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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-27A0160 RB Original Issue: April 01, 2024 ATA System: 2711 SUBJECT: FLIGHT CONTROLS - Aileron and Aileron Trim Control System - Lateral Control Box Support Assembly Change and Actuator Lateral Control Fitting Replacement EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.
9E991ECCN:
Copyright © 2024 The Boeing Company 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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, 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.
Original Issue: April 01, 2024 757-27A0160 RB 1 of 33
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Export Controlled ECCN: 9E991 See page 1 for details Original Issue: April 01, 2024 757-27A0160 RB 2 of 33 REQUIREMENTS BULLETIN 757-27A0160
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Table of Contents
1. EFFECTIVITY5
A. Airplanes5
B. Spares Affected8
2. CONCURRENT REQUIREMENTS8
3. COMPLIANCE8
4. APPROVAL9
5. ACCOMPLISHMENT INSTRUCTIONS11
A. General Information11
B. Work Instructions12
FIGURE 1: MAIN LANDING GEAR WHEEL WELL - LATERAL CONTROL BOX SUPPORT ASSEMBLY
CHANGE [Group 1, 4-5]15
FIGURE 2: MAIN LANDING GEAR WHEEL WELL - AILERON TRIM ACTUATOR BRACKET INSTALLATION
[Group 1, 4-5]17
FIGURE 3: MAIN LANDING GEAR WHEEL WELL - ACTUATOR LATERAL CONTROL FITTING
REPLACEMENT [Group 2]23
FIGURE 4: MAIN LANDING GEAR WHEEL WELL - ACTUATOR LATERAL CONTROL FITTING
REPLACEMENT [Group 3]28
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Export Controlled ECCN: 9E991 See page 1 for details Original Issue: April 01, 2024 757-27A0160 RB 4 of 33 REQUIREMENTS BULLETIN 757-27A0160
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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-27A0160 RB Original Issue: April 01, 2024 ATA System: 2711 SUBJECT: FLIGHT CONTROLS - Aileron and Aileron Trim Control System - Lateral Control Box Support Assembly Change and Actuator Lateral Control Fitting Replacement
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING
PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1. Effectivity A. Airplanes This bulletin is applicable to 757-200, 757-200CB, 757-200PF, 757-300 Airplane(s), line number(s) 1-2, 5, 14-15, 42, 46, 56, 74-75, 80, 97, 101-102, 106, 111-115, 117, 123, 127, 130, 132, 139, 141, 143, 145, 147-151, 153, 155, 162-163, 165-167, 169, 173-174, 176, 178, 180-184, 186-187, 189, 191, 193, 195, 197, 199-200, 203-204, 208-209, 211-215, 218-221, 224-232, 235-236, 238-239, 246, 248-250, 255-257, 259, 264-265, 267-268, 270-271, 273-275, 279, 281, 285, 287-288, 291-294, 298, 300-302, 306, 312, 314, 317-319, 322-323, 325-326, 330, 332-335, 339-345, 347-350, 353-355, 359-364, 369-372, 374, 376-379, 382-389, 392-395, 397-400, 402-404, 407, 409-412, 414-418, 421-422, 424-425, 429-430, 432-433, 435-443, 445-446, 448-449, 453, 455, 458-459, 461, 465-466, 470-478, 480-482, 485-486, 489, 493, 495-503, 506, 508, 510-516, 518-519, 521, 523, 525-528, 530-546, 548-549, 551-556, 558-559, 561-571, 573-575, 577-586, 588-590, 592-597, 599, 601-605, 607-619, 622-625, 627-683, 685-707, 709-717, 719, 721, 723-780, 782-800, 802-834, 836-875, 877-888, 890-894, 896-1050 in 5 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 757-200 airplanes with Support Box Assembly - Lateral Control Part Number 251N1264-7 installed.
-1 757-200 airplanes with Support Box Assembly - Lateral Control Part Number 251N1135-6 installed.
