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ALERT ALERT

Commercial

Airplanes 747

ALERT ALERT

Service Bulletin

Number: 747-53A2507

Original Issue: April 21, 2005

Revision 1: January 14, 2010

ATA System: 5310

SUBJECT: FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2005 The Boeing Company

Unpublished Work - All Rights Reserved

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

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

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

parties. Treatment of the document and the information it contains is governed by contract with Boeing. For 

more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

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

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

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 Table of Contents

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Table of Contents

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

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 32

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 33

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 33

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 36

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 37

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1

ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIGURE 2: Deleted (Revision 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2). . . . . . . . . . . . . . . 55

FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) . . . . . . . . . . 58

FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY) . . . . . . . . . . . . . . . . . . . . 61

FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220 . . . . . . . . . . . . . . . . . . . . 67

FIGURE 7: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS . . . . . . . . . . 72

FIGURE 8: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1

ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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FIGURE 9: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) . . . . . . . . . . . 80

FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY) . . . . . . . . . . . . . . . . . . . . 83

FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220 . . . . . . . . . . . . . . . . . . . 89

FIGURE 12: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS . . . . . . . . . 94

FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE . . . . . . . . . . . . . . . . . . 97

FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE

LOCATIONS (Revision 1 - More Work) . . . . . . . . . . . . . . . . . . . . . . . . . 102

FIGURE 15: STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140 . . . . . . . . . . . . . . 109

APPENDIX A: Deleted (Revision 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

APPENDIX B: TENSION TIE DISCONNECTION METHODS. . . . . . . . . . . . . . . . . . . . . . 112

APPENDIX C: COMMON FASTENER TYPE REQUIREMENT . . . . . . . . . . . . . . . . . . . . 114
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ALERT ALERT

Commercial

Airplanes 747

ALERT ALERT

Service Bulletin

Number: 747-53A2507 Revision Transmittal Sheet

Original Issue: April 21, 2005

Revision 1: January 14, 2010

ATA System: 5310

SUBJECT: FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2007-23-18 is related to this service bulletin. 

AD 2007-23-18 supersedes AD 2006-06-11.

Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 is related to this service bulletin.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2009-NM-024-AD, is related to this 

service bulletin.

More work is necessary on airplanes inspected as shown in the original issue of this service bulletin. 

Compliance times for Stage 1 inspections have been revised to match the requirements of FAA AD 2007-23-

18. This revision also recommends new compliance times for Stage 2 inspections, which is not included in FAA 

AD 2007-23-18. For airplanes that are past the new compliance time for Stage 2 inspections, continue to do 

the Stage 1 inspection work at the repeat interval specified until the Stage 2 inspection work is started. Also, a 

requirement has been added to do eddy current inspection of twelve additional fastener holes in the tension tie 

inboard of the aluminum straps at STA 1140. Boeing recommends that operators incorporate this additional 

inspection requirement before 10,000 total flight cycles or within 3,000 flight cycles after the Revision 1 date of 

this service bulletin, whichever is later.

Group 1, Configuration 1: In addition, more work is necessary on airplanes that have not been modified to SF 

or BCF. A new inspection of the shear panels for a mislocated angle is recommended within 3,000 flight cycles 

after the Revision 1 date of this service bulletin.

Group 1, Configuration 2; Group 2-3: In addition, more work is necessary on airplanes that have been modified 

by Boeing to Special Freighter (SF) or Boeing Converted Freighter (BCF). A new inspection of fastener holes 

in the frames at locations where tension ties existed before freighter modification is recommended within 3,000 

flight cycles after the Revision 1 date of this service bulletin. 

For other clarifications or corrections to work instructions that are transmitted with this revision, Boeing 

recommends that operators incorporate the revised instructions at the next planned Stage 1 or Stage 2 

inspection as given in this service bulletin.

No airplanes were added to this service bulletin effectivity.
 

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REASON FOR REVISION

This alert revision is sent to revise compliance times of Stage 1 inspections to match the requirements of AD 

2007-23-18, and reduce the initial Stage 2 inspection compliance time. In addition, this revision adds references 

to Structural Repair Manual (SRM) repairs that were released after the original issue of this service bulletin, and 

adds new inspection requirements. 

Many other changes have also been made in Revision 1. The following list describes important changes.

Changes to this service bulletin include:

— In Summary, Reason, and Description sections: Updated these sections with current data.

— In Paragraph 1.A., Effectivity: Revised effectivity to remove RT631, RT632, RT743, and RT876. These 

airplanes no longer have tension ties. Also, the Effectivity has been divided into three groups. Group 1 is 

for passenger airplanes. Groups 2 and 3 are for airplanes modified by Boeing to SF or BCF.

— In Paragraph 1.E., Compliance: This section is changed to recommend new compliance times for Stage 

1 and Stage 2 inspections. Also, added compliance information for new inspections, updated existing AD 

callouts to 2004-07-22 R1, and added reference to AD 2007-23-18.

— In Paragraph 1.F., Approval: Updated this section with Alternative Method of Compliance (AMOC) 

information.

— In Paragraph 1.J., References: Added new SRM and AD references.

— In Paragraph 1.K., Publications Affected: This section has been revised to add Damage Tolerance 

Inspection information.

— In Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Updated table to reflect additional parts 

that may be necessary to support new inspections.

— In Paragraph 3.A., General Information: Some existing notes have been updated and new notes have 

been added.

— In Paragraph 3.B., Work Instructions: Added reference to SRM repairs. Revised to provide separate 

instructions for passenger airplanes and SF/BCF airplanes. Also, added instructions for new inspections 

and revised instructions for additional inspections when a severed tension tie is found.

— In Figure 1: Revised figure to clarify shear web information.

— In Figure 2: This figure is deleted. In previous revisions of this service bulletin, Figure 2 gave instructions 

for additional inspections that were required if a tension tie was found severed. Boeing now recommends 

instructions given in the Accomplishment Instructions section and Figure 5 for additional inspections if a 

tension tie is found severed.

— In Figure 5: Revised figure to clarify shear web information and to clarify the location of view E-E. Revised 

instructions to require that all removed fasteners be re-installed wet with BMS 3-27 or BMS 3-38 in close 

ream holes, instead of installed dry in transition fit holes. Note (g) has been revised to remove instruction 

to contact Boeing for repair instructions. Repair instructions are contained in the Accomplishment 

Instructions section. Also, some footnotes and footnote identifiers have been revised.

— In Figure 6: Revised figure to clarify shear web information, to remove instruction to contact Boeing for 

repair instructions, and to add instruction to repair as given in the Accomplishment Instructions. Revised 

instructions to require that all removed fasteners be re-installed wet with BMS 3-27 or BMS 3-38 in close 

ream holes, instead of installed dry in transition fit holes. Also, some footnotes and footnote identifiers have 

been revised.

— New Figure 8 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 8 is similar 

to Figure 1.

— New Figure 9 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 9 is similar 

to Figure 4.

— New Figure 10 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 10 is 

similar to Figure 5.

— New Figure 11 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 11 is 

similar to Figure 6.
 

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ALERT ALERT

— New Figure 12 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 12 is 

similar to Figure 7.

— New Figure 13 has been added for passenger airplanes (airplanes not modified by Boeing to SF or BCF). 

Figure 13 is a one-time inspection for a mislocated angle common to the shear panel and tension tie at 

STA 1140.

— New Figure 14 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 14 is a 

one-time inspection for cracks in frames at locations where tension ties existed before SF or BCF 

modification.

— New Figure 15 has been added for all airplanes to specify eddy current inspection of twelve additional 

fastener holes in the tension tie inboard of the aluminum straps at STA 1140.

— Appendix A has been deleted.

— Appendix B has been revised to delete Method 2 and Method 4 for disconnecting tension ties.

Paragraph 1.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 1.A., Effectivity, to show the location 

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: April 21, 2005

Revision 1: January 14, 2010
 

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ALERT ALERT

Commercial

Airplanes 747

ALERT ALERT

Service Bulletin

Number: 747-53A2507 Summary

Original Issue: April 21, 2005

Revision 1: January 14, 2010

ATA System: 5310

SUBJECT: FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair

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

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

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

BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin gives instructions for inspection and repair of upper deck tension ties and adjacent frame 

structure on stretched upper deck (SUD) airplanes. The tension ties have been determined to be structure that 

is susceptible to Widespread Fatigue Damage (WFD). WFD could cause tension ties to become severed or 

disconnected from the frames. Severed or disconnected tension ties and/or frames at multiple locations could 

result in rapid in-flight decompression of the airplane.

For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.

Tension ties are installed just aft of the floor beams that support the upper deck. Tension ties are installed at 

Stations (STA) 1120, 1140, 1160, 1180, 1200, and 1220 and extend from the left side to the right side of the 

airplane.

During routine maintenance an operator found two severed upper deck tension ties at STA 1120 and STA 1140. 

The cause of the severed tension ties was fatigue cracking due to an incorrect configuration. As a result of this 

report, Boeing released Service Bulletin 747-53-2483 which recommended a one time inspection to make sure 

proper configuration and a crack free condition. 

During inspections per Service Bulletin 747-53-2483 one operator found severed tension ties at both STA 1120 

and STA 1140 at approximately 14,000 total flight cycles, and a second operator found a severed tension tie at 

STA 1120 at approximately 28,000 total flight cycles. For these three additional severed tension tie reports, the 

tension tie configuration was as shown on Boeing Engineering Drawings.
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

In addition, before the original issue of this service bulletin, operators reported finding 10 cracks in tension ties, 

10 broken fasteners, 9 cracks in frames adjacent to tension ties, and 8 cracks in the shear ties adjacent to the 

tension ties. The cracks and broken fasteners were at STA 1120, STA 1140, STA 1160, STA 1180, STA 1200, 

and STA 1220. There were also 4 reports of cracks in the shear web between the STA 1120 and STA 1140 

tension ties. For these additional reports, the airplanes had between 7,000 and 28,000 total flight cycles. 

Subsequent to the release of the original issue of this service bulletin, one operator reported that three adjacent 

tension ties were found severed on a 747-300 series airplane with approximately 18,400 flight cycles. Another 

operator reported that two adjacent tension ties were found severed on a 747-300 series airplane with 

approximately 14,000 flight cycles. In addition, multiple operators have reported finding cracks in tension ties 

and frames during inspections per the original issue of this service bulletin. Due to these reports, Boeing finds 

it necessary to reduce the compliance times and repeat intervals for the inspections recommended by this 

service bulletin.

In addition to receiving multiple crack reports after the release of the original issue of this service bulletin, Boeing 

has determined that Stage 2 inspections should include open hole eddy current inspection at twelve additional 

fastener locations in the STA 1140 tension tie inboard of the aluminum straps. The aluminum straps create load 

conditions in the STA 1140 tension tie that could cause cracks at these additional fastener locations, which are 

farther inboard than where eddy current inspections are done on other tension ties.

Also, due to operator reports of a mislocated angle common to the shear panel, a one-time inspection has been 

added to inspect for the mislocated angle and install a new angle in the correct location, as necessary. A 

mislocated angle could lead to cracks in the shear panel.

Also, Boeing has determined that it is necessary to add a one-time inspection of fastener holes in the frames of 

Boeing Special Freighter and Boeing Converted Freighter airplanes at locations where tension ties existed 

before freighter modification. These fastener holes were not inspected during modification at Boeing. 

Inspection is necessary to ensure the fastener holes are crack free.

This service bulletin provides instructions for inspections and repair of the tension ties and frames at the aft end 

of the upper deck. 

The tension ties and frames have been found to be structually significant in that they are critical to the structural 

integrity of the airplane. Tension tie and frame cracks not found before they reach critical crack lengths can 

cause in-flight depressurization.

Boeing Service Related Problem (SRP) 747-SRP-53-0215 is related to this service bulletin.

Modification Service Bulletin 747-53A2559 has been released to address Widespread Fatigue Damage (WFD) 

in the tension ties and adjacent frame structure. Accomplishment of Service Bulletin 74753A2559 will terminate 

the repeat inspection requirements of this service bulletin. For more information about WFD, refer to Boeing 

Service Letter 747-SL-53-088A.

ACTION

Get access to the frame to tension tie joints at STA 1120 through STA 1220. Do Stage 1 or Stage 2 inspections 

for cracks, and broken, loose, or missing fasteners in the tension ties, the shear webs, and the attached frames. 

If cracks are found, or if broken, loose, or missing fasteners are found, do the repairs given in this service bulletin 

before the airplane is returned to service. Repeat inspections at the specified intervals.
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This service bulletin contains a flight safety inspection program. The flight safety inspection program is the 

minimum inspection program to maintain the structural integrity of the affected area of the airplane. An optional 

economics based inspection, to be done earlier than the flight safety inspection, would usually be included in 

this type of bulletin. However, for this area there is no economics based inspection program. The repair 

necessary when a crack is found in the flight safety inspection is the same as the repair necessary if a crack is 

found earlier.

EFFECTIVITY

747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes. Refer to paragraph 1.A.1, Effectivity.

NOTE: For 747-200B airplanes, only airplanes that have been modified to Stretched Upper Deck are affected.

COMPLIANCE

Refer to paragraph 1.E, Compliance.

Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 is related to this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive 2007-23-18 is related to this service bulletin. AD 

2007-23-18 supersedes AD 2006-06-11.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2009-NM-024-AD, is related to this 

service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection or repair procedures given in this service bulletin.

MANPOWER

Refer to paragraph 1.G., Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

REPAIR IF NECESSARY

AND LOOSE OR MISSING FASTENERS.

INSPECT TENSION TIES FOR CRACKS

1120

STA

1220

STA

1120

STA

1220

STA

REPAIR IF NECESSARY

CRACKS AND LOOSE OR MISSING FASTENERS.

TO 2 STRINGERS BELOW TENSION TIES FOR

INSPECT FRAMES FROM 2 STRINGERS ABOVE

CRACKS. REPAIR IF NECESSARY

INSPECT SHEAR WEBS FOR

1140

STA

FWD

466909
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ALERT ALERT

Commercial

Airplanes 747

ALERT ALERT

Service Bulletin

Number: 747-53A2507

Original Issue: April 21, 2005

Revision 1: January 14, 2010

ATA System: 5310

SUBJECT: FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair

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

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

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

BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below. Refer to PRR 85901-53RS for data about 

this change. 

Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line 

Number, and Serial Number data.
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

NOTE: Some airplanes were delivered with Extended Upper Deck Modifications that installed

floor beams aft of Station 740. These airplanes are not the same as airplanes delivered

with a Stretched Upper Deck (SUD), which includes 747-300, 747-400 passenger

airplanes, and some 747-100 and 747-200 airplanes that have been modified to SUD.

NOTE: Revision 1 changed the effectivity to remove RT631, RT632, RT743, and RT876. These

airplanes have been modified to Large Cargo Freighter (LCF) configuration and no

longer have tension ties.

Airplane models:

747-100B SUD 747-200B 747-300 747-400

747-400D

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AEROLINEAS ARGENTINAS (ARG)

1 RT701–RT702 RT704

AEROSUR (REO)

1 RM354 RS235

AIR ATLANTA ICELANDIC (AID)

1 RS211 RS233 RS237 RS332–RS333

RT515 RT777 RT834

3 RT776

AIR CARGO GERMANY (CGU)

1 RT633–RT634

AIR CHINA (BEJ)

1 RM341 RM811–RM813 RT034–RT035 RT878–RT880

3 RT033

GROUP CONFIGURATION DESCRIPTION

1 - 747-100B/-200B/-300/-400/-400D airplanes, 

built in a Stretched Upper Deck (SUD) 

configuration, or modified to SUD by Boeing, 

except airplanes modified by Boeing to Special 

Freighter (SF) or Boeing Converted Freighter 

(BCF) configuration before Revision 1.

