

3. Put the airplane back to a serviceable condition.

4. Do repetitive inspections of the vertical stabilizer leading edge structure at the splice at Station

Zfs=52.267, and the left and right vertical stabilizer front spar cap forward flanges and either the

aft flanges or side skins at Station Zfs=52.267, at intervals specified in Paragraph 1.E., Compliance.

PART B - REPETITIVE INSPECTION:

1. Inspection - Vertical Stabilizer Leading Edge:

a. Do a detailed inspection of the vertical stabilizer leading edge at the splice at Station Zfs=52.267

(fasteners not removed) for indications of loose fasteners and missing fasteners.

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ALERT ALERT
NOTE: The inspection area is two rows of fasteners above the splice and two rows of

fasteners below the splice at Station Zfs=52.267.

b. Based on inspection results, do as follows:

CONDITION 4 (No Loose Leading Edge Fasteners and No Missing Leading Edge

Fasteners)

(1) Do repetitive detailed inspection of the vertical stabilizer leading edge at the splice at

Station Zfs=52.267 (fasteners not removed) for indications of loose fasteners and missing

fasteners at intervals specified in Paragraph 1.E., Compliance.

CONDITION 5 (Loose Leading Edge Fasteners or Missing Leading Edge Fasteners)

(1) Do leading edge repair in accordance with Figure 29 or Figure 30 or Figure 31 of MD80

SRM 55-03, dated March 15, 2010, or Service General Repair Drawing SG09550004,

as applicable.

NOTE: At operator's discretion, replace 9911813-503 vertical stabilizer leading edge

splice band or repair in accordance with Figure 29 of MD80 SRM 55-03, dated

March 15, 2010, or Service General Repair Drawing SG09550004, as applicable.

(2) Do repetitive detailed inspection of the vertical stabilizer leading edge at the splice at

Station Zfs=52.267 (fasteners not removed) for indications of loose fasteners and missing

fasteners at intervals specified in Paragraph 1.E., Compliance.

2. Inspection - Vertical Stabilizer Front Spar Cap Forward Flanges and either the Aft Flanges or Side

Skins:

a. Do an inspection for cracking on the left and right vertical stabilizer front spar cap forward

flanges and either the aft flanges or side skins at Station Zfs=52.267 in accordance with

APPENDIX B, using one of the options as follows:

NOTE: The inspection area is defined as 12.50 inches +/- 0.25 inch above the leading edge

skin splice and 12.50 inches +/- 0.25 inch below the leading edge skin splice at

Station Zfs=52.267.

OPTION 1:

(1) Do an ETHF inspection of the left and right vertical stabilizer front spar cap forward flanges

as follows:

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ALERT ALERT
(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do an RT inspection of the left and right vertical stabilizer front spar cap aft flanges in

accordance with the inspection procedure in APPENDIX B, Inspection Sequence 2 -

Option 1.

OPTION 2:

(1) Do an ETHF inspection of the left and right vertical stabilizer front spar cap forward flanges

as follows:

(a) Remove and keep fasteners common to the left and right vertical stabilizer front spar

cap forward flanges, above and below the leading edge skin splice at Station

Zfs=52.267.

(b) Do an open hole ETHF inspection of the left and right vertical stabilizer front spar

cap forward flanges at the fastener holes above and below the leading edge skin

splice at Station Zfs=52.267 in accordance with the inspection procedure in

APPENDIX B, Inspection Sequence 1.

(2) Do an ETHF surface inspection of the side skin at the left and right vertical stabilizer front

spar cap aft flanges in accordance with the inspection procedure in APPENDIX B,

Inspection Sequence 2 - Option 2.

b. Based on inspection results, do as follows:

CONDITION 6 (No Crack Found during either Option 1 or Option 2 Inspection)

(1) Install kept fasteners common to the left and right vertical stabilizer front spar cap forward

flanges.

(2) Install kept leading edge fasteners.

CONDITION 7 (Any Crack Found during either Option 1 or Option 2 Inspection)

(1) Crack Found on the Vertical Stabilizer Front Spar Cap Forward Flange

(a) Remove and keep nut plate gang channel on the vertical stabilizer front spar cap

forward flange where the crack indication was found.

(b) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer front spar cap forward flange. Refer to NDTSPM 06-00-07 for applicable

Crack/Defect Evaluation/Verification.

1) Crack Indication Not Confirmed

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ALERT ALERT
a) Install kept nut plate gang channel on the vertical stabilizer front spar cap

forward flange.

b) Install kept fasteners common to the left and right vertical stabilizer front

spar cap forward flanges.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap forward

flange and do the repair in accordance with Boeing's instructions.

(2) Crack Found on the Vertical Stabilizer Side Skin or Front Spar Cap Aft Flange

(a) Do an evaluation/verification to confirm any crack indication found on the vertical

stabilizer side skins. Refer to NDTSPM 06-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer side skins and do the

repair in accordance with Boeing's instructions.

(b) Do an evaluation/verification to confirm any crack indication found on the front spar

cap aft flange. Refer to NDTSPM 02-00-07 for applicable Crack/Defect

Evaluation/Verification.

