1T-38-842.pdf

DEPARTMENT OF THE AIR FORCE

TECHNICAL ORDER

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TO 1T-38-842

DATA CODE 0106126

22 September 2010

NON-DESTRUCTIVE INSPECTION (NDI) OF

FATIGUE CRITICAL LOCATIONS (FCL) ON THE

LEFT AND RIGHT COCKPIT LONGERON AT

FUSELAGE STATION (FS) 236.0, 244.0, 260.0,

269.0 AND CANTED FUSELAGE STATION (CFS)

264.0 ON T-38 AIRCRAFT

NOTE

Commanders are responsible for bringing this technical order to the attention of all Air Force personnel cleared for operation of the affected system.

1. APPLICATION.

1.1 Identification. This Time Compliance Technical Order (TCTO) is applicable to the following T-38 aircraft:

1.2 Kit Applicability. Kits are not required by this TCTO.

1.3 Proofing. Verification of NDI at FS 236.0, 244.0, 260.0 and 269.0 was accomplished In Accordance With

(IAW) TO 00-5-15, at Randolph AFB Texas on aircraft Serial Number 66-8358 on 1 July 2010. Verification of

NDI procedures for CFS 264.0 was accomplished by desktop analysis and due to similarity of previously complied with inspections at Randolph AFB Texas on 1 July 2010 on aircraft 66-8358, no verification is required IAW TO

00-5-15.

6100000863 6100000880 6100000940 6200003660 6200003678 6200003752 6400013171 6400013172

6400013233 6400013239 6400013259 6400013266 6400013269 6500010336 6500010339 6500010359

6500010414 6500010422 6500010445 6500010466 6600004333 6600004345 6600004346 6600004351

6600004367 6600004378 6600008352 6600008361 6600008372 6600008373 6600008374 6600008379

6600008389 6600008391 6600008392 6600008393 6600008397 6700014841 6700014846 6700014849

6700014919 6700014937 6700014955 6800008104 6800008119 6800008142 6800008155 6800008157

6800008203 6800008210 6900007073 6900007077 6900007078 7000001557 7000001565 7000001578

2. PURPOSE.

The purpose of this technical order is to inspect the left and right FCLs for cracks along the cockpit longeron between

FS 236.0 and 269.0. The Aircraft Structural Integrity Program (ASIP) has determined these aircraft to be at risk for cracking.

3. WHEN TO BE ACCOMPLISHED.

Not later than 180 days after receipt of this TCTO. Failure to accomplish the work by expiration of the compliance period shall be justification for withdrawing affected system or equipment from service until compliance is accomplished. If the compliance period cannot be met before the TCTO rescission date, the performing organization will request an extended compliance period IAW TO 00-5-15.

3.1 TCTO RESCISSION DATE. The TCTO Rescission date is 21 September 2012, unless extended via TCTO supplement or notices received through the Reliability and Maintainability Information System (REMIS) or other management information systems. This TCTO will be retained until listed as rescinded in the applicable index.

3.2 Remove From Service. The Remove from Service date is the expiration of the TCTO compliance period OR

60 days prior to the rescission date, whichever comes first.

4. BY WHOM TO BE ACCOMPLISHED.

Organizational/Intermediate Level Maintenance or Contractor Equivalent.

5. WHAT IS REQUIRED.

5.1 Supply Information and Requirements.

5.1.1 Kits/Parts/Materials Required. The following parts, materials and tooling will not be furnished in a kit and shall be obtained from the appropriate supply source. The complete kit concept is waived by John Michalski (Chief, Primary

Trainer Aircraft Section), HQ AETC/A4MAT, DSN 487-3171.

AF activities shall ensure TCTO kits/parts are requisitioned in an expeditious manner to ensure accomplishment of this TCTO within the designated time period.

Item quantity was estimated for removal/replacement for one aircraft.

Qty Stock Number Part Number Nomenclature Source

2* 5320-01-349-8953 HL63PB-8-7 Pin Rivet, CSK Hi-Lok AF Supply

4* 5320-01-249-7907 HL63PB-6-6 Pin Rivet, CSK Hi-Lok AF Supply

2 5320-00-968-9210 HL 79-8 Collar, Hi-Lok AF Supply

4 5320-00-968-9212 HL 79-6 Collar, Hi-Lok AF Supply

*Grip length of fasteners to be determined upon installation to account for differences in aircraft structure thickness.

5.1.2 Action Required on Items in Chief of Supply or Units Stock. Not applicable.

5.1.3 Kits/Parts/Materials Required to Modify Items in Stock. Not applicable.

5.1.4 Disposition of Removed and Replaced Parts/Materials.

Parts removed, but not listed, shall be processed to the local Defense

Reutilization and Marketing Office if unserviceable or not cataloged.

