Commercial 

Airplanes MD90

Service Bulletin

ALERT

Number: MD90-57A026

Original Issue: February 11, 2010

Revision 1: February 23, 2011

ATA System: 5710

SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station

Xrs=164.000

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

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

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Unpublished Work - All Rights Reserved

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

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

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

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3.0
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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT

BLANK PAGE
Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 23

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 43

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 44

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH

FREQUENCY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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BOEING SERVICE BULLETIN MD90-57A026

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes MD90

Service Bulletin

ALERT

Revision Transmittal Sheet Number: MD90-57A026

Original Issue: February 11, 2010

Revision 1: February 23, 2011

ATA System: 5710

SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station

Xrs=164.000

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on the airplane(s) changed in accordance with the original issue of this service

bulletin, however the repetitive inspections called for in the original issue are still required.

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

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

mandatory

REASON FOR REVISION

This revision is sent to incorporate engineering released subsequent to original release of this service bulletin,

which incorporates an option to do a splice repair of the upper and/or lower rear spar caps.

The data given in Information Notice MD90-57A026 IN 01 is included in this revision.

These sections were changed:

1. In Paragraph 1.C., Reason, added spar splice option.

2. In Paragraph 1.D., Description, added Condition titles, Option 1 heading and Option 2 splice repair, and

added repair options for Condition 3.

3. In Paragraph 1.E., Compliance, added Option 1 heading, Option 2 splice repair, and repair options for

Condition 3.

4. In Paragraph 1.F., Approval, added approval statement for Principle Structural Element (PSE) inspection

requirements.

5. In Paragraph 1.G., Manpower, added a table for splice repair hours.

6. In Paragraph 1.J.1., Existing Data, changed Aircraft Maintenance Manual (AMM) references to reflect correct

chapter references.

7. In Paragraph 1.J.2., Data supplied with this Service Bulletin, added drawings and updated DCN/REV column.

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8. In Paragraph 2.A., Material - Price and Availability, added Service Kits, Reorder Lead Time (ROLT), and

unit price.

9. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, changed supplier address.

10. In Paragraph 2.C.1., Kits/Parts, changed Service Kit applicability table to add new kits and added new kit

parts list.

11. In Paragraph 2.C.3., Parts Modified and Reidentified, added parts changed based on repair configuration.

12. In Paragraph 3.A., General Information, removed one Note and renumbered remaining Notes.

13. In Paragraph 3.B., Work Instructions, added Option 1 heading, Option 2 splice repair, and repair options

for Condition 3, changed work step order, and corrected Aircraft Maintenance Manual Chapter references.

14. Changed Figure 1 and Note for clarity of work required.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: February 11, 2010

Revision 1: February 23, 2011

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Commercial 

Airplanes MD90

Service Bulletin

ALERT

Summary Number: MD90-57A026

Original Issue: February 11, 2010

Revision 1: February 23, 2011

ATA System: 5710

SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station

Xrs=164.000

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

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

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

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Two MD-80 operators, while doing an investigation for fuel leaks, reported five instances of cracking of the wing

rear spar lower cap at the outboard flap, inboard drive hinge at station Xrs=164.000. Boeing has determined

that cracks are the result of material fatigue from normal flap operating loads. No MD-90 failures have yet been

reported but this is a fatigue issue and it was determined that MD-90s are also susceptible to cracking. Inspecting

this area for cracks will stop any crack migration and ensure repairs are done before additional damage occurs.

Installation of doublers or doing the spar cap splice will provide a permanent repair. If not corrected, fuel leaks

and damage to the wing skin or other structure may occur, resulting in flight disruptions and possible loss of the

structural integrity of the wing.

ACTION

Refer to Paragraph 1.D., for Description.

EFFECTIVITY

MD-90-30 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

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

bulletin.

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MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes MD90

Service Bulletin

ALERT

Number: MD90-57A026

Original Issue: February 11, 2010

Revision 1: February 23, 2011

ATA System: 5710

SUBJECT: WINGS - Main Frame - Inspect/Repair Upper and Lower Rear Spar Caps at Station

Xrs=164.000

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

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

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

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

MD-90 Airplanes with a Multi-component Bulkhead at Wing Station

Xrs=137.750

1 -

MD-90 Airplanes with a Machined Bulkhead at Wing Station

Xrs=137.750

2 -

Airplane Models:

MD-90-30

Fuselage Num- Group

ber

2094 - 2100 1

2115 1

2117 1

2120 1

2122 - 2123 1

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Fuselage Num- Group

ber

2125 - 2126 1

2129 1

2131 1

2133 1

2136 1

2138 1

2140 - 2144 1

2146 - 2147 1

2149 - 2150 1

2153 - 2154 1

2156 - 2159 1

2161 - 2166 1

2169 - 2171 1

2173 1

2175 1

2177 1

2179 1

2181 1

2184 1

2186 1

2190 - 2191 1

2193 - 2195 1

2197 - 2198 1

2200 1

2202 - 2203 1

2205 1

2207 1

2209 - 2213 1

2215 - 2217 2

2219 - 2233 2

2235 - 2238 2

2240 2

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Fuselage Num- Group

ber

2242 - 2243 2

2245 2

2248 2

2250 - 2251 2

2253 2

2255 - 2256 2

2258 - 2263 2

2288 - 2290 2

4001 - 4002 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Two MD-80 operators, while doing an investigation for fuel leaks, reported five instances of cracking

of the wing rear spar lower cap at the outboard flap, inboard drive hinge at station Xrs=164.000. Boeing

has determined that cracks are the result of material fatigue from normal flap operating loads. No MD-90

failures have yet been reported but this is a fatigue issue and it was determined that MD-90s are also

susceptible to cracking. Inspecting this area for cracks will stop any crack migration and ensure repairs

are done before additional damage occurs. Installation of doublers or doing the spar cap splice will

provide a permanent repair. If not corrected, fuel leaks and damage to the wing skin or other structure

may occur, resulting in flight disruptions and possible loss of the structural integrity of the wing.

Revision 1 is sent to incorporate engineering released subsequent to original release of this service

bulletin, which incorporates an option to do a splice repair of the upper and/or lower rear spar caps.

The data given in Information Notice MD90-57A026 IN 01 is included in this revision.

MD-80 Service History

Flight-Hours Landing Cycles

51,293 to 69,453 32,958 to 39,338

D. Description

This service bulletin does Eddy Current Testing High Frequency (ETHF) inspection on the aft side of

the left and right wing rear spar lower caps at station Xrs=164.000 for cracks and based on inspection

results does as follows:

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Condition 1 (No Cracks)

1. Does repeat ETHF inspections.

Condition 2 (Crack 2.0 Inches or Shorter and Not in the Rear Spar Lower Cap Forward Horizontal

Leg Radius)

1. Does ETHF inspection on the aft side of the left and/or right wing rear spar upper cap, as applicable,

at station Xrs=164.000 for cracks and based on inspection results does as follows:

Condition 2a (No Crack in Rear Spar Upper Cap)

a. Do Option 1 or Option 2

Option 1

(1) Does doubler repair to rear spar lower cap in accordance with Service Rework Drawing

J060271.

(2) Does repeat ETHF inspections of rear spar lower cap doubler repair.

Option 2

(1) Does splice repair to rear spar lower cap in accordance with Service Rework Drawing

J060165.

(2) Does Eddy Current Testing Low Frequency (ETLF) and Ultrasonic (UT) inspections of

rear spar lower cap splice repair.

Condition 2b (Crack 2.0 Inches or Shorter in Rear Spar Upper Cap)

a. Do Option 1 or Option 2.

NOTE: Operators can do Option 1 or Option 2 or any combination of Options 1 and 2.

Option 1

(1) Does doubler repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060271.

(2) Does ETHF inspection of rear spar upper and lower cap doubler repairs.

Option 2

(1) Does splice repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060165.

(2) Does ETLF and UT inspections of rear spar lower cap splice repair.

Condition 2c (Crack Longer than 2 Inches in Rear Spar Upper Cap)

a. Do Option 1 or Option 2.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Option 1

(1) Does splice repair to rear spar upper cap in accordance with Service Rework Drawing

J060165 and doubler repair to rear spar lower cap in accordance with Service Rework

Drawing J060271.

(2) Does ETHF inspections of rear spar lower cap splice repair.

Option 2

(1) Does splice repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060165.

(2) Does ETLF and UT inspections of rear spar lower cap splice repair.

Condition 3 (Crack Longer than 2.0 Inches or Crack in the Rear Spar Lower Cap Forward

Horizontal Leg Radius)

1. Does ETHF inspection on the aft side of the left and/or right wing rear spar upper cap, as applicable,

at station Xrs=164.000 for cracks and based on inspection results does as follows:

Condition 3a (No Crack in Rear Spar Upper Cap)

a. Does splice repair to rear spar lower cap in accordance with Service Rework Drawing J060165.

b. Does ETLF and UT inspections of rear spar lower cap splice repair.

Condition 3b (Crack 2.0 Inches or Shorter in Rear Spar Upper Cap)

a. Do Option 1 or Option 2

Option 1

(1) Does doubler repair to rear spar upper cap in accordance with Service Rework Drawing

J060271 and splice repair to rear spar lower cap in accordance with Service Rework

Drawing J060165.

