1T-38-847.PDF

DEPARTMENT OF THE AIR FORCE

TECHNICAL ORDER

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TO 1T-38-847

DATA CODE 0106141

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:

6300008156 6300008184 6300008192 6400013183 6400013193 6400013206 6400013217 6400013222 6400013224 6400013225 6400013230 6400013240 6400013247 6400013265 6400013268 6400013270 6400013272 6400013279 6400013280 6400013283 6400013285 6400013295 6400013301 6400013304 6500010317 6500010322 6500010324 6500010337 6500010340 6500010342 6500010348 6500010358 6500010361 6500010377 6500010379 6500010380 6500010384 6500010394 6500010401 6500010416 6500010418 6500010419 6500010421 6500010427 6500010429 6500010435 6500010438 6500010442 6500010449 6500010452 6500010458 6500010459 6500010460 6500010463 6500010469 6500010470 6600004321 6600004324 6600004325 6600004332 6600004339 6600004340 6600004341 6600004342 6600004343 6600004344 6600004347 6600004348 6600004349 6600004350 6600004355 6600004358 6600004363 6600004366 6600004369 6600004372 6600004374 6600004375 6600004379 6600004382 6600004384 6600004386 6600004387 6600008350 6600008353 6600008356 6600008357 6600008359 6600008360 6600008362 6600008364 6600008365 6600008366 6600008367 6600008369 6600008375 6600008377 6600008378 6600008380 6600008388 6600008390 6600008394 6600008395 6600008402 6700014826 6700014831 6700014837 6700014844 6700014845 6700014848 6700014850 6700014851

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.

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 450 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.

6700014857 6700014858 6700014920 6700014924 6700014926 6700014927 6700014928 6700014930 6700014931 6700014933 6700014935 6700014942 6700014950 6700014953 6700014957 6800008098 6800008101 6800008102 6800008110 6800008114 6800008122 6800008128 6800008129 6800008134 6800008136 6800008143 6800008144 6800008145 6800008146 6800008147 6800008148 6800008150 6800008163 6800008166 6800008167 6800008172 6800008179 6800008180 6800008185 6800008189 6800008191 6800008193 6800008207 6800008213 6900007074 6900007076 6900007080 6900007085 7000001549 7000001559 7000001563 7000001567 7000001573 7000001574 7000001576 7000001581 7000001589 7000001590 7000001950 7000001955

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.

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 shall 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.

CAUTION

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.

WARNING

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.

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