1 Group 1 airplane that have not been modified by 

Boeing to SF or BCF.

2 Group 1 airplanes that are modified to BCF 

configuration after release of Revision 1 of this 

service bulletin.

2 - 747-200B SUD and -300 airplanes that have 

been modified by Boeing to SF configuration.

3 - 747-400 airplanes that have been modified by 

Boeing to BCF configuration before release of 

Revision 1 of this service bulletin.
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

AIR CHINA CARGO (CGC)

1 RT101 RT103

3 RT031–RT032

AIR FRANCE (AFA)

1 RM401–RM403 RT073–RT074 RT121 RT591

RT711–RT716

3 RT071–RT072 RT075 RT751

AIR INDIA (AIN)

1 RS781–RS782 RU001–RU006

AIR NEW ZEALAND (ANZ)

1 RM082 RM191–RM192 RT671–RT673 RT703

RT932

AIR PACIFIC (APC)

1 RT502 RT504

AIR PULLMANTUR (PUL)

1 RT523 RT525 RT749

AIRBRIDGE CARGO (ABM)

2 RS762

AL WAFEER (WFR)

1 RU016

ALL NIPPON AIRWAYS (ANA)

1 RT753–RT755 RU831 RU833–RU841

ASIANA AIRLINES (AAR)

1 RM071 RT131–RT136 RU032

ATLAS AIR (TLS)

1 RM232–RM233

2 RS722

3 RT752

BAHRAIN ROYAL FLIGHT (BHR)

1 RM426

BRITISH AIRWAYS (BAB)

1 RM096–RM097 RM136–RM145 RM261–RM264 RT471–RT499

RU121–RU132

CATHAY PACIFIC AIRWAYS (CAT)

1 RT451–RT455 RT457–RT460 RT462–RT469 RT511–RT512

RT514 RT517 RT522 RT529

3 RT456 RT461 RT508 RT518–RT519

RT524 RT528 RT781–RT782 RT837
 

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ALERT ALERT

CHINA AIRLINES (CHI)

1 RM021–RM024 RM441–RM443 RM445 RT636–RT640

CORSAIR (COR)

1 RS239–RS240 RT613–RT614 RT616 RT618–RT619

RT621

DRAGONAIR (DRG)

3 RT510 RT513 RT516

DUBAI AIR WING (DAW)

1 RM167–RM168 RT102

EAGLE AVIATION EUROPE (EAU)

1 RT831

EL AL ISRAEL AIRLINES (ELA)

1 RM091 RT527 RU081–RU083

EVA AIR (EVA)

1 RM116–RM117 RT162–RT163 RT165–RT168 RT951–RT955

EXPORT RESTRICTED AIRPLANES (YWV)

1 RS751–RS752 RT602 RT606 RT620

FINOVA (GRB)

1 RS761

GARUDA INDONESIA (GIA)

1 RT931 RU061–RU062

GECAS (GEF)

1 RT412 RT615 RT622

GENERIC CUSTOMER/SUPPLIER (XXX)

1 RD382 RS331

GOVERNMENT OF JAPAN (JAG)

1 RT681–RT682

GREAT WALL AIRLINES (GWL)

3 RT520

HIS MAJESTY THE SULTAN'S FLIGHT (BWN)

1 RT440

JAL INTERNATIONAL (JAL)

1 RM126–RM127 RM129–RM132 RM316–RM318 RS251–RS252

RS259 RT641 RT643–RT654 RT861–RT864

RT966 RU801–RU809

3 RM128 RT642 RT655–RT657 RT967
 

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ALERT ALERT

KALITTA AIR (KAC)

3 RT021–RT022

KINGDOM HOLDING COMPANY (KBA)

1 RT877

KLM - ROYAL DUTCH AIRLINES (KLM)

1 RM801–RM803 RT001–RT014 RT531–RT535

KOREAN AIR (KAL)

1 RM011–RM013 RT061 RT571 RT577–RT588

RT590 RT811–RT814

3 RT572–RT576

KUWAIT AIRWAYS (KUW)

1 RT151

LION AIR (MLI)

1 RT503 RT505

LUFTHANSA GERMAN AIRLINES (DLH)

1 RM001–RM007 RT041–RT047 RT431–RT439 RT441–RT447

MALAYSIA AIRLINES (MAS)

1 RM036–RM040 RM366–RM367 RT744 RT746

RT748 RT750 RU017

MARTINAIR HOLLAND (MTH)

3 RT501 RT506–RT507 RT509

MAX AIR (MXE)

1 RS266–RS267

NORTHWEST AIRLINES (NWA)

1 RM241–RM246 RT401–RT410

OMAN ROYAL FLIGHT (RFO)

1 RM010

ORIENT THAI AIRLINES (OTH)

1 RS001–RS002 RS253–RS254 RS257

PAKISTAN INT'L AIRLINES (PIA)

1 RS301–RS303 RS305–RS306

PHILIPPINE AIRLINES (PAL)

1 RT152 RU051–RU052 RU059–RU060

PHUKET AIRLINES (PHK)

1 RD381 RD605 RS238 RS241

RS711
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

PRESIDENTIAL FLIGHT (ABD)

1 RM084 RT137

QANTAS (QAN)

1 RF001–RF006 RM331–RM333 RS273–RS274 RS276

RT551–RT568 RT741–RT742 RU031

ROYAL AIR MAROC (RAM)

1 RT717

SATAIR (SAI)

1 RD606

SAUDI ARABIAN AIRLINES (SVA)

1 RM156–RM157 RS311–RS320 RU101–RU102

SAUDI ROYAL FLIGHT (SRF)

1 RM158 RS699

SINGAPORE AIRLINES (SIA)

1 RM041–RM045 RT521 RT530 RT833

RT835

3 RT526

SKYTECH-AIC (SKC)

1 RT832

SONAIR (SON)

1 RM231

SOUTH AFRICAN AIRWAYS (SAA)

1 RM081 RM083 RM147 RS212

RS232 RS236

SOUTHERN AIR (SOF)

2 RD601–RD602 RS721 RS786

SURINAM AIRWAYS (SUR)

1 RS713

TAAG (ANGOLA AIRLINES) (ANG)

1 RS703 RS742

THAI AIRWAYS INTERNATIONAL (TII)

1 RM026–RM030 RM431 RT691–RT699 RT801–RT803

TRANSAERO AIRLINES (TRX)

1 RM146 RS255 RS258 RS263

RS268 RS271 RT783–RT784

UNICAL AVIATION (UNL)

1 RS341–RS342
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

UNITED AIR LINES (UAL)

1 RM166 RM169–RM177 RT411 RT601

RT603–RT605 RT607–RT612 RT617 RT623–RT630

UPS (UPS)

3 RT161 RT164

VIRGIN ATLANTIC AIRWAYS (VAA)

1 RM051–RM053 RM351–RM353 RM355 RT945–RT949

WORLD AIRWAYS, INC. (WLD)

1 RT745 RT747

YANGTZE RIVER EXPRESS (YTH)

1 RT756–RT757

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

RD381–RD383 1

RD601–RD602 2

RD603–RD607 1

RD721–RD722 1

RF001–RF006 1

RM001–RM007 1

RM010–RM013 1

RM021–RM024 1

RM026–RM030 1

RM036–RM045 1

RM051–RM053 1

RM071 1

RM081–RM084 1

RM091 1

RM096–RM097 1

RM116–RM117 1

RM126–RM127 1

RM128 3

RM129–RM132 1

RM136–RM147 1

RM156–RM158 1

RM166–RM177 1

RM191–RM192 1

RM231–RM233 1

RM241–RM246 1
 

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ALERT ALERT

RM261–RM264 1

RM316–RM318 1

RM331–RM333 1

RM341 1

RM351–RM355 1

RM366–RM367 1

RM401–RM403 1

RM426 1

RM431 1

RM441–RM443 1

RM445 1

RM801–RM803 1

RM811–RM813 1

RS001–RS002 1

RS201 1

RS211–RS212 1

RS221–RS222 1

RS231–RS241 1

RS251–RS259 1

RS263 1

RS265–RS268 1

RS271–RS276 1

RS291–RS292 1

RS301–RS306 1

RS311–RS320 1

RS331–RS333 1

RS341–RS342 1

RS699 1

RS701–RS703 1

RS711–RS713 1

RS721–RS722 2

RS731–RS732 1

RS741 2

RS742 1

RS743 2

RS751–RS752 1

RS761 1

RS762 2

RS771 2

Variable Group
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

RS781–RS782 1

RS786 2

RT001–RT014 1

RT021–RT022 3

RT031–RT033 3

RT034–RT035 1

RT041–RT047 1

RT061 1

RT071–RT072 3

RT073–RT074 1

RT075 3

RT101–RT103 1

RT121 1

RT131–RT137 1

RT151–RT152 1

RT161 3

RT162–RT163 1

RT164 3

RT165–RT168 1

RT401–RT412 1

RT431–RT447 1

RT451–RT455 1

RT456 3

RT457–RT460 1

RT461 3

RT462–RT469 1

RT471–RT499 1

RT501 3

RT502–RT505 1

RT506–RT510 3

RT511–RT512 1

RT513 3

RT514–RT515 1

RT516 3

RT517 1

RT518–RT520 3

RT521–RT523 1

RT524 3

RT525 1

Variable Group
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

RT526 3

RT527 1

RT528 3

RT529–RT535 1

RT551–RT568 1

RT571 1

RT572–RT576 3

RT577–RT591 1

RT601–RT630 1

RT633–RT641 1

RT642 3

RT643–RT654 1

RT655–RT657 3

RT671–RT673 1

RT681–RT682 1

RT691–RT699 1

RT701–RT704 1

RT711–RT717 1

RT741–RT742 1

RT744–RT750 1

RT751–RT752 3

RT753–RT757 1

RT776 3

RT777 1

RT781–RT782 3

RT783–RT784 1

RT801–RT803 1

RT811–RT814 1

RT831–RT836 1

RT837 3

RT861–RT864 1

RT877–RT880 1

RT931–RT932 1

RT945–RT949 1

RT951–RT955 1

RT966 1

RT967 3

RU001–RU006 1

RU016–RU017 1

Variable Group
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions for inspection and repair of upper deck tension ties and 

adjacent frame structure on stretched upper deck (SUD) airplanes. The tension ties have been 

determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). WFD could 

cause tension ties to become severed or disconnected from the frames. Severed or disconnected 

tension ties and/or frames at multiple locations could result in rapid in-flight decompression of the 

airplane.

For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.

Tension ties are installed just aft of the floor beams that support the upper deck. Tension ties are 

installed at Stations (STA) 1120, 1140, 1160, 1180, 1200, and 1220 and extend from the left side to 

the right side of the airplane.

During routine maintenance an operator found two severed upper deck tension ties at STA 1120 and 

STA 1140. The cause of the severed tension ties was fatigue cracking due to an incorrect 

configuration. As a result of this report, Boeing released Service Bulletin 747-53-2483 which 

recommended a one time inspection to make sure proper configuration and a crack free condition. 

During inspections per Service Bulletin 747-53-2483 one operator found severed tension ties at both 

STA 1120 and STA 1140 at approximately 14,000 total flight cycles, and a second operator found a 

severed tension tie at STA 1120 at approximately 28,000 total flight cycles. For these three additional 

severed tension tie reports, the tension tie configuration was as shown on Boeing Engineering 

Drawings.

In addition, before the original issue of this service bulletin, operators reported finding 10 cracks in 

tension ties, 10 broken fasteners, 9 cracks in frames adjacent to tension ties, and 8 cracks in the shear 

ties adjacent to the tension ties. The cracks and broken fasteners were at STA 1120, STA 1140, STA 

1160, STA 1180, STA 1200, and STA 1220. There were also 4 reports of cracks in the shear web 

between the STA 1120 and STA 1140 tension ties. For these additional reports, the airplanes had 

between 7,000 and 28,000 total flight cycles. 

RU031–RU032 1

RU051–RU052 1

RU059–RU062 1

RU081–RU083 1

RU101–RU102 1

RU121–RU132 1

RU801–RU809 1

RU831–RU841 1

Variable Group
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

Subsequent to the release of the original issue of this service bulletin, one operator reported that three 

adjacent tension ties were found severed on a 747-300 series airplane with approximately 18,400 

flight cycles. Another operator reported that two adjacent tension ties were found severed on a 747-

300 series airplane with approximately 14,000 flight cycles. In addition, multiple operators have 

reported finding cracks in tension ties and frames during inspections per the original issue of this 

service bulletin. Due to these reports, Boeing finds it necessary to reduce the compliance times and 

repeat intervals for the inspections recommended by this service bulletin.

In addition to receiving multiple crack reports after the release of the original issue of this service 

bulletin, Boeing has determined that Stage 2 inspections should include open hole eddy current 

inspection at twelve additional fastener locations in the STA 1140 tension tie inboard of the aluminum 

straps. The aluminum straps create load conditions in the STA 1140 tension tie that could cause 

cracks at these additional fastener locations, which are farther inboard than where eddy current 

inspections are done on other tension ties.

Also, due to operator reports of a mislocated angle common to the shear panel, a one-time inspection 

has been added to inspect for the mislocated angle and install a new angle in the correct location, as 

necessary. A mislocated angle could lead to cracks in the shear panel.

Also, Boeing has determined that it is necessary to add a one-time inspection of fastener holes in the 

frames of Boeing Special Freighter and Boeing Converted Freighter airplanes at locations where 

tension ties existed before freighter modification. These fastener holes were not inspected during 

modification at Boeing. Inspection is necessary to ensure the fastener holes are crack free.

This service bulletin provides instructions for inspections and repair of the tension ties and frames at 

the aft end of the upper deck. 

The tension ties and frames have been found to be structurally significant in that they are critical to 

the structural integrity of the airplane. Tension tie and frame cracks not found before they reach critical 

crack lengths can cause in-flight depressurization.

Boeing Service Related Problem (SRP) 747-SRP-53-0215 is related to this service bulletin.

Modification Service Bulletin 747-53A2559 has been released to address Widespread Fatigue 

Damage (WFD) in the tension ties and adjacent frame structure. Accomplishment of Service Bulletin 

74753A2559 will terminate the repeat inspection requirements of this service bulletin. For more 

information about WFD, refer to Boeing Service Letter 747-SL-53-088A.

Revision 1 is sent to revise compliance times of Stage 1 inspections to match the requirements of AD 

2007-23-18, and reduce the initial Stage 2 inspection compliance time. In addition, this revision adds 

references to Structural Repair Manual (SRM) repairs that were released after the original issue of this 

service bulletin, and adds new inspection requirements. A list of Revision 1 changes can be found on 

the Revision Transmittal Sheet for Revision 1.