(2) Does ETHF inspection of rear spar upper cap doubler repair.

(3) Does ETLF and UT inspections of rear spar lower cap splice repair.

Option 2

(1) Does splice repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060165.

(2) Does ETLF and UT inspections of rear spar lower cap splice repair.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Condition 3c (Crack Longer than 2.0 Inches in Rear Spar Upper Cap)

a. Does splice repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060165.

b. Does ETLF and UT inspections of rear spar lower cap splice repair.

Revision 1 - No more work is necessary on the airplane(s) changed in accordance with the original

issue of this service bulletin, however the repetitive inspections called for in the original issue are still

required.

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

Affected Maintenance Zones

Model Zone

MD-90-30 511, 611

E. Compliance

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

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

service bulletin mandatory.

Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack at Station Xrs = 164.000

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 10,000 -

flight cycles after

the original issue

date on this service bulletin.

Before the accumulation of

30,000 total flight

cycles.

Do Eddy Current, High Frequency

(ETHF) inspection of the left and

right wing rear spar lower cap at

station Xrs=164.000 in accordance

with Accomplishment Instruction

3.B.

All airplanes

2,550 flight

cycles.

Do ETHF inspection of the left and - -

right wing rear spar lower caps at

station Xrs=164.000 in accordance

with Accomplishment Instruction

3.B.

Condition 1:

No Crack

Before further

flight.

Do ETHF inspection of the left

and/or right wing rear spar upper

cap at station Xrs=164.000 in accordance with Accomplishment Instruction 3.B..

Condition 2:

Crack 2.0 Inches or

Shorter and Not in the

Rear Spar Lower Cap

Forward Horizontal Leg

Radius

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack at Station Xrs = 164.000

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further - -

flight.

Option 1:

Do doubler repair of rear spar lower

cap in accordance with Accomplishment Instruction 3.B.

Condition 2a:

No Crack in Rear Spar

Upper Cap.

AND

8,500 flight

cycles.

13,500 flight cy- -

cles after doubler

repair.

Do ETHF inspection in the repaired

area of the rear spar lower cap in

accordance with Accomplishment

Instruction 3.B.

OR

Before further - -

flight.

Option 2:

Do splice repair in accordance with

Accomplishment Instruction 3.B.

AND

3,000 flight

cycles.

20,000 flight cy- -

cles after splice

repair.

Do Eddy Current, Low Frequency

(ETLF) and Ultrasonic (UT) inspections in the repaired area of the rear

spar lower cap in accordance with

Accomplishment Instruction 3.B.

Before further - -

flight.

Option 1:

Do doubler repair of rear spar upper

and lower caps in accordance with

Accomplishment Instruction 3.B.

Condition 2b:

Crack 2.0 Inches or

Shorter in Rear Spar

Upper Cap.

(Operators may do Option 1 or Option 2 or

any combination of Option 1 and 2.)

AND

8,500 flight

cycles.

13,500 flight cy- -

cles after doubler

repair.

Do ETHF inspection in the repaired

area of the rear spar upper and

lower caps in accordance with Accomplishment Instruction 3.B.

OR

Before further - -

flight.

Option 2:

Do splice repair of rear spar upper

and lower caps in accordance with

Accomplishment Instruction 3.B.

AND

3,000 flight

cycles.

20,000 flight cy- -

cles after splice

repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instruction 3.B.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack at Station Xrs = 164.000

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further - -

flight.

Option 1:

Do splice repair of rear spar upper

cap and doubler repair of rear spar

lower cap in accordance with Accomplishment Instruction 3.B.

Condition 2c:

Crack Longer than 2.0

Inches in Rear Spar

Upper Cap.

AND

8,500 flight

cycles.

13,500 flight cy- -

cles after doubler

repair.

Do ETHF inspection in the repaired

area of the rear spar lower cap in

accordance with Accomplishment

Instruction 3.B.

OR

Before further - -

flight.

Option 2:

Do splice repair of rear spar upper

and lower caps in accordance with

Accomplishment Instruction 3.B.

AND

3,000 flight

cycles.

20,000 flight cy- -

cles after splice

repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instruction 3.B.

Before further - -

flight.

Do ETHF inspection of the left

and/or right wing rear spar upper

cap at station Xrs=164.000 in accordance with Accomplishment Instruction 3.B.

Condition 3:

Crack Longer than 2.0

Inches or Crack in the

Rear Spar Lower Cap

Forward Horizontal Leg

Radius.

Before further -

flight.

Do splice repair of rear spar lower

cap in accordance with Accomplishment Instruction 3.B.

Condition 3a:

No Crack in Rear Spar

Upper Cap.

AND

3,000 flight

cycles.

20,000 flight cycles after splice

repair.

Do ETLF and UT inspections in the

repaired area of the lower rear spar

cap in accordance with Accomplishment Instruction 3.B.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack at Station Xrs = 164.000

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further - -

flight.

Option 1:

Do doubler repair of rear spar upper

cap and splice repair of rear spar

lower cap in accordance with Accomplishment Instruction 3.B.

Condition 3b:

Crack 2.0 Inches or

Shorter in Rear Spar

Upper Cap.

AND

8,500 flight

cycles.

13,500 flight cy- -

cles after doubler

repair.

Do ETHF inspection in the repaired

area of the rear spar upper cap in

accordance with Accomplishment

Instruction 3.B.

AND

3,000 flight

cycles.

20,000 flight cy- -

cles after splice

repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instruction 3.B.

OR

Before further - -

flight.

Option 2:

Do splice repair of rear spar upper

and lower caps in accordance with

Accomplishment Instruction 3.B.

AND

3,000 flight

cycles.

20,000 flight cy- -

cles after splice

repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instruction 3.B.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Table 1: Inspect Left and Right Wing Rear Spar Upper and Lower Caps for Crack at Station Xrs = 164.000

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Before further - -

flight.

Do splice repair of rear spar upper

and lower caps in accordance with

Accomplishment Instruction 3.B.

Condition 3c:

Crack Longer than 2.0

Inches in Rear Spar

Upper Cap. AND

3,000 flight

cycles.

20,000 flight cy- -

cles after splice

repair.

Do ETLF and UT inspections in the

repaired area of the rear spar lower

cap in accordance with Accomplishment Instruction 3.B.

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.

In addition, the Manager of the FAA Los Angeles, Aircraft Certification Office approves the action (i.e.

inspection or modification or repair) defined in this service bulletin as a method of compliance to the

requirements of Principle Structural Element (PSE) 57.11.02.2 for those areas of the PSE addressed

by this service bulletin.

G. Manpower

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

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

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

examples of lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

— Time to make reference standards.

1. Use applicable table for Manpower as follows:

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
TABLE 1: NO CRACK

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 2 1.0 0.5

Inspect 2 4.0 2.0

Close Access 2 1.0 0.5

TOTAL FOR EACH WING 6.0 3.0

TABLE 2: DOUBLER REPAIR

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 2 1.0 0.5

Inspect 2 4.0 2.0

Open Access to 2 1.0 0.5

Tanks

Defuel 1 4.0 4.0

Purge 1 8.0 8.0

Repair 2 200.0* 100.0*

Close Access 2 1.0 0.5

Test 2 4.0 2.0

TOTAL FOR EACH WING 223.0* 117.5*

* Actual task hours and elapsed hours for repair are contingent upon inspection

results.

TABLE 3: SPLICE REPAIR

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 2 1.0 0.5

Inspect 2 4.0 2.0

Open Access to 2 1.0 0.5

Tanks

Defuel 1 4.0 4.0

Purge 1 8.0 8.0

Repair 2 400.0* 200.0*

Close Access 2 1.0 0.5

Test 2 4.0 2.0

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
TABLE 3: SPLICE REPAIR

Number of Per- Task Hours Elapsed Hours

sons

Task

TOTAL FOR EACH WING 423.0* 317.5*

* Actual task hours and elapsed hours for repair are contingent upon inspection

results.

H. Weight and Balance Changes

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

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

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

airplane weight and balance report.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Non-Destructive Test Standard Practices Manual (NDTSPM) 01-00-01, 06-00-01, 06-10-01.001,

Part 06, 06-20-01.

b. MD-90 Aircraft Maintenance Manual (AMM) 06-35-00, 06-36-00, 12-11-01, 27-00-00, 27-10-00,

27-50-00, 27-50-01, 27-60-00, 28-00-00, 28-11-00 , 29-00-00, 32-10-00, 57-20-03, 57-40-01.

c. MD90 Structural Repair Manual (SRM) 51-10-03, 51-10-05, 51-10-09, 51-20-00, 51-30-01,

51-30-02, 51-30-03, 51-30-05, 51-31-02, 51-40-00.

d. MD-90 Airworthiness Limitations Instructions (ALI), Principal Structural Element (PSE)

57.11.02.2.

