This revision is issued to revise the inspection requirements of the
forward hinge fitting on the landing gear door, and the fastener holes in
the flap track web.
This will be in phase with Service Bulletin
727-57-0178 which is recommended to be performed concurrently with this
bulletin.
Notice of Status Changes 2 and 3 have been incorporated.
Airplane effectivity is updated to reflect current airplane ownership.
Airplanes modified per Revision 2 of this service bulletin do not require
additional work.
A revision bar in the left margin along with this revision number and date
indicates a change.
Absence of a revision bar on a page bearing this
revision number and date means only that existing copy has been moved or
that a minor typographical error has been corrected.
Original
Revision
Revision
Revision
Issue:
1:
2:
3:
January 22, 1987
December 10, 1987
September 7, 1989
May 24, 1990
Twenty operators have reported 40
broken main landing gear door forward
hinge fittings on the airplanes. The
airplanes had
accumulated between
8,100 - 50,600 flight hours when hinge
fittings broke. The hinge fitting is
attached to the inboard track of the
inboard flap. The hinge fittings are
made
from
7079-T6
or
7075-T73
materials.
Cracks have occurred in
both types of fittings. At least 16
cases of cracking in the flap track
web have been reported, including 3
cases
in
which
the
crack
had
propagated downward and completely
severed the lower horizontal flange.
The track is made of 4330M steel.
Recently, one of the doors was lost.
The cause of breakage and cracks are
due to fatigue.
a.
Within 12,000 flight cycles or 8
years
since
repair,
whichever
occurs first, or
b.
Within 1,000 flight cycles or 6
months after the receipt of this
service bulletin, whichever occurs
first.
Modify unrepaired tracks by oversize
and cold work of the common attachment
holes in the hinge fitting and flap
track.
Reinstall the hinge in the
track with new
bolts,
nuts
and
washers.
EFFECTIVITY
All 727 airplanes
MANPOWER
Modifications, 29 Man-Hours per
Airplane
ACTION
MATERIAL INFORMATION
Inspect for cracks and corrosion at
the main landing gear door forward
hinge attachment on the inboard track
of the wing trailing edge flap, and
the flap track web.
Tracks having
cracks within the defined limits may
be repaired by stop drilling at the
end of the cracks.
Operator furnished parts
Tracks previously repaired per Repair
Drawing 65-68420 should be replaced
because
Damage
Tolerance
Analysis
Methods indicates that the repair does
not provide for adequate inspection of
the damaged track. Replace the track
within the time interval of a. or b.
below, whichever occurs later:
Summary Page 1 of 2
Jan 22/87
REV. 3: May 24/90
Summary Page 2 of 2
I.
PLANNING INFORMATION
A.
Effectivity
1.
Airplanes Affected
See Service Bulletin Index Part 3 for cross reference of Variable
Number to Airplane Serial Number.
This change is applicable to all 727 airplanes.
2.
Spares Affected
None
Jan 22/87
REV. 3: May 24/90
727-32-0340
Page 1 of 16
B.
Reason
This modification will reduce the probability of main landing gear
door forward hinge fitting breakage or cracks in the inboard track of
the inboard flap and loss of the main landing gear door, inboard flap
track and flap system.
Twenty operators have reported 40 broken main landing gear door
The airplanes had
forward hinge fittings on the airplanes.
accumulated between 8,100 - 50,600 flight hours when hinge fittings
The hinge fitting is attached to the inboard track of the
broke.
inboard flap. The hinge fittings are made from 7079-T6 or 7075-T73
Cracks
Cracks have occurred in both types of fittings.
materials.
is
fitting
hinge
the
where
web
track
have also been found in the
have
web
track
flap
the
in
cracking
of
cases
16
At
least
attached.
been reported, incluidng 3 cases in which the crack had propagated
The
downward and completely severed the lower horizontal flange.
track is made of 4330M steel. Tracks previously repaired per Repair
Drawing 65-68420 should be replaced because Damage Tolerance Analysis
Methods indicates that the repair does not provide for adequate
inspection of the damaged track. Replace the track within the time
interval of a. or b. below, whichever occurs later:
a.
Within 12,000 flight cycles or 8 years since repair, whichever
occurs first, or
b.
Within 1,000 flight cycles or 6 months after the receipt of this
service bulletin, whichever occurs first.
Recently, one of the doors was lost.
is due to fatigue.
Jan 22/87
REV. 3: May 24/90
The cause of breakage and cracks
727-32-0340
2
Revision 1 was issued to amend the kit number for the Fatigue
Technology Inc. cold working kit, and to revise the cold working
instructions in Figure 1.