-2 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: April 01, 2024 757-27A0160 RB 5 of 33
DESCRIPTIONCONFIGURATIONGROUP 757-200 airplanes with Support Box Assembly - Lateral Control Part Number 251N1135-1 installed.
-3 757-200, 757-200CB and 757-200PF airplanes with Support Box Assembly - Lateral Control Part Number 251N1264-8 installed.
-4 757-200, 757-200PF and 757-300 airplanes with Support Box Assembly - Lateral Control Part Number 251N1264-9 installed.
-5 Airplane Models:
757-200, 757-200CB, 757-200PF, 757-300 GroupVariable Number 3NA001 2NA002 2NA005 1NA021 - NA023 4NA024 - NA028 4NA195 4NA197 - NA199 2NA205 4NA227 - NA228 4NA230 4NA235 - NA239 4NA301 - NA305 4NA343 - NA344 4NA346 - NA352 4NA392 - NA399 2NA401 1NA404 4NA406 4NA441 - NA447 1NA505 1NA519 - NA521 4NA522 GroupVariable Number 4NA549 - NA552 4NA554 - NA555 4NA558 - NA576 4NA578 - NA586 1NB023 1NB037 4NB041 1NB053 4NB062 - NB066 4NB070 - NB073 4NB079 4NB131 - NB148 4NB161 - NB162 4NB167 - NB168 4NB201 - NB202 4NB221 - NB226 5NB227 - NB228 5NB230 4NB236 4NB239 4NB261 - NB267 4NB291 - NB299 GroupVariable Number 4NB301 - NB302 4NB311 - NB312 4NB321 - NB330 4NB421 4NB424 4NB428 - NB431 4NB434 - NB435 4NB437 - NB438 4NB446 4NB451 - NB454 4NB501 - NB523 5NB571 5NB581 - NB583 1NC042 4NC051 - NC052 4NC056 - NC062 4NC066 - NC078 5NC079 - NC084 4NC091 5NC092 - NC094 4NC151 4NC161 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: April 01, 2024 757-27A0160 RB 6 of 33 REQUIREMENTS BULLETIN 757-27A0160
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GroupVariable Number 4NC901 - NC951 4NC973 - NC974 4ND004 4ND012 4ND017 4ND032 4ND039 - ND041 4ND044 4ND046 4ND048 4ND052 - ND053 4ND111 4ND161 4ND163 - ND166 4ND169 - ND176 4ND178 - ND188 4ND190 - ND199 4ND201 - ND202 4ND221 - ND225 4ND241 - ND242 4ND244 - ND247 4ND301 - ND317 5ND318 - ND322 5ND401 4ND895 4NE001 - NE003 4NE008 4NE012 4NE017 4NE021 - NE022 4NE025 4NE029 4NE031 GroupVariable Number 4NE036 - NE037 4NE040 - NE041 4NE044 4NE048 - NE051 4NE054 - NE055 4NE067 - NE075 4NE077 - NE081 4NE083 - NE088 4NE092 - NE094 4NE145 4NE147 4NE161 - NE164 4NE166 4NE168 4NE170 - NE172 4NE174 - NE176 4NE201 4NE204 4NE301 4NE311 - NE325 5NJ001 - NJ004 5NJ031 - NJ032 5NJ551 - NJ555 5NL001 - NL002 5NL006 - NL017 5NL101 - NL109 5NL141 5NL601 - NL616 5NN001 - NN002 5NN051 - NN052 5NP901 - NP904 4NS601 - NS610 5NS611 - NS616 GroupVariable Number 5NT001 - NT009 5NT201 - NT202 5NT231 - NT234 5NT237 - NT240 5NT242 5NT245 - NT248 5NT281 - NT284 5NT286 - NT289 5NT341 - NT343 5NT345 - NT347 5NT351 - NT360 5NT371 - NT373 5NT375 - NT379 5NT381 - NT386 5NT401 - NT409 5NT411 - NT412 5NT426 - NT427 5NT431 - NT432 5NT436 - NT438 5NT441 - NT442 5NT446 5NT701 - NT750 5NT752 - NT769 5NT791 - NT796 5NT861 - NT862 5NT881 5NT884 - NT885 5NT901 - NT903 5NT905 - NT916 5NT971 - NT985 5NU031 - NU038 5NU701 - NU705 5NU721 - NU728 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: April 01, 2024 757-27A0160 RB 7 of 33 REQUIREMENTS BULLETIN 757-27A0160
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GroupVariable Number 5NU731 - NU732 GroupVariable Number -- GroupVariable Number -- B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2019-12-13 is related to this service bulletin. The effective date of AD 2019-12-13 is July 12, 2019.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 757-27A0160 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-27A0160 RB mandatory.