2. Data supplied with this Service Bulletin:

No data is supplied with this service bulletin. To obtain the data necessary to support this service

bulletin submit a data request to:

Data and Services Management

MS D800-0019

3855 Lakewood Boulevard

Long Beach, California 90846

Phone: (562) 593-6996

Fax: (562) 593-2001

E-mail: dse.boecom@boeing.com

a. Drawings:

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

EDDY CURRENT INSPECTION - WING DWG C -

REAR SPAR TEMPORARY REPAIR STA

Xrs=164.000

3668XXX

SERVICE REWORK - WING REAR SPAR AEO U Y

CAP SPLICE SERVICE REWORK DWG

J060165

AEO U W

AEO U V

AEO U Z

DWG U AA

SERVICE REWORK - TEMPORARY RE- DWG T U

PAIR, WING REAR SPAR, STATION

Xrs=164.000

J060271

INSPECTION, REAR SPAR - LOWER CAP DWG - -

AT Xrs=192.00

SN90570001

INSPECTION - REAR SPAR AFT TANG DWG - -

SERVICE NDI DRAWING

SN90570006

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

None.

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. DTI requirements for the structure affected

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

L. Interchangeability and Intermixability of Parts

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

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ALERT ALERT
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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the date of this

Service Bulletin

(US Dollars)

ROLT as of the

date of this Service Bulletin (Calendar Days)

Kit Number Name

SA90570026-3 Service Kit 120 $40,558.00

SA90570026-5 Service Kit 120 40,558.00

SA90570026-7 Service Kit 120 42,624.00

SA90570026-9 Service Kit 120 42,624.00

SA90570026-11 Service Kit 120 80,026.00

SA90570026-13 Service Kit 120 80,026.00

SA90570026-15 Service Kit 120 138,297.00

SA90570026-17 Service Kit 120 138,297.00

SA90570026-19 Service Kit 120 81,125.00

SA90570026-21 Service Kit 120 81,125.00

SA90570026-23 Service Kit 120 192,024.00

SA90570026-25 Service Kit 120 192,024.00

SA90570026-27 Service Kit 120 138,306.00

SA90570026-29 Service Kit 120 138,306.00

SA90570026-31 Service Kit 120 72,115.00

SA90570026-33 Service Kit 120 72,115.00

SA90570026-35 Service Kit 120 192,043.00

SA90570026-37 Service Kit 120 192,043.00

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
B. Industry Support Information

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

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

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

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by

the Operator, are necessary for each airplane.

Group 1:

Table 1: Service Kit Applicability

Service Kit Drawing Configuration Description

Doubler Repair for Crack in Rear Spar Upper Cap

(Left Wing)

SA90570026-3 J060271-511

Doubler Repair for Crack in Rear Spar Upper Cap

(Right Wing)

SA90570026-5 J060271-512

Doubler Repair for Crack in Rear Spar Lower Cap

(Left Wing)

SA90570026-7 J060271-517

Doubler Repair for Crack in Rear Spar Lower Cap

(Right Wing)

SA90570026-9 J060271-518

Doubler Repair for Crack in Rear Spar Upper and

Lower Cap (Left Wing)

SA90570026-11 J060271-519

Doubler Repair for Crack in Rear Spar Upper and

Lower Cap (Right Wing)

SA90570026-13 J060271-520

Splice Repair for Crack in Rear Spar Upper Cap on

airplanes with a multi-component bulkhead without

bolts at wing station Xrs=137.750 (Left Wing)

SA90570026-15 J060165-517

Splice Repair for Crack in Rear Spar Upper Cap on

airplanes with a multi-component bulkhead without

bolts at wing station Xrs=137.750 (Right Wing)

SA90570026-17 J060165-518

Splice Repair for Crack in Rear Spar Lower Cap on

airplanes with a multi-component bulkhead without

bolts at wing station Xrs=137.750 (Left Wing)

SA90570026-19 J060165-519

Splice Repair for Crack in Rear Spar Lower Cap on

airplanes with a multi-component bulkhead without

bolts at wing station Xrs=137.750 (Right Wing)

SA90570026-21 J060165-520

Splice Repair for Crack in Rear Spar Upper and

Lower Caps on airplanes with a multi-component

bulkhead without bolts at wing station Xrs=137.750

(Left Wing)

SA90570026-23 J060165-521

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Group 1:

Table 1: Service Kit Applicability

Service Kit Drawing Configuration Description

Splice Repair for Crack in Rear Spar Upper and

Lower Caps on airplanes with a multi-component

bulkhead without bolts at wing station Xrs=137.750

(Right Wing)

SA90570026-25 J060165-522

Group 2:

Table 1: Service Kit Applicability

Service Kit Drawing Configuration Description

Doubler Repair for Crack in Rear Spar Upper Cap

(Left Wing)

SA90570026-3 J060271-511

Doubler Repair for Crack in Rear Spar Upper Cap

(Right Wing)

SA90570026-5 J060271-512

Doubler Repair for Crack in Rear Spar Lower Cap

(Left Wing)

SA90570026-7 J060271-517

Doubler Repair for Crack in Rear Spar Lower Cap

(Right Wing)

SA90570026-9 J060271-518

Doubler Repair for Crack in Rear Spar Upper and

Lower Cap (Left Wing)

SA90570026-11 J060271-519

Doubler Repair for Crack in Rear Spar Upper and

Lower Cap (Right Wing)

SA90570026-13 J060271-520

Splice Repair for Crack in Rear Spar Upper Cap on

airplanes with a machined bulkhead at wing station

Xrs=137.750 (Left Wing)

SA90570026-27 J060165-523

Splice Repair for Crack in Rear Spar Upper Cap on

airplanes with a machined bulkhead at wing station

Xrs=137.750 (Right Wing)

SA90570026-29 J060165-524

Splice Repair for Crack in Rear Spar Lower Cap on

airplanes with a machined bulkhead at wing station

Xrs=137.750 (Left Wing)

SA90570026-31 J060165-525

Splice Repair for Crack in Rear Spar Lower Cap on

airplanes with a machined bulkhead at wing station

Xrs=137.750 (Right Wing)

SA90570026-33 J060165-526

Splice Repair for Crack in Rear Spar Upper and

Lower Caps on airplanes with a machined bulkhead

at wing station Xrs=137.750 (Left Wing)

SA90570026-35 J060165-527

Splice Repair for Crack in Rear Spar Upper and

Lower Caps on airplanes with a machined bulkhead

at wing station Xrs=137.750 (Right Wing)