D. Description

Get access to the frame to tension tie joints at STA 1120 through STA 1220. Do Stage 1 or Stage 2 

inspections for cracks, and broken, loose, or missing fasteners in the tension ties, the shear webs, and 

the attached frames. If cracks are found, or if broken, loose, or missing fasteners are found, do the 

repairs given in this service bulletin before the airplane is returned to service. Repeat inspections at 

the specified intervals.
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This service bulletin contains a flight safety inspection program. The flight safety inspection program 

is the minimum inspection program to maintain the structural integrity of the affected area of the 

airplane. An optional economics based inspection, to be done earlier than the flight safety inspection, 

would usually be included in this type of bulletin. However, for this area there is no economics based 

inspection program. The repair necessary when a crack is found in the flight safety inspection is the 

same as the repair necessary if a crack is found earlier.

Revision 1 includes the following work:

1. More work is necessary on airplanes inspected as shown in the original issue of this service 

bulletin. Compliance times for Stage 1 inspections have been revised to match the requirements 

of FAA AD 2007-23-18. This revision also recommends new compliance times for Stage 2 

inspections, which is not included in FAA AD 2007-23-18. For airplanes that are past the new 

compliance time for Stage 2 inspections, continue to do the Stage 1 inspection work at the repeat 

interval specified until the Stage 2 inspection work is started. Also, a requirement has been 

added to do eddy current inspection of twelve additional fastener holes in the tension tie inboard 

of the aluminum straps at STA 1140. Boeing recommends that operators incorporate this 

additional inspection requirement before 10,000 total flight cycles or within 3,000 flight cycles 

after the Revision 1 date of this service bulletin, whichever is later.

2. Group 1, Configuration 1: In addition, more work is necessary on airplanes that have not been 

modified to SF or BCF. A new inspection of the shear panels for a mislocated angle is 

recommended within 3,000 flight cycles after the Revision 1 date of this service bulletin.

3. Group 1, Configuration 2; Group 2-3: In addition, more work is necessary on airplanes that have 

been modified by Boeing to Special Freighter (SF) or Boeing Converted Freighter (BCF). A new 

inspection of fastener holes in the frames at locations where tension ties existed before freighter 

modification is recommended within 3,000 flight cycles after the Revision 1 date of this service 

bulletin. 

NOTE: For other clarifications or corrections to work instructions that are transmitted with Revision

1, Boeing recommends that operators incorporate the revised instructions at the next planned

Stage 1 or Stage 2 inspection as given in this service bulletin.

NOTE: If the damaged area is more than the specified limits, contact Boeing for repair instructions.

Give the size and location of the damage. When possible, send sketches and photographs.

If the damage includes corrosion, send data on the length, width, and largest depth of clean

up.

PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION 

RESULTS WHEN EACH INSPECTION IS COMPLETE.

Send your report to:

BOEING COMMERCIAL AIRPLANES GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

Because of common access, the inspections specified in Service Bulletin 747-53-2483 "FUSELAGE 

- Frame to Tension Tie Joint Inspection - Body Station 1120 to 1220" can be done at the same time 

as the changes specified in this service bulletin.
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

E. Compliance

Table 1: Compliance Time for STAGE 1 and STAGE 2 Inspection

Condition Action Compliance Time (Whichever is earlier)

Repeat Interval 

(Not to Exceed)

Airplanes that 

accumulated 

less than 

12,000 total 

flight cycles 

as of 

November 28, 

2007. (and 

DID NOT do a 

STAGE 1 

inspection 

prior to 

November 

28,2007)

Do detailed 

inspections for 

damage as given in 

the STAGE 1 

INSPECTION section 

of the Work 

Instructions, 

Paragraph 3.B. 

(b)(c)(d)

At the earlier of the 

following:

Before 8,000 total flight 

cycles, or within 1,500 

flight cycles after April 26, 

2006, or within 4,000 flight 

cycles since inspection per 

Service Bulletin 747-

53A2483, whichever 

occurs later,

-ORBefore 10,000 total flight 

cycles, or within 250 flight 

cycles after November 28, 

2007, whichever occurs 

later.

At the later of the 

following:

Before 12,000 

total flight cycles,

-ORWithin 50 flight 

cycles or 20 days 

after November 

28, 2007, 

whichever is 

earlier.

Do the next 

inspection before 

10,000 total flight 

cycles or within 250 

flight cycles after the 

initial STAGE 1 

inspection, whichever 

occurs later,

-ANDDo inspections 

thereafter every 250 

flight cycles.

Airplanes that 

accumulated 

less than 

12,000 total 

flight cycles 

as of 

November 28, 

2007. (and 

DID do a 

STAGE 1 

inspection 

prior to 

November 28, 

2007)

Do detailed 

inspections for 

damage as given in 

the STAGE 1 

INSPECTION section 

of the Work 

Instructions, 

Paragraph 3.B. 

(b)(c)(d)

- - Do the next 

inspection before 

10,000 total flight 

cycles or within 250 

flight cycles after 

November 28, 2007, 

whichever occurs 

later,

-ANDDo inspections 

thereafter every 250 

flight cycles.

Airplanes that 

accumulated 

12,000 total 

flight cycles or 

more as of 

November 28, 

2007. (and 

DID NOT do a 

STAGE 1 

inspection 

prior to 

November 

28,2007)

Do detailed 

inspections for 

damage as given in 

the STAGE 1 

INSPECTION section 

of the Work 

Instructions, 

Paragraph 3.B. 

(b)(c)(d)

Within 50 flight cycles after 

November 28, 2007.

Within 20 days 

after November 

28, 2007.

250 flight cycles.
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

Airplanes that 

accumulated 

12,000 total 

flight cycles or 

more as of 

November 28, 

2007. (and 

DID do a 

STAGE 1 

inspection 

prior to 

November 

28,2007)

Do detailed 

inspections for 

damage as given in 

the STAGE 1 

INSPECTION section 

of the Work 

Instructions, 

Paragraph 3.B. 

(b)(c)(d)

- - At the later of the 

following:

Within 250 flight 

cycles after last 

STAGE 1 inspection

-ORWithin 50 flight cycles 

or 20 days after 

November 28, 2007, 

whichever is earlier.

-ANDDo inspections 

thereafter every 250 

flight cycles.

All airplanes. Do detailed and HFEC 

inspections for 

damage as given in 

the STAGE 2 

INSPECTION section 

of the Work 

Instructions, 

Paragraph 3.B. 

(a)(b)(c)(d)

Before 10,000 

total flight cycles 

or within 1,000 

flight cycles after 

the Revision 1 

date of this 

service bulletin, 

whichever is 

later.

3,000 flight cycles.

All airplanes. Do a HFEC inspection 

for cracks in the 

tension tie as given in 

the STAGE 2 

INSPECTION - 

ADDITIONAL WORK 

at STA 1140 section of 

the Work Instructions, 

Paragraph 3.B.

Before 10,000 

total flight cycles 

or within 3,000 

flight cycles after 

the Revision 1 

date of this 

service bulletin, 

whichever is 

later.

3,000 flight cycles.

No damage 

found, or 

damage has 

been 

repaired.

Repeat the STAGE 1 

or STAGE 2 inspection 

as given in this 

compliance table.

At the times 

given in this 

compliance 

table.

-

Damage 

found. (d)

Repair as given in the 

Work Instructions, 

paragraph 3.B.

Before further 

flight.

-

(a) Revision 1 of this service bulletin reduces the initial inspection threshold for STAGE 2 inspection work. 

Continue to do STAGE 1 inspection work at the times specified until the STAGE 2 inspection work is started. 

Table 1: Compliance Time for STAGE 1 and STAGE 2 Inspection

Condition Action Compliance Time (Whichever is earlier)

Repeat Interval 

(Not to Exceed)
 

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 is related to this service 

bulletin.

(b) The requirement to do the STAGE 1 INSPECTION ends when the STAGE 2 INSPECTION work is started.

(c) Once the STAGE 2 INSPECTION work is started, continue doing the STAGE 2 inspections. Do not do the 

STAGE 1 inspections after the STAGE 2 inspections are started.

(d) For this table, damage is defined as: Any crack, broken fastener, loose fastener, or fastener that is 

missing.

Group 1, Configuration 1: One-Time Inspection for Mislocated Angles (Revision 1 - More Work)

Condition Action Compliance Time

All airplanes. Do the ONE-TIME INSPECTION FOR 

MISLOCATED ANGLES as given in the 

Work Instructions, Paragraph 3.B.

Within 3,000 flight cycles after the Revision 1 

date of this service bulletin. (a)

No mislocated 

angle found.

No further action. -

Mislocated angle 

found.

Correctly install a new angle as given in 

the Work Instructions, Paragraph 3.B.

Before further flight.

All airplanes. After inspection and rework as 

necessary, continue STAGE 1 or 

STAGE 2 inspections as applicable at 

the times shown in Table 1.

-

(a) Due to common access the inspection can be done concurrent with the next planned Stage 2 inspection 

as given in this service bulletin.

Group 1, Configuration 2; Group 2-3: One-Time Inspection of Frames at Previous Tension Tie Locations

(Revision 1 - More Work)

Condition Action Compliance Time

All airplanes. Do the ONE-TIME INSPECTION FOR 

CRACKS IN FRAMES AT PREVIOUS 

TENSION TIE LOCATIONS as given in 

the Work Instructions, Paragraph 3.B.

Within 3,000 flight cycles after the Revision 1 

date of this service bulletin. (a)

No crack found, or 

crack has been 

repaired.

No further action. -

Any crack found. Repair as given in the Work 

Instructions, paragraph 3.B.

Before further flight.

All airplanes. After inspection and rework as 

necessary, continue STAGE 1 or 

STAGE 2 inspections as applicable at 

the times shown in Table 1.

-

(a) Due to common access the inspection can be done concurrent with the next planned Stage 2 inspection 

as given in this service bulletin.

Table 1: Compliance Time for STAGE 1 and STAGE 2 Inspection

Condition Action Compliance Time (Whichever is earlier)

Repeat Interval 

(Not to Exceed)
 

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ALERT ALERT

Federal Aviation Administration (FAA) Airworthiness Directive 2007-23-18 is related to this service 

bulletin. AD 2007-23-18 supersedes AD 2006-06-11.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2009-NM-024-AD, is related 

to this service bulletin.

F. Approval

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

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

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

JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval 

were based on the airplane in its original Boeing delivery configuration or as modified by other 

approved Boeing changes.

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

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

approval before incorporating this service bulletin.

This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle 

Aircraft Certification Office approves the inspection and repair procedures with the corresponding 

compliance times specified in Table 1, under paragraph 1.E., "Compliance" of Service Bulletin 747-

53A2507, Revision 1, as an AMOC to the inspections and repairs required by paragraphs (h), (i), and 

(j) of AD 2004-07-22 R1, for the inspection of Structural Significant Item (SSI) F-19A of Supplemental 

Structural Inspection Document (SSID) D6-35022, Revision G. This AMOC only applies to the areas 

inspected by this service bulletin. When this service bulletin specifies contacting Boeing for repair 

instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of 

the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph, 

including the initial inspection threshold per paragraph (i) of AD 2004-07-22 R1, remain fully applicable 

and must be complied with.

In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspection and 

repair procedures with corresponding compliance times specified in Table 1, under paragraph 1.E., 

"Compliance" of Service Bulletin 747-53A2507, Revision 1, as an AMOC to the inspection and repair 

procedures specified in Table 1, under paragraph 1.E., "Compliance" of Service Bulletin 747-

53A2507, dated April 21, 2005, with the corresponding compliance times required by paragraphs (f), 

(g), (h) and (i) of AD 2007-23-18. When this service bulletin specifies contacting Boeing for repair 

instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of 

the AD. All provisions of AD 2007-23-18 that are not specifically referenced in this paragraph remain 

fully applicable and must be complied with.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this Service Bulletin for each 

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

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

examples of lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts
 

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ALERT ALERT

— Time to find the tools.

Group 1, Configuration 1: 

Task

Number of 

Persons Task-Hours

Elapsed 

Hours

Open Access (Stage 1 and 2) 2 12.00 6.00

Figure 1 (Stage 1) 2 8.00 4.00

Figure 3 (Stage 1 and 2) 2 1.00 0.50

Figure 4 (Stage 1 and 2) 2 10.00 5.00

Figure 5 (Stage 2) 2 72.00 36.00

Figure 6 (a) (b) 1 0.50 0.50

Figure 7 (b) 1 0.15 0.15

Figure 13 (c) 1 0.10 0.10

Figure 15 (Stage 2) 2 3.00 1.50

Close Access (Stage 1 and 2) 2 14 7

TOTAL FOR EACH AIRPLANE (Stage 1 only) 45.1 22.6

TOTAL FOR EACH AIRPLANE (Stage 2 only) 112.1 56.1

(a) If required. Not included in total.

(b) Estimate given is for repair/inspection of one hole location. Actual task-hours 

necessary will depend on the number of holes that need to be repaired/inspected.

(c) One-time inspection. Hours will not be required after inspection is done the first time. 

Estimate given is for inspection only. Time for part fabrication and replacement is not 

included.

Group 1, Configuration 2; Group 2-3: 

Task

Number of 

Persons Task-Hours

Elapsed 

Hours

Open Access (Stage 1 and 2) 2 12.00 6.00

Figure 8 (Stage 1) 2 8.00 4.00

Figure 9 (Stage 1 and 2) 2 10.00 5.00

Figure 10 (Stage 2) 2 72.00 36.00

Figure 11 (a) (b) 1 0.50 0.50

Figure 12 (b) 1 0.15 0.15

Figure 14 (c) 2 9.00 4.50

Figure 15 (Stage 2) 2 3.00 1.50

Close Access (Stage 1 and 2) 2 14 7

TOTAL FOR EACH AIRPLANE (Stage 1 only) 53.0 26.5

TOTAL FOR EACH AIRPLANE (Stage 2 only) 120.0 60.0

(a) If required. Not included in total.

(b) Estimate given is for repair/inspection of one hole location. Actual task-hours 

necessary will depend on the number of holes that need to be repaired/inspected.

(c) One-time inspection. Hours will not be required after inspection is done the first time.
 

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ALERT ALERT

The times for any additional repairs that are found because of the inspections are listed within the 

SRM.

The times shown for the Figures above are for the tension ties at six station locations, both left side 

and right side.

H. Weight and Balance Changes

None.

NOTE: No significant weight and balance changes are expected due to inspection or fastener

replacement procedures in this service bulletin. However, SRM repairs and/or use of

substitute fasteners could cause a significant weight and balance change.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. 747-100/200/300 Aircraft Maintenance Manual (AMM) 24-22-00, 25-14-02, 25-22-04, 

25-24-00, 25-25-01, 25-59-01, 25-59-05

b. 747-100/200/300 Structural Repair Manual (SRM) 51-30-02, 51-30-03, 51-30-05, 53-10-04, 

53-10-11, 53-30-03, Chapter 51

c. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 25-22-00, 25-22-04, 25-24-00, 

25-25-01, 25-59-01, 25-59-05

d. 747-400 Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05, 53-40-01, 

53-40-07, 53-40-30, Chapter 51

e. 747-400SF Structural Repair Manual (SRM) 53-40-01, Chapter 51

f. 747 Non-Destructive Testing (NDT) Manual, Part 6, 51-00-00

g. FAA Airworthiness Directive 2004-07-22 R1

h. FAA Airworthiness Directive 2007-23-18

i. FAA Notice of Proposed Rule Making 2009-NM-024-AD

j. Standard Overhaul Practices Manual (SOPM) 20-41-05, 20-50-19

2. Data supplied with this Service Bulletin:

None.
 

