Service Bulletin

Commercial Airplane 727 Group Service Bulletin

Number: 727-57-0112 Revision Transmittal Sheet Date: September 2, 1970 Revision 5: July 31, 1997 ATA System: 5712

SUBJECT: WINGS - RIB UPPER CHORD AT BL 70.5 - INSPECTION, MODIFICATION, AND REPAIR

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed by Revision 4 of this service bulletin.

More work is necessary on Group 1 airplanes changed by Revisions 2 or 3, Part V of the Accomplishment Instructions of this service bulletin. On Group 1 Airplanes with the Major Repair/Preventive Modification installed, it is necessary to make an inspection at BL 70.5 for a repair strap. If a strap is not installed, it is necessary to make an inspection of the frame for cracks.

SUMMARY

This revision is sent to tell operators that new kits are available for Group 1 and 2 Airplanes. The drawings used to install the kits are sent with this revision (the drawings have been revised since the release of Notice of Status Change 3). The format used to show the removal of parts and installation of the kits has changed. Also repairs, that operators have requested, are included, and the compliance information has been clarified.

This revision is sent to tell the 727 airplane operators that this service bulletin has been identified by the 727 Structures Working Group (SWG), and the structural change and inspection given in this service bulletin are recommended to be included on applicable 727 airplanes. The change and inspection given in this service bulletin must be included at the times given in the Description and Accomplishment Instructions.

As a result of the Aging Fleet Conference held by the FAA, the 727 SWG was made and included 727 airline operators from a large part of the high time 727 fleet, persons from the Boeing Company, and monitors from the FAA. The SWG examined the structural changes and inspections given in applicable Boeing service bulletins. A selection of these service bulletins was made that contain structural changes and inspections that are important to the continued structural airworthiness of 727 airplanes. The structural changes given in these service bulletins are recommended to be included, and the inspections are recommended to be a part of the regularly scheduled maintenance on applicable 727 airplanes.

The data given in Notice of Status Change 727-57-0112 NSC 1, 2 and 3 are included in this revision.

Paragraph I.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph I.A., Effectivity, to show the location of important changes. Pages with a revision number and date, but no vertical lines, have no important changes.

REVISION HISTORY

Initial Release: September 2, 1970 Revision 1: April 23, 1976 Revision 2: May 19,1988 Revision 3: December 21, 1989 Revision 4: October 29, 1992 Revision 5: July 31, 1997

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

Commercial Airplane 727 Group Service Bulletin

Number: 727-57-0112 Summary Date: September 2, 1970 Revision 5: July 31, 1997 ATA System: 5712

SUBJECT: WINGS - RIB UPPER CHORD AT BL 70.5 - INSPECTION, MODIFICATION, AND REPAIR

BACKGROUND If no cracks are found, increase the hole diameter, cold work the hole, and install a new fastener in six The Structures Working Group (SWG) has places. Continue the inspection at regularly examined the structural change and inspection in scheduled times as given in the Accomplishment this service bulletin, and recommends that the Instructions, Part II.A.2, or B.1, Inspection. The change and inspection be included on 727 approved time between one inspection and the airplanes. subsequent inspection must not be more than 14,000 flights. To stop the inspection given in this During a 727 primary fatigue test at Boeing, two service bulletin, do the preventive modification or cracks were found in the upper vertical flange of the large repair. wing-to-body rib upper chord at Body Station 760. One crack in the rib upper chord was between the If cracks are found, make a change to the rib upper two aft fastener holes of the frame at Body Station chord as given in this service bulletin. 760.95. The other crack in the rib upper chord was immediately aft of the lower fastener hole in the EFFECTIVITY frame. All 727 airplanes, divided into 2 groups. To increase the fatigue life of the rib chord and to reduce the risk of repair and maintenance not MANPOWER scheduled, make the change given in this service bulletin. See Service Bulletin

ACTION (PRR 24791-R and PRR 24803-R) MATERIAL INFORMATION

As recommended by the 727 SWG, make the Boeing supplied kits and Operator supplied Parts. Preventive Modification or Large Repair structural Refer to Paragraph I.G., Material - Price and change given in the Accomplishment Instructions at Availability. or before the airplane collects a total of 60,000 flights, and make the inspection given in the Accomplishment Instructions, Part II.A.1, Inspection, at or before the airplane collects a total of 14,000 flights, or within 3,000 flights, whichever occurs later.

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207 Summary Page 1 of 2 BOEING SERVICE BULLETIN 727-57-0112

STA 970

STA 870

STA 760.95

STA 660

INSPECT 6 FASTENER HOLES IN WING−TO−BODY RIB UPPER CHORD INSTALL PREVENTIVE MODIFICATION OR REPAIR R44683

Sep 2/70 REV 5: Jul 31/97 Summary Page 2 of 2 Commercial Airplane 727 Group Service Bulletin

Number: 727-57-0112 Date: September 2, 1970 Revision 5: July 31, 1997 ATA System: 5712

SUBJECT: WINGS - RIB UPPER CHORD AT BL 70.5 - INSPECTION, MODIFICATION, AND REPAIR

I. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-9825, Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

A.J. WALTER AVIATION LTD (AJW) 1 E0210 E3343

ACES (ACE) 1 E3781 E3783 QA633 QB619 QD031 QD504 2 QD904

ADC AIRLINES (ADN) 1 QA517 QA521

AECA AIRLINES (AED) 1 E0341

AERO CONTROLS, INC (AEO) 1 QA415 QA418 QA422

AERO COSTA RICA (AOR) 1 E0305

AERO PERU (PER) 1 E3286-E3288 QA040 QD607 2 QD685

AERO REPUBLICA (REU) 1 E3146 E3149

AERO UNION (AUC) 1 E0328

AEROCAR AVIATION CORPORATION (AAH) 1 QA872 QA874 QA917

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AEROEJECUTIVO (AEJ) 1 E0404 E0423 QA225 QA608 QA611 QA628 QA632 QD001 QD004 QD007-QD012

AEROLINEAS ARGENTINAS (ARG) 1 E3222 QD603

AEROLINEAS CARGUERAS S.A. (AEROCAR) (CRQ) 1 E3071 E3575

AEROLINEAS INTERNACIONALES (MXC) 1 E0325 E0334 QA129

AEROMEXPRESS (MEX) 2 QD972

AERON EQUITIES CORP (AAV) 1 E3148 QA618 QA622

AEROSUCRE S.A. (SUS) 1 E0346 E3221 E3402 QA021

AEROSUR S.A. (REO) 1 E0312 E0332 E0345

AGASSI ENTERPRISES (AGA) 1 E3420

AIMS LTD (MES) 1 E0212

AIR ALFA (ALV) 1 QB102

AIR ALGERIE (ALG) 1 QA574-QA576 QB451-QB458

AIR ATLANTIC NIGERIA LTD (NGE) 1 E0041

AIR COLOMBIA (CLM) 1 E3519

AIR DABIA (DBI) 1 QA701

AIR FRANCE (AFA) 1 QA562 2 QD764-QD765

AIR GABON S.A. (GBN) 2 QD763

AIR JAMAICA (JAM) 2 QD282-QD283

AIR NACOIA LDA (NAO) 1 E5114 QA871

Sep 2/70 727-57-0112 REV 5: Jul 31/97 2 BOEING SERVICE BULLETIN 727-57-0112

AIR SLOVAKIA (SLO) 1 QB103-QB104

AIR TRANSPORT OFFICE (TOZ) 1 QA501

AIR 4000 INC (FTO) 1 QA333

AIRCRAFT MANAGEMENT COMPANY LTD (AMI) 1 E3509

AL-ANWA EST. (SVE) 2 QD407

AL-ATHEER EST (ALN) 1 E3410

ALLCANADA EXPRESS LTD. (EXM) 1 E3652 2 QD662-QD663

ALLEGRO AIR (AEG) 1 QA675 QA902 QA906

AMERICAN AIRLINES, INC. (AAL) 1 QA114 QA119-QA120 QA123-QA124 QA136 QA142-QA149 QA158-QA199 QA854 QA856-QA869 QB801-QB810

AMERICAN INTERNATIONAL AIRWAYS, INC. (CKF) 1 E0336 E5050 QA107-QA109 QA111-QA113 QA117 QA132 QA135 QA139 QA155 QA157 QA705

AMERICAN TRANS AIR (AAT) 1 QA374-QA376 QA378 QA928 QB066-QB068 QB618 QB620-QB623 QB625-QB628 QD702 QD791 2 QD683 QD951-QD952

AMERICANA DE AVIATION S. A. (AMY) 1 E3751 QB305

AMERIJET INTERNATIONAL, INC. (AMJ) 1 E0344 E3028 E3145 E5161 E5403 QA336 QA727 QA875 QA886 2 QD206 QD211-QD212 QD781

AMWAY CORPORATION (AMA) 1 E3681

ANGOLA AIR CHARTER (AOH) 1 E0333

ANSETT AUSTRALIA (ANS) 1 QD034 QD040 2 QD043-QD046

Sep 2/70 727-57-0112 REV 5: Jul 31/97 3 BOEING SERVICE BULLETIN 727-57-0112

ARIANA AFGAN AIRLINES CO., LTD (AFG) 1 E5410 E5424 2 QD767-QD768

ARRIVA AIR INTERNATIONAL (ARV) 1 QA002

ASIAN EXPRESS AIRLINES (EXZ) 2 QL007

ATASCO USA, INC. (ATJ) 1 E0032 QB301-QB304

AVENSA (AVN) 1 E0034 E0036 E3072 E3244 E3246 E3248 E3511 E3654 QA036 QA039 QA042-QA043 QA853 QD121 QD124-QD126 QD444

AVIANCA (AVI) 1 QA572 QD553-QD554

AVIATION CAPITAL CORPORATION (ACD) 1 E0039

AVIATION LEASING GROUP (ALW) 1 E0317

AVIATION PROFESSIONAL CORP (PRP) 1 QA630-QA631

AVIOGENEX AIR TRANSPORT (AVG) 1 QD191-QD192 QD518

AZERBAIJAN AIRLINES (BAKU) (AHY) 1 QA211-QA212

BAHRIAN AMRI FLIGHT (BHR) 1 QD451

BAKRIE AVIATION INC. (FES) 1 E3346

BELGIAN AIR FORCE (BLG) 1 E5351-E5352

BIN MAHFOOZ AVIATION (BMV) 1 QA566-QA567

BLENHEIM AVIATION (BLM) 1 QD305

BRADLEY AIR SERVICES/FIRST AIR (BRS) 1 E3065 E5112 E5141 E5482 QA614 2 QD207 QD210

C-S AVIATION SERVICES INC. (CSV) 1 E0302-E0303 E0307 E0315 E0320 E0326

Sep 2/70 727-57-0112 REV 5: Jul 31/97 4 BOEING SERVICE BULLETIN 727-57-0112

CAPITAL CARGO AIRLINES (CCA) 1 QA371 QD087 QD701

CAPRICORN FLIGHTS (CPR) 1 E3075 E3520

CARNIVAL AIR (CVL) 1 QA636 QA641 QD304 2 QD822-QD823 QD953

CHINESE AIR FORCE (CAF) 1 E3506 E3512 E5409 E5435

CIS AIR HOLDINGS, LTD. (CIS) 1 QA718 QA721-QA722

CLAY LACY AVIATION, INC. (CYA) 1 E3035 E3077

COMPAGNIE AERIENNE BELAIR ILE DE FRANCE (SMH) 1 QA573

CONNOR AIRCRAFT (COD) 1 QA366

CONSTELLATION INTERNATIONAL AIRLINES (COT) 2 QD782

CONTINENTAL AIRLINES, INC. (CAL) 1 QA020 QA059-QA061 QA063-QA065 QA067 QA069-QA072 QA331 QA339-QA342 QA345-QA349 QA873 QA882 QA885 QA890-QA896 QB034 QB036 QB039-QB040 QB901-QB904 QD501-QD502 QD505 QD507-QD510 2 QD905 QD909 QD931-QD932