SA90570026-37 J060165-528

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number QTY Name Notes

-3 -5 -7 -9 -11 -13

2917053-501 . . 1 1 1 1 WASHER

2917053-509 . . 1 1 1 1 WASHER

3D0006-4 27 27 46 46 46 46 NUT ASSY

4894213-1 26 26 . . 26 26 SPACER CONICAL

4894213-501 . . 18 18 18 18 SPACER CONICAL

4894213-503 50 50 47 47 97 97 SPACER

4894213-505 . . 7 7 7 7 CONICAL SPACER

4894213-547 4 4 4 4 8 8 CONICAL SPACER

9910010-39 1 1 1 1 1 1 STIFFENER

9924775-27 1 . . . . . CLIP

9924775-28 . 1 . . . . CLIP

HL328-6-10 . . 4 4 4 4 PIN

HL328-6-18 . . 4 4 4 4 PIN

HL328-6-8 6 6 . . 6 6 PIN

HL328-8-10 14 14 6 6 20 20 PIN

HL328-8-6 . . 3 3 3 3 PIN

HL328-8-8 . . 5 5 5 5 PIN

HL329-6-14 . . 3 3 3 3 PIN

HL329-6-16 . . 2 2 2 2 PIN

HL329-6-5 . . 15 15 15 15 PIN

HL329-6-6 16 16 . . 16 16 PIN

HLT1001PB-6-10 . . 4 4 . . PIN, OVERSIZE

HLT1001PB-6-12 26 26 2 2 28 28 PIN, OVERSIZE

HLT1001PB-6-14 7 7 8 8 15 15 PIN, OVERSIZE

HLT1001PB-6-16 . . 8 8 8 8 PIN, OVERSIZE

HLT1001PB-6-18 . . 2 2 2 2 PIN, OVERSIZE

HLT1001PB-8-10 . . 2 2 2 2 PIN, OVERSIZE

HLT1001PB-8-12 2 2 14 14 16 16 PIN, OVERSIZE

HLT1001PB-8-14 29 29 19 19 48 48 PIN, OVERSIZE

HLT1001PB-8-16 1 1 6 6 7 7 PIN, OVERSIZE

HLT1001PB-8-18 18 18 11 11 29 29 PIN, OVERSIZE

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number QTY Name Notes

-3 -5 -7 -9 -11 -13

HLT428-6-8 6 6 5 5 11 11 PIN

HLT428-8-10 13 13 13 13 26 26 PIN

HLT428-8-12 32 32 20 20 52 52 PIN

HLT428-8-8 . . 2 2 2 2 PIN

HLT629-8-6 1 1 . . 1 1 PIN, OVERSIZE

HLT629-8-7 . . 2 2 2 2 PIN, OVERSIZE

J060271-13 . . . . 1 1 SHIM

J060271-17 . . . . 1 1 SHIM

J060271-19 1 1 1 1 . . SHIM

J060271-21 1 1 1 1 . . SHIM

J060271-27 1 . . . 1 . DOUBLER

J060271-28 . 1 . . . 1 DOUBLER

J060271-31 . . 1 1 1 1 FILLER

J060271-33 . . 1 . 1 . CLIP

J060271-34 . . . 1 . 1 CLIP

J060271-35 . . 1 . 1 . CLIP

J060271-36 . . . 1 . 1 CLIP

J060271-37 . . 2 2 2 2 SPACER

J060271-39 1 . . . 1 . DOUBLER

J060271-40 . 1 . . . 1 DOUBLER

J060271-41 1 . . . 1 . DOUBLER

J060271-42 . 1 . . . 1 DOUBLER

J060271-43 . . 1 . 1 . DOUBLER

J060271-44 . . . 1 . 1 DOUBLER

J060271-45 . . 1 . 1 . DOUBLER

J060271-46 . . . 1 . 1 DOUBLER

J060271-47 . . 1 . 1 . DOUBLER

J060271-48 . . . 1 . 1 DOUBLER

J060271-49 . . 1 1 1 1 FILLER

J060271-51 . . 1 1 1 1 FILLER

J060271-53 . . 1 1 1 1 SHIM

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ALERT ALERT
Kit SA90570026

New Part Number QTY Name Notes

-3 -5 -7 -9 -11 -13

J060271-57 1 1 1 1 1 1 STIFFENER

J060271-65 . . 1 . 1 . TEE

J060271-66 . . . 1 . 1 TEE

J060271-67 . . 1 . 1 . RADIUS BLOCK

J060271-68 . . . 1 . 1 RADIUS BLOCK

MS20470AD6-10D 2 2 2 2 2 2 RIVET

MS20470AD6-8D 2 2 . . 2 2 RIVET

MS20470AD6-9D 3 3 3 3 3 3 RIVET

MS20470AD8-12D 16 16 16 16 16 16 RIVET

MS21042L3 57 57 48 48 105 105 NUT

MS21042L4 107 107 89 89 196 196 NUT

MS21059L3 . . 2 2 2 2 NUTPLATE

NAS1252-10H 22 22 28 28 50 50 WASHER

NAS1252-416H 14 14 14 14 28 28 WASHER

NAS1401-3D3 24 24 . . 24 24 WASHER

PIC239-3-10 . . 4 4 4 4 BOLT

PIC239-3-12 . . 4 4 4 4 BOLT

PIC239-3-15 . . 3 3 3 3 BOLT

PIC239-3-17 3 3 . . 3 3 BOLT

PIC239-3-6 . . 2 2 2 2 BOLT

S2931983-30A06 35 35 20 20 55 55 WASHER

S2931983-40A06 95 95 85 85 180 180 WASHER

Kit SA90570026

New Part Number Name Notes -15 -17 -19 -21 -23 -25

3D0006-3 22 22 15 15 22 22 NUT ASSY

3D0006-4 155 155 74 74 216 216 NUT ASSY

3D0006-5 40 40 17 17 57 57 NUT ASSY

3D0097-10X12 4 4 . . 4 4 PIN

3D0097-10X13 4 4 . . 4 4 PIN

3D0097-10X14 . . 17 17 17 17 PIN

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ALERT ALERT
Kit SA90570026

New Part Number Name Notes -15 -17 -19 -21 -23 -25

3D0097-10X17 12 12 . . 12 12 PIN

3D0097-10X18 16 16 . . 16 16 PIN

3D0097-10X20 4 4 . . 4 4 PIN

3D0097-6-7 2 2 . . 2 2 PIN

3D0097-8X10 21 21 . . 21 21 PIN

3D0097-8X11 11 11 . . 11 11 PIN

3D0097-8X12 1 1 . . 1 1 PIN

3D0097-8X13 3 3 . . 3 3 PIN

3D0097-8X14 4 4 . . 4 4 PIN

3D0097-8X15 12 12 . . 12 12 PIN

3D0097-8X16 12 12 . . 12 12 PIN

HL325-6-10 4 4 3 3 7 7 PIN

HL325-6-11 2 2 . . 2 2 PIN

HL325-6-12 2 2 5 5 7 7 PIN

HL325-6-13 15 15 . . 15 15 PIN

HL325-6-14 . . 2 2 2 2 PIN

HL325-6-8 . . 1 1 1 1 PIN

HL325-6-9 . . 5 5 5 5 PIN

HL325-8-6 . . 23 23 23 23 PIN

HL325-8-7 . . 2 2 2 2 PIN

HL325-8-8 . . 8 8 8 8 PIN

HLT1001PB-6-6 . . 7 7 7 7 PIN, OVERSIZE

HLT425-6-13 4 4 . . 4 4 PIN

HLT425-8-10 . . 7 7 7 7 PIN

HLT425-8-11 . . 17 17 17 17 PIN

HLT425-8-9 . . 31 31 31 31 PIN

HLT426-10-18 10 10 4 4 4 4 PIN

HLT426-6-10 56 56 35 35 44 44 PIN

HLT426-6-12 24 24 18 18 24 24 PIN

HLT426-6-13 4 4 . . 4 4 PIN

HLT426-6-14 2 2 18 18 18 18 PIN

HLT426-6-15 4 4 2 2 6 6 PIN

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number Name Notes -15 -17 -19 -21 -23 -25

HLT426-6-16 4 4 4 4 8 8 PIN

HLT426-6-17 . . 2 2 2 2 PIN

HLT426-6-3 . . 3 3 3 3 PIN

HLT426-6-4 9 9 9 9 11 11 PIN

HLT426-6-5 . . 22 22 22 22 PIN

HLT426-6-6 41 41 74 74 74 74 PIN

HLT426-6-7 30 30 22 22 50 50 PIN

HLT426-6-8 9 9 8 8 8 8 PIN

HLT426-8-10 85 85 98 98 98 98 PIN

HLT426-8-11 9 9 10 10 10 10 PIN

HLT426-8-12 109 109 108 108 108 108 PIN

HLT426-8-13 3 3 19 19 16 16 PIN

HLT426-8-14 24 24 14 14 14 14 PIN

HLT426-8-15 . . 31 31 31 31 PIN

HLT426-8-16 12 12 1 1 7 7 PIN

HLT426-8-17 . . 58 58 58 58 PIN

HLT426-8-18 . . 18 18 18 18 PIN

HLT426-8-19 . . 24 24 24 24 PIN

HLT426-8-22 . . 16 16 16 16 PIN

HLT426-8-24 . . 10 10 10 10 PIN

HLT426-8-4 32 32 28 28 32 32 PIN

HLT426-8-5 20 20 22 22 23 23 PIN

HLT426-8-6 28 28 26 26 28 28 PIN

HLT426-8-7 1 1 16 16 16 16 PIN

HLT426-8-8 74 74 83 83 83 83 PIN

HLT426-8-9 2 2 . . 2 2 PIN

HLT426-10-7 6 6 6 6 PIN

HLT427-10-18 . . 9 9 9 9 PIN

HLT427-10-20 . . 12 12 12 12 PIN

HLT427-10-22 . . 35 35 35 35 PIN

HLT427-10-24 . . 6 6 6 6 PIN

HLT427-10-26 . . 2 2 2 2 PIN

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number Name Notes -15 -17 -19 -21 -23 -25

