Airworthiness Directives; The Boeing Company Airplanes
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Issuing agencies
Abstract
The FAA is adopting a new airworthiness directive (AD) for all The Boeing Company Model 777-200, -200LR, -300, -300ER, and 777F series airplanes. This AD was prompted by a report of a 5-inch crack on the upper wing skin at a certain wing station of the right wing. This AD requires repetitive inspections for cracking of the upper wing skin common to certain fasteners and applicable on-condition actions. The FAA is issuing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 90 Issue 52 (Wednesday, March 19, 2025)</title>
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[Federal Register Volume 90, Number 52 (Wednesday, March 19, 2025)]
[Rules and Regulations]
[Pages 12682-12685]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2025-04440]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2023-2151; Project Identifier AD-2023-00984-T;
Amendment 39-22990; AD 2025-06-02]
RIN 2120-AA64
Airworthiness Directives; The Boeing Company Airplanes
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all
The Boeing Company Model 777-200, -200LR, -300, -300ER, and 777F series
airplanes. This AD was prompted by a report of a 5-inch crack on the
upper wing skin at a certain wing station of the right wing. This AD
requires repetitive inspections for cracking of the upper wing skin
common to certain fasteners and applicable on-condition actions. The
FAA is issuing this AD to address the unsafe condition on these
products.
DATES: This AD is effective April 23, 2025.
The Director of the Federal Register approved the incorporation by
reference of a certain publication listed in this AD as of April 23,
2025.
ADDRESSES:
AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2023-2151; or in person at Docket Operations between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD
docket contains this final rule, any comments received, and other
information. The address for Docket Operations is U.S. Department of
Transportation, Docket Operations, M-30, West Building Ground Floor,
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
Material Incorporated by Reference:
<bullet> For Boeing material identified in this AD, contact Boeing
Commercial Airplanes, Attention: Contractual & Data Services (C&DS),
2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-5600;
telephone 562-797-1717; website <a href="http://myboeingfleet.com">myboeingfleet.com</a>.
<bullet> You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 2200 South 216th St., Des
Moines, WA. For information on the availability of this material at the
FAA, call 206-231-3195. It is also available at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2023-2151.
FOR FURTHER INFORMATION CONTACT: Luis Cortez-Muniz, Aviation Safety
Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 206-
231-3958; email: <a href="/cdn-cgi/l/email-protection#c985bca0bae788e78aa6bbbdacb3e484bca7a0b389afa8a8e7aea6bf"><span class="__cf_email__" data-cfemail="aae6dfc3d984eb84e9c5d8decfd087e7dfc4c3d0eacccbcb84cdc5dc">[email protected]</span></a>.
SUPPLEMENTARY INFORMATION:
Background
The FAA issued a notice of proposed rulemaking (NPRM) to amend 14
CFR part 39 by adding an AD that would apply to all The Boeing Company
Model 777-200, -200LR, -300, -300ER, and 777F series airplanes. The
NPRM published in the Federal Register on November 17, 2023 (88 FR
80216). The NPRM was prompted by a report of a 5-inch crack on the
upper wing skin at wing station (WSTA) 460 of the right wing. In the
NPRM, the FAA proposed to require repetitive inspections for cracking
of the upper wing skin common to certain fasteners and applicable on-
condition actions, including repair.
The FAA issued a supplemental notice of proposed rulemaking (SNPRM)
to amend 14 CFR part 39 by adding an AD that would apply to all The
Boeing Company Model 777-200, -200LR, -300, -300ER, and 777F series
airplanes. The SNPRM published in the Federal Register on September 20,
2024 (89 FR 77049). The SNPRM was prompted by reports from Boeing of
two events of cracking at the fastener 6 and 7 locations where the
cracks initiated in the spanwise (inboard/outboard) direction. These
cracks were detected only because of a repair accomplished on an
adjacent fastener. The areas around the repaired fasteners were
subsequently inspected with an open hole high frequency eddy current
(HFEC) inspection, rather than with the ultrasonic (UT) inspection that
was proposed in the NPRM. The SNPRM therefore proposed to require open
hole HFEC inspections instead of UT inspections. The FAA is issuing
this AD to address the possibility of an undetected upper wing skin
crack.
[[Page 12683]]
Discussion of Final Airworthiness Directive
Comments
The FAA received comments from five commenters, including Boeing
and three individuals who supported the SNPRM without change, and
American Airlines who supported the inspections specified in the SNPRM
and also provided additional comments.