CONTINENTAL AVIATION SERVICES INC. (CVS) 1 E3407

COOK AIRCRAFT LEASING (CKL) 1 E3504-E3505

CORP AIR INC. (EKO) 1 E5418

CORSAIR (CRA) 1 E3011 E3508

CUSTOM AIR SERVICES INC. (CUS) 1 E3205 QA343 QA661

CYPRUS TURKISH AIRWAYS (KHT) 1 QD321-QD322 QD324 2 QD766

D. J. AEROSPACE (DJA) 1 E0351

Sep 2/70 727-57-0112 REV 5: Jul 31/97 5 BOEING SERVICE BULLETIN 727-57-0112

DALLAH AVCO (AVO) 1 E3038

DALLAS AEROSPACE, INC. (DAA) 1 QA358

DAVIS OIL CO. (DOC) 1 E3206

DELTA AIR LINES, INC. (DAL) 1 QA073-QA079 QA081-QA092 QA096-QA099 QA647 QA649 QA663-QA665 QA907 QA909-QA916 QA919-QA921 QA929-QA933 QA939-QA946 QA949 QB501-QB558 QB560-QB575

DHL CORPORATION/WORLDWIDE COURIER EXP. (DHL) 1 E0030 E0124 E0342 E3622 E5046-E5047 E5273-E5274 E5281 E5382 E5402 QA552-QA553 QA555-QA556 QA563-QA564 QA646 2 QD991-QD992

DHL LATIN AMERICA GROUP AIRLINES (DHA) 1 E3073 QB038

DIGEX AERO CARGO (DGX) 1 E5481

DOMINICANA AIRLINES (DOM) 1 E3755 QD351

EAS EUROPE AIRLINES (EUR) 1 QA855

EASTERN AIR LINES, INC. (EAL) 1 QA643

ECUATORIANA AIRLINES (ECU) 1 QD445 QD604

EMERY WORLDWIDE AIRLINES (EAF) 1 E0313-E0314

EUROPEAN AIR TRANSPORT (EPT) 1 E3074 E3076 E3701-E3703 QA115 QA137 QA150-QA152 QA156 QB307

EUROPEAN AVIATION AIR CHARTER LTD (EUL) 1 E3022

EVERGREEN INTERNATIONAL AIRLINES (EVR) 1 E3101 E3151 E3276 E5104-E5105 E5108

EXPRESS ONE INTERNATIONAL, INC. (EOI) 1 E0421-E0422 E3117 E3347-E3348 E3350 E3602 QA014 QA062 QA101 QA116 QA121 QA125-QA127 QA138 QA140-QA141 QA656 QA713 QB624 QD032 QD441 QD453 2 QD821 QD824-QD826

Sep 2/70 727-57-0112 REV 5: Jul 31/97 6 BOEING SERVICE BULLETIN 727-57-0112

FALCON AIR EXPRESS (FAX) 1 QA329 QA716

FAMCO AVIATION AND MARITIME SERVICES LTD (FAM) 1 E5353

FAUCETT (COMPANIA DE AVIATION S.A. (FCT) 1 E3068 QA901 QB042

FEDERAL AVIATION ADMINISTRATION (FAA) 1 E5241

FEDERAL EXPRESS (FED) 1 E0120 E0122-E0123 E0125-E0129 E0131-E0132 E0134-E0138 E3256-E3261 E3263-E3274 E3277-E3281 E3283 E3290 E5048-E5049 E5052-E5054 E5056-E5057 E5063 E5067 E5101-E5102 E5163-E5164 E5221-E5224 E5226 E5230 E5233-E5234 E5238-E5240 E5242 E5408 E5420 E5454 QA093-QA095 QA644-QA645 QA648 QA650 QA653 QA658 QA677 QA679-QA680 QA897-QA899 QA922-QA926 QB601-QB617 QD035-QD039 QD041-QD042 2 QD201-QD205 QD208-QD209 QD213-QD239 QD691-QD692 QL501-QL515

FINOVA (GRB) 1 QA627

FIRST SECURITY BANK OF UTAH (FSB) 1 QA335 QB114

FLY LINHAS AEREAS (FLF) 1 QA579 QA585

FORBES, INC. (FRB) 1 E3655

FUNAIR (FUN) 1 E3419

GE CAPITAL AVIATION SERVICES, INC. (GEH) 1 E0038 E0040 E3241 E3245 E3247 E3253 QA206 QA304 QA306 QA310 QA313-QA314 QA325 QA328

GENERAL AVIATION PTY LTD (GEL) 1 QB316

GEORGETOWN AIRCRAFT SERVICES (GEO) 1 E0216

GLENHOLME ENTERPRISES INC. (GLE) 1 E3144

GLOBAL AIRCRAFT SALES (GAC) 1 QA057 QA851

GM AIRLINES (GMA) 1 QB110

Sep 2/70 727-57-0112 REV 5: Jul 31/97 7 BOEING SERVICE BULLETIN 727-57-0112

GOMAIR (GOM) 1 E3753

GOVERNMENT OF SENEGAL (SEN) 2 QD402

GOVT. OF BURKINA FASO (HTV) 1 E3176

GPA GROUP LTD. (GUI) 1 QB037 QD571

GRAND HOLDINGS (GRD) 1 E3510 QA105 QA122 QA337-QA338

HAPAG LLOYD (HAP) 1 E3114

HCL AVIATION, INC. (HCL) 1 E0308 E0316 E0324 E0338 QA638 QA671 QD581 2 QD902 QD954

HMS AIRWAYS (HSA) 1 E3005 2 QD401

HOLIDAY AIR (HOI) 1 QA642

HUNTING CARGO AIRLINES INC. (HCA) 1 QA022 QA033 QA037 QA106 QA118 QA131 QA133 QA615 QA888 QD506

IBERIA (LINEAS AEREAS DE ESPANA S.A.) (IBE) 1 QB124 QB127 QB129-QB133 QB135-QB145 QB147-QB149 QB151-QB153 QB155-QB158

IDG (CAYMAN) LTD (IDG) 1 E3150

IMPERIAL PALACE AIR LTD. (IPA) 1 E0213

INTER AIR (ITI) 1 E0318-E0319

INTERNATIONAL AIR LEASES (IAL) 1 QA673-QA674 QA676 QA918

INTERNATIONAL AIRLINE SUPPORT GROUP (ASG) 1 E0202 E0205

INTERNATIONAL PACIFIC TRADING CO. (IPT) 1 E3032-E3033 E3069 E3289

Sep 2/70 727-57-0112 REV 5: Jul 31/97 8 BOEING SERVICE BULLETIN 727-57-0112

IRAN AIR (IRN) 1 E0204 E3118 E3472-E3473 QD101-QD104 2 QD761-QD762

IRAQI AIRWAYS (IRQ) 2 QD421-QD426

ISLENA DE AVIACION (ISD) 1 E3345 QA704 QB002

ISTANBUL AIRLINES (IST) 1 QA557-QA558 QB310-QB314

ITAPEMIRIM TRANSPORTES AEREOS S.A. (ITP) 1 E3152 E3344 E5279 E5406 QA678 QD583

JET AVIONICS SYSTEMS INC (JAV) 1 QA602

JETAIR TRADING & LEASING INT©L, INC. (JTL) 1 QB033

JUGOSLOVENSKI AEROTRANSPORT (JAT) 1 QD142-QD149

KABO AIR LIMITED (KAB) 1 E0103 E0107 QA019 QA330 QA332 QA334 QA604 QA620

KELOWNA FLIGHTCRAFT AIR CHARTER LTD. (KEL) 1 E5001 E5059-E5062 E5201 E5228-E5229 E5428 QA359 QA609-QA610 QA870 QA876 QA879-QA880 QA883-QA884

KITTY HAWK AIR CARGO, INC. (KHC) 1 QA110 QA128 QA134 QA153-QA154 QA344 QA372-QA373 QA728-QA729 2 QD281 QD284

KIWI INTERNATIONAL AIR LINES (KIW) 1 QA629 QA635 QA637 QA639-QA640 QA654-QA655 QA657 QA708-QA709 QA714 QB115

KUWAIT AIRWAYS CORPORATION (KUW) 2 QD801

LAKER AIRWAYS (LAK) 1 QD085-QD086

LEAR ASTRONICS (LEA) 1 QA411

LIBYAN ARAB (LAA) 1 QA316 QA318-QA322 QB651 2 QA323-QA324

LINEAS AEREAS CANARIAS (LCI) 1 QD601-QD602

Sep 2/70 727-57-0112 REV 5: Jul 31/97 9 BOEING SERVICE BULLETIN 727-57-0112

LINEAS AEREAS SURAMERICANAS (LAR) 1 E0119 E5451 E5453

LLOYD AERO BOLIVIANO (LAB) 1 E3102 E3522 E5421 QD161 2 QD162-QD163 QL006

LUFTHANSA CARGO INDIA PRIVATE LTD (LUI) 1 QD512-QD513 QD516-QD517

MEXICAN AIR FORCE (MXA) 1 E3171-E3172 E3175

MEXICANA (CMA) 1 QA041 QB043-QB049 QB051-QB058 QB060-QB064 QD556-QD557 QD605

MEXICARGO (MXO) 1 QA616

MIAMI AIR INTERNATIONAL INC. (MIB) 1 QA659-QA660 QA662 QA669-QA670 QA672 2 QB219

MIBA MINING CO. (MIZ) 1 E3275

MID EAST JET INC (SKL) 1 E3421

MILLION AIR (MIL) 1 E0301 E0322 E0329-E0330

MMG AVIATION (MME) 1 E0209

MONGOLIAN AIRLINES MIAT (MNG) 1 QA015 QA034-QA035

NATIONAL AIRLINES (NAW) 1 QD446

NATIONS AIR EXPRESS (NAX) 1 QA504

NATIONWIDE AIR (NWR) 1 E3517 E3573

NEW ACS LIMITED (NEC) 1 QA355

NIGERIA, GOV OF (NGA) 2 QL081

NOMADS, INC. (NOM) 2 QD827

NORTHERN AIR CARGO (NAC) 1 E0340

Sep 2/70 727-57-0112 REV 5: Jul 31/97 10 BOEING SERVICE BULLETIN 727-57-0112

NORTHWEST AIRLINES, INC. (NWA) 1 QA651-QA652 QA667-QA668 QA681-QA684 QA686 QA706 QA725 QA734-QA743 QA745-QA753 QD442 QD447-QD449 2 QD711-QD717