HLT427-6-10 . . 5 5 5 5 PIN

HLT427-6-11 2 2 12 12 12 12 PIN

HLT427-6-12 10 10 10 10 10 10 PIN

HLT427-6-14 . . 6 6 6 6 PIN

HLT427-6-7 2 2 . . 2 2 PIN

HLT427-6-8 . . 2 2 2 2 PIN

HLT427-6-9 . . 6 6 6 6 PIN

HLT427-8-10 9 9 34 34 43 43 PIN

HLT427-8-11 . . 19 19 19 19 PIN

HLT427-8-12 . . 49 49 49 49 PIN

HLT427-8-13 2 2 . . 2 2 PIN

HLT427-8-14 2 2 22 22 24 24 PIN

HLT427-8-15 4 4 1 1 5 5 PIN

HLT427-8-16 2 2 36 36 36 36 PIN

HLT427-8-17 2 2 56 56 56 56 PIN

HLT427-8-18 20 20 15 15 20 20 PIN

HLT427-8-19 21 21 2 2 21 21 PIN

HLT427-8-20 2 2 4 4 6 6 PIN

HLT427-8-21 2 2 1 1 3 3 PIN

HLT427-8-22 . . 2 2 2 2 PIN

HLT427-8-23 2 2 2 2 2 2 PIN

HLT427-8-24 . . 13 13 13 13 PIN

HLT427-8-25 2 2 . . 2 2 PIN

HLT427-8-26 2 2 . . 2 2 PIN

HLT427-8-27 11 11 . . 11 11 PIN

HLT427-8-28 . . 10 10 10 10 PIN

HLT427-8-6 . . 13 13 13 13 PIN

HLT427-8-8 1 1 4 4 4 4 PIN

HLT427-8-9 5 5 5 5 5 5 PIN

HLT437-6-6 5 5 . . 5 5 PIN

J060165-10 . . . 1 . 1 ANGLE

J060165-13 . . 1 . 1 . FILLER

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ALERT ALERT
Kit SA90570026

New Part Number Name Notes -15 -17 -19 -21 -23 -25

J060165-14 . . . 1 . 1 FILLER

J060165-15 . . 1 1 1 1 FILLER

J060165-17 . . 1 1 1 1 FILLER

J060165-19 . . 1 1 1 1 FILLER

J060165-21 1 1 1 1 . . TEE

J060165-23 . . 1 1 1 1 STIFFENER

J060165-27 . . 1 1 1 1 PLATE

J060165-31 1 . . . 1 . ANGLE

J060165-32 . 1 . . . 1 ANGLE

J060165-33 1 . . . 1 . FILLER

J060165-34 . 1 . . . 1 FILLER

J060165-35 1 . . . 1 . FILLER

J060165-36 . 1 . . . 1 FILLER

J060165-37 1 . . . 1 . ANGLE

J060165-38 . 1 . . . 1 ANGLE

J060165-39 1 . . . 1 . DOUBLER

J060165-40 . 1 . . . 1 DOUBLER

J060165-41 1 1 . . 1 1 FILLER

J060165-43 1 1 . . 1 1 FILLER

J060165-45 1 1 . . 1 1 FILLER

J060165-47 1 1 . . 1 1 FILLER

J060165-49 1 1 . . 1 1 FILLER

J060165-5 . . 1 . 1 . ANGLE

J060165-51 . . . . 1 1 TEE

J060165-53 1 1 1 1 1 1 STIFFENER

J060165-55 1 1 1 1 1 1 SPLICE

J060165-57 . . 1 1 1 1 SPACER

J060165-59 . . 1 1 1 1 SPACER

J060165-6 . . . 1 . 1 ANGLE

J060165-61 . . 1 . 1 . DOUBLER

J060165-62 . . . 1 . 1 DOUBLER

J060165-63 . . 1 . 1 . SPAR CAP

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ALERT ALERT
Kit SA90570026

New Part Number Name Notes -15 -17 -19 -21 -23 -25

J060165-64 . . . 1 . 1 SPAR CAP

J060165-65 1 1 1 1 1 1 SPLICE

J060165-67 . . 7 7 7 7 BUSHING

J060165-69 1 . . . 1 . SPAR CAP

J060165-7 . . 1 . 1 . FILLER

J060165-70 . 1 . . . 1 SPAR CAP

J060165-8 . . . 1 . 1 FILLER

J060165-9 . . 1 . 1 . ANGLE

MS20426AD6-12D 3 3 . . 3 3 RIVET

MS20426AD6-14D 4 4 18 18 18 18 RIVET

MS20426AD6-8D . . 2 2 2 2 RIVET

MS20470AD4-6D . . 5 5 5 5 RIVET

MS20470AD5-9D . . 2 2 2 2 RIVET

MS20470AD6-10D 63 63 71 71 63 63 RIVET

MS20470AD6-11D 10 10 10 10 10 10 RIVET

MS20470AD6-12D 22 22 29 29 22 22 RIVET

MS20470AD6-14D 4 4 4 4 4 4 RIVET

MS20470AD6-15D . . 4 4 4 4 RIVET

MS20470AD6-16D . . 4 4 4 4 RIVET

MS20470AD6-8D 48 48 58 58 48 48 RIVET

MS20470AD6-9D 2 2 . . 2 2 RIVET

MS20470AD8-10D 58 58 50 50 58 58 RIVET

MS20470AD8-11D . . 4 4 4 4 RIVET

MS20470AD8-12D 33 33 33 33 33 33 RIVET

MS20470AD8-13D . . 28 28 28 28 RIVET

MS20470AD8-14D 42 42 42 42 42 42 RIVET

MS20470AD8-16D . . 4 4 4 4 RIVET

MS20470AD8-17D . . 1 1 1 1 RIVET

MS20470AD8-18D . . 6 6 6 6 RIVET

MS20470AD8-19D . . 1 1 1 1 RIVET

MS20470AD8-7D . . 5 5 5 5 RIVET

MS20470AD8-9D . . 18 18 18 18 RIVET

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number Name Notes -15 -17 -19 -21 -23 -25

MS21042L3 218 218 191 191 273 273 NUT

MS21042L4 565 565 565 565 565 565 NUT

MS21042L5 10 10 84 84 84 84 NUT

NAS1203-4 . . 2 2 2 2 BOLT

NAS1203-8 . . 7 7 7 7 BOLT

NAS1204-12 . . 8 8 8 8 BOLT

NAS1204-13 . . 4 4 4 4 BOLT

NAS1204-14 . . 1 1 1 1 BOLT

NAS1205-15 . . 7 7 7 7 BOLT

NAS1252-10H 228 228 191 191 273 273 WASHER

NAS1252-416H 558 558 558 558 558 558 WASHER

NAS1252-516H 10 10 81 81 91 91 WASHER

NAS1252-616H 10 10 14 14 14 14 WASHER

NAS1704-8 . . 1 1 1 1 BOLT

NAS6205-10 . . 22 22 22 22 BOLT

NAS6205-16 . . 8 8 8 8 BOLT

NAS6205-26 . . 8 8 8 8 BOLT

NAS679A5 . . 17 17 17 17 NUT

PIC239-3-10 . . 4 4 4 4 BOLT

PIC239-3-15 . . 3 3 3 3 BOLT

S4931917-8X10 6 6 . . 6 6 PIN

S4931917-8X11 6 6 . . 6 6 PIN

S4931917-8X13 1 1 . . 1 1 PIN

S4931917-8X16 1 1 . . 1 1 PIN

S4931917-8X9 1 1 . . 1 1 PIN

Kit SA90570026

New Part Number Name Notes -27 -29 -31 -33 -35 -37

3D0006-3 22 22 15 15 22 22 NUT ASSY

3D0006-4 155 155 74 74 216 216 NUT ASSY

3D0006-5 40 40 17 17 57 57 NUT ASSY

3D0097-10X12 4 4 . . 4 4 PIN

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number Name Notes -27 -29 -31 -33 -35 -37

3D0097-10X13 4 4 . . 4 4 PIN

3D0097-10X14 . . 17 17 17 17 PIN

3D0097-10X17 12 12 . . 12 12 PIN

3D0097-10X18 16 16 . . 16 16 PIN

3D0097-10X20 4 4 . . 4 4 PIN

3D0097-6-7 2 2 . . 2 2 PIN

3D0097-8X10 21 21 . . 21 21 PIN

3D0097-8X11 11 11 . . 11 11 PIN

3D0097-8X12 1 1 . . 1 1 PIN

3D0097-8X13 3 3 . . 3 3 PIN

3D0097-8X14 4 4 . . 4 4 PIN

3D0097-8X15 12 12 . . 12 12 PIN

3D0097-8X16 12 12 . . 12 12 PIN

HL325-6-10 4 4 3 3 7 7 PIN

HL325-6-11 2 2 . . 2 2 PIN

HL325-6-12 2 2 5 5 7 7 PIN

HL325-6-13 15 15 . . 15 15 PIN

HL325-6-14 . . 2 2 2 2 PIN

HL325-6-8 . . 1 1 1 1 PIN

HL325-6-9 . . 5 5 5 5 PIN

HL325-8-6 . . 23 23 23 23 PIN

HL325-8-7 . . 2 2 2 2 PIN

HL325-8-8 . . 8 8 8 8 PIN

HLT1001PB-6-6 . . 7 7 7 7 PIN, OVERSIZE

HLT425-6-13 4 4 . . 4 4 PIN

HLT425-8-10 . . 7 7 7 7 PIN

HLT425-8-11 . . 17 17 17 17 PIN

HLT425-8-9 . . 31 31 31 31 PIN

HLT426-10-7 . . 6 6 6 6 PIN

HLT426-10-18 10 10 4 4 4 4 PIN

HLT426-6-10 56 56 35 35 44 44 PIN

HLT426-6-12 24 24 18 18 24 24 PIN

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ALERT ALERT
Kit SA90570026

New Part Number Name Notes -27 -29 -31 -33 -35 -37

HLT426-6-13 4 4 . . 4 4 PIN

HLT426-6-14 2 2 18 18 18 18 PIN

HLT426-6-15 4 4 2 2 6 6 PIN

HLT426-6-16 4 4 4 4 8 8 PIN

HLT426-6-17 . . 2 2 2 2 PIN

HLT426-6-3 . . 3 3 3 3 PIN

HLT426-6-4 9 9 9 9 11 11 PIN

HLT426-6-5 . . 22 22 22 22 PIN

HLT426-6-6 41 41 74 74 74 74 PIN

HLT426-6-7 30 30 22 22 50 50 PIN

HLT426-6-8 9 9 8 8 8 8 PIN

HLT426-8-10 77 77 98 98 98 98 PIN

HLT426-8-11 9 9 10 10 10 10 PIN

HLT426-8-12 105 105 108 108 108 108 PIN

HLT426-8-13 3 3 16 16 19 19 PIN

HLT426-8-14 20 20 14 14 14 14 PIN

HLT426-8-15 . . 31 31 31 31 PIN

HLT426-8-16 12 12 1 1 7 7 PIN

HLT426-8-17 . . 58 58 58 58 PIN

HLT426-8-18 . . 18 18 18 18 PIN

HLT426-8-19 . . 24 24 24 24 PIN

HLT426-8-22 . . 16 16 16 16 PIN

HLT426-8-24 . . 10 10 10 10 PIN

HLT426-8-4 32 32 28 28 32 32 PIN

HLT426-8-5 20 20 22 22 23 23 PIN

HLT426-8-6 28 28 26 26 28 28 PIN

HLT426-8-7 1 1 16 16 16 16 PIN

HLT426-8-8 74 74 83 83 83 83 PIN

HLT426-8-9 2 2 . . 2 2 PIN

HLT427-10-18 . . 9 9 9 9 PIN

HLT427-10-20 . . 12 12 12 12 PIN

HLT427-10-22 . . 35 35 35 35 PIN

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number Name Notes -27 -29 -31 -33 -35 -37