The FAA received additional comments from five commenters,
including All Nippon Airways, Air France, FedEx, American Airlines, and
United Airlines (United). The following presents the comments received
on the SNPRM and the FAA's response to each comment.
Request for Compliance Time Extension
American Airlines and United requested a compliance time extension
for previously inspected airplanes. American Airlines requested that
airplanes on which Boeing Alert Requirements Bulletin 777-57A0125 RB,
dated July 25, 2023, is accomplished by completing the UT inspections
without the fastener 6 and 7 open hole HFEC inspections and had no
crack findings be allowed to fly up to 4,700 flight cycles or 10,300
flight hours from the time of the inspection before they have to be
brought back to accomplish the inspections with the newly proposed open
hole HFEC inspections. The commenters did not provide justification for
the request.
United requested an additional grace period to conduct the fastener
6 and 7 open hole HFEC inspection on airplanes where the UT inspection
was already conducted prior to the issuance of the final rule. United
stated that this additional time is requested to allow for proper
planning and execution of the open hole HFEC inspection; these
inspections require a significant amount of time and effort to
accomplish and will impact United's maintenance check scheduling.
Additionally, United noted the materials required for the on-condition
corrective action are currently out of stock and are subject to
extended lead times from Boeing.
The FAA disagrees with the request for an extended compliance time
for airplanes on which UT inspections have been done as specified in
the NPRM prior to the publication of the final rule. As the UT
inspection would not adequately detect cracks common to the 6 and 7
fasteners, a grace period extension or allowing credit for accomplish
the UT inspection may not adequately maintain an acceptable level of
safety due to factors such as airplane age, utilization, inspection
history, etc. In addition, the FAA notes that the on-condition
corrective action is to contact Boeing for repair instructions and do
the repair. The parts needed to do the repair will vary depending on
the inspection findings. If parts for a specific repair are not
available, operators may request a compliance time extension through
alternative methods of compliance (AMOC) in accordance with paragraph
(i) of this AD provided sufficient supporting data is submitted to show
an acceptable level of safety is maintained.
Request for Clarification of Inspection Compliance Time
Air France requested that the FAA clarify the fastener inspection
compliance time for airplanes that have already accomplished inspection
instructions in accordance with Boeing Alert Requirements Bulletin 777-
57A0125 RB, dated July 25, 2023, prior to the emergence of the issue
regarding open hole HFEC inspection of fasteners 6 and 7. Air France
requested compliance time clarification since Air France had already
inspected some group 4 airplanes with no finding after the UT
inspection to comply with Boeing Alert Requirements Bulletin 777-
57A0125 RB, dated July 25, 2023. Air France stated that no open hole
HFEC inspection was performed on fasteners 6 and 7 on these airplanes
and they are scheduled to be reinspected within 4,700 flight cycles or
10,300 flight hours, whichever occurs first, after the first
inspection. For these affected airplanes, Air France would like the FAA
to specify if the open hole HFEC inspection on fasteners 6 and 7 is to
be performed within 12 months or 4,300 flight hours, whichever occurs
first, from the effective date of the proposed AD or at the next repeat
inspection per Boeing Alert Requirements Bulletin 777-57A0125 RB, dated
July 25, 2023, instructions.
The FAA agrees to clarify the inspection compliance time. For
airplanes on which the inspections specified in Boeing Alert
Requirements Bulletin 777-57A0125 RB, dated July 25, 2023, were
accomplished, without the open hole HFEC inspection for fasteners 6 and
7, accomplishing the open hole HFEC inspection for the subject
fasteners is required within the inspection compliance times required
by this AD, as required by paragraphs (g) and (h) of this AD, which
includes a grace period of within 12 months or 4,300 flight hours,
whichever occurs first, after the effective date of this AD. For any
airplanes inspected in accordance with Boeing Alert Requirements
Bulletin 777-57A0125 RB, dated July 25, 2023, without the open hole
HFEC inspection of the subject fasteners prior to the issuance of this
AD, the FAA may consider compliance time extensions through AMOCs in
accordance with paragraph (i) of this AD, provided sufficient
supporting data is submitted to show an acceptable level of safety is
maintained.
Request Credit for Previous Actions
American Airlines and United requested credit for previous actions
for fasteners 6 and 7. American Airlines requested that previous
accomplishment of open hole HFEC inspections at fastener 6 and 7 during
repairs of cracks in the subject inspection area are considered
compliant with the initial inspections on the subject wing side. United
requested credit for conducting open hole HFEC inspections on fasteners
6 and 7 on group 4 airplanes before the AD issue date. The commenters
did not provide justification for this request.