OCCIDENTAL PETROLEUM CORP (OCP) 1 E3004

OKADA AIR (OKD) 1 QA703 QB116 QB308

OLYMPIC AIRWAYS (OLY) 1 QA001 QA801-QA805 QB117-QB118 QB309

OMNI AIR EXPRESS (OAX) (OAE) 1 E5142 QA427-QA428

ORCA BAY AVIATION (OBA) 1 QA066

ORIENT EXPRESS (CAK) 1 QA606 QA626 QA889

PACIFIC AIR EXPRESS AUSTRALIA PTY LTD (PAE) 1 QA044

PACIFIC INTERNATIONAL AIRLINES, S.A. (PCF) 1 E0304 E0310

PANAGRA AIRWAYS (PAG) 1 E0349

PANAVIA (PVI) 1 E3341

PEGUSUS CAPITAL CORPORATION (PSS) 1 QA024 QA702 QA720 QA723 QD088 QD450 QD606

PLM TRANSPORTATION EQUIPMENT CORP. (PLI) 1 QA711

PRECISION AIR LTD (PRT) 2 QD906

PRESTIGE AIRWAYS (PAR) 1 QA505 QA518 QA523 QA581

QATAR AIRWAYS (QTA) 1 QB065 QD452 QD572 2 QD475

QATAR AMIRI FLIGHT (QAT) 2 QD403

QUAKER COAL COMPANY (QCC) 1 E3014 QA045-QA046 QA068

Sep 2/70 727-57-0112 REV 5: Jul 31/97 11 BOEING SERVICE BULLETIN 727-57-0112

R. B. HARIRI (RBH) 2 QD973 QE002

RATHEON E-SYSTEMS INC (ESM) 2 QD908

REEVE ALEUTIAN AIRWAYS, INC. (RVV) 1 E5035 E5040

RELIANCE GROUP, INC. (RGI) 1 E3285

REPUBLIC OF CAMEROON (CMR) 2 QD410

REPUBLIC OF ZAIRE (ZAR) 1 E0214

ROTHSCHILD AUSTRALIA AIRCRAFT LEASING (ROI) 1 E5501

ROYAL AIR MAROC (RAM) 1 QA583-QA584

ROYAL AIRLINES (ROY) 1 QB035 QD033 2 QD903 QL003 QL008 QL031-QL032

ROYAL NEW ZEALAND AIR FORCE (RNZ) 1 E5065 E5068

RYAN INTERNATIONAL AIRLINES (RYN) 1 E0418 E0420 E3003 E3201 E3411 E3415-E3418 E5003 E5007-E5011 E5031-E5032 E5039 E5041-E5042 E5058 E5381 E5411 E5413 E5415 E5433 E5483 E5502 QA416 QA419-QA421 QA423-QA426 QA666

SABRE AIRWAYS (SBE) 1 QD005 QD123

SAETA S.A. (SAE) 1 E0414 E3576 QA733 QA744 QD302

SAFAIR FREIGHTERS (PTY) LTD. (SFA) 1 E0331 QB106 QB108 QB119 QB351-QB352 2 QD661 QD971

SAMCO (SMO) 1 E3604

SCIBE-AIRLIFT KINSHASA (SAK) 1 E0208 E3451

SEAGREEN AIR TRANSPORT (SEG) 1 E0104 E0211 E5419

SERVICIOS AEREOS NACIONALES, S.A. (SAN) 1 E3684

Sep 2/70 727-57-0112 REV 5: Jul 31/97 12 BOEING SERVICE BULLETIN 727-57-0112

SIGAIR (SIG) 1 E0207

SKY TREK (SKY) 1 QA717 QB107 QD006

SKYLINE INTERNATIONAL, LTD. (SKT) 1 E3006

STARCOM LTD (STK) 1 QA369-QA370

STELLAR AVIATION (STL) 1 E0347

STERLING EUROPEAN AIRLINES (STR) 1 QD443 2 QD164 QD427 QD684 QD907 QL001

SUN COUNTRY AIRLINES (SCA) 1 QA687-QA688 QA710 QB629 QD303 QD555 QD558 QD582 2 QL002 QL004-QL005

SUN PACIFIC INTERNATIONAL (SUI) 1 E3452 QA877 QA881 QD503 2 QD828

SUNWORLD INTERNATIONAL AIRLINES (SUO) 1 QA732

SYRIAN ARAB AIRLINES (SYR) 1 QD471-QD473 2 QD802-QD804

TAESA (TES) 1 E0035 E0311 E0348 E0413 E3024 E3174 E3553 E5455

TATARSTAN FLIGHT LTD. (TAK) 1 E3507

THE AGES GROUP (AGJ) 1 QB101

THE K. B. A. FOUNDATION (KBA) 1 E3574

THE LIMITED, INC. (LII) 1 E3704

TOP AIR (TOP) 1 QD325 QD330 QD511

TRACINDA CORPORATION (TRD) 1 E3284

Sep 2/70 727-57-0112 REV 5: Jul 31/97 13 BOEING SERVICE BULLETIN 727-57-0112

TRANS WORLD AIRLINES, INC. (TWA) 1 E0406-E0408 E0412 E0416-E0417 E0419 QA502 QA509-QA515 QA519-QA520 QA522 QA525-QA527 QA529-QA537 QB201-QB203 2 QB204-QB218 QB220

TRANSAFRIK (TCL) 1 E0335 E0343 E3025 E3242 E3577 E3601

TRANSMERIDIAN AIRLINES (TAL) 1 QA730-QA731

TRANSPORTES AEREOS MILITAR EQUATORIANOS (TAM) 1 E3513 E3516 E3682 QB105 QB109 QB315 2 QD741

TRANSPORTES AEREOS PRESIDENCIALES (MXG) 1 E3037

TRANSTEL S.A. (TTL) 1 QA508 QD514

TRIANGLE AIRCRAFT SERVICES CORP. (TRI) 2 QD910

TRIAX AIRLINES (TIX) 1 E3603 QB031

TRITON ENERGY (TRY) 1 E0206

TUNISAIR (TUN) 1 QA571 QB401-QB405 QB407

TUR EUROPEAN AIRWAYS (TOU) 1 QB306

TURKISH AIRLINES (THY) 1 QD327-QD329

UNITED AIR LINES, INC. (UAL) 1 QA401-QA402 QA404-QA405 QA408 QA429-QA473 QA475-QA499 QB701-QB705

UNITED PARCEL SERVICE (UPS) 1 E5002 E5004-E5006 E5033-E5034 E5036 E5038 E5043-E5045 E5051 E5106-E5107 E5109-E5111 E5113 E5115-E5116 E5162 E5225 E5227 E5231-E5232 E5235-E5237 E5243-E5245 E5251-E5252 E5271 E5275-E5276 E5280 E5301-E5306 E5401 E5405 E5417 E5422-E5423 E5426-E5427 E5429 QA927 QA934-QA938 QD551-QD552

UNITED STATES AIR FORCE (USF) 1 E3061 E3063 E3066-E3067

UNITED STATES MARSHAL©S SERVICE (USV) 1 E0215 E3059 QA726

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USAIR SHUTTLE (TSI) 1 QA010-QA012 QA017-QA018 QA617 QA619 QA623 QA625 QA878 QA887 2 QD474

USAIR, INC. (USA) 1 QA026-QA028 QA030-QA032 2 QD681-QD682

USAL, LTD. (ULL) 1 E3523

VALLEJO CORPORATION (VAC) 1 E3683

VARIG AIRLINES (VAR) 1 E3752 E3754 E5272 E5407 E5412

VASP (VSP) 1 QB041 QD515

VIASA AIRWAYS (VIA) 1 QB123 QB125-QB126 QB128 QB134

VICA - VIACAO CHARTER AEREA LTDA (TCT) 1 QA908

WEDGE TRANSPORTATION (WST) 2 QE001

WESTFIELD AVIATION LTD. (WEF) 1 E0350

WETRAFA AIRLIFT (WET) 1 E0140

WILMINGTON TRUST CO. (WTC) 1 QA601 QA603 QA605 QA612-QA613 QA624

YEMEN AIRWAYS (YEM) 2 QD621-QD624 QD641

Sep 2/70 727-57-0112 REV 5: Jul 31/97 15 BOEING SERVICE BULLETIN 727-57-0112

IDENTIFICATION BY VARIABLE NUMBER

GROUP 1 E0001-E0042 E0101-E0140 E0201-E0216 E0301-E0351 E0401-E0423 E3001-E3006 E3011-E3014 E3021-E3040 E3059 E3061-E3077 E3101-E3103 E3111-E3118 E3141-E3152 E3171-E3177 E3201-E3206 E3221-E3224 E3241-E3290 E3341-E3350 E3401-E3421 E3451-E3452 E3471-E3474 E3501-E3513 E3516-E3523 E3551-E3553 E3571-E3578 E3601-E3604 E3621-E3622 E3651-E3655 E3677 E3681-E3684 E3701-E3704 E3751-E3755 E3781-E3784 E5001-E5011 E5031-E5068 E5101-E5116 E5141-E5143 E5161-E5164 E5201-E5203 E5221-E5245 E5251-E5252 E5271-E5281 E5301-E5306 E5351-E5353 E5381-E5382 E5401-E5424 E5426-E5429 E5433 E5435 E5451-E5455 E5481-E5483 E5501-E5502 QA001-QA046 QA051-QA099 QA101-QA199 QA201-QA225 QA301-QA322 QA325-QA349 QA351-QA376 QA378 QA401-QA499 QA501-QA537 QA551-QA579 QA581-QA585 QA601-QA688 QA701-QA753 QA801-QA805 QA851-QA899 QA901-QA946 QA949 QB001-QB002 QB031-QB049 QB051-QB068 QB101-QB110 QB114-QB119 QB121-QB149 QB151-QB158 QB201-QB203 QB301-QB316 QB351-QB352 QB401-QB407 QB451-QB458 QB501-QB575 QB601-QB629 QB651 QB701-QB705 QB801-QB810 QB901-QB904 QD001-QD012 QD031-QD042 QD085-QD088 QD101-QD105 QD121-QD127 QD141-QD149 QD161 QD191-QD192 QD301-QD305 QD321-QD330 QD351 QD441-QD453 QD471-QD473 QD501-QD518 QD551-QD558 QD571-QD572 QD581-QD583 QD601-QD607 QD701-QD702 QD791

GROUP 2 QA323-QA324 QB204-QB220 QD043-QD046 QD162-QD164 QD201-QD239 QD281-QD284 QD401-QD403 QD407 QD410 QD421-QD427 QD474-QD475 QD621-QD624 QD641 QD661-QD663 QD681-QD685 QD691-QD692 QD711-QD717 QD741 QD761-QD769 QD781-QD782 QD801-QD804 QD821-QD828 QD901-QD910 QD931-QD932 QD951-QD954 QD971-QD973 QD991-QD992 QE001-QE002 QL001-QL008 QL031-QL032 QL081 QL501-QL515

2. Spares

None

Sep 2/70 727-57-0112 REV 5: Jul 31/97 16 BOEING SERVICE BULLETIN 727-57-0112

B. Reason

As a result of the Aging Fleet Conference held by the FAA, the 727 Structures Working Group (SWG) was made and included 727 airline operators from a large part of the high time 727 fleet, persons from the Boeing Company, and monitors from the FAA. The SWG examined the structural changes and inspections given in applicable Boeing service bulletins. A selection of these service bulletins was made that contain structural changes and inspections that are important to the continued structural airworthiness of 727 airplanes. The structural change given in this service bulletin is recommended to be included, and the inspection are recommended to be a part of the regularly scheduled maintenance on applicable 727 airplanes.

During a 727 primary fatigue test at Boeing, two cracks were found in the upper vertical flange of the wing-to-body rib upper chord at Body Station 760. One crack in the rib upper chord was between the two aft fastener holes of the frame at Body Station 760.95. The other crack in the rib upper chord was immediately aft of the lower fastener hole in the frame.

To increase the fatigue life of the rib upper chord and to reduce the risk of repair and maintenance not scheduled, make the change given in this service bulletin.

