### Commercial Airplane Group 

# 727 Service Bulletin

Number: 727-53-0041 

## Revision Transmittal Sheet Date: March 8, 1968 Revision 6: September 5, 1991 ATA System: 5311

SUBJECT:FUSELAGE - MAIN FRAME - INSTALLATION OF STRINGER TO BODY FRAME TIE CLIPS - BODY CROWN
This revision includes all pages of the service bulletin. SUMMARY This revision is sent to tell the 727 airplane operators that this service bulletin has been identified by the 727 Structures Working Group (SWG), and the post-modification inspection given in this service bulletin is recommended to be included on applicable 727 airplanes. The post-modification inspection given in this service bulletin must be done at the times given in the Description and Accomplishment Instructions. The structural change was recommended to be included by the SWG in Revision 5 of this service bulletin. As a result of the Aging Fleet Conference held by the FAA, the 727 SWG was made and included 727 airline operators from a large part of the high time 727 fleet, persons from the Boeing Company, and monitors from the FAA. The SWG examined the inspections given in applicable Boeing service bulletins. A selection of these service bulletins was made that contain inspections that are important to the continued structural airworthiness of 727 airplanes. The inspections given in these service bulletins are recommended to be a part of the regularly scheduled maintenance on applicable 727 airplanes. The time of a 'D' check is changed to a time that is not to be more than 14,000 flights. A post-modification inspection is necessary on airplanes that installed the preventive modification in the initial release or Revision 1 through 6 of this service bulletin. Paragraph I.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. Vertical lines are put on the left edge of each page, except in paragraph I.A., Effectivity, to show the location of important changes.
REVISION HISTORY Initial Release: Revision 1: Revision 2: Revision 3: Revision 4: Revision 5: Revision 6: March 8, 1968 June 11, 1968 December 16, 1968 July 6, 1970 July 27, 1973 January 25, 1990 September 5, 1991

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207

### Commercial Airplane Group 

# 727 Service Bulletin

Number: 727-53-0041 

## Summary Date: March 8, 1968 Revision 6: September 5, 1991 ATA System: 5311

SUBJECT:FUSELAGE - MAIN FRAME - INSTALLATION OF STRINGER TO BODY FRAME TIE CLIPS - BODY CROWN

BACKGROUND The SWG has examined the structural change and the post-modification inspection in this service bulletin, and recommends that the change and inspection be included on 727 airplanes. Fatigue tests conducted by Boeing and service experience show that repeated pressurization cycles result in fatigue cracks at some of the stringer-to-frame connections along the crown of the fuselage. Since the previous release of this service bulletin, four operators have reported numerous instances of stringer and frame cracking on eleven airplanes. The airplanes had accumulated from 16,000 to 38,000 flight cycles and from 20,000 to 43,000 flight hours. In addition, one operator reported several instances of stringer cracking between frame stations 990 and 1070 after modification. Incorporation of this modification per this service bulletin will extend the fatigue life of body crown frames and stringers. Continued operation with undetected cracks could result in a significant reduction in structural integrity requiring downtime for repairs. ACTION (PRR 21609) As recommended by the 727 SWG, make the structural change given in the Accomplishment Instructions at or before the airplane collects a total of 60,000 flights, and do the post-modification inspection as given in the Accomplishment Instructions at or before the airplane collects a total of 25,000 flights after Part IV or Part V of the Accomplishment Instructions is done, or within 6,000 flights after you get Revision 6 of this service bulletin. Continue the post-modification inspection at regularly scheduled times. The approved time between one inspection and the subsequent inspection must not be more than 14,000 flights. Within 3,000 flight cycles after accumulating 16,000 flight cycles, gain access to stringer-to-frame attach locations in the forward and aft upper lobes. Perform visual and high frequency eddy current inspections to detect cracks in stringers and frames. If cracks are detected at fastener holes, enlarge fastener holes to remove fatigue-damaged material. If cracks at fastener holes cannot be removed by oversizing, or if cracks are found in the frame or stringer radius, repair per 727 Structural Repair Manual. Repeat inspections at 6,000 flight cycle intervals until the modification per Revision 6 of this service bulletin is accomplished. Airplanes having accumulated more than 16,000 flight cycles should be inspected within 3,000 flight cycles following receipt of Revision 6 of this service bulletin. Airplanes modified or repaired per this service bulletin require post-modification inspections as described in this bulletin. EFFECTIVITY All 727-100 airplanes, Line Position 1 through 165. MANPOWER Total Man-hours - 600 for each airplane Elapsed Time - 75 Hours MATERIAL INFORMATION Kit Delivery Price 65-87582-1 22 weeks $ 11,481.00 65-87582-5 32 weeks $ 1,426.00 65-87582-7 22 weeks $ 2,529 Refer to Paragraph I.F., Material - Price and Availability.

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207 Summary Page 1 of 2

### BOEING SERVICE BULLETIN 727-53-0041

Mar 8/68 REV. 6: Sep 5/91 Summary Page 2 of 2

### Commercial Airplane Group 

# 727 Service Bulletin

Number: 727-53-0041 Date: March 8, 1968 Revision 6: September 5, 1991 ATA System: 5311

SUBJECT:FUSELAGE - MAIN FRAME - INSTALLATION OF STRINGER TO BODY FRAME TIE CLIPS - BODY CROWN

I. PLANNING INFORMATION A. Effectivity 1. Airplanes Refer to Service Bulletin Index Document D6-9825, Part 3, for Airplane Variable Number, Line Number, and Serial Number data. An equivalent change is on subsequent production airplanes. Refer to PRR 21609 for data about this change.

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER CUSTOMER GROUP VARIABLE NUMBER A. L. I. (IBA) 5 E3026 ACES (ACE) 2 E0130 AEROEJECUTIVO (AEJ) 2 E0101 6 E0404 AERONICA (ANC) 2 E0133 AIRCRAFT SUPPORT GROUP (ASG) 5 E3202 ALLRED INTERNATIONAL, INC. (RED) 4 E0206 AMERICAN AIRLINES, INC. (AAL) 3 E0301-E0303 E0305-E0309 E0311-E0326 AMERIJET INTERNATIONAL, INC. (AMJ) 2 E0104 5 E3028 ANSETT AIRLINES OF AUSTRALIA (ANS) 2 E0119 AVENSA (AVN) 1 E0034-E0036

Mar 8/68 727-53-0041 REV. 6: Sep 5/91 Page 1of 40

### BOEING SERVICE BULLETIN 727-53-0041

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (continued) CUSTOMER GROUP VARIABLE NUMBER AVIANCA (AVI) 5 E3064 BRADLEY AIR SERVICES (BRS) 5 E3065 BRITHEN LTD. (BTN) 4 E0211 CONNIE KALITTA FLYING SERVICES (CKF) 3 E0304 CONTINENTAL AIRLINES, INC. (CAL) 1 E0038-E0042 4 E0202 E0205 5 E3001 CORSAIR (CRA) 5 E3002 E3011-E3012 DHL CORPORATION/WORLDWIDE COURIER EXP. (DHL) 1 E0030 2 E0124 DIRECTORATE OF POLICE AVIATION (OMAN) (OMA) 4 E0210 EVERGREEN INTERNATIONAL AIRLINES (EVR) 5 E3101 FEDERAL AVIATION ADMINISTRATION (FAA) 4 E0201 FEDERAL EXPRESS (FED) 1 E0023-E0028 2 E0120 E0122-E0123 E0125-E0129 E0131-E0132 3 E0310 HAPAG LLOYD (HAP) 5 E3114 IRAN ISLAMIC REPUBLIC AIRLINE (IRN) 4 E0204 JET EAST, INC. (JTE) 5 E3201 6 E0418 E0420 KABO AIR LIMITED (KAB) 2 E0103 E0107 KEY AIRLINES (KEY) 1 E0029 E0033 5 E3027