Subsequent to the initial issue of the subject bulletin, it was found
that simultaneous cold working of aluminum and steel could not be
accomplished utilizing Kit FTI-727-32-0340-1 as listed. -Therefore,
Fatigue Technology Inc. developed FTI-727-32-0340-2 that can be used
for the required cold working.
Revision 2 revised the inspection requirement and added the
replacement requirement of the flap track. The permissible length of
cracks was reduced to one inch or less, providing all other criteria
per Figure 1 could be met, the interim repair by stop drilling could
be done. If cracks were longer, progressing towards the lower flange,
or could not meet directional requirements per Figure 1, the track
must be replaced.
The landing gear door hinge installation was
changed to use all steel washers and added countersunk washers under
the bolthead.
Revision 3 revises the inspection requirements to be in phase with
Service Bulletin 727-57-0178 which is recommended to be performed
concurrently with this bulletin. Notice of Status Changes 2 and 3
have been incorporated.
Jan 22/87
REV. 3: May 24/90
727-32-0340
3
C.
Description
1.
Accomplish inspection a. or b. for the main landing gear door
forward hinge and attachment area on the inboard track of the
wing trailing edge flap as follows:
a.
Perform close visual inspection of track at the main landing
gear door forward hinge attachment area and the hinge
The flaps or flap tracks are not required to be
itself.
removed for this inspection.
If no cracking or corrosion is found, repeat the close
visual inspection at intervals not to exceed 3,000 flight
cycles or 18 months, whichever occurs first, or install
preventive modification per Figure 1.
If cracks are found and are less than one inch in length and
not progressing towards the lower flange and not with an
orientation 30 degrees either side of the vertical, stop
drill the crack. Repeat a close visual inspection every
3,000 flight cycles or 18 months, whichever occurs first
until flap track replacement.
If cracks found are longer than one inch or progressing
towards lower flange, or not meeting specified directional
requirements per Figure 1, the track must be replaced.
If only superficial corrosion
deferred for 12 months.
Jan 22/87
REV. 3: May 24/90
is
found,
repair
may
be
727-32-0340
4
b.
Remove the door hinge fitting from the flap track and
penetrant inspect for cracks in the hinge fitting. If no
cracks are found, remove the finish and bushing and
High frequency eddy current or
shot-peen the fitting.
magnetic particle inspect the flap track hinge attachment
holes and area around, common to the hinge fittings.
If cracks are found and are less than one inch in length and
are not progressing towards the lower flange and are not
with an orientation 30 degrees either side of the vertical
(see Figure 1), stop drill the cracks and repeat a close
visual inspection every 3,000 flight cycles or 18 months,
whichever occurs first until the flap track replacement.
If cracks found are longer than one inch or progressing
specified
towards the lower flange, or not meeting
directional requirements per Figure 1, the track must be
replaced.
If no cracks are found in either the hinge or the track,
oversize and cold work common attachment holes in hinge
fitting and flap track. Flap or shot peen the flap track
and reinstall the hinge fitting with new bolts, nuts and
washers.
Repeat cold work and/or shot peen is not required if already
performed.
The modification of the hinge fitting and the flap track may
be deferred for 12,000 flight cycles provided that a close
visual inspection is repeated every 3,000 flight cycles or
18 months, whichever occurs first. If corrosion is found,
contact Boeing with details.
2.
For tracks and hinge fittings that have not been modified or
repaired per Service Bulletin 727-32-0340, accomplish inspection
and/or modification per item 1 above within the following time
intervals, whichever occurs later:
a.
Prior to the accumulation of 7,000 flight cycles or five
years since manufacture, whichever occurs first, or
b.
Within the next 3,000 flight cycles or 18 months since last
visual inspection, whichever occurs first, or
c.
Within the next 9,000 flight cycles or six years since the
last visual, penetrant and high frequency eddy current or
magnetic particle inspections, whichever occurs first, or
d.
Within the next 1,000 flight cycles or six months after
receipt of this service bulletin, whichever occurs first.
Jan 22/87
REV. 3: May 24/90
727-32-0340
5
3.
For tracks that have been modified per Service Bulletin
727-32-0340, original issue or Revision 1, accomplish inspection
per item 1 above within the following time intervals, whichever
occurs later:
since
Within the next 9,000 flight cycles, or
modification, whichever occurs first, or
b.
Within the next 9,000 flight cycles or six years since the
last visual, penetrant and high frequency eddy current or
magnetic particle inspection, whichever occurs first, or
c.
Within the next 3,000 flight cycles or 18 months since last
visual inspection, whichever occurs first, or
d.
Within the next 1,000 flight cycles or six months after
receipt of this service bulletin, whichever occurs first.
NOTE:
If no cracks are found in either the hinge or the track,
reinstall the hinge fitting with new bolts, nuts and
washers.