The initial release of this service bulletin recommended that operators cold work six holes in the wing-to-body rib upper chord to extend the chord fatigue life. Cold work the holes at a primary overhaul near 30,000 total flight cycles, but before 35,000 total flight cycles.

Revision 1 of this service bulletin decreased the time permitted before the operator should make the change given in this service bulletin. Also, information was given to repair cracked holes in the vertical flange of the rib upper chord. Since the initial release of this service bulletin, two operators reported cracks in these holes on three airplanes. These airplanes had between 19,700 and 24,500 flight cycles.

Revision 2 of this service bulletin added new inspection information and repair instructions for the rib upper chord. Since the release of Revision 1 of this service bulletin, seven operators reported long cracks in the rib upper chord and the repair was not given in the service bulletin on six airplanes. These airplanes had between 34,000 and 54,000 flight hours and between 27,000 and 49,000 flight cycles.

Revision 3 of this service bulletin was sent to give the recommendation of the 727 SWG (renamed the Structures Task Group (STG)).

Revision 4 was sent to tell operators that new kits are available for Group 1 and 2 Airplanes. There are separate kits for modifications to airplanes with small cracks or no cracks, and for repairs to airplanes with larger cracks. This revision also gives instructions and figures to show parts installation details for the new kits. It is necessary for Group 1 Airplanes with the Major Repair/Preventive Modification installed to be inspected at BL 70.5 for a repair strap. If a repair strap is not installed, it is necessary to make an inspection of the frame for cracks, see Service Bulletin 727-53-0197. Install the repair strap when the repair or preventive modification shown in Service Bulletin 727-53-0197 is installed, or at a convenient maintenance time. If cracks are found, do the repair shown in Service Bulletin 727-53-0197.

Revision 4 can also be used as a guide to install the Kits 65C33202-1, and -2. See the drawing sent with Revision 3 of the bulletin for the part numbers, the hole diameters and fastener callout. Revision 4 gives information on the limits the angles in Kits 65C33202-1, and -2 can be trimmed.

If the strap from Service Bulletin 727-53-0197 is installed at Body Station 760.95, or will be installed concurrent with this service bulletin, use the strap from Service Bulletin 727-53-0197 in place of the strap shown in this service bulletin.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 17 BOEING SERVICE BULLETIN 727-57-0112

Since the recommendation of the inspection called out in this service bulletin was made by the STG there have been numerous reports of cracks. It has been necessary to install the Preventive Modification or Large Repair for many of the cracks. Most cracks have been in the forward two holes.

Revision 5 is sent to tell operators that new kits are available to order for Group 1 and 2 Airplanes. The drawings used to install the kits are sent with this revision (the drawings have been revised since the release of Notice of Status Change 3). The format used to show the removal of parts and installation of the kits has changed. Also the compliance information has been clarified.

Also, for Group 1 airplanes that were changed by Revisions 2 or 3, Part V of the Accomplishment Instructions of this service bulletin there are changes to the instructions. If the repair strap has not been installed, a new repair strap is shown. The new strap is the same as the strap installed in the new "Large Repair" and new "Preventive Modification " kits.

Revision 5 is also sent to give the inspection recommendation of the 727 STG. Also repairs, that operators have requested, are included.

C. Description

The STG has examined the structural change and inspection in this service bulletin, and recommends that the Preventive Modification or Large Repair structural change given in the Accomplishment Instructions be included at or before the airplane collects a total of 60,000 flights, and to do the inspection given in the Accomplishment Instructions, Part II.A.1, Inspection, at or before the airplane collects a total of 14,000 flights, or within 3,000 flights, whichever occurs later.

If no cracks are found, increase the hole diameter, cold work the hole, and install a new fastener in six places. Continue the inspection at regularly scheduled times as given in the Accomplishment Instructions, Part II.A.2, or B.1, Inspection. The approved time between one inspection and the subsequent inspection must not be more than 14,000 flights. To stop the inspection given in this service bulletin, do the preventive modification or large repair.

If cracks are found, make a change to the rib upper chord as given in this service bulletin.

It is necessary for Group 1 Airplanes with the Major Repair/Preventive Modification installed to be inspected at BL 70.5 for a repair strap at a maintenance check before 3000 flight cycles. If a repair strap is not installed, it is necessary to make an inspection of the frame for cracks. Continue the inspection of the frame for cracks as given in Service Bulletin 727-53-0197. If cracks are found, do the repair shown in Service Bulletin 727-53-0197.

The airplane effectivity is divided in two groups. Group 1 airplanes are basic weight and Group 2 are high gross weight airplanes.

It is recommended that the changes shown in Service Bulletin 727-53-0197 be done at the same time that the work for Service Bulletin 727-57-0112 is done.

NOTES:

1. Boeing Document D6-54860, "Aging Airplane Service Bulletin Structural Modification and Inspection Program", is applicable to this service bulletin.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 18 BOEING SERVICE BULLETIN 727-57-0112

2. If the damaged area is more than the specified limits, write to Boeing for repair instructions. To help Boeing send a reply, give the limits 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.

SEND TO:BOEING COMMERCIAL AIRPLANE GROUP ATTENTION: MANAGER, AIRLINE SUPPORT

An evaluation form is attached to this service bulletin. Please use this form to tell us what you think of the quality of this service bulletin.

D. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and are FAA approved. This service bulletin and the FAA approval were based on the airplane in its original Boeing delivery configuration or as modified by other FAA 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.

E. Manpower

The data below shows an estimate of the man-hours necessary to do this change for each wing. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-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.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 19 BOEING SERVICE BULLETIN 727-57-0112

Small Repair Number of Persons Man-Hours Elapsed Time (Hours) Open Access 4 24 6 Inspection 2 6 3 Modification 1 24 24 Restoration 4 24 6 TOTAL FOR EACH WING 72 36 Preventive Modification/ Large Repair Number of Persons Man-Hours Elapsed Time (Hours) Open Access 4 24 6 Inspection 2 6 3 Modification 3 246 82 Restoration 4 24 6 TOTAL FOR EACH WING 300 97 Inspection for and Installation of Repair Strap Number of Persons Man-Hours Elapsed Time (Hours) Open Access 4 24 6 Inspection 1 .5 .5 Inspection of Strap 1 8 8 Restoration 4 24 6 TOTAL FOR EACH WING 56.5 20.5

F. Material - Price and Availability

Boeing can supply the kits shown in Paragraph II.A., Parts Necessary For Each Airplane, (and Paragraph II.B., Parts Necessary to Change Spares,) as shown below. If there is a limit to the quantity of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

ROLT Unit Price thru Kit Number Name Date Quantity (weeks) Dec 30/97 65-68492-1 (a) Upper Rib Chord Repair - - - - 65-68492-2 (a) Upper Rib Chord Repair - - - - 65-68492-9 (a) Strap - - - - 65-68492-10 (a) Strap - - - - 65-68492-11 (a) Upper Rib Chord Repair - - - - 65-68492-12 (a) Upper Rib Chord Repair - - - - 65-68492-17 (a) Upper Rib Chord Repair - - - - 65-68492-18 (a) Upper Rib Chord Repair - - - - 65-68492-25 (a) Upper Rib Chord Repair - - - - 65-68492-26 (a) Upper Rib Chord Repair - - - - 65-68492-33 Upper Rib Chord Repair - - 34 $3,346.00 65-68492-34 Upper Rib Chord Repair - - 34 $3,346.00 65-68492-35 Upper Rib Chord Repair - - 34 $3,095.00 65-68492-36 Upper Rib Chord Repair - - 34 $3,095.00 69-78758-1 (a)(b) Strap - - - -

Sep 2/70 727-57-0112 REV 5: Jul 31/97 20 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

ROLT Unit Price thru Kit Number Name Date Quantity (weeks) Dec 30/97 69-78758-2 (a)(b) Strap - - - - 69-78758-3 (a)(c) Strap - - - - 69-78758-4 (a)(c) Strap - - - - 69-78758-5 (b) Strap - - 32 $192.00 69-78758-7 (c) Strap - - 32 $192.00 65C33202-1 (a) Repair Installation - - - - 65C33202-2 (a) Repair Installation - - - - 65C33202-19 (a) Large Repair - - - - 65C33202-20 (a) Large Repair - - - - 65C33202-21 (a) Preventive Modification - - - - 65C33202-22 (a) Preventive Modification - - - - 65C33202-23 (a) Preventive Modification - - - - 65C33202-24 (a) Preventive Modification - - - - 65C33202-61 (a) Large Repair - - - - 65C33202-62 (a) Large Repair - - - - 65C33202-73 (a) Large Repair - - - - 65C33202-74 (a) Large Repair - - - - 65C33202-79 (a) Preventive Modification - - - - 65C33202-80 (a) Preventive Modification - - - - 65C33202-91 (a) Large Repair - - - - 65C33202-92 (a) Large Repair - - - - 65C33202-93 (a) Preventive Modification - - - - 65C33202-94 (a) Preventive Modification - - - - 65C33202-97 Large Repair - - 38 $12,139.00 65C33202-98 Large Repair - - 38 $12,139.00 65C33202-99 Preventive Modification - - 38 $11,006.00 65C33202-100 Preventive Modification - - 38 $11,006.00 65C33202-101 Large Repair - - 38 $12,040.00 65C33202-102 Large Repair - - 38 $12,040.00 65C33202-103 Preventive Modification - - 38 $10,614.00 65C33202-104 Preventive Modification - - 38 $10,614.00 (a) Inactive for procurement (b) 727-200 Airplanes (c) 727-100 Airplanes

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price (and ROLT) data is applicable. Prices are in United States Dollars. Terms: Net 30 days.

Send purchase orders and letters about the supply data to the Director of Spares and refer to this service bulletin number.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 21 BOEING SERVICE BULLETIN 727-57-0112

G. Special Tools - Price and Availability

The 727 Structural Repair Manual Subject 51-30-10 gives data about cold working tools and sleeves necessary to do the work given in this service bulletin. These tools are available from industry sources.

Engineering, service, and a kit of cold working tools made for this change are available from Fatigue Technology, Inc. or West Coast Industries, Inc.

Refer To:

FTI Kit Number: FTI-727-57-0112-1 Fatigue Technology, Inc. P.O. Box C-88388 Seattle, WA 98188 Phone Number (206) 246-2010 Fax (206) 244-9886

Refer To:

WCI Kit Number: WCI-727-57-0112 West Coast Industries, Inc. 14900 Whitman Avenue North Seattle, WA 98133-6532 Phone Number (206) 365-7513 Fax (206) 365-7483

H. Weight and Balance

Change in Weight Change in Moment Airplane/Engine (Pounds) (Pound-Inches) Group 1 +(-) +(-) Small Repair - Part III +3.4 +2,587 Large Repair - Part IV +9.5 +7230 Preventive Modification - Part V +7.7 +5860 Installation of Repair Strap +0.2 +152 Group 2 Small Repair - Part III +2.2 +1674 Large Repair - Part IV 65C33202-101 (left) +11.4 +8675 65C33202-102 (right) +11.2 +8523 Preventive Modification - Part V 65C33202-103 (left) +7.7 +5860 65C33202-104 (right) +7.1 +5403

Sep 2/70 727-57-0112 REV 5: Jul 31/97 22 BOEING SERVICE BULLETIN 727-57-0112

I. References

1. Existing Data:

a Engineering Change Memo PRR 24791-R

b 727 Maintenance Manual Subjects 12-30-2, 25-20-31, 25-20-32, 25-21-1, 25-22-0, 27-81-0, 28-10-0, 28-11-0, 28-11-21, 28-12-11, 28-12-1, 28-12-21, 28-12-31, 28-23-0, 51-30-1 and 53-20-11

c 727 Structural Repair Manual Subjects 51-10-1, 51-30-8 and 51-30-10

d 727 Nondestructive Test Manual, D6-48875, Part 6, Subject 51-00-00, Figures 1 and 4

e Boeing Document D6-54860 "Aging Airplane Service Bulletin Structural Modification and Inspection Program - Model 727"

f Boeing Service Bulletin 727-53-0197, FUSELAGE - MAIN FRAME - FRAMES AND BULKHEADS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION AT BODY STATION 760.95, 783.95, 825.95, AND 848.95.

g Boeing Standard Overhaul Practices Manual 20-42-10.

