2010-14-07 The Boeing Company: Amendment 39-16352. Docket No. FAA- 2008-0981; Directorate Identifier 2008-NM-073-AD. \n\nEffective Date \n\n\t(a) This AD becomes effective August 5, 2010. \n\nAffected ADs \n\n\t(b) This AD supersedes AD 2006-05-06, Amendment 39-14503. \n\nApplicability \n\n\t(c) This AD applies to The Boeing Company Model 747-100, 747- 100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR, and 747SP series airplanes, certificated in any category, line numbers 1 though 1307 inclusive. \n\nSubject \n\n\t(d) Air Transport Association (ATA) of America Code 53: Fuselage. \n\nUnsafe Condition \n\n\t(e) This AD results from reports of cracked aft inner chords on airplanes after certain requirements of the existing AD were done. We are issuing this AD to prevent fatigue cracking of the body station (BS) 2598 bulkhead structure, which could result in inability of the structure to carry horizontal stabilizer flight loads, and loss of controllability of the airplane. \n\nCompliance \n\n\t(f) You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done. \n\nRestatement of Requirements of AD 2006-05-06 \n\nRepetitive High Frequency Eddy Current (HFEC) Inspections of the Bulkhead Frame Supports \n\n\t(g) Before the accumulation of 10,000 total flight cycles, or within 1,000 flight cycles after August 16, 2001 (the effective date of AD 2001-14-07, Amendment 39-12318, which was superseded by AD 2006-05-06), whichever occurs later: Do an open-hole HFEC inspection to find cracking of the bulkhead frame support under the hinge support fittings of the horizontal stabilizer on the left and right sides at BS 2598, in accordance with Figure 2 of the Accomplishment Instructions of Boeing Service Bulletin 747-53A2449, Revision 1, dated May 24, 2001; or Revision 2, dated March 14, 2002. Repeat the inspection after that at intervals not to exceed 3,000 flight cycles. Inspections accomplished before August 16, 2001, per Boeing Alert Service Bulletin 747-53A2449, dated June 8, 2000, are considered acceptable for compliance with the applicable inspection specified in this paragraph. \n\nRepair of Any Cracked Bulkhead Frame Support \n\n\t(h) If any cracking is found during any inspection required by paragraph (g) of this AD, before further flight, repair using a method approved in accordance with the procedures specified in paragraph (x) of this AD. \n\nRepetitive Inspections of Inner Chords, Frame Support Fitting, and Splice Fitting \n\n\t(i) Do a surface HFEC inspection of the forward and aft inner chords, the frame support, and the splice fitting of the forward inner chord of the upper corners of the station 2598 bulkhead to find cracking, in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2427, Revision 2, dated October 5, 2000; Revision 3, dated September 27, 2001; or Boeing Service Bulletin747-53A2427, Revision 5, dated October 1, 2009; at the latest of the times specified in paragraphs (i)(1) and (i)(2) of this AD, as applicable. Repeat the inspection after that at intervals not to exceed 1,500 flight cycles. After the effective date of this AD, Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, must be used. \n\n\t(1) For airplanes having line numbers 1 through 1241 inclusive: \n\n\t(i) Before the accumulation of 6,000 total flight cycles. \n\n\t(ii) Within 500 flight cycles after August 28, 2001 (the effective date of AD 2001-15-03, Amendment 39-12337, which was superseded by AD 2006-05-06). \n\n\t(iii) For airplanes inspected before August 28, 2001, in accordance with Boeing Alert Service Bulletin 747-53A2427, dated December 17, 1998 (including inspections of the splice fitting); or Revision 1, dated October 28, 1999: Within 1,500 flight cycles after accomplishment of the last inspection done in accordance with the original service bulletin or Revision 1, as applicable. \n\n\t(2) For airplanes having line numbers 1242 through 1307 inclusive: \n\n\t(i) Before the accumulation of 16,000 total flight cycles.\n\n\t(ii) Within 500 flight cycles after August 28, 2001. \n\n\t(iii) For airplanes inspected before August 28, 2001, in accordance with Boeing Alert Service Bulletin 747-53A2427, dated December 17, 1998 (including inspections of the splice fitting), or Revision 1, dated October 28, 1999: Within 1,500 flight cycles after accomplishment of the last inspection done in accordance with Boeing Alert Service Bulletin 747-53A2427, dated December 17, 1998; or Revision 1, dated October 28, 1999; as applicable. \n\nRepair of Any Cracked Inner Chord, Frame Support, or Splice Fitting \n\n\t(j) If any cracking is found during the inspections required by paragraph (i) of this AD, before further flight, repair in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2427, Revision 2, dated October 5, 2000; Revision3, dated September 27, 