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ALERT ALERT

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

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

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

may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications

None.

2. Damage Tolerance Based Structural Inspections:

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

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

Maintenance Program. This service bulletin affects FCS and new DTI requirements for the 

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

L. Interchangeability and Intermixability of Parts

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

Drawing Number Title

65B01749 FRAME INSTALLATION - BODY STA 1120

65B18703 FRAME INSTALLATION - BODY STA 1140

65B01751 FRAME INSTALLATION - BODY STA 1160

65B01752 FRAME INSTALLATION - BODY STA 1180

65B01753 FRAME INSTALLATION - BODY STA 1200

65B01754 FRAME INSTALLATION - BODY STA 1220

65B09631 TENSION TIE INSTALLATION - AFT OF UPPER DECK FLOOR

657U7304 TENSION TIE INSTALLATION - STA 880 - STA 1220, MOD
 

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ALERT ALERT

BLANK PAGE
 

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ALERT ALERT

2. MATERIAL INFORMATION

A. Material - Price and Availability

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

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service 

bulletin does not show the Boeing price and supply data.

B. Industry Support Information

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

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.
 

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ALERT ALERT

2. Parts and Materials Supplied by the Operator:

Part Number / Specification QTY Name Notes

BACB30MY6K4Y 2 Hex Drive Bolt (a)

BACB30MY6K5X 2 Hex Drive Bolt (a)

BACB30NX( )K( ) 380 Hex Drive Bolt (a) (c) (d) (e) (f)

BACB30VT6K3X 2 Hex Drive Bolt (a) (g)

BACB30VT8K3 4 Hex Drive Bolt (a) (d) (e)

BACC30BL6 2 Collar (a) (g)

BACC30BL8 4 Collar (a) (d) (e)

BACC30M6 2 Collar (a) (j)

BACC30R6 2 Collar (a) (j)

BACN10YT( )CD 380 Nut (a) (c) (d) (e) (f)

BACR15BB6D( ) 24 Rivet (a) (j)

BACR15BB7D( ) 28 Rivet (a) (j)

BACR15FT5D( )C 10 Rivet (a) (g) (h)

BACR15FT6D( ) 36 Rivet (a) (j)

BACW10BP( )DP 380 Washer (a) (c) (d) (e)

BMS 3-23, Type II 16 Ounces Corrosion Inhibiting Compound (b) (e)

BMS 3-27 (BMS 3-38 optional) 8 Ounces Corrosion Inhibiting Compound (b) (e)

BMS 10-11, Type 1 8 Ounces Primer (b) (e)

Alodine as required Chemical Conversion Coating (b) (e) (i)

65B09631-139/-140 as required Angle (g)

(a) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(c) Operators should have access to 3/16 inch and 1/4 inch fasteners in the first and second oversize 

diameters. Operators should also have access to 5/16 inch standard diameter fasteners. Grip lengths from -

3 to -8 could be required.

(d) Quantities are approximate, operators may need more or less fasteners, but these quantities are to be 

used as a guide and are for the total number of fasteners including all the grip lengths specified.

(e) The quantity required will depend on the inspection results and if any repairs are necessary.

(f) To allow for easier removal during repeat inspections, it is optional to install BACB30MR( )K( ) bolts and 

BACW10BP( )CD washers, with BACN11Z( )CD nuts and BACW10BP( )DP washers at fastener locations 

common to the steel plates. However, availability of BACB30MR( )K( ) bolts is limited. Also, if fasteners are 

substituted, the same type of fastener should be used throughout each joint, as shown in Appendix C, Figure 

F.

(g) Group 1, Configuration 1: These parts may be necessary if it is necessary to re-install a mislocated angle. 

Refer to the "INSPECTION FOR MISLOCATED ANGLE" section of the paragraph 3.B., Work Instructions. 

Make from BAC1503-100031 extrusion, 7075-T6511 per QQ-A-200/11.

(h) Grip lengths -5 and -6 are expected, but grip length -7 could be necessary.

(i) Refer to SOPM 20-43-03 for material alternatives.

(j) This part is only needed for Group 1, Configuration 2; Group 2-3. For rivets, grip length as required.
 

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ALERT ALERT

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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ALERT ALERT

BLANK PAGE
 

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ALERT ALERT

3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED

MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES

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

SPARKS OR OTHER ELECTRICAL DAMAGE.

NOTE:

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

definition of the acronyms.

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

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

— Linear dimensions are in inches

— Tolerance on linear dimensions, other than rivet and bolt edge margins, 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

— Hole dimensions for standard solid rivets are given in 747 SRM, Chapter 51

— Torque limits to tighten nuts and bolts are given in 747 SRM, Chapter 51.

4. For approved fastener and process material substitutions, refer to 747 SRM, Chapter 51 

or Boeing Drawing 012W6100. Alternate fasteners are given in 747 SRM Chapter 51 

and Boeing Drawing 65B88700.

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

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

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

standards given in SRM Chapter 51 may be used.

6. A Detailed Inspection is defined as: An intensive examination of a specific item, 

installation, or assembly to detect damage, failure, or irregularity. Available lighting is 

normally supplemented with a direct source of good lighting at an intensity deemed 

appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. 

Surface cleaning and elaborate procedures may be required.

7. These work instructions refer to procedures included on other Boeing documents. When 

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

the accepted alternative procedure can be used. When the words "as given in" are 

included in the instruction, the procedure in the Boeing document must be used.

8. In the instructions and figures, the tension tie to frame joint configuration shown is a 

typical representative view. Actual configurations vary depending on location.

9. In the following work instructions, it is structurally satisfactory to substitute fasteners per 

747-100/200/300 SRM 51-30-03 or 747-400 SRM 51-40-03. However, if fasteners are 

substituted, the same type fasteners should be used throughout each joint, as shown in 

Appendix C.
 

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10. Airplanes that have been modified by Boeing to Special Freighter (SF) or Boeing 

Converted Freighter (BCF) configuration have tension ties installed from Station (STA) 

880 to STA 1220. However, only tension ties from STA 1120 to STA 1220 need to be 

inspected as given in this Service Bulletin. Inspection per Supplemental Structural 

Inspection Document (SSID), Revision G, are still required for tension ties at STA 880 

through STA 1100.

11. Do not remove the fasteners from adjacent tension tie to frame joints at the same time. 

Refer to Appendix B for allowable methods to disconnect the tension ties.

12. In Figures 1, 2, 5, and 6 of this Service Bulletin Right Buttock Line (RBL) 26, and Left 

Buttock Line (LBL) 26 are used as reference points. RBL 26 is defined as the 

perpendicular distance 26 inches right of the fuselage vertical center line. LBL 26 is 

defined as the perpendicular distance 26 inches left of the fuselage center line.

13. Airplanes that have been modified by Boeing to SF or BCF configuration have had the 

shear panel removed by trimming. The STA 1120 tension tie is replaced during 

modification. The only remaining part of the shear panel is a strip common to the lower 

flange of the STA 1140 forward tension tie channel.

14. 747-300 and 747-400 airplanes that have been modified by Boeing to SF or BCF do not 

have an Aluminum Channel attached to the tension tie at STA 1220. 747-200 SUD 

airplanes that have been modified by Boeing to SF configuration do have an Aluminum 

Channel attached to the tension tie at STA 1220.

15. Tension tie configurations created by "non-Boeing" modifications are not shown in this 

service bulletin. Operators of airplanes with non-Boeing tension tie configurations 

should seek approval of alternate inspection plans from their local regulatory agency.

16. If previous frame repairs are found during accomplishment of detailed inspections given 

in this service bulletin, also do a detailed inspection of the entire repaired area.

17. 747 SRM repairs for frame cracks include the following: 

— 747-100/200/300 SRM 53-10-04, Figures 123 through 131.

— 747-400 SRM 53-40-07, Repairs 1 through 9.

18. 747 SRM repairs for tension tie cracks include the following: 

— 747-100/200/300 SRM 53-10-04

— 747-400 SRM 53-40-07Repair 1.

19. For airplanes that have been modified by Boeing to BCF, equivalent tension tie and 

frame structure repairs have not yet been added to the 747-400SF SRM. It is acceptable 

to use the referenced 747-400 SRM repairs for repair of the tension tie and frame 

structure on BCF airplanes until the 747-400SF SRM is updated.

B. WORK INSTRUCTIONS

Do the Stage 1 or Stage 2 Inspections at the compliance times specified in paragraph 1.E. of this 

service bulletin.
 

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ALERT ALERT

ACCESS

1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 

747-400 AMM 24-22-00 as an accepted procedure.

2. Get access to the tension ties and frames:

a. Group 1, Configuration 1: Remove the seats as necessary between STA 1120 and STA 

1220. Refer to 747-100/200/300 AMM 25-25-01 or 747-400 AMM 25-25-01 as an accepted 

procedure.

b. Group 1, Configuration 1: Remove the main deck ceiling panels as necessary between STA 

1120 and STA 1220 to get access to the tension ties and frames. Refer to 747-100/200/300 

AMM 25-22-04 or 747-400 AMM 25-22-04 as an accepted procedure.

c. Group 1, Configuration 1: Remove insulation as necessary to get access to the tension ties 

and frames. Refer to 747-100/200/300 AMM 25-14-02 or 747-400 AMM 25-22-00 as an 

accepted procedure.

NOTE: Additional access to the STA 1120 tension tie joints can be obtained through the

upper deck aft partition or closet(s). Refer to 747-100/200/300 AMM 25-24-00 or

747-400 AMM 25-24-00. However, this access is not required to accomplish the

inspections as given in this service bulletin.

d. Group 1, Configuration 2; Group 2-3: Remove main deck cargo compartment lining panels 

as necessary to get access to the tension ties and frames from STA 1120 to STA 1220. 

Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted 

procedure.

e. Group 1, Configuration 2; Group 2-3: Remove main deck cargo compartment insulation as 

necessary to get access to the tension ties and frames from STA 1120 to STA 1220. Refer 

to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure.

STAGE 1 INSPECTION

CAUTION: IF FASTENER REMOVAL IS NECESSARY, DO NOT REMOVE THE FASTENERS

FROM ADJACENT TENSION TIE TO FRAME JOINTS AT THE SAME TIME. IF

FASTENERS ARE REMOVED FROM ADJACENT TENSION TIES, DAMAGE TO THE

AIRPLANE STRUCTURE MAY OCCUR. REFER TO APPENDIX B FOR ALLOWABLE

METHODS TO DISCONNECT THE TENSION TIES.

1. Do the ACCESS steps as given in this service bulletin.

2. Group 1, Configuration 1: Do a detailed inspection of the tension ties and steel plates from STA 

1120 to STA 1220 as given in Figure 1.

3. Group 1, Configuration 2; Group 2-3: Do a detailed inspection of the tension ties and steel plates 

from STA 1120 to STA 1220 as given in Figure 8.

4. Group 1, Configuration 1: Do a detailed inspection of the shear web components that attach to 

the tension ties as given in Figure 3.
 

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5. Group 1, Configuration 1: Do a detailed inspection of each of the frames from 2 stringers above 

to 2 stringers below the tension ties, as given in Figure 4.

6. Group 1, Configuration 2; Group 2-3: Do a detailed inspection of each of the frames from 2 

stringers above to 2 stringers below the tension ties, as given in Figure 9. 

7. If no cracks are found, and there are no broken, loose, or missing fasteners, do the 

RESTORATION steps as given in this service bulletin.

8. If a severed tension tie is found, do the following before further flight:

a. Do a detailed inspection of the frame web, frame inner chord, fail-safe chord, shear ties, and 

fasteners from stringer 3 to stringer 18, for cracks and broken, loose, or missing fasteners. 

Do this inspection on both sides of the frame, and on both sides of the airplane, for the 

severed tension tie only.

b. Group 1, Configuration 1: Do the additional inspections (Open Hole HFEC, Surface HFEC, 

and Detailed) as given in Figure 5. Do the Figure 5 inspections at the severed tension tie 

and at the tension ties adjacent to the severed tension tie. If one of the inspected tension 

ties is at STA 1140, also do the open hole HFEC inspections as given in Figure 15.

c. Group 1, Configuration 2; Group 2-3: Do the additional inspections (Open Hole HFEC, 

Surface HFEC, and Detailed) as given in Figure 10. Do the Figure 10 inspections at the 

severed tension tie and at the tension ties adjacent to the severed tension tie. If one of the 

inspected tension ties is at STA 1140, also do the open hole HFEC inspections as given in 

Figure 15.

d. If no more cracks are found, and there are no broken, loose, or missing fasteners, repair the 

severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30.

e. If more cracks are found, or if there are broken, loose, or missing fasteners, do the following:

(1) Repair the severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 

SRM 53-40-30.

(2) Do the STRUCTURE REPAIR steps as given in this service bulletin, as necessary.

f. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 

1140, also install fasteners as given in Figure 15, as necessary.

g. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 

10. At STA 1140, also install fasteners as given in Figure 15, as necessary. 

h. Do the RESTORATION steps as given in this service bulletin.

9. If cracks are found in a tension tie, steel plate, frame or shear web components (and the tension 

tie is NOT severed), or if there are broken, loose, or missing fasteners, do the following before 

further flight:

a. Do the STRUCTURE REPAIR steps as given in this service bulletin, as necessary.

b. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 

1140, also install fasteners as given in Figure 15, as necessary.
 

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c. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 

10. At STA 1140, also install fasteners as given in Figure 15, as necessary. 

d. Do the RESTORATION steps as given in this service bulletin.

10. Repeat the inspections at the intervals specified in paragraph 1.E., Compliance.

11. Report all inspection findings to Boeing.

STAGE 2 INSPECTION

CAUTION: DO NOT REMOVE THE FASTENERS FROM ADJACENT TENSION TIE TO FRAME

JOINTS AT THE SAME TIME. IF FASTENERS ARE REMOVED FROM ADJACENT

TENSION TIES, DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR. REFER

TO APPENDIX B FOR ALLOWABLE METHODS TO DISCONNECT THE TENSION

TIES.

1. Do the ACCESS steps as given in this service bulletin.

2. Group 1, Configuration 1: Do HFEC and detailed inspections of the tension ties, frames, and steel 

plates as given in Figure 5.

3. Group 1, Configuration 2; Group 2-3: Do HFEC and detailed inspections of the tension ties, 

frames, and steel plates as given in Figure 10.

4. Group 1, Configuration 1: Do a detailed inspection of the shear web components that attach to 

the tension ties as given in Figure 3.

5. Group 1, Configuration 1: Do a detailed inspection of each of the frames from 2 stringers above 

to 2 stringers below the tension ties, as given in Figure 4.

NOTE: If there are insulation blanket studs attached to the frames in the inspection area, check

to see if the studs are bonded on to the frames, or if they go through holes in the frames.

At locations where the studs go through holes in the frames, remove the stud and

inspect the hole as given in Figure 7. 

6. Group 1, Configuration 2; Group 2-3: Do a detailed inspection of each of the frames from 2 

stringers above to 2 stringers below the tension ties, as given in Figure 9. 

NOTE: If there are insulation blanket studs attached to the frames in the inspection area, check

to see if the studs are bonded on to the frames, or if they go through holes in the frames.

At locations where the studs go through holes in the frames, remove the stud and

inspect the hole as given in Figure 12. 

7. Group 1, Configuration 1: If no cracks are found, and there are no broken, loose, or missing 

fasteners, install steel plates and fasteners as given in Figure 5, then do the RESTORATION 

steps.

