# Boeing Alert Service Bulletin 757-27A0153: Revision 1

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- Title as filed: U.S. DOT/FAA - SB-757-27A0153-00--
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### Page 1

Commercial 
Airplanes
757
Service Bulletin
ALERT
Number: 757-27A0153
Original Issue: May 09, 2012
ATA System: 2721
SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod
Bolt Replacement
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 300-774). An export license may be required before it is used for development, production or use by foreign
persons from specific countries. The controller of this data has the individual responsibility to abide by all export
laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 2012 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner™,
BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing
liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection
with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management
Company.
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757-27A0153
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5.0

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Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
2. Spares Affected ........................................ 1 3
B. Concurrent Requirements ...................................... 1 3
C. Reason ................................................ 1 3
D. Description .............................................. 1 3
E. Compliance .............................................. 1 3
F. Approval ............................................... 1 5
G. Manpower .............................................. 1 6
H. Weight and Balance Changes .................................... 1 8
I. Electrical Load Data ......................................... 1 8
J. References .............................................. 1 8
1. Existing Data: ......................................... 1 8
2. Data Supplied with this Service Bulletin: ........................... 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8
K. Publications Affected ........................................ 1 8
L. Interchangeability and Intermixability of Parts ........................... 1 9
M. Software Accomplishment Summary ................................ 1 9
2. MATERIAL INFORMATION ........................................ 2 1
A. Material - Price and Availability ................................... 2 1
B. Industry Support Information .................................... 2 1
C. Parts Necessary for Each Airplane ................................. 2 1
1. Kits/Parts ............................................ 2 1
2. Parts and Materials Supplied by the Operator ........................ 2 2
3. Parts Modified and Reidentified ................................ 2 2
4. Parts Removed and Not Replaced .............................. 2 3
D. Parts Necessary to Change Spares ................................. 2 3
E. Special Tooling - Price and Availability ............................... 2 3
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 6
FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN
AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER
RUDDER PEDAL ARM ASSEMBLIES ............................ 3 0
FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER
PEDAL ARM ASSEMBLY ................................... 3 4
FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE
BUSHING ............................................ 3 8
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING
TWO BUSHINGS ........................................ 4 2
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Commercial 
Airplanes
757
Service Bulletin
ALERT
SummaryNumber: 757-27A0153Original Issue: May 09, 2012
ATA System: 2721
SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod
Bolt Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND
This service bulletin gives the instructions and a kit of parts to inspect the rudder pedal arm assembly holes,
install stronger rudder pedal pushrod bolt, and provides an option to replace the rudder pedal assembly or repair
the rudder pedal arm assembly if the holes are worn. If the change in this service bulletin is not done, a bolt
fracture under heavy braking during a high-speed takeoff (RTO) may result in a loss of control of the airplane
and subsequent runway excursion.
Boeing received three reports of fractured rudder pedal pushrod bolts in the rudder pedal assembly on 757
aircraft. In one incident, the operator found a fractured bolt during the airplane pushback when the captain
applied brakes. The operator reported that the rudder pedal shifted when applying brakes and the rudder moved
to the hard left. The left rudder sudden movement occurred after the bolt fractured. Investigation and analysis
of the three incidents has shown that the rudder pedal pushrod bolts are under strength for high loading
applications.
Accomplishment of this service bulletin installs new stronger rudder pedal pushrod bolts. The installation of the
new bolts will prevent runway excursion under heavy braking during a high-speed takeoff (RTO) due to bolt
fracture.
Boeing Service Related Problem (SRP) 757-SRP-27-0209 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 757 FTD 27-09004 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
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ReferenceAffectedPlanning Data
Paragraph 1.E., ComplianceNoAD Related
Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedYesPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsYesKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
YesOperator Supplied Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION (PRR 54530-295RS)
Get access to the rudder pedal assembly for the captain and first officer and remove the rudder pedal pushrod