The FAA agrees that previous accomplishment of open hole HFEC
inspections at the subject fasteners are considered compliant if done
as specified in paragraphs (g) and (h) of this AD. Paragraph (f) of
this AD states to accomplish the required actions within the compliance
times specified, ``unless already done.'' Therefore, if operators have
accomplished the initial inspections required for compliance with this
AD before the effective date of this AD, they are in compliance with
those requirements. The FAA has not revised this AD in this regard.
Request for FAA To Allow Open Hole HFEC Inspections in Lieu of UT
Inspections
All Nippon Airways requested that the FAA accept the procedure to
perform open hole HFEC inspections in lieu of UT inspections for
affected fasteners or release an AD that requires revised service
information reflecting this content. The commenter states that Boeing
Information Notice 777-57A0125 IN 01, dated July 19, 2024, instructs
operators to perform open hole HFEC in lieu of UT inspection. The
commenter also stated formal Boeing approval via FAA Form 8100-9 will
be needed because the open hole HFEC inspection in lieu of UT
inspection has not been considered acceptable by the FAA.
The FAA disagrees with the request to release an AD that requires
revised service information to accept the procedure to perform open
hole HFEC inspections in lieu of UT inspections for affected fasteners
because the FAA has already identified the open hole HFEC procedure as
indicated in paragraphs
[[Page 12684]]
(h)(4) through (7) of this AD. Additional approval would not be
required as the open hole HFEC procedure is already required by the FAA
in this AD. The FAA has not changed this AD in this regard.
Request To Limit Inspection to Certain Airplanes
FedEx requested that paragraph (h)(7) of the proposed AD be revised
to limit it to Model 777F (Group 6) airplanes with more than 40,000
total flight hours or 6,500 total flight cycles. FedEx stated that
based on its inspection results, the inspection intervals in Boeing
Alert Requirements Bulletin 777-57A0125 RB, dated July 25, 2023, and
the added requirements in paragraph (h)(7) of the proposed AD are not
in the public interest.
FedEx noted that no cracks were found on airplanes with less than
48,000 total flight hours and for airplanes with more than 40,000 total
flight hours, there is a low rate of crack findings with small cracks
being found. FedEx concluded that the mandate to perform open hole HFEC
inspections would result in a requirement to perform at least three
sets of invasive, open hole inspections before an airplane reached
48,000 total flight hours when micro-cracking was first observed. FedEx
also stated that the removal of interference fit fasteners will
typically require subsequent installation of an oversize fasteners and
multiple fastener replacements is expected to adversely affect the
joint stiffness and fatigue life of the subject wing spar region.
The FAA acknowledges that removal of interference fit fasteners may
require oversizing the fastener hole but does not agree with delaying
the inspections because the FAA considered crack reports across the
entire 777 fleet of airplanes in determining the compliance times. The
FAA received reports of crack findings earlier than 40,000 total flight
hours or 6,500 total flight cycles. Therefore, the FAA has not changed
this AD in this regard. The FAA will, however, consider AMOCs in
accordance with the paragraph (i) of this AD for compliance time
extensions provided substantiation data is submitted to show an
acceptable level of safety is maintained with the alternate inspection
intervals.
Conclusion
The FAA reviewed the relevant data, considered any comments
received, and determined that air safety requires adopting this AD as
proposed. Accordingly, the FAA is issuing this AD to address the unsafe
condition on these products. Except for minor editorial changes, this
AD is adopted as proposed in the SNPRM. None of the changes will
increase the economic burden on any operator.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Boeing Alert Requirements Bulletin 777-57A0125 RB,
dated July 25, 2023. This material specifies procedures for repetitive
inspections for cracking of the upper wing skin common to certain
fasteners and applicable on-condition actions. On-condition actions
include repair.
This material is reasonably available because the interested
parties have access to it through their normal course of business or by
the means identified in the ADDRESSES section.
Costs of Compliance
The FAA estimates that this AD affects 323 airplanes of U.S.
registry. The FAA estimates the following costs to comply with this AD:
Estimated Costs
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Cost on U.S.
Action Labor cost Parts cost Cost per product operators
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Inspections...................... 40 work-hours x $85 * $1,480 $4,880 per $1,576,240 per
per hour = $3,400 inspection cycle. inspection cycle.
per inspection
cycle.
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* An inspection kit is required.
The FAA has received no definitive data on which to base the cost
estimates for the on-condition repairs specified in this AD.
The FAA has included all known costs in its cost estimate.