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### BOEING SERVICE BULLETIN 727-53-0041

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (continued) CUSTOMER GROUP VARIABLE NUMBER LADECO (LDE) 1 E0032 5 E3103 LLOYD AERO BOLIVIANO (LAB) 5 E3102 MEXICAN AIR FORCE (MXA) 5 E3171-E3172 MME AVIATION (CAYMAN ISLANDS) LTD. (MME) 4 E0209 NORTHWEST AIRLINES, INC. (NWA) 5 E3021-E3023 E3025 E3173 PRIVATE JET EXPEDITIONS, INC. (PJE) 6 E0413 ROYAL BRUNEI (RBA) 4 E0212 SAETA OF ECUADOR (SAE) 6 E0414 SCIBE-AIRLIFT KINSHASA (SAK) 4 E0208 SIGAIR (SIG) 4 E0207 TAESA (TES) 5 E3024 TAN SAHSA HONDURAS AIRLINES (SAH) 5 E3113 TRANS WORLD AIRLINES, INC. (TWA) 6 E0401 E0405-E0408 E0412 E0416-E0417 E0419 TRUMP SHUTTLE, INC. (TSI) 2 E0106 E0116 E0121 UNITED AIR LINES, INC. (UAL) 1 E0003 E0005-E0022 USAF - 727 C-22A PROGRAM (UO5) 4 E0203 USAF - 727 C-22B PROGRAM (UO6) 5 E3061 E3063 E3066-E3067

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### BOEING SERVICE BULLETIN 727-53-0041

LISTING BY VARIABLE NUMBER
GROUP 1 E0001-E0042 GROUP 2 E0101-E0133 GROUP 3 E0301-E0327 GROUP 4 E0201-E0212 GROUP 5 E3001-E3002 E3011-E3012 E3021-E3028 E3061-E3067 E3101-E3103 E3111-E3114 E3171-E3173 E3201-E3202 GROUP 6 E0401-E0420 2. Spares The part numbers shown in Paragraph II.D., Existing Parts Accountability, are related to this service bulletin. Examine your spares supply for these parts. If any parts are found, refer to Paragraph II.D., Existing Parts Accountability, for the recommended use.

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### BOEING SERVICE BULLETIN 727-53-0041

B. Reason As a result of the Aging Fleet Conference held by the FAA, the 727 SWG was made and included 727 airline operators from a large part of the high time 727 fleet, persons from the Boeing Company, and monitors from the FAA. The SWG examined the structural changes and inspections given in applicable Boeing service bulletins. A selection of these service bulletins was made that contain structural changes and inspections that are important to the continued structural airworthiness of 727 airplanes. The structural changes given in these service bulletins are recommended to be included, and the inspections are recommended to be a part of the regularly scheduled maintenance on applicable 727 airplanes. Incorporation of this modification per this service bulletin will extend the fatigue life of body crown frames and stringers. Continued operation with undetected cracks could result in a significant reduction in structural integrity requiring downtime for repairs. Fatigue tests conducted by Boeing and service experience show that repeated pressurization cycles result in fatigue cracks at some of the stringer-to-frame connections along the crown of the fuselage. In addition, several 707 operators have reported finding numerous cracks in the stringers and frames during accomplishment of skin panel replacements and channel clip installations on several airplanes. This experience has shown that cracks characteristically propagate along the faying surface of the stringer or frame before extending to the visible surface. Prior to the release of Revision 5 of this service bulletin, four operators have reported numerous instances of stringer and frame cracking on eleven airplanes. The airplanes had accumulated from 16,000 to 38,000 flight cycles and from 20,000 to 43,000 flight hours. In addition, one operator reported several instances of stringer cracking between frame stations 990 and 1070 after modification. The affected stringer-to-frame connections are between Stringers 9 Left and 9 Right, from Body Stations (BS) 360 to BS 720 and BS 970 to BS 1110, and between Stringers 6 Left and 13 Right, from BS 270 to BS 360. The remainder of the body crown area is considered to have sufficient service life expectation. During installation of "wide-body" interiors at the Boeing Wichita Modification Center, stringer-to-frame joints along Stringers 4, 5 and 7 were inspected using an eddy-current disc probe on the faying surfaces. Frame cracks, 0.1 to 0.5 inches long, were found at most of the joints inspected on the thirty airplanes that had accumulated 20,000 to 24,000 flight cycles. Revision 5 of this bulletin was issued to provide the modification recommendations of the Aging Fleet 727 Structures Working Group. A post-modification repetitive inspection has been added, and the bulletin has been completely rewritten to conform to current service bulletin format. The affected airplanes have been divided into 6 groups based on differences in kit parts, molded insulation part numbers and locations, and conduit wire bundle clamp locations. The intent of the Notice of Status Changes dated October 19, 1973 and December 15, 1978 was included in this revision. Revision 6 of this service bulletin is sent to give the inspection recommendation of the 727 SWG. The time of a 'D' check is changed to a time that is not to be more than 14,000 flights.

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### BOEING SERVICE BULLETIN 727-53-0041

C. Description The SWG has examined the structural changes and the inspections in this service bulletin, and recommends that the structural change as given in the Accomplishment Instructions of this service bulletin be included at or before the airplane collects a total of 60,000 flights, and the post-modification inspection be made as given in the Accomplishment Instructions of this service bulletin at or before the airplane collects a total of 25,000 flights after Part IV or Part V of the Accomplishment Instructions is done, or within 6,000 flights after you get Revision 6 of this service bulletin. Continue the post-modification inspection at regularly scheduled times. The approved time between one inspection and the subsequent inspection must not be more than 14,000 flights. Within 3,000 flight cycles after accumulating 16,000 flight cycles, gain access to stringer-to-frame attach locations between Stringers S-9L and S-9R from Body Stations (BS) 360 to BS 720, and from BS 970 to BS 1110; and between Stringers S-6L and S-13R from BS 270 to BS 360. Perform visual inspection to detect cracks along radii of stringer and frame, and perform high frequency eddy current inspection to detect frame or stringer cracks initiating at fastener hole edges. If cracks are detected at fastener holes, enlarge fastener holes up to specified limit to remove fatigue-damaged material. If cracks at fastener holes cannot be removed by oversizing, or if radius cracks are found in the frame or stringer, repair cracks per 727 Structural Repair Manual. Airplanes having accumulated more than 16,000 flight cycles should be inspected within 3,000 flight cycles following receipt of Revision 5 of this Service bulletin. Repeat inspections at 6,000 flight cycle intervals until the modification per this service bulletin is accomplished. Based on operator reports of post-modification cracking and the possibility of inadequate removal of fatigued material following inspection and modification or repair per previous releases of this bulletin, a close visual inspection is recommended on airplanes modified, or repaired with stringer clips and radius fillers installed, per the original issue or Revision 1 through 6 of this service bulletin after accumulating 25,000 flight cycles since modification. For airplanes exceeding 25,000 flight cycles since modification, inspect at or prior to the next convenient maintenance interval, not to exceed 6,000 flight cycles. Repeat inspections at a regularly scheduled time that is not to exceed 14,000 flight cycles. Cracks that have been repaired without installation of a stringer clip or radius filler require preventive modification per Part IV of this service bulletin. Previous kits included clips with bowed legs and stiffening flanges which made them difficult to insert in damaged stringers. These kits have been superseded by kits containing clips with straight legs which may be more easily formed to fit damaged stringers. Instructions for trimming the flanges of the "bow-legged" clips, permitting additional flexing of the clip to facilitate installation, are included in this service bulletin. NOTES: 1. Prior or concurrent incorporation of the Service Bulletin 727-53-0080, "Stringer Replacement, Left Body Station 259.5 to 303.9 and Clip and Radius Filler Installation Right Body Station 294.5", is suggested on commonly affected airplanes. 2. Boeing Document D6-54860 is applicable to this service bulletin. D. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The repairs and changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and are FAA approved.

