01-75paa-3-1.1 structural repair fuse,gear,nacelles sept04r

NAVAIR 01-75PAA-3-1.1TECHNICAL MANUAL

ORGANIZATIONAL AND INTERMEDIATE LEVEL MAINTENANCE

STRUCTURAL REPAIR INSTRUCTIONSNAVY MODEL P-3A, P-3B, AND P-3C AIRCRAFTN00421-98-D-1339

THIS MANUAL IS INCOMPLETE WITHOUT NAVAIR 01-75PAA-3-1. This manual supersedes NAVAIR 01-75PAA-3-1.1 dated 1 November 1985 with Change 12 dated 1 May 2002. IRACs 1 through 6 incorporated.

DISTRIBUTION STATEMENT C. Distribution authorized to U.S. Government agencies and their contractors to protect publications required for official use or for administrative or operational purposes only, determined on 01 September 2004. Other requests for this document shall be referred to Commanding Officer, Naval Air Technical Data and Engineering Service Command, Naval Air Station North Island, P.O. Box 357031, Building 90 Distribution, San Diego, CA 92135-7031. DESTRUCTION NOTICE For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published by Direction of Commander, Naval Air Systems Command

0801LP1037139

1 September 2004

NATEC ELECTRONIC MANUAL

NAVAIR 01-75PAA-3-1.1

LIST OF EFFECTIVE PAGESInsert latest changed page; dispose of superseded pages in accordance with applicable regulations. NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical line or other change symbol in the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands or vertical lines. Changes to wiring diagrams are indicated by shaded areas. Dates of issue for original and changed pages are: Original 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Sept 2004 (Including IRACs 16)

The total number of pages in this manual is 938, consisting of the following: Page # Change Page No. No. No. Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . A .............................. iv............................ vi Blank . . . . . . . . . . . . . . . . . . . . . . . . vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Blank . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-11 . . . . . . . . . . . . . . . . . . . . . . 4-12 Blank . . . . . . . . . . . . . . . . . . . . . . 4-13 4-469 . . . . . . . . . . . . . . . . . . . . 4-470 Blank . . . . . . . . . . . . . . . . . . . . . 4-471 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-472 Blank . . . . . . . . . . . . . . . . . . . . . 4-473 4-487 . . . . . . . . . . . . . . . . . . . 0 0 0 0 0 0 0 0 0 0 0 0 0

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4-488 Blank . . . . . . . . . . . . . . . . . . . . . 5-1 5-28 . . . . . . . . . . . . . . . . . . . . . . 6-1 6-83 . . . . . . . . . . . . . . . . . . . . . . 6-84 Blank . . . . . . . . . . . . . . . . . . . . . . 7-1 7-55 . . . . . . . . . . . . . . . . . . . . . . 7-56 Blank . . . . . . . . . . . . . . . . . . . . . . 8-1 8-91 . . . . . . . . . . . . . . . . . . . . . . 8-92 Blank . . . . . . . . . . . . . . . . . . . . . . 9-1 9-43 . . . . . . . . . . . . . . . . . . . . . . 9-44 Blank . . . . . . . . . . . . . . . . . . . . . . 9-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46 Blank . . . . . . . . . . . . . . . . . . . . . . 9-47 9-51 . . . . . . . . . . . . . . . . . . . . .

9-52 Blank . . . . . . . . . . . . . . . . . . . . . . 9-53 9-97 . . . . . . . . . . . . . . . . . . . . . 9-98 Blank . . . . . . . . . . . . . . . . . . . . . . 10-1 10-41 . . . . . . . . . . . . . . . . . . . . 10-42 Blank . . . . . . . . . . . . . . . . . . . . . 11-1 11-7 . . . . . . . . . . . . . . . . . . . . . . 11-8 Blank . . . . . . . . . . . . . . . . . . . . . . A-1 A-19 . . . . . . . . . . . . . . . . . . . . . . A-20 Blank . . . . . . . . . . . . . . . . . . . . . . B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Blank . . . . . . . . . . . . . . . . . . . . . . . Index 1 Index 10 . . . . . . . . . . . . . . .

#Zero in this column indicates an original page

A

NAVAIR 01-75PAA-3-1.1 TABLE OF CONTENTSSection/Para Page Section/Para Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . ii LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . v LIST OF TECHNICAL PUBLICATION DEFICIENCY REPORTS INCORPORATED . . . . . . . . . . . . . . . . . . . . . . . vii INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . v-i IV FUSELAGE GROUP . . . . . . . . . . . . . . . . . . . 4-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Battery Access Door Bonding Spring Replacement . . . . . . . . . . . . . 4-2 4-3 Bomb Bay Door Bonding Spring Wear Criteria . . . . . . . . . . . . . 4-2 4-4 Fuselage Main Frame Fitting Crack Flight Restrictions . . . . . . . . . . 4-2 4-4.1 Pilot and Copilot Interconnect Engine Power Control Torque Tube Repair . . . . . . . . . . . . . . 4-3 4-5 Fuel Bladder Cell Drain Mast Repair . . . . . . . . . . . . . . . . . . . 4-253 V 5-1 5-2 LANDING GEAR . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-2 5-3 6-1 6-1 6-1 6-2 7-1 4-1 4-2

VIII INBOARD NACELLES . . . . . . . . . . . . . . . . . 8-1 8-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 IX TYPICAL REPAIRS . . . . . . . . . . . . . . . . . . . . 9-1 9-1 9-2 9-3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 VHF Blade antenna Repair . . . . . . . . . . . . 9-1 Erosion-Resistant Tape or Teflon Filled Polyurethane Paint on Leading Edges . . . . . . . . . 9-68 9-4 Erosion-Resistant Cap on Nose Radome . . . . . . . . . . . . . . . . . . 9-70 9-5 Oil Cooler Flap Free Play Limits . . . . . . . . . . . . . . . . . . . . . . . . . 9-72 X FUEL TANK SEALING . . . . . . . . . . . . . . . . 10-1 10-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Integral Fuel Tank Maintenance Procedures . . . . . . . . 10-3 Classification of Sealant Features . . . . . . . . . . . . . . . . . . . . . . 10-4 Leak Locating and Resealing Procedures-Integral Fuel tank . . . . . . . . . . . . . . . . . . . . . . 10-5 Fuel Tank Access Door Maintenance Procedures . . . . . . . . 10-6 Main Landing Gear Trunnion Bolt Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . 10-7 Fuel Leak Repairs for Protruding Head Fasteners . . . . . . 10-1 10-8 10-13 10-13 10-27 10-29 10-29

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Landing Gear Drag Strut Outboard Support Fitting Crack Limits . . . . . . . . . . . . . . . . . . . . 5-3 Landing Gear Axle Limits . . . . . . . . . . . . . . . . . . . . . . . . . . VI ENGINE GROUP . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2 6-3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire-Resistant Coating Repair . . . . . . . . . . Engine Mount Access Panels P103 and P104 Attachment Plate Nut Replacement . . . . . . . . . . . VII OUTBOARD ACCESS . . . . . . . . . . . . . . . . . 7-1

XI SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 11-1 APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 APPENDIX B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

i

NAVAIR 01-75PAA-3-1.1 LIST OF ILLUSTRATIONSFigure 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29 4-30 Title Page Figure Title Page 4-158 4-162 4-168 4-170 4-192 4-196 4-205 4-207 4-211 4-215 4-220 4-227 4-228 4-231 4-234 4-247 4-251 4-254 4-255 4-256 4-257 4-259 4-260 4-265 4-268 4-271 4-275 4-276 4-277 Fuselage Group Index Diagram . . . . . . . . 4-4 Fuselage Nose Section Index Diagram . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Fuselage Nose Section Skin Panels . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Fuselage Skin Repairs . . . . . . . . . . . . . . . 4-10 Fuselage Nose Section Stringers . . . . . . . . . . . . . . . . . . . . . . 4-23 Fuselage Nose Section Stringer Repairs . . . . . . . . . . . . . . . . 4-28 Fuselage Nose Section Frames and Bulkheads . . . . . . . . . . . . . . . . . 4-31 Fuselage Station 156 Bulkhead Repairs . . . . . . . . . . . . . . . 4-53 Fuselage Forward Pressure Bulkhead Repairs . . . . . . . . . . . . . . . 4-56 Fuselage Station 185 Bulkhead Repairs . . . . . . . . . . . . . . . . . . . . . . . 4-64 Fuselage Stations 185 Upper, 203.62, 218.4, 230, and 248 Frame Repairs . . . . . . . . . . . . . 4-74 Fuselage Station 288 Bulkhead Repairs . . . . . . . . . . . . . . . . . . . . . . . 4-82 Heat Exchanger Mounting Bracket Replacement . . . . . . . . . . . 4-86 Fuselage Nose Section Floor and Floor Support Structure . . . . . . . . . . . . . . . . . . . . . . 4-87 Fuselage Nose Section Floor Support Structure Repairs . . . . . . . 4-99 Metal Honeycomb Floor Panel Repair . . . . . . . . . . . . . . . . . 4-103 Combination Metallic/Nonmetallic Honeycomb Floor Panel Repair . . 4-104 Fuselage Nose Section Pressure Web . . . . . . . . . . . . . . . . . 4-105 Fuselage Nose Section Pressure Web Repairs . . . . . . . . . 4-111 Windshield Structure . . . . . . . . . . . . . . . . 4-115 Windshield Frame Repairs . . . . . . . . . . . 4-119 Fuselage Nose Radome . . . . . . . . . . . . . 4-124 Fuselage Nose Radome Repair . . . . . . 4-130 Microwave Absorber Repair . . . . . . . . . . 4-132 Infrared Detection System Mount and Doors . . . . . . . . . . . . . . 4-133 Fuselage Forebody Section Index Diagram . . . . . . . . . . . . . . . . 4-135 Fuselage Forebody Section Skin Panels . . . . . . . . . . . . . . . . . . . 4-136 Fuselage Forebody Section Stringers . . . . . . . . . . . . . . . . . . . . . 4-140 Observers Window Doubler Repair . . . 4-150 Fuselage Forebody Section Stringer Repairs . . . . . . . . . . . . . . . 4-152 4-31 Bomb Bay Sidewall Structure . . . . . . . . 4-32 Bomb Bay Sidewall Structure Repair . . . . . . . . . . . . . . . . . . . . . . . 4-33 Fus Sta 477 to 553 Vertical Shear Panel . . . . . . . . . . . . . . . . . . 4-34 Fuselage Forebody Section Frames and Bulkheads . . . . . . . . . 4-35 Fuselage Frame Repairs . . . . . . . . . . . . 4-36 Fuselage Station 405.1 Bulkhead Repairs . . . . . . . . . . . . . . 4-37 Fuselage Station 323, 477 and 553 Bulkhead Negligible Damage Limits . . . . . . . . . . . . . . . . 4-38 Fuselage Station 323 Bulkhead Repairs . . . . . . . . . . . . . . . . . . . . . . 4-39 Fuselage Station 477 Bulkhead Repairs . . . . . . . . . . . . . . . . . . . . . . 4-40 Fuselage Station 553 Bulkhead Repairs . . . . . . . . . . . . . . . . . . . . . . 4-41 Fuselage Forebody Section Floor and Floor Support Structure . . . . . . . . . . . . . . . . . . . . . 4-42 Fuselage Forebody Floor Support Structure Repair . . . . . . . 4-43 Nonmetallic Honeycomb Floor Panel Repair . . . . . . . . . . . . . 4-44 Plywood Floor Panel Repairs . . . . . . . . 4-45 Fuselage Forebody Section Pressure Web . . . . . . . . . . . . . . . . . 4-46 Fuselage Forebody Section Pressure Web Repairs . . . . . . . . . 4-47 Auxiliary Power Unit (APU) Mount and Fire Barrier . . . . . . . . . 4-48 Auxiliary Power Unit (APU) Fire Barrier Repair, Aircraft Incorporating AFC-578 . . . . . . . . . 4-49 Tacan Antenna Nut Plate Repair . . . . . . 4-50 Fuselage Midbody Section Index Diagram . . . . . . . . . . . . . . . . 4-51 Fuselage Midbody Section Skin Panels . . . . . . . . . . . . . . . . . . . 4-52 Radio Compass Antenna Honeycomb Panel Repair . . . . . . . 4-53 Fuselage Midbody Section Stringers . . . . . . . . . . . . . . . . . . . . . 4-54 LS6501 Stringer Repairs . . . . . . . . . . . . 4-55 LS6515 Stringer Repairs . . . . . . . . . . . . 4-56 Fuselage BL 13.80 Longeron Repairs . . . . . . . . . . . . . . . . . . . . . . 4-57 Wing-To-Fuselage Skate Angle Repair . . . . . . . . . . . . . . . . . . 4-58 Wing Stub To Fuselage Splice . . . . . . . . . . . . . 4-59 Fuselage Midbody Section Frames and Bulkheads . . . . . . . . .

ii

NAVAIR 01-75PAA-3-1.1Figure Title Page 4-282 4-283 4-295 4-296 4-303 4-304 4-316 4-319 4-320 4-336 4-343 4-345 4-361 4-368 4-369 4-372 4-375 4-378 4-392 4-399 4-409 4-412 4-413 4-439 4-451 4-462 4-463 4-470 4-472 4-473 4-474 4-476 6-12 6-13 6-14 6-15 Figure Title Page 4-479 4-480 4-482 4-483 4-485 4-486 4-487 5-4 5-5 5-7 5-11 5-15 5-18 5-19 5-22 5-23 5-24 5-26 5-28 6-3 6-4 6-7 6-16 6-19 6-22 6-23 6-24 6-25 6-27 6-28 6-29 6-33 6-44 6-48

4-60 Fuselage Station 570.97 and 695.09 Main Frame Repairs . . . . . . . . . 4-61 Fuselage Midbody Section Floor and Floor Support Structure . . . . . . . 4-62 Fuselage Aft Body Section Index Diagram . . . . . . . . . . . . . . . . . . . . 4-63 Fuselage Aft Body Section Skin Panels . . . . . . . . . . . . . . . . . . . . . 4-64 Aft Emergency Exit Opening Doubler Repair . . . . . . . . . . . . . . . . . . . . . 4-65 Fuselage Aft Body Section Stringers . . . . . . . . . . . . . . . . . . . 4-66 LS3224-3 Stringer Repairs . . . . . . . . . 4-67 LS7569 Longeron Repairs . . . . . . . . . 4-68 Fuselage Aft Body Section Frames and Bulkheads . . . . . . . . . . . . . . 4-69 Fuselage Aft Pressure Bulkhead Repairs . . . . . . . . . . . . . . . . . . . . 4-70 Fuselage Aft Body Section Door Frame Repairs . . . . . . . . . . . . . . 4-71 Fuselage Aft Body Section Floor and Floor Support Structure . . . . . . . 4-72 Fuselage Aft Body Section Floor Support Structure Repairs . . . . 4-73 Fuselage Tail Section Index Diagram . . . . . . . . . . . . . . . . . . . . 4-74 Fuselage Tail Section Skin Panels . . . . . . . . . . . . . . . . . . . . . 4-75 Fuselage Tail Section Stringers . . . . . . . . . . . . . . . . . . . 4-76 Stabilizer Skate Angle Repairs . . . . . . . . . . . . . . . . . . . . 4-77 Fuselage Tail Section Frames and Bulkheads . . . . . . . . . . . . . . . . . . 4-78 Fuselage Tail Section Frame and Bulkhead Repairs . . . . . . . . . . . . 4-79 Aft Radome and Boom . . . . . . . . . . . . 4-80 Aft Radome and Boom Repairs . . . . . . . . . . . . . . . . . . . . 4-81 MAD Head Track Shimming Procedure, P-3C Aircraft . . . . . . 4-82 Fuselage Doors Structure . . . . . . . . . 4-83 Bomb Bay Door Repairs . . . . . . . . . . . 4-84 Fuselage Door Repairs . . . . . . . . . . . . 4-85 Main Entrance Door Repairs . . . . . . . 4-86 Auxiliary Power Unit (APU) Exhaust Door Repairs . . . . . . . . . . . . . . . . 4-87 BL 41.75 (Right) Longeron, FS 288 to 323, Replacement . . . . . . . . . . . . . . . . 4-88 Auxiliary Power Unit (APU) Access Door Hinge Repair . . . . . . . . . . . 4-89 Emergency Exit Latch Stop Repair . . . . . . . . . . . . . . . . . . . . . 4-90 Entry Ladder Upper Section Tread Repair . . . . . . . . . . . . . . . . 4-91 Entry Ladder Wheel Chassis Repair . . . . . . . . . . . . . . . . . . . . .