bolt, washer, nut, and cotter pin. Inspect the rudder pedal arm assembly holes for wear. If holes are worn, replace
the rudder pedal assembly or repair the rudder pedal arm assembly by installing bushings as necessary. Install
the new rudder pedal pushrod bolt, washer, nut, and cotter pin.
EFFECTIVITY
All 757 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service
bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin
mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are available for airplanes in warranty as of October 16, 1997. Please refer to
Paragraph 2.B., Industry Support Information.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
RUDDER
RUDDER  PEDAL ARMS
PEDAL
PUSHRODS
REMOVE BOLTS,
INSPECT THE HOLES,
REPLACE THE RUDDER
PEDAL ARM ASSEMBLY
OR INSTALL BUSHINGS
AS NECESSARY.
INSTALL NEW BOLTS.
FIRST OFFICER'S RUDDER PEDALS SIMILAR  CAPTAIN'S RUDDER PEDALS SHOWN  2104633
Original Issue: May 09, 2012
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Commercial 
Airplanes
757
Service Bulletin
ALERT
Number: 757-27A0153
Original Issue: May 09, 2012
ATA System: 2721
SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod
Bolt Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplane(s) shown below. Refer to PRR 54530-295RS for data about
this change.
DESCRIPTIONCONFIGURATIONGROUP
All 757 airplanes line numbers 1 through 1050.-1
Airplane Models:
757-200, 757-200CB, 757-200PF, 757-300
GroupVariable Number
1NA001 - NA028
1NA191 - NA199
1NA201 - NA239
1NA301 - NA305
1NA341 - NA352
1NA391 - NA399
1NA401 - NA408
1NA441 - NA447
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GroupVariable Number
1NA501 - NA586
1NB001 - NB004
1NB021 - NB023
1NB036 - NB041
1NB051 - NB053
1NB061 - NB073
1NB079
1NB131 - NB148
1NB161 - NB162
1NB166 - NB168
1NB201 - NB204
1NB221 - NB228
1NB230
1NB236
1NB239
1NB261 - NB267
1NB291 - NB299
1NB301 - NB302
1NB311 - NB312
1NB321 - NB331
1NB421 - NB438
1NB446
1NB451 - NB454
1NB501 - NB523
1NB561
1NB571
1NB581 - NB583
1NC001 - NC033
1NC041 - NC042
1NC051 - NC052
1NC056 - NC062
1NC066 - NC084
1NC091 - NC094
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GroupVariable Number
1NC151
1NC161
1NC901 - NC951
1NC971 - NC974
1ND001 - ND007
1ND011 - ND059
1ND111 - ND113
1ND161 - ND199
1ND201 - ND203
1ND221 - ND225
1ND241 - ND248
1ND301 - ND322
1ND401
1ND891
1ND895
1NE001 - NE008
1NE011 - NE088
1NE091 - NE094
1NE141 - NE150
1NE161 - NE177
1NE201 - NE204
1NE301 - NE302
1NE311 - NE325
1NJ001 - NJ004
1NJ031 - NJ032
1NJ551 - NJ555
1NL001 - NL002
1NL006 - NL017
1NL101 - NL109
1NL141
1NL601 - NL616
1NN001 - NN002
1NN051 - NN052
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GroupVariable Number
1NP901 - NP904
1NS601 - NS616
1NT001 - NT009
1NT201 - NT202
1NT231 - NT234
1NT237 - NT240
1NT242
1NT245 - NT248
1NT281 - NT289
1NT341 - NT347
1NT351 - NT360
1NT371 - NT373
1NT375 - NT379
1NT381 - NT386
1NT401 - NT409
1NT411 - NT412
1NT426 - NT427
1NT431 - NT432
1NT436 - NT438
1NT441 - NT442
1NT446
1NT701 - NT769
1NT791 - NT796
1NT861 - NT862
1NT881 - NT885
1NT901 - NT916
1NT971 - NT985
1NU031 - NU038
1NU701 - NU705
1NU721 - NU728
1NU731 - NU732
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2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
This service bulletin gives the instructions and a kit of parts to inspect the rudder pedal arm assembly
holes, install stronger rudder pedal pushrod bolt, and provides an option to replace the rudder pedal
assembly or repair the rudder pedal arm assembly if the holes are worn. If the change in this service
bulletin is not done, a bolt fracture under heavy braking during a high-speed takeoff (RTO) may result
in a loss of control of the airplane and subsequent runway excursion.
Boeing received three reports of fractured rudder pedal pushrod bolts in the rudder pedal assembly on
757 aircraft. In one incident, the operator found a fractured bolt during the airplane pushback when the
captain applied brakes. The operator reported that the rudder pedal shifted when applying brakes and
the rudder moved to the hard left. The left rudder sudden movement occurred after the bolt fractured.
Investigation and analysis of the three incidents has shown that the rudder pedal pushrod bolts are
under strength for high loading applications.
Accomplishment of this service bulletin installs new stronger rudder pedal pushrod bolts. The installation
of the new bolts will prevent runway excursion under heavy braking during a high-speed takeoff (RTO)
due to bolt fracture.
Boeing Service Related Problem (SRP) 757-SRP-27-0209 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 757 FTD 27-09004 is related to this service bulletin.
D. Description
Get access to the rudder pedal assembly for the captain and first officer and remove the rudder pedal
pushrod bolt, washer, nut, and cotter pin. Inspect the rudder pedal arm assembly holes for wear. If
holes are worn, replace the rudder pedal assembly or repair the rudder pedal arm assembly by installing
bushings as necessary. Install the new rudder pedal pushrod bolt, washer, nut, and cotter pin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
113, 114, 211, 212757-200, 757-200CB, 757-
200PF, 757-300
E. Compliance
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to
this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this
service bulletin mandatory.
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Accomplish the required action(s), based on the applicable condition(s) in Table(s) 1, in accordance
with Paragraph 3. Accomplishment Instructions.
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Table 1: INSPECTION AND REPAIR OF THE RUDDER PEDAL ARM ASSEMBLIES
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
15000 flight cyclesWithin 60 months
from the original is-
sue date on this
service bulletin.
Do a detailed inspection
on both holes in each of
the captain and the first