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### BOEING SERVICE BULLETIN 727-53-0041

E. Manpower Approximately 600 man-hours and 8 persons are necessary to do this change for each airplane. Approximately 60 man-hours and 4 persons are necessary to do this post-modification inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-hour data if necessary. It does not include lost time such as: - Time to adjust to the workplace - Time to schedule the work - Time to examine the work - Time to cure the materials - Time to make the parts - Time to find the tools. F. Material - Price and Availability Boeing can supply the kits shown in Paragraphs II.A., Parts Necessary For Each Airplane, as shown below. Operators should include the scheduled dates of the change on the purchase orders. If there is a limit in the quantity of kits, then these conditions are used to decide the supply sequence: 1) the date the purchase order is received by Boeing, 2) the date of the scheduled change.
Kit Number Name Delivery Unit Price 65-98574-1 Kit Not available for purchase 65-98574-2 Kit Not available for purchase 65-98574-3 Kit Not available for purchase 65-98574-4 Kit Not available for purchase 65-98574-5 Kit Not available for purchase 65-98574-6 Kit Not available for purchase 65-98574-7 Kit Not available for purchase 65-98574-8 Kit Not available for purchase 65-87582-1 Kit 22 weeks $ 11,481.00 65-87582-5 Kit, Contingency 32 weeks $ 1,426.00 65-87582-7 Kit, Fastener 22 weeks $ 2,529.00 DateSeptember 5, 1991 The kits are subject to the terms and conditions of Boeing's standard purchase order acknowledgment. The prices are subject to acceptance within 180 days from the date shown above. After 180 days, new price data is applicable. Prices are in United States Dollars. Terms: Net 30 days. Send purchase orders and letters about the supply data to the Director of Spares and refer to this service bulletin number.

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### BOEING SERVICE BULLETIN 727-53-0041

G. Special Tools - Price and Availability The operator can supply the tools shown in Paragraph II.C., Special Tools and Equipment. Thus, tool price and supply data are not shown. H. Weight and Balance Change in Weight (Pounds) Change in Moment (Pound-Inches) + 26.4 + 16,209.6
I. References

1. Existing Data: a. Engineering Change Memo PRR 21609 b. 727 Maintenance Manual Subject 25-21-1 c. 727 Structural Repair Manual Subject 51-30-2, 51-50, and 53-10 d. 727 Nondestructive Test Manual Part 6, Subjects 53-10-27, Figure 1 and 53-10-00, Figure 2 e. Boeing Service Bulletin 727-53-0080, "STRINGER REPLACEMENT, LEFT BODY STATION 259.5 TO 303.9 AND CLIP AND RADIUS FILLER INSTALLATION RIGHT BODY STATION 294.5" f. Boeing Document D6-54860, "Aging Airplane Service Bulletin Structural Modification Program - Model 727"

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### BOEING SERVICE BULLETIN 727-53-0041

2. Data supplied with this service bulletin: Drawings: Drawing No. Sheet DCNADCNTitle 65-58869 1 2 B B 1

- Tie Installation - Stringer, Body Frame
65-79848 1 A

- Clip-Stringer, Optional Modification 65-87582 1 B

- Stringer Clip Installation - Kit ST1010-31 1 D

- Rivet Yoke - "C" Type - CP 351 ST1010-43 1 B

- Rivet Yoke - Alligator Type - CP 351 ST1010-97 1

- - Rivet Yoke - Alligator Type - CP 351 ST1010-451 1

- - Rivet Yoke - Alligator Type - CP 214T ST1010B 1

- - Bushing for Rivet Yoke ST1050B-249B 1

- - Draw Die - Spring Loaded ST1093 1 B

- Retainer Spring ST1111A-249 1 B

- Rivet Set Assembly - Flush head Rivet Squeeze Set ST1111A-249H 1 A

- Squeeze Set - 249 - Shank for Flat Head Rivets ST1112A-249 1 A

- Rivet Set Assembly - Universal Head Squeeze Set ST1161 1 A

- Insert Tool - Rivet
3. Process Data: Boeing Process Specifications referred to on drawings are not given in this service bulletin since these procedures are frequently used as standard shop practices. J. Publications Changed None

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### BOEING SERVICE BULLETIN 727-53-0041

II. MATERIAL INFORMATION A. Parts Necessary For Each Airplane 1. The kits shown below are not available for purchase. The kits are replaced by the 65-87582-1 Kit. NOTES: 1. Kits contains excess parts not required for installation. Discard excess parts or return them to operator's spares stock. 2. If installing kit 65-87582-1, using bolts rather than squeeze rivets, operator should have sufficient quantities of fasteners, as specified in the Accomplishment Instructions, before starting the modification. 65-98574 - KIT, RETROFIT BODY FRAME TO STRINGER CONNECTION SERVICE BULLETIN 53-41 -4 -3 -2 -1 Quantity Part Number Name

. . . - 65-98574-1 (a) Kit Assembly

. . - . 65-98574-2 (b) Kit Assembly

. - . . 65-98574-3 (c) Kit Assembly

- . . . 65-98574-4 (d) Kit Assembly

-8 -7 -6 -5 Quantity Part Number Name

. . . - 65-98574-5 (e) Kit Assembly

. . - . 65-98574-6 (f) Kit Assembly

. - . . 65-98574-7 (c) Kit Assembly

- . . . 65-98574-8 (h) Kit Assembly (a) Applicable to Group 1 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-5. Inactive for procurement, superseded by Kit 65-87582-1. (b) Applicable to Group 2 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-6. Inactive for procurement, superseded by Kit 65-87582-1. (c) Applicable to Group 3 and 4 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-7. Inactive for procurement, superseded by Kit 65-87582-1. (d) Applicable to Group 5 and 6 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-8. Inactive for procurement, superseded by Kit 65-87582-1.