HLT427-10-24 . . 6 6 6 6 PIN

HLT427-10-26 . . 2 2 2 2 PIN

HLT427-6-10 . . 2 2 5 5 PIN

HLT427-6-11 2 2 12 12 12 12 PIN

HLT427-6-12 10 10 10 10 10 10 PIN

HLT427-6-14 . . 6 6 6 6 PIN

HLT427-6-7 2 2 . . 2 2 PIN

HLT427-6-8 . . 2 2 2 2 PIN

HLT427-6-9 . . . . 6 6 PIN

HLT427-8-10 9 9 34 34 43 43 PIN

HLT427-8-11 . . 19 19 19 19 PIN

HLT427-8-12 . . 49 49 49 49 PIN

HLT427-8-13 2 2 . . 2 2 PIN

HLT427-8-14 2 2 22 22 24 24 PIN

HLT427-8-15 4 4 1 1 5 5 PIN

HLT427-8-16 2 2 36 36 36 36 PIN

HLT427-8-17 2 2 56 56 56 56 PIN

HLT427-8-18 20 20 15 15 20 20 PIN

HLT427-8-19 21 21 2 2 21 21 PIN

HLT427-8-20 2 2 4 4 6 6 PIN

HLT427-8-21 2 2 1 1 3 3 PIN

HLT427-8-22 . . 2 2 2 2 PIN

HLT427-8-23 2 2 2 2 2 2 PIN

HLT427-8-24 . . 13 13 13 13 PIN

HLT427-8-25 2 2 . . 2 2 PIN

HLT427-8-26 2 2 . . 2 2 PIN

HLT427-8-27 11 11 . . 11 11 PIN

HLT427-8-28 . . 10 10 10 10 PIN

HLT427-8-6 13 13 13 13 13 13 PIN

HLT427-8-8 1 1 4 4 4 4 PIN

HLT427-8-9 5 5 5 5 5 5 PIN

HLT437-6-6 5 5 . . 5 5 PIN

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number Name Notes -27 -29 -31 -33 -35 -37

J060165-10 . . . 1 . 1 ANGLE

J060165-13 . . 1 . 1 . FILLER

J060165-14 . . . 1 . 1 FILLER

J060165-15 . . 1 1 1 1 FILLER

J060165-17 . . 1 1 1 1 FILLER

J060165-19 . . 1 1 1 1 FILLER

J060165-21 1 1 1 1 . . TEE

J060165-23 . . 1 1 1 1 STIFFENER

J060165-27 . . 1 1 1 1 PLATE

J060165-31 1 . . . 1 . ANGLE

J060165-32 . 1 . . . 1 ANGLE

J060165-33 1 . . . 1 . FILLER

J060165-34 . 1 . . . 1 FILLER

J060165-35 1 . . . 1 . FILLER

J060165-36 . 1 . . . 1 FILLER

J060165-37 1 . . . 1 . ANGLE

J060165-38 . 1 . . . 1 ANGLE

J060165-39 1 . . . 1 . DOUBLER

J060165-40 . 1 . . . 1 DOUBLER

J060165-41 1 1 . . 1 1 FILLER

J060165-43 1 1 . . 1 1 FILLER

J060165-45 1 1 . . 1 1 FILLER

J060165-47 1 1 . . 1 1 FILLER

J060165-49 1 1 . . 1 1 FILLER

J060165-5 . . 1 . 1 . ANGLE

J060165-51 . . . . 1 1 TEE

J060165-53 1 1 1 1 1 1 STIFFENER

J060165-55 1 1 1 1 1 1 SPLICE

J060165-57 . . 1 1 1 1 SPACER

J060165-59 . . 1 1 1 1 SPACER

J060165-6 . . . 1 . 1 ANGLE

J060165-61 . . 1 . 1 . DOUBLER

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Kit SA90570026

New Part Number Name Notes -27 -29 -31 -33 -35 -37

J060165-62 . . . 1 . 1 DOUBLER

J060165-63 . . 1 . 1 . SPAR CAP

J060165-64 . . . 1 . 1 SPAR CAP

J060165-65 1 1 1 1 1 1 SPLICE

J060165-67 . . 7 7 7 7 BUSHING

J060165-69 1 . . . 1 . SPAR CAP

J060165-7 . . 1 . 1 . FILLER

J060165-70 . 1 . . . 1 SPAR CAP

J060165-8 . . . 1 . 1 FILLER

J060165-9 . . 1 . 1 . ANGLE

MS20426AD4-6D . . 5 5 5 5 RIVET

MS20426AD6-12D 3 3 . . 3 3 RIVET

MS20426AD6-14D 4 4 18 18 18 18 RIVET

MS20426AD6-8D . . 2 2 2 2 RIVET

MS20470AD5-9D . . 2 2 2 2 RIVET

MS20470AD6-10D 63 63 71 71 63 63 RIVET

MS20470AD6-11D 10 10 10 10 10 10 RIVET

MS20470AD6-12D 22 22 29 29 22 22 RIVET

MS20470AD6-14D 4 4 4 4 4 4 RIVET

MS20470AD6-15D . . 4 4 4 4 RIVET

MS20470AD6-16D . . 4 4 4 4 RIVET

MS20470AD6-8D 48 48 58 58 48 48 RIVET

MS20470AD6-9D 2 2 . . 2 2 RIVET

MS20470AD8-10D 58 58 50 50 58 58 RIVET

MS20470AD8-11D . . 4 4 4 4 RIVET

MS20470AD8-12D 33 33 33 33 33 33 RIVET

MS20470AD8-13D . . 28 28 28 28 RIVET

MS20470AD8-14D 36 36 42 42 42 42 RIVET

MS20470AD8-16D . . 4 4 4 4 RIVET

MS20470AD8-17D . . 1 1 1 1 RIVET

MS20470AD8-18D . . 6 6 6 6 RIVET

MS20470AD8-19D . . 1 1 1 1 RIVET

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ALERT ALERT
Kit SA90570026

New Part Number Name Notes -27 -29 -31 -33 -35 -37

MS20470AD8-7D . . 5 5 5 5 RIVET

MS20470AD8-9D . . 18 18 18 18 RIVET

MS21042L3 218 218 191 191 273 273 NUT

MS21042L4 549 549 565 565 565 565 NUT

MS21042L5 10 10 84 84 84 84 NUT

NAS1203-4 . . 2 2 2 2 BOLT

NAS1203-8 . . 7 7 7 7 BOLT

NAS1204-12 . . 8 8 8 8 BOLT

NAS1204-13 . . 4 4 4 4 BOLT

NAS1204-14 . . 1 1 1 1 BOLT

NAS1205-15 . . 7 7 7 7 BOLT

NAS1252-10H 228 228 191 191 273 273 WASHER

NAS1252-416H 542 542 558 558 558 558 WASHER

NAS1252-516H 10 10 81 81 91 91 WASHER

NAS1252-616H 12 12 14 14 14 14 WASHER

NAS1704-8 . . 1 1 1 1 BOLT

NAS6205-10 . . 22 22 22 22 BOLT

NAS6205-16 . . 8 8 8 8 BOLT

NAS6205-26 . . 8 8 8 8 BOLT

NAS679A5 . . 17 17 17 17 NUT

PIC239-3-10 . . 4 4 4 4 BOLT

PIC239-3-15 . . 3 3 3 3 BOLT

S4931917-8X10 6 6 . . 6 6 PIN

S4931917-8X11 6 6 . . 6 6 PIN

S4931917-8X13 1 1 . . 1 1 PIN

S4931917-8X16 1 1 . . 1 1 PIN

S4931917-8X9 1 1 . . 1 1 PIN

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BOEING SERVICE BULLETIN MD90-57A026

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

Part Number/Specification QTY Supplier CAGE

As Re- PRC - DeSoto International, Incorporated 92108

quired

PR-1422 B-2 Sealant (DMS 2082)

or P.O. Box 1800

Equivalent Sylmar, California 91342

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The Quantity (QTY) is the

number of parts changed on each airplane.

NOTE: Not applicable to all repair/modification configurations.