officer rudder pedal arm
assemblies in accordance
with Paragraph 3.B.,
Work Instructions, step 7.
All Airplanes
-Before further flightReplace the rudder pedal
pushrod bolt, nut, washer,
and cotter pin in accor-
dance with Paragraph
3.B., Work Instructions,
Condition 1.
Pedal arm assemblies with
the diameter of both holes
are within 0.3120-0.3140
inches.
-Before further flightReplace the rudder pedal
assembly in accordance
with Paragraph 3.B.,
Work Instructions, Condi-
tion 2. Or
Pedal arm assemblies with
the diameter of one hole is
greater than 0.3140 inches.
-Before further flightRepair the rudder pedal
arm assembly by in-
stalling one bushing as
necessary in accordance
with Paragraph 3.B.,
Work Instructions, Condi-
tion 3. Or
-Before further flightReplace the rudder pedal
assembly in accordance
with Paragraph 3.B.,
Work Instructions, Condi-
tion 2. Or
Pedal arm assemblies with
the diameter of two holes
are greater than 0.3140
inches.
-Before further flightRepair the rudder pedal
arm assembly by in-
stalling two bushings as
necessary in accordance
with Paragraph 3.B.,
Work Instructions, Condi-
tion 4.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
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changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
G. Manpower
The table below shows an estimate of the task hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
 Time to adjust to the workplace
 Time to schedule the work
 Time to inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
TABLE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT AND INSPECTION OF THE
HOLE IN THE RUDDER PEDAL ARM ASSEMBLIES
Elapsed HoursTask HoursNumber of PersonsTask
0.900.901Open Access
1.001.001Figure 1
0.900.901Close Access
0.500.501Test
3.303.30TOTAL FOR EACH AIRPLANE
TABLE 2: CONDITION 1, INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLTS
Elapsed HoursTask HoursNumber of PersonsTask
0.250.251Figure 2
0.250.25TOTAL FOR EACH AIRPLANE (a)
(a) Estimate shown is per one rudder pedal arm assembly that requires only
rudder pedal pushrod bolt installation. Multiply the number of rudder pedal
arm assemblies replaced by the estimate shown to reach the total for each
airplane.
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TABLE 3: CONDITION 2, REPLACEMENT OF THE RUDDER PEDAL ASSEMBLY
Elapsed HoursTask HoursNumber of PersonsTask
1.001.001Remove Rudder
Pedal assembly
1.001.001Install Rudder Pedal
assembly
2.002.00TOTAL FOR EACH AIRPLANE (a)
(a) Estimate shown is per one rudder pedal assembly removed and replaced.
Multiply the number of rudder pedal assemblies replaced by the estimate
shown to reach the total for each airplane.
TABLE 4: CONDITION 3, REPAIR OF THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING
ONE BUSHING
Elapsed HoursTask HoursNumber of PersonsTask
1.001.001Remove Rudder
Pedal assembly
1.001.001Figure 3
1.001.001Install Repaired Rud-
der Pedal assembly
3.003.00TOTAL FOR EACH AIRPLANE (a)
(a) Estimate shown is per rudder pedal arm assembly requiring only one hole to
be repaired. Multiply the number of the rudder pedal arm assemblies repaired
by the estimate shown to reach the total for each Airplane.
TABLE 5: CONDITION 4, REPAIR OF THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING
TWO BUSHINGS
Elapsed HoursTask HoursNumber of PersonsTask
1.001.001Remove Rudder
Pedal assembly
2.002.001Figure 4
1.001.001Install Repaired Rud-
der Pedal assembly
4.004.00TOTAL FOR EACH AIRPLANE (a)
(a) Estimate shown is per rudder pedal arm assembly requiring both holes to be
repaired. Multiply the number of the rudder pedal arm assemblies repaired by
the estimate shown to reach the total for each Airplane.
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H. Weight and Balance Changes
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
NegligibleNegligibleGroup 1
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 54530-295RS
b. Boeing Service Related Problem (SRP) 757-SRP-27-0209
c. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-02, 20-50-03
d. 757 Aircraft Maintenance Manual (AMM) 27-21-02, 29-11-00
e. 757 Fleet Team Digest (FTD) 27-09004
f. Component Maintenance Manual (CMM) CMM 27-21-47
g. Boeing Parts Standards Document D-590
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Arm assy - rudder pedal251N3140
Pedal instl - rudder251N3013
The table above lists applicable drawings used to prepare this service bulletin. The drawings are
not necessary to make the specified changes, and are not supplied with this service bulletin. The
drawings may not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
Chapter-SectionPublication
27-21757 Aircraft Maintenance Manual
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Chapter-SectionPublication
27-21757 Illustrated Parts Catalog
27-21Component Maintenance Manual
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators
are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the original issue
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
original issue
date of this Ser-
vice Bulletin (Cal-
endar Days)
QTYDateNameKit Number
217.00245709/22/11TOP KIT, RETROFIT -
RUDDER PEDAL
PUSHROD BOLT RE-
PLACEMENT
012N8932-21
201/25/12
18903/12/12
B. Industry Support Information
Boeing warranty remedies are available for 757 airplanes in warranty as of October 16, 1997. For task
hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing
Commercial Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be
supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service
bulletin number and reference the airplane variable number in your purchase order.
C. Parts Necessary for Each Airplane
1. Kits/Parts
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane.
Kit 012N8932
NotesExisting Part
Number
NameQTYNew Part Number
-21
(a)AN970-5WASHER4AN970-5
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### Page 22