4-92 Entry Ladder Siderail Replacement . . . . . . . . . . . . . 4-93 Entry Ladder Handrail Repair . . . . . . 4-94 Entry Ladder Step Nonslip Covering Replacement . . . . . 4-95 Entry Ladder Carriage Ramp Seal Hinge Replacement . . . . . . . . 4-96 Static Port Fitting Replacement . . . . . . . . . . . . . 4-97 HF 2 Antenna Coupler Support Clip Replacement . . . . . . . . . . 4-98 Fuselage Contour Coordinates . . . . . . . . . . . . . . 5-1 5-2 5-3 5-4 5-5 5-6 Landing Gear Index Diagram . . . . . . . . Main Gear . . . . . . . . . . . . . . . . . . . . . . . . Main Gear Forward Doors . . . . . . . . . . Main Gear Aft Doors . . . . . . . . . . . . . . . Main Gear Door Repairs . . . . . . . . . . . Main Gear Door Attachments Allowable Wear, Reaming, and Bushing Limits . . . . . . . . . . . . . 5-7 Nose Gear . . . . . . . . . . . . . . . . . . . . . . . 5-8 Nose Gear Torque Arm Linkage Allowable Wear, Reaming, and Bushing Limits . . . . . . . . . 5-9 Nose Gear Upper Drag Strut Fulcrum Bushing Rework . . . . 5-10 Nose Gear Doors . . . . . . . . . . . . . . . . . . 5-11 Nose Gear Door Repairs . . . . . . . . . . . 5-12 Nose Gear Door Attachments Allowable Wear, Reaming, and Bushing Limits . . . . . . . . . 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 Engine Group Index Diagram . . . . . . . . Engine Cowling Skin Panels . . . . . . . . . Engine Cowling Skin Repairs . . . . . . . . Engine Air Inlet Duct and Lip . . . . . . . . Engine Air Inlet Lip Repairs . . . . . . . . . Engine Air Inlet Duct Negligible Damage Limits . . . . . . . . . . . . . Engine Air Inlet Duct Silver Brazing Repair . . . . . . . . . . . . . . . . . . . . Engine Air Inlet Duct Skin Repair . . . . . . . . . . . . . . . . . . . . Engine Air Inlet Duct Frame Repairs . . . . . . . . . . . . . . . . . . . Engine Air Inlet Duct Aft Half Ring Repair . . . . . . . . . . . . . . . . . . . . Engine Air Inlet Duct Side Attachment Angle Repair . . . . . . . . . . . . . . . . . . . . Nose Cowl and V-Frame . . . . . . . . . . . Nose Cowl and V-Frame Repairs . . . . . . . . . . . . . . . . . . . Top Cowl . . . . . . . . . . . . . . . . . . . . . . . . . Top Cowl Repairs . . . . . . . . . . . . . . . . .

iii

NAVAIR 01-75PAA-3-1.1Figure 6-16 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 8-10 8-11 8-12 8-13 9-1 9-2 9-3 9-4 9-5 9-6 9-7 Title Side Cowl . . . . . . . . . . . . . . . . . . . . . Side Cowl Repairs . . . . . . . . . . . . . . Side Cowl Hinges Allowable Wear, Reaming, and Bushing Limits . . . . . . . . . . . . . . . . . . . . . . Bottom Cowl . . . . . . . . . . . . . . . . . . . Bottom Cowl Repairs . . . . . . . . . . . Bottom Cowl Drip Pan Repair . . . . Engine Attachments Allowable Wear, Reaming, and Bushing Limits . . . . . . . . . . . . . . . Engine Oil Tank Repairs . . . . . . . . . Engine Fireseal Nib Repair . . . . . . Outboard Nacelle Index Diagram . . . . . . . . . . . . . . . . . . . . . . Outboard Nacelle Skin Panels . . . . . Outboard Nacelle Skin Repairs . . . . . . . . . . . . . . . . . . . . . . . Outboard Nacelle Stringers . . . . . . . . Outboard Nacelle Stringer Repairs . . Outboard Nacelle Frames . . . . . . . . . Outboard Nacelle Frame Repairs . . . Outboard Nacelle Shroud and Tailpipe . . . . . . . . . . . . . . . . . . . Outboard Nacelle Fillets . . . . . . . . . . . Inboard Nacelle Index Diagram . . . . . Inboard Nacelle Skin Panels . . . . . . . Inboard Nacelle Skin Repairs . . . . . . Inboard Nacelle Tailpipe Door Hinged Cover Repair . . . . . . . . . . . Inboard Nacelle Stringers . . . . . . . . . . Inboard Nacelle Stringer Repairs . . . . . . . . . . . . . . . . . . . . . . . Inboard Nacelle Frames . . . . . . . . . . . Fireshield Repairs . . . . . . . . . . . . . . . . Inboard Nacelle Shroud and Tailpipe . . . . . . . . . . . . . . . . . . . Inboard Nacelle Fillets . . . . . . . . . . . . Inboard Nacelle Drip Pan Repair . . . . . . . . . . . . . . . . . . . . . . . . Seal Assembly Access Door Tailpipe Inboard and Outboard Repair . . . . . . . . . . . . . . . Tailpipe Door Seal Assembly Repair Skin Negligible Damage Repair . . . . Minor Damage Repairs . . . . . . . . . . . . Skin Panel Oil Canning Repair . . . . . Typical Web Repairs . . . . . . . . . . . . . . Extruded and Formed Cap and Stiffener Repairs . . . . . . . . . . . Rib and Former Repairs . . . . . . . . . . . Negligible Damage Limits for Machined Fittings,Forgings, and Castings . . . . . . . . . . . . . . . . . . Page 6-55 6-57 6-63 6-64 6-68 6-75 6-76 6-80 6-83 7-2 7-3 7-8 7-17 7-23 7-27 7-40 7-43 7-52 8-2 8-3 8-14 8-23 8-24 8-33 8-40 8-70 8-74 8-83 8-88 8-89 8-90 9-2 9-3 9-5 9-6 9-10 9-20 9-26 Figure 9-8 9-9 9-10 9-11 9-12 9-13 9-14 9-15 9-16 9-17 9-18 9-19 9-20 9-21 9-22 9-23 9-24 9-25 926 9-27 928 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 11-1 Title Nacelle Frame Repairs . . . . . . . . . . . . Tailpipe Door Repair . . . . . . . . . . . . . . Nacelle Stringer Repairs . . . . . . . . . . Nacelle Fillet Repairs . . . . . . . . . . . . . Nacelle Tailpipe Repairs . . . . . . . . . . . Nacelle Shroud Repair . . . . . . . . . . . . Nacelle Trailing Edge Former Repairs Swirl Straightener Repairs . . . . . . . . . Oil Cooler Flap Repair . . . . . . . . . . . . Oil Cooler Flap Actuator Support Repairs . . . . . . . . . . . . . . . Nacelle Skate Angle Repairs . . . . . . . Tailpipe Support Repair . . . . . . . . . . . Tailpipe Aft Support Fittings Allowable Wear and Repair . . . . . . . . . . . . . . . Erosion-Resistant Tape Installation on Leading Edges . . . . . . . . . . . . . . Repair of Erosion-Resistant Tape on Leading Edges and Nose Radome . . . . . . . . . . . . . . . . . . . . . . Erosion-Resistant Cap Installation on Nose Radome . . . . . . . . . . . . . . ECS Distribution Duct Slide Fastener (Zipper) Joint Repair . . . . . . . . . . . . . . . . . . . . . . . . Remove and Replace Insulation Blanket Strap Assemblies . . . . . . . APU A/C Ground Bracket Repair . . . Engine Nacelle Lower Aft Fairing Attach Angle Repair . . . . . . . . . . . . I.B. Nacelle, Lower Aft Fairing Channel . . . . . . . . . . . . . . . . . . . . . . Typical Safety Equipment Used in Fuel Tank Sealing Repairs . . . . . . . . . . . . . . . . . . . . . . . Fuel Leak Classification . . . . . . . . . . . Air Blowback Fuel Leak Detection . . . . . . . . . . . . . . . . . . . . . Blowback Method of Leak Detection Using Air or Fluid . . . . . Leak Locator . . . . . . . . . . . . . . . . . . . . Sealant Removal and Application Hand Tools . . . . . . . . . Sealant Removal . . . . . . . . . . . . . . . . . Sealant Repair Techniques . . . . . . . . Wing Fuel Tank Access Cover Installation . . . . . . . . . . . . . . Main Landing Gear Trunnion Bolt Installation . . . . . . . . . . . . . . . . Wing Fuel Tanks, Protruding Head Fastener Leak Repair . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . Page 9-27 9-32 9-34 9-35 9-39 9-43 9-53 9-54 9-57 9-60 9-63 9-66 9-67 9-73 9-76 9-77 9-79 9-82 9-83 9-85 9-88

10-9 10-12 10-14 10-15 10-16 10-17 10-18 10-20 10-30 10-39 10-40 11-2

iv

NAVAIR 01-75PAA-3-1.1 LIST OF TABLESNumber 10-1 10-2 A-1 A-2 A-3 B-1 Title Page Number Title Page

Fuel Tank Cleaner Mixture . . . . . . . . . 10-15 Leading Particulars of Sealing Compounds . . . . . . . . . . . . . . . . . . . 10-21 Consumable Materials . . . . . . . . . . . . A-2 Metallic Repair Materials . . . . . . . . . . A-15 Repair Fasteners . . . . . . . . . . . . . . . . . A-17 Support Equipment . . . . . . . . . . . . . . . B-1

v/( vi blank)


TECHNICAL PUBLICATION DEFICIENCY REPORT INCORPORATION LISTThe following TPDRs are incorporated as part of this change. This page shall remain with this change; next change will provide new listing page with latest TPDR incorporation. Identification No./ QA Sequence No. 44328000153 44328020128 90032990001 Location LOEP LOEP Pg. 730 Pg. 738 Pg. 857 Pg. 869 Pg. 89 Pg. 811 Pg. 812 Pg. 936 Pg. 108 Pg. 1010 Pgs. 1020 thru 1023 Pgs. 1025 thru 1027 Pg. 1029 Appendix B-1

AAFFF960009 44374970062 33208020077 33208020076 62849980001 62849970003 33208020075

vii/(viii blank)


SECTION IV

FUSELAGE GROUP4-1. GENERAL.a. Description. The fuselage group (see figure 4-1) consists of a nose section, forebody, midbody, aftbody, and tail section. The fuselage shell is a typical semi-monocoque structure. (1) The fuselage stringers are spaced approximately 6 inches apart around the circumference of the shell. They are either extruded sections or fabricated from sheet material. Extruded sections are used in local, highly loaded regions of the fuselage shell. The majority of the stringers are fabricated from 2024-T81 bare or clad sheet material. Formed stringers above waterline 150 are made from bare material, while those below waterline 150 are made from clad material. (2) The fuselage frames or rings are generally spaced 19 inches apart along the longitudinal axis of the aircraft. Rings are either extruded sections or fabricated from sheet material. Extruded sections are used along the edges of all large cutouts. The majority of the rings are fabricated from 7075-T6 clad sheet material. Flanged oval and circular lightening holes are used extensively in the webs of formed rings. The formed rings are generally fabricated in five segments: top, upper left and right sides, and lower left and right sides. The segments are lap spliced at their junctions. (3) The fuselage skin is fabricated from either 2024-T3 or 2024-T42 clad sheet or plate. The skin is divided into panels ranging in gage from 0.040 to 0.100. The panels are joined by butt or lap joints with two or more rows of attachments through the splice area. Chemically milled skin panels are used in the following regions of the shell: (a) The lower side panels in the bomb bay-fuel bay region. (b) The panel directly above the left side emergency exit. (c) The panels above the floor in the aft portion of the aftbody. (4) Main frames are located at fuselage station 571.2 and fuselage station 695.1. The main frames are stout I-sections, which widen in depth in the vicinity of the stub wing box to attach to the stub wing box front and rear spar caps and webs. Each main frame consists of three parts: a left part, a right part, and a top center part. The left and right parts are 7075-T6 forgings. The top center part is a 7075-T6 extrusion. The structure of each main frame below the level of the stub wing lower surface consists of a 7075-T6 extruded angle cap lying along contour, a 2024-T3 clad vertical shear web, and 7075-T6 extruded vertical angle stiffeners tying the extruded angle cap to the stub wing box spar web. (5) Fuselage bulkheads are located at fuselage stations 175 (canted), 185 (partial), 288, 323 (partial), 405.1, 477 (partial), 553 (partial), and 1117 (aft pressure). Bulkheads generally consist of 7075-T6 clad or 2024-T3 clad webs and 7075-T6 extruded caps and stiffeners. The aft pressure bulkhead (fuselage station 1117) consists of a 2024-T42 clad web, 7075-T6 extruded caps, 7075-T6 extruded stiffeners, and 2024-T3 clad formed stiffeners. (6) Pressure webs are located in the nose section and forebody. The upper surface of the wing center section acts as a pressure web in the midbody. The pressure webs in the nose section and forebody are made of 0.032 and 0.040 2024-T3 clad sheet, and are stiffened by 7075-T6 aluminum alloy extrusions. The pressure webs are attached to the bottoms of built up transverse and longitudinal beams, fabricated from 7075-T6 clad, and bare aluminum alloy. Floor panels are attached to the tops of the beams. In the midbody, a grid-work of interconnected transverse and longitudinal beams, fabricated from 7075-T6 extruded or sheet metal sections, support the floor panels. A grid work of transverse beams, and longitudinal intercostals, fabricated from 7178-T6 extruded channel or J-sections, support the floor panels in the aftbody. Floor panels are fabricated from 3/8-inch honeycomb and plywood panels. Plywood panels are used in areas that are subjected to high local loads or hard usage. 4 - 2 . B AT T E RY A C C E S S D O O R B O N D I N G SPRING REPLACEMENT. Install replacement bonding springs (cadmium plated) as follows: a. Remove defective bonding spring by carefully drilling out rivets.