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### BOEING SERVICE BULLETIN 727-53-0041

(e) Applicable to Group 1 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-1. Inactive for procurement, superseded by Kit 65-87582-1. (f) Applicable to Group 2 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-2. Inactive for procurement, superseded by Kit 65-87582-1. (g) Applicable to Group 3 and 4 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-3. Inactive for procurement, superseded by Kit 65-87582-1. (h) Applicable to Group 5 and 6 airplanes. Contained bow-legged clips and Hi-Loks for fastening stringers. Optional to Kit 65-98574-4. Inactive for procurement, superseded by Kit 65-87582-1. 2. To get the kits shown below, refer to Paragraph I.F., Material - Price and Availability. NOTE: The top kit is divided into subkits to make the installation easier. One top kit and the operator supplied materials specified in Paragraph II.A.3., Parts and Materials Supplied by the Operator, are necessary for each airplane. 65-87582 - STRINGER CLIP INSTALLATION - KIT

-7 -5 -4 -3 -2 -1 Quantity Part Number Name

. . . . . - 65-87582-1 (a) Top Kit

. . . . - 1 65-87582-2 (b) Subkit

. . . - . 1 65-87582-3 (c) Subkit

. . - . . 1 65-87582-4 (d) Subkit

. - . . . . 65-87582-5 (e) Clip Package

- . . . . . 65-87582-7 (f) Fastener Assortment

. . 70 2 7

. 65-87582-6 Radius Filler 25

. . . . . 65-9220-51 Rivet Package 11

. . . . . 65-9220-55 Rivet Package

. . . 62

. . 65-50473-26 Clip

. . 55

. 258

. 65-50473-36 Clip

. 62

. . . . 65-50473-800 Clip 158

. . . . . BACB30MB8-5 Bolt 158

. . . . . BACB30MB10-5 Bolt 158

. . . . . BACB30MD8-5 Bolt 158

. . . . . BACC30AC8 Collar 158

. . . . . BACC30X8 Collar 158

. . . . . BACC30X10 Collar 750

. . . . . BACR15BB8B8 (g) Rivet 750

. . . . . BACR15BB10B10 (g) Rivet 750

. . . . . BACR15ET9B9 Rivet

9

. . . . . BACS12CB3-16 Screw 9

. . . . . NAS42DD6-32 Spacer 2

. . . . . NAS42DD6-64 Spacer 2

. . . . . NAS603-22 Screw

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### BOEING SERVICE BULLETIN 727-53-0041

(a) Applicable to all affected airplanes. Contains straight-legged clips and fasteners suitable for squeeze riveting at all fastener locations. Supersedes kits 65-98574-1 through -8. (b) Subkit of 65-87582-1. Contains clips required for modification of airplane section 43. (c) Subkit of 65-87582-1. Contains clips required for modification of airplane section 41. (d) Subkit of 65-87582-1. Contains clips required for modification of airplane section 46. (e) Applicable to all affected airplanes. This contingency package contains clips for installation at hose locations where width of crushed stringers will not permit installation of clips provided in basic kit. It is anticipated that one package contains more than enough clips for such locations on one airplane. (f) Subkit of 65-87582-1. Contains fasteners suitable for squeeze riveting at all affected fastener locations. (g) Rivet MS20470B( )-( ) optional to Rivet BACR15BB( )B( ). Rivet MS20470D( )-( ) optional to Rivet BACR15BB( )D( ). 3. Parts and Materials Supplied by the Operator:
Quantity Part Number (Specification) Name As NecessaryBMS 5-30 Sealing Adhesive As NecessaryBMS 8-95, Type I Flame Resistant Fabric As NecessaryBMS 10-11, Type I Primer As NecessaryBACB30MD8-5 Bolt As NecessaryBACB30MB10-5 Bolt As NecessaryBACC30AC8 Collar As NecessaryBACC30X10 Collar As NecessaryBACR15ET9B9 (a) Rivet As NecessaryMS20470B7-( ) Rivet As NecessaryMS20470B10-10 (b) Rivet (a) Bolt BACB30MD8-( ), with collar BACC30AC8, are optional to rivet BACR15ET9B9. (b) Bolt BACB30MB10-( ) with collar BACC30X10 is optional to rivet MS20470B10-10.

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### BOEING SERVICE BULLETIN 727-53-0041

B. Parts Necessary to Modify Spares None C. Special Tools and Equipment To get the tools shown below, refer to Paragraph I.G., Special Tools - Price and Availability. 1. The following kits are suitable for installing squeezed rivets. Three tool kits are required to accomplish this modification: 65-96210-3 and either 65-96210-1 or 65-96210-2, each supplemented by 65-96210-6 or 65-96210-4, and 65-96210-5. Kit number 65-96210-7 is optional to 65-96210-4. The tools may be purchased from Boeing or fabricated by the operator in accordance with drawings supplied with this bulletin. Rivet sets and draw tools may also be obtained from vendors listed in Table I - Tool Vendor Information. Compression riveters should be obtained from the manufacturer. Kit Number Usage 65-96210-1 Not Available for Purchase. 65-96210-2 Not Available for Purchase. 65-96210-3 Used with Chicago Pneumatic compression riveter CP-0214-FANEL to squeeze rivets attaching clips to frames. May also be used with Deutsch/American Pneumatic compression riveter APT 720 (less yoke) or equivalent. See tool drawing for tool installation. 65-96210-4 or -7 Used with Chicago Pneumatic compression riveter CP-0351-FUNEL or equivalent, to squeeze rivets attaching stringer to frame. See tool drawing for tool installation. 65-96210-5 Used with Chicago Pneumatic compression riveter CP-0351-FUNEL or equivalent, to squeeze rivets attaching clips to stringer. See tool drawing for tool installation. 65-96210-6 Used to supplement kits 65-96210-1 or -2 to enable rivet yokes to fit compression riveter.

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### BOEING SERVICE BULLETIN 727-53-0041

NOTES: 1. Kits 65-96210-4 and -5 are equivalent to kits 65-96210-1and -2, each supplemented by kit 65-96210-6. 2. Kit 65-96210-7 includes an offset yoke and is optional 65-96210-1 or 65-96210-4. The 65-96210-7 set of tools is recommended for accomplishing Service Bulletins 727-53-0059 and 727-53-0092. 65-96210 - KIT - TOOL

-7 -6 -5 -4 -3 Quantity Part Number Name

. . . . - 65-96210-3 Kit

. . . - . 65-96210-4 (b) Kit

. . - . . 65-96210-5 (c) Kit

. - . . . 65-96210-6 Kit, Supplemental

- . . . . 65-96210-7 Kit

. . . 1

. ST1010-31-3 (d) Rivet Yoke

. . . 1

. ST1010-31-4 (d) Rivet Yoke

. . 1

. . ST1010-43-8 Rivet Yoke 1

. . . . ST1010-97 (a) Rivet Yoke

. . . . 1 ST1010-451 Rivet Yoke

. 2

. . . ST1010B-3135 Bushing

. 2

. . . ST1010B-4385 Bushing

. . 1

. 1 ST1050B-249B Draw Tool

. . 1

. 1 ST1111A-249-43A Rivet Set - Flush 1

. . . . ST1111A-249-46A Rivet Set - Flush 1

. . 1

. ST1111A-249-48A Rivet Set - Flush

. . . 1

. ST1111A-249-412A Rivet Set - Flush

. . . 1

. ST1111A-249-414A Rivet Set - Flush

. . . 1

. ST1111A-249-416A Rivet Set - Flush

. . . 1

. ST1111A-249H Rivet Set - Flush

. . 1

. . ST1112A-249-52 Rivet Set - Universal

. . 1

. . ST1112A-249-53 Rivet Set - Universal

. . 1

. . ST1112A-249-54 Rivet Set - Universal

. . . . 1 ST1112A-249-56 Rivet Set - Universal

. . . . 1 ST1112A-249-58 Rivet Set - Universal

. . . . 1 ST1112A-249-66 Rivet Set - Universal

. . . . 1 ST1112A-249-68 Rivet Set - Universal 1

. . 1

. ST1112A-249-83 Rivet Set - Universal 1

. . 1

. ST1112A-249-84 Rivet Set - Universal 1

. . 1

. ST1112A-249-85 Rivet Set - Universal

. . . . 1 ST1112A-249-86 Rivet Set - Universal

. . . . 1 ST1112A-249-88 Rivet Set - Universal 1

. . 1

. ST1112A-249-103 Rivet Set - Universal

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### BOEING SERVICE BULLETIN 727-53-0041