Kit 012N8932
NotesExisting Part
Number
NameQTYNew Part Number
-21
No sub-
stitu-
tion is
al-
lowed
for this
fasten-
er. (a)
BACB30NM5DK47BOLT4BACB30UU5K48D
(a)BACN11N5CDNUT, CASTELLAT-
ED
4BACN11N5CD
(a)BACP18BC02A05PPIN4BACP18BC02A06P
(b)WASHER4NAS1149D0416J
(b)WASHER4NAS1149D0432J
(b)WASHER4NAS1149D0463J
(a) Discard existing part.
(b) There are more parts than are necessary.
2. Parts and Materials Supplied by the Operator
NotesNameQTYPart Number/ Specifica-
tion
(a)ARM ASSY - RUDDER
PEDAL
-251N3140-( )
CONVERSION COATING-ALODINE TYPE 2, CLASS
A OR C
(b)PRIMER-BMS10-11 TYPE 1
(a)BUSHING-REPAIR, RUD-
DER PEDAL PUSHROD
4001N0004-1
(b)SEALANT-BMS5-95
(a) Boeing Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Wash-
ington 98124-2207 USA.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
3. Parts Modified and Reidentified
The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the
number of parts changed on each airplane.
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### Page 23

NotesNew Part NumberNameQTYExisting Part
Number
(a) (b)-RUDDER PEDAL ARM
ASSY
-251N3140-()
(a) Make the change in accordance with this service bulletin.
(b) There is no equivalent Boeing part number for the changed part. Identify on the part that
the change done in accordance with this service bulletin was made.
4. Parts Removed and Not Replaced
NotesQTYNameExisting Part
Number
4BOLTBACB30NM5DK47
4PINBACP18BC02A05P
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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BLANK PAGE