4-1

NAVAIR 01-75PAA-3-1.1b. Remove any corrosion from bonding spring attachment area on door as described in NAVAIR 01-1A-509. If dam-age to door fairing is deeper than 0.015 inch, obtain special engineering disposi-tion for repair. c. T r e a t a l l e x p o s e d m e t a l i n a r e a f o r corrosion prevention as described in Section I and apply paint finish as described in NAVAIR 01-75PAA-2-2.1. to 1.5g and 250 knots indicated airspeed (kias). (2) I f c r a c k e x t e n d s b e y o n d 2 . 7 5 i n . upward from bottom of fitting, or 2.75 in. inboard from outboard edge of fitting, suspend flight operations and send details of crack length and orientation to a Depot level activity, requesting disposition. b. Cracks in Horizontal Flange in Base of Fitting: Use sealing compound in a well-ventilated area. Keep away from heat and open flame. Avoid inhalation and skin contact. Rubber or polyethylene gloves must be used when mixing or using sealing compound. Wash hands before eating or smoking. Apply lanolin-base hand cream upon completion of operation. d. A p p l y a b r u s h c o a t o f M I L - S - 8 1 7 3 3 , Ty p e I s e a l i n g c o m p o u n d ( t a b l e A - 1 , item 49) to all areas of bonding spring that will contact door (See section I for sealing procedures). e. I n s t a l l b o n d i n g s p r i n g w i t h t h r e e MS20427M3 rivets wet with MIL-S-81733, Type I sealing compound. Install rivets flush both sides. 4-3. BOMB BAY DOOR BONDING SPRING WEAR CRITERIA. It is permissible to retain cracked or worn bonding springs in place until they do not satisfy aircraft bonding requirements. Replace any bonding springs that have sharp projecting points, to minimize injury to personnel. 4-4. FUSELAGE MAIN FRAME FITTING CRACK FLIGHT RESTRICTIONS. Flight restrictions for aircraft with a crack in a main frame fitting at fuselage station 571 or 695 are as follows: a. Cracks in Spotface Area For 5/8-in. Dia Bolthole at Lower Outboard Corner of Fitting: (1) I f c r a c k i s l e s s t h a n 2 . 7 5 i n . l o n g , aircraft is restricted to a one-time flight to a Depot level activity for repair. Flight loads must be limited (1) If crack does not extend more than 1.5 in. up from bottom of fitting, aircraft is restricted to a one-time flight to a Depot level activity for repair. Flight loads must be limited to 1.5g and 250 Kias. (2) I f c r a c k e x t e n d s b e y o n d 1 . 5 i n . u p from bottom of fitting, suspend flight operations and send details of crack length and orientation to a Depot level activity, requesting disposition. c. Cracks in Outboard Vertical Flange Above 5/8-in. Dia Bolthole (Restricted to Lower 9.3 in. of Fitting): (1) I f c r a c k i s l e s s t h a n 1 . 0 i n . l o n g , involves two or less flange fastener holes, and does not extend into radius of horizontal flange above bolthole or radius of horizontal flange 7.5 in. above bottom of fitting or radius of fitting web, aircraft is restricted to a one-time flight to a Depot level activity for repair. Flight loads must be limited to 1.5g and 250 kias.

(2) If crack exceeds criteria graph (1) above, suspend tions and send details of and orientation to a Depot requesting disposition.

of subparaflight operacrack length level activity,

d. Cracks in Adjacent Primary Structure Other Than as Described Above. Suspend flight operations and send details of crack length and orientation to a Depot level activity, requesting disposition.

4-2

NAVAIR 01-75PAA-3-1.14-4.1. PILOT AND COPILOT INTERCONNECT ENGINE POWER CONTROL TORQUE TUBE REPAIR. This repair is for drilling and reaming new fastener holes when enlarged or elongated holes in the torque tubes are found. Proceed as follows: NOTE See NAVAIR 01-75PAA-2-4.5, WP 004 00 for removal and installation of the interconnect torque tubes. a. Rotate torque tube 90 degrees from original fastener (spring pin) holes. b. Drill and ream new holes in accordance with the drawing corresponding to the engine number that the torque tube controls, as listed below:

Engine Power Control Torque Tube No. 1 2 3 4

Lockheed Aeronautical Systems Co. Drawing No. 808083 808084 808085 808086

4-3


ITEM1 2 3 4 5 6 TAIL SECTION . . . . . FIGURE 473 AFT BODY . . . . . . . . FIGURE 462

MIDBODY . . . . . . . . . FIGURE 450 FOREBODY . . . . . . . FIGURE 426 NOSE SECTION . . . FIGURE 42

DOORS . . . . . . . . . . . FIGURE 482 1

4-46 6 3 1 4 6 2 3 6 5

2

NOTEFOR ENTRY LADDER REPAIRS, SEE FIGURES 490 THROUGH 495. FOR ALLOWABLE GAPS, CLEARANCES, AND MISMATCHES, SECTION I. FOR REPLACEMENT OF STATIC PORT FITTINGS, SEE FIGURE 496.

Figure 4-1.

Fuselage Group Index Diagram

004001


FS 288.0

1

7

2 3

4

5

6

8

ITEM1 SKINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 43 2 STRINGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 45 3 FRAMES AND BULKHEADS . . . . . . . . . . . . . . . FIGURE 47 4 PRESSURE WEB . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 418 5 FLOOR AND FLOOR SUPPORTS . . . . . . . . . . FIGURE 414 6 RADOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 422 7 WINDSHIELD STRUCTURE . . . . . . . . . . . . . . . FIGURE 420 8 INFRARED DETECTION SYSTEM MOUNT AND DOORS . . . . . . . . . . . . . . . . . . . . FIGURE 425

NOTE1 SEE FIGURE 424 FOR MICROWAVE ABSORBER REPAIR. 2 SEE PILOT AND COPILOT INTER CONNECT ENGINE POWER CONTROL TORQUE TUBE REPAIR PARAGRAPH FOR REPAIR OF WORN HOLES IN THE TORQUE TUBES.

Figure 4-2.

Fuselage Nose Section Index Diagram

004002

4-5


FS 288 1 2 3 4 5 6 7 27 26 25

FS 288

A

B

FLOOR LEVEL

3 5

2

1

VIEW LOOKING FORWARD FS 8 156 FS 156 8 28 29

9 24 10 11 23FLOOR LEVEL

9

4-6

30 12FLOOR LEVEL

12 13

22

21

20

19

17 VIEW A

18

17

16 15

14

VIEW B

7

14 31 6 11

SECTION

CC00400301

Figure 4-3.

Fuselage Nose Section Skin Panels (Sheet 1)


DVIEW LOOKING FWD SYMMETRICAL ABOUT EXCEPT AS NOTED

WL 116.5

32 48

35 41 33

E

42 43

FS 156 CANTED FS 182.78 FS 185 FS 195.4

44

52

51 FS 228 FS 238 FS 248 FS 261 FS 270

40 46 47 45

49 50

FS 288 BL 18.7L VIEW

D

BL 18.7R

32 36 48

38 41

39

37

34 FS 156 CANTED FS 182.78 FS 185

DETAIL

E

(BUNO 151388 AND SUBSEQUENT)

00400302

Figure 4-3.

Fuselage Nose Section Skin Panels (Sheet 2)

4-7

NAVAIR 01-75PAA-3-1.1S e r i a l

Item No.

Drawing No. g

Description p

LS No No. or Gage

Repair Figure Material NAVAIR 01-75PAA-3 -1 -2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

41 42 43 44 45 46 47 48 49 50 51 52

900744-5 900779-1 900744-17 900744-13 /-14 900744-3 900744-21 /-22 906005-1 /-2 900744-83 900744-11 /-12 916923-1 /-2 900744-25 /-26 916328-3 900742-37 /-38 900744-9 /-10 900744-27 /-28 900744-85 /-86 801152-39 900742-23 /-24 900742-25 /-26 900742-33 900742-27 /-28 900742-35 900742-47 915977-1 900744-19 /-20 900744-7 900744-23 /-24 900744-105 900744-97 900744-115 900742-8 900744-77 /-78 916925-1 /-2 916328-23 916328-103 916328-5 916328-21 916328-105 /-106 916328-111 /-112 916328-107 /-108 969570-113 916328-108 916328-115 963544-113 /-114 903171-17 /-19 903171-21 /-23 903171-25 /-27 935985-101 /-103 935985-105 /-107 935985-109 /-111 917059-1 /-2 917059-101 /-102 934550-105 934359-101 934399-105 /-107 934399-235 /-237 934399-109 /-111 934399-199 /-201 934399-203 /-205 934399-217 /-219 934399-247 /-249 934399-223 934690-103 934699-103 934399-281 /-282

A B

D J C D E F K L L J K M M M N N N H G G H

G H

SKIN DOUBLER DOUBLER DOUBLER SKIN GUSSET PLATE SPLICE SKIN DOUBLER DOUBLER SKIN SKIN SKIN DOUBLER DOUBLER DOUBLER DOUBLER DOUBLER DOUBLER DOUBLER DOUBLER SKIN DOUBLER DOUBLER SKIN SPLICE SKIN DOUBLER DOUBLER SKIN FILLER DOUBLER DOUBLER SKIN SKIN SKIN SKIN SKIN DOUBLER DOUBLER, LEFT DOUBLER, RIGHT SUPPORT LOUVER PLATE ACCESS PANEL ASSY OUTER SKIN INNER SKIN ACCESS PANEL ASSY OUTER SKIN INNER SKIN DOUBLER DOUBLER DOUBLER SUPPORT SKIN SKIN SKIN DOUBLER DOUBLER DOUBLER DOUBLER DOUBLER DOOR DOOR DOUBLER

0.050 0.160 0.063 0.071 0.050 0.090 0.125 0.063 0.050 0.063 0.050 0.032 0.050 0.050 0.063 0.063 0.050 0.050 0.040 0.032 0.063 0.063 0.050 0.125 0.063 0.050 0.050 0.050 0.071 0.063 0.040 0.032 0.063 0.063 0.050 0.032 0.032 0.032 0.032 0.063 0.050 0.063 0.050 0.040 0.040 0.025 0.040 0.025 0.063 0.063 0.050 0.063 0.040 0.040 0.050 0.040 0.071 0.040 0.040 0.040 0.040 0.040 0.050

2024-T42 CLAD SEE NOTE 1 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 7075-T6 CLAD 2024-T3 CLAD 2024-T42 CLAD 7075-T6 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD SEE NOTE 1 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 7075-T6 CLAD 2024-T42 CLAD 2024-T3 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T3 CLAD 2024-T3 CLAD 2024-T3 CLAD 7075-T6 CLAD 2024-T3 CLAD 2024-T42 CLAD 2024-T3 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 7075-T6 CLAD 7075-T6 CLAD 2024-T42 CLAD 7075-T6 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T3 CLAD 2024-T3 CLAD 2024-T42 CLAD

4 - 4, 9 -3

4 - 4, 9 -3

4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3

4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3

4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3

9-5 4 -83 4 -83 4 -83 4 -83

9-5 4 - 4, 9 -3 4 - 4, 9 -3 4 - 4, 9 -3

Figure 4-3. Key

4-8

NAVAIR 01-75PAA-3-1.1S e r i a lRepair Figure Description p LS No No. or Gage Material NAVAIR 01-75PAA-3

Item No.

Drawing No. g

-1

-2

NOTE 1 2024-T42 CLAD, CHEM MILLED.

SERIAL CODE A B C D E F G H J K L M N APPLICABLE TO BUNO 148883 APPLICABLE TO BUNO 148884 AND SUBSEQUENT APPLICABLE TO PRODUCTION BLOCKS -01 THROUGH -10 APPLICABLE TO BUNO 153443 THROUGH 159888 AND 159890 THROUGH 160289 APPLICABLE TO BUNO 151388 THROUGH 160612 APPLICABLE TO BUNO 160761 AND SUBSEQUENT APPLICABLE TO BUNO 152164 AND SUBSEQUENT APPLICABLE TO BUNO 148883 THROUGH 152163 APPLICABLE TO BUNO 151388 AND SUBSEQUENT APPLICABLE TO BUNO 159889, 160290 AND SUBSEQUENT APPLICABLE TO BUNO 151388 THROUGH 159888 AND 159890 THROUGH 160289 APPLICABLE TO BUNO 148883 THROUGH 152167 APPLICABLE TO BUNO 152168 AND SUBSEQUENT

Figure 4-3.

Key - Continued

4-9


FLOOR LEVEL

1 81

7

AFT ACCESS DOOR (INTERNAL ACCESS TO SKIN AFT OF PRESSURE BULKHEAD). REMOVE CONTROLS OR ELECTRICAL EQUIPMENT AS NECESSARY. HYDRAULIC BAY AND SONOBUOY ACCESS DOORS (INTERNAL ACCESS TO SKIN BELOW FLOOR LEVEL AFT OF REAR SPAR). REMOVE DUCTS, HYDRAULIC OR ELECTRICAL EQUIPMENT, OR CONTROLS AS NECESSARY. MAIN ENTRANCE DOOR (INTERNAL ACCESS TO SKIN ABOVE FLOOR LEVEL). REMOVE CONSOLES, EQUIPMENT RACKS OR DUCTS AS NECESSARY. PEEL BACK TRIM AND INSULATION MATERIALS. FUEL AND WATER TANK ACCESS DOORS (INTERNAL ACCESS TO SKIN BELOW FLOOR LEVEL, AND BETWEEN FRONT SPAR AND BOMB BAY).

ITEM

6

5

2 4 4 ACCESS PROVISIONS5 6

3

2

BOMB BAY SIDEWALL PANELS (INTERNAL ACCESS TO SKIN BELOW FLOOR LEVEL AT SIDE OF BOMB BAY). AIR CONDITIONING ACCESS DOOR (INTERNAL ACCESS TO SKIN BELOW FLOOR LEVEL, AND BETWEEN BOMB BAY AND NOSE GEAR WHEEL WELL). REMOVE DUCTS OR AIR CONDITIONING EQUIPMENT AS NECESSARY. NOSE GEAR DOORS (INTERNAL ACCESS TO SKIN BELOW FLOOR IN NOSE GEAR WHEEL WELL). REMOVE DUCTS OR EQUIPMENT AS NECESSARY. NOSE RADOME (INTERNAL ACCESS TO SKIN IN FRONT OF FORWARD PRESSURE BULKHEAD).