According to the manufacturer, however, some or all of the costs of
this AD may be covered under warranty, thereby reducing the cost impact
on affected operators.
Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, section 106, describes the
authority of the FAA Administrator. Subtitle VII: Aviation Programs,
describes in more detail the scope of the Agency's authority.
The FAA is issuing this rulemaking under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701: General requirements.
Under that section, Congress charges the FAA with promoting safe flight
of civil aircraft in air commerce by prescribing regulations for
practices, methods, and procedures the Administrator finds necessary
for safety in air commerce. This regulation is within the scope of that
authority because it addresses an unsafe condition that is likely to
exist or develop on products identified in this rulemaking action.
Regulatory Findings
This AD will not have federalism implications under Executive Order
13132. This AD will not have a substantial direct effect on the States,
on the relationship between the national government and the States, or
on the distribution of power and responsibilities among the various
levels of government.
For the reasons discussed above, I certify that this AD:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866,
(2) Will not affect intrastate aviation in Alaska, and
(3) Will not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
The Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA amends 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
0
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(f), 40113, 44701.
Sec. 39.13 [Amended]
0
2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive:
[[Page 12685]]
2025-06-02 The Boeing Company: Amendment 39-22990; Docket No. FAA-
2023-2151; Project Identifier AD-2023-00984-T.
(a) Effective Date
This airworthiness directive (AD) is effective April 23, 2025.
(b) Affected ADs
None.
(c) Applicability
This AD applies to all The Boeing Company Model 777-200, -200LR,
-300, -300ER, and 777F series airplanes, certificated in any
category.
(d) Subject
Air Transport Association (ATA) of America Code 57, Wings.
(e) Unsafe Condition
This AD was prompted by a report of a 5-inch crack on the upper
wing skin at wing station (WSTA) 460 of the right wing. The FAA is
issuing this AD to address the possibility of an undetected upper
wing skin crack. The unsafe condition, if not addressed, could
result in the inability of the primary structural element to sustain
limit load and could adversely affect the structural integrity of
the airplane, resulting in loss of control of the airplane.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Required Actions
Except as specified by paragraph (h) of this AD: At the
applicable times specified in the ``Compliance'' paragraph of Boeing
Alert Requirements Bulletin 777-57A0125 RB, dated July 25, 2023, do
all applicable actions identified in, and in accordance with, the
Accomplishment Instructions of Boeing Alert Requirements Bulletin
777-57A0125 RB, dated July 25, 2023.
Note 1 to paragraph (g): Guidance for accomplishing the actions
required by this AD can be found in Boeing Alert Service Bulletin
777-57A0125, dated July 25, 2023, which is referred to in Boeing
Alert Requirements Bulletin 777-57A0125 RB, dated July 25, 2023.
(h) Exceptions to Service Information Specifications
(1) Where Boeing Alert Requirements Bulletin 777-57A0125 RB,
dated July 25, 2023, uses the phrase ``the original issue date of
Requirements Bulletin 777-57A0125 RB,'' this AD requires using the
effective date of this AD.
(2) Where Boeing Alert Requirements Bulletin 777-57A0125 RB,
dated July 25, 2023, specifies contacting Boeing for repair
instructions: This AD requires doing the repair before further
flight using a method approved in accordance with the procedures
specified in paragraph (i) of this AD.
(3) Where note (a) of the tables in the ``Compliance'' paragraph
and Accomplishment Instructions of Boeing Alert Requirements
Bulletin 777-57A0125 RB, dated July 25, 2023, specifies that a
``repair for any crack found on the left wing is terminating action
to the repeat inspection on the left wing only,'' or that a ``repair
for any crack found on the right wing is terminating action to the
repeat inspection on the right wing only,'' for this AD, performing
a repair for any crack in accordance with the procedures specified
in paragraph (i) of this AD terminates the repetitive inspections
required by (g) of this AD at the repaired area only.
(4) For Model 777-300 (Group 3) airplanes, where Boeing Alert
Requirements Bulletin 777-57A0125 RB, dated July 25, 2023, specifies
an ultrasonic (UT) inspection of the upper wing skin common to
fasteners 11 and 12, this AD requires an open hole high frequency
eddy current (HFEC) inspection of fasteners 11 and 12 in accordance
with Figures 5 and 6 (for the left wing) or Figures 18 and 19 (for
the right wing), as applicable.