### Page 25

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque limits to tighten nuts and bolts are in SRM Chapter 51
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
6. A Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate procedures may be required.
7. A General Visual Inspection is defined as: A visual examination of an interior or
exterior area, installation or assembly to detect obvious damage, failure or irregularity.
This level of inspection is made from within touching distance unless otherwise
specified. A mirror may be necessary to enhance visual access to all exposed surfaces
in the inspection area. This level of inspection is made under normally available
lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may
require removal or opening of access panels or doors. Stands, ladders or platforms
may be required to gain proximity to the area being checked.
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8. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
9. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
10. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
11. This service bulletin includes functional test procedures for the systems changed by
this service bulletin. More functional tests can possibly be necessary in accordance
with standard maintenance practices because of interruption to other airplane systems.
B. WORK INSTRUCTIONS
1. Get access to the flight compartment.
2. Remove pressure from the main hydraulic system. Refer to the 757 AMM 29-11-00 as an accepted
procedure.
3. At the P61 right side panel, move the FLT CONTROL SHUTOFF switches L, C, and R to OFF
position.
NOTE: Attach DO-NOT-OPERATE tags and make sure that the amber switch-position legend
lights come ON.
4. At the overhead circuit breaker panel, P11, open these circuit breakers and install safety tags.
NameNumberColRow
FLT CONT SHUTOFF
TAIL L
C0403317H
FLT CONT SHUTOFF
TAIL C
C0403518H
FLT/CONT S/O TAIL RC0403428H
5. Open the forward access door 113AL.
6. Move the towing lever to the tow position and install the NLG towing lever pin, SPL-1499 in the
nose gear.
7. Remove the rudder pedal pushrod bolt, washer, nut, and cotter pin from each of the captain and
the first officer rudder pedal assemblies and do a detailed inspection on both holes to make sure
that the diameter of the holes are within 0.3120-0.3140 inches in each of the captain and the first
officer rudder pedal assemblies in accordance with FIGURE 1.
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### Page 27

a. If the diameter of both holes are within 0.3120-0.3140 inches in each rudder pedal arm
assembly, then install the new rudder pedal pushrod bolt, washers, nut, and cotter pin in
accordance with condition 1.
b. If the diameter of one hole is greater than 0.3140 inches in any rudder pedal arm assembly,
then do one of the options below:
(1) Remove and replace the rudder pedal assembly in accordance with condition 2. Or
(2) Repair the rudder pedal arm assembly in accordance with condition 3.
c. If the diameter of both holes are greater than 0.3140 inches in any rudder pedal arm assembly,
then do one of the options below:
(1) Remove and replace the rudder pedal assembly in accordance with condition 2. Or
(2) Repair the rudder pedal arm assembly in accordance with condition 4.
Condition 1: The diameter of both holes are within 0.3120-0.3140 inches.
1. Install the new rudder pedal pushrod bolt, washers, nut, and cotter pin for each rudder pedal arm
assembly in accordance with FIGURE 2.
NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already
installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin
included in the top kit 012N8932-21. Use a combination of the different sizes of washers
that were included in the top kit to meet the torque specification of 110-150 inch-pounds,
while allowing installation of the cotter pin without disturbing the nut torque.
WARNING: KEEP PERSONS AND EQUIPMENT AWAY FROM ALL CONTROL SURFACES WHEN
HYDRAULIC POWER IS SUPPLIED. AILERONS, ELEVATORS, RUDDER, FLAPS,
SLATS, SPOILERS, AND STABILIZER ARE FULLY POWERED SURFACES. INJURY
TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC
POWER IS SUPPLIED.
2. Supply the power from the left, right, and center hydraulic systems. Refer to the 757 AMM 29-11-00
as an accepted procedure.
3. At the overhead circuit breaker panel, P11, close these circuit breakers.
NameNumberColRow
FLT CONT SHUTOFF
TAIL L
C0403317H
FLT CONT SHUTOFF
TAIL C
C0403518H
FLT/CONT S/O TAIL RC0403428H
4. At the P61 right side panel, Remove the DO-NOT-OPERATE tags and move the FLT CONTROL
SHUTOFF switches L, C, and R to ON position.
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### Page 28