2

7

3

8

4

10H (MIN)H T

Y

A

ABA BDEPTH = H

T

TYPE B DAMAGE SECTION

AA

DEPTH = H

TYPES OF DAMAGESMOOTH DENT (Y = 8H MIN). CORROSION, SCRATCHES, ABRADED AREA. MAX CLEANEDUP DEPTH H = T/4 EXCEPT AT SKIN SPLICES WHERE MAX DEPTH H = T/16. DAMAGE EXCEEDING THIS DEPTH IS CONSIDERED AS TYPE C DAMAGE. Y (MAX) = T/4H.

Y

A CY STOPDRILL 1/4 (0.250) DIA

TWO ATTACHMENT DIAMETERS (MIN)

C

D1

4Y (MIN) Y X = MIN DISTANCE BETWEEN . AFFECTED ATTACHMENTS

PUNCTURE TRIMMED TO SMOOTH, ROUND HOLE OR STOPDRILLED CRACK. PLUG SMALL HOLES WITH STRUCTURALTYPE ATTACHMENTS. EDGE DAMAGE CLEAR OF ATTACHMENTS. EDGE DAMAGE TERMINATING AT AN ATTACHMENT.

D1 D2 1Y

D2

Y = MAX PERCENTAGE OF AFFECTED FASTENERS IN ANY ONE ROW OF ATTACHMENTS

NOTE (THIS SHEET ONLY)WHERE MULTIPLE DAMAGES ARE SEPARATED BY LESS THAN 6Y (WHERE Y IS OF LARGER HOLE), ADD THE INDIVIDUAL DIAMETERS TO OBTAIN Y. STOPDRILL CRACKS USING 1/4 (0.250) DIA DRILL, OR TRIM OUT COMPLETELY. COVER ALL NEGLIGIBLE DAMAGE HOLES WITH A NEGLIGIBLE DAMAGE PATCH AS SHOWN ON FIGURE 91. AFTER CLEANUP OF DAMAGE, TREAT EXPOSED SURFACES FOR CORROSION PREVENTION (SEE SECTION I).

24Y OR FOUR ATTACHMENT DIAMETERS (MIN), WHICHEVER IS GREATER, BUT 2 INCHES (MIN) (TYP)

C

3 4

TYPE OF DAMAGE(AREA CODING AS SHOWN ON SHEET 2).

C AH (MAX) 0.13 0.19 PRESSURIZED UNPRESSURIZED AREA AREA

D1

D210% 20%

Y (MAX)0.19 0.19

Y (MAX)0.75 1.00

Y (MAX) X (INCHES) Y0.10 0.20 10 5

Figure 4-4.

4-10

NEGLIGIBLE DAMAGE00400401

Fuselage Skin Repairs (Sheet 1)


REPAIR ZONE CODING DIAGRAMS REPAIR ATTACHMENT REQUIREMENTS TABLEREPAIR ZONE CODING (SEE DIAGRAMS ABOVE) ORIGINAL SKIN GAGE 0.032 0 032 0.040 0 040 0.050 0 050 0.063 0 063 0.071 0 071 0.100 0 100 0.025 0 025 0.032 0 032 0.040 0 040 0.040 6 (7075 T6 CLAD) 0.050 0 050 0.063 0 063 0.071 0 071 MINIMUM EDGE DISTANCE 1 REPAIR PLATE GAGE 0.040 0 040 0.050 0 050 0.063 0 063 0.071 0 071 0.080 0 080 0.125 0 125 0.032 0 032 0.040 0 040 0.050 0 050 0.050 6 (7075 T6 CLAD) 0.063 0 063 0.071 0 071 0.080 0 080 REPAIR TYPE 5 EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT INT 0.31 5 6 5 6 5 6 6 6 6 6 1.03$0.15 0.99$0.08 0.97$0.13 1.00$0.13 0.89$0.11 0.94$0.11 0.89$0.11 0.86$0.03 0.85$0.11 0.84$0.06 NO. ROWS 6 6 MS20426 RIVETS AD4 SPACING 0.91$0.05 0 91$0 05 0.83$0.05 NO. ROWS 6 6 6 6 6 6 AD5 SPACING 1.02$0.08 1 02$0 08 0.99$0.08 0.94$0.08 0.89$0.05 0.88$0.02 0.84$0.02 NO. ROWS 6 6 6 4 AD6 SPACING 1.30$0.06 1 30$0 06 1.24$0.06 1.15$0.04 NO. ROWS 5 5 5 6 5 6 5 6 6 6 5 5 6 5 6 5 6 5 6 5 5 5 5 1.09$0.10 1 09$0 10 1.10$.015 1.07$0.07 1.07$0.15 1.08$0.13 0.97$0.06 0.98$0.03 1.01$0.15 1.01$0.10 0.95$0.12 0.94$0.09 0.90$0.08 0.89$0.06 0.34 (c) 5 6 5 5 5 5 0.41 1.24$0.12 1.26$0.08 1.23$0.15 1.16$0.05 1.20$0.15 1.15$0.07 6 5 6 1.39$0.17 1.33$0.15 1.33$0.15 4 4 5 4 6 4 5 4 4 4 4 0.41 5 1.30$0.08 1.40$0.23 1.30$0.08 1.27$0.10 1.30$0.08 1.27$0.15 1.36$0.19 1.23$0.14 1.19$0.07 1.22$0.17 1.15$0.06 0.28 DD6 SPACING 1.24$0.16 1 24$0 16 1.34$0.16 1.21$0.09 1.27$0.09 1.17$0.09 1.25$0.13 1.16$0.11 1.21$0.12 1.03$0.08 1.03$0.03 2 3 3 4 4 0.59$0.06 0 59$0 06 0.67$0.14 0 67$0 14 0.60$0.07 0 60$0 07 0.64$0.11 0 64$0 11 0.61$0.08 0 61$0 08 2 3 3 3 4 4 0.34 0.73$0.07 0 73$0 07 0.83$0.17 0 83$0 17 0.75$0.09 0 75$0 09 0.72$0.06 0 72$0 06 0.80$0.14 0 80$0 14 0.74$0.08 0 74$0 08 2 2 3 3 3 3 0.90$0.11 0 90$0 11 0.86$0.07 0 86$0 07 0.97$0.18 0 97$0 18 0.95$0.16 0 95$0 16 0.90$0.11 0 90$0 11 0.84$0.05 0 84$0 05 0.41 2 2 2 2 2 3 0.41 9 0.90$0.11 0 90$0 11 0.90$0.11 0 90$0 11 0.90$0.11 0 90$0 11 0.87$0.08 0 87$0 08 0.86$0.07 0 86$0 07 1.01$0.22 1 01$0 22 3 4 3 3 3 4 3 3 3 3 3 3 1.24$.020 1.26$0.18 1.27$0.28 1.10$0.06 1.14$0.16 1.16$0.13 1.18$0.24 1.08$0.10 1.15$0.23 1.10$0.16 1.13$0.23 1.08$0.15 0.41 2 2 2 2 2 2 0.91$0.11 0 91$0 11 0.90$0.10 0 90$0 10 0.91$0.11 0 91$0 11 0.88$0.08 0 88$0 08 0.96$0.16 0 96$0 16 1.03$0.23 1 03$0 23 0.41 3 5 3 4 4 4 4 4 4 4 4 4 0.41 1.39$0.05 1.59$0.21 1.35$0.06 1.43$0.10 1.54$0.26 1.44$0.11 1.46$0.26 1.36$0.06 1.43$0.24 1.38$0.14 1.39$0.25 1.34$0.15 NO. ROWS 4 4 5 6 6 AD4 SPACING 0.66$0.06 0 66$0 06 0.59$0.06 0 59$0 06 0.58$0.05 0 58$0 05 0.60$0.07 0 60$0 07 0.56$0.03 0 56$0 03 AD5 NO. ROWS 4 3 4 5 5 SPACING 0.62$0.04 0 62$0 04 0.70$0.04 0 70$0 04 0.71$0.05 0 71$0 05 0.76$0.10 0 76$0 10 0.71$0.05 0 71$0 05 NO. ROWS 4 3 4 4 4 6 MS20470 RIVETS AD6 SPACING 0.86$0.11 0 86$0 11 0.90$0.11 0 90$0 11 0.94$0.15 0 94$0 15 0.89$0.10 0 89$0 10 0.83$0.04 0 83$0 04 0.82$0.03 0 82$0 03 DD6 NO. ROWS 4 3 3 3 3 5 SPACING 0.85$0.16 0 85$0 16 0.95$0.16 0 95$0 16 0.92$0.13 0 92$0 13 0.90$0.11 0 90$0 11 0.86$0.05 0 86$0 05 0.86$0.07 0 86$0 07 NO. ROWS 3 4 3 4 3 4 4 4 3 4 4 4 HL51 HILOKS 6 SPACING 1.03$0.08 1.05$0.08 1.06$0.08 1.08$0.05 0.99$0.05 1.07$0.08 1.14$0.21 1.08$0.14 0.95$0.05 1.06$0.14 1.06$0.20 0.96$0.09 HL506 HILOKS NAS6233 SCREWS NO. ROWS 3 3 3 3 3 3 SPACING 0.86$0.15 0 86$0 15 0.95$0.15 0 95$0 15 0.93$0.13 0 93$0 13 1.02$0.21 1 02$0 21 1.02$0.22 1 02$0 22 0.96$0.16 0 96$0 16 NAS517 SCREWS 3 NO. ROWS 5 6 5 6 5 6 5 5 5 5 5 6 SPACING 1.24$0.21 1.42$0.18 1.51$0.21 1.51$0.18 1.40$0.17 1.43$0.13 1.36$0.17 1.31$0.08 1.32$0.18 1.28$0.08 1.19$0.18 1.23$0.15

2 (a) (b)

NOTE (SHEETS 2 THROUGH 7 ONLY) MAKE REPAIR PLATES OF SAME MATERIAL AND TEMPER AS THE ORIGINAL SKIN PANEL. GAGE AS SHOWN IN TABLE ON SHEET 2. WHEN NECESSARY, 2024T42 CLAD MAY BE SUBSTITUTED FOR 2024T3 CLAD. IN FUSELAGE AREAS HAVING SHARP OR DOUBLE CURVATURE, FORM PLATE TO CURVATURE BEFORE DRILLING.FOR CLEANEDUP DAMAGE WHICH DOES NOT EXCEED 1.0 INCH ACROSS THE GREATEST DIMENSION, INSTALL TWO ROWS (IN UNPRESSURIZED SKIN, ONE ROW) OF MS20426AD4 OR MS20470AD4 RIVETS ON EACH SIDE OF DAMAGE. FOLLOW SPACING REQUIREMENTS TABULATED ON SHEET 2 FOR RIVET TYPE SELECTED. IF NOT TABULATED, USE SPACING OF 0.95 $ 0.10. FOR CLEANEDUP DAMAGE WHICH DOES NOT EXCEED 2.50 INCHES ACROSS THE GREATEST DIMENSION, ONLY HALF THE NUMBER OF ROWS OF ATTACHMENTS TABULATED ON SHEET 2 ARE REQUIRED (USE NEXT HIGHER WHOLE NUM BER WHEN A FRACTION IS INVOLVED). USE THE SPACING SPECIFIED IN THE TABLE, IN THE APPROPRIATE SECTION, FOR THE TYPE OF ATTACHMENT SELECTED.

FOR CLEANEDUP DAMAGE WHICH EXCEEDS 2.50 INCHES ACROSS THE GREATEST DIMENSION, SELECT ANY OF THE ATTACHMENT CONFIGURATION FROM THE APPROPRIATE REPAIR PLATE GAGE SECTION OF THE TABLE ON SHEET 2. THE TABULATED NUMBER OF ROWS REQUIRED IS THE MINI MUM ON EACH SIDE OF DAMAGE, UNLESS PICKING UP AN EXISTING SPLICE. MAKE ALL REPAIR RIVET PATTERNS CHAIN (NONSTAG GERED) TYPE. PICK UP ALL EXISTING ATTACHMENTS COVERED BY A RE PAIR PLATE, PROVIDING THE EDGE DISTANCE IS MAIN TAINED. USE SAME TYPE AND SIZE ATTACHMENTS AS ORIGINALS. COUNT AS ONE ROW IF SAME AS, OR LARGER THAN, REPAIR ATTACHMENTS.

IN THE TABLE EXT INDICATES EXTERNAL PATCH TYPE REPAIRS (INCLUDING LAPTYPE SKIN SPLICES) AND INT INDICATES INTER NAL, OR FLUSH TYPE REPAIRS. HOTDIMPLING IS REQUIRED FOR 7075T6 CLAD MATERIAL. SEAL ALL REPAIRS IN ACCORDANCE WITH THE INSTRUCTIONS IN SECTION I. FOR TYPICAL LAYOUTS OF DIFFERENT TYPES OF REPAIR SEE THE FOLLOWING SHEETS OF THIS FIGURE:

6 7 8

(BUNO 148883 THROUGH 163003) FOR REPAIRS TO THIS PANEL USE A REPAIR PLATE OF 0.032 1/4H CRES, PICKING UP A MINI MUM OF TWO ROWS OF NAS1200M4 OR MS20427M4 RIVETS AT 0.60 TO 0.80 INCH SPACING ON EACH SIDE OF DAMAGE. COUN TERSINK HOLES IN EXTERNAL REPAIR PLATE. (BUNO 163004 AND SUBSEQUENT) FOR REPAIRS TO THIS PANEL USE A REPAIR PLATE OF 0.050 15V3CR3SN3AL TITANIUM OR 1/4H CRES, PICKING UP A MINIMUM OF TWO ROWS OF NAS1200M5 RIVETS AT 0.80 TO 1.00 INCH SPACING ON EACH SIDE OF DAMAGE. COUNTERSINK HOLES IN EXTERNAL REPAIR PLATE.

(d) (e)

TYPE OF REPAIR EXTERNAL PATCH INTERNAL (FLUSH) LARGE INTERNAL (FLUSH) EXTERNAL PATCH AT CORNER OF OPENING SPLICINGIN A PARTIAL PANEL EXTERNAL PATCH AT MAIN FRAMES, FS 570.97 AND 695.09

SHEET 3 4 5 AND 6 7 8 AND 9 10, 11, 12 00400402

4

3 4

DEMAGNETIZE ALL STEEL ATTACHMENTS INSTALLED WITHIN 30 INCHES OF THE MAGNETIC COMPASS. IF MS20426 RIVETS ARE INSTALLED IN DIMPLED HOLES, FOLLOW REQUIREMENTS FOR MS20470 RIVETS.

Figure 4-4.