2. Data supplied with this service bulletin:

a. Drawings:

Drawing Number Sheet DCN ADCN Title 65C36390 PL - 1 "Rib Chord Repair Installation - Fairing 1 - 1 Rework (Kit)" 65-68492 PL B - "Uppr Rib Chord Repair - BBL 70.5 4 - - Body Station 760.95 Kit" 65C33202 1 F - Rib Chord Repair Installation Upper, 7 B - BBL 70.5, S-16 thru S-21 8B- 11 A - 12 A -

3. Installation Drawings

Boeing Process Specifications referred to on the drawings are not given in this service bulletin since these procedures are frequently used as standard shop practices.

J. Publications Changed

Publication Chapter-Section 727 Structural Repair Manual 57-10

Sep 2/70 727-57-0112 REV 5: Jul 31/97 23 BOEING SERVICE BULLETIN 727-57-0112

II. MATERIAL INFORMATION

A. Parts Necessary For Each Airplane

1. Kits:

To get the kits shown below, refer to Paragraph I.H., Material - Price and Availability.

NOTE: Two top kits and the items shown in Paragraph II.A.2., Parts and Materials Supplied by the Operator, are necessary for each airplane.

65-68492 UPR RIB CHORD REPAIR - BBL 70.5 B. STA 760.95 KIT -36 -35 -34 -33 Quantity Part Number Name . . . - 65-68492-33 Top Kit, Upper Rib Chord - Small Repair (Left) - Group 1 . . - . 65-68492-34 Top Kit, Upper Rib Chord - Small Repair (Right) - Group 1 . - . . 65-68492-35 Top Kit, Upper Rib Chord - Small Repair (Left) - Group 2 - . . . 65-68492-36 Top Kit, Upper Rib Chord - Small Repair (Right) - Group 2 . . . 1 65-68492-37 Strap . . 1 . 65-68492-38 Strap . . . 1 65-68492-39 Angle . . 1 . 65-68492-40 Angle . 1 . 1 65-68492-41 Strap 1 . 1 . 65-68492-42 Strap . . . 1 65-68492-43 Strap . . 1 . 65-68492-44 Strap . . 1 1 65-68492-45 Plate . . 1 1 65-68492-46 Stock Plate . . 1 1 65-68492-47 Stock Strap 1 1 . . 65-68492-48 Plate . 1 . 1 65-68492-49 Stock Angle 1 . 1 . 65-68492-50 Stock Angle . 1 . . 65-68492-51 Strap 1 . . . 65-68492-52 Strap . 1 . . 65-68492-53 Angle 1 . . . 65-68492-54 Angle 1 1 . . 65-68492-55 Stock Plate 1 1 . . 65-68492-56 Stock Strap . 1 . 1 65-68492-57 Tee Clip 1 . 1 . 65-68492-58 Tee Clip 111165-68492-59 Shim-Laminated 111165-68492-60 Shim-Laminated

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(Continued)

65-68492 UPR RIB CHORD REPAIR - BBL 70.5 B. STA 760.95 KIT -36 -35 -34 -33 Quantity Part Number Name 111165-68492-61 Shim-Laminated Stock 111165-68492-62 Shim-Laminated Stock . 1 . 1 65C37221-7 Stock Tee Clip 1 . 1 . 65C37221-8 Stock Tee Clip 111169-78758-5 Stock Strap . . 1 1 69-78758-7 Stock Strap 2222BACB30MY8K11Y Hi-Lok, 1/32 Oversized 4444BACB30MY8K7Y Hi-Lok, 1/32 Oversized . . 2 2 BACB30NW8K12Y Hi-Lok, 1/32 Oversized 1 1 . . BACB30NW8K13Y Hi-Lok, 1/32 Oversized . . 3 3 BACB30NW8K14Y Hi-Lok, 1/32 Oversized . . 3 3 BACB30NX10K12Y Hi-Lok, 1/32 Oversized . . 1 1 BACB30NX10K14 Hi-Lok . . . 1 BACB30NX10K15Y Hi-Lok, 1/32 Oversized . . 5 5 BACB30NX10K16Y Hi-Lok, 1/32 Oversized 1111BACB30NX10K17 Hi-Lok . . 1 1 BACB30NX10K19 Hi-Lok . . 1 . BACB30NX10K19Y Hi-Lok, 1/32 Oversized 1 1 . . BACB30NX10K20 Hi-Lok . . 1 . BACB30NX10K21Y Hi-Lok, 1/32 Oversized 1 1 . . BACB30NX10K22 Hi-Lok . . 1 . BACB30NX12K14Y Hi-Lok, 1/32 Oversized . . . 1 BACB30NX12K15Y Hi-Lok, 1/32 Oversized . . 3 3 BACB30NX12K16Y Hi-Lok, 1/32 Oversized . . 2 3 BACB30NX12K19Y Hi-Lok, 1/32 Oversized . . . 1 BACB30NX12K21Y Hi-Lok, 1/32 Oversized 3 3 . . BACB30NX14K12Y Hi-Lok, 1/32 Oversized 1 1 . . BACB30NX14K13Y Hi-Lok, 1/32 Oversized 4 2 . . BACB30NX14K14Y Hi-Lok, 1/32 Oversized 4 7 . . BACB30NX14K16Y Hi-Lok, 1/32 Oversized 3 2 . . BACB30NX14K18Y Hi-Lok, 1/32 Oversized 1 2 . . BACB30NX14K20Y Hi-Lok, 1/32 Oversized 3 3 . . BACB30NX8K10Y Hi-Lok, 1/32 Oversized . . 1 1 BACB30NX8K12Y Hi-Lok, 1/32 Oversized 1 1 . . BACB30NX8K13Y Hi-Lok, 1/32 Oversized . . 2 2 BACB30NX8K14 Hi-Lok . . 1 1 BACB30NX8K14Y Hi-Lok, 1/32 Oversized 1 1 . . BACB30NX8K17Y Hi-Lok, 1/32 Oversized

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(Continued)

65-68492 UPR RIB CHORD REPAIR - BBL 70.5 B. STA 760.95 KIT -36 -35 -34 -33 Quantity Part Number Name . . 3 3 BACB30NX8K9Y Hi-Lok, 1/32 Oversized . . 5 4 BACB30NY10K12Y Hi-Lok, 1/32 Oversized . . 1 1 BACB30NY10K14 Hi-Lok, 1/32 Oversized 2222BACB30NY10K17 Hi-Lok, 100 Deg . . 1 1 BACB30NY10K19 Hi-Lok, 100 Deg 2211BACB30NY10K20 Hi-Lok, 100 Deg 2 2 . . BACB30NY10K22 Hi-Lok, 100 Deg 3 3 . . BACB30NY8K10Y Hi-Lok, 1/32 Oversized . . 1 1 BACB30NY8K12Y Hi-Lok, 1/32 Oversized 1 1 . . BACB30NY8K13Y Hi-Lok, 1/32 Oversized . . 3 3 BACB30NY8K14 Hi-Lok, 100 Deg . . 1 1 BACB30NY8K14Y Hi-Lok, 1/32 Oversized 4 4 . . BACB30NY8K17 Hi-Lok, 100 Deg 4 4 . . BACB30NY8K17Y Hi-Lok, 1/32 Oversized . . 3 3 BACB30NY8K9Y Hi-Lok, 1/32 Oversized 13 13 10 10 BACC30AC8 Collar 7 7 11 11 BACC30R8 Collar 9988BACC30X10 Collar 4455BACC30X8 Collar . . 15 13 HL375-10AW Collar, Self-Align . . 6 8 HL375-12AW Collar, Self-Align 15 14 . . HL375-14AW Collar, Self-Align

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 1 -100 -99 -98 -97 Quantity Part Number Name . . . - 65C33202-97 Repair Installation - Left (Large Repair) . . - . 65C33202-98 Repair Installation - Right (Large Repair) . - . . 65C33202-99 Repair Installation - Left (Preventive Modification) - . . . 65C33202-100 Repair Installation - Right (Preventive Modification) 1 . 1 . 65C33202-10 Filler - Outboard . 1 . 1 65C33202-105 Angle - Outboard 1 . 1 . 65C33202-106 Angle - Outboard . 1 . 1 65C33202-107 Angle - Inboard

Sep 2/70 727-57-0112 REV 5: Jul 31/97 26 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 1 -100 -99 -98 -97 Quantity Part Number Name 1 . 1 . 65C33202-108 Angle - Inboard . 1 . 1 65C33202-11 Filler - Tapered 1 1 1 1 65C33202-113 Fitting . 1 . 1 65C33202-117 Angle - Forward, Inboard 1 . 1 . 65C33202-118 Angle - Forward, Inboard 1 . 1 . 65C33202-12 Filler - Tapered . 1 . 1 65C33202-15 Spacer 1 . 1 . 65C33202-16 Spacer . . 1 1 65C33202-67 Filler . . 1 1 65C33202-85 Shim - Laminated 1 1 . . 65C33202-86 Shim - Laminated 1 . 1 . 65C33202-87 Filler 1 . 1 . 65C33202-88 Shim - Laminated . 1 . 1 65C33202-89 Filler . 1 . 1 65C33202-9 Filler - Outboard 1 1 1 1 65C33202-90 Shim - Laminated 4 4 4 4 65C21524-14 Filler - Radius . 1 . 1 65C21524-19 Angle - Outboard 1 . 1 . 65C21524-20 Angle - Outboard . 1 . 1 65C21524-21 Angle - Inboard 1 . 1 . 65C21524-22 Angle - Inboard 1 1 1 1 65C37221-1 Tension Tie - Inboard Upper 2 2 2 2 65C37221-10 Filler - Radius 1 1 1 1 65C37221-11 Filler - Radius 2 . 2 . 65C37221-12 Filler - Radius . 1 . 1 65C37221-13 Filler - Radius 2 . 2 . 65C37221-14 Filler - Radius . 2 . 2 65C37221-15 Filler - Radius . 1 . 1 65C37221-16 Filler - Radius 1 1 1 1 65C37221-2 Tension Tie - Inboard Lower . 1 . 1 65C37221-3 Tension Tie - Outboard 1 . 1 . 65C37221-4 Tension Tie - Outboard . 1 . 1 65C37221-7 Tee - Frame Attachment 1 . 1 . 65C37221-8 Tee - Frame Attachment 2 2 2 2 65C37221-9 Filler - Radius 15 15 29 29 66-2955-57 Washer - Countersink Repair 1 1 1 1 69-78758-5 Strap