5. Do the rudder pedal operation test as follows:
a. Push the STATUS switch on the P9 Display Select Panel to show the control surface position
indicator on the bottom EICAS display.
b. Operate the rudder pedals through their full travel range and make sure the following:
(1) The rudder operates smoothly and correctly when the pedals are moved through their
full sweep from both the captain's and first officer's pedals.
(2) The rudder position indicator operates correctly and shows full rudder travel in each
direction.
(3) The rudder goes back to its neutral position when the pedals are released slowly.
6. Make sure that the nose wheels are in their center position and remove the towing lever lockpin
from the nose gear.
WARNING: STAY AWAY FROM THE NOSE WHEELS WHEN THE LOCKPIN IS REMOVED. THE
WHEELS CAN TURN TO THE CENTER POSITION QUICKLY, AND CAN CAUSE INJURY
TO PERSONS AND DAMAGE TO EQUIPMENT.
7. Close the forward access door 113AL.
8. Remove the power from the left, right, and center hydraulic systems. Refer to the 757 AMM 29-11-00
as an accepted procedure.
9. Put the airplane back to a serviceable condition.
Condition 2 : The diameter of any hole is greater than 0.3140 inches, replace the rudder pedal
assembly.
1. Remove the rest of the rudder pedal assembly. Refer to 757 AMM 27-21-02 as an accepted
procedure.
2. Install and test the new rudder pedal assembly. Refer to 757 AMM 27-21-02 as an accepted
procedure.
NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already
installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin
included in the top kit 012N8932-21. Use a combination of the different sizes of washers
that were included in the top kit to meet the torque specification of 110 - 150 inch-pounds,
while allowing installation of the cotter pin without disturbing the nut torque.
3. Put the airplane back to a serviceable condition.
Condition 3: The diameter of one hole is greater than 0.3140 inches, repair the rudder pedal arm
assembly by installing one bushing.
1. Remove and keep the rest of the rudder pedal assembly. Refer to 757 AMM 27-21-02 as an
accepted procedure.
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### Page 29

2. Install one bushing at the worn hole for any rudder pedal arm assembly in accordance with FIGURE
3.
3. Install and test the repaired rudder pedal arm assembly along with the rest of the kept rudder pedal
assembly components and the rudder pedal pushrod bolt, washers, nut, and cotter pin. Refer to
757 AMM 27-21-02 as an accepted procedure.
NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already
installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin
included in the top kit 012N8932-21. Use a combination of the different sizes of washers
that were included in the top kit to meet the torque specification of 110 - 150 inch-pounds,
while allowing installation of the cotter pin without disturbing the nut torque.
4. Put the airplane back to a serviceable condition.
Condition 4: The diameter of two holes are greater than 0.3140 inches, repair the rudder pedal
arm assembly by installing two bushings.
1. Remove and keep the rest of the rudder pedal assembly. Refer to 757 AMM 27-21-02 as an
accepted procedure.
2. Install two bushings at the two worn holes for any rudder pedal arm assembly in accordance with
FIGURE 4.
3. Install and test the repaired rudder pedal arm assembly along with the rest of the kept rudder pedal
assembly components and the rudder pedal pushrod bolt, washers, nut, and cotter pin. Refer to
757 AMM 27-21-02 as an accepted procedure.
NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already
installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin
included in the top kit 012N8932-21. Use a combination of the different sizes of washers
that were included in the top kit to meet the torque specification of 110 - 150 inch-pounds,
while allowing installation of the cotter pin without disturbing the nut torque.
4. Put the airplane back to a serviceable condition.
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### Page 30 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
CAPTAIN'S RUDDER PEDALS SHOWN  2104715
FIRST OFFICER'S RUDDER PEDALS SIMILAR
FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN
AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL
ARM ASSEMBLIES
(SHEET 1 OF 4)
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
FIRST OFFICER'S RUDDER PEDALS SIMILAR  CAPTAIN'S RUDDER PEDALS SHOWN  2104711
FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN
AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL
ARM ASSEMBLIES
(SHEET 2 OF 4)
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### Page 32