Existing Part QTY Name New Part Number Notes

Number

9919474-1 1 ANGLE J060271-59 (a) (b) (c)

or

9919474-501

or

9919474-503

9919474-2 1 ANGLE J060271-60

or

9919474-502

or

9919474-504

9919472-23 1 CAP J060271-61

9919472-24 1 CAP J060271-62

(a) Make the change in accordance with in this service bulletin.

(b) There is no equivalent Boeing part number for the changed part. Identify on the part that

the change done in accordance with this service bulletin was made.

(c) This part is not used in production.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
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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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

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

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

CAN OCCUR.

CAUTION: 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.

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

TO THE AIRPLANE OR EQUIPMENT.

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

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

bulletin can be changed.

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

definition of the acronyms.

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

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

MD-90 SRM, Chapter 51, Volume 2.

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

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

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

SRM Chapter 51 may be used.

6. A 1/8-inch thick stack of the same type washers called for in this service bulletin is

the maximum thickness which may be used under fastener head or nut to counteract

accumulation of tolerances.

EXCEPTION: When the available fastener length increments are greater than

1/16-inch, a 3/16-inch thick stack of the same type washers may be used.

7. 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 in MD-90 SRM, Chapter 51.

— Torque limits to tighten nuts and bolts are in MD-90 SRM,Chapter 51.

8. Use of equivalent parts as given in the AEPL, Drawing 7595091, is permitted.

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BOEING SERVICE BULLETIN MD90-57A026

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

Service Rework Drawings.

10. Refer to the following MD-90 SRM Chapters as and accepted procedure for the

applicable operation:

MD90 SRM 51-10-03, Volume 2 - Corrosion/Erosion Control And Prevention.

MD90 SRM 51-10-05, Volume 2 - Drilling, Countersinking, And Dimpling.

MD90 SRM 51-10-09, Volume 2 - Cold-Working of Holes And Countersinks.

MD90 SRM 51-20-00, Volume 2 - Repair Sealing.

MD90 SRM 51-30-01, Volume 2 - Bolts, Screws And Washers.

MD90 SRM 51-30-02, Volume 2 - Rivets.

MD90 SRM 51-30-03, Volume 2 - Lockbolts.

MD90 SRM 51-30-05, Volume 2 - Hi-Lok Fasteners

MD90 SRM 51-31-02, Volume 2 - Conical Spacers.

MD90 SRM 51-40-00, Volume 2 - Substitution and Interchangeability

11. Follow applicable safety instructions and precautions in accordance with NDTSPM

01-00-01 and NDTSPM 06-00-01.

12. 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.

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

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

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

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

must be used.

B. WORK INSTRUCTIONS

WARNING: BEFORE MOVING FLAP/SLAT HANDLE, MAKE CERTAIN THAT AREAS AROUND

FLAPS AND SLATS ARE CLEAR OF PERSONNEL AND EQUIPMENT.

1. Extend wing flaps to full down position. Refer to MD-90 AMM 27-00-00 as an accepted procedure.

WARNING: BEFORE OPERATING FLAPS, MAKE CERTAIN THAT AREAS AROUND FLAPS ARE

CLEAR OF PERSONNEL AND EQUIPMENT.

2. Depressurize left and right hydraulic systems. Refer to MD-90 AMM 29-00-00 as an accepted

procedure.

3. Open main landing gear doors and install door keepers. Refer to MD-90 AMM 32-10-00 as an

accepted procedure.

4. Open inboard and center Bent Up Trailing Edge (BUTE) doors. Refer to MD-90 AMM 57-20-03

as an accepted procedure.

5. At Operator's option for ease of access to the inspection area, remove and retain the fixed flap

fairing by removing and retaining its attaching parts.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
6. Clean the area at top of flap hinge fitting and around and under flap hinge fitting and visually inspect

for evidence of fuel leakage or if fuel tanks have been drained, visually inspect for crack.

7. Fabricate DAC GSET AL.01 reference standard. Refer to NDTSPM Part 06, 06-20-01 as an

accepted procedure.

8. Do Eddy Current, High Frequency (ETHF) inspection on the aft side of the left and right wing rear

spar lower caps at station Xrs=164.000 for crack in accordance with Figure 1 and Service Rework

Drawing J060271, General Note 29, and based on findings do as follows:

CONDITION 1: NO CRACK

a. Close inboard and center bent up trailing edge (BUTE) doors. Refer to MD-90 AMM 57-20-03

as an accepted procedure.

b. If removed, install kept fixed flap fairing.

c. Remove door keepers and close main landing gear doors. Refer to MD-90 AMM 32-10-00 as

an accepted procedure.

d. Pressurize left and right hydraulic systems. Refer to MD-90 AMM 29-00-00 as an accepted

procedure.

WARNING: BEFORE OPERATING FLAPS, MAKE CERTAIN THAT AREAS AROUND FLAPS

ARE CLEAR OF PERSONNEL AND EQUIPMENT.

e. Retract wing flaps. Refer to MD-90 AMM 27-50-00 as an accepted procedure.

f. Put the airplane back to a serviceable condition.

g. Do repeat ETHF inspection on the aft side of the left and right wing rear spar lower caps at

station Xrs=164.000 in accordance with Paragraph 1.E., Compliance.

CONDITION 2: CRACK 2.0 INCHES OR SHORTER AND NOT IN THE REAR SPAR LOWER

CAP FORWARD HORIZONTAL LEG RADIUS

a. Disconnect aileron control, aileron trim, aileron bus, and outboard spoiler mechanical cables

at nearest turnbuckles to station Xrs=164.000, left and right sides. Refer to MD-90 AMM

27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

NOTE: Only cables which run through the lightening hole of flap hinge fitting at station

Xrs=164.000 need to be disconnected.

b. Defuel and purge left and right fuel tanks if/as required. Refer to MD-90 AMM 12-11-01, MD-90

AMM 28-00-00 and MD-90 AMM 28-11-00 as accepted procedures.

c. Remove and retain door number 520DT on the left wing main tank and/or door number 620CT

on the right wing main tank and attaching parts as required. Refer to MD-90 AMM 06-35-00

and MD-90 AMM 06-36-00.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
d. Prepare left and/or right wing fuel tanks, as required, for entry and gain access to reach

attachments of flap hinge fitting at station Xrs=164.000. Refer to MD-90 AMM 28-00-00 as

an accepted procedure.

e. Remove and retain the inboard hinge fitting for the left and/or right wing outboard flap and

attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01

as an accepted procedure.

f. Do Eddy Current High Frequency (ETHF) inspection on the aft side of the left and/or right

wing rear spar upper cap at station Xrs=164.000 for cracks in accordance with Figure 1 and

Service Rework Drawing J060271, General Note 29, and based on inspection results, do as

follows:

Condition 2a: No Crack in Rear Spar Upper Cap

(1) Do Option 1 or Option 2:

Option 1

(a) Do doubler repair to rear spar lower cap in accordance with Service Rework Drawing

J060271 using the applicable service kit as follows:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060271-517 - SA90570026-7

Lower - J060271-518 SA90570026-9

(b) Do repeat ETHF inspections of rear spar lower cap repair in accordance with Service

Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E., Compliance.

Option 2

(a) Do splice repair to rear spar lower cap in accordance with Service Rework Drawing

J060165 using the applicable service kit as follows:

Group 1:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-519 - SA90570026-19

Lower - J060165-520 SA90570026-21

Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-525 - SA90570026-31

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower - J060165-526 SA90570026-33

(b) Do Eddy Current Low Frequency (ETLF) and Ultrasonic (UT) inspections of rear spar

lower cap splice repair in accordance with Service NDI Drawing SN90570001 on

forward side and SN90570006 on aft side at intervals defined in Paragraph 1.E.,

Compliance.

(2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching

parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as

an accepted procedure.

(3) Install door number 520DT on the left wing main tank and door number 620ET on the

right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM

06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure.

NOTE: In addition to monitoring the fuel tank access doors for leaks during the

installation, monitor all areas of the rear spar changed during the accomplishment

of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed

areas.

(4) Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler

mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides.

Refer to MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

(5) Go to work step 3.B.9.

Condition 2b: Crack 2.0 Inches or Shorter in Rear Spar Upper Cap

(1) Do Option 1 or Option 2.

NOTE: Operators can do Option 1 or Option 2 or any combination of Options 1 and 2.

Option 1

(a) Do doubler repair to rear spar upper and lower caps in accordance with Service

Rework Drawing J060271 using the applicable service kit as follows:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060271-519 - SA90570026-11

Upper and Lower - J060271-520 SA90570026-13

(b) Do repeat ETHF inspections of rear spar lower cap repair in accordance with Service

Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E., Compliance.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Option 2

(a) Do splice repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060165 using the applicable service kit as follows:

Group 1:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA90570026-23

Upper and Lower - J060165-522 SA90570026-25

Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA90570026-35

Upper and Lower - J060165-528 SA90570026-37

(b) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with

Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at

intervals defined in Paragraph 1.E., Compliance.

(2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching

parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as

an accepted procedure.

(3) Install door number 520DT on the left wing main tank and door number 620ET on the

right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM

06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure.