8. Group 1, Configuration 2; Group 2-3: If no cracks are found, and there are no broken, loose, or 

missing fasteners, install steel plates and fasteners as given in Figure 10, then do the 

RESTORATION steps.

9. If a severed tension tie is found, do the following before further flight:
 

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ALERT ALERT

a. Do a detailed inspection of the frame web, frame inner chord, fail-safe chord, shear ties, and 

fasteners from stringer 3 to stringer 18, for cracks and broken, loose, or missing fasteners. 

Do this inspection on both sides of the frame, and on both sides of the airplane, for the 

severed tension tie only.

b. If no more cracks are found and there are no more broken, loose, or missing fasteners, 

repair the severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 

53-40-30.

c. If more cracks or broken, loose, or missing fasteners are found, do the following:

(1) Repair the severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 

SRM 53-40-30.

(2) Do the STRUCTURE REPAIR steps specified in this service bulletin, as necessary.

d. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 

1140, also install fasteners as given in Figure 15, as necessary.

e. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 

10. At STA 1140, also install fasteners as given in Figure 15, as necessary.

f. Do the RESTORATION steps as given in this service bulletin.

10. If cracks are found in a tension tie, steel plate, frame or shear web components (and the tension 

tie is NOT severed), or if there are broken, loose, or missing fasteners, do the following before 

further flight:

a. Do the STRUCTURE REPAIR steps as given in this service bulletin, as necessary.

b. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 

1140, also install fasteners as given in Figure 15, as necessary.

c. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 

10. At STA 1140, also install fasteners as given in Figure 15, as necessary.

d. Do the RESTORATION steps as given in this service bulletin.

11. Repeat the inspections at the intervals specified in paragraph 1.E., Compliance.

12. Report all inspection findings to Boeing.

STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140 (Revision 1 - More Work)

1. Do an open hole HFEC inspection for cracks in the forward and aft tension tie channels at twelve 

fastener locations (six left side and six right side) inboard of the aluminum straps as given in 

Figure 15.
 

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ALERT ALERT

NOTE: Group 1, Configuration 1: When possible, Figure 15 is intended to be done concurrently

with Figure 5 during accomplishment of STAGE 2 inspections.

NOTE: Group 1, Configuration 2; Group 2-3: When possible, Figure 15 is intended to be done

concurrently with Figure 10 during accomplishment of STAGE 2 inspections.

2. If any crack is found, remove the crack by doing OVERSIZE HOLE REPAIR, or repair the tension 

tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30.

3. If no crack is found, repeat the open hole HFEC inspection for cracks in the forward and aft 

tension tie channels at twelve fastener locations (six left side and six right side) inboard of the 

aluminum straps at the interval specified in paragraph 1.E., Compliance.

4. Repeat the inspection at the interval specified in paragraph 1.E., Compliance.

5. Report all inspection findings to Boeing.

STRUCTURE REPAIR

1. If there are broken, loose, or missing fasteners common to the tension tie to frame joint, do the 

following before further flight:

a. Group 1, Configuration 1: If the fasteners common to the steel plate, and three rows inboard 

of the steel plate have not already been removed, then remove them as given in Figure 5.

b. Group 1, Configuration 2; Group 2-3: If the fasteners common to the steel plate, and three 

rows inboard of the steel plate have not already been removed, then remove them as given 

in Figure 10. 

c. Group 1, Configuration 1: If the fastener holes common to the steel plate, and three rows 

inboard of the steel plate have not already been open hole HFEC inspected per Figure 5, 

then do an open hole HFEC inspection, as given in Figure 5, at all locations where fasteners 

were removed.

d. Group 1, Configuration 2; Group 2-3: If the fastener holes common to the steel plate, and 

three rows inboard of the steel plate have not already been open hole HFEC inspected per 

Figure 10, then do an open hole HFEC inspection, as given in Figure 10, at all locations 

where fasteners were removed.

e. At STA 1140, if the fastener holes three rows inboard of the aluminum straps have not 

already been open hole HFEC inspected per Figure 15, then do an open hole HFEC 

inspection as given in Figure 15.

f. If cracks are found, see STRUCTURE REPAIR steps 3 through 10 for repair instructions.

2. If there are broken, loose, or missing fasteners at any other location (not common to the tension 

tie to frame joint), contact Boeing for repair instructions before further flight.

3. If a crack is found in a shear tie at the flange common to the skin, do the following:

a. Remove all fasteners common to the cracked shear tie and skin.
 

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ALERT ALERT

b. Do an Open Hole HFEC inspection of the skin at all fastener locations common to the 

cracked shear tie as given in 747 NDT, Part 6, 51-00-00, Figure 16.

c. If a crack is found in the skin, repair the skin as given in 747-100/200/300 SRM 53-30-03 or 

747-400 SRM 53-40-01, or 747-400SF SRM 53-40-01. Repair the shear tie as given in 

747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07.

d. If no cracks are found in the skin, repair the shear tie as given in 747-100/200/300 SRM 

53-10-04 or 747-400 SRM 53-40-07. Install new fasteners as given in 747-100/200/300 

SRM Chapter 51, or 747-400 SRM Chapter 51, or 747-400SF SRM Chapter 51, as 

applicable.

4. If a crack is found at a bolt, hilok, or rivet hole common to a frame, shear tie, failsafe chord, shear 

web component, tension tie, or steel plate, do the OVERSIZE HOLE REPAIR steps given in this 

service bulletin. If a crack is found at an insulation blanket stud hole common to a frame, contact 

Boeing for repair instructions.

5. If a crack is found in a shear tie and cannot be removed by doing the OVERSIZE HOLE REPAIR, 

repair the shear tie as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07.

6. If a crack is found in a frame and cannot be removed by doing the OVERSIZE HOLE REPAIR, 

repair as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07.

7. If a crack is found in the failsafe chord and cannot be removed by doing the OVERSIZE HOLE 

REPAIR, then repair the failsafe chord by splicing in a new segment as given in 747-100/200/300 

SRM 53-10-04 or 747-400 SRM 53-40-07. The dimensions of the new Chord should be 

increased to maintain a 2D minimum edge margin.

8. If a crack is found in a shear web component and cannot be removed by doing the OVERSIZE 

HOLE REPAIR, contact Boeing for repair instructions.

9. If a crack is found in a tension tie and cannot be removed by doing the OVERSIZE HOLE 

REPAIR, repair the tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 

53-40-30.

10. If a crack is found in a steel plate and cannot be removed by doing OVERSIZE HOLE REPAIR, 

repair as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30 or replace the steel 

plate with a new steel plate as given in one of the following two options:

a. Option 1: Replace the steel plate with a new steel plate made by Boeing, or

b. Option 2: If required, fabricate a new steel plate per Boeing engineering drawing 

requirements same as existing steel plate, except make the new steel plate wider as 

required to maintain minimum 1.5D fastener edge margins in the steel plate. Make from the 

same material as existing steel plate, or it is also acceptable to make from alternative 

material 15-5 CRES per AMS5659, with heat treat to 150-170 ksi. Make sure that wider 

steel plates do not interfere with the flanges of the tension tie forward channel when 

installed.

11. If any other crack is found that cannot be repaired per the instructions above, contact Boeing for 

repair instructions.
 

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ALERT ALERT

OVERSIZE HOLE REPAIR

1. Group 1, Configuration 1: Remove cracks and install new fasteners as shown in Figure 6.

2. Group 1, Configuration 2; Group 2-3: Remove cracks and install new fasteners as shown in 

Figure 11.

Group 1, Configuration 1: ONE-TIME INSPECTION FOR MISLOCATED ANGLES (Revision 1 - 

More Work)

1. On both sides of the airplane, do the ANGLE INSPECTION steps as shown in Figure 13.

2. If any angle has the incorrect installation, do the ANGLE REPLACEMENT steps as shown in 

Figure 13.

3. If both angles have the correct installation, no more work is required for the mislocated angles.

4. Continue STAGE 1 or STAGE 2 inspections, as applicable, as given in paragraph 1.E., 

Compliance.

Group 1, Configuration 2; Group 2-3: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT 

PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

1. At STA 1120, 1160, 1200, and 1220, do open hole HFEC inspections at the fastener locations 

where the tension tie was previously attached to the frame prior to modification to SF or BCF 

configuration. Do the inspection as given in Figure 14.

2. If any crack is found, remove the crack by doing OVERSIZE HOLE REPAIR, or repair the frame 

as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07.

3. If no crack is found, no more work is required for inspection of frames at previous tension tie 

locations.

4. Continue STAGE 1 or STAGE 2 inspections, as applicable, as given in paragraph 1.E., 

Compliance.

RESTORATION

1. Apply BMS 3-23, Type II, Corrosion Inhibiting Compound to all areas where fasteners were 

removed, and where repairs were done. Refer to SOPM 20-41-05 as an accepted procedure.

2. Group 1, Configuration 1: Install insulation between STA 1120 and STA 1220. Refer to 747-100/

200/300 AMM 25-14-02 or 747-400 AMM 25-22-00 as an accepted procedure.

3. Group 1, Configuration 1: Install ceiling panels between STA 1120 and STA 1220. Refer to 

747-100/200/300 AMM 25-22-04 or 747-400 AMM 25-22-04 as an accepted procedure.

4. Group 1, Configuration 1: Install seats between STA 1120 and STA 1220. Refer to 747-100/200/

300 AMM 25-25-01 or 747-400 AMM 25-25-01 as an accepted procedure.

5. Group 1, Configuration 1: If additional access to STA 1120 tension tie joints was obtained through 

the upper deck aft partition or closet(s) close the access. Refer to 747-100/200/300 AMM 

25-24-00 or 747-400 AMM 25-24-00 as an accepted procedure.
 

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ALERT ALERT

NOTE: This access was not required to accomplish the inspections as given in this Service

Bulletin.

6. Group 1, Configuration 2; Group 2-3: Install main deck cargo compartment insulation as 

necessary from STA 1120 to STA 1220. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 

AMM 25-59-05 as an accepted procedure.

7. Group 1, Configuration 2; Group 2-3: Install main deck cargo compartment lining panels as 

necessary from STA 1120 to STA 1220. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 

AMM 25-59-01 as an accepted procedure.

8. Return airplane to a Serviceable Condition.
 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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ALERT ALERT

FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

FWD

480026

(SHEET 1 OF 5)
 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

TENSION TIE AFT CHANNEL

VERTICAL POST

ATTACHMENT

C

C

D

D

E

E A A

G

G

BL26

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

A-A

STEEL

PLATE

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

NOTE:

SLOPING AND HORIZONTAL SHEAR WEB

ONLY AT STA 1120 AND STA 1140.

SHEAR WEB ATTACHES TO THE BOTOM

OF THE TENSION CHANNEL AT STA

1140.

(VIEW G-G SHOWN

FOR STA 1120 AND

STA 1140 ONLY)

UP

INBD

A

TENSION TIE

FORWARD CHANNEL

FRAME

1

2

STRINGERS

FRAME

FAILSAFE

CHORD

1

1

1

1

482472

(SHEET 2 OF 5)
 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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ALERT ALERT

C

C

D

D

F

F B B

G

G

BL26

STRINGERS

FRAME

FAILSAFE

CHORD

B-B

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

VERTICAL POST

ATTACHMENT

STEEL

PLATE

NOTE:

SLOPING AND HORIZONTAL SHEAR WEB

ONLY AT STA 1120 AND STA 1140.

SHEAR WEB ATTACHES TO THE BOTTOM

OF THE TENSION TIE CHANNEL AT

STA 1140.

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

(VIEW G-G SHOWN

FOR STA 1120 AND

STA 1140 ONLY)

UP

INBD

2

B

TENSION TIE FORWARD CHANNEL

TENSION TIE AFT CHANNEL FRAME

1 1

1

1

1

482473

(SHEET 3 OF 5)
 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FRAME

ALUMINUM

CHANNEL

HORIZONTAL

SHEAR WEB

TENSION TIE

AFT CHANNEL TENSION TIE

FORWARD CHANNEL

STEEL PLATE

HORIZONTAL

SHEAR WEB

C-C

E-E F-F

(STA 1220)

(STA 1140)

(AT ALL OTHER STATIONS)

D-D

G-G

D-D

(STA 1120)

G-G

(TYPICAL)

(TYPICAL) (TYPICAL)

2 2 2 2

1

1

1

1

1

1

1

1

1

1

1 1

1 1

482474

(SHEET 4 OF 5)
 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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ALERT ALERT

This Figure applies to Group 1, Configuration 1: 

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

1 Inspect Tension Tie and 

Steel Plate 

Detailed 

Inspection

65B09631-( ) 

65B09614-( )

(a) (c)

2 Inspect Fasteners Detailed 

Inspection

- (b)

(a) Inspect for cracks in the forward and aft channels of the tension tie from Buttock Line (BL) 26 

outboard to side of body on the left and right side of the airplane. Inspect for cracks in the steel 

plate on the left and right side of the airplane. Pay special attention to the tension tie at the frame 

joint, at all fastener locations common to the steel plate and 3 fastener rows inboard of the steel 

plate. Also, pay special attention to the tension tie at the vertical post attachments. At STA 1120 

and STA 1140, pay special attention to the tension ties where they attach to the sloping shear web 

and horizontal shear web.

(b) Inspect the fasteners common to the steel plate and 3 fastener rows inboard of the steel plate, for 

broken, loose, or missing fasteners. At STA 1220, also inspect all fasteners common to the 

aluminum channel on the underside of the tension tie in the area under the steel plate. 

(c) The sloping and horizontal shear web are only at STA 1120 and STA 1140.

(SHEET 5 OF 5)
 FIGURE 2: Deleted (Revision 1)

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ALERT ALERT

FIGURE 2: Deleted (Revision 1)

THIS FIGURE IS DELETED.

D38438

(SHEET 1 OF 1)
 FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2)

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ALERT ALERT

FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2)

STA

1120

STA

1140

STA

1120

STA

1140

SEE A SEE B

FWD

482133

(SHEET 1 OF 3)
 FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2)

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ALERT ALERT

1120

STA

1140

STA

SHEAR WEB

HORIZONTAL

INBD

1120

STA

1140

STA

SHEAR WEB

HORIZONTAL

INBD

WEB

SHEAR

SLOPING

VIEW LOOKING UP

VIEW LOOKING UP

WEB

SHEAR

SLOPING

3 1 2

A

2 1 3

B

482181

(SHEET 2 OF 3)
 FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 1: 

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

1 Inspect Sloping and 

Horizontal Shear 

Webs and 

Fasteners

Detailed 

Inspection

- (a) (b)

2 Inspect Bends in Sloping 

Shear Web

Detailed 

Inspection

- (a)

3 Inspect Sloping Shear Web 

to Supporting 

Structure (Gussets) 

and Fasteners

Detailed 

Inspection

- (a) (b)

(a) Inspect for cracks.

(b) Inspect for broken, loose, or missing fasteners.

(SHEET 3 OF 3)
 FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

STA

1140

FWD

482449

(SHEET 1 OF 3)
 FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

TRIPLER

DOUBLER, AND

FRAME WEB,

CHORD

FAILSAFE

VIEW LOOKING AFT

STRINGERS

CHORD

FAILSAFE

VIEW LOOKING AFT

TIE (TYP)

SHEAR

CHORD

INNER

TIE (TYP)

SHEAR

TRIPLER

DOUBLER, AND

FRAME WEB,

CHORD

INNER

VARIES DEPENDING ON LOCATION.