More DataQtyIdentificationNameTaskStep
Move one pedal for-
ward and the other
pedal aft to create
clearance for the
fasteners replace-
ment.
--RUDDER PEDALMove1
If installed.8251A3131-( )RETAINERRemove / Keep2
8BACS12GU08K8SCREWRemove / Keep
8NAS1149CN832RWASHERRemove / Keep
8PLH508CDNUTRemove / Keep
4BACP18BC02A05PCOTTER PINRemove3
FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN
AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL
ARM ASSEMBLIES
(SHEET 3 OF 4)
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### Page 33

More DataQtyIdentificationNameTaskStep
4BACN11N5CDNUTRemove4
4AN970-( )WASHERRemove
4BACB30NM5DK47BOLTRemove
Verify that the diam-
eter of each hole is
within 0.3120-0.3140
inches.
--HOLEInspect5
FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN
AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL
ARM ASSEMBLIES
(SHEET 4 OF 4)
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### Page 34 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
(FWD
CAPTAIN'S RUDDER PEDALS SHOWN  2104741
FIRST OFFICER'S RUDDER PEDALS SIMILAR
FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL
ARM ASSEMBLY
(SHEET 1 OF 4)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
FIRST OFFICER'S RUDDER PEDALS SIMILAR  CAPTAIN'S RUDDER PEDALS SHOWN  2104742
FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL
ARM ASSEMBLY
(SHEET 2 OF 4)
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### Page 36

FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL
ARM ASSEMBLY
(SHEET 3 OF 4)
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### Page 37

More DataQtyIdentificationNameTaskStep
No substitution is al-
lowed for this fasten-
er.
1BACB30UU5K48DBOLTInstall (New)1
1AN970-5WASHERInstall (New)
(a)1NAS1149D0416JWASHERInstall (New)
(a)1NAS1149D0432JWASHERInstall (New)
(a)1NAS1149D0463JWASHERInstall (New)
Torque specification
is 110 - 150 inch-
pounds.
1BACN11N5CDNUT, CASTELLATEDInstall (New)
Refer to the SOPM
20-50-02 as an ac-
cepted procedure.
4BACP18BC02A06PCOTTER PINInstall (New)
If installed.2251A3131-( )RETAINERInstall (Kept)2
2BACS12GU08K8SCREWInstall (Kept)
2NAS1149CN832RWASHERInstall (Kept)
2PLH508CDNUTInstall (Kept)
1-RUDDER PEDALRelease3
(a) Use each washer alone or in a combination with other washers provided in the kit as required to meet
the torque specification of 110 - 150 inch-pounds, while allowing installation of the cotter pin without dis-
turbing the nut torque.
FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL
ARM ASSEMBLY
(SHEET 4 OF 4)
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### Page 38 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
CAPTAIN'S RUDDER PEDALS SHOWN  2104770
FIRST OFFICER'S RUDDER PEDALS SIMILAR
FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE
BUSHING
(SHEET 1 OF 4)
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### Page 39 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
• RUDDER  PEDAL ARM
CAPTAIN'S RUDI  PEDALS SHOWN
FIRST OFFICER'S  RUDDER PEDALS SIMILAR
TYPICAL  2104743
FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE
BUSHING
(SHEET 2 OF 4)
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### Page 40 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
0.375% 1 3  0.3750
0.035
0.030
• 0.03R
0.70 € €
0.020
0.010
X 45° COUNTERSINK
A-A
3125 6  3135
2104773
FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE
BUSHING
(SHEET 3 OF 4)
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### Page 41