65-96210 - KIT - TOOL

-7 -6 -5 -4 -3 Quantity Part Number Name 1

. . 1

. ST1112A-249-104 Rivet Set - Universal 1

. . 1

. ST1112A-249-105 Rivet Set - Universal

. . . . 1 ST1112A-249-510 Rivet Set - Universal

. . . . 1 ST1112A-249-610 Rivet Set - Universal

. . . . 1 ST1112A-249-810 Rivet Set - Universal (a) The ST1010-36 Rivet Yoke plus the 65-96210-6 Supplemental Kit and ST1115-249-M531 Adapter are optional to the ST1010-97 Rivet Yoke. (b) Kit 65-96210-1 (not available for purchase) plus supplemental Kit 65-96210-6 is equivalent to Kit 65-96210-4. (c) Kit 65-96210-2 (not available for purchase) plus supplemental Kit 65-96210-6 is equivalent to Kit 65-96210-5. (d) The ST1010-31-3 Rivet Yoke is optional to the ST1010-31-4 Rivet Yoke. 2. The following tool is suitable to assist in insertion of rivets through clips and structure. Quantity Part Number Nomenclature As NecessaryST1161 Rivet Insertion Tool 3. See applicable Nondestructive Test Manual Section for Nondestructive tool requirements. 4. Eddy-current probes which are suitable to accomplish the stringer-to-frame inspection may be fabricated per 727 Boeing Nondestructive Test Document, Part 6, or obtained from industry sources listed in Table II - Disc Probe Vendor Information and Table III - Modified Disc Probe Vendor Information.

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### BOEING SERVICE BULLETIN 727-53-0041

TABLE I - Tool Vendor Information Boeing Tool NumberVendor Tool NumberVendor ST1010-43-8 ST1010-451B ST1161 -

-

- The Boeing Company P. O. Box 3707 Seattle, WA 98124-2207 USA Pacific Tool Company 15235 Northeast 92nd Street Redmond, WA 98052-3815 USA West Coast Industries inc. 14900 Whitman Avenue North Seattle, WA 98133 USA Manufactures Tool Service 1215 Southeast Ivon Street Portland, OR 97202 USA ST1050B-249B ST1111A-249-( ) ST1112A-249-( ) -

-

- McAllister Machining Inc. 35700 Southeast Bluff Road Boring, OR 97009 USA Manufactures Tool Service 1215 Southeast Ivon Street Portland, OR 97202 USA Beaver RX Enterprises Unit 3 9531 192nd Street Surrey, B.C. VST4WZ CANADA The Boeing Company P. O. Box 3707 Seattle, WA 98124-2207 USA

-

- CP-0351-FUNEL (a) CP-0214-FANEL (b)Chicago Pneumatic Tool Company 2200 Bleecker Street Utica, NY 13501 USA

- APT 720 (less yoke)Deutsch/American Pneumatic Tool Company 14710 Maple Avenue Gardena, CA 90248 USA (a) Rivet capacity of CP-0351-FUNEL is 1/4 inch diameter. (b) Rivet capacity of CP-0214-FANEL is 3/16 inch diameter.

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TABLE II - Disc Probe Vendor Information
Fastener Hole Diameter Part Number Vendor (a) 0.1875 0.250 0.3125 DISC 12 DISC 16 DISC 20 Nortec Inc. 3001 George Washington Way Richland, WA 99352 USA 0.1875 0.250 0.3125 C-104-.1875 C-104-.250 C-104-.3125 Zetec Inc. P. O. Box 140 Issaquah, WA 98027 USA 0.1875 0.250 0.3125 6160-3/16 6160-1/4 6160-5/16 Ideal Specialty Co., Inc. 2529 East Independence Tulsa, OK 74110 USA
TABLE III - Modified Disc Probe Vendor Information
Fastener Hole Diameter Part Number Vendor (a) 0.1875 0.250 0.3125 DISC 12A DISC 16A DISC 20A Nortec Inc. 3001 George Washington Way Richland, WA 99352 USA 0.1875 0.250 0.3125 C-103-.1875 C-103-.250 C-103-.3125 Zetec Inc. P. O. Box 140 Issaquah, WA 98027 USA 0.1875 0.250 0.3125 DPM-1 DPM-2 DPM-3 USEC Laboratories 12692 Shorewood Drive Southwest Seattle, WA 98146 USA (a) Refer to 727 Nondestructive Test Manual, Part 6, Subject 53-10-00.

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### BOEING SERVICE BULLETIN 727-53-0041

D. Existing Parts Accountability The parts shown below are changed by this service bulletin. Quantity is the number of parts changed on the airplane.

Existing Part Number Part Name QuantityRUCNew Part NumberPNC RC (a,d) 65-19400-221 Insulation Panel 1 RWK65-19400-409 R,S A (a,d) 65-19400-222 Insulation Panel 1 RWK65-19400-410 R,S A (b,e) 65-19400-217 Insulation Panel 1 RWK65-19400-408 R,S A (c,f) 65-19400-239 Insulation Panel 1 RWK65-19400-419 R,S A (c,f) 65-19400-244 Insulation Panel 1 RWK65-19400-420 R,S A (c,g) 65-21893-1 Insulation Panel 1 RWK65-19400-414 R,S A (c,g) 65-21893-3 Insulation Panel 1 RWK65-19400-417 R,S A (c,h) 65-19400-254 Insulation Panel 1 RWK65-19400-407 R,S A (c,i) 65-19400-338 Insulation Panel 1 RWK65-19400-416 R,S A (c,i) 65-19400-339 Insulation Panel 1 RWK65-19400-413 R,S A (c,j) 65-19400-230 Insulation Panel 1 RWK65-19400-411 R,S A (c,j) 65-19400-236 Insulation Panel 1 RWK65-19400-415 R,S A (c,k) 65-19400-264 Insulation Panel 1 RWK65-19400-412 R,S A (c,k) 65-21893-3 Insulation Panel 1 RWK65-19400-418 R,S A (a) Group 5 airplanes. (b) Group 4 and 5 airplanes. (c) All Airplanes. (d) Body Station 400 to 420. (e) Body Station 420 to 440. (f) Body Station 440 to 460. (g) Body Station 480 to 500. (h) Body Station 500 to 520. (i) Body Station 600 to 620. (j) Body Station 950 to 970. (k) Body Station 990 to 1010.

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### BOEING SERVICE BULLETIN 727-53-0041

RUC Recommend Use Code RWK - Make the change as specified in this service bulletin. PNC Part Number Code R - The part number after the change. S - New equivalent or replacement part number. RC Replacement Code A - Not Interchangeable: Do not replace one part with the other.