4-11/(4-12 Blank)


41.5 (MIN) (SEE ITEM NO. 1) 0.25R(TYP)

1 2

3 4

6

70.25R (MIN) (TYP)

5

3

4

SUGGESTED PROCEDURE FOR REPAIRA B DETERMINE REPAIR REQUIREMENTS FROM ILLUSTRATION. LAY OUT REPAIR ON FUSELAGE SKIN. 1

ITEM (THIS SHEET ONLY)REPAIR PLATE SEE SHEET 3, NOTE 1 DESIGN TO PICK UP NECESSARY ATTACHMENTS, BUT IF EDGE OF PLATE EXTENDS TO WITHIN 1.50 INCHES OF ADJACENT INTERNAL STRUCTURE (SEE ILLUSTRATION ABOVE). CONTINUE PLATE TO PICK UP THE INTERNAL STRUCTURE ATTACHMENTS. CHAMFER AND CRIMP ALL EDGES (SEE SECTION I). REPAIR ATTACHMENTS INDICATED THUS: NOTE 2. SEE SHEET 3,

C PILOTDRILL REPAIR ATTACHMENT HOLES CAPABLE OF BEING BACKDRILLED FROM INSIDE FUSELAGE. D REMOVE EXISTING ATTACHMENTS THAT WILL BE INCLUDED IN THE REPAIR ATTACHMENTS. E F PLACE OVERSIZED REPAIR PLATE (CONTOURED, IF NECESSARY) OVER DAMAGED AREA AND HOLD IN POSITION. BACKDRILL ATTACHMENT HOLES. START NEAR CENTER OF REPAIR PLATE AND INSTALL TEMPORARY FASTENERS AS HOLES ARE DRILLED. 4 5 6 2 3

G LAY OUT AND DRILL ANY ATTACHMENT HOLES NOT CAPABLE OF BEING BACKDRILLED. H REMOVE REPAIR PLATE. I J K L TRIM REPAIR PLATE TO SIZE. BURR ALL EDGES AND HOLES. CHAMFER AND CRIMP EDGES OF REPAIR PLATE. DIMPLE AND/OR COUNTERSINK HOLES AS NECESSARY.

EXISTING ATTACHMENTS INDICATED THUS: USE COUNTERSINK FILLERS, OR DIMPLE REPAIR PLATE WHEN PICKING UP EXISTING COUNTERSUNK ATTACHMENTS (REFER TO SECTION I FOR DIMPLING INFORMATION) TRIM REPAIR PLATE TO CLEAR ANY EXISTING PROTRUDING HEAD TYPE ATTACHMENT TOO NEAR EDGE TO PICK UP, OR REMOVE AND REPLACE ATTACHMENT WITH A FLUSH TYPE. EXISTING INTERNAL STRUCTURE. ORIGINAL SKIN. FILLER 2024T42 CLAD, SAME GAGE AS ORIGINAL SKIN. OUTLINE INDICATED THUS: USE IN DAMAGED AREA OVER INTERNAL STRUCTURE AS NECESSARY CLEANEDUP DAMAGE

7

REQUIRED TOOLS AND MATERIALS

M TREAT REPAIR FOR CORROSION PREVENTION (REFER TO SECTION I). N POSITION REPAIR PLATE AND INSTALL ATTACHMENTS AFTER APPLYING APPLICABLE SEALING COMPOUND (SEE SECTION I). O APPLY FINAL PAINT FINISH AS NECESSARY.

COMMON HAND TOOLS RIVET GUN AND BUCKING BARS 2024T3 OR 7075T6 CLAD SHEET (GAGE AS REQUIRED) DESIRED ATTACHMENTS SEALING MATERIALS (SEE SECTION I) CORROSION PREVENTION MATERIALS

EXTERNAL PATCH TYPE

Figure 4-4.


00400404

4-13

NAVAIR 01-75PAA-3-1.1B5 1JOGGLE BEND UP FLANGE 9

1.5 (MIN) (SEE ITEM NO. 1)

0.25R (TYP)

SECTION 2 3

BB

B

(SHOWING TYPICAL METHODS OF ATTACHING EXTENDED REPAIR PLATE TO INTERNAL STRUCTURE, WHEN NECESSARY)

D

4 5 6

7 5 5 10

10 SECTION

1

CC1

E8 D

E0.03 GAP (MAX) 0.25R (MIN) (TYP)

7 8 10 5 SECTION D 10 8

7

C

C

D5

4A B C D DETERMINE REPAIR REQUIREMENTS FROM ILLUSTRATION. LAY OUT REPAIR ON FUSELAGE SKIN. REMOVE EXISTING ATTACHMENTS THAT WILL BE INCLUDED IN THE REPAIR ATTACHMENTS. CUT AWAY INTERNAL STRUCTURE, AS NECESSARY TO ACCOMMODATE REPAIR PLATE. REPAIR ACCORDING TO APPLICABLE REPAIR ILLUSTRATION. MAKE AERODYNAMIC FILLER. PLACE REPAIR PLATE (CONTOURED, IF NECESSARY) UNDER DAMAGED AREA AND HOLD IN POSITION. DRILL ATTACHMENT HOLES. START NEAR CENTER OF REPAIR PLATE AND INSTALL TEMPORARY FASTENERS AS HOLES ARE DRILLED. HOLD FILLER IN POSITION AND DRILL ATTACHMENT HOLES. REMOVE REPAIR PLATE AND FILLER. TRIM REPAIR PLATE TO SIZE. BURR ALL EDGES AND HOLES. DIMPLE AND/OR COUNTERSINK HOLES AS NECESSARY. TREAT REPAIR FOR CORROSION PREVENTION (SEE SECTION I). POSITION REPAIR PLATE, FILLER AND ANY INTERNAL STRUCTURE REPAIR MEMBERS, AND INSTALL ATTACHMENTS AFTER APPLYING APPLICABLE SEALING COMPOUND (SEE SECTION I). APPLY FINAL PAINT FINISH AS NECESSARY. 5 2 3 1

SUGGESTED PROCEDURE FOR REPAIR

7

11

SECTION

EE

1

3

E F G

REPAIR PLATE SEE SHEET 3, NOTE 1 DESIGN TO PICK UP NECESSARY ATTACHMENTS BUT IF EDGE OF PLATE EXTENDS TO WITHIN 1.5 INCHES OF ADJACENT INTERNAL STRUCTURE (SEE ILLUSTRATION ABOVE), CONTINUE PLATE AND ATTACH TO THE INTERNAL STRUCTURE (SEE SECTION B B) REPAIR ATTACHMENTS INDICATED THUS: NOTE 2. SEE SHEET 3

ITEM (THIS SHEET ONLY)

H I J K L M N

4

AERODYNAMIC FILLER 2024T42 CLAD, SAME GAGE AS ORIGINAL SKIN ATTACH TO REPAIR PLATE WITH ONE ROW OF RIVETS SPACED NOT LESS THAN FOUR ATTACHMENT DIAMETERS APART IF FILLER IS MORE THAN 4 INCHES ACROSS, ADD ANOTHER ROW OF RIVETS ACROSS THE CENTER EXISTING ATTACHMENTS INDICATED THUS: SUBDIMPLE OR SUBCOUNTERSINK REPAIR PLATE WHEN PICKING UP EXISTING DIMPLED ATTACHMENTS REFER TO SECTION I FOR DIMPLING INFORMATION EXISTING INTERNAL STRUCTURE CUT SKIN FLANGES AWAY AS SHOWN TO ACCOMMODATE REPAIR PLATE BREAK SHARP EDGES AND CORNERS CLEANEDUP DAMAGE ORIGINAL SKIN STRINGERTOFRAME REINFORCING CLIP WHEN NECESSARY, REMOVE ANY EXISTING CLIPS AND INSTALL REPLACEMENT CLIPS, PICKING UP ORIGINAL ATTACHMENTS REPAIR ATTACHMENTS MS20470AD4 RIVETS AT 1.0 INCH SPACING INTERNAL STRUCTURE REPAIR MEMBER SEE APPLICABLE REPAIR ILLUSTRATION SHIM INSTALL AS NECESSARY

6 7 8

O

REQUIRED TOOLS AND MATERIALS

COMMON HAND TOOLS RIVET GUN AND BUCKING BARS 2024T3 OR 7075T6 CLAD SHEET (GAGE AS REQUIRED) DESIRED ATTACHMENTS SEALING MATERIALS (SEE SECTION I) CORROSION PREVENTION MATERIALS

9 10 11

INTERNAL (FLUSH) TYPE

Figure 4-4.


00400405

4-14

NAVAIR 01-75PAA-3-1.11 11 2 2 2 3

0.50R (TYP)

(SEE ITEM NO. 3) 1.5 (MIN)

0.25R (MIN) (TYP)

20.25R (MIN)(TYP)

4REPAIR SYMMETRICAL ABOUT

8

10

9

7

8

7

7

7

6

5

1 2

3

ITEM (SHEETS 5 AND 6) ORIGINAL SKIN EXISTING INTERNAL STRUCTURE CUT SKIN FLANGES AWAY AS SHOWN TO ACCOMMODATE REPAIR PLATE, BREAK SHARP EDGES AND CORNERS. REPAIR PLATE SEE SHEETS 2 AND 3. DESIGN TO PICK UP NECESSARY ATTACHMENTS, BUT IF EDGE OF PLATE EXTENDS TO WITHIN 1.5 INCHES OF ADJACENT INTERNAL STRUCTURE (SEE ILLUSTRATION ABOVE), CONTINUE PLATE AND ATTACH TO THE INTERNAL STRUCTURE (SEE SECTION I I)REPAIR PLATE ATTACHMENTS INDICATED THUS: SEE SHEETS 2 AND 3 REPAIR PLATE SAME MATERIAL AND GAGE AS ORIGINAL SKIN REPAIR PLATE ATTACHMENTS INDICATED THUS: . SEE SHEETS 2 AND 3 FOR ATTACHMENT REQUIREMENTS TABULATED FOR REPAIR PLATE GAGE.

7

8

4 5 6

9 10 11

12 13 14

FILLER 2024T42 CLAD. SAME GAGE AS REPAIR PLATE. OUTLINE INDICATED THUS: . USE IN LIGHTENING HOLE OF REPAIR PLATE OVER INTERNAL STRUCTURE. STRINGERTOFRAME REINFORCING CLIP WHEN NECESSARY, REMOVE ANY EXISTING CLIPS AND INSTALL REPLACEMENT CLIPS, PICKING UP ORIGINAL ATTACHMENTS. LIGHTENING HOLE IN INNER REPAIR PLATE. CLEANEDUP DAMAGE EXISTING ATTACHMENTS INDICATED THUS: SUBDIMPLE OR SUBCOUNTERSINK INNER REPAIR PLATE WHEN PICKING UP EXISTING DIMPLED ATTACHMENTS REFER TO SECTION I FOR DIMPLING INFORMATION INTERNAL STRUCTURE REPAIR MEMBER SEE APPLICABLE REPAIR ILLUSTRATION SHIM INSTALL AS NECESSARY. REPAIR ATTACHMENTS MS20470AD4 RIVETS AT 1.0 INCH SPACING

LARGE INTERNAL (FLUSH) TYPE

Figure 4-4.


00400406

4-15


8 13 12 RADIUS 12 1 2 SECTION G

2 2 12

2 1 12

5

3 SECTION H

H

G

1 3 5 SECTION F 14 FLANGEBEND UP

JOGGLE

F

A B C D

E F

G

H I J K L M N

O

DETERMINE REPAIR REQUIREMENTS FROM ILLUSTRATION. LAY OUT REPAIR ON FUSELAGE SKIN. REMOVE EXISTING ATTACHMENTS THAT WILL BE INCLUDED IN THE REPAIR ATTACHMENTS. CUT AWAY INTERNAL STRUCTURE AS NECESSARY TO ACCOMMODATE INTERNAL REPAIR PLATE. REPAIR ACCORDING TO APPLICABLE REPAIR ILLUSTRATION. MAKE ITEM 5 REPAIR PLATE, AND LAY OUT ATTACHMENTS. PLACE ITEM 3 REPAIR PLATE (CONTOURED, IF NECESSARY) UNDER DAMAGED AREA AND HOLD IN POSITION. DRILL ATTACHMENT HOLES. START NEAR CENTER OF REPAIR PLATE AND INSTALL TEMPORARY FASTENERS AS HOLES ARE DRILLED. HOLD ITEM 5 REPAIR PLATE IN POSITION AND DRILL ATTACHMENT HOLES. REMOVE REPAIR PLATES. TRIM ITEM 3 REPAIR PLATE TO SIZE. CUT LIGHTENING HOLE IN CENTER. BURR ALL EDGES AND HOLES. DIMPLE AND/OR COUNTERSINK HOLES, AS NECESSARY. TREAT REPAIR PLATES FOR CORROSION PREVENTION (SEE SECTION I). POSITION REPAIR PLATES AND ANY INTERNAL STRUCTURE REPAIR MEMBERS, AND INSTALL ATTACHMENTS AFTER APPLYING APPLICABLE SEALING COMPOUND (SEE SECTION I). APPLY FINAL PAINT FINISH AS NECESSARY.


SECTION I I (SHOWING TYPICAL METHODS OF ATTACHING EXTENDED REPAIR PLATE TO INTERNAL STRUCTURE, WHEN NECESSARY)

REQUIRED TOOLS AND MATERIALSCOMMON HAND TOOLS RIVET GUN AND BUCKING BARS 2024T3 OR 7075T6 CLAD SHEET (GAGE AS REQUIRED) DESIRED ATTACHMENTS SEALING MATERIALS (SEE SECTION I) CORROSION PREVENTION MATERIALS

LARGE INTERNAL (FLUSH) TYPE

Figure 4-4.


4-16

NAVAIR 01-75PAA-3-1.11.5 (MIN) OR 0.5 (MIN) AS APPLICABLE (SEE ITEM 2) 1 2 3

0.50R (MIN) (TYP)

11

8

1 0.25R (TYP)

7

6

5

4

A B C D E

F

G H I J K L M N

O

DETERMINE REPAIR REQUIREMENTS FROM ILLUSTRATION. LAY OUT REPAIR ON FUSELAGE SKIN. PILOTDRILL REPAIR ATTACHMENT HOLES CAPABLE OF BEING BACK DRILLED FROM INSIDE FUSELAGE. REMOVE EXISTING ATTACHMENTS WHICH WILL BE INCLUDED IN THE REPAIR ATTACHMENTS. PLACE OVERSIZED REPAIR PLATE (CONTOURED, IF NECESSARY) OVER DAMAGED AREA AND HOLD IN POSITION. BACKDRILL ATTACHMENT HOLES. START NEAR CENTER OF REPAIR PLATE AND INSTALL TEMPORARY FASTENERS AS HOLES ARE DRILLED. LAY OUT AND DRILL ANY ATTACHMENT HOLES NOT CAPABLE OF BEING BACK DRILLED. REMOVE REPAIR PLATE. TRIM REPAIR PLATE TO SIZE. BURR ALL EDGES AND HOLES. CHAMFER AND CRIMP EDGES OF REPAIR PLATE. DIMPLE AND/OR COUNTERSINK HOLES AS NECESSARY. TREAT REPAIR FOR CORROSION PREVENTION (SEE SECTION I). POSITION REPAIR PLATE AND INSTALL ATTACHMENTS AFTER APPLYING APPLICABLE SEALING COMPOUND (SEE SECTION I). APPLY FINAL PAINT FINISH AS NECESSARY.