Sep 2/70 727-57-0112 REV 5: Jul 31/97 27 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 1 -100 -99 -98 -97 Quantity Part Number Name 1 1 1 1 69-78758-7 Strap 2 2 2 2 BACB30MY8K11Y Bolt - 1/32 Oversized 4 4 4 4 BACB30MY8K7Y Bolt - 1/32 Oversized 2 . 2 . BACB30NW10K15Y Bolt - 1/32 Oversized 1 1 1 1 BACB30NW8K12Y Bolt - 1/32 Oversized 3 3 3 3 BACB30NW8K13Y Bolt - 1/32 Oversized 2 2 2 2 BACB30NW8K14Y Bolt - 1/32 Oversized 4 4 4 4 BACB30NW8K18Y Bolt - 1/32 Oversized 1 1 1 1 BACB30NW8K19Y Bolt - 1/32 Oversized 2 2 4 4 BACB30NX10K13Y Bolt - 1/32 Oversized 9 9 14 14 BACB30NX10K14Y Bolt - 1/32 Oversized 10 12 14 16 BACB30NX10K15Y Bolt - 1/32 Oversized 4 6 6 8 BACB30NX10K16Y Bolt - 1/32 Oversized 1 1 1 1 BACB30NX10K23 Bolt - 1/32 Oversized 1 1 1 1 BACB30NX10K25 Bolt - 1/32 Oversized 1 1 1 1 BACB30NX10K26 Bolt - 1/32 Oversized 1 1 1 1 BACB30NX10K28 Bolt - 1/32 Oversized 3 3 3 3 BACB30NX10K4 Bolt - 1/32 Oversized 1 1 2 2 BACB30NX12K15Y Bolt - 1/32 Oversized 7 7 9 9 BACB30NX12K16Y Bolt - 1/32 Oversized 7 7 13 13 BACB30NX12K17Y Bolt - 1/32 Oversized 6 5 14 13 BACB30NX12K18Y Bolt - 1/32 Oversized 4 4 8 8 BACB30NX12K19Y Bolt - 1/32 Oversized 1 1 1 1 BACB30NX12K20 Bolt 1 . 1 . BACB30NX12K21Y Bolt - 1/32 Oversized . 1 . 1 BACB30NX12K23Y Bolt - 1/32 Oversized 2 2 2 2 BACB30NX8K12Y Bolt - 1/32 Oversized 14 14 25 25 BACB30NX8K16Y Bolt - 1/32 Oversized . . 3 3 BACB30NX8K17Y Bolt - 1/32 Oversized 4 4 4 4 BACB30NX8K20 Bolt 5 5 5 5 BACB30NX8K20Y Bolt - 1/32 Oversized 1 1 1 1 BACB30NX8K23Y Bolt - 1/32 Oversized 1 1 1 1 BACB30NX8K26 Bolt 1 1 1 1 BACB30NY10K23 Bolt 1 1 1 1 BACB30NY10K25 Bolt 1 1 1 1 BACB30NY8K19Y Bolt - 1/32 Oversized 1 1 1 1 BACB30NY8K20Y Bolt - 1/32 Oversized

Sep 2/70 727-57-0112 REV 5: Jul 31/97 28 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 1 -100 -99 -98 -97 Quantity Part Number Name 2 2 2 2 BACB30US6K20 Bolt 2 2 2 2 BACB30US6K23 Bolt 6 6 6 6 BACB30US6K24 Bolt 2 2 2 2 BACB30US6K27 Bolt 25 29 38 42 BACC30AC10 Collar 26 25 47 46 BACC30AC12 Collar 22 22 36 36 BACC30AC8 Collar 2 . 2 . BACC30R10 Collar 17 17 17 17 BACC30R8 Collar 10 10 10 10 BACC30X10 Collar 5 5 5 5 BACC30X8 Collar 2 2 2 2 BACF3T02L28-11 Filler - Tapered 12 12 12 12 BACN10HR6CD Nut 2 2 2 2 BACN10JC4CD Nut 8 12 8 12 BACR10AK6 Retainer, Nut 1 . 1 . BACR15BA10D22 Rivet 2 2 2 2 BACW10BN42AP Washer 12 12 12 12 BACW10BP6AC Washer 12 12 12 12 BACW10BP6AP Washer 16 24 16 24 MS20427M4C5 Rivet

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 2 -104 -103 -102 -101 Quantity Part Number Name . . . - 65C33202-101 Repair Installation - Left side (Large Repair) . . - . 65C33202-102 Repair Installation - Right side (Large Repair) . - . . 65C33202-103 Repair Installation - Left side (Preventive Modifition) - . . . 65C33202-104 Repair Installation - Right side (Preventive Modifition) . 1 . 1 65C33202-105 Angle - Outboard 1 . 1 . 65C33202-106 Angle - Outboard . 1 . 1 65C33202-107 Angle - Inboard 1 . 1 . 65C33202-108 Angle - Inboard 111165C33202-113 Fitting

Sep 2/70 727-57-0112 REV 5: Jul 31/97 29 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 2 -104 -103 -102 -101 Quantity Part Number Name 111165C33202-115 Radius Filler . 1 . 1 65C33202-117 Angle - Forward, Inboard 1 . 1 . 65C33202-118 Angle - Forward, Inboard 111165C33202-44 Angle - Inoard . 1 . 1 65C33202-45 Angle - Outboard 1 . 1 . 65C33202-46 Angle - Outboard 111165C33202-47 Spacer 111165C33202-48 Filler - Tapered 111165C33202-50 Filler - Outboard 111165C33202-51 Shim - Laminated . . 1 1 65C33202-52 Shim - Laminated 111165C33202-53 Shim - Laminated 111165C33202-54 Angle - Pressure Retaining 1 . 1 . 65C33202-55 Filler 1 . 1 . 65C33202-56 Shim - Laminated . 1 . 1 65C33202-59 Shim - Laminated . 1 . 1 65C33202-60 Filler 444465C33202-68 Radius Filler 111165C33202-69 Filler . . 1 1 65C33202-71 Shim - Circular . 1 . 1 65C33202-95 Shim - Laminated 1 . 1 . 65C33202-96 Shim - Laminated 111165C37073-1 Tension Tie 1 . 1 . 65C37073-2 Tension Tie 2 . 2 . 65C37073-3 Radius Filler 2 . 2 . 65C37073-4 Radius Filler . 1 . 1 65C37083-1 Tension Tie . 1 . 1 65C37083-2 Radius Filler . 1 . 1 65C37083-3 Radius Filler . 1 . 1 65C37083-4 Radius Filler . 1 . 1 65C37083-5 Radius Filler . 1 . 1 65C37221-7 Tee Clip 1 . 1 . 65C37221-8 Tee Clip 111169-78758-5 Strap 2222BACB30MY14K7Y Bolt - 1/32 oversized . 2 . 2 BACB30MY14K10Y Bolt - 1/32 oversized

Sep 2/70 727-57-0112 REV 5: Jul 31/97 30 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 2 -104 -103 -102 -101 Quantity Part Number Name 2222BACB30MY14K13Y Bolt - 1/32 oversized 2222BACB30MY14K14Y Bolt - 1/32 oversized 1 1 . . BACB30MY8K10Y Bolt - 1/32 oversized 3322BACB30MY8K11Y Bolt - 1/32 oversized . . 2 2 BACB30MY8K12Y Bolt - 1/32 oversized 2 2 . . BACB30MY8K13Y Bolt - 1/32 oversized 2626BACB30MY8K6Y Bolt - 1/32 oversized 4444BACB30MY8K7Y Bolt - 1/32 oversized 2222BACB30NW8K12Y Bolt - 1/32 oversized 1111BACB30NW8K13Y Bolt - 1/32 oversized 1111BACB30NW8K14Y Bolt - 1/32 oversized . 1 . 1 BACB30NX10K19 Bolt 2121BACB30NX10K20 Bolt 2323BACB30NX10K21 Bolt 1313BACB30NX10K23 Bolt 1 . 1 . BACB30NX10K24 Bolt 2121BACB30NX10K25 Bolt 3356BACB30NX14K14Y Bolt - 1/32 oversized 6678BACB30NX14K15Y Bolt - 1/32 oversized 10 12 12 14 BACB30NX14K16Y Bolt - 1/32 oversized 5488BACB30NX14K17Y Bolt - 1/32 oversized 9 8 21 21 BACB30NX14K18Y Bolt - 1/32 oversized . . 8 8 BACB30NX14K19Y Bolt - 1/32 oversized 4454BACB30NX14K20Y Bolt - 1/32 oversized 12 14 26 28 BACB30NX8K17Y Bolt - 1/32 oversized 4242BACB30NX8K20 Bolt 4444BACB30NX8K21Y Bolt - 1/32 oversized 1111BACB30NY10K18 Bolt 1111BACB30NY10K19 Bolt 2222BACB30NY10K20 Bolt 1111BACB30NY10K21 Bolt 2222BACB30NY10K23 Bolt 1111BACB30NY10K25 Bolt 3333BACB30NY8K18Y Bolt - 1/32 oversized 2 . 2 . BACB30US7K20 Bolt 1111BACB30US7K20Y Bolt - 1/32 oversized 3232BACB30US7K24Y Bolt - 1/32 oversized

Sep 2/70 727-57-0112 REV 5: Jul 31/97 31 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16 THRU S-21 - GROUP 2 -104 -103 -102 -101 Quantity Part Number Name . 1 . 1 BACB30US7K25Y Bolt - 1/32 oversized 2424BACB30US7K26Y Bolt - 1/32 oversized 2222BACB30US7K27Y Bolt - 1/32 oversized 2222BACF3T02M26-12 Filler - Tapered 37 37 66 69 BACC30AC14 Collar 19 21 33 35 BACC30AC8 Collar 6868BACC30R14 Collar 16 20 14 18 BACC30R8 Collar 16 17 16 17 BACC30X14 Collar 4242BACC30X8 Collar 10 10 10 10 BACN10HR7 Nut 1111BACS40R019E036F Shim - Laminated 8888BACR10AK7 Retainer, Nut 2 . 2 . BACW10BP7AC Washer 8 10 8 10 BACW10BP72AC Washer 2 . 2 . BACW10BP7AP Washer 8 10 8 10 BACW10BP72AP Washer 8888MS20427M4C10 Rivet 8888MS20427M4C5 Rivet

Sep 2/70 727-57-0112 REV 5: Jul 31/97 32 BOEING SERVICE BULLETIN 727-57-0112

2. Parts and Materials Supplied by the Operator:

Quantity Part Number (Specification) Name As Necessary RTV 174 (a), (b) Silicone Rubber Adhesive As Necessary BMS 5-26, Type II, Class B Integral Fuel Tank Sealant As Necessary BMS 5-95 Sealant As Necessary BMS 10-11, Type I Primer As Necessary BACB30NW10K( ) (c)(k) Bolt As Necessary BACB30MY10K( ) (c)(l) Bolt 1 65C37221-7 (j) Tee 1 65C37221-8 (j) Tee 1 69-78758-5 (d) (e) Strap (On 727-200 Airplanes) 1 69-78758-7 (d) (e) Strap (On 727-100 Airplanes) (g) BACC30M8 (d), (e) Collar 6 BACC30M10 (c) Collar 1 BACC30M12 (e) Collar 1 BACB30MK8K16 (e) Fastener 1 BACB30MK8K20 (e) Fastener 3 BACB30MK8K16Y (e) Fastener 2 BACB30MK8K18Y (e) Fastener (h) BACB30MK8K20Y (d), (e) Fastener 1 BACB30MK12K20Y (e) Fastener 2 BACB30NW8K12Y (d), (e) Fastener 2 BACB30NW8K13Y (d), (e) Fastener 1 BACB30NW8K14Y (d), (e) Fastener 1 BACB30NW8K15Y (d), (e) Fastener 1 BACB30NW8K20Y (d), (e) Fastener 2 BACN10HR6 (e) Nut As Necessary 2024-T3 Aluminum Alloy (i) Shim As Necessary 7075-T6 Aluminum Alloy (i) Shim As Necessary BAC1506-855 x 4 (j) Tee extrusion As Necessary 7075-T73511 Aluminum (j) Tee (a) General Electric Co. (V9172) Materials Information Services 1285 Boston Ave. Bldg 29EE Bridgeport, Connecticut 06602, USA (b) RTV 102, and DC Q3-7063 are optional to RTV 174. The DC Q3-7063 is available from: Dow Corning Corporation (V71984) 3901 South Saginaw Road Midland, Michagan 48641-2721, USA (c) Necessary to make the change given in Figure 2. On 727-100 Airplanes the grip lenths can range from -9 to -14. The grip lengths on 727-200 Airplanes can range from -12 to -18. Larger diameters can be necessary if cracks were found in Figure 1.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 33 BOEING SERVICE BULLETIN 727-57-0112