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### BOEING SERVICE BULLETIN 727-53-0041

BLANK PAGE

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### BOEING SERVICE BULLETIN 727-53-0041

III. ACCOMPLISHMENT INSTRUCTIONS NOTES: 1. The paragraphs identified with letters give the general work instructions and the necessary tests. The instructions identified with numbers on the figures give the recommended sequence of steps. 2. As recommended by the 727 SWG, make the structural change as given in Part IV of the Accomplishment Instructions at or before the airplanes collects a total of 60,000 flights, and do the post-modification inspection as given in NOTE 4 below, at or before the airplane collects a total of 25,000 flights after Part IV or Part V is done, or within 6,000 flights after you get Revision 6 of this service bulletin. Continue the post-modification inspection at regularly scheduled times. The approved time between one inspection and the subsequent inspection must not be more than 14,000 flights. 3. Airplanes having accumulated more than 16,000 flight cycles should be inspected within 3,000 flight cycles following receipt of Revision 5 of this Service bulletin. Repeat inspections at 6,000 flight cycle intervals until the modification per this service bulletin is accomplished. 4. Airplanes modified, or repaired with stringer clips and radius fillers installed, per the original issue or Revision 1 through 6 of this service bulletin require repeat post-modification inspections as follows: after accumulating 25,000 flight cycles, repeat close visual inspection; for airplanes exceeding 25,000 flight cycles since modification, inspect at or prior to the next convenient maintenance interval, not to exceed 6,000 flight cycles. Repeat inspections at a regularly scheduled time that is not to exceed 14,000 flight cycles. 5. Cracks that have been repaired without installation of a stringer clip or radius filler require preventive modification per Part IV of this service bulletin. 6. If cracks are found on previously modified airplanes, contact Boeing. 7. Unless specified differently, these dimensions and tolerances are used: - All linear dimensions are in inches - Tolerance on linear dimensions other than rivet and bolt edge margin is plus or minus 0.03

inch - Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch - Angular tolerance is plus or minus 2 degrees - The hole dimensions for standard solid rivets are found in 727 Structural Repair Manual

Chapter 51 - The torque limits to tighten nuts and bolts are found in 727 Structural Repair Manual

Chapter 51. 8. Obey all warnings and cautions in the specified manual sections.

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### BOEING SERVICE BULLETIN 727-53-0041

Part I - Access Data Gain access to affected stringer-to-frame joints noted in Drawing 65-58869, Sheet 1, Zones A-4 through C-4 or in Drawing 65-87582, Pages 6 through 11. Part II - Jacking Data Airplane jacking during stringer-to-frame joint inspection or tie clip or filler installation is dependent upon the operator's planned action and the availability of body cradles at the time of service bulletin accomplishment. Operators should determine the program to be followed and comply with one of the following jacking instructions. A. If no more than five stringer-to-frame joints are to be unfastened at the same time in either the forward or the aft body, or both, no jacking is required. B. If more than five stringer-to-frame joints are to be unfastened at the same time, jack the airplane as follows: 1. Fabricate a body support cradle for Body Station 600, for 727-100, similar to those shown in Structural Repair Manual Section 51-50 using the coordinates shown below.
X 0 5 10 15 20 25 30 35 40 45 50 Y 0 0.170.66 1.502.694.276.278.7211.6915.2719.59 2. Defuel wing tanks per operator's standard procedure. 3. Raise, level, and stabilize the airplane (Reference Structural Repair Manual Chapter 51). 4. Place cradle in position and snug up against airplane body. Part III - Inspection Data NOTE: If no cracks are found and stringer-to-frame attach holes have been enlarged to 0.25 inch diameter per previous inspections, accomplish preventive modification per Part IV. A. Per Figure 1, remove the fasteners common to the stringer and frame and perform an eddy-current inspection per 727 Non Destructive Test Manual, Part 6, Subject 53-10-27, Figure 1 (preferred) or per Part 6, Subject 53-10-00, Figure 2, to detect fatigue cracks in stringers or frames originating at or near stringer-to-frame attachment fastener holes. See Drawing 65-58869, Sheet 1 or 65-87582, Pages 6 through 9, for applicable stringer-to-frame joints. NOTE: This inspection should be performed only by personnel well qualified in eddy-current inspection techniques. It is essential that this inspection be performed at the faying surfaces. B. Visually inspect stringer and frame radii for cracks per Figure 1. C. If cracks are found in stringer or frame at the attach fastener hole, repair per Part V, Repair Data. D. If cracks are found in stringer or frame radii, repair per 727 Structural Repair Manual, Section 53-10. E. If no cracks are found, accomplish the preventive modification per Part IV (preferred) or enlarge hole 1/32 inch and install rivet MS20470B( )-( ) and inspect at 6,000 flight cycle intervals until the preventive modification is accomplished.

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### BOEING SERVICE BULLETIN 727-53-0041

Part IV - Preventive Modification Data NOTE: Two different kits of clips have been provided to accomplish this modification. The installation of the "bow-legged" clips provided in the original kit is defined on Drawing 65-58869. Experience has indicated some difficulty may be encountered during installation of these clips, consequently, a superseding kit including straight-leg clips, was developed. Installation of this kit is defined on Drawing 65-87582. Installation of clips per either of these drawings constitutes compliance with this service bulletin. A. During inspection of the stringer-to-frame attachment fastener holes, if no cracks were found accomplish the following per Figure 2, at each location requiring a channel clip. See Drawing 65-58869, Sheet 1, or Drawing 65-87582, Pages 6 through 9, for applicable locations. CAUTION: DO NOT REMOVE THE RADIUS FILLER BONDED TO THE FLANGE OF THE STRINGER. Install applicable channel clip per Drawing 65-58869, Sheets 1 and 2 or Drawing 65-87582. Figure 2, Rear View shows installation of clips per Drawing 65-58869 or see Drawing 65-87582, page 5 for fastener callouts for clip installation. Also, see Paragraph C for additional rework of existing structure to allow clip installation. B. If no cracks were found during inspection, install a filler in the frame radius, per Figure 2, at each location requiring a filler in the frame radius. See Drawing 65-87582, Page 5, or installation 65-58869-12 in Drawing 65-58869, Sheet 2. C. Clip installations requiring rework to existing structure in addition to that illustrated on rework Drawing 65-58869, Sheet 2, are as follows: 1. At frame stations 640 and 680, stringer 4 Right, relocate oxygen tubing support nutplate and rotate clamp per Figure 5. 2. At frame station 294.5, stringers 2 LH, 3 LH and 3 RH, remove clamp BACC10DK5 attaching oxygen tubing 65-20900-16 to stringer and reinstall clamp rotated 180 degrees from its original position so that tubing will clear channel clip. Install channel clip per Paragraph A. 3. Modify wire bundle clamp as follows: a. Modify wire bundle clamps per Figures 6 and 7. b. Install channel clip per Paragraph A. 4. Modify clamps for anti-icing tubing of #1 VHF antenna at Station 620, per Figure 8. 5. Rework molded insulation panels to clear wire bundle conduits and anti-icing tubing supports, modified per Steps 3 and 4 above, per Figure 9. D. Reinstall all parts and equipment removed to gain access.