2024T3 OR 7075T6 CLAD SHEET (GAGE AS REQUIRED) DESIRED ATTACHMENTS SEALING MATERIALS (SEE SECTION I) CORROSION PREVENTION MATERIALS 1 2 EXISTING INTERNAL STRUCTURE REPAIR PLATE SEE SHEET 3, NOTE 1, DESIGN TO PICK UP NECESSARY ATTACHMENTS, BUT IF EDGE OF PLATE EXTENDS TO WITHIN 1.5 INCHES (OR 0.5 INCHES WHEN SKIN IS REINFORCED BY AN EXISTING DOUBLER) OF ADJACENT INTERNAL STRUCTURE (SEE ILLUSTRATION ABOVE), CONTINUE PLATE TO PICK UP THE INTERNAL STRUCTURE ATTACHMENTS. CHAMFER AND CRIMP ALL EDGES (SEE SECTION I). REPAIR ATTACHMENTS INDICATED THUS: SEE SHEET 3, NOTE 2. INCORPORATE INTO EXISTING ATTACHMENT PATTERN TO MEET TABULATED REQUIREMENTS. FILLER 2024T42 CLAD, SAME GAGE AS ORIGINAL SKIN. OUTLINE INDICATED THUS: USE IN DAMAGED AREA OVER INTERNAL STRUCTURE, AS NECESSARY. CLEANEDUP DAMAGE EXISTING DOUBLER ORIGINAL SKIN EXISTING ATTACHMENTS INDICATED THUS: F USE COUNTERSINK FILLERS, OR DIMPLE REPAIR PLATE WHEN PICKING UP EXISTING COUNTERSUNK ATTACHMENTS. REFER TO SECTION I FOR DIMPLING INFORMATION. TRIM REPAIR PLATE TO CLEAR ANY EXISTING PROTRUDING HEAD TYPE ATTACHMENTS TOO NEAR EDGE TO PICK UP, OR REMOVE AND REPLACE ATTACHMENT WITH A FLUSH TYPE.00400408

ITEM (THIS SHEET ONLY)

3

4

5 6 7 8

REQUIRED TOOLS AND MATERIALSCOMMON HAND TOOLS RIVET GUN AND BUCKING BARS

EXTERNAL PATCH TYPE AT CORNER OF OPENING

Figure 4-4.


4-17


1

2

3

4

5

6

7

4

8

5

4

8

5

4

7

1

5

4

6

FWD, OR LAPPEDUNDER, END OF SPLICEDIN PANEL

AFT, OR LAPPEDOVER, END OF SPLICEDIN PANEL

4-18

1 2 3 4 5

ITEM (SHEETS 8 AND 9 ONLY) TAPERED SHIM 2024T42 CLAD. LENGTH SUFFICIENT TO PICK UP APPROXIMATELY THREE ATTACHMENTS TAPER THICKNESS DOWN TO 0.020 MINIMUM USE WHERE NECESSARY ADJACENT SKIN PANELEXISTING SPLICE ATTACHMENTS INDICATED THUS: . REPLACE USING SAME TYPE AND SIZE ATTACHMENT AS ORIGINAL SUBDIMPLE OR SUBCOUNTERSINK SPLICEDIN PANEL, AS NECESSARY EXISTING INTERNAL STRUCTURE EXISTING ATTACHMENTS INDICATED THUS: . PICK UP ALL EXISTING ATTACHMENTS. USING SAME TYPE AND SIZE ATTACHMENT AS ORIGINAL DUPLICATE TYPE OF ORIGINAL INSTALLATION, DIMPLED OR COUNTERSUNK SUBDIMPLE OR SUBCOUNTERSINK SPLICEDIN PANEL, IF NECESSARY, WHEN LAPPING UNDER EXISTING PANEL DIMPLE OR USE COUNTERSINK FILLERS, IF NECESSARY WHEN LAPPING OVER EXISTING PANEL. REPAIRSPLICE ATTACHMENTS INDICATED THUS: . USE ATTACHMENT REQUIREMENTS TABULATED ON SHEET 9 FOR SPLICING TO REMAINDER OF EXISTING SKIN PANEL FOR SKIN GAGES NOT LISTED IN TABLE ON SHEET 9. SEE TABLE ON SHEET 2. GAGES LISTED IN REPAIR PLATE GAGE COLUMN. CLEANEDUP EDGE OF REMAINDER OF EXISTING PANEL CHAMFER AND CRIMP EXTERNAL EDGES SPLICEDIN PARTIAL PANEL SAME MATERIAL AND GAGE AS THE ORIGINAL SKIN PANEL. DESIGN TO PICK UP EXISTING SKIN SPLICES WHERE POSSIBLE WHEN SPLICING TO REMAINDER OF EXISTING PANEL. LOCATE SPLICE TO PICK UP SOME INTERNAL STRUCTURE ATTACHMENTS, AS SHOWN IN FUSELAGE AREAS HAVING SHARP OR DOUBLE CURVATURE, FORM PANEL TO CURVATURE BEFORE DRILLING POSITION BETWEEN ADJACENT SKIN PANELS SIMILARLY TO ORIGINAL PANEL AT REPAIR SPLICE. OVERLAP AND INSERT TAPERED SHIMS AS NECESSARY. PARTIAL PANEL SPLICE

6

7 8

Figure 4-4.


00400409

REPAIR SPLICE ATTACHMENT REQUIREMENTSREPAIR ZONE CODING (SEE SHEET 2 OF THIS FIGURE) REPAIR PANEL GAGE 0.040 0.100 0.025 3 0.040 7075T6CLAD MINIMUM EDGE DISTANCE 5 6 1.02$0.12 0.97$0.14 0.31 5 1.00$0.05 0.34 6 1.26$0.04 0.41 5 1.33$0.11 0.41 HL506 HILOKS NAS517 SCREWS NAS6233 3 SCREWS NO. NO. NO. NO. NO. NO. NO. NO. NO. NO. SPACING ROWS SPACING ROWS SPACING ROWS SPACING ROWS SPACING ROWS SPACING ROWS SPACING NO. ROWS ROWS SPACING ROWS SPACING ROWS SPACING ROWS SPACING MS20426 RIVETS MS20470 RIVETS AD4 AD5 AD6 DD6 AD4 AD5 AD6 DD6 HL51 HILOKS 6 6 0.90$0.07 6 1.03$0.08 5 1.05$0.05 2 3 0.68$0.15 0.62$0.09 0.28 3 0.86$0.20 0.34 2 0.88$0.09 0.41 2 1.03$0.24 0.41 3 1.12$0.09 0.41 2 1.04$0.24 0.41 3 1.39$0.06 0.41 3 0.57$0.04 3 0.79$0.13 2 5 0.82$0.03 0.83$0.04 2 4 0.86$0.07 0.87$0.08 4 3 1.22$0.19 0.92$0.05 2 2 0.86$0.06 0.86$0.06 4 4 1.37$0.04 1.11$0.04

A B C D

E

F G H I J K L M N O

DETERMINE EXTENT OF SKIN PANEL TO BE REPLACED. REMOVE ATTACHMENTS AS NECESSARY. CUT AND REMOVE DAMAGED PORTION OF PANEL. HOLD OVERSIZE PANEL (CONTOURED IF NECESSARY) IN POSITION. DRILL ATTACHMENT HOLES. START NEAR CENTER OF PANEL AND INSTALL TEMPORARY FASTENERS AS HOLES ARE DRILLED. LAY OUT AND DRILL REPAIRSPLICE ATTACHMENT HOLES. REMOVE PANEL. TRIM PANEL TO SIZE. BURR ALL EDGES AND HOLES. CHAMFER AND CRIMP EXTERNAL EDGES OF PANEL. DIMPLE AND/OR COUNTERSINK HOLES, AS NECESSARY. TREAT PANEL FOR CORROSION PREVENTION (SEE SECTION I). POSITION PANEL, INSERT TAPERED SHIMS AND INSTALL ATTACHMENTS. APPLY SEALING COMPOUNDS (SEE SECTION I). APPLY FINAL PAINT FINISH, AS NECESSARY.


1

2 3 4 5

NOTE (SHEETS 8 AND 9 ONLY) DEMAGNETIZE ALL STEEL ATTACHMENTS INSTALLED WITHIN 30 INCHES OF THE MAGNETIC COMPASS. SEAL REPAIR AS DESCRIBED IN SECTION I. HOTDIMPLING IS REQUIRED FOR 7075T6 CLAD MATERIAL SEE SECTION I FOR DIMPLING INFORMATION. SEE SECTION I FOR CHAMFER AND CRIMPING INFORMATION.

4-19

REQUIRED TOOLS AND MATERIALSCOMMON HAND TOOLS RIVET GUN AND BUCKING BARS 2024T3 AND 7075T6 CLAD SHEET (GAGE AS REQUIRED) DESIRED ATTACHMENTS SEALING MATERIALS (SEE SECTION I) CORROSION PREVENTION MATERIALS


PARTIAL PANEL SPLICE

Figure 4-4. Fuselage Skin Repairs (Sheet 9)

00400410

NAVAIR 01-75PAA-3-1.1DOUBLER STRINGER SPLICE CLIP MAIN FRAME DOUBLER SKIN EXISTING ATTACHMENTS 0.25R (TYP)

SKIN

STRINGER

2 0.25R(MIN)(TYP) DAMAGE AREA 1 2 3

STRINGER

AT SKIN BUTT JOINT

EXTERNAL PATCH TYPE REPAIR AT MAIN FRAMES FS 570.97 AND FS 695.09

Figure 4-4.


00400411

4-20


MAIN FRAME

DOUBLER

SKIN

SKIN 1 0.25R (TYP)

STRINGER SPLICE CLIP

3 DAMAGE AREA

STRINGER

2 0.25R (MIN)(TYP)

EXISTING ATTACHMENTS

STRINGER 2 NEW ATTACHMENTS AT SKIN LAP JOINT

EXTERNAL PATCH TYPE REPAIR AT MAIN FRAMES FS 570.97 AND FS 695.09

00400412

Figure 4-4.


4-21

NAVAIR 01-75PAA-3-1.1ITEM (SHEETS 10, 11, AND 12 ONLY)1 REPAIR PLATE-SEE GENERAL REPAIR REQUIREMENTS (SHEETS 2 AND 3) FOR MATERIAL AND THICKNESS. USE THE THICKEST DAMAGED SKIN IN DETERMINING REPAIR PLATE THICKNESS. 2 REPAIR FILLER 2024-T3 CLAD SHEET, THICKNESS AS REQUIRED. 3 TAPERED SHIM 2024-T4 AL ALLOY OR 2024-T3 CLAD SHEET, LENGTH SUFFICIENT TO PICK UP THREE ATTACHMENTS. TAPER FROM REQUIRED THICKNESS DOWN TO 0.020.

SUGGESTED PROCEDURE FOR REPAIRA B C DETERMINE REPAIR REQUIREMENTS FROM ILLUSTRATION. CLEAN UP DAMAGED AREA. REMOVE ANY INTERFERING UNDAMAGED STRINGER SPLICE MEMBERS AND TAPERED SHIMS FOR LATER REPLACEMENT. OUTLINE REPAIR PLATE ON FUSELAGE SKIN INCLUDING NEW ATTACHMENTS. REMOVE EXISTING FASTENERS WITHIN REPAIR PLATE AREA. PILOT-DRILL NEW ATTACHMENT HOLES. FABRICATE OVERSIZED REPAIR PLATE. (CONTOURED IF NECESSARY.) FABRICATE FILLERS AND TAPERED SHIMS AS AS REQUIRED. POSITION REPAIR MEMBERS OVER DAMAGED AREA AND HOLD IN PLACE. BACK-DRILL ATTACHMENT HOLES. START NEAR CENTER OF REPAIR MEMBERS AND INSTALL TEMPORARY FASTENERS AS HOLES ARE DRILLED. REMOVE REPAIR PLATE AND TRIM TO SIZE. BURR ALL HOLES AND EDGES OF REPAIR PLATE. CHAMFER ALL EDGES OF REPAIR PLATE. DIMPLE OR COUNTERSINK HOLES AS NECESSARY. TREAT BARED EDGES IN CLEANED-UP DAMAGE AREA AND REPAIR MEMBERS FOR CORROSION PREVENTION (SEE SECTION I). INSTALL REPAIR MEMBERS, USING COUNTER SINK FILLERS WHERE NECESSARY, AND REINSTALLING ANY PREVIOUSLY REMOVED UNDAMAGED STRINGER SPLICE MEMBERS AND TAPERED SHIMS. SEAL REPAIR AS DESCRIBED IN SECTION I. APPLY FINAL PAINT FINISH AS NECESSARY.

D E F G H I J

NOTE (SHEETS 10, 11, AND 12 ONLY)1 USE SIZE AND NUMBER OF ATTACHMENTS AS INDICATED IN GENERAL REPAIR REQUIREMENTS OF THIS FIGURE. 2 USE COUNTERSINK FILLER IN SKIN WHERE COUNTERSINK IS COVERED BY REPAIR MEMBERS USING EXISTING HOLE PATTERN. CHAMFER ALL EDGES (SEE SECTION I). 4 TRIM REPAIR PLATE TO CLEAR ANY PRO TRUDING HEAD TYPE ATTACHMENT TOO NEAR EDGE TO PICK UP, OR REMOVE AND REPLACE ATTACHMENT WITH A FLUSH TYPE.

K L M N

REQUIRED TOOLS AND MATERIALSCOMMON HAND TOOLS RIVET GUN AND BUCKING BAR 2024-T3 CLAD SHEET (GAGE AS REQUIRED) 2024-T4 AL ALLOY (THICKNESS AS REQUIRED) REQUIRED ATTACHMENTS SEALING MATERIALS CORROSION PREVENTION MATERIALS Q P O

EXTERNAL PATCH TYPE REPAIR AT MAIN FRAMES FS570.97 AND FS695.09

Figure 4-4.


4-22

FS 288 1 STR 72 58 57 2 3 4

5

FS 2886 107 7 8 9 10 11

59

60STR 1

41 39 37 36 35 34 113 112 111 109 108 33 31 30

42 40 38 12

FS 156

FS 156

13 14

15 16 17 18 19 20

43 44 45 46 47 48 49 50 110 114 32

24

21 25 23 22 26 27

4-23

29 28

STRINGER 50

VIEW ASTRINGER 72 STRINGER 1

VIEW B (OPPOSITE TO VIEW A, EXCEPT AS SHOWN)

STRINGER 23


FLOOR LEVEL STRINGER 50 LOOKING FWD00400501

STRINGER 23

Figure 4-5.