(Continued)

(d) Necessary for the Repair Strap Installation, Left Side (Figure 20). (e) Necessary for the Repair Strap Installation, Right Side (Figure 21). (f) Deleted (g) 9 (left side repair), 15 (right side repair) (h) 2 (left side repair), 1 (right side repair) (i) To fill gaps, maximum thickness 0.060 inches, as specified in Accomplishment Instructions, Note 7. (j) Necessary only if there was not sufficient edge margin on the existing Tee after removal of cracks found in Figure 1. Can use the Tee 65C37221-7, or -8 Opposite, or make a tee from extrusion BAC1506-855 or Aluminum 7075-T73511 as shown in Figure 23. (k) Optional: BACB30FN10A( ) or BACB30FN10( ) (l) Optional: BACB30FM10A( ) or BACB30FM10( )

B. Parts Necessary to Change Spares

None

C. Special Tools and Equipment

Cold working tools are necessary to do the change given in this service bulletin. To get the cold working tools, refer to Paragraph I.I., Special Tools - Price and Availability.

D. Existing Parts Accountability

None

Sep 2/70 727-57-0112 REV 5: Jul 31/97 34 BOEING SERVICE BULLETIN 727-57-0112

III. ACCOMPLISHMENT INSTRUCTIONS

NOTES:

1. As recommended by the 727 SWG, make the Preventive Modification or Large Repair structural change given in Part IV or Part V at or before the airplane collects a total of 60,000 flights. Make the inspection given in Part II.A.1, Inspection, at or before the airplane collects a total of 14,000 flights, or within 3,000 flights, whichever occurs later. Continue the inspection at regularly scheduled times as given in Part II.A.2, or B.1, Inspection. The approved time between one inspection and the subsequent inspection must not be more than 14,000 flights.

2. The paragraphs identified with a letter give the general work instructions and the necessary tests. The instructions identified with numbers on the figures give the recommended sequence of steps.

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 fasteners are given in 727 Structural Repair Manual Chapter 51. - Torque limits to tighten nuts and bolts are given in 727 Structural Repair Manual Chapter 51.

4. Alternative fasteners are given in 727 Structural Repair Manual Chapter 51.

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

6. On Figures 1 and 2 do inspections as shown in the figures. On the remaining figures, make an eddy current inspection of the holes at the locations where the fasteners are replaced. Refer to the 727 Nondestructive Test Manual, Part 6, Subject 51-00-00. If fasteners other than those specified in the bulletin are removed, do an eddy current inspection of those holes too. If no cracks are found, oversize the hole by 1/32 inch diameter. Install equivalent or better oversize fasteners as shown in the 727 Structural Repair Manual. If cracks are found contact the Boeing Company for instructions.

7. The maximum clearance between parts must not be more than 0.005 inches. If the distance is more than 0.005 inches shim with 2024-T3 or 7075-T6 aluminum alloy to a maximum of 0.060 inches.

8. Maintain a 2 diameter (2D) edge margin or greater on all parts unless told differently.

9. Install all fasteners, that touch fuel, wet with Sealant BMS 5-26, type II. Install fluid tight fasteners common to the fuel tanks. Install all parts, that touch fuel, with a faying surface Sealant BMS 5-26, type II. Fill all voids with sealant.

10. Install all fasteners, that do not touch fuel, wet with Sealant BMS 5-95. Install all parts, that do not touch fuel, with a faying surface Sealant BMS 5-95. Fill all voids with sealant.

11. Revision 4 can be used as a guide to install the Kits 65C33202-1, and -2. See the drawing sent with Revision 3 of the bulletin for the part numbers, the hole diameters and fastener callout. Revision 4 also gives information on the limits that the angles in Kits 65C33202-1, -2, -19, -20, -61, and -62 can be trimmed.

12. Look at the 727 Structural Repair Manual Subject 51-30-8 for the proper size of the countersink repair washers called out in the figures or make them from the removed fasteners.

13. Make a 125 microinch finish on all edges.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 35 BOEING SERVICE BULLETIN 727-57-0112

14. Group 1 - The Repair Strap, installed at Body Station 760.95, in the preferred Kit 65C36279-35, or -36 used in Service Bulletin 727-53-0197 Revision 2 is identical to the strap used in this service bulletin. If a strap from an earlier revision of Service Bulletin 727-53-0197 has been installed, use the strap shown in this service bulletin.

15. Group 2 - If the Repair Strap 65C36279-14, 65C36279-35, or -36, from Service Bulletin 727-53-0197 is installed at Body Station 760.95, or will be installed concurrent with this service bulletin, use the strap shown in Service Bulletin 727-53-0197.

PART I - ACCESS

A Remove the seats as necessary to get access to the center section upper surface, Body Station 740 through 783. Refer to the 727 Maintenance Manual Subject 25-22-0.

B Remove the carpets as necessary to get access to the center section upper surface, Body Station 740 through 783. Refer to the 727 Maintenance Manual Subject 25-20-31 for standard passenger airplanes or 25-20-32 for passenger/cargo convertible airplanes.

C Remove the floor panels as necessary to get access to the center section upper surface, Body Station 740 through 783. Refer to the 727 Maintenance Manual Subject 53-20-11.

D Remove the interior access panels as necessary to get access to the center section upper surface, Body Station 740 through 783. Refer to the 727 Maintenance Manual Subject 25-21-1.

E Remove the pressure seal and the pressure pan to get access to the chord, Body Station 740 through 760. Refer to the 727 Maintenance Manual Subject 51-30-1.

F Remove the wing-to-body fairing as necessary to get access to Body Station 740 through 783. Refer to the 727 Maintenance Manual Subject 12-30-2.

PART II - INSPECTION

A Airplanes not changed as given in Figure 2.

1 Make an inspection for cracks as given in Figure 1, at or before the airplane collects a total of 14,000 flight cycles, or in 3,000 flights, whichever occurs later.

2 If no cracks are found, cold work the holes as given in Figure 2, install the size and type of fastener shown in Figure 2 and return the airplane to a serviceable condition as given in Part VI. Make the inspection as given in Figure 1 at regularly scheduled times. The time between one inspection and the subsequent inspection must not be more than 14,000 flight cycles. To stop the inspection made necessary by this service bulletin, make the change as given in Part V - PREVENTIVE MODIFICATION.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 36 BOEING SERVICE BULLETIN 727-57-0112

3 If cracks are found:

a That are less than one inch total in length and do not go into the horizontal flange.

NOTE: The length includes the fastener hole diameter, the crack length and the final stop hole diameter.

There are four options for repair. Before you start the repair, estimate if a stop drill will be necessary, or if the hole can be oversized sufficiently to remove the damage. Estimate the amount of edge margin between the upper fasteners and the upper flange. Also determine if the crack goes through one or more fastener holes.

NOTE: It is easier to estimate the crack length if the Frame Attach Tee is removed. This will give visual access to the vertical flange of the plus chord from the inboard side.

i Options 1 and 2: A stop drill is not necessary, and there is more than 1.0 diameter edge margin to the upper flange after the hole has been oversized:

Increase the fastener hole size in 1/64 inch increments to remove the damage. Do a second inspection for cracks as given in Figure 1. If no cracks are found, increase the hole diameter by 1/32 inch diameter. Cold work and ream the holes as given in Figure 2. After you make the fastener hole larger, and have coldworked and reamed the hole:

- Option 1: If there is 1.5 diameter edge margin to the upper flange, and a 0.375 inch diameter or smaller hole, install the size and type of fastener shown in Figure 2. Return the airplane to a serviceable condition as given in Part VI - RETURN TO SERVICE. Make the inspection as given in Figure 1 at regularly scheduled times. The time between one inspection and the subsequent inspection must not be more than 14,000 flight cycles. To stop the inspection made necessary by this service bulletin, make the change as given in Part V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR.

NOTE: If the Tee has less than 1.2 diameter edge margin install a new Tee 65C37221-7, -8 Opposite, or make a new Tee as shown in Figure 23.

- Option 2: If the hole diameter is larger than 0.375 inch, or if there is between 1.5 and 1.0 diameter edge margin to the upper flange, get alternate repair data and inspection times from Boeing or do Part III- SMALL REPAIR, or Part V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR.

ii Option 3: If a stop drill is necessary, or if the crack goes through two fastener holes, or if there is less then 1.0 diameter edge margin, do Part III - SMALL REPAIR. Continue the Small Repair inspections at 3500 flight cycle intervals, as shown in Part III.A. To terminate the inspections do Part V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR.

iii Option 4: If a stop drill is necessary, or if the crack goes through two or more fastener holes, or if there is less then 1.0 diameter edge margin, do Part V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR. This terminates the inspection made necessary by this service bulletin.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 37 BOEING SERVICE BULLETIN 727-57-0112

b That are more than one inch total in length, but do not extend aft of B.S. 766 or go into the horizontal flange, make the change as given in PART V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR. The change given in the PART V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR stops the inspections made necessary by this service bulletin.

c That extend aft of B.S. 766, but do not extend aft of B.S. 775.5 or go into the horizontal flange, make the change as given in Part IV - LARGE REPAIR. The change given in the PART IV - LARGE REPAIR stops the inspections made necessary by this service bulletin.

d That go into the horizontal flange, but do not extend aft of B.S. 775.5.

CAUTION: IF THE CRACK GOES INTO THE HORIZONTAL FLANGE, DO NOT DRILL A STOP HOLE VERTICALLY INTO THE HORIZONTAL FLANGE. THE REPAIR WITH A VERTICAL STOP HOLE TAKES MORE TIME THAN THE REPAIR WITH A HORIZONTAL STOP HOLE.

i. Remove the crack as shown in Figure 22.

ii. After the crack is removed write to Boeing for instructions. Include the information shown below:

- The distance (dimension "A") from the upper surface of the inboard horizontal flange to the deepest point of the blend out.

- A side view that shows where the blendout starts and ends. Indicate the blendout lengths and widths.

- The blend out lengths forward to aft (dimension "C"), and inboard to outboard (dimension "B").

- If possible, the minimum remaining thickness of the rib chord in the area of the blend out. Measure ultrasonically.

e That extend aft of B.S. 775.5, write to Boeing for instructions.

B Airplanes changed as given in Figure 2. Make the inspection as given in Figure 1 at the next D check (or equivalent major inspection) or before the airplane collects 14,000 more flight cycles, since the change. Use the time or flight cycles that occurs first.