More DataQtyIdentificationNameTaskStep
Ream the worn hole
in line with the other
hole. Refer to view
A-A.
1251N3140-( )ARM ASSY - RUDDER
PEDAL
Ream1
Refer to view A-A.1251N3140-( )ARM ASSY - RUDDER
PEDAL
Machine2
Refer to view A-A.1251N3140-( )ARM ASSY - RUDDER
PEDAL
Countersink
Refer to SOPM 20-
43-03 as an accept-
ed procedure.
-ALODINE TYPE 2,
CLASS A OR C
CONVERSION COAT-
ING
Apply3
Use the shrink fit
procedure to install
the bushing. Refer
to SOPM 20-50-03
as an accepted pro-
cedure. Refer to
view A-A.
1001N0004-1BUSHING-REPAIR,
RUDDER PEDAL
PUSHROD
Install (New)4
-BMS5-95SEALANTApply
As necessary, refer
to SOPM 20-41-02
as an accepted pro-
cedure.
-BMS10-11 TYPE 1PRIMERApply5
Ream the hole in
line. Refer to view A-
A.
1251N3140-( )ARM ASSY - RUDDER
PEDAL
Ream6
Refer to SOPM 20-
43-03 as an accept-
ed procedure.
-ALODINE TYPE 2,
CLASS A OR C
CONVERSION COAT-
ING
Apply7
FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE
BUSHING
(SHEET 4 OF 4)
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### Page 42 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
CAPTAIN'S RUDDER PEDALS SHOWN  2104771
FIRST OFFICER'S RUDDER PEDALS SIMILAR
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING
TWO BUSHINGS
(SHEET 1 OF 4)
Original Issue: May 09, 2012
Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  757-27A0153
Work - See page 1 for details.  42 of 45

### Page 43 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
•RUDDER  PEDAL ARM
CAPTAIN'S RUDI  PEDALS SHOWN
FIRST OFFICER'S  RUDDER PEDALS SIMILAR
TYPICAL  2104767
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING
TWO BUSHINGS
(SHEET 2 OF 4)
Original Issue: May 09, 2012
Export Controlled ECCN: 9E991 - BOEING  757-27A0153
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  43 of 45

### Page 44 (OCR)

BOEING SERVICE BULLETIN 757-27A0153
ALERT  ALERT
0.375% 13  0.3750
0.035-
0.030
0.03R  10.03R
2) 3) 0.70  0.70 € 3
0.035
0.030
0.020
0.010
× 45°
A-A
6 T 0.3135  0.3125  3135(6)
2104837
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING
TWO BUSHINGS
(SHEET 3 OF 4)
Original Issue: May 09, 2012
Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  757-27A0153
Work - See page 1 for details.  44 of 45

### Page 45

More DataQtyIdentificationNameTaskStep
Ream the worn
holes. Refer to view
A-A.
2251N3140-( )ARM ASSY - RUDDER
PEDAL
Ream1
Refer to view A-A.2251N3140-( )ARM ASSY - RUDDER
PEDAL
Machine2
Refer to view A-A.2251N3140-( )ARM ASSY - RUDDER
PEDAL
Countersink
Refer to SOPM 20-
43-03 as an accept-
ed procedure.
-ALODINE TYPE 2,
CLASS A OR C
CONVERSION COAT-
ING
Apply3
Use the shrink fit
procedure to install
the bushing. Refer
to SOPM 20-50-03
as an accepted pro-
cedure. Refer to
view A-A.
2001N0004-1BUSHING-REPAIR,
RUDDER PEDAL
PUSHROD
Install (New)4
-BMS5-95SEALANTApply
As necessary, refer
to SOPM 20-41-02
as an accepted pro-
cedure.
-BMS10-11 TYPE 1PRIMERApply5
Ream both bushings
in-line. Refer to view
A-A.
2251N3140-( )ARM ASSY - RUDDER
PEDAL
Ream6
Refer to SOPM 20-
43-03 as an accept-
ed procedure.
-ALODINE TYPE 2,
CLASS A OR C
CONVERSION COAT-
ING
Apply7
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING
TWO BUSHINGS
(SHEET 4 OF 4)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: May 09, 2012
757-27A0153
45 of 45
BOEING SERVICE BULLETIN 757-27A0153
ALERTALERT

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