Fuselage Nose Section Stringers (Sheet 1)


LOOKING FORWARD

STR 48 51 52 53 FS 185 72 FS 195.4 71 FS 206.8 70 74 FS 218.4 69 FS 228.1 68 FS 238 66 FS 248 65 76 106 82 94 96 67 75 101 81 84 93 55 92 80 102 103 80 80 80 56 104 78 86 79 79 97 90 99 54 77 87 91 98 73

SYMMETRICAL ABOUT

STR 25

EXCEPT AS SHOWN

88 89

100

85 85

85

95 95

83 83

FS 261.30

FS 270 62 61 63 64 105

FS 288 STR STR 48 47 STR 46 STR STR STR 42 44 40 STR STR STR 45 43 41 STR STR STR 29 33 31 VIEW STR 27 STR 26 STR 25

C

STR STR 32 30

STR 28

00400502

Figure 4-5.

Fuselage Nose Section Stringers (Sheet 2)

4-24

NAVAIR 01-75PAA-3-1.1Item No. 1 2 3 4 5 6 7 8 Drawing No. 900744-71 /-72 900985-1 /-2 900744-69 /-70 900744-67 /-68 903762-1 /-2 900744-73 /-74 903761-1 /-2 903761-3 /-4 903761-5 /-6 904528-1 /-2 904528-3 /-4 904528-7 /-8 903760-1 /-2 903760-3 /-4 903760-5 /-6 903760-7 904529-1 /-2 900744-65 /-66 900744-41 /-42 900744-39 /-40 907216-1 /-2 947396-105 /-106 900744-37 /-38 900744-125 /-126 900744-33 900744-35 /-36 906137-1 /-2 906137-3 /-4 917056-1 /-2 902917-1 /-2 905416-3 /-4 905416-5 /-6 917056-3 /-4 900744-43 /-44 900744-119 /-120 900744-45 /-46 900742-31 /-32 917056-5 /-6 917087-1 /-2 907355-1 /-2 900742-21 /-22 801152-33 /-34 900742-19 /-20 908600-1 900742-17 /-18 900744-47 900744-49 900744-51 900744-111 900744-55 900744-57 900744-59 /-60 900744-61 /-62 900744-63 /-64 900744-101 900744-99 907584-2 900744-95 900744-93 900744-91 900744-89 906537-2 917086-1 /-2 907355-5 /-6 907355-3 /-4 905261-171 /-172 905261-173 /-174 905261-57 /-58 905261-151 /-152 914405-1 914195-1S e r i a l

Description STRINGER LONGERON STRINGER STRINGER FORMER STRINGER FORMER ASSEMBLY CHANNEL CAP FORMER ASSEMBLY CAP WEB FORMER ASSEMBLY CHANNEL CHANNEL DOUBLER FORMER STRINGER STRINGER STRINGER FORMER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER FORMER ASSEMBLY STIFFENER DOUBLER STRINGER STRINGER STRINGER STRINGER ANGLE STRINGER STRINGER STRINGER STRINGER ANGLE STRINGER INTERCOSTAL STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER CAP STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER REINFORCEMENT REINFORCEMENT DOUBLER DOUBLER BRACE BRACE

LS No No. or Gage 6228-23 7484* 6228-3 6228-3 0.063 6228-23 0.063 0.063 0.090 0.050 0.063 0.063 0.100 0.063 6228-3 6228-3 6228-3 0.071 159-2 6228-3 6228-3 249 6228-3 6226-20 6226-20 6226-20 0.063 0.063 6226-20 6228-7 6228-7 6228-3 5103 6226-20 6226-20 0.032 6228-4 0.040 6228-4 0.040 6228-4 6228-4 6228-4 6228-4 6228-23 6228-23 6228-23 6228-23 6228-23 6228-23 6228-23 6228-23 0.071 6228-23 6228-23 6228-23 6228-23 0.071 6226-20 0.032 0.032 0.050 0.050 0.050 0.050 0.050 0.040

Repair Figure Material 2024-T81 AL ALLOY 7075-T6 EXTR 2024-T81 AL ALLOY 2024-T81 AL ALLOY 7075-T6 CLAD 2024-T81 AL ALLOY 7075-T6 CLAD 7075-T6 CLAD 2024-T42 CLAD 7075-T6 CLAD 7075-T6 CLAD 7075-T6 CLAD 7075-T6 CLAD 7075-T6 CLAD 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 7075-T6 CLAD 2024-T81 CLAD 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T4 EXTR 2024-T81 AL ALLOY 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 7075-T6 CLAD 7075-T6 CLAD 2024-T81 CLAD 2024-T81 AL ALLOY 2024-T3 BARE 2024-T81 AL ALLOY 7075-T6 EXTR 2024-T81 CLAD 2024-T81 CLAD 7075-T6 CLAD 2024-T3 CLAD 2024-T4 CLAD 2024-T3 CLAD 2024-T42 CLAD 2024-T3 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T3 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 7075-T6 CLAD 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 2024-T81 AL ALLOY 7075-T6 CLAD 2024-T81 CLAD 7075-T6 CLAD 7075-T6 CLAD 2024-T6 CLAD 2024-T6 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 2024-T42 CLAD 4 - 6 4 4 9 4 6 6 2, 9 - 6 6 NAVAIR 01-755PAA-3 -1 -2

9 - 2, 9 - 5 9 - 5 9 - 5 9 - 4 9 - 5 9 - 5 9 4 4 4 9 4 4 4 4 4 4 4 2, 9 - 6 6 6 6 2, 9 - 6 6 6 6 6 6 6 6

9

10 11 12 13 14 15 16 17 18 19 20 21

J K J K

9 - 5 4 4 4 4 9 4 4 9 4 9 4 9 4 4 4 4 4 4 4 4 4 4 4 4 9 4 4 4 4 9 4 9 9 6 6 6 6 5 6 6 5 6 5 6 2, 9 - 6 6 6 6 6 6 6 6 6 6 6 6 6 5 6 6 6 6 5 6 5 5

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

G H

A A B B C D

9 9 9 9

-

2 2 5 5

Figure 4-5.

Key

4-25

NAVAIR 01-75PAA-3-1.1S e r i a l LS No No. or Gage0.050 0.050 6228-4 6228-8 4842 30206-3 0.050 6463 0.050 6228-4 6228-4 6228-4 6228-4 6228-8 6228-8 6228-8 6228-16 6228-16 6228-16 6228-4 0.050 1171-3 157-18 157-18 157-18 157-18 6228-4 6228-4 157-18 157-18 6228-4 6228-16 6228-16 6228-16 6228-8 6228-8 6228-8 6228-8 6228-4 6228-4 6228-4 157-18 157-18 157-18 157-18 157-18 157-18 6228-4 6227-8 0.063 6228-4 1430 1430 0.040 0.063 6228-4 6228-4 0.040 6228-4 6228-4 6228-4 0.040

Repair Figure Material NAVAIR 01-75PAA-3 -1 -2

Item No.59 60 61 62 63

Drawing No.

Description

64

65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114

924110-1 924111-1 934399-167 /-169 934399-175 /-177 934760-101 /-102 934760-103 /-104 934760-105 /-106 934760-101 /-102 934760-103 /-104 934760-105 /-106 934399-207 /-209 934399-149 /-150 934399-267 /-268 934399-265 /-266 934399-139 /-140 934399-133 /-134 934399-123 /-124 934399-113 /-114 934399-115 /-116 934399-253 /-254 934399-125 /-126 934399-151 /-152 934399-211 /-213 934403-101 /-103 934399-261 /-262 934399-263 /-264 934399-147 /-148 934399-153 /-154 934399-159 934399-161 934399-171 934399-172 934399-141 /-142 934399-127 /-128 934399-117 934399-255 934399-119 934399-239 934399-129 /-130 934399-135 /-136 934399-157 934399-269 934399-173 934399-165 934399-163 934399-143 /-144 934399-137 /-138 934399-131 /-132 934399-121 934399-271 /-272 934399-273 /-274 934399-277 /-278 934399-279 /-280 934318-105 934318-115 934399-227 939869-101 900742-15 /-16 900742-13 /-14 908601-1 900742-11 /-12 900742-9 /-10 900744-109 977476-101

E F

E F E F

J K I

L

INTERCOSTAL INTERCOSTAL STRINGER STRINGER STIFFENER ASSEMBLY ANGLE TEE STIFFENER ASSEMBLY WEB CAP STIFFENER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STIFFENER STIFFENER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER STRINGER SUPPORT SUPPORT LONGERON BRACKET STRINGER STRINGER INTERCOSTAL STRINGER STRINGER STRINGER STIFFENER

2024-T42 CLAD 2024-T42 CLAD 2024-T81 CLAD 2024-T81 CLAD 7075-T6 EXTR 7075-T6 EXTR 7075-T6 CLAD 7075-T6 EXTR 7075-T6 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 7075-T6 CLAD 7075-T6 EXTR 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T81 CLAD 2024-T42 CLAD 2024-T81 CLAD 2024-T42 EXTR 2024-T42 EXTR 2024-T42 CLAD 2024-T42 CLAD 2024-T3 CLAD 2024-T3 CLAD 2024-T42 CLAD 2024-T3 CLAD 2024-T3 CLAD 2024-T81 CLAD 2024-T3 CLAD

9 9 4 4

-

2, 9 - 6 2, 9 - 6 6 6

9 - 5 9 - 5 9 9 9 4 4 4 4 4 4 4 4 4 4 4 9 9 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 9 4 9 9 9 9 4 4 9 4 4 4 9 4 5 5 6 6 6 6 6 6 6 6 6 6 6 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 2 6 5 5 5 2, 9 - 6 6 6 2, 9 - 6 6 6 6 6

Figure 4-5.

Key - Continued

4-26

NAVAIR 01-75PAA-3-1.1S e r i a l Repair Figure Description LS No No. or Gage Material NAVAIR 01-75PAA-3 -1 -2

Item No.

Drawing No.

NOTE * MODIFIED

SERIAL CODE A B C D E F G H I J K L APPLICABLE TO BUNO 148883 THROUGH 151387 APPLICABLE TO PRODUCTION BLOCKS -10 AND SUBSEQUENT APPLICABLE TO PRODUCTION BLOCK -01 APPLICABLE TO PRODUCTION BLOCKS -05 AND SUBSEQUENT APPLICABLE TO BUNO 152164 AND SUBSEQUENT APPLICABLE TO BUNO 148883 THROUGH 162163 APPLICABLE TO PRODUCTION BLOCKS -01 THROUGH -30 APPLICABLE TO PRODUCTION BLOCKS -35 AND SUBSEQUENT APPLICABLE TO BUNO 152740, 152749 AND SUBSEQUENT APPLICABLE TO PRODUCTION BLOCKS -01 THROUGH -105 APPLICABLE TO PRODUCTION BLOCKS -110 AND SUBSEQUENT APPLICABLE TO BUNO 161764 AND SUBSEQUENT

Figure 4-5.

Key - Continued

4-27


FLOOR LEVEL

8

7

6

5

4 4

2 ACCESS PROVISIONS

3

2

1

ITEM1 AFT ACCESS DOOR (ACCESS TO STRINGERS AFT OF PRESSURE BULKHEAD) REMOVE CONTROLS OR ELECTRICAL EQUIPMENT AS NECESSARY. 2 HYDRAULIC BAY AND SONOBUOY ACCESS DOORS (ACCESS TO STRINGERS BELOW FLOOR LEVEL AFT OF REAR SPAR) REMOVE DUCTS, HYDRAULIC OR ELECTRICAL EQUIPMENT, OR CONTROLS AS NECESSARY. 3 MAIN ENTRANCE DOOR (ACCESS TO STRINGERS ABOVE FLOOR LEVEL) REMOVE CONSOLES, EQUIPMENT RACKS OR DUCTS AS NECESSARY. PEEL BACK TRIM AND INSULATION MATERIALS. 4 FUEL AND WATER TANK ACCESS DOORS (ACCESS TO STRINGERS BELOW FLOOR LEVEL, AND BETWEEN FRONT SPAR AND BOMB BAY)

5 6

BOMB BAY SIDEWALL PANELS (ACCESS TO STRINGERS BELOW FLOOR LEVEL AT SIDE OF BOMB BAY) AIR CONDITIONING ACCESS DOOR (ACCESS TO STRINGERS BELOW FLOOR LEVEL, AND BETWEEN BOMB BAY AND NOSE GEAR WHEEL WELL) REMOVE DUCTS OR AIR CONDITIONING EQUIPMENT AS NECESSARY.

7

NOSE GEAR DOORS (ACCESS TO STRINGERS BELOW FLOOR IN NOSE GEAR WHEEL WELL) REMOVE DUCTS OR EQUIPMENT AS NECESSARY.

8

NOSE RADOME (ACCESS TO STRINGERS IN FRONT OF FORWARD PRESSURE BULKHEAD)

45 TWO ATTACHMENT DIAMETERS (MIN) 4Y OR FOUR ATTACHMENT DIAMETERS, WHICHEVER IS GREATER (MIN) Y 0.15 TRUE 4Y (MIN) Y

AY 4Y (MIN)

Y

F4Y (MIN)

0.05

G

DEPTH = H 0.10

0.15

AY

C B D

A

RADIUS (TYP) 0.02 (TYP)

AY

ADDEPTH = H

0.05 EXISTING ATTACHMENT HOLES DEPTH = H

4Y (MIN)

F0.05 0.10 0.02

AY

E

A

AA

4Y (MIN) 0.05 (TYP)

TWO ATTACHMENT DIAMETERS (MIN) DEPTH = H 0.05 Y

TYPES OF DAMAGEA B EDGE DAMAGE CLEAR OF ATTACHMENTS MAX DEPTH Y = 0.15. CORROSION, SCRATCHES, ABRASIONS IN AREAS SHADED THUS : MAX DEPTH H = T/20 OR DEPTH OF CLADDING. PUNCTURE CLEANEDUP TO A SMOOTH, ROUND HOLE MAX DIAMETER Y = 0.20. CORROSION, SCRATCHES, ABRADED AREA MAX DEPTH H = T/4 IN STEM EXCEPT AT SPLICES, MAX DEPTH H = T/8 IN SKIN FLANGE AND IN STEM AT SPLICES. SMOOTH DENT (Y = 8H MIN) MAX DEPTH H = THICKNESS OF STRINGER MATERIAL. EDGE DAMAGE LIMITED TO AREAS SHADED THUS: CORROSION, SCRATCHES, ABRADED AREA MAX DEPTH H = T/20.

F4Y (MIN) RADIUS (EQUAL TO TWICE THE ATTACHMENT DIAMETER)

A AG

Y

C D

F

4Y (MIN)

DEPTH = H 0.05 10H (MIN) T

EH

F G

FTYPE B, D, OR G DAMAGE Y 4Y (MIN)

SECTION

AA

NOTE (THIS SHEET ONLY) STOPDRILL CRACKS IN JSECTION STRINGERS USING AN 0.25 DIAMETER DRILL.

JSECTION STRINGER NEGLIGIBLE DAMAGE

Figure 4-6.