1 If no cracks are found, install new fasteners. Install the size and type of fastener shown in Figure 2 and return the airplane to a serviceable condition as given in Part VI - RETURN TO SERVICE. Make the inspection as given in Figure 1 at regularly scheduled times. The time between one inspection and the subsequent inspection must not be more than 14,000 flight cycles. To stop the inspection made necessary by this service bulletin, make the change as given in Part V - PREVENTIVE MODIFICATION.

2 If cracks are found:

a That are less than one inch total in length, and do not go into the horizontal flange.

NOTE: The length includes the fastener hole diameter, the crack length and the final stop hole diameter.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 38 BOEING SERVICE BULLETIN 727-57-0112

NOTE: It is easier to estimate the crack length if the Frame Attach Tee is removed. This will give visual access to the vertical flange of the plus chord from the inboard side.

i Options 1 and 2: A stop drill is not necessary, and there is more than 1.0 diameter edge margin to the upper flange after the hole has been oversized:

NOTE: If the Tee has less than 1.2 diameter edge margin install a new Tee 65C37221-7, -8 Opposite, or make a new Tee as shown in Figure 23.

b That are more than one inch in length, but do not extend aft of B.S. 766 or go into the horizontal flange, make the change as given in PART V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR. The change given in the PART V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR stops the inspections made necessary by this service bulletin.

d That go into the horizontal flange, but do not extend aft of B.S. 775.5.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 39 BOEING SERVICE BULLETIN 727-57-0112

i. Remove the crack as shown in Figure 22.

ii. After the crack is removed write to Boeing for instructions. Include the information shown below:

- The distance (dimension "A") from the upper surface of the inboard horizontal flange to the deepest point of the blend out.

- A side view that shows where the blendout starts and ends. Indicate the blendout lengths and widths.

- The blend out lengths forward to aft (dimension "C"), and inboard to outboard (dimension "B").

- If possible, the minimum remaining thickness of the rib chord in the area of the blend out. Measure ultrasonically.

e That extend aft of B.S. 775.5, write to Boeing for instructions.

C On Group 1 Airplanes that had the Major Repair/ Preventive Modification (65C33202-1, -2 Opposite) done as shown in Revision 2, or 3, a repair strap was omitted from the drawings and kits for Revision 2, and 3. It is necessary for Group 1 Airplanes that have the Major Repair/Preventive Modification installed, as shown in Revision 2 or 3, to make an inspection at BL 70.5 for the repair strap as follows:

NOTE: Some operators have installed the strap used in Service Bulletin 727-53-0197, or an operator-furnished strap

1. Make an inspection for the repair strap at a maintenance check before the airplane collects a total of 3,000 more flight cycles, see Figure 19.

2. If the strap was not installed, refer to Service Bulletin 727-53-0197 for the inspection of the BS 760.95 frame. Install the repair strap when the repair or preventive modification shown in Service Bulletin 727-53-0197 is installed, or at a convenient maintenance time, as shown below.

a. Left Side:

1. Make the changes to the left side as shown in Figure 20.

2. Return the airplane to serviceable condition as given in Part VI.

b. Right Side:

1. Gain access to the wing upper surface and the wing fuel cell. Use the appropriate access instructions given in Part IV - LARGE REPAIR. A - Access.

2. Make the changes to the right side as shown in Figure 21.

3. Close access to the wing upper surface and the wing fuel cell. Use the appropriate access instructions given in Part IV - LARGE REPAIR. E - Restoration.

3. If the strap was not installed, and there are cracks, do Service Bulletin 727-53-0197.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 40 BOEING SERVICE BULLETIN 727-57-0112

PART III - SMALL REPAIR -

A Make the repair, refer to Drawing 65-68492 and install 65-68492-33 and/or 65-68492-34 opposite (Group 1 Airplanes) or install 65-68492-35 and/or 65-68492-36 opposite (Group 2 Airplanes).

NOTE:

1. Do not cold work the hole where the crack started. Enlarge the diameter of the hole, in the rib chord only, where the crack started. Enlarge the hole by 1/64 to 1/32 inch diameter larger than the repair fastener.

2. Airplanes that have been repaired by previous kits (65-68492-1, -2, -11, -12, -17, -18, -25, and -26) are structurally satisfactory.

Return the airplane to a serviceable condition as given in Part Vl - RETURN TO SERVICE.

Make the inspection as given in the 727 Nondestructive Test Manual, D6-48875, Part 6, Subject 51-00-00, Figure 4 (or operators equal procedure) at regularly scheduled times. The time between one inspection and the subsequent inspection must not be more than 3,500 flight cycles.

NOTES:

1. It is not necessary to remove the repair or the fasteners to do the subsequent inspections.

2. Do the inspection of the vertical flange of the rib chord from the inboard side.

3. Carefully inspect the radius of the rib chord below the inboard repair plate, and the area of the rib chord near the forward and aft sides of the inboard repair plate.

To stop the inspection given in this service bulletin, make the change as given in Part V - PREVENTIVE MODIFICATION, or Part IV - LARGE REPAIR.

B Do Part V - PREVENTIVE MODIFICATION.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 41 BOEING SERVICE BULLETIN 727-57-0112

PART IV - LARGE REPAIR

A. Access

1 Provide System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

2 Fully extend the leading edge slats. Refer to the 727 Maintenance Manual Subject 27-81-0.

3 Remove System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

4 Defuel the left wing tank, right wing tank, and center section tank. Refer to the 727 Maintenance Manual Subject 28-23-0.

5 Purge the center section fuel cells and the necessary wing fuel tank(s). Refer to the 727 Maintenance Manual Subject 28-10-0.

6 Remove and keep the center section access panel. Refer to the 727 Maintenance Manual Subject 28-11-21.

7 Remove and keep the center section fuel cell access panel. Refer to the 727 Maintenance Manual Subject 28-12-11.

8 If fuel cell bladders are installed and the Number 1 fuel cell bladder is not installed remove the intercell access panel. Refer to the 727 Maintenance Manual Subject 28-12-31.

9 Remove and keep the intercell baffle plate(s). Refer to the 727 Maintenance Manual Subject 28-12-21.

10 If fuel cell bladders are installed remove and keep the fuel cell bladder. Refer to the 727 Maintenance Manual Subject 28-12-1.

11 Remove and keep the fuel tank access panel in the wing front spar. Refer to the 727 Maintenance Manual Subject 28-11-21.

12 Remove and keep the forward retainer strip used to hold the fairing to the body.

B. Cracks

1. Drill a stop hole at the end of the cracks that do not terminate in a fastener hole (use the 727 Structural Repair Manual Subject 51-10-1). If the hole will be farther than 1 inch aft of the reference holes, shown in Figure 1, increase the stop hole diameter to 0.625 inch. Deburr the holes and make a 32 microinch finish in the holes.

2. Oversize all of the fastener holes, in the chord only, that are cracked. Increase the diameter of these holes an additional 1/64 to 1/32 inch larger than final hole size shown in Figures 4, 6, 8, 10. Only increase the hole size in the chord, not the hole size in the body skin or the structures to be added in this bulletin. The oversized holes in the chord are oversized more than the diameter of the fasteners installed through these holes. This is done so that no load is transferred from the fastener to the chord, at the crack locations.

C. Change (Group 1 Airplanes):

1 Left Chord: Make the changes shown in Figures 3 and 4.

2 Right Chord: Make the changes shown in Figures 5 and 6.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 42 BOEING SERVICE BULLETIN 727-57-0112

D. Change (Group 2 Airplanes):

1 Left Chord: Make the changes shown in Figures 7 and 8.

2 Right Chord: Make the changes shown in Figures 9 and 10.

E. Restoration

1 Install the access panels on the vent stringers, use the fasteners kept and Sealant BMS 5-26, type II.

2 Install the fuel tank access panel in the wing front spar. Refer to the 727 Maintenance Manual Subject 28-11-21.

3 Install the fuel cell bladders if they were removed. Refer to the 727 Maintenance Manual Subject 28-12-1.

4 Install the intercell baffle plate(s). Refer to the 727 Maintenance Manual Subject 28-12-21.

5 If the fuel cell bladders were installed and the Number 1 fuel cell bladder was not installed install the intercell access panel. Refer to the 727 Maintenance Manual Subject 28-12-31.

6 Install the center section fuel cell access panel. Refer to the 727 Maintenance Manual Subject 28-12-11.

7 Install the center section access panel. Refer to the 727 Maintenance Manual Subject 28-11-21.

8 Fuel the left wing tank, right wing tank, and center section tank and check for leaks. Refer to the 727 Maintenance Manual Subject 28-11-0.

9 Provide System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

10 Fully retract the leading edge slats. Refer to the 727 Maintenance Manual Subject 27-81-0.

11 Remove System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

12 Return the airplane to serviceable condition as given in Part VI.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 43 BOEING SERVICE BULLETIN 727-57-0112

PART V - PREVENTIVE MODIFICATION

A Access

1 Provide System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

2 Fully extend the leading edge slats. Refer to the 727 Maintenance Manual Subject 27-81-0.

3 Remove System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

4 Defuel the left wing tank, right wing tank, and center section tank. Refer to the 727 Maintenance Manual Subject 28-23-0.

5 Purge the center section fuel cells and the necessary wing fuel tank(s). Refer to t.0he 727 0..0Maintenance Manual Subject 28-10-0.

6 Remove and keep the center section access panel. Refer to the 727 Maintenance Manual Subject 28-11-21.

7 Remove and keep the center section fuel cell access panel. Refer to the 727 Maintenance Manual Subject 28-12-11.

8 If fuel cell bladders are installed and the Number 1 fuel cell bladder is not installed remove the intercell access panel. Refer to the 727 Maintenance Manual Subject 28-12-31.

9 Remove and keep the intercell baffle plate(s). Refer to the 727 Maintenance Manual Subject 28-12-21.

10 If fuel cell bladders are installed remove and keep the fuel cell bladder. Refer to the 727 Maintenance Manual Subject 28-12-1.

11 Remove and keep the fuel tank access panel in the wing front spar. Refer to the 727 Maintenance Manual Subject 28-11-21.

12 Remove and keep the forward retainer strip used to hold the fairing to the body.

B Cracks

1. Drill a stop hole at the end of the cracks that do not terminate in a fastener hole (use 727 Structural Repair Manual Subject 51-10-1). If the hole will be farther than 1 inch aft of the reference holes, shown in Figure 1, increase the stop hole diameter to 0.625 inch. Deburr the holes and make a 32 microinch finish in the holes.

2. Oversize all of the fastener holes, in the chord only, that are cracked. Increase the diameter of these holes an additional 1/64 to 1/32 inch larger than final hole size shown in Figures 12, 14, 16, 18. Only increase the hole size in the chord, not the hole size in the body skin or the structures to be added in this bulletin. The oversized holes in the chord are oversized more than the diameter of the fasteners installed through these holes. This is done so that no load is transferred from the fastener to the chord, at the crack locations.

C Change (Group 1 Airplanes):

1 Left Chord: Make the changes shown in Figures 11 and 12.

2 Right Chord: Make the changes shown in Figures 13 and 14.

Sep 2/70 727-57-0112 REV 5: Jul 31/97 44 BOEING SERVICE BULLETIN 727-57-0112

D Change (Group 2 Airplanes):

1 Left Chord: Make the changes shown in Figures 15 and 16.

2 Right Chord: Make the changes shown in Figures 17 and 18.

E Restoration