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

4

UP

INBD

A

1 2 3 5 6

4

UP

INBD

B

1 2 3 5 6

STRINGERS

482493

(SHEET 2 OF 3)
 FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 1: 

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

1 Inspect Frame Web Detailed 

Inspection

(a) (c) (d)

2 Inspect Frame Doubler Detailed 

Inspection

(a) (c) (d)

3 Inspect Frame Tripler Detailed 

Inspection

(a) (c) (d)

4 Inspect Inner chord Detailed 

Inspection

(a) (c) (d)

5 Inspect Fail Safe Chord Detailed 

Inspection

(a) (c) (d)

6 Inspect Shear Tie Detailed 

Inspection

(a) (b) (c) (d)

(a) Pay special attention to the corners of the stringer cut outs and fastener locations common to the 

tension ties.

(b) Pay special attention to the bends in the shear ties common to the skin.

(c) Inspect for cracks.

(d) Inspect for broken, loose, or missing fasteners.

(SHEET 3 OF 3)
 FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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ALERT ALERT

FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

STA

1140

FWD

482450

(SHEET 1 OF 6)
 FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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ALERT ALERT

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

(VIEW E-E SHOWN

FOR STA 1120 AND

STA 1140 ONLY)

C

C

D

D A A

E

E BL26

NOTE:

SLOPING AND HORIZONTAL SHEAR WEB

ONLY AT STA 1120 AND STA 1140. SHEAR

WEB ATTACHES TO THE BOTTOM OF THE

TENSION TIE CHANNEL AT STA 1140.

A-A

VERTICAL

POST

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

UP

INBD

2

A

TENSION TIE

FORWARD CHANNEL

FRAME TENSION TIE

AFT CHANNEL

2

8

8

1 3

9 5

7

STRINGERS

FRAME

FAILSAFE

CHORD

4

REMOVED STEEL PLATE

OPEN HOLE HFEC

SURFACE HFEC

7

7

482484

(SHEET 2 OF 6)
 FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

(VIEW F-F SHOWN

FOR STA 1120 AND

STA 1140 ONLY)

C

C

D

D B B

F

BL26 F

B-B

STRINGERS

FAILSAFE

CHORD

FRAME

VERTICAL

POST

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

NOTE:

SLOPING AND HORIZONTAL SHEAR WEB

ONLY AT STA 1120 AND STA 1140.

SHEAR WEB ATTACHES TO THE BOTTOM

OF THE TENSION TIE CHANNEL AT STA

1140.

UP

INBD

8

B

TENSION TIE

FORWARD CHANNEL

TENSION TIE FRAME

AFT CHANNEL

2 8

1 3 9

2

4

REMOVED STEEL PLATE

5

7

OPEN HOLE HFEC

SURFACE HFEC

7 7

482485

(SHEET 3 OF 6)
 FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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ALERT ALERT

8

STEEL

PLATE

2

8

STEEL

PLATE

2

8

STEEL

PLATE

2

FRAME

ALUMINUM

CHANNEL

TENSION

TIE

FORWARD

CHANNEL

HORIZONAL

SHEAR WEB

SLOPING

SHEAR WEB

HORIZONTAL

SHEAR WEB

SLOPING

SHEAR WEB

HORIZONAL

SHEAR WEB

SLOPING

SHEAR WEB

SLOPING

SHEAR WEB

HORIZONTAL

SHEAR WEB

TENSION

TIE

AFT

CHANNEL

C-C

(STA 1220) (AT ALL OTHER STATIONS)

D-D D-D

E-E

(STA 1140)

E-E

(STA 1120)

(TYPICAL)

F-F

(STA 1120) (STA 1140)

F-F

9

3

9

3 10

6

3 10

6

3

7

7

7

7

7

1

1

1

1

3

7 9

1

7

1 3 10

6 7

6 7

1 3 10

5

5

5

5

5

5

5

5

482487

(SHEET 4 OF 6)
 FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 1: 

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

numbers shown below are the number of parts necessary for each tension tie.

STEP TASK NAME PART NUMBER QTY MORE DATA

CAUTION: DO NOT REMOVE THE FASTENERS FROM ADJACENT TENSION TIE TO FRAME JOINTS

AT THE SAME TIME. IF FASTENERS ARE REMOVED FROM ADJACENT TENSION TIES,

DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR. REFER TO APPENDIX B FOR

ALLOWABLE METHODS TO DISCONNECT THE TENSION TIES.

1 Remove Fasteners - - (a)

2 Remove/Keep Steel Plates 65B09614-( ) 2 -

3 Inspect Tension Tie and 

Frame

- - Open Hole HFEC (b)

4 Inspect Steel Plates 65B09614-( ) 2 Open Hole HFEC (c)

5 Inspect Tension Tie 65B09631-( ) - Surface HFEC (d)

6 Inspect Tension Tie 65B09631-( ) - Surface HFEC (e)

7 Inspect Tension Tie and 

Fasteners

65B09631-( ) - Detailed (f)

8 Install (Kept) Steel Plates 65B09614-( ) 2 (g) 

9

Install (New) Hex Drive Bolts BACB30NX( )K( ) - (g) (h) (i) (j) (k)

Washers BACW10BP( )DP - Install washers under nuts.

Nuts BACN10YT( )CD -

10 Install (New) Hex Drive Bolts BACB30VT( )K( ) 4 (g) (h) (i) (j) (k)

Collar BACC30BL( ) 4

(a)

Remove all fasteners common to steel plates, and three fastener rows inboard of the inboard ends of 

the steel plates. Also remove one fastener common to the intersection of the horizontal and sloping 

shear webs at STA 1120 and STA 1140 (two fasteners on each side of the airplane common to the 

shear webs) as shown in view E-E and view F-F. Refer to Appendix B for allowable methods to 

disconnect the tension ties.

(b) Do an Open Hole HFEC inspection for cracks at all locations where fasteners were removed 

common to the tension tie, as given in 747 NDT, Part 6, 51-00-00, Figure 1, 11, or 16.

(c) Do an Open Hole HFEC inspection for cracks at all holes in the steel plates, as given in 747 NDT, 

Part 6, 51-00-00, Figure 19.

(d)

Do a Surface HFEC inspection for cracks around the heads and tails of all remaining fasteners 

common to the tension tie outboard of BL 26 where fasteners have not been removed, as given in 

747 NDT, Part 6, 51-00-00, Figure 4 or Figure 23.

(e)

Do a Surface HFEC inspection for cracks in the tension tie at the internal bend radii defined in views 

E-E and F-F adjacent to the sloping shear web intersection for cracks, as given in 747 NDT, Part 6, 

51-00-00, Figure 4 or Figure 23.

(f)

Do a detailed inspection of the entire tension tie and attaching fasteners for cracks and broken, 

loose, or missing fasteners, from BL 0 to Side of Body. Pay special attention at locations where other 

structure attaches to the tension tie, such as the area near the vertical post. At STA 1120 and STA 

1140, pay special attention to the tension tie internal bend radii in the area of the shear web.

(SHEET 5 OF 6)
 FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

(g)

Only install if no cracks are indicated from the inspections, or if cracks were removed per oversizing 

procedures and limitations shown in the OVERSIZE HOLE REPAIR steps of the Accomplishment 

Instructions.

(h)

Install fasteners in close ream holes using hole sizes specified in 747-100/200/300 SRM 51-30-05, or 

747-400 SRM 51-40-05, as applicable. Install fasteners as specified in 747-100/200/300 SRM 

51-30-02, or 747-400 SRM 51-40-02, as applicable, except that fasteners should be installed wet 

with BMS 3-27 or BMS 3-38 instead of sealant. Refer to SOPM 20-50-19 wet fastener installation 

method 2 as an accepted procedure. If BACB30NX hex-drive bolts are installed with BMS 3-27 or 

BMS 3-38, they must be installed with the following torque value applied to the nut: 3/16 inch bolt = 

20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 poundinches. If oversized fasteners are required, refer to OVERSIZE HOLE REPAIR for limitations on 

fastener size, edge margin, and spacing.

(i) Use same grip length as removed fasteners.

(j) If necessary, it is acceptable to substitute fasteners per 747-100/200/300 SRM 51-30-03, or 747-400 

SRM 51-40-03, as applicable. However, if fasteners are substituted, the same type of fastener 

should be used throughout each joint as shown in Appendix C.

(k) To allow for easier removal during repeat inspections, it is optional to install BACB30MR( )K( ) bolts 

and BACW10BP( )CD washers, with BACN11Z( )CD nuts and BACW10BP( )DP washers. However, 

availability of BACB30MR( )K( ) bolts is limited. Also, if fasteners are substituted, the same type of 

fastener should be used throughout each joint, as shown in Appendix C. If BACB30MR bolts are 

used, install wet with BMS 3-27 or BMS 3-38 and apply the following torque values to the nut: 3/16 

inch bolt = 20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 

pound-inches.

STEP TASK NAME PART NUMBER QTY MORE DATA

(SHEET 6 OF 6)
 FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

STA

1140

FWD

482496

(SHEET 1 OF 5)
 FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

A A

BL26

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATION SIMILAR)

A-A

STEEL PLATE

VERTICAL

POST

NOTE:

SLOPING AND HORIZONTAL SHEAR WEB

ONLY AT STA 1120 AND STA 1140.SHEAR

WEB ATTACHES TO THE BOTTOM OF THE

TENSION TIE CHANNEL AT STA 1140.

UP

INBD

4

A

TENSION TIE FORWARD CHANNEL

FRAME TENSION TIE AFT CHANNEL

1

4

STRINGERS 2 3 5

FRAME

FAILSAFE

CHORD

482498

(SHEET 2 OF 5)
 FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

B B

BL26

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

B-B

NOTE:

SLOPING AND HORIZONTAL SHEAR WEB

ONLY AT STA 1120 AND STA 1140.

SHEAR WEB ATTACHES TO THE BOTTOM

OF THE TENSION TIE CHANNEL AT STA

1140.

UP

INBD

B

TENSION TIE

FORWARD CHANNEL

FRAME TENSION TIE AFT CHANNEL

4

4

1 2 3 5 STRINGERS

FRAME

FAILSAFE

CHORD

STEEL

PLATE

VERTICAL

POST

482514

(SHEET 3 OF 5)
 FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 1: 

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

numbers shown below are the number of parts necessary for one tension tie.

NOTE: Only do these steps at locations where crack indications in the frame and/or tension tie can be cleaned

up by oversizing the hole to a maximum hole size of 0.313 inch. If the crack is larger, repair as given in

the Accomplishment Instructions, STRUCTURE REPAIR steps, as applicable.

STEP TASK NAME PART NUMBER QTY NOTES

CAUTION: DO NOT REMOVE THE FASTENERS FROM ADJACENT TENSION TIE TO FRAME JOINTS

AT THE SAME TIME. IF FASTENERS ARE REMOVED FROM ADJACENT TENSION TIES,

DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR. REFER TO APPENDIX B FOR

ALLOWABLE METHODS TO DISCONNECT THE TENSION TIES.

1 Oversize Holes in Tension Tie 

Channels, Frame, Steel Plate 

and associated parts in 

stackup

- 1 Fastener Hole (a) (c)

2 Inspect Holes in Tension Tie 

Channels, Frame, Steel Plate 

and associated parts in 

stackup

- - Open Hole HFEC (b) (c)

3 Measure Edge Margin and Spacing - - (d) (c)

4 Install (Kept) Steel Plates 65B09614-( ) 2 (e) (d)

5 Install (New) Hex Drive Bolt BACB30NX( )K( ) - (f) (g) (h) (i) (j)

Washers BACW10BP( )DP - Install washer under nut.

Nut BACN10YT( )CD -

(a) Oversize the cracked hole through the stack by 0.0156 inch increments up to a maximum total 

diameter of 0.313 inches.

(b) Inspect the hole to make sure that all cracks have been removed as given in 747 NDT, Part 6, 

51-00-00, Figure 1, 11, or 16 for inspection of holes in aluminum, or as given in 747 NDT, Part 6, 

51-00-00, Figure 19 for inspection of holes in steel parts. Repeat steps 1, and 2 until no cracks are 

found in the hole.

(c) Repeat steps 1 to 3 for each hole found to be cracked.

(d) A minimum of 1.5D edge margin (center of hole to edge of part) and 2.5D spacing (center of hole to 

center of hole) should be maintained on all oversized holes. If these requirements cannot be met, 

repair as given in the SRM or contact Boeing for repair instructions.

(e) Steel plates were only removed if inspections per Figure 5 were being done.

(f) Use same grip length as the removed fasteners.

(g) For fasteners common to the steel plates plus three fastener rows inboard of the steel plates, install 

fastener in close ream hole using hole size as specified in 747-100/200/300 SRM 51-30-05, or 

747-400 SRM 51-40-05, as applicable. Install fastener as specified in 747-100/200/300 SRM 

51-30-02, or 747-400 SRM 51-40-02, as applicable, except that fastener should be installed wet with 

BMS 3-27 or BMS 3-38 instead of sealant. Refer to SOPM 20-50-19 wet fastener installation 

method 2 as an accepted procedure. If BACB30NX hex-drive bolt is installed with BMS 3-27 or BMS 

3-38, it must be installed with the following torque value applied to the nut: 3/16 inch bolt = 20 to 25 

pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 pound-inches.

(SHEET 4 OF 5)
 FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

(h) If necessary, it is acceptable to substitute fasteners per 747-100/200/300 SRM 51-30-03, or 747-400 

SRM 51-40-03. However, if fasteners are substituted, the same type of fastener should be used 

throughout each joint as shown in Appendix C.

(i) To allow for easier removal during repeat inspections, it is optional to install BACB30MR( )K( ) bolt 

and BACW10BP( )CD washer, with BACN11Z( )CD nut and BACW10BP( )DP washer. However, 

availability of BACB30MR( )K( ) bolts is limited. Also, if fasteners are substituted, the same type of 

fastener should be used throughout each joint, as shown in Appendix C. If BACB30MR bolt is used, 

install wet with BMS 3-27 or BMS 3-38 and apply the following torque value to the nut: 3/16 inch bolt 

= 20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 poundinches.

(j) For fasteners not common to the steel plates or three fastener rows inboard of the steel plates, 

install original type fasteners, except oversize as required. Install fasteners as specified in 747-100/

200/300 SRM 51-30-02 or 747-400 SRM 51-40-02, as applicable.

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 5 OF 5)
 FIGURE 7: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 7: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

STA

1140

FWD

D71316

(SHEET 1 OF 3)
 FIGURE 7: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

PATTERN AND FRAME CONFIGURATION MAY VARY DEPENDING ON LOCATION.

NOTE: TYPICAL CONFIGURATION. ACTUAL INSULATION BLANKET STUD

(TYPICAL)

INSULATION BLANKET STUD

TRIPLER

DOUBLER, AND

FRAME WEB,

CHORD

FAILSAFE

VIEW LOOKING AFT

STRINGERS

CHORD

FAILSAFE

VIEW LOOKING AFT

CHORD

INNER

TRIPLER

DOUBLER, AND

FRAME WEB,

CHORD

INNER

TIE

TENSION

TIE

TENSION

ATTACH STUD

INSULATION BLANKET

UP

INBD

A

UP

INBD

B

STRINGERS

SEE C

1 3 2

C

1 3

D72072

(SHEET 2 OF 3)
 FIGURE 7: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 1: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1

Remove / Keep Insulation Blanket 

Stud

- 1 Only remove studs that are 

installed through the frame 

web in the inspection area. 