2001; or Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009. After the effective date of this AD, Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, must be used. Where Boeing Alert Service Bulletin 747-53A2427, Revision 2, dated October 5, 2000; Revision 3, dated September 27, 2001; or Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009; specifies that the manufacturer may be contacted for disposition of certain repair conditions, before further flight, repair using a method approved in accordance with the procedures specified in paragraph (x) of this AD. \n\nRepetitive Detailed Inspections of BS 2598 Bulkhead \n\n\t(k) Before the accumulation of 10,000 total flight cycles, or within 1,000 flight cycles after October 27, 2003 (the effective date of AD 2003-19-08, Amendment 39-13311, which was superseded by AD 2006-05-06), whichever is later: Do a detailed inspection of the BS 2598 bulkhead for discrepancies (cracking, elongated fastener holes) of the areas specified in paragraphs (k)(1) and (k)(2) of this AD, in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2467, dated July 26, 2001; or Boeing Service Bulletin 747-53A2467, Revision 1, dated April 28, 2005. Repeat the inspections after that at intervals not to exceed 3,000 flight cycles, except as required by paragraph (m) of this AD. Doing the modification specified in paragraph (m) or (q) of this AD terminates the inspection of the area specified in paragraph (k)(1) of this AD. \n\t(1) The lower aft inner chords. \n\n\t(2) The upper aft outer chords, and the diagonal brace attachment fittings, flanges, and rods. \n\n\tNote 1: For the purposes of this AD, a detailed inspection is "an intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required.'' \n\nRepair of Any Cracked BS 2598 Bulkhead \n\n\t(l) If any discrepancy is found during any inspection required by paragraph (k) of this AD: Before further flight, repair in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2467, dated July 26, 2001; or Boeing Service Bulletin 747-53A2467, Revision 1, dated April 28, 2005. If Boeing Alert Service Bulletin 747-53A2467, dated July 26, 2001; or Boeing Service Bulletin 747-53A2467, Revision 1, dated April 28, 2005; specifies to contact Boeing for appropriate action: Before further flight, repair using a method approved in accordance with the procedures specified in paragraph (x) of this AD. \n\nTerminating Modification With New Compliance Time for Certain Airplanes for the Inspection Specified in Paragraph (k)(2) of This AD \n\n\t(m) Except as provided by paragraph (q) of this AD: Before the accumulation of 20,000 total flight cycles, or within 48 months after April 13, 2006 (the effective date of AD 2006-05-06), whichever occurs later, modify the bulkhead by doing all applicable actions including surface and open-hole HFEC inspections for cracking of the upper forward inner chords, aft inner chords, upper splice fittings, and frame support fittings, as specified in the Accomplishment Instructions of Boeing Service Bulletin 747-53-2473, dated March 24, 2005; Revision 1, dated February 20, 2007; or Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009. Repair any cracks before further flight, in accordance with Boeing Service Bulletin 747-53-2473, dated March 24, 2005; Revision 1, dated February 20, 2007; or Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009. Where Boeing Service Bulletin 747-53-2473, dated March 24, 2005; Revision 1, dated February 20, 2007; or Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009; specifies that the manufacturer may be contacted for disposition of certain repair conditions: Before further flight, repair the cracks using a method approved in accordance with the procedures specified in paragraph (x) of this AD. Accomplishment of the modification terminates the requirements of paragraphs (g), (i), and (k)(1) of this AD. After the effective date of this AD, Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009, must be used for the actions specified in this paragraph. For airplanes that are converted to the Model 747-400 Large Cargo Freighter (LCF) configuration, repeat the inspection specified in paragraph (k)(2) of this AD thereafter at intervals not to exceed 1,800 flight cycles. \n\nPost-Modification Inspection and Repair \n\n\t(n) Except as provided by paragraphs (q) and (r) of this AD: Within 20,000 flight cycles after doing the modification required by paragraph (m) of this AD, inspect the BS 2598 bulkhead for cracks, and repair any cracks before further flight, in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO). \n\nNew Requirements of This AD \n\nTerminating Repair for Repetitive Surface HFEC Inspections \n\n\t(o) As of the effective date of this AD, accomplishing the aft inner chord repair required by paragraph (j) of this AD in accordance with the Accomplishment Instructions of Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, ends the repetitive surface HFEC inspections required by paragraph (i) of this AD for that side of the bulkhead only. \n\nReplacement of Previously Repaired Aft Inner Chord and Reinstallation of Terminating Modification \n\n\t(p) For airplanes on which the terminating modification required by paragraph (m) of this AD has been done in accordance with Boeing Service Bulletin 747-53-2473, dated March 24, 2005: Within 1,500 flight cycles after doing the modification, or within 1,000 flight cycles after the effective date of this AD, whichever occurs later, do a one-time general visual inspection for repairs installed previously on the left and right side aft inner chords. For airplanes with previously installed repairs, before further flight, do rework (i.e., replace any previously repaired aft inner chord with a new aft inner chord and reinstall the terminating modification), using a method approved in accordance with the procedures specified in paragraph (x) of this AD. \n\nRevised Terminating Modification \n\n\t(q) Doing the applicable modification required by paragraph (q)(1) or (q)(2) of this AD at the applicable time terminates the requirements of paragraph (m) of this AD and the repetitive inspections required by paragraphs (g), (i), and (k)(1) of this AD. For airplanes that are converted to the Model 747-400 LCF configuration, the inspection specified in paragraph (k)(2) of this AD must be repeated thereafter at intervals not to exceed 1,800 flight cycles. \n\n\t(1) For airplanes on which the terminating modification required by paragraph (m) of this AD has not been done as of the effective date of this AD: Before the accumulation of 20,000 total flight cycles, or within 18 months after the effective date of this AD, whichever occurs later, modify the bulkhead, in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747- 53A2473, Revision 2, dated August 28, 2009; except that where Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009, specifies to contact Boeing for modification data, the modification data must be approved in accordance with the procedures specified in paragraph (x) of this AD, and the modification must be done within the times specified in this paragraph. \n\n\t(2) For airplanes on which the terminating modification required by paragraph (m) of this AD has been done in accordance with Boeing Service Bulletin 747-53-2473, dated March 24, 2005; or Revision 1, dated February 20, 2007; as of the effective date of this AD: Within 1,000 flight cycles after the effective date of this AD, or within 1,500 flight cycles after doing the modification, whichever occurs later, do a general visual inspection of the applicable areas specified in paragraph (q)(2)(i) and (q)(2)(ii) of this AD to determine if certain fasteners are installed, and, before further flight, do all applicable related investigative and corrective actions, in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009; except where Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009, specifies to contact Boeing for repair or rework data, the data must be approved in accordance with the procedures specified in paragraph (x) of this AD and the repair or rework must be done before further flight. \n\n\t(i) For airplanes modified in accordance with Boeing Service Bulletin 747-53-2473, dated March 24, 2005:Inspect the upper forward inner chord, frame support fitting, and splice fitting, in accordance with paragraph 3.B.7.d. of the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009. \n\n\t(ii) For airplanes modified in accordance with Boeing Service Bulletin 747-53-2473, Revision 1, dated February 20, 2007: Inspect the frame web and upper shear deck aft side, and the upper forward inner chord, frame support fitting, and splice fitting, in accordance with paragraphs 3.B.7.c and 3.B.7.d of the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009. \n\nPost-Modification Inspection and Repair \n\n\t(r) For airplanes on which the terminating modification has been done in accordance with paragraph (m) or (q) of this AD: Perform post-modification inspections of the BS 2598 bulkhead for cracking, in accordance with Parts 1, 2, and 3 of the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009. Do the inspections at the applicable times specified in Tables 6 through 9 of paragraph 1.E., "Compliance,'' of Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009; except where Boeing Alert Service Bulletin 747- 53A2473, Revision 2, dated August 28, 2009, specifies a compliance time after the date of that service bulletin, this AD requires compliance within the specified compliance time after the effective date of this AD. If any cracking