Serviceable stock listed items shall not be returned to stock unless the quantity removed exceeds $25.00 line item value.

5.1.5 Drawings and Instructions Required. Not applicable.

5.1.6 Size, Weight and Cost of Kits/Parts/Materials. Not applicable.

5.1.7 Disposition of Kits/Parts/Materials. Not applicable.

5.2 Personnel Information and Requirements.

WORK PHASES AFSC SKILLS MAN-HOURS

Unpacking N/A 0.0

Disassembly 2A3X3, 2A6X3 and 2A7X3 or equivalent

6.0

Installation 2A752 or NAS-410 Level II 3.0

Assembly 2A3X3, 2A6X3 and 2A7X3 or equivalent

9.0

Operational check N/A 0.0

Total Man-Hours 18.0

5.3 Special Tools, Fixtures, Test Equipment and Software Required. Not applicable.

6. HOW WORK IS ACCOMPLISHED.

Personnel are advised to read and thoroughly familiarize themselves with the information contained in this TCTO. Minor deviations are authorized providing the intent of this TCTO is accomplished and safety is not compromised.

a. Make aircraft safe for maintenance IAW TO 1T-38A/C-2-1, and TO 1T-38A/C-2-2.

6.1 Disassembly.

a. Remove rear canopy IAW TO 1T-38A/C-2-2.

b. Remove rear ejection seat IAW TO 1T-38A/C-2-2.

All stress panels shall be installed prior to any jacking, down-jacking and/or towing operation or damage to aircraft may result.

c. Remove access door numbers 185 and 186 or 171 and 174 (door number depends on aircraft serial number)

IAW TO 1T-38A/C-2-2.

CAUTION

d. Remove left and right rear cockpit side panels adjacent to CFS 264.0 IAW TO 1T-38A/C-2-2 to access

Hi-Lok fasteners.

Only non-metallic scrapers and/or sealant removal tools shall be used to remove sealant on or around Hi-Lok collars to facilitate removal of Hi-Lok fasteners for bolt hole eddy current inspection or damage to the longeron may result.

e. Remove sealant from six Hi-Lok fastener collars, three on left and three on right side of longeron at CFS 264.0 to facilitate Hi-Lok collar/fastener removal prior to inspection. See Figure 1.

f. Make sure inspection areas are clean of grease, oil, dirt, chipped paint or other contaminants

IAW TO 1T-38A/C-23.

Hi-Lok fastener heads shall not be drilled off to facilitate removal from aircraft cockpit longeron structure at CFS 264.0. Extreme care must be taken to ensure cockpit longeron surfaces are not damaged by Hi-Lok removal tooling. Hi-Lok fastener collars will be unscrewed counterclockwise and the fasteners pushed out of the longeron structure.

Drilling these fasteners during removal could result in damage to the aircraft structure.

See Figure 1 for area of interest.

g. Unscrew Hi-Lok collars and carefully remove six Hi-Lok fasteners listed in paragraph 6.1e.

h. Clean Hi-Lok fastener holes IAW TO 1T-38A/C-23 prior to performing inspection.

6.2 Inspections. Perform inspection method listed below for the areas outlined in paragraphs 6.3.1 and 6.3.2 as required.

The performance of these inspections requires one inspector. This person shall be as a minimum an Air Force Skill Code 2A752 or NAS-410 Level II certified eddy current and fluorescent penetrant.

a. Inspection 1 – Bolt Hole Eddy Current Aluminum. IAW TO 33B-1-2 WP 404.00, Eddy Current, Aluminum, Weakly Ferromagnetic and NonFerromagnetic Alloys, Rotary Fastener Holes for setup and calibration of equipment. IAW TO 33B-1-2 WP 404.00, Eddy Current, Aluminum, Weakly Ferromagnetic and NonFerromagnetic Alloys, Rotary Fastener Holes, paragraph 4.5 or 4.6 Identifying Scanner Zero for crack locations.

b. Inspection 2 – Penetrant. IAW TO 33B-1-2 WP 201.00 Fluorescent Penetrant General Procedure, Solvent Removable, Method C.

c. Inspection 3 – Surface Eddy Current - Aluminum. IAW TO 33B-1-2, WP 402.00, Eddy Current, General

Surface, Aluminum, Weakly Ferromagnetic and NonFerromagnetic Alloys for setup and calibration of equipment.

6.3 Maintenance Actions and Inspection Areas.

6.3.1 Cockpit Longeron Inspection at CFS 264.0.

a. Perform Inspection 1, paragraph 6.2a, automatic bolt hole scan on six Hi-Lok fastener holes, three each on left and right CFS 264.0 called out in paragraph 6.1e. See Figure 1.

b. Mark all suspect defects.

c. Backup procedure – None.