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### BOEING SERVICE BULLETIN 727-53-0041

Part V - Repair Data NOTES: 1. If a frame is cracked at three or more stringer locations requiring repair per the Structural Repair manual, it is suggested that the operator consider cutting out and replacing the damaged frame segment. 2. Cracks that have been repaired without installation of a stringer clip or radius filler require preventive modification per Part IV of this service bulletin. A. If a crack is found in the frame or stringer, originating at or near the stringer-to-frame attachment hole, enlarge the hole and eddy-current inspect the hole, per Figure 3, Instruction 1, to assure a crack free condition. B. If no crack is detected during inspection after the first fastener hole oversize, install fastener per Figure 3, Instruction 2. C. If crack indication still exists, enlarge hole an additional 1/32 inch diameter and inspect using eddy-current technique per Figure 3, Instruction 3. D. If no crack is detected during inspection following the second fastener hole oversize, install fastener per Figure 3, Instruction 3. E. If crack indication still exists after second oversize, repair frame or stringer per Structural Repair Manual, Section 53-10. F. If crack is found in frame or stringer radii, repair per Structural Repair Manual, Section 53-10. G. Restore airplane to normal.

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### BOEING SERVICE BULLETIN 727-53-0041

Illustration Table of Contents Title Page Figure 1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Figure 2. Preventive Modification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Figure 3. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 4. Optional Trimming of Flanged Bow-Legged Clips to Facilitate Installation . . . . . . . 33 Figure 5. Oxygen Tubing Support Clamp Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 6. Dual Conduit Wire Bundle Clamp Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 7. Single Conduit Wire Bundle Clamp Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 8. Anti-Icing Tubing Clamp Rework. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 9. Molded Panel Insulation Rework. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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FIGURE 1. INSPECTION
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The instructions given below agree with the numbers shown inside the circle symbols in the figure. 1Locate and remove the fasteners common to the stringer and frame, using care not to damage the hole. 2Perform an eddy-current inspection per 727 Non Destructive Test Manual, Part 6, Subject 53-10-27, Figure 1 (preferred) or per Part 6, Subject 53-10-00, Figure 2, to detect fatigue cracks in stringers or frames originating at or near stringer-to-frame attachment fastener holes. See Drawing 65-58869, Sheet 1 or 65-87582, Pages 6 through 9, for applicable stringer-to-frame joints. (Ref. Structural Repair Manual Subject 51-30-2 for fastener removal and installation.) NOTES: 1. This inspection should be performed only by personnel well qualified in eddy-current inspection techniques. It is essential that this inspection be performed at the faying surfaces. 2. If holes are out-of-round so that eddy-current inspection cannot be satisfactorily performed, holes should be reamed no more than is required to accomplish the inspection. If necessary remove any burrs or chips from faying surface. 3. Cracks characteristically propagate along the faying surface before extending to the visible surface of the frame or stringer. Fatigue test results show that 95 percent of cracks found occurred in the frames. 3Visually inspect stringer and frame radii for cracks.

FIGURE 1. INSPECTION
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FIGURE 2. PREVENTIVE MODIFICATION
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### BOEING SERVICE BULLETIN 727-53-0041

The instructions given below agree with the numbers shown inside the circle symbols in the figure. NOTES: 1. Two different kits of clips have been provided to accomplish this modification. The installation of the "bow-legged" clips provided in the original kit is defined on Drawing 65-58869. Experience has indicated some difficulty may be encountered during installation of these clips, consequently, a superseding kit including straight-leg clips, was developed. Installation of this kit is defined on Drawing 65-87582. Installation of clips per either of these drawings constitutes compliance with this service bulletin. 2. View A-A to Figure 2 provides fastener location dimensions. 3. See Figures 5 through 9 for additional rework of existing structure to facilitate clip installation. 1Enlarge stringer-to-frame attachment fastener hole 1/16 inch with a size F (0.257 inch diameter) drill and install rivet MS20470B8-8. Optionally, enlarge hole to 0.2500 (+ or - 0.0005) inch diameter and install bolt BACB30MB8-( ) and collar BACC30X8, or equivalent. NOTE: For starting hole sizes larger than 3/16 inch diameter, enlarge hole 1/16 inch and install rivet MS20470B10-10 for 1/4 inch diameter starting hole size, or BACR15ET9B9 for 7/32 inch diameter starting hole size. Optionally, install bolt BACB30MB10-( ) with collar BACC30X10, or bolt BACB30MD8-( ) with collar BACC30AC8. Install bolts in close reamed holes. Maximum allowable hole size is 5/16 inch diameter. At each location requiring a filler in the frame radius, enlarge stringer-to-frame attachment hole to 0.2500 (+ or - 0.0005) inch diameter. Drill filler 65-58869-30, or 65-87582-6, to match. Install filler with bolt BACB30MB8-5 and collar BACC30X8, (optional bolt BACB30FM8-5 and collar BACC30M8). See Drawing 65-87582, Page 5, or installation 65-58869-12 in Drawing 65-58869, Sheet 2. NOTE: For starting hole sizes larger than 3/16 inch diameter, enlarge hole 1/16 inch and install bolt BACB30MB10-5 with collar BACC30X10 for 1/4 inch diameter starting hole size, or bolt BACB30MD8-5 with collar BACC30AC8 for 7/32 inch diameter starting hole size. Install bolts in close reamed holes. Maximum allowable hole size is 5/16 inch diameter. CAUTION: DO NOT REMOVE THE RADIUS FILLER BONDED TO THE FLANGE OF THE STRINGER. 2Locate applicable channel clip, per Drawing 65-58869, Sheets 1 and 2 or Drawing 65-87582, at stringer to frame area and drill a No. 21 (0.159 inch diameter) hole through the stringer and clip and install rivet MS20470D5-5, 4 places per clip. Optional, drill a 0.187 (+ 0.003 or - 0.000) inch diameter hole through stringer and clip and install bolt BACB30GZ6-2 and collar BACC30P6, 4 places.

FIGURE 2. PREVENTIVE MODIFICATION
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### BOEING SERVICE BULLETIN 727-53-0041

3Drill the appropriate hole through frame and clip. See Drawing 65-58869, Sheet 2, for fastener callouts for clip installation. NOTES: 1. Fasteners which attach clip to frame may vary in location with each installation. Location of fasteners will be along center line of clips wherever possible. While installing clips, interference with rivets attaching nutplates to frame may be encountered. When this occurs, drill out rivets and countersink the frame 100 degrees. Reinstall nutplate with rivets BACR15CE5B6. Install clip as shown in Figure 2 or Drawing 65-87582, but relocate affected rivet, used to attach clip to frame, outboard, 1/4 inch to provide sufficient rivet spacing. 2. If difficulty is encountered installing "bow-leg" clips of kit 65-96210-( ), the clips may be trimmed per Figure 4 to facilitate installation in crushed stringers. 3. It is suggested that rivets be installed with squeeze tools to avoid damage to stringer or frame which might occur from a driven installation. 4. Special tool ST1161, or equivalent, may be used to insert rivets through clip and structure. See Paragraph II.C for procurement.