1) Crack Indication Not Confirmed

a) Install kept leading edge fasteners.

2) Crack Indication Confirmed

a) Contact Boeing for repair of the vertical stabilizer front spar cap aft flange

and do the repair in accordance with Boeing's instructions.

3. Put the airplane back to a serviceable condition.

4. Do repetitive detailed inspection of the vertical stabilizer leading edge at the splice at Station

Zfs=52.267 (fasteners not removed) for indications of loose fasteners and missing fasteners at

intervals specified in Paragraph 1.E., Compliance.

5. Do repetitive inspection of the left and right vertical stabilizer front spar cap forward flanges and

either the aft flanges or side skins at Station Zfs=52.267 at intervals specified in Paragraph 1.E.,

Compliance.

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ALERT ALERT
APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE INSPECTION

1. This flowchart describes the initial inspection and repetitive inspection requirements and can be used as a

supplement to Paragraph 1.D., Description, Paragraph 1.E., Compliance, and Paragraph 3.B., Work

Instructions.

APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE INSPECTION

(SHEET 1 OF 3)

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APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE INSPECTION

(SHEET 2 OF 3)

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APPENDIX A: FLOWCHART - INITIAL INSPECTION AND REPETITIVE INSPECTION

(SHEET 3 OF 3)

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APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

1. Model Affected: MD-80

2. Drawing Reference: 5912123, 5930609, 5911394, 9911833

Description:

1. The inspection area consists of the vertical stabilizer front spar caps at Station Zfs=52.267. The purpose

of Inspection Sequence 1 is to inspect the fastener holes common to the left and right front spar cap forward

flanges and leading edge panels in accordance with Figure 1. The purpose of Inspection Sequence 2 is to

detect fatigue cracks initiating at the fastener holes common to the left and right spar cap aft flanges and/or

side skins in accordance with Figure 2 or Figure 3. The fatigue cracks will travel in the forward and aft

directions from the fastener holes.

NOTE: Two inspection methods are acceptable for Inspection Sequence 2 as follows:

Option 1 - Radiographic Testing (RT)

Option 2 - Eddy Current, High Frequency (ETHF)

Inspection Sequence 1:

1. Eddy Current, High Frequency (ETHF)

Inspection Sequence 2:

1. Radiographic Testing (RT) or Eddy Current, High Frequency (ETHF)

Preparation for Inspection

1. Remove all dirt, grease, and loose paint from the inspection area.

2. Thoroughly clean the inspection area with an approved cleaning agent.

Table 1 - Equipment/Materials

Test Equipment Type QTY CAGE Supplier

Portable X-ray machine Sperry SPX 160 1 0M421 Staveley Instruments

(1.5 mm projected focal

spot).

1329 East Kemper Road

Cincinnati, Ohio 45246

APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 1 OF 10)

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Table 1 - Equipment/Materials

Test Equipment Type QTY CAGE Supplier

X-ray film Kodak M 10 19139 Eastman Kodak Company

(Refer to Table 2 for 343 State Street

sizes) Rochester, New York 14650

X-ray film Kodak AA 4 19139

(Refer to Table 2 for

sizes)

For radiographic identifica- - - Source Optional

tion.

Lead numbers

Masking Tape - - - Source Optional

In conformance with envi- - Source Optional

ronmental regulations and

harmless to surfaces contacted.

Cleaning Agent

NOTE: The equipment/materials listed above were used to develop this procedure. Refer to NDTSPM

Part 02-00-04 and NDTSPM Part 06-00-04 for supplier/vendor information.

1.

2. Equipment/material substitutions producing results equivalent to those defined by this document

may also be used. Refer to NDTSPM Part 01-00-03, NDTSPM Part 02-00-03, and NDTSPM

Part 06-00-03 for equipment/material information.

Inspection Procedure:

1. Inspection Sequence 1 (Front Spar Cap Forward Flange Area)

Inspection Method 01 (Eddy Current, High Frequency)

a. Perform an open hole ETHF inspection of the left and right vertical stabilizer front spar cap forward

flanges above and below the leading edge skin splice at Station Zfs=52.267 within the specified

dimensions in accordance with Figure 1. Scan the circumference of the holes following the instructions

found in the Nondestructive Testing Standard Practice Manual NDTSPM 06-10-01.003 (ETHF -

Procedure 3).

NOTE: Scoring of the fastener hole bore caused by the removal of fasteners may cause crack-like

indications. Removal of nut plate may be necessary for proper clean up of the hole. Refer to

NDTSPM 06-10-01.003 "Access" and "Preparation and Cleaning" for further information. The

nut plate may also interfere with the probe scan with some open hole eddy current probe

designs.

APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 2 OF 10)

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APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 3 OF 10)

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ALERT ALERT
2. Inspection Sequence 2 (Front Spar Cap Aft Flange Area)

OPTION 1: Inspection Method 01 (Radiographic Testing)

a. Inspection for cracks of the vertical stabilizer front spar cap aft flange at Station Zfs=52.267 in accordance

with Figure 2.

