67-05-03 MCDONNELL DOUGLAS: Amend. 39-347 as amended by amendment 39-1160. Applies to Model DC-8 Series (except DC-8-61) and DC-8F Series Airplanes as Indicated Herein. \n\n\tCompliance required as indicated. \n\n\tNumerous reports have been received concerning cracks in the inboard and outboard pylons and pylon stub wing structure. These cracks have been found in the skins, bulkheads, and spar caps. The cracks have varied in length, and in some cases, the parts have cracked completely through. To prevent further failure of this nature, accomplish the following, or an equivalent approved by the Chief, Aircraft Engineering Division, FAA Western Region: \n\n\t(a)\tFor all inboard and outboard pylons that have accumulated a total of 6,000 or more hours' time in service at the effective date of this AD, unless already accomplished within the last 2,000 hours' time in service, and for all inboard and outboard pylons accumulating a total of 6,000 hours' time in service after the effective date of this AD, within the next 1,000 hours' time in service, conduct a visual inspection as follows: \n\n\t\t(1)\tInspect outboard pylons in the area of the pylon stub wing lower skin and doubler for cracks in the cutout for the leading edge lower slot door on airplanes with Serial Numbers 45256-45272, 45274-45277, 45282, 45284-45289, 45292-45300, 45304-45306, 45376=45382, 45384-45390, 45392, 45393, 45408-45413, 45418, 45419, 45421, 45425-45427, 45429-45431, 45433-45437, 45445, 45565-45567, 45569, 45570, 45596, 45597, 45602, 45603, 45605, 45606, 45609-45612, 45626, 45627, 45638, 45645, 45646, 45649, 45650, 45672, 45673, 45687-45690, 45806-45808, 45815, 45877. Refer to Service Sketch No. 754 of Douglas Engineering Service Letter C1-78-2016/DBA, October 18, 1966, or later revisions for location of the cracks. If no cracks are found during this inspection, repeat the inspection at intervals not to exceed 3,000 hours' time in service from the date of the last inspection. If cracks arefound during this inspection or any reinspection, the defective parts must be replaced before further flight with uncracked parts, or parts reworked in a manner approved by the Chief, Aircraft Engineering Division, FAA Western Region. When a rework is accomplished, or a replacement part is installed that is specifically intended as a redesign to prevent further cracking of these areas and approved as such, the repetitive inspection requirements may be discontinued. \n\n\t\t(2)\tInspect at Station YOP 229 the outboard pylon inboard skin in the vicinity of the slot leading edge on airplanes with Serial Numbers 45252-45272, 45274-45283, 45289, 45291-45300, 45304-45306, 45376-45382, 45384-45393, 45418, 45419, 45421-45427, 45429-45431, 45433-45437, 45442-45445, 45565-45567, 45569, 45570, 45588-45597, 45602, 45603, 45605, 45609-45612, 45626, 45627, 45638, 45645, 45646, 45649, 45650. If no cracks are found during this inspection, repeat the inspection at intervals not to exceed 3,000 hours' time in service from the date of the last inspection. Parts found cracked during the inspection or any reinspection must be reworked before further flight in accordance with Douglas Service Bulletins Nos. 54-30, Kits J and K, dated November 27, 1962, 54-31, Kits L and M dated November 30, 1962, or 54-32, Kits J and K, dated December 28, 1962, or later FAA-approved revisions, whichever is applicable to the serial number of the airplanes listed therein. After rework in accordance with this AD, the repetitive inspection requirement may be discontinued. \n\n\t\t(3)\tInspect at YOP Station 252 to YOP Station 262 the aft inboard flex panel on the outboard pylons on airplanes with Serial Numbers 45252-45263, 45274-45276, 45278-45283, 45289, 45291-45297, 45376-45379, 45384-45387, 45391, 45392, 45416, 45418, 45419, 45422-45427, 45429, 45442-45445, 45567, 45569, 45588-45595, 45598-45600, 45602, 45603. If no cracks are found during this inspection, repeat the inspection at intervals not to exceed 3,000 hours' time in service from the date of the last inspection. Parts found cracked during the inspection or any reinspection must be repaired in a manner approved by the Chief, Aircraft Engineering Division, FAA Western Region, before further flight or replaced before further flight in accordance with Douglas Service Bulletins Nos. 54-10 Kit F, dated August 17, 1960, 54-14, Kit B, dated November 3, 1960, or later FAA approved revisions, whichever is applicable to the serial number of the airplane listed therein. After repair or replacement in accordance with this AD, the repetitive inspection requirement may be discontinued. \n\n\t\t(4)\tInspect the inboard side of the inboard pylon in the area of the D-duct spar angle and the pylon side skin on airplanes with Serial Numbers 45253-45272, 45274-45283, 45289, 45291-45300, 45304-45306, 45376-45382, 45384-45393, 45418, 45419, 45421-45427, 45429-45431, 45433-45437, 45442-45445, 45565-45567, 45569, 45570, 45588-45597, 45602, 45603, 45605,45606, 45609-45612, 45626, 45627, 45638. Refer to Service Sketch No. 756, Douglas Service Engineering Letter C1-78-2106/DBA, October 18, 1966, or later revisions for location of cracks. If no cracks are found during this inspection, repeat the inspection at intervals not to exceed 3,000 hours' time in service from the date of the last inspection. Parts found cracked during this inspection or any reinspection, must be replaced before further flight with uncracked parts or parts reworked in a manner approved by the