Airworthiness Directive · Amendment 39-16737 · Fuselage
The Boeing Company Model 767 Airplanes
This AD applies to all The Boeing Company Model 767-200, -300, -300F, and -400ER series airplanes, certificated in any category.
The FAA is superseding an existing airworthiness directive (AD) that applies to all Model 767 airplanes. The existing AD currently requires repetitive detailed and high frequency eddy current (HFEC) inspections of the station (STA) 1809.5 bulkhead for cracking, and corrective actions if necessary. This AD expands the inspection area to include the vertical inner chord at STA 1809.5. This AD results from reported fatigue cracking in the vertical inner chord and the forward outer chord while doing the detailed inspection of the horizontal inner chord at STA 1809.5. We are issuing this AD to detect and correct fatigue cracking in the bulkhead structure at STA 1809.5 and the vertical inner chord at STA 1809.5, which could result in failure of the bulkhead structure for carrying the flight loads of the horizontal stabilizer, and consequent loss of controllability of the airplane.
You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done.
Before the accumulation of 15,000 total flight cycles, or within 3,000 flight cycles after January 2, 2007 (the effective date of AD 2006-24-04 (71 FR 68432, November 27, 2006)), whichever is later: Do the detailed and high frequency eddy current (HFEC) inspections for cracking as specified in Parts 1, 2, 3, and 4 of the Accomplishment Instructions of Boeing Alert Service Bulletin 767-53A0131, dated March 30, 2006; or Revision 1, dated March 12, 2009; and do all corrective actions before further flight; by accomplishing all the actions specified in the Accomplishment Instructions of Boeing Alert Service Bulletin 767-53A0131, dated March 30, 2006; or Revision 1, dated March 12, 2009; except as provided by paragraph (h) of this AD. After the effective date of this AD, use only Boeing Alert Service Bulletin 767-53A0131, Revision 1, dated March 12, 2009. Repeat the inspections thereafter at intervals not to exceed 6,000 flight cycles. Accomplishing the corrective action for the inspections specified in Part 1, 2, 3, or 4, as applicable, of Boeing Alert Service Bulletin 767-53A0131, dated March 30, 2006; or Revision 1, dated March 12, 2009; as applicable; terminates the repetitive inspections for that area only.
If any cracking is found in the skin or in any structure other than the forward outer chord, horizontal inner chord, or vertical inner chord during any inspection required by paragraph (g) or (k) of this AD, and Boeing Alert Service Bulletin 767-53A0131, dated March 30, 2006; or Revision 1, dated March 12, 2009; specifies to contact Boeing for appropriate action: Before further flight, repair the cracking using a method approved in accordance with the procedures specified in paragraph (n) of this AD; except that repairing or replacing stringers in accordance with Subject 53-00-03—Fuselage Stringers, of the applicable SRM identified in table 1 of this AD is an acceptable method of compliance for those specific actions required by this AD.
(i) For airplanes on which no cracking is found during the most recent detailed and HFEC inspections for a specified area as required by paragraph (g) of this AD: Paragraphs (i)(1) through (i)(5) of this AD provide optional terminating action for the repetitive inspections required by paragraph (g) of this AD for the specified area only.
(1) Modification of a specified area in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA, terminates the repetitive inspections required by paragraph (g) of this AD for that area only.
(2) Modification of a forward outer chord in accordance with the procedures specified in paragraphs (i)(2)(i) through (i)(2)(v) of this AD, as applicable, terminates the repetitive inspections required by paragraph (g) of this AD for that area only.
(i) For Model 767-200 series airplanes: Steps 4.A through 4.C and Steps 4.G through 4.P of Repair 9, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-200 Structural Repair Manual (SRM), Document D634T201.
(ii) For Model 767-300 series airplanes: Steps 4.A through 4.C and Steps 4.G through 4.P of Repair 9, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-300 SRM, Document D634T210.
(iii) For Model 767-300F series airplanes: Steps 4.A through 4.C and Steps 4.G through 4.P of Repair 9, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-300F SRM, Document D634T215.
(iv) For Model 767-300BCF series airplanes: Steps 4.A through 4.C and Steps 4.G through 4.P of Repair 9, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-300BCF SRM, D634T235.
(v) For Model 767-400 series airplanes: Steps 4.A through 4.C and Steps 4.G through 4.P of Repair 9, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-400 SRM, Document D634T225.
(3) Modification of a forward outer chord in accordance with Steps 4.A through 4.C and 4.G through 4.P of Repair 9 of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the applicable SRM identified in table 1 of this AD also terminates the repetitive inspections required by paragraph (g) of this AD for that area.
(4) Modification of a horizontal inner chord in accordance with the procedures specified in paragraphs (i)(4)(i) through (i)(4)(v) of this AD, as applicable, terminates the repetitive inspections required by paragraph (g) of this AD for that area.
(i) For Model 767-200 series airplanes: Steps 4.A, 4.B, and 4.F through 4.P of Repair 10, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-200 SRM, Document D634T201.
(ii) For Model 767-300 series airplanes: Steps 4.A, 4.B, and 4.F through 4.P of Repair 10, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-300 SRM, Document D634T210.
(iii) For Model 767-300F series airplanes: Steps 4.A, 4.B, and 4.F through 4.P of Repair 10, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-300F SRM, Document D634T215.
