MIL-DTL-9854D
3.2.3 Repairs. The scope of the repairs to the various components shall provide for the repair of any
repairable damage in any location. Deinitive statements regarding repair decisions shall be made to preclude
misinterpretation and indecision in connection with typical repairs. Cautions shall be included to prohibit
unauthorized repairs and materials. Where the loads, material thickness, and margin of safety vary, a
table indicating the station, material, thickness, fastener, diameter, number of fastener rows, fastener
spacing, doubler overlap, and bonding requirements, extent of allowable damage, and information regarding
reinforcement data to transfer design loads, shall be provided. Where the loads do not vary, typical loads
and minimum design loads for tension, compression, and shear shall be shown.
3.2.3.1 Description of repairs. The description of repairs shall be complete and show compliance with all
relevant design requirements. The repair shall be such as to make the strength of the repaired structure equal
to or greater than that required. It shall also maintain the structural capability of the aircraft with due
considerations to stiffness and thermal problems. Illustrations of the members of components showing where
the various types of repairs are to be employed shall be given and the areas where each type is to be used
shall be indicated by shading or other appropriate means. When a combination of two or more repairs will
weaken or over stiffen the member beyond the safe limit, the combination shall be indicated and a caution
shall be given to prohibit such a combination. All speciic repairs shall be identiied by part numbers.
3.2.3.2 Use of standard parts. Where ever possible, Government standard parts shall be speciied for
use in repair or replacement. References in the manual to these parts shall be by the applicable
Government standard part designation.
3.2.4 Illustrations. In addition to the illustrations speciied in 3.2.3.1, the following illustrations, diagrams,
and charts shall be included in the manual with as many additions as required to illustrate detailed repair of
the aircraft. Illustrations shall be located as close as possible to the related text.
3.2.4.1 Frontispiece. Electronic media: The link to the frontispiece illustration of the aircraft shall be
located at the beginning of Section I.
Print media: A three-quarter view frontispiece illustration of the aircraft shall face the irst page of Section I.
3.2.4.2 Front view. A three-quarter front view illustration in exploded form, indexing all major structural
groups, shall be placed in Section I (F), Chapter 1 (A).
3.2.4.3 Section I. Diagram(s) shall be provided in Section I identifying, by number, the airplane stations.
Numbers shall be identiied with the stations by use of connecting lines.
3.2.4.4 Major structural groups. The manual shall include an illustration of each major structural group in
the applicable repair section. This illustration shall be indexed to show the location of the repair index of
each component. Component repair index illustrations shall be coded and an accompanying table shall
indicate, as applicable, the index number, major or subassembly drawing number, description, size, gage,
material, heat treatment, and reference to the repair illustrations. Print media only: The illustration of each
major structural group in the applicable repair section shall be a full page illustration.
3.2.4.5 Principal symmetry check dimensions. Diagrams(s) shall be provided showing the principal symmetry
check dimensions and permissible ield variations. These variations shall never be less than the original
manufacturing tolerances. Measurements shall be taken from clearly deined points which may be easily
located and identiied in the ield. Diagrams and text shall also be provided giving alignment check data for
landing gear, wing, stabilizers, etc., to ensure proper aerodynamic performance.
3.2.4.6 Leveling of aircraft. An illustration shall be included clearly showing and identifying the special
points used in leveling the airplane transversely and longitudinally. Leveling tools shall be described
and illustrated, as necessary.
3.2.4.7 Repair diagrams. Repair diagrams and illustrations shall be provided. These diagrams and
illustrations shall show all dimensions required for repairs. Such diagrams and illustrations shall consist of
patch size, patch overlaps, cover plates, extrusions, stringers, longerons; rivet, bolt, plug, and screw sizes;
spacings, edge distances, materials, etc. Sketches shall be included of speciic repairs, and repairs typical to
the construction of the applicable aircraft, which are not covered in general manuals for structural repair.
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