Chief, Aircraft Engineering Division, FAA Western Region. When a rework is accomplished, or a replacement part is installed that is specifically intended as a redesign to prevent further cracking of these areas, and approved as such, the repetitive inspections required may be discontinued. \n\n\t(b)\tOn all airplanes having Serial Numbers 45252-45272, 45274-45289, 45291-45306, 45376-45393, 45408-45413, 45416-45427, 45429-45431, 45433-45437, 45442-45445, 45526, 45565-45570, 45588-45614, 45616-45630, 45632-45638, 45640-45651, 45653, 45655-45663, 45665-45673, 45676, 45684, conduct an inspection for cracks on all upper inboard and outboard spar caps of the outboard pylons in the area between Sta. YOP 214 and Sta. YOP 255, and repair or replace if necessary as follows: \n\n\t\t(1)\tUnless already accomplished within the last 475 hours' time in service within the next 25 hours' time in service after the effective date of this AD, visually inspect the outboard pylons that have accumulated a total of 8,000 hours' time in service as of the effective date of this AD; or \n\n\t\t(2)\tFor outboard pylons that have not accumulated a total of 8,000 hours' time in service as of the effective date of this AD, visually inspect them within 25 hours' time in service after 8,000 hours' time in service is reached. \n\n\t\t(3)\tIf no cracks are found during the inspections required by paragraphs (b)(1) or (b)(2), the inspections required therein must be repeated at intervals not to exceed 500 hours' time in service from the date of the last inspection. If cracks are found during this inspection or any reinspection before further flight, replace or repair in accordance with Douglas Service Bulletins Nos. 54-33, dated March 15, 1963, 54-35, dated April 9, 1965, or later FAA-approved revisions, whichever is applicable to the affected airplane. Upon replacement or repair as provided for in this AD, the 500 hours' repetitive inspection may be discontinued. \n\n\t\t(4)\tThe inspections required in Paragraph (b)(1) and (b)(2) do not apply to airplanes modified in accordance with McDonnell Douglas Service Bulletin Nos. 54-33, dated March 15, 1963; 54-35, dated April 9, 1965; or later FAA-approved revisions. Each service bulletin contains the airplane serial numbers to which it is applicable. \n\n\tHowever, all airplanes modified in accordance with S.B. Nos. 54-33 or 54-35 must be reinspected per Paragraph (b) above within the next 1500 hours' time in service after the effective date of this AD amendment, unless already accomplished within the last 1500 hours' time in service, and thereafter at intervals not to exceed 3000 hours' time in service. Upon installation of an improved spar kit per McDonnell Douglas S.B. 54-57, Revision 1, dated December 9, 1969, or later FAA approved revision, these repetitive inspections may be discontinued. \n\n\t(c)\tOn all airplanes with Serial Number 45252-45272, 45274-45289, 45291-45306, 45376-45393, 45408-45413, 45416-45427, 45429-45431, 45433-45437, 45442-45445, 45526, 45565-45570, 45588-45614, 45616-45630, 45632-45638, 45640-45651, 45653, 45655-45694, 45750, 45752-45760, 45762-45769, 45800, 45809, 45814-45821, 45824, 45850-45862, 45877-45882, 45886, 45916, conduct an inspection on the cant bulkhead fittings in all outboard pylons, and on the cant bulkhead fittings in all inboard pylons for the referenced serial numbers, with the addition of Serial Number 45883, in the area shown on Service Sketch No. 669, Douglas Engineering Service Letter C1-78-2016/DBA, October 18, 1966, or later FAA-approved revision, and rework or replace, if necessary, as follows - \n\n\t\t(1)\tUnless already accomplished within the last 2,000 hours' time in service, within the next 1,000 hours' time in service after the effective date of this AD, visually inspect the inboard and outboard pylons that have accumulated 10,000 or more hours' time in service as of the effective date of this AD; or \n\n\t\t(2)\tFor those inboard and outboard pylons referenced in paragraph (c) that have not accumulated a total of 10,000 hours' time in service as of the effective date of this AD, visually inspect them within 1,000 hours' time in service after 10,000 hours' time in service is reached. \n\n\t\t(3)\tIf no cracks are found during the inspection required by paragraphs (c)(1) and (2), repeat the inspection at intervals not to exceed 3,000 hours' time in service from the date of the last inspection. If cracks are found during inspection or reinspectionbefore further flight, replace the defective parts with uncracked parts, or rework in a manner approved by the Chief, Aircraft Engineering Division, FAA Western Region. When a rework is accomplished, or a replacement part is installed that is specifically intended to prevent further cracking of the structure and is approved as such, the repetitive inspection requirement may be discontinued. \n\n\t(d)\tUpon request of the operator, an FAA maintenance inspector, subject to prior approval of the Chief, Aircraft Engineering Division, FAA Western Region, may adjust the repetitive inspection intervals specified in this AD to permit compliance at an established inspection period of the operator if the request contains substantiating data to justify the increase for the operator. \n\n\t(Douglas Service Engineering Letter C1-78-2016/DBA dated October 18, 1966, or later revisions, covers this subject.) \n\n\tAmendment 39-347 effective February 4, 1967. \n\n\tThis Amendment 39-1160 becomes effectiveApril 4, 1971.