6.3.2 Cockpit Longeron Inspection at FS 236.0, 244.0, 260.0 and 269.0.

a. Perform Inspection 2, paragraph 6.2b, fluorescent-penetrant on the upper cockpit longeron inboard upstanding leg forward transition runout and aft transition runout at FS 236.0, 244.0, 260.0 and 269.0.

Inspect left and right sides. See Figure 2 for area(s) of interest.

b. Mark all suspect defects.

c. Backup procedure – None.

d. Perform Inspection 3, paragraph 6.2c, surface eddy current on the upper cockpit longeron inboard upstanding leg forward transition runout and aft transition runout at FS 236.0, 244.0, 260.0 and 269.0.

Inspect left and right sides. See Figure 2 for area(s) of interest.

e. Mark all suspect defects.

f. Backup procedure – None.

6.4 Reporting. Immediately report all suspect defects IAW TO 00-25-107.

6.5 Reassembly.

EPOXY PRIMER MIL-PRF-23377 is toxic to skin, eyes and respiratory tract.

Skin/eye protection required. Avoid repeated/prolonged contact. Use in well ventilated areas. Keep away from open flames and other sources of ignition.

CORROSION INHIBITIVE SEALANT MIL-PRF-81733 is toxic to skin, eyes and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Use in well ventilated areas. Keep away from open flames and other sources of ignition.

All nicks and gouges to surfaces will be blended out and bare metal surfaces primed with

MIL-PRF-23377 or equivalent, IAW TO 1T-38A/C-23 prior to installation of new Hi-

Lok fasteners. Failure to treat bare metal surface and/or tooling nicks and gouges may cause structural damage.

Hi-Lok fasteners called out in Paragraph 5.1.1 are first oversize for their respective diameters as called out in the aircraft drawings for the cockpit longeron and are for reference only. Fastener grip lengths shall be determined prior to installation of new Hi-

Lok fasteners.

a. Measure grip length and diameter of fastener holes and install six new Hi-Lok fasteners at left and right CFS 264.0 wet with MIL-PRF-81733 sealant or equivalent IAW TO 1T-38A/C-3.

WARNING

b. Coat six new Hi-Lok fastener collars at left and right CFS 264.0 with MIL-PRF-81733 sealant or equivalent IAW TO 1T-38A/C-23.

c. Coat heads of six installed Hi-Lok fasteners, three each on left and right CFS 264.0 with MIL-PRF-23377 epoxy primer or equivalent, and topcoat with appropriate MIL-PRF paint system IAW TO 1T-38A/C-23.

d. Install left and right rear cockpit side panels adjacent to CFS 264.0 IAW TO 1T-38A/C-2-2.

All stress panels shall be installed prior to any jacking, down-jacking and/or towing operation or damage to aircraft may result.

e. Install access door numbers 185 and 186 or 171 and 174 (door number depends on aircraft serial number) IAW TO 1T-38A/C-2-2.

f. Install rear ejection seat IAW TO 1T-38A/C-2-2.

g. Install rear canopy removed in paragraph 6.1a IAW TO 1T-38A/C-2-2.

h. Perform Egress Final Inspection IAW TO 1T-38A/C-2-2CL-1.

Figure 1 Inspection 1 - Hi-Lok Fasteners at Cockpit Longeron CFS 264.0

Figure 2 Inspection 2 and 3 – Upper Cockpit Longeron Vertical Leg Transition Runout

7. SUPPLEMENTAL INFORMATION.

7.1 Fuel System Defuel/Purge. Defueling/purging of the fuel system is not required prior to accomplishing this TCTO.

7.2 Operational Checkout Requirements. Functional Check Flight is not required.

7.3 Weight and Balance Information. There are no weight or balance changes resulting from the instructions contained herein.

7.4 Technical Manuals Affected. Not applicable.

8. RECORDS.

8.1 Action Required on Maintenance Records.

a. Report TCTO compliance IAW TO 00-20-2, Chapter 3.

b. Annotate Pass/Fail and document IAW TO 00-5-15, Chapter 3.

c. Update AFTO Form 95 to show TCTO compliance.

d. Immediately report all defects IAW TO 00-25-107.

8.2 Action Required on Supply Records. Not applicable.

8.3 Retrofit Change or Inspection Identification Marking. Not applicable.

BY ORDER OF THE SECRETARY OF THE AIR FORCE

NORTON A. SCHWARTZ, General, USAF

Chief of Staff

DONALD HOFFMAN, General, USAF

Commander, AFMC

Prepared by Gary Ash for OO-ALC/GHMEH, DSN 586-6464