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

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 2
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

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 3
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.

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 4
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.

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 5
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.

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 6
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

Date September 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.

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 7
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"

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 8
BOEING SERVICE BULLETIN 727-53-0041

2. Data supplied with this service bulletin:

Drawings:

Drawing No. Sheet DCN ADCN Title

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

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 9
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.

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 10
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

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 11
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 Necessary BMS 5-30 Sealing Adhesive

As Necessary BMS 8-95, Type I Flame Resistant Fabric

As Necessary BMS 10-11, Type I Primer

As Necessary BACB30MD8-5 Bolt

As Necessary BACB30MB10-5 Bolt

As Necessary BACC30AC8 Collar

As Necessary BACC30X10 Collar

As Necessary BACR15ET9B9 (a) Rivet

As Necessary MS20470B7-( ) Rivet

As Necessary MS20470B10-10 (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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REV. 6: Sep 5/91 13
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 Necessary ST1161 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 Number Vendor Tool Number Vendor

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 Quantity RUC New Part Number PNC RC

(a,d) 65-19400-221 Insulation Panel 1 RWK 65-19400-409 R,S A

(a,d) 65-19400-222 Insulation Panel 1 RWK 65-19400-410 R,S A

(b,e) 65-19400-217 Insulation Panel 1 RWK 65-19400-408 R,S A

(c,f) 65-19400-239 Insulation Panel 1 RWK 65-19400-419 R,S A

(c,f) 65-19400-244 Insulation Panel 1 RWK 65-19400-420 R,S A

(c,g) 65-21893-1 Insulation Panel 1 RWK 65-19400-414 R,S A

(c,g) 65-21893-3 Insulation Panel 1 RWK 65-19400-417 R,S A

(c,h) 65-19400-254 Insulation Panel 1 RWK 65-19400-407 R,S A

(c,i) 65-19400-338 Insulation Panel 1 RWK 65-19400-416 R,S A

(c,i) 65-19400-339 Insulation Panel 1 RWK 65-19400-413 R,S A

(c,j) 65-19400-230 Insulation Panel 1 RWK 65-19400-411 R,S A

(c,j) 65-19400-236 Insulation Panel 1 RWK 65-19400-415 R,S A

(c,k) 65-19400-264 Insulation Panel 1 RWK 65-19400-412 R,S A

(c,k) 65-21893-3 Insulation Panel 1 RWK 65-19400-418 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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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.

Mar 8/68 727-53-0041

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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 0.17 0.66 1.50 2.69 4.27 6.27 8.72 11.69 15.27 19.59

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.

Mar 8/68 727-53-0041

REV. 6: Sep 5/91 23
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.

1 Locate and remove the fasteners common to the stringer and frame, using care not to damage the hole.

2 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. (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.

3 Visually inspect stringer and frame radii for cracks.

FIGURE 1. INSPECTION

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BOEING SERVICE BULLETIN 727-53-0041

FIGURE 2. PREVENTIVE MODIFICATION

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REV. 6: Sep 5/91 28
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.

1 Enlarge 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.

2 Locate 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

3 Drill 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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BOEING SERVICE BULLETIN 727-53-0041

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.

1 Enlarge 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.

2 If 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.

3 If 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.

4 If a crack still exists, repair frame or stringer per SRM, Section 53-10 and accomplish preventive modification

per Part IV.

5 If 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.

1 Trim clip to the dimensions shown to remove indicated shaded area.

2 Apply 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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BOEING SERVICE BULLETIN 727-53-0041

The instructions given below agree with the numbers shown inside the circle symbols in the figure.

1 Use a No. 20 drill (0.161 inch diameter) to drill a hole through the frame and nutplate. Install rivet

MS20470D5-5.

2 Relocate 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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REV. 6: Sep 5/91 35
BOEING SERVICE BULLETIN 727-53-0041

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 Stringer Airplane 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

1 Remove clamp assembly from frame and conduit. Retain clamp and fastener for reinstallation.

2 Locate clamp BACC10DK16, retained, 0.35 inches aft of existing location along stringer.

3 Install clamp with retained fastener.

4 Remove clamp assembly from frame and conduit. Retain clamp and nut for reinstallation. Discard screw.

5 Install 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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FIGURE 7. SINGLE CONDUIT WIRE BUNDLE CLAMP RELOCATION

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REV. 6: Sep 5/91 37
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 Stringer Airplane 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

1 Remove clamp assembly from frame and conduit. Retain clamp and nut for reinstallation. Discard screw.

2 Install clamp BACC10DK16 retained with spacer NAS42DD6-32, screw BACS12CB3-16 and retained nut

NAS679A3W.

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.

1 Remove clamp assembly from anti-icing tube. Retain clamp and nut for reinstallation.

2 Install retained clamp BACC10DK16 with spacer NAS42DD6-64 and screw NAS603-22.

FIGURE 8. ANTI-ICING TUBING CLAMP REWORK

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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: See Paragraph II.D., Existing Parts Accountability, for part numbers and location.

1 Trim molded insulation panels at the aft end, which overlaps the frame, to clear clamps.

2 Trim molded panel leg at stringer S-7 to clear wire bundle conduits and tubing modified per Figures 6, 7,

and 8.

3 At Station 620, the panel should be trimmed as shown at stringer S-7.

4 Seal the edges of the trimmed panels. (Reference 727 Maintenance Manual, Subject 25-21-1).

5 Ensure adequate clearance to avoid chafing.

6 Renumber panels as shown in Section II, paragraph D., of this service bulletin.

FIGURE 9. MOLDED PANEL INSULATION REWORK

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REV. 6: Sep 5/91 40
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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Please give us this data:

OPERATOR: TODAY'S DATE:

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form.

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form

directly to this address:

R.G. Kelsey, Manager

Service Bulletin Engineering

Boeing Commercial Airplane Group

P.O. Box 3707, Mail Stop 2L-02

Seattle, WA 98124-2207

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