NOTE: The following steps must be done to both left and right sides of the vertical stabilizer.

EXPOSURE 1:

(1) Prepare Exposure 1 radiographic identification tag with the data as follows, using operator's shop

practice:

– Service Bulletin number

– Exposure number and left or right side

– Aircraft I.D.

– Date

(2) Attach Exposure 1 identification tag to film pack for each exposure using operator's shop practice.

(3) Use masking tape to attach film to inspection element for Exposure 1 in accordance with Figure

2.

(4) Expose film in accordance with x-ray parameters in Table 2 and Figure 2.

EXPOSURE 2:

(1) Prepare Exposure 2 radiographic identification tag with the data as follows, using operator's shop

practice:

– Service Bulletin number

– Exposure number and left or right side

– Aircraft I.D.

– Date

(2) Attach Exposure 2 identification tag to film pack for each exposure using operator's shop practice.

(3) Use masking tape to attach film to inspection element for Exposure 2 in accordance with Figure

2.

(4) Expose film in accordance with x-ray parameters in Table 2 and Figure 2.

EXPOSURE 3:

(1) Prepare Exposure 3 radiographic identification tag with the data as follows, using operator's shop

practice:

APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 4 OF 10)

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ALERT ALERT
– Service Bulletin number

– Exposure number and left or right side

– Aircraft I.D.

– Date

(2) Attach Exposure 3 identification tag to film pack for each exposure using operator's shop practice.

(3) Use masking tape to attach film to inspection element for Exposure 3 in accordance with Figure

2.

(4) Expose film in accordance with x-ray parameters in Table 2 and Figure 2.

EXPOSURE 4:

(1) Prepare Exposure 4 radiographic identification tag with the data as follows, using operator's shop

practice:

– Service Bulletin number

– Exposure number and left or right side

– Aircraft I.D.

– Date

(2) Attach Exposure 4 identification tag to film pack for each exposure using operator's shop practice.

(3) Use masking tape to attach film to inspection element for Exposure 4 in accordance with Figure

2.

(4) Expose film in accordance with x-ray parameters in Table 2 and Figure 2.

EXPOSURE 5:

(1) Prepare Exposure 5 radiographic identification tag with the data as follows, using operator's shop

practice:

– Service Bulletin number

– Exposure number and left or right side

– Aircraft I.D.

– Date

(2) Attach Exposure 5 identification tag to film pack for each exposure using operator's shop practice.

(3) Use masking tape to attach film to inspection element for Exposure 5 in accordance with Figure

2.

(4) Expose film in accordance with x-ray parameters in Table 2 and Figure 2.

APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 5 OF 10)

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APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 6 OF 10)

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APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 7 OF 10)

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ALERT ALERT
Table 2: Radiographic Exposure Data for Vertical Stabilizer Front Spar Cap Aft Flange at Station

Zfs=52.267

DIM "A" FILM REMARKS

(Inch)

mas

(a)

EXPOSURE kV

NUMBER SIZE

(Inch)

ASTM TYPE QTY

1 80 600 36 +/- 0.5 1 (b) 2 5 X 7

2 80 600 36 +/- 0.5 1 and 2 (c) 2 5 X 7

3 80 600 36 +/- 0.5 1 and 2 (c) 2 5 X 7

4 80 600 36 +/- 0.5 1 (b) 2 5 X 7

5 80 600 36 +/- 0.5 1 (b) 2 5 X 7

(a) May adjust mas as necessary to achieve a 1.7 to 3.5 H & D Density in the area of interest.

(b) Kodak M or equivalent type with similar speed.

(c) Kodak M and AA or equivalent type with similar speed (double load film pack).

OPTION 2: Inspection Method 01 (Eddy Current, High Frequency)

a. Perform an ETHF surface inspection of the vertical stabilizer side skins at those fasteners common to

the left and right vertical stabilizer front spar cap aft flanges within the specified dimensions in accordance

with Figure 3. Scan around the fasteners looking for cracks in the forward and aft direction. Scan around

fasteners following the instructions found in the Nondestructive Testing Standard Practice Manual

NDTSPM 06-10-01.001 (ETHF - Procedure 1). Use Calibration Method "P" and Scan Method "47".

APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 8 OF 10)

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APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

(SHEET 9 OF 10)

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BOEING SERVICE BULLETIN MD80-55A067

ALERT ALERT
Inspection Results

1. Any indication is considered a crack 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.

2. Crack indications found during ETHF inspection shall be confirmed. Refer to NDTSPM 06-00-07 for applicable

Crack/Defect Evaluation/Verification sections(s).

3. Crack indications found during RT inspection shall be confirmed. Refer to NDTSPM 02-00-07 for applicable

Crack/Defect Evaluation/Verification section(s).

Post Inspection Procedure

1. Remove and secure all test equipment and materials from the area.

APPENDIX B: INSPECTION OF VERTICAL STABILIZER FRONT SPAR CAP AT STATION ZFS=52.267

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Original Issue: June 24, 2010

MD80-55A067

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BOEING SERVICE BULLETIN MD80-55A067

ALERT ALERT