85-01-02 R1 McDONNELL DOUGLAS: Amendment 39-4978 as amended by Amendment 39-5241. Applies to Model DC-9 and C-9 (Military) series airplanes, Fuselage Numbers 1 through 1087, certificated in any category. \n\n\tCompliance required as indicated, unless previously accomplished. \n\n\tTo detect fatigue cracks and prevent structural failure of the fuselage cabin aft ventral pressure bulkhead, P/N 5910130 (and rework drawing numbers 5924597 and 5924350), accomplish the following: \n\n\tA.\tExcept for those airplanes that are subject to paragraph K., below, for airplanes with 15,000 or more landings on or after the effective date of this AD, within the next 700 additional landings or, for airplanes which have been inspected in accordance with AD 80-10-03, at the next inspection scheduled in accordance with AD 80-10-03 after the effective date of this AD, conduct visual and x-ray inspections in accordance with the instructions contained in Service Sketch 2934C, of McDonnell Douglas Service Bulletin 53-137, Revision 3, dated August 4, 1983. \n\n\tNOTE: McDonnell Douglas Service Bulletin 53-137, Revision 3, dated August 4, 1983, is herein referred to as SB 53-137, R3. \n\n\tB.\tIf no cracks are found in the bulkhead web and doublers, in the areas of the doorjamb upper LH and RH corners, identified in Figure 1 of Service Sketch 2934C of SB 53-137, R3, for those corner areas: \n\n\t\t1.\tAt intervals not to exceed 2,000 landings from last inspection, repeat the visual inspections required by paragraph A., above; and \n\n\t\t2.\tAt intervals not to exceed 4,000 landings from last inspection, repeat the x-ray inspections required by paragraph A., above. \n\n\t\t3.\tRepetitive inspections must be continued until terminating action in accordance with paragraph K., below, has been accomplished. \n\n\tC.\tIf cracks are found in the bulkhead web and doublers, for both Group I and II airplanes (as defined in SB 53-137, R3) accomplish the following: \n\n\t\t1.\tFor cracks found in the upper left and/or right bend radius, with no radial cracks, modify and inspect upper corners of bulkhead in accordance with paragraph 2.C. (Accomplishment Instructions) of SB 53-137, R3. \n\n\t\t2.\tFor new cracks found in the upper left bend radius, with no radial cracks and with Condition II modification installed, modify and inspect corners of bulkhead per paragraph 2.D. of SB 53-137, R3. \n\n\t\t3.\tFor new cracks found in the upper right bend radius, with no radial cracks and with Condition I modification installed, modify and inspect upper corners of bulkhead in accordance with paragraph 2.E. of SB 53-137, R3. \n\n\t\t4.\tFor radial crack(s) found in any or all members of upper right corner, with or without bend radius cracks, modify and inspect corners of bulkhead in accordance with paragraph 2.I. of SB 53-137, R3. \n\n\t\t5.\tFor radial and/or bend radius crack(s), found in upper left and/or right corner(s) or portion of upper left and/or right bulkhead skin which exceeds the repairable limits of Conditions I through XVII, XX, or XXII through XXXIV (any noted conditions), or at operator's option for replacement of cracked parts that are within repairable limits, in lieu of repair modification, replace cracked parts in accordance with paragraph 2.J. of SB 53-137, R3. Reinstate repetitive inspections of the upper corners within 15,000 landings and at intervals noted in paragraphs B.1., B.2., and B.3., above. \n\n\t\t6.\tFor radial crack(s) found in any or all members of lower left and/or right corner radius (except P/N 5910130-9/-11 side channel), with or without cracks in the lower inboard tab portion of the P/N 5910130-3/-5 bulkhead skin, modify and inspect corners of bulkhead in accordance with paragraph 2.L. of SB 53-137, R3. \n\n\t\t7.\tFor crack(s) found in any or all members which extends below the lower edge of the P/N 5910130-37 channel forward vertical leg; replace cracked parts, and inspect corners in accordance with paragraph 2.N. of SB 53-137, R3. Reinstate repetitive inspectionswithin 15,000 landings and at intervals noted in paragraphs B.1., B.2., and B.3., above. \n\n\t\t8.\tFor radial crack(s) found in P/N 5910130-3/-5 side bulkhead skin at one or more of the five lower inboard fasteners through the P/N 5910130-9/-11 side channel, install doublers and inspect lower corners in accordance with paragraph 2.0. of SB 53-137, R3. \n\n\t\t9.