is found during any inspection required by this paragraph, before further flight, repair using a method approved in accordance with the procedures specified in paragraph (x) of this AD. Repeat the inspections thereafter at the applicable times specified in Tables 6 through 9 of paragraph 1.E., "Compliance,'' of Boeing Alert Service Bulletin 747-53A2473, Revision 2, dated August 28, 2009. Accomplishing the applicable inspections required by this paragraph terminates the requirements of paragraph (n) of this AD. \n\nOpen-Hole HFEC Inspection(s) and Terminating Repair \n\n\n\t(s) For airplanes on which the terminating modification required by paragraph (m) or (q) of this AD has not been done: Do an initial open-hole HFEC inspection to detect cracks in the bulkhead splice fitting, frame support fitting, and forward and aft inner chords on the left and right sides of the BS 2598 bulkhead, in accordance with the Accomplishment Instructions of Boeing Service Bulletin 747- 53A2427, Revision 5, dated October 1, 2009. Do the initial inspection at the applicable time specified in Table 1 or 3 of paragraph 1.E., "Compliance,'' of Boeing Service Bulletin 747- 53A2427, Revision 5, dated October 1, 2009; except where Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, specifies a compliance time after the date on that service bulletin, this AD requires compliance within the specified compliance time after the effective date of this AD. \n\n\t(1) If no crack is detected, repeat the open-hole HFEC inspection thereafter at intervals not to exceed 1,500 flight cycles. \n\n\t(2) If any crack is detected, before further flight, repair it in accordance with the Accomplishment Instructions of Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009; except where Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, specifies to contact Boeing for appropriate action, before further flight, repair the crack using a method approved in accordance with the procedures specified in paragraph (x) of this AD. Accomplishing the aft inner chord repair in accordance with the Accomplishment Instructions of Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, ends the repetitive surface and open-hole HFEC inspections required by paragraphs (i) and (s)(1), respectively, of this AD for that side of the bulkhead only. \n\nInterim Modification \n\n\t(t) For Group 1 airplanes, as identified in Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, on which the repair required by paragraph (j) or (s)(2) of this AD has not been done; and on which the terminating modification required by paragraph (m) or (q) of this AD has not been done: Before the accumulation of 12,000 total flight cycles, or within 1,500 flight cycles after the effective date of this AD, whichever occurs later, install the interim modification for the aft inner chords, in accordance with the Accomplishment Instructions of Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009. Accomplishing the interim modification ends the repetitive surface and open-hole HFEC inspections required by paragraphs (i) and (s)(1), respectively, of this AD. \n\nPost-Interim Modification/Repair Repetitive Surface and Open-Hole HFEC Inspections \n\n\t(u) For airplanes on which the interim modification required by paragraph (t) of this AD has been done or the repair required by paragraph (j) or (s)(2) of thisAD has been done; and on which the terminating modification required by paragraph (m) or (q) of this AD has not been done: At the applicable times specified in Table 1, 2, or 3 of paragraph 1.E., "Compliance,'' of Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, do a surface HFEC inspection to detect cracks on the forward side (unmodified area) of the bulkhead, and open-hole and surface HFEC inspections to detect cracks in the modified or repaired area, in accordance with the Accomplishment Instructions of Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009. Repeat the open-hole and surface HFEC inspections thereafter at intervals not to exceed 1,500 flight cycles, until the modification required by paragraph (q) of this AD is done, as applicable; except that for airplanes on which the repair of any cracked aft inner chord has been done on only one side of the bulkhead in accordance with the applicable requirements specified in paragraph (j) or (s)(2) of this AD, the repetitive surface and open-hole HFEC inspections required by paragraphs (i) and (s)(1), respectively, of this AD must continue to be done for the other side of the bulkhead. \n\nRepair of Any Cracked Inner Chord, Splice Fitting, or Frame Support Fitting \n\n\t(v) If any crack is detected during any surface or open-hole HFEC inspection required by paragraph (u) of this AD, before further flight, repair any cracked inner chord, splice fitting, or