Studs that are bonded on to 

the frame web do not need 

to be removed.

2

Inspect Hole - 1 Do an open hole HFEC 

inspection of the hole as 

given in 747 NDT, Part 6, 

51-00-00, Figure 1, 11, or 

16.

NOTE: If there is a crack indication during the HFEC inspection, contact Boeing for repair and/or 

re-installation instructions.

3 Install (Kept) Insulation Blanket 

Stud

- 1-

(SHEET 3 OF 3)
 FIGURE 8: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 8: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

FWD

1872498

(SHEET 1 OF 5)
 FIGURE 8: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

(VIEW G-G SHOWN

FOR STA 1140 ONLY)

TENSION TIE AFT CHANNEL

VERTICAL POST

ATTACHMENT

C

C

D

D

E

E A A

G

G

BL26

A-A

STEEL

PLATE

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

UP

INBD

A

TENSION TIE

FORWARD CHANNEL

FRAME

1

2

STRINGERS

FRAME

FAILSAFE

CHORD

1

1

1

1

1872501

(SHEET 2 OF 5)
 FIGURE 8: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

(VIEW G-G

SHOWN FOR

STA 1140

ONLY)

C

C

D

D

F

F B B

G

G

BL26

STRINGERS

FRAME

FAILSAFE

CHORD

B-B

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

VERTICAL POST

ATTACHMENT

STEEL

PLATE

UP

INBD

2

B

TENSION TIE FORWARD CHANNEL

TENSION TIE AFT CHANNEL FRAME

1 1

1

1

1

1872503

(SHEET 3 OF 5)
 FIGURE 8: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FRAME

ALUMINUM

CHANNEL

TENSION TIE

AFT CHANNEL TENSION TIE

FORWARD

CHANNEL

STEEL

PLATE

C-C

E-E F-F

(STA 1140 ONLY)

(AT ALL OTHER STATIONS)

D-D

G-G

D-D (THIS VIEW FOR AIRPLANES

RD601 AND RD602 AT

STA 1220 ONLY.)

(TYPICAL)

(TYPICAL) (TYPICAL)

SHEAR WEB STRIP

(FASTENER COMMON TO 

THE OUTBOARD END OF

SHEAR WEB STRIP)

2

2

2 2

1

1

1

1

1

1

1

1

1

1

1

1

1

1872506

(SHEET 4 OF 5)
 FIGURE 8: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 2; Group 2-3: 

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

1 Inspect Tension Tie and 

Steel Plate 

Detailed 

Inspection

- (a)

2 Inspect Fasteners Detailed 

Inspection

- (b)

(a) Inspect for cracks in the forward and aft channels of the tension tie from Buttock Line (BL) 26 

outboard to side of body on the left and right side of the airplane. Inspect for cracks in the steel 

plate on the left and right side of the airplane. Pay special attention to the tension tie at the frame 

joint, and at all fastener locations common to the steel plate and 3 fastener rows inboard of the 

steel plate. Also, pay special attention to the tension tie common at the vertical post attachments. 

At STA 1140, pay special attention at the fastener common to the outboard end of the shear web 

strip. The shear web strip is the only remaining part of the shear panel that was removed during 

conversion to freighter (SF or BCF).

(b) Inspect the fasteners common to the steel plate and 3 fastener rows inboard of the steel plate, for 

broken, loose, or missing fasteners. For airplanes RD601 and RD602 that have an aluminum 

channel attached to the tension tie at STA 1220, also inspect all fasteners common to the 

aluminum channel on the underside of the tension tie in the area under the steel plate. 

(SHEET 5 OF 5)
 FIGURE 9: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 9: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

FWD

1872550

(SHEET 1 OF 3)
 FIGURE 9: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FRAME WEB,

DOUBLER, AND

TRIPLER

FAILSAFE

CHORD

VIEW LOOKING AFT

STRINGERS

FAILSAFE

CHORD

VIEW LOOKING AFT

SHEAR

TIE (TYP)

INNER

CHORD

SHEAR

TIE (TYP)

FRAME WEB,

DOUBLER, AND

TRIPLER

INNER

CHORD

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

4

UP

INBD

A

1 2 3 5 6

4

UP

INBD

B

1 2 3 5 6

STRINGERS

1872552

(SHEET 2 OF 3)
 FIGURE 9: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 2; Group 2-3: 

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

1 Inspect Frame Web Detailed 

Inspection

(a) (c) (d)

2 Inspect Frame Doubler Detailed 

Inspection

(a) (c) (d)

3 Inspect Frame Tripler Detailed 

Inspection

(a) (c) (d)

4 Inspect Inner chord Detailed 

Inspection

(a) (c) (d)

5 Inspect Fail Safe Chord Detailed 

Inspection

(a) (c) (d)

6 Inspect Shear Tie Detailed 

Inspection

(a) (b) (c) (d)

(a) Pay special attention to the corners of the stringer cut outs and fastener locations common to the 

tension ties.

(b) Pay special attention to the bends in the shear ties common to the skin.

(c) Inspect for cracks.

(d) Inspect for broken, loose, or missing fasteners.

(SHEET 3 OF 3)
 FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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ALERT ALERT

FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

FWD

1872579

(SHEET 1 OF 6)
 FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

(VIEW E-E SHOWN

FOR STA 1140 ONLY)

C

C

D

D A A

E

E BL26

VIEW LOOKING AFT

A-A

VERTICAL

POST

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

UP

INBD

2

A

TENSION TIE

FORWARD CHANNEL

FRAME TENSION TIE

AFT CHANNEL

2

8

8

1 3 9

5

7

STRINGERS

FRAME

FAILSAFE

CHORD

4

REMOVED STEEL PLATE

OPEN HOLE HFEC

SURFACE HFEC

7

7

1872585

(SHEET 2 OF 6)
 FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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ALERT ALERT

VIEW LOOKING AFT

(STA 1120 SHOWN, OTHER STATIONS SIMILAR)

(VIEW E-E SHOWN

FOR STA 1140 ONLY)

C

C

D

D B B

E

BL26 E

B-B

STRINGERS

FAILSAFE

CHORD

FRAME

VERTICAL

POST

NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION

VARIES DEPENDING ON LOCATION.

UP

INBD

8

B

TENSION TIE

FORWARD CHANNEL

FRAME

TENSION TIE

AFT CHANNEL

2 8

1 3

9

2

4

REMOVED STEEL PLATE

5

7

OPEN HOLE HFEC

SURFACE HFEC

7 7

1872592

(SHEET 3 OF 6)
 FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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ALERT ALERT

2 8

ALUMINUM

CHANNEL

STEEL

PLATE

2 8

STEEL

PLATE

2 8

STEEL

PLATE

FRAME

TENSION TIE

AFT CHANNEL

TENSION TIE

FORWARD

CHANNEL

SHEAR WEB STRIP

C-C

(THIS VIEW FOR

RD601 AND RD602

AT STA 1220)

(AT ALL OTHER STATIONS)

D-D

D-D

(STA 1140 ONLY)

E-E

(FASTENER COMMON TO 

THE OUTBOARD END OF

SHEAR WEB STRIP)

9

3 9

3 9

3 10

6

3 7

7

7

7 7

7

1

1

1

1

5

5

1872612

(SHEET 4 OF 6)
 FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 2; Group 2-3: 

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

numbers shown below are the number of parts necessary for each Tension Tie.

STEP TASK NAME PART NUMBER QTY MORE DATA

CAUTION: DO NOT REMOVE THE FASTENERS FROM ADJACENT TENSION TIE TO FRAME JOINTS

AT THE SAME TIME. IF FASTENERS ARE REMOVED FROM ADJACENT TENSION TIES,

DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR. REFER TO APPENDIX B FOR

ALLOWABLE METHODS TO DISCONNECT THE TENSION TIES.

1 Remove Fasteners - - (a)

2 Remove/Keep Steel Plates - 2 -

3 Inspect Tension Tie and 

Frame

- - Open Hole HFEC (b)

4 Inspect Steel Plates - 2 Open Hole HFEC (c)

5 Inspect Tension Tie - - Surface HFEC (d)

6 Inspect Tension Tie - - Surface HFEC (e)

7 Inspect Tension Tie and 

Fasteners

- - Detailed (f)

8 Install (Kept) Steel Plates - 2 (g) 

9

Install (New) Hex Drive Bolts BACB30NX( )K( ) - (g) (h) (i) (j) (k)

Washers BACW10BP( )DP - Install washers under nuts.

Nuts BACN10YT( )CD -

10 Install (New) Hex Drive Bolts BACB30VT( )K( ) 2 (g) (h) (i) (j) (k)

Collar BACC30BL( ) 2

(a)

Remove all fasteners common to steel plates, and three fastener rows inboard of the inboard ends of 

the steel plates. At STA 1140, remove one fastener on each side of the airplane common to the 

tension tie and the outboard end of the shear web strip. The shear web strip is the only remaining 

part of the shear panel that was removed during conversion to freighter (SF or BCF). Refer to 

Appendix B for allowable methods to disconnect the tension ties.

(b) Do an Open Hole HFEC inspection for cracks at all locations where fasteners were removed 

common to the tension tie, as given in 747 NDT, Part 6, 51-00-00, Figure 1, 11, or 16.

(c) Do an Open Hole HFEC inspection for cracks at all holes in the steel plates, as given in 747 NDT, 

Part 6, 51-00-00, Figure 19.

(d)

Do a Surface HFEC inspection for cracks around the heads and tails of all remaining fasteners 

common to the tension tie outboard of BL 26 where fasteners have not been removed, as given in 

747 NDT, Part 6, 51-00-00, Figure 4 or Figure 23.

(e) Do a Surface HFEC inspection for cracks in the tension tie at the internal bend radii defined in view 

E-E, as given in 747 NDT, Part 6, 51-00-00, Figure 4 or Figure 23. 

(f)

Do a detailed inspection of the entire tension tie and attaching fasteners for cracks and broken, 

loose, or missing fasteners, from BL 0 to side of body. Pay special attention at locations where other 

structure attaches to the tension tie, such as the area near the vertical post. At STA 1140, pay 

special attention to the tension tie internal bend radii next to the shear web strip. The shear web strip 

is the only remaining part of the shear panel that was removed during modification to freighter (SF or 

BCF).

(SHEET 5 OF 6)
 FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES 

FROM STA 1120 TO STA 1220 (STAGE 2 ONLY)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

(g)

Only install if no cracks are indicated from the inspections, or if cracks were removed per oversizing 

procedures and limitations shown in the OVERSIZE HOLE REPAIR steps of the Accomplishment 

Instructions.

(h)

Install fasteners in close ream holes using hole sizes specified in 747-100/200/300 SRM 51-30-05, or 

747-400 SRM 51-40-05, as applicable. Install fasteners as specified in 747-100/200/300 SRM 

51-30-02, or 747-400 SRM 51-40-02, as applicable, except that fasteners should be installed wet 

with BMS 3-27 or BMS 3-38 instead of sealant. Refer to SOPM 20-50-19 wet fastener installation 

method 2 as an accepted procedure. If BACB30NX hex-drive bolts are installed with BMS 3-27 or 

BMS 3-38, they must be installed with the following torque value applied to the nut: 3/16 inch bolt = 

20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 poundinches. If oversized fasteners are required, refer to OVERSIZE HOLE REPAIR for limitations on 

fastener size, edge margin, and spacing.

(i) Use same grip length as removed fasteners.

(j) If necessary, it is acceptable to substitute fasteners per 747-100/200/300 SRM 51-30-03, or 747-400 

SRM 51-40-03, as applicable. However, if fasteners are substituted, the same type of fastener 

should be used throughout each joint as shown in Appendix C.

(k) To allow for easier removal during repeat inspections, it is optional to install BACB30MR( )K( ) bolts 

and BACW10BP( )CD washers, with BACN11Z( )CD nuts and BACW10BP( )DP washers. However, 

availability of BACB30MR( )K( ) bolts is limited. Also, if fasteners are substituted, the same type of 

fastener should be used throughout each joint, as shown in Appendix C. If BACB30MR bolts are 

used, install wet with BMS 3-27 or BMS 3-38 and apply the following torque values to the nut: 3/16 

inch bolt = 20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 

pound-inches.

STEP TASK NAME PART NUMBER QTY MORE DATA

(SHEET 6 OF 6)
 FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

FWD

1872630

(SHEET 1 OF 5)
 FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

A A

BL26

VIEW LOOKING AFT

A-A

STEEL PLATE

VERTICAL

POST

UP

INBD

4

A

TENSION TIE FORWARD CHANNEL

FRAME TENSION TIE AFT CHANNEL

1

4

2 3 5 STRINGERS

FRAME

FAILSAFE

CHORD

1872634

(SHEET 2 OF 5)
 FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

B B

BL26

VIEW LOOKING AFT

B-B

UP

INBD

B

TENSION TIE

FORWARD CHANNEL

FRAME TENSION TIE AFT CHANNEL

4

4

1 2 3 5 STRINGERS

FRAME

FAILSAFE

CHORD

STEEL

PLATE

VERTICAL

POST

1872638

(SHEET 3 OF 5)
 FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 2; Group 2-3: 

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

numbers shown below are the number of parts necessary for one tension tie.

NOTE: Only do these steps at locations where crack indications in the frame and/or tension tie can be cleaned

up by oversizing the hole to a maximum hole size of 0.313 inch. If the crack is larger, repair as given in

the Accomplishment Instructions, STRUCTURE REPAIR steps, as applicable.

STEP TASK NAME PART NUMBER QTY NOTES

CAUTION: DO NOT REMOVE THE FASTENERS FROM ADJACENT TENSION TIE TO FRAME JOINTS

AT THE SAME TIME. IF FASTENERS ARE REMOVED FROM ADJACENT TENSION TIES,

DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR. REFER TO APPENDIX B FOR

ALLOWABLE METHODS TO DISCONNECT THE TENSION TIES.

1 Oversize Holes in Tension Tie 

Channels, Frame, Steel Plate 

and associated parts in 

stackup

- 1 Fastener Hole (a) (c)

2 Inspect Holes in Tension Tie 

Channels, Frame, Steel Plate 

and associated parts in 

stackup

- - Open Hole HFEC (b) (c)

3 Measure Edge Margin and Spacing - - (d) (c)

4 Install (Kept) Steel Plates - 2 (e) (d)

5 Install (New) Hex Drive Bolt BACB30NX( )K( ) - (f) (g) (h) (i) (j)

Washers BACW10BP( )DP - Install washer under nut.

Nut BACN10YT( )CD -

(a) Oversize the cracked hole through the stack by 0.0156 inch increments up to a maximum total 

diameter of 0.313 inches.

(b) Inspect the hole to make sure that all cracks have been removed as given in 747 NDT, Part 6, 

51-00-00, Figure 1, 11, or 16 for inspection of holes in aluminum, or as given in 747 NDT, Part 6, 

51-00-00, Figure 19 for inspection of holes in steel parts. Repeat steps 1, and 2 until no cracks are 

found in the hole.

(c) Repeat steps 1 to 3 for each hole found to be cracked.