\tFor new radial crack(s) found in P/N 5910130-3/-5 side bulkhead skin at one or more of the five inboard fasteners through the P/N 5910130-9/-11 side channel, and preventive corner repair modification in accordance with Condition XIII has been installed, modify and inspect in accordance with paragraph 2.P. of SB 53-137, R3. \n\n\t\t10.\tFor new radial crack(s) found in any or all members of upper right corner, with or without bend radius cracks in P/N 5910130-13 doubler, and with Condition I modification installed, modify and inspect upper corners in accordance with paragraph 2.Y. of SB 53-137, R3. \n\n\tD.\tIf no crack(s) are found inthe lower corners of the bulkhead web and doublers, for both Groups I and II airplanes (as defined in SB 53-137, R3); install preventive repair modification and repetitively inspect lower corners at 15,000 landing intervals in accordance with paragraph 2.M. of SB 53-137, R3. If preventive repair is not installed, repetitively inspect at intervals in accordance with paragraph B., above. \n\n\tE.\tIf cracks are found in the bulkhead web and doublers in Group I airplanes, accomplish the following: \n\n\t\t1.\tFor radial crack(s) found in any or all members of upper left or both upper left/right corners, with or without bend radius cracks, modify and inspect corners of bulkhead in accordance with paragraph 2.F. of SB 53-137, R3. \n\n\t\t2.\tFor new radial crack(s) found in any or all members of upper right corners, with or without bend radius cracks, and with Condition XXII modification installed, modify and inspect corners of bulkhead in accordance with paragraph 2.Q. of SB 53-137, R3. \n\n\t\t3.For radial crack(s) found in P/N 5910130-13 doubler at upper left and/or right corner running along heel line of P/N 5910130-95 left and/or -96 right door stop angle, with or without radial cracks in any or all member of upper left and/or right corners, and with or without crack(s) in upper left and/or right bend radius of the forward flange of P/N 5910130-13 doubler, modify and inspect upper corners of bulkhead in accordance with paragraph 2.T. of SB 53-137, R3. \n\n\t\t4.\tFor new radial crack(s) found in any or all members of upper left corner, with or without bend radius cracks, and with Condition V modification installed, modify and inspect upper corners of bulkhead in accordance with paragraph 2.V. of SB 53-137, R3. \n\n\t\t5.\tFor new radial crack(s) found in any or all members of upper left corner, with or without bend radius cracks in P/N 5910130-13 doubler, and with Condition II modification installed, modify and inspect upper corners in accordance with paragraph 2.W. of SB 53-137,R3. \n\n\tF.\tIf no crack(s) are found in the bulkhead web and doublers in Group I airplanes, the interim crack preventative repair modification may be installed and the upper corners repetitively inspected at 15,000 landing intervals in accordance with paragraph 2.G. of SB 53-137, R3. If preventive repair modification is not installed, repetitively inspect at intervals specified in accordance with paragraph B., above. \n\n\tG.\tIf cracks are found in the bulkhead web and doublers for Group II airplanes, accomplish the following: \n\n\t\t1.\tFor radial crack(s) found in any or all members of upper left or both upper left/right corners, with or without bend radius cracks, modify and inspect corners of bulkhead in accordance with paragraph 2.H. of SB 53-137, R3. \n\n\t\t2.\tFor new radial crack(s) found in any or all members of upper right corner, with or without bend radius cracks, and with Condition IV modification installed, accomplish paragraph 2.R. of SB 53-137, R3. \n\n\t\t3.\tFor new radialcrack(s) found in any or all members of upper left corner, with or without bend radius cracks, and with Condition V modification installed, accomplish paragraph 2.S. of SB 53-137, R3. \n\n\t\t4.\tFor radial crack(s) found in P/N 5910130-13 doubler, at upper left and/or right corner running along heel line of P/N 5910130-95/-96, side door stop angle, with or without radial cracks in any or all members of upper left and/or right corners, and with or without crack(s) in upper left and/or right bend radius of forward flange of P/N 5910130-13, doubler, modify and inspect corners of bulkhead in accordance with paragraph 2.U. of SB 53-137, R3. \n\n\t\t5.