FIGURE 2. PREVENTIVE MODIFICATION
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FIGURE 3. REPAIR
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The instructions given below agree with the numbers shown inside the circle symbols in the figure. NOTE: If a frame is cracked at three or more stringer locations, requiring repair per the 727 Structural Repair Manual (SRM), it is suggested that the operator consider cutting out and replacing the damaged frame segment. 1Enlarge the hole 1/32 inch and inspect using eddy-current per 727 Non Destructive Test Manual, Part 6, Subject 53-10-27, Figure 1 (preferred) or Part 6, Subject 53-10-00, Figure 2. 2If no crack is detected during inspection, install fastener as follows: a. If clip is to be installed concurrently, enlarge hole using a Size K (0.281 inch diameter) drill and install rivet BACR15ET9B9 (BACR15WB9-9 optional). Optionally, enlarge hole to 0.2812 (+ or - 0.0005) inch diameter and install bolt BACB30KK8-( ) and collar BACC30R8 or equivalent. b. If radius filler 65-58869-30 or 65-87582-6 is to be installed concurrently, enlarge hole to 0.2812 (+ or - 0.0005) inch diameter, drill filler to match and install with bolts BACB30MD8-5 and collars BACC30AC8. c. If clip and radius fillers are not to be installed concurrently, enlarge hole with a size F (0.257 inch diameter) drill and install rivet MS20470B8-8. NOTE: Airplanes repaired per this option require a repeat inspection and accomplishment of the preventive modification per Part IV within 6,000 flight cycles of repair.

3If crack indication still exists, enlarge hole an additional 1/32 inch diameter and inspect using eddy-current technique as in Instruction 1. If crack is still indicated, refer to Instruction 4. If crack is undetectable, install fastener as follows and accomplish the preventive modification per Part IV. a. Enlarge hole using a size O (0.316 inch diameter) drill and install rivet MS20470B10-10. Optionally, enlarge hole to 0.3125 (+ or -0.0005) inch diameter and install bolt BACB30FM10-( ) and collar BACC30M10 or equivalent. b. If radius filler 65-58869-30 or 65-87582-6 is to be installed, enlarge hole to 0.3125 (+ or - 0.0005) inch diameter, drill filler to match and install with bolts BACB30MB10-5 and collars BACC30X10. NOTE: Maximum allowable hole size is 5/16 inch diameter. However, extreme difficulty may be encountered during installation of 5/16 inch diameter fasteners if existing hole is not centered in the stringer and frame flanges. This is due to fastener head interference with stringer or frame radii. If rivet head interference is encountered, rivet head may be trimmed to clear stringer or frame radii or stringer and frame may be repaired per 727 SRM, Section 53-10. If bolt head or collar interference is encountered, install locally fabricated radius filler to eliminate interference, or repair as required.

4If a crack still exists, repair frame or stringer per SRM, Section 53-10 and accomplish preventive modification per Part IV. 5If a crack is found in frame or stringer radii repair per SRM, Section 53-10 and accomplish preventive modification per Part IV.

FIGURE 3. REPAIR
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The instructions given below agree with the numbers shown inside the circle symbols in the figure. 1Trim clip to the dimensions shown to remove indicated shaded area. 2Apply chemical film treatment (Alodine or Iridite) and one coat of chemical and solvent resistant primer (BMS 10-11, Type I) to bare surfaces.

FIGURE 4. OPTIONAL TRIMMING OF FLANGED BOW-LEGGED CLIPS TO FACILITATE INSTALLATION
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The instructions given below agree with the numbers shown inside the circle symbols in the figure. 1Use a No. 20 drill (0.161 inch diameter) to drill a hole through the frame and nutplate. Install rivet MS20470D5-5. 2Relocate spacer nutplate BACN10NY3-10, and clamp BACC10DK12 assembly, 1.70 inches from the original position, as shown. Rotate clamp 180 degrees from the original position.

FIGURE 5. OXYGEN TUBING SUPPORT CLAMP RELOCATION
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FIGURE 6. DUAL CONDUIT WIRE BUNDLE CLAMP RELOCATION
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The instructions given below agree with the numbers shown inside the circle symbols in the figure. NOTES: 1. The following Instructions, 1 through 5, apply to frame locations and airplane groups as identified in Table IV. 2. To avoid chafing, ensure adequate clearance between wire bundles and structure. TABLE IV - Dual Conduit Wire Bundle Clamp Location Station StringerAirplane Group

420 7 Left 5 440 7 Left 4,5 460 7 Left 6 500 7 Left 1,2,3,4,5,6 520 7 Left 6
1Remove clamp assembly from frame and conduit. Retain clamp and fastener for reinstallation. 2Locate clamp BACC10DK16, retained, 0.35 inches aft of existing location along stringer. 3Install clamp with retained fastener. 4Remove clamp assembly from frame and conduit. Retain clamp and nut for reinstallation. Discard screw. 5Install retained clamp BACC10DK16 at existing location with spacer NAS42DD6-32, screw BACS12CB3-16 and retained nut NAS679A3W.

FIGURE 6. DUAL CONDUIT WIRE BUNDLE CLAMP RELOCATION
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### BOEING SERVICE BULLETIN 727-53-0041

FIGURE 7. SINGLE CONDUIT WIRE BUNDLE CLAMP RELOCATION
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### BOEING SERVICE BULLETIN 727-53-0041

The instructions given below agree with the numbers shown inside the circle symbols in the figure. NOTE: The following Instructions, 1 and 2, apply to frame locations and airplane groups as identified in Table V. TABLE V - Single Conduit Wire Bundle Clamp Location Station StringerAirplane Group

460 7 Left 1,2,3,4,5 520 7 Left 1,2,3,4,5 970 8 Left 1,2,3,4,5,6 1010 7 Left 1,2,3,4,5,6
1Remove clamp assembly from frame and conduit. Retain clamp and nut for reinstallation. Discard screw. 2Install clamp BACC10DK16 retained with spacer NAS42DD6-32, screw BACS12CB3-16 and retained nut NAS679A3W.

FIGURE 7. SINGLE CONDUIT WIRE BUNDLE CLAMP RELOCATION
Mar 8/68 727-53-0041 REV. 6: Sep 5/91 38

### BOEING SERVICE BULLETIN 727-53-0041

The instructions given below agree with the numbers shown inside the circle symbols in the figure. 1Remove clamp assembly from anti-icing tube. Retain clamp and nut for reinstallation. 2Install retained clamp BACC10DK16 with spacer NAS42DD6-64 and screw NAS603-22.

FIGURE 8. ANTI-ICING TUBING CLAMP REWORK
Mar 8/68 727-53-0041 REV. 6: Sep 5/91 39

### BOEING SERVICE BULLETIN 727-53-0041

The instructions given below agree with the numbers shown inside the circle symbols in the figure. NOTE: See Paragraph II.D., Existing Parts Accountability, for part numbers and location. 1Trim molded insulation panels at the aft end, which overlaps the frame, to clear clamps. 2Trim molded panel leg at stringer S-7 to clear wire bundle conduits and tubing modified per Figures 6, 7, and 8. 3At Station 620, the panel should be trimmed as shown at stringer S-7. 4Seal the edges of the trimmed panels. (Reference 727 Maintenance Manual, Subject 25-21-1). 5Ensure adequate clearance to avoid chafing. 6Renumber panels as shown in Section II, paragraph D., of this service bulletin.

FIGURE 9. MOLDED PANEL INSULATION REWORK
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### Commercial Airplane Group 

# 727 Service Bulletin

Number: 727-53-0041 

## Evaluation Form Date: March 8, 1968 Revision 6: September 5, 1991 ATA System: 5311 Prepared By: Stephen Holzman

SUBJECT:FUSELAGE - MAIN FRAME - INSTALLATION OF STRINGER TO BODY FRAME TIE CLIPS - BODY CROWN
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BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207