(iv) For Model 767-300BCF series airplanes: Steps 4.A, 4.B, and 4.F through 4.P of Repair 10, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-300BCF SRM, Document D634T235.
(v) For Model 767-400 series airplanes: Steps 4.A, 4.B, and 4.F through 4.P of Repair 10, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-400 SRM, Document D634T225.
(5) Modification of a horizontal inner chord in accordance with Steps 4.A, 4.B, and 4.F through 4.P of Repair 10 of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the applicable SRM identified in Table 1 of this AD also terminates the repetitive inspections required by paragraph (g) of this AD for that area.
| SRM | Revision | Date |
|---|---|---|
| Boeing 767-200 SRM, Document D634T201 | 105 | December 15, 2010. |
| Boeing 767-300 SRM, Document D634T210 | 85 | December 15, 2010. |
| Boeing 767-300F SRM, Document D634T215 | 49 | December 15, 2010. |
| Boeing 767-300BCF SRM, Document D634T235 | 9 | December 15, 2010. |
| Boeing 767-400 SRM, Document D634T225 | 32 | December 15, 2010. |
Note 1: We have reformatted paragraph (i) of this AD to differentiate the methods of compliance specified in that paragraph.
Repair of a forward outer chord done before January 2, 2007, in accordance with Repair 9, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-200 SRM, Document D634T201; Boeing 767-300 SRM, Document D634T210; Boeing 767-300F SRM, Document D634T215; Boeing 767-300BCF SRM, D634T235; or Boeing 767-400 SRM, Document D634T225; as applicable; is acceptable for compliance with the requirements of paragraph (g) of this AD for that area only. Repair of a horizontal inner chord before January 2, 2007, in accordance with Repair 10, dated April 15, 2006, of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the Boeing 767-200 SRM, Document D634T201; Boeing 767-300 SRM, Document D634T210; Boeing 767-300F SRM, Document D634T215; Boeing 767-300BCF SRM, Document D634T235; or Boeing 767-400 SRM, Document D634T225; as applicable; is acceptable for compliance with the terminating requirements of paragraph (g) of this AD for that area only.
At the later of the times specified in paragraphs (k)(1) and (k)(2) of this AD: Do the detailed and HFEC inspections for cracking as specified in Parts 5 and 6 of the Accomplishment Instructions of Boeing Alert Service Bulletin 767-53A0131, Revision 1, dated March 12, 2009; and do all applicable corrective actions by accomplishing all the actions specified in the Accomplishment Instructions of Boeing Alert Service Bulletin 767-53A0131, Revision 1, dated March 12, 2009; except as provided by paragraph (h) of this AD. Do all applicable corrective actions before further flight. Repeat the inspections thereafter at intervals not to exceed 6,000 flight cycles. Accomplishing the corrective action for the inspections specified in Part 5 or 6 of the Accomplishment Instructions of Boeing Alert Service Bulletin 767-53A0131, Revision 1, dated March 12, 2009, as applicable, terminates the repetitive inspections for that area only.
(1) Before the accumulation of 15,000 total flight cycles or within 6,000 flight cycles after the inspection required by paragraph (g) of this AD, whichever occurs later.
(2) Within 30 days after the effective date of this AD.
For airplanes on which no cracking is found during the most recent detailed and HFEC inspections for a specified area, as required by paragraph (k) of this AD: Paragraphs (l)(1) and (l)(2) of this AD provide optional terminating action for the repetitive inspections required by paragraph (k) of this AD for that area only. After the effective date of this AD, only the applicable SRM identified in table 1 of this AD or a method approved by the Manager, Seattle ACO, may be used.
(1) Modify the specified area in accordance with Steps 4.A through 4.C and 4.G through 4.Q of Repair 11 of Subject 53-80-08, Fuselage Bulkheads—Section 48, of the applicable SRM identified in table 1 or table 2 of this AD, except as provided by paragraph (m) of this AD.
(2) Modify the specified area in accordance with a method approved by the Manager, Seattle ACO.
| Steps— | Dated— | Of— |
|---|---|---|
| 4.A through 4.C and 4.G through 4.Q of Repair 11 of Subject 53-80-08 | August 15, 2008 | Boeing 767-200 SRM, Document D634T201. |
| 4.A through 4.C and 4.G through 4.Q of Repair 11 of Subject 53-80-08 | August 15, 2008 | Boeing 767-300 SRM, Document D634T210. |
| 4.A through 4.C and 4.G through 4.Q of Repair 11 of Subject 53-80-08 | August 15, 2008 | Boeing 767-300F SRM, Document D634T215. |
| 4.A through 4.C and 4.G through 4.Q of Repair 11 of Subject 53-80-08 | August 15, 2008 | Boeing 767-300BCF SRM, Document D634T235. |
| 4.A through 4.C and 4.G through 4.Q of Repair 11 of Subject 53-80-08 | August 15, 2008 | Boeing 767-400 SRM, Document D634T225. |
Note 2: We have reformatted paragraph (l) of this AD to differentiate the methods of compliance specified in that paragraph.
If, during accomplishment of any modification in accordance with paragraph (l) of this AD, any cracking is found and the applicable SRM referenced in paragraph (l) of this AD specifies to contact Boeing for appropriate action: Before further flight, repair the cracking in accordance with a method approved by the Manager, Seattle ACO. 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.