NOTE: In addition to monitoring the fuel tank access doors for leaks during the

installation, monitor all areas of the rear spar changed during the accomplishment

of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed

areas.

(4) Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler

mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides.

Refer to MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

(5) Go to work step 3.B.9.

Condition 2c: Crack Longer than 2.0 Inches in Rear Spar Upper Cap

(1) Do Option 1 or Option 2

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Option 1

(a) Do doubler repair to rear spar lower cap in accordance with Service Rework Drawing

J060271 and splice repair to rear spar upper cap in accordance with Service Rework

Drawing J060165. using the applicable service kit as follows:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060271-517 - SA90570026-7

Lower - J060271-518 SA90570026-9

Upper J060165-517 - SA90570026-15

Upper - J060165-518 SA90570026-17

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060271-517 - SA90570026-7

Lower - J060271-518 SA90570026-9

Upper J060165-523 - SA90570026-27

Upper - J060165-524 SA90570026-29

(b) Do repeat ETHF inspections of rear spar lower cap doubler repair in accordance

with Service Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E.,

Compliance.

Option 2

(a) Do splice repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060165 using the applicable service kit as follows:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA90570026-23

Upper and Lower - J060165-522 SA90570026-25

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA90570026-33

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower - J060165-528 SA90570026-35

(b) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with

Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at

intervals defined in Paragraph 1.E., Compliance.

(2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching

parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as

an accepted procedure.

(3) Install door number 520DT on the left wing main tank and door number 620ET on the

right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM

06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure.

NOTE: In addition to monitoring the fuel tank access doors for leaks during the

installation, monitor all areas of the rear spar changed during the accomplishment

of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed

areas.

(4) Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler

mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides.

Refer to MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

(5) Go to work step 3.B.9.

CONDITION 3: CRACK LONGER THAN 2.0 INCHES OR CRACK IN THE REAR SPAR LOWER

CAP FORWARD HORIZONTAL LEG RADIUS

a. Disconnect aileron control, aileron trim, aileron bus, and outboard spoiler mechanical cables

at nearest turnbuckles to station Xrs=164.000, left and right sides. Refer to MD-90 AMM

27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

NOTE: Only cables which run through the lightening hole of flap hinge fitting at station

Xrs=164.000 need to be disconnected.

b. Defuel and purge left and right fuel tanks if/as required. Refer to MD-90 AMM 12-11-01, MD-90

AMM 28-00-00 and MD-90 AMM 28-11-00 as accepted procedures.

c. Remove and retain door number 520DT on the left wing main tank and/or door number 620CT

on the right wing main tank and attaching parts as required. Refer to MD-90 AMM 06-35-00

and MD-90 AMM 06-36-00.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
d. Prepare fuel tanks for entry and gain access to fuel tanks as required to reach attachments

in vicinity of wing flap inboard hinge fitting.

e. Remove and retain the inboard hinge fitting for the left and/or right wing outboard flap and

attaching parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01

as an accepted procedure.

f. Do Eddy Current High Frequency (ETHF) inspection on the aft side of the left and/or right

wing rear spar upper cap at station Xrs=164.000 for cracks in accordance with Figure 1 and

Service Rework Drawing J060271, General Note 29, and based on inspection results, do as

follows:

Condition 3a: No Crack in Rear Spar Upper Cap

(1) Do splice repair to rear spar lower cap in accordance with Service Rework Drawing

J060165 using the applicable service kit as follows:

Group 1:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-519 - SA90570026-19

Lower - J060165-520 SA90570026-21

Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Lower J060165-525 - SA90570026-31

Lower - J060165-526 SA90570026-33

(2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with

Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at

intervals defined in Paragraph 1.E., Compliance.

(3) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching

parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as

an accepted procedure.

(4) Install door number 520DT on the left wing main tank and door number 620ET on the

right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM

06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
NOTE: In addition to monitoring the fuel tank access doors for leaks during the

installation, monitor all areas of the rear spar changed during the accomplishment

of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed

areas.

(5) Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler

mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides.

Refer to MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

(6) Go to work step 3.B.9.

Condition 3b: Crack 2.0 Inches or Shorter in Rear Spar Upper Cap

(1) Do Option 1 or Option 2

Option 1

(a) Do doubler repair to rear spar upper cap in accordance with Service Rework Drawing

J060271 and splice repair to rear spar lower cap in accordance with Service Rework

Drawing J060165. using the applicable service kit as follows:

Group 1:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper J060271-511 - SA90570026-3

Upper - J060271-512 SA90570026-5

Lower J060165-519 - SA90570026-19

Lower - J060165-520 SA90570026-21

Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper J060271-511 - SA90570026-3

Upper - J060271-512 SA90570026-5

Lower J060165-525 - SA90570026-31

Lower - J060165-526 SA90570026-33

(b) Do ETHF inspections of rear spar upper cap doubler repair in accordance with Service

Sketch 3668XXX Revision C at intervals defined in Paragraph 1.E., Compliance.

(c) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with

Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at

intervals defined in Paragraph 1.E., Compliance.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Option 2

(a) Do splice repair to rear spar upper and lower cap in accordance with Service Rework

Drawing J060165, using the applicable service kit as follows:

Group 1:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA90570026-23

Upper and Lower - J060165-522 SA90570026-25

Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA90570026-35

Upper and Lower - J060165-528 SA90570026-37

(b) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with

Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at

intervals defined in Paragraph 1.E., Compliance.

(2) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching

parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as

an accepted procedure.

(3) Install door number 520DT on the left wing main tank and door number 620ET on the

right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM

06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure.

NOTE: In addition to monitoring the fuel tank access doors for leaks during the

installation, monitor all areas of the rear spar changed during the accomplishment

of this service bulletin for fuel leaks. No fuel leaks are allowed in the changed

areas.

(4) Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler

mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides.

Refer to MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

(5) Go to work step 3.B.9.

Condition 3c: Crack Longer than 2.0 Inches in Rear Spar Upper Cap

(1) Do splice repair to rear spar upper and lower caps in accordance with Service Rework

Drawing J060165, using the applicable service kit as follows:

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
Group 1:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-521 - SA90570026-23

Upper and Lower - J060165-522 SA90570026-25

Group 2:

Rear Spar Cap Repair Configuration Service Kit

Left Wing Right Wing

Upper and Lower J060165-527 - SA90570026-35

Upper and Lower - J060165-528 SA90570026-37

(2) Do ETLF and UT inspections of rear spar lower cap splice repair in accordance with

Service NDI Drawing SN90570001 on forward side and SN90570006 on aft side at

intervals defined in Paragraph 1.E., Compliance.

(3) Install retained inboard hinge fitting for the left and/or right wing outboard flap and attaching

parts (including any shims) at station Xrs=164.000. Refer to MD-90 AMM 57-40-01 as

an accepted procedure.

(4) Install door number 520DT on the left wing main tank and door number 620ET on the

right wing main tank and attaching parts. Refer to MD-90 AMM 06-35-00, MD-90 AMM

06-36-00 for location and MD-90 AMM 28-00-00 as an accepted procedure.

NOTE: In addition to monitoring the fuel tank access doors for leaks during the

installation, monitor all areas of the rear spar changed during the accomplishment

of this service bulletin for fuel leaks. No fuel leaks are allowed in the repaired

areas.

(5) Install previously removed aileron control, aileron trim, aileron bus, and outboard spoiler

mechanical cables at nearest turnbuckles to station Xrs=164.000, left and right sides.

Refer to MD-90 AMM 27-10-00 and MD-90 AMM 27-60-00 as accepted procedures.

(6) Go to work step 3.B.9.

9. Close inboard and center Bent Up Trailing Edge (BUTE) doors. Refer to MD-90 AMM 57-20-03

as an accepted procedure.

10. If removed, install kept fixed flap fairing(s) using retained attaching parts.

11.

12. Remove door keepers and close main landing gear doors. Refer to MD-90 AMM 32-10-00 as an

accepted procedure.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
13. Pressurize left and right hydraulic systems. Refer to MD-90 AMM 29-00-00 as an accepted

procedure.

14. Retract wing flaps to full up position. Refer to MD-90 AMM 27-50-00 as an accepted procedure.

15. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT
FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH

FREQUENCY INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN MD90-57A026

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 each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Inspect (Scan 1) Eddy Lower Rear Spar Cap 5911301-XXX 1 (a) (b)

Current Testing High

Frequency (ETHF)

1

Inspect (Scan 2) Eddy Upper Rear Spar Cap 5911300-XXX 1 (a) (b)

Current Testing High

Frequency (ETHF)

2

Note: Inspection not required when

Lower Rear

Spar Cap has

no crack.

(a) Use calibration scan method "R" and calibrate the N2 notch using DAC GSET AL.01 in accordance

with NDTSPM 06-10-01.001 , Procedure 1. Scan wing rear spar upper and lower caps with method

45.

(b) The -XXX represents the different dash numbered spar caps that may exist on the airplane.

FIGURE 1: WING REAR SPAR LOWER CAP - LEFT AND RIGHT - EDDY CURRENT TESTING HIGH

FREQUENCY INSPECTION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN MD90-57A026

ALERT ALERT