Repeat cold work and/or shot peen
already performed.
4.
six years
a.
is not
required if
The modification of the hinge fitting and the flap track after
the visual, penetrant and high frequency eddy current or magnetic
particle inspections will terminate the special inspection
requirement of this service bulletin. Therefore, as an economic
consideration, an early incorporation of the modification is
recommended.
NOTE:
Jan 22/87
REV. 3: May 24/90
Concurrent incorporation of
727-57-0178 is recommended.
Boeing
Service
Bulletin
727-32-0340
6
D.
Approval
This service bulletin has been reviewed by the Federal Aviation
Administration (FAA) and the modifications herein comply with the
applicable Federal Aviation Regulations (FAR's) and are FAA approved.
E.
Manpower
Approximately 29 man-hours are required to accomplish the modification
per airplane.
The following breakdown of manpower requirements is suggested as a
guide to assist operators in planning and accomplishing this
modification.
This estimate is for direct labor performed by an
experienced
crew.
It
does
not
include
setup,
planning,
familiarization, cure time, part fabrication, tool acquisition, or
lost time.
Factor this estimate as necessary based on your own
experience.
Crew size
Man-Hours
Elapsed
Time
(Hours)
Access
4
4
1.0
Inspection
4
5
1.3
Modification
4
14
3.5
Restoration
4
6
1.5
29
7.3
Operation
TOTAL PER AIRPLANE
Jan 22/87
REV. 3: May 24/90
727-32-0340
7
F.
Material - Price and Availability
The kits identified in Paragraphs II.A may be obtained from Boeing
The quotation is
within the terms and conditions defined below.
computed from date of receipt of operator's purchase orders. Improved
flow times may be possible if necessary to support operator's planned
modification schedule. Therefore, operators are requested-to include
planned dates of incorporation on their purchase orders.
Kit Number
Description
Delivery
65-26763-17
65-26763-18
65-19270-12
Fitting
Fitting
Track Assembly
36 wks
38 wks
51 wks
Unit Price
$ 686.00
$ 686.00
$45,151.00
Date May 24. 1990
The prices quoted are subject to the terms and conditions of Boeing's
standard purchase order acknowledgement. Quotations are subject to
acceptance within 120 days from date hereon. After expiration of the
quotation, price and delivery data will be provided upon request.
Prices quoted in United States Dollars. Terms: Net 30 days.
Address purchase orders and correspondence pertaining to this
quotation to Director of Spares, and refer to this service bulletin
number.
G.
Tooling - Price and Availability
All required cold work tools and sleeves for accomplishment of this
service bulletin may be selected from appropriate tables in
727 Structural Repair Manual Subject 51-30-10 and procured from
industry sources, as required.
Two sources which provide cold work tools, as well as engineering and
service, are Fatigue Technology, Inc., and West Coast Industries, Inc.
Also available from both companies is a kit of cold work tooling
specifically tailored to the requirements of this service bulletin.
Jan 22/87
REV. 3: May 24/90
727-32-0340
8
H.
Weight and Balance
None
I.
References
1.
2.
Existing Data:
a.
727 Maintenance Manual Subjects 27-51-1, 27-51-31, 32-12-11
b.
727 Structural Item Interim Advisories 727-45, 727-206
c.
727 Structural Repair Manual Subject 51-30-10
d.
Boeing Standard Overhaul Practices Manual 20-10-3
e.
Boeing Service Bulletin 727-32-234, "Main Landing Gear Wing
Door Bushing Replacement"
f.
Boeing Repair Drawing 65-68420 provided to operators per
individual request.
g.
Boeing Service Bulletin 727-57-0178, Rev. 2 "Wings - Inboard
TE Flaps Inboard Track - Track Modification and Repair"
Data supplied in support of this service bulletin:
None
J.
Publications Affected
Publication
Chapter-Section
727 Illustrated Parts Catalog................. 32-10
Jan 22/87
REV. 3: May 24/90
727-32-0340
9
II.
MATERIAL INFORMATION
A.
Parts Required Per Airplane
1.
The following hinge fitting and flap
obtained as noted in Paragraph I.F.
NOTE:
1
1
2
Quantity
2
4
4
6
4
10
4
6
4
B.
Part Number
Nomenclature
65-26763-17
65-26763-18
65-19270-12
Fitting, Left Side
Fitting, Right Side
Track Assembly
(Left or Right Side)
The following parts and materials are to be
operator.
As
As
As
As
be
New hinge fittings and flap track assemblies, if existing
ones are broken or cracked beyond limits, and operator
furnished materials listed in Paragraph II.A.2 are
required to modify each airplane.