frame support fitting, in accordance with the Accomplishment Instructions of Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009; except where Boeing Service Bulletin 747-53A2427, Revision 5, dated October 1, 2009, specifies to contact Boeing for appropriate action, before further flight, repair the crack using a method approved in accordance with the procedures specified in paragraph (x) of this AD. \n\nActions Accomplished According to Previous Issue of Service Bulletin \n\n\t(w) Inspections, interimmodification, and repairs accomplished before the effective date of this AD in accordance with Boeing Alert Service Bulletin 747-53A2427, Revision 4, dated March 6, 2008, are considered acceptable for compliance with the corresponding action specified paragraphs (i), (j), (s), (t), (u), and (v) of this AD. \n\nAlternative Methods of Compliance (AMOCs) \n\n\t(x)(1) The Manager, Seattle ACO, FAA, has the authority to approve AMOCs for this AD, if requested using the procedures found in 14 CFR 39.19. Send information to ATTN: Ivan Li, Aerospace Engineer, Airframe Branch, ANM-120S, FAA, Seattle ACO, 1601 Lind Avenue SW., Renton, Washington 98057-3356; telephone (425) 917-6437; fax (425) 917-6590. Information may be e-mailed to: 9-ANM-Seattle- ACO-AMOC-Requests@faa.gov. \n\n\t(2) To request a different method of compliance or a different compliance time for this AD, follow the procedures in 14 CFR 39.19. Before using any approved AMOC on any airplane to which the AMOC applies, notify your principal maintenance inspector (PMI) or principal avionics inspector (PAI), as appropriate, or lacking a principal inspector, your local Flight Standards District Office. The AMOC approval letter must specifically reference this AD. \n\n\t(3) An AMOC that provides an acceptable level of safety may be used for any repair required by this AD, if it is approved by Boeing Commercial Airplanes Organization Designation Authorization (ODA) that has been authorized by the Manager, Seattle ACO, to make those findings. For a repair method to be approved, the repair must meet the certification basis of the airplane, and the approval must specifically refer to this AD. \n\n\t(4) AMOCs approved previously in accordance with AD 2006-05-06 are approved as AMOCs for the corresponding provisions of this AD. \n\nMaterial Incorporated by Reference \n\n\t(y) You must use the service information contained in Table 1 of this AD, as applicable, to do the actions required by this AD, unless the AD specifies otherwise. \n\t\nTable 1--All Material Incorporated by reference\n\n\nDocument\nRevision\nDate\nBoeing Alert Service Bulletin 747-53A2467 \nOriginal\nJuly 26, 2001\nBoeing Alert Service Bulletin 747-53A2473 \n2\nAugust 28, 2009\nBoeing Service Bulletin 747-53A2427 \n5\nOctober 1, 2009\nBoeing Service Bulletin 747-53A2449\n1\nMay 24, 2001\nBoeing Service Bulletin 747-53A2449\n2\nMarch 14, 2002\nBoeing Service Bulletin 747-53A2467\n1\nApril 28, 2005\n\n\t(1) The Director of the Federal Register approved the incorporation by reference of the service information contained in Table 2 of this AD under 5 U.S.C. 552(a) and 1 CFR part 51. \n\t\nTable 2--New Material Incorporated by Reference\n\n\nDocument\nRevision\nDate\nBoeing Alert Service Bulletin 747-53A2473 \n2\nAugust 28, 2009\nBoeing Service Bulletin 747-53A2427 \n5\nOctober 1, 2009\n\n\t(2) On April 13, 2006 (71 FR 12125, March 9, 2006), the Director of the Federal Register approved the incorporation by reference of Boeing Service Bulletin 747-53A2449, Revision 2, dated March 14, 2002; and Boeing Service Bulletin 747-53A2467, Revision 1, dated April 28, 2005. \n\n\t(3) On October 27, 2003 (68 FR 54990, September 22, 2003), the Director of the Federal Register approved the incorporation by reference of Boeing Alert Service Bulletin 747-53A2467, dated July 26, 2001. \n\n\t(4) On August 16, 2001 (66 FR 36443, July 12, 2001), the Director of the Federal Register approved the incorporation by reference of Boeing Service Bulletin 747-53A2449, Revision 1, dated May 24, 2001. \n\n\t(5) For service information identified in this AD, contact Boeing Commercial Airplanes, Attention: Data & Services Management, P.O. Box 3707, MC 2H-65, Seattle, Washington 98124-2207; telephone 206-544-5000, extension 1; fax 206-766-5680; e-mail me.boecom@boeing.com; Internet https://www.myboeingfleet.com. \n\n\t(6) You may review copies of the service information at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington. For information on the availability of this material at the FAA, call 425-227-1221. \n\n\t(7) You may also review copies of the service information that is incorporated by reference at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http:// www.archives.gov/federal_register/code_of_federal_regulations/ ibr_locations.html.