(d) A minimum of 1.5D edge margin (center of hole to edge of part) and 2.5D spacing (center of hole to 

center of hole) should be maintained on all oversized holes. If these requirements cannot be met, 

repair as given in the SRM or contact Boeing for repair instructions.

(e) Steel plates were only removed if inspections per Figure 10 were being done.

(f) Use same grip length as the removed fasteners.

(g) For fasteners common to the steel plates plus three fastener rows inboard of the steel plates, install 

fastener in close ream hole using hole size as specified in 747-100/200/300 SRM 51-30-05, or 

747-400 SRM 51-40-05, as applicable. Install fastener as specified in 747-100/200/300 SRM 

51-30-02, or 747-400 SRM 51-40-02, as applicable, except that fastener should be installed wet with 

BMS 3-27 or BMS 3-38 instead of sealant. Refer to SOPM 20-50-19 wet fastener installation 

method 2 as an accepted procedure. If BACB30NX hex-drive bolt is installed with BMS 3-27 or BMS 

3-38, it must be installed with the following torque value applied to the nut: 3/16 inch bolt = 20 to 25 

pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 pound-inches.

(SHEET 4 OF 5)
 FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

(h) If necessary, it is acceptable to substitute fasteners per 747-100/200/300 SRM 51-30-03, or 747-400 

SRM 51-40-03. However, if fasteners are substituted, the same type of fastener should be used 

throughout each joint as shown in Appendix C.

(i) To allow for easier removal during repeat inspections, it is optional to install BACB30MR( )K( ) bolt 

and BACW10BP( )CD washer, with BACN11Z( )CD nut and BACW10BP( )DP washer. However, 

availability of BACB30MR( )K( ) bolts is limited. Also, if fasteners are substituted, the same type of 

fastener should be used throughout each joint, as shown in Appendix C. If BACB30MR bolt is used, 

install wet with BMS 3-27 or BMS 3-38 and apply the following torque value to the nut: 3/16 inch bolt 

= 20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 125 poundinches.

(j) For fasteners not common to the steel plates or three fastener rows inboard of the steel plates, 

install original type fasteners, except oversize as required. Install fasteners as specified in 747-100/

200/300 SRM 51-30-02 or 747-400 SRM 51-40-02, as applicable.

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 5 OF 5)
 FIGURE 12: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 12: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

STA

1120

STA

1220

STA

1120

STA

1220

SEE A SEE B

FWD

1872643

(SHEET 1 OF 3)
 FIGURE 12: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

NOTE: TYPICAL CONFIGURATION. ACTUAL INSULATION BLANKET STUD

PATTERN AND FRAME CONFIGURATION MAY VARY DEPENDING ON LOCATION.

INSULATION BLANKET STUD

(TYPICAL)

FRAME WEB,

DOUBLER, AND

TRIPLER FAILSAFE

CHORD

VIEW LOOKING AFT

STRINGERS

FAILSAFE

CHORD

VIEW LOOKING AFT

INNER

CHORD

FRAME WEB,

DOUBLER, AND

TRIPLER

INNER

CHORD

TENSION

TIE

TENSION

TIE

INSULATION BLANKET

ATTACH STUD

UP

INBD

A

UP

INBD

B

STRINGERS

SEE C

2 1 3

C

1 3

1872646

(SHEET 2 OF 3)
 FIGURE 12: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 2; Group 2-3: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1

Remove / Keep Insulation Blanket 

Stud

- 1 Only remove studs that are 

installed through the frame 

web in the inspection area. 

Studs that are bonded on to 

the frame web do not need 

to be removed.

2

Inspect Hole - 1 Do an open hole HFEC 

inspection of the hole as 

given in 747 NDT, Part 6, 

51-00-00, Figure 1, 11, or 

16.

NOTE: If there is a crack indication during the HFEC inspection, contact Boeing for repair and/or 

re-installation instructions.

3 Install (Kept) Insulation Blanket 

Stud

- 1-

(SHEET 3 OF 3)
 FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE

STA

1100

STA

1220

SEE B

A

SEE A

FWD

1872656

(SHEET 1 OF 5)
 FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

1140

STA

TENSION TIE

S-10L

A-A

TENSION

TIE

S-9L

(TYPICAL)

SLOPING

SHEAR

WEB

ANGLE

HORIZONTAL

SHEAR WEB

A

A

B B

UP

INBD

B

FWD

UP

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1872665

(SHEET 2 OF 5)
 FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

STA

1140

CORRECT INSTALLATION

(LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE)

HORIZONTAL

SHEAR WEB

ANGLE

SLOPING

SHEAR WEB

FORWARD TENSION

TIE CHANNEL

INCORRECT INSTALLATION

(LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE)

STA

1140

AFT TENSION TIE CHANNEL

HORIZONTAL

SHEAR WEB

ANGLE

SLOPING

SHEAR WEB

FORWARD TENSION

TIE CHANNEL

VIEW LOOKING UP

AFT TENSION TIE CHANNEL

VIEW LOOKING UP

INBD

FWD

INBD

FWD

B

A

B

B

B

B

B

1 2 3 4

B-B

B-B

1

1872833

(SHEET 3 OF 5)
 FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

This Figure applies to Group 1, Configuration 1: 

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

numbers shown below are the number of parts necessary for one side of the airplane. However, the inspection 

(and replacement, if necessary) should be done on both sides of the airplane as given in this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Angle 65B09631-( ) 1 (a)

(a) Inspect the angle to determine if it has the correct installation. The aft end of the angle should 

connect to the forward tension tie channel.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

2 Remove (Discard) Angle 65B09631-( ) 1 as required. (b)

3 Make Angle 65B09631-139 (left side) and 

65B09631-140 (right side) 

1 as required. (b)

4 Install Angle 65B09631-139 (left side) and 

65B09631-140 (right side) 

1 (b)

(b)

Remove and install new angle, as necessary, to match the correct installation. Fabricate a new 

angle the same length as the existing angle. Make from BAC1503-100031 extrusion, 7075-T6511 

per QQ-A-200/11. Apply alodine and one coat of BMS 10-11, Type I primer.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

V75018

(SHEET 4 OF 5)
 FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

The QTY numbers shown below are the number of fasteners necessary for this figure.

Substitute fasteners may be used. Boeing Document D-590 and Boeing drawing 012W6100 are used to 

determine the part numbers used as substitutes. 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

A Bolt BACB30VT6K3X 1 0.200 - 0.203

Collar BACC30BL6 1

B Rivet BACR15FT6D( )C 5 0.191 - 0.202 Grip length as required.

(SHEET 5 OF 5)
 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

Original Issue: April 21, 2005

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE 

LOCATIONS (Revision 1 - More Work)

STA

1120

STA

1220

SEE B

A

SEE A

SEE C

SEE D

SEE E

FWD

1873065

(SHEET 1 OF 7)
 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

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ALERT ALERT

STR-10L

10 LOCATIONS

1120

STA

LBL

80

A

A

UP

INBD

1

B

FWD

UP

5 6

A-A

A

A

A

A

A A A

A

A B

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1873067

(SHEET 2 OF 7)
 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

Original Issue: April 21, 2005

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ALERT ALERT

10 LOCATIONS

1160

STA

S-9L

SKIN

TENSION TIE

CHANNELS

B

B

UP

INBD

2

C

FWD

UP

5 6

B-B

LBL

70

C

A

A

A

A A A

A A A

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1873080

(SHEET 3 OF 7)
 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

Original Issue: April 21, 2005

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ALERT ALERT

12 LOCATIONS

1200

STA

S-8L

S-9L

LBL

70

TENSION TIE

C

C

UP

INBD

3

D

FWD

UP

5 6

C-C

D

D

D

D

D D D

D

D D D

D

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1873088

(SHEET 4 OF 7)
 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

1220

STA

14 LOCATIONS

S-8L

S-9L

CREASE

BEAM

BRACKETS

D

D

UP

INBD

E

FWD

UP

4 5 6

D-D

E

E

E

E E

E

E

E

E

E

E E

E

E

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1873133

(SHEET 5 OF 7)
 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

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ALERT ALERT

This Figure applies to Group 1, Configuration 2; Group 2-3: 

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

numbers shown below are the number of parts necessary for one side of the airplane. However, both sides of 

the airplane require inspection as given in this figure.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

The QTY numbers shown below are the number of fasteners necessary for one side of the airplane.

Substitute fasteners may be used. Boeing Document D-590 and Boeing drawing 012W6100 are used to 

determine the part numbers used as substitutes. 

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Fasteners - 10 at STA 1120.

2 Remove Fasteners - 10 at STA 1160.

3 Remove Fasteners - 12 at STA 1200.

4 Remove Fasteners - 14 at STA 1220.

5 Inspect Holes - 46 (a)

6 Install Fasteners - 46 (b)

(a) Do an open hole HFEC inspection for cracks as given in 747 NDT, Part 6, 51-00-00, Figure 1, 

11, or 16.

(b) Install oversize fasteners as necessary if oversize hole repair was done to remove cracks.

CODE NAME IDENTIFICATION QTY

HOLE 

DIA MORE DATA

A Rivet BACR15FT6D( ) 18 - Install in existing hole. 

Grip length as required.

B Bolt BACB30MY6K4Y 1 - Install in existing hole.

Collar BACC30R6 1 - -

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

V75018

(SHEET 6 OF 7)
 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work)

Original Issue: April 21, 2005

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ALERT ALERT

C Bolt BACB30MY6K5X 1 - Install in existing hole.

Collar BACC30M6 1 - -

D Rivet BACR15BB6D( ) 12 - Install in existing hole. 

Grip length as required.

E Rivet BACR15BB7D( ) 14 - Install in existing hole. 

Grip length as required.

CODE NAME IDENTIFICATION QTY

HOLE 

DIA MORE DATA

(SHEET 7 OF 7)
 FIGURE 15: STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140

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ALERT ALERT

FIGURE 15: STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140

S-10L

A-A

TENSION TIE

END OF STEEL

PLATE

FRAME

ALUMINUM STRAPS

S-9L

1140

STA

B

A

UP

INBD

1 2 3

FWD

UP

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1880646

(SHEET 1 OF 2)
 FIGURE 15: STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140

Original Issue: April 21, 2005

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BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

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

numbers shown below are the number of parts necessary for one side of the airplane. However, both sides of 

the airplane require inspection as given in this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Fasteners - 6 (a)

2 Inspect Tension Tie - - Open hole HFEC (b)

3

Install (New) Hex Drive Bolts BACB30NX( )K( ) 6 (c) (d) (e) (f) (g)

Install washers under 

nuts. Washers BACW10BP( )DP 6

Nuts BACN10YT( )CD 6

(a) Remove six fasteners inboard of the aluminum straps in the area shown.

(b) Do an Open Hole HFEC inspection for cracks at all locations where fasteners were removed 

common to the tension tie, as given in 747 NDT, Part 6, 51-00-00, Figure 1, 11, or 16.

(c)

Only install if no cracks are indicated from the inspections, or if cracks were removed per 

oversizing procedures and limitations shown in the OVERSIZE HOLE REPAIR steps of the 

Accomplishment Instructions.

(d)

Install fasteners in close ream holes using hole sizes specified in 747-100/200/300 SRM 51-30-05, 

or 747-400 SRM 51-40-05, as applicable. Install fasteners as specified in 747-100/200/300 SRM 

51-30-02, or 747-400 SRM 51-40-02, as applicable, except that fasteners should be installed wet 

with BMS 3-27 or BMS 3-38 instead of with sealant. Refer to SOPM 20-50-19 wet fastener 

installation method 2 as an accepted procedure. If BACB30NX hex-drive bolts are installed with 

BMS 3-27 or BMS 3-38, they must be installed with the following torque value applied to the nut: 3/

16 inch bolt = 20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/16 inch bolt = 90 to 

125 pound-inches. If oversized fasteners are required, refer to OVERSIZE HOLE REPAIR for 

limitations on fastener size, edge margin, and spacing.

(e) Use same grip length as removed fasteners.

(f)

If necessary, it is acceptable to substitute fasteners per 747-100/200/300 SRM 51-30-03, or 

747-400 SRM 51-40-03, as applicable. However, if fasteners are substituted, the same type of 

fastener should be used throughout each joint as shown in Appendix C.

(g) To allow for easier removal during repeat inspections, it is optional to install BACB30MR( )K( ) 

bolts and BACW10BP( )CD washers, with BACN11Z( )CD nuts and BACW10BP( )DP washers. 

However, availability of BACB30MR( )K( ) bolts is limited. Also, if fasteners are substituted, the 

same type of fastener should be used throughout each joint, as shown in Appendix C. If 

BACB30MR bolts are used, install wet with BMS 3-27 or BMS 3-38 and apply the following torque 

values to the nut: 3/16 inch bolt = 20 to 25 pound-inches. 1/4 inch bolt = 50 to 75 pound-inches. 5/

16 inch bolt = 90 to 125 pound-inches.

(SHEET 2 OF 2)
 APPENDIX A: Deleted (Revision 1)

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ALERT ALERT

APPENDIX A: Deleted (Revision 1)

THIS APPENDIX IS DELETED.

1551112
 APPENDIX B: TENSION TIE DISCONNECTION METHODS.

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ALERT ALERT

APPENDIX B: TENSION TIE DISCONNECTION METHODS.

SYMMETRICAL ABOUT

1

CL

1

OF AIRPLANE

VIEW LOOKING DOWN

CL

WEB

SHEAR

WEB

SHEAR

TENSION TIE AT BOTH ENDS.

METHOD 1: DISCONNECT EVERY OTHER

496700
 APPENDIX B: TENSION TIE DISCONNECTION METHODS.

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ALERT ALERT

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

METHOD TASK NOTES

1 With the airplane on its gear, disconnect every other tension tie 

from the frame at both ends, as shown in the view for Method 1.

(a)

2 Deleted. (b)

3 

not 

shown

With the airplane on its gear, remove all but four fasteners at each 

end of each tension tie. Do the necessary Work Instructions 

specified in this service bulletin, and re-install fasteners. Remove 

the remaining four fasteners at each end of each tension tie and 

do the necessary Work Instructions at those locations.

4 Deleted. (b)

(a) Once work is done, re-install the fasteners and disconnect the remaining tension ties.

(b) Method 2 and Method 4 have been deleted.
 APPENDIX C: COMMON FASTENER TYPE REQUIREMENT

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ALERT ALERT

APPENDIX C: COMMON FASTENER TYPE REQUIREMENT

STEEL

PLATE

STEEL

PLATE

ALL STATIONS EXCEPT 1140

IF FASTENERS ARE SUBSTITUTED IN THIS

AREA COMMON TO THE STEEL PLATE, ALL

FASTENERS MUST BE THE SAME TYPE

IF FASTENERS ARE SUBSTITUTED IN THIS

AREA INBOARD OF THE STEEL PLATE, ALL

FASTENERS MUST BE THE SAME TYPE

IF FASTENERS ARE SUBSTITUTED IN THIS

AREA COMMON TO THE STEEL PLATE, ALL

FASTENERS MUST BE THE SAME TYPE

IF FASTENERS ARE SUBSTITUTED IN THIS

AREA INBOARD OF THE STEEL PLATE, ALL

FASTENERS MUST BE THE SAME TYPE

STA 1140

UP

INBD

STRINGER

FRAME

FAILSAFE CHORD

UP

INBD

STRINGER

FRAME

FAILSAFE CHORD

D35369