Quantity
2.
track assembly may
Required
Required
Required
Required
furnished by
Part Number or
Specification
Nomenclature
BACB30LE5-24
BACB30LE5-26
BACB30LE6-24
BACN1OHR5
BACN1OHR6
BACW1OBP5P
BACW1OBP6P
BACWlOBP5C
BACW1OBP6C
65-72718-3
BMS 10-11,Type I
BMS 10-11,Type II
BMS 5-95, Class B
Bolt
Bolt
Bolt
Nut
Nut
Washer
Washer
Washer
Washer
Shim
Epoxy Primer
Semi-Gloss, Epoxy Enamel
Sealant
the
Parts Required to Modify Spares
None
C.
Special Tools and Equipment Required
Cold Working Tools are required during accomplishment of this service
bulletin.
See Paragraph I.G. for details.
Jan 22/87
REV. 3: May 24/90
727-32-0340
10
D.
Existing Parts Accountability
The
The following parts are affected by this service bulletin.
quantity (Qty) column lists the quantity affected per airplane.
Existing
Part Number
Nomenclature
65-26763-()
Fitting
Qty
DC
2
RWK
DIS
65-19270-()
Track Assembly
2
65-26763-17
(-18 Opposite)
RWK
DIS
DC
New
Part Number
65-19270-12
PNC
IC
N
C
S
C
N
C
S
C
Disposition Code
DIS - Discard Part.
RWK - Rework existing
bulletin.
PNC
IC
part
in
accordance
with
this
service
Part Number Code
N -
No equivalent Boeing part number for reworked part.
Indicate on the part that this service bulletin has been
accomplished.
S -
Superseding or new equivalent part number.
Interchangeability Code
C -
Jan 22/87
REV. 3: May 24/90
Conditionally Interchangeable: Installation of superseded
part negates the intent of this service bulletin.
727-32-0340
11
THIS PAGE INTENTIONALLY LEFT BLANK
727-32-0340
Jan 22/87
REV. 3:
May 24/90
12
III. ACCOMPLISHMENT INSTRUCTIONS
NOTES: 1. The following paragraphs outline the general accomplishment
instructions. The suggested sequence of operations and detailed
accomplishment instructions are indicated by circle notes on the
figures.
2. Observe all warning and caution notes in the referenced manual
sections.
A.
Remove main landing gear doors and
Maintenance Manual Subject 32-12-11).
B.
Remove main landing gear door forward hinge fitting from inboard flap
inboard track and check for cracks per Figure 1.
C.
Check flap track holes common to hinge holes and area around holes for
cracks per Figure 1.
D.
If cracks are found and are less than one inch in length and are not
progressing towards the lower flange and are not with an orientation
30 degrees either side of the vertical, stop drill the cracks per SRM
51-10-1, Page 6A, and perform modification per item F. below.
Repeat a close visual inspection every 3,000 flight cycles or 18
months, whichever occurs first, until flap track replacement.
E.
If cracks are found in flap track and exceed one inch, are progressing
towards the lower flange (shaded area on Figure 1), or do not meet
specified directional requirements per Figure 1, remove inboard wing
flap (Ref.727 Maintenance Manual Subject 27-51-1) and remove and
install new flap track (Ref.727 Maintenance Manual Subject 27-51-31).
F.
If no cracks are found, shot-peen hinge fitting, oversize and cold
work holes in hinge fitting and flap track per Figure 1.
G.
Reinstall hinge fitting in flap track per Figure 1.
H.
Use K-Hole locating tool P/N 67993-1 (Ref. 727 Maintenance Manual
Subject 27-51-31) to ensure that track is reinstalled in correct
position.
If no locating tool is available, lay a straight edge
across the inboard and outboard tracks of the inboard flap to
establish a reference point on the fuselage to ensure correct flap
track position upon reinstallation.
I.
Install and test Flap Track 65-19270-( ) (Ref. 727 Maintenance Manual
Subject 27-51-1).
J.
Reinstall main landing gear doors with retained fasteners (Ref. 727
Maintenance Manual Subject 32-17-11).
K.
Return airplane to normal condition.
Jan 22/87
REV. 3: May 24/90
retain
fasteners
(Ref.
727
727-32-0340
13
FIGURE
Jan 22/87
REV. 3: May 24/90
1.
INSPECTION AND MODIFICATION
727-32-0340
14
FIGURE
Jan 22/87
REV. 3: May 24/90
1.
INSPECTION AND MODIFICATION
727-32-0340
15
FIGURE
Jan 22/87
REV. 3: May 24/90
1.
INSPECTION AND MODIFICATION
727-32-0340
16
This service bulletin was prepared by:
Per Jacobsen
Please give us the following data:
OPERATOR:
TODAY'S DATE:
PREPARED BY:
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