\tFor radial crack(s) found in any or all members of upper left corner, with or without bend radius cracks in 5910130-13 doubler, and with Condition II modification installed, modify and inspect upper corners in accordance with paragraph 2.X. of SB 53-137, R3. \n\n\tH.\tIf no crack(s) are found in the bulkhead web and doublers in Group II airplanes, the interim crack preventive modification may be installed and the upper corners repetitively inspected at 15,000 landing interval in accordance with paragraph 2.K. of SB 53-137, R3. If preventive repair modification is not installed, repetitively inspect at intervals specified in accordance with paragraph B., above. \n\n\tI.\tMcDonnell Douglas DC-9 Service Bulletin A53-144, or later FAA approved revisions, must be accomplished within 18 months after the effective date of this AD. \n\n\tJ.\tFor aircraft modified per DC-9 Service Bulletin 53-139 (basic), or production equivalent, accomplish McDonnell Douglas DC-9 Service Bulletin 53-157 within 18 months after effective date of this AD. \n\n\tK.\tFor airplanes previously modified in accordance with DC-9 Service Bulletin 53-139 (Original Issue or Revision 1), or production equivalent, accomplish modification of the pressure bulkhead in accordance with Part 2 of the Accomplishment Instructions of DC-9 Service Bulletin 53-165 prior to the accumulation of 15,000 cycles after accomplishment of the modification or aircraft delivery (as applicable) or prior to the accumulation of the 5,400 landings after the effective date of Amendment 39-5241, whichever occurs later. Accomplishment of the modification referenced above constitutes terminating action for the requirements of this AD. \n\n\tL.\tFor airplanes not previously modified in accordance with DC-9 Service Bulletin 53-139 (Original Issue and Revision 1), or production equivalent, accomplishment of modifications in accordance with DC-9 Service Bulletin 53-166, Revision 1, dated January 31, 1983, or later FAA-approved revision, constitutes terminating action for the requirements of this AD. \n\n\tM.\tPrevious accomplishment of any rework or inspection(s), or portion(s) thereof, which is outlined in McDonnell Douglas DC-9 Service Bulletin 53-137, Revision 1, dated December 6, 1979, required by AD 80-10-03, Amendment 39-3769, effective May 15, 1980, which is also outlined in McDonnellDouglas DC-9 Service Bulletin 53-137, Revision 2, or SB 53-137, R3, provided for in AD 80-10-03, may be considered an equivalent to that requirement of this AD. \n\n\tN.\tThe inspections and modifications required by this AD need not be accomplished if, after the effective date of this AD, the aircraft is operated without cabin pressurization and a placard is installed in the cockpit, in full view of the pilots, stating: "OPERATION WITH CABIN PRESSURIZATION IS PROHIBITED." \n\n\tO.\tSpecial flight permits may be issued in accordance with FAR 21.197 and 21.199 to operate airplanes to a base for the accomplishment of modifications required by this AD. \n\n\tP.\tUpon the request of an operator, an FAA Maintenance Inspector, subject to prior approval by the Manager, Los Angeles Aircraft Certification Office, FAA, Northwest Mountain Region, may adjust the repetitive inspection intervals of the operator if the request contains substantiating data to justify the increase for that operator. \n\n\tQ.Alternate means of compliance which provide an equivalent level of safety may be used when approved by the Manager, Los Angeles Aircraft Certification Office, FAA, Northwest Mountain Region. \n\n\tAll persons affected by this directive who have not already received the appropriate service documents from the manufacturer may obtain copies upon request to McDonnell Douglas Corporation, 3855 Lakewood Boulevard, Long Beach, California 90846, Attention: Director, Publications and Training, C1-750 (54-60). These documents also may be examined at the FAA, Northwest Mountain Region, 17900 Pacific Highway South, Seattle, Washington, or the Los Angeles Aircraft Certification Office, 4344 Donald Douglas Drive, Long Beach, California. \n\n\tThis supersedes AD 80-10-03, Amendment 39-3769 (45 FR 31052; May 15, 1980). \n\n\tAmendment 39-4978 became effective February 14, 1985. \n\n\tThis Amendment 39-5241 becomes effective March 31, 1986.