Fuselage Nose Section Stringer Repairs (Sheet 1)

4-28

00400601

NAVAIR 01-75PAA-3-1.1STRINGER COMPLETE REPAIR ORIGINAL STRINGER BASIC LS NO. 20374 DIMENSION A B C 0.49 0.35 5

157, 6226, 6227, 6228 0.55 1.00 0.30 0.75

9

4 3 2 1REPAIR SYMMETRICAL ABOUT CLEANEDUP DAMAGE

7

6

8 4 5

A

TO MATCH ORIGINAL STRINGER C

TWO ATTACHMENT DIAMETERS (MIN) (TYPICAL EDGE DISTANCE)

0.40 0.80

B

3

R (TYP)

7

SECTION ADJACENT TO DAMAGED AREATYPICAL EXCEPT AS NOTED NUMBER OF RIVETS REQD IN EACH FLANGE SKIN FLANGE RIVET SIZE: AD5 STEM RIVETS

REPAIR MEMBER GAGE OF GAGE MATERIAL BEND ORIGINAL RADIUS STRINGER R

REPAIR STRAP GAGE MATERIAL

AD4 STEM RIVETS AD4 AD5 5 5 6 7 5 6 7 8 5 5 6 7 7

DD6 STEM RIVETS AD6 DD6

AD6 DD6 AD4 AD5

AD6 DD6 AD5

0.025 0.032 0.040 0.050 0.063 0.071 0.080

0.040 0.050 0.063 0.071 0.071 0.063 0.071

2024T3 CLAD 2024T3 CLAD 2024T3 CLAD 2024T3 CLAD 2024T3 CLAD 7075T6 CLAD 7075T6 CLAD

0.19 0.19 0.22 0.25 0.25 0.25 0.25 2 2 5

NONE NONE NONE NONE

NONE NONE NONE NONE

5 6 7

5 6

5 5 6 5 6 7 7 8 4 5 6 6 7 4 5 4 4 5 6 6 4 4 5 5 5

0.071 2024T3 CLAD 0.063 0.071 7075T6 CLAD 7075T6 CLAD

ITEM (THIS SHEET ONLY)1 2 3 4 FILLER 2024 T3 CLAD, SAME GAGE AS ORIGINAL STRINGER. FILLER 2024T3 CLAD, SAME GAGE AS ORIGINAL STRINGER. INSTALL WHEN A REPAIR STRAP IS USED. REPAIR STRAP USE ONLY WHEN REQUIRED IN TABLE. REPAIR MEMBER SEE TABLE FOR MATERIAL, UPPER FLANGE MAY BE CURVED SIMILAR TO ORIGINAL STRINGER, IF NECESSARY, TO CLEAR ADJACENT STRUCTURE. ORIGINAL STRINGER. SKIN FLANGE ATTACHMENTS REPLACE SAME TYPE AND SIZE ATTACHMENTS AS ORIGINALS. PICK UP SAME NUMBER OF ATTACHMENTS AS IN STEM. STEM ATTACHMENTS MS20470 RIVETS. NUMBER REQUIRED DEPENDS UPON SIZE OF RIVET IN SKIN FLANGE. FROM COLUMNS IN TABLE BENEATH APPLICABLE SKIN FLANGE RIVET SIZE, SELECT ANY STEM RIVET SIZE AND INSTALL THE NUMBER TABULATED, ON EACH SIDE OF DAMAGE. PLACE IN LINE WITH EXISTING SKIN FLANGE ATTACHMENTS. SHIM 2024T3 CLAD, THICKNESS AS REQUIRED. ADD IF NECESSARY ON TOP FLANGE (AS SHOWN) OR SKIN FLANGE.

9

TOP FLANGE ATTACHMENTS MS20470AD4 RIVETS. LOCATE IN CENTER OF STRINGER RADIUS. PLACE IN LINE WITH SKIN FLANGE ATTACHMENTS. 4

1

NOTE (THIS SHEET ONLY)1 INSTALL AN INSERTION MEMBER (SAME MATERIAL AND SHAPE AS ORIGINAL STRINGER) IN DAMAGED AREAS LONGER THAN 1.0 INCH, WHEN REPAIRING STRINGERS OF 0.063 GAGE OR HEAVIER. HOTFORM 7075T6 CLAD REPAIR MEMBERS IN ACCORDANCE WITH INSTRUCTIONS IN SECTION I. IF REPAIR MEMBERS COVER STRINGER DRAINAGE HOLES, DRILL NEW HOLES (3/16 DIA) IN STRINGER OUTSIDE OF REPAIR. TOPFLANGE ATTACHMENTS NOT REQUIRED FOR REPAIRS TO LS20374. 0.16 FOR LS20374 REPAIR MEMBERS. SEE SHEET 3 FOR REPAIR PROCEDURE AND LIST OF REQUIRED TOOLS AND MATERIALS ADAPT REPAIRS IN AREAS MODIFIED IN ACCORDANCE WITH P3 AIRFRAME CHANGE NO. 188, TO PICK UP EXISTING FASTENER LOCATIONS, RETAIN (OR REPLACE IF DAMAGED) ALL REINFORCING MEMBERS.

2 3 4 5 6 7

5 6

7

8

J SECTION STRINGER REPAIR

Figure 4-6.


00400602

4-29

NAVAIR 01-75PAA-3-1.11 2 3

STRINGER PARTIAL REPAIRTWO ATTACHMENT DIAMETERS (MIN)R

13

0.88 (LS 6226, LS6227, LS6228) 0.63 (LS20374) 4TWO ATTACHMENT DIAMETERS (MIN)

SECTION THROUGH DAMAGED AREA5 6 7

0.19 (MIN) RADIUS 0.05 GAP RADIUS

2

SECTION ADJACENT TO DAMAGED AREA

SHOWING A TYPICAL FUSELAGE FRAME CUT TO ACCOMMODATE REPAIR MEMBER. REPAIR FRAME ACCORDING TO APPLICABLE REPAIR ILLUSTRATION. 4 REMOVE AND REPLACE ANY EXISTING STRINGERTO FRAME REINFORCING CLIPS.

TWO ATTACHMENT DIAMETERS (MIN) (TYPICAL EDGE DISTANCE) REPAIR SYMMETRICAL ABOUT CLEANED UP DAMAGE

1 2

ITEM (THIS SHEET ONLY) ORIGINAL STRINGER.STEM ATTACHMENTS MS20470 RIVETS. NUMBER REQUIRED DEPENDS UPON SIZE OF RIVET IN SKIN FLANGE. FROM COLUMNS IN TABLE ON SHEET 2. BENEATH APPLICABLE SKIN FLANGE RIVET SIZE, SELECT ANY STEM RIVET SIZE AND INSTALL THE NUMBER TABULATED, ON EACH SIDE OF DAMAGE. PLACE IN LINE WITH EXISTING SKIN FLANGE ATTACHMENTS. PARTIAL DAMAGE REPAIR MEMBER USE SAME MATERIAL, GAGE AND BEND RADIUS AS TABULATED FOR COMPLETE DAMAGE REPAIR MEMBER, ON SHEET 2. FILLER 2024T3 CLAD, SAME GAGE AS ORIGINAL STRINGER. EXISTING FUSELAGE FRAME OR BULKHEAD CUT FLANGE AS NECESSARY TO ACCOMMODATE REPAIR MEMBER, AND REPAIR ACCORDING TO APPLICATION REPAIR ILLUSTRATION. REPAIR MEMBER (TYPICAL). FRAME REPAIR MEMBER SEE APPLICABLE REPAIR ILLUSTRATION. SKIN FLANGE ATTACHMENTS REPLACE SAME TYPE AND SIZE ATTACHMENTS AS ORIGINALS, PICK UP SAME NUMBER OF ATTACHMENTS AS IN STEM.

E

CLAMP REPAIR MEMBER IN POSITION AND DRILL SKIN FLANGE ATTACHMENT HOLES. INSTALL TEMPORARY FASTENERS. MARK OFF AND DRILL STEM ATTACHMENT HOLES. MAKE UP AND DRILL ANY FILLERS OR OTHER REPAIR MEMBERS REQUIRED. REMOVE ALL REPAIR MEMBERS AND FILLERS, AND TRIM TO SIZE. BURR ALL HOLES. TREAT ALL MEMBERS FOR CORROSION PREVENTION (SEE SECTION I). POSITION REPAIR MEMBERS AND FILLERS, AND INSTALL ATTACHMENTS. SEAL REPAIR AS DESCRIBED IN SECTION I. INSTALL TOPFLANGE ATTACHMENTS BEFORE STEM ATTACHMENTS WHEN A REPAIR STRAP IS USED.

F G H I J K

3

4 5

6 7 8

REQUIRED TOOLS AND MATERIALSCOMMON HAND TOOLS RIVET GUN AND BUCKING BARS MS20426 AND MS20470 RIVETS, SIZES AS NECESSARY 2024T3 CLAD OR 70756 CLAD SHEET, GAGE AS NECESSARY HOTFORMING EQUIPMENT (IF 7075T6 CLAD SHEET IS USED) SEE SECTION I. CORROSION PREVENTION MATERIALS SEALING MATERIALS PAINT MATERIALS

NOTE (THIS SHEET ONLY)1 THE PARTIAL REPAIR, AS SHOWN, APPLIES TO SKIN FLANGE DAMAGE WHICH DOES NOT PENETRATE BEYOND THE BEND RADIUS. IF THE STRINGER FLANGE HAS BEEN CUT TO ACCOMMODATE A SKIN REPAIR PLATE, USE FILLERS AS NECESSARY BETWEEN REPAIR MEMBER AND EITHER SKIN REPAIR PLATE OR ORIGINAL STRINGER SKIN FLANGE.

SUGGESTED PROCEDURE FOR REPAIRA B C D DETERMINE REPAIR REQUIREMENTS FROM ILLUSTRATION. REMOVE NECESSARY NUMBER OF SKIN RIVETS. MAKE UP REPAIR MEMBER(S). CUT ADJACENT STRUCTURE AS NECESSARY TO ACCOMMODATE REPAIR MEMBERS.

Figure 4-6.


00400603

4-30

NAVAIR 01-75PAA-3-1.1 A1 2 3 4

A

B

5 4 6 7 8 4 10

X7

9 VIEW LOOKING FWD FUSELAGE STATION 156.0 CANTED SECTION

AA

8 166 4 167 AIRCRAFT 5 SYMMETRICAL ABOUT 282

DETAIL X (BUNO 159889, 160290 AND SUBSEQUENT)

266

264 265 263 167 259 AIRCRAFT DETAIL X (BUNO 151388 THROUGH 159888, 159890 THROUGH 160289)00400701

SYMMETRICAL ABOUT

DETAIL B (BUNO 151388 AND SUBSEQUENT)

Figure 4-7.

Fuselage Nose Section Frames and Bulkheads (Sheet 1)

4-31

NAVAIR 01-75PAA-3-1.116 13 86 AIRCRAFT 15 14 17 86 11 38 18 19 20 36 30 39 28 29

31 26

32 25 35 33 34 WL 120

WL 120 24

238

241

267

12

239

17

12

Y

23

237

22

21

VIEW C

VIEW LOOKING AFT240 27

(APPLICABLE TO BUNO 151388 AND SUBSEQUENT) LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE BL 42 9.0L BL 9.0R 43 41 FS 166

DETAIL

Y

40 44 46 18

41

59

60

45 268 47

61

37

48 49 50

414 31

32

D52 54 53

C

62

63

64

35

WL 120 58 55 56

25

51

WL 120 57 45 FS 175

VIEW

D00400702

VIEW LOOKING FORWARD FORWARD PRESSURE BULKHEAD

Figure 4-7.


4-32

NAVAIR 01-75PAA-3-1.166 65

67

SYMMETRICAL ABOUT CENTERLINE EXCEPT AS NOTED

68

93 69

70 71 72 BL 20.02L 74 76 77 78 96

73

BL 20.02L 75 BL 18.70L

92 91 90 89 88 87 94

V V84 85 83 82 244 81 80 79

WVIEW LOOKING AFT269

VIEW LOOKING FORWARD

FUSELAGE STATION 185

95

247 NOSE LANDING GEAR TRUSS (REF)

243

248

95

SECTION VV(BUNO 151388 AND SUBSEQUENT)

DETAIL W(BUNO 151388 AND SUBSEQUENT)

00400703

Figure 4-7.


4-33

NAVAIR 01-75PAA-3-1.1120 WL 160.00 117 116 130 129

F217 122 118 119 121 206

115

F

102 114 113 103 104

G

G

112 99 105

WL 119.21 FUSELAGE STATION 195.4RIGHT SIDE VIEW LOOKING AFT (OPPOSITE TO LEFT SIDE EXCEPT AS SHOWN)

WL 119.21

111 106 WL 118.78 FUSELAGE STATION 203.6VIEW LOOKING AFT CENTERLINE OF AIRPLANE

H H123 107

122

122

127 FUSELAGE STATION 195.4LEFT SIDE VIEW LOOKING AFT

126

125

128 FUSELAGE STATION 204.0VIEW LOOKING FORWARD

98

102

100

108

111 101

110 112 SECTION 116 SECTION GG 103

109 SECTION HH

FF

NOTE

LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE EXCEPT AS NOTED.00400704

Figure 4-7.


4-34

WL 118.62 438

K

439

142 141 140 139 435 BL 18.5

K143

437 440

436

FUSELAGE STATION 206.8VIEW LOOKING FORWARD

L

L

CENTERLINE OF AIRCRAFT 150

4-35

WL 118.05 446 445 442 444 443 FUSELAGE STATION 218.4VIEW LOOKING FORWARD

149 441 FUSELAGE STATION 213.5VIEW LOOKING FORWARD

BL 18.5


137

138

146 145

SECTION

KK

SECTION

LL

Figure 4-7.


00400705

NAVAIR 01-75PAA-3-1.1 N

N152 FUSELAGE STATION 224.5 VIEW LOOKING FWD 151

WL 117.5

447

156

157

FUSELAGE STATION 228.1 VIEW LOOKING FWD

SECTION

NN

463

BL 40.0

WL 117.4 FUSELAGE STATION 230 VIEW LOOKING FWD

00400706

Figure 4-7.


4-36

NAVAIR 01-75PAA-3-1.1420

P160

Q Q169 162 163 164

P

OF AIRPLANE

165 WL117.03 WL 117.03

168

VIEW LOOKING FWD FUSELAGE STATION 238.0

159 201 161 199 158 158 162

201

200 SECTION PP SECTION

QQ

00400707

Figure 4-7.


4-37


WL 215

213

AIRCRAFT

FUSELAGE STATION 255.10 VIEW LOOKING AFT

AIRCRAFT 170 177

172 181 174 175 176 434 421 180 180 180 202

179 198

S S

183 186 197 180 180 180 189 WL 116.5 WL 116.5 WL 116.5

198 183 184 188 185 224 190 187

4-38WL 116.5 450 449 182 178 FUSELAG

01-75paa-3-1.1 structural repair fuse,gear,nacelles sept04r

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