(5) For Model 777-300ER (Group 4) airplanes, where Boeing Alert
Requirements Bulletin 777-57A0125 RB, dated July 25, 2023, requires
a UT inspection of the upper wing skin common to fasteners 6 and 7,
this AD requires this AD requires an open hole HFEC inspection of
fasteners 6 and 7 in accordance with Figures 30 and 34 (for the left
wing) or Figures 39 and 43 (for the right wing), as applicable.
(6) For Model 777-200LR (Group 5) airplanes, where Boeing Alert
Requirements Bulletin 777-57A0125 RB, dated July 25, 2023, requires
a UT inspection of the upper wing skin common to fasteners 6 and 7,
this AD requires an open hole HFEC inspection of fasteners 6 and 7
in accordance with Figures 30 and 34 (for the left wing) or Figures
39 and 43 (for the right wing), as applicable.
(7) For Model 777F (Group 6) airplanes, where Boeing Alert
Requirements Bulletin 777-57A0125 RB, dated July 25, 2023, requires
a UT inspection of the upper wing skin common to fasteners 6 and 7,
this AD requires an open hole HFEC inspection of fasteners 6 and 7
in accordance with Figures 30 and 34 (for the left wing) or Figures
39 and 43 (for the right wing), as applicable.
(i) Alternative Methods of Compliance (AMOCs)
(1) The Manager, AIR-520, Continued Operational Safety Branch,
FAA, has the authority to approve AMOCs for this AD, if requested
using the procedures found in 14 CFR 39.19. In accordance with 14
CFR 39.19, send your request to your principal inspector or
responsible Flight Standards Office, as appropriate. If sending
information directly to the manager of the certification office,
send it to the attention of the person identified in paragraph
(j)(1) of this AD. Information may be emailed to: <a href="/cdn-cgi/l/email-protection#eeafa3a1adae888f8fc0898198"><span class="__cf_email__" data-cfemail="46070b09050620272768212930">[email protected]</span></a>.
(2) Before using any approved AMOC, notify your appropriate
principal inspector, or lacking a principal inspector, the manager
of the responsible Flight Standards Office.
(3) An AMOC that provides an acceptable level of safety may be
used for any repair, modification, or alteration required by this AD
if it is approved by The Boeing Company Organization Designation
Authorization (ODA) that has been authorized by the Manager, AIR-
520, Continued Operational Safety Branch, FAA, to make those
findings. To be approved, the repair method, modification deviation,
or alteration deviation must meet the certification basis of the
airplane, and the approval must specifically refer to this AD.
(j) Related Information
(1) For more information about this AD, contact Luis Cortez-
Muniz, Aviation Safety Engineer, FAA, 2200 South 216th St., Des
Moines, WA 98198; phone: 206-231-3958; email: <a href="/cdn-cgi/l/email-protection#e1ad948892cfa0cfa28e9395849bccac948f889ba1878080cf868e97"><span class="__cf_email__" data-cfemail="87cbf2eef4a9c6a9c4e8f5f3e2fdaacaf2e9eefdc7e1e6e6a9e0e8f1">[email protected]</span></a>.
(2) Material identified in this AD that is not incorporated by
reference is available at the address specified in paragraph (k)(3)
this AD.
(k) Material Incorporated by Reference
(1) The Director of the Federal Register approved the
incorporation by reference (IBR) of the service information listed
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
(2) You must use this service information as applicable to do
the actions required by this AD, unless the AD specifies otherwise.
(i) Boeing Alert Requirements Bulletin 777-57A0125 RB, dated
July 25, 2023.
(ii) [Reserved]
(3) For Boeing material, contact Boeing Commercial Airplanes,
Attention: Contractual & Data Services (C&DS), 2600 Westminster
Blvd., MC 110-SK57, Seal Beach, CA 90740-5600; telephone 562-797-
1717; website <a href="http://myboeingfleet.com">myboeingfleet.com</a>.
(4) You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 2200 South 216th St.,
Des Moines, WA. For information on the availability of this material
at the FAA, call 206-231-3195.
(5) You may view this material at the National Archives and
Records Administration (NARA). For information on the availability
of this material at NARA visit <a href="http://www.archives.gov/federal-register/cfr/ibr-locations">www.archives.gov/federal-register/cfr/ibr-locations</a> or email <a href="/cdn-cgi/l/email-protection#395f4b1750574a495c5a4d5056577957584b58175e564f"><span class="__cf_email__" data-cfemail="583e2a7631362b283d3b2c3137361836392a39763f372e">[email protected]</span></a>.
Issued on March 13, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft
Certification Service.
[FR Doc. 2025-04440 Filed 3-18-25; 8:45 am]
BILLING CODE 4910-13-P
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