Group 1, 4-5:
Accomplish the required action(s), based on the applicable condition(s) in Table 1, in accordance with Accomplishment Instructions.
Group 2-3:
Accomplish the required action(s), based on the applicable condition(s) in Table 2, in accordance with Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Group 1, 4-5:
Table 1: Lateral Control Box Support Assembly Change and Aileron Trim Actuator Bracket Installation Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs First) ActionCondition -Within 10,000 Flight Hours (FH) after the Original Issue date of the Requirements Bulletin 757- 27A0160 RB.
ACTION 1:
Change the lateral control box support assembly. (a) All Airplanes.
ACTION 2:
Install aileron trim actuator bracket. (a) orWithin 30 Months after the Original Issue date of the Requirements Bulletin 757- 27A0160 RB.
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Group 1, 4-5:
Table 1: Lateral Control Box Support Assembly Change and Aileron Trim Actuator Bracket Installation Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs First) ActionCondition
(a) Accomplishment of ACTION 1 and ACTION 2 terminates the repetitive Aileron Trim Actuator attachment lug detailed inspection and the Aileron Trim Actuator bearing rotation check specified in Boeing Alert Requirements Bulletin 757-27A0159 RB.
Group 2-3:
Table 2: Actuator Lateral Control Fitting Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs First) ActionCondition -Within 10,000 Flight Hours (FH) after the Original Issue date of the Requirements Bulletin 757- 27A0160 RB.
Replace existing actuator lateral control fitting with an aileron trim actuator bracket. (a) All Airplanes.
or Within 30 Months after the Original Issue date of the Requirements Bulletin 757- 27A0160 RB
(a) Accomplishment of this action terminates the repetitive Aileron Trim Actuator attachment lug detailed inspection and the Aileron Trim Actuator bearing rotation check specified in Boeing Alert Requirements Bulletin 757-27A0159 RB.
4. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document comply with the applicable regulations and are FAA approved, as well as European Union Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in this Requirements Bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
In addition, the Manager of the FAA Continued Operational Safety Branch approves accomplishment of the change defined in this bulletin as an alternative method of compliance to accomplishing the requirements of paragraph (g) of AD 2019-12-13. All provisions of AD 2019-12-13 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly.
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5. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION NOTE: 1. This is an Enhanced Required for Compliance document. There will be a separate Service Bulletin (SB) and a separate Requirements Bulletin (RB). If an RB is mandated by an Airworthiness Directive (AD), then all applicable requirements specified in the RB must be done. In the RB, the "Refer to the listed procedures..." column of the table(s) in the Work Instructions is for reference only. The procedures in that column are not required by the AD and are for guidance only. For the related SB, some locations are marked RC Start and RC End to identify the requirements that are restated from the RB. For the related SB, the areas between RC Start and RC End, including sub-steps and any figures identified between RC Start and RC End, must be done to comply with the AD. Therefore, an Alternative Method of Compliance (AMOC) is required for any deviations to steps between RC Start and RC End, including substeps and identified figures. For the related SB, the steps not between RC Start and RC End may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC; this is provided that the steps between RC Start and RC End, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. Figures not required for compliance are omitted from the RB.
2. This is an Enhanced Required for Compliance document. The Boeing processes used to create the Service Bulletin (SB) and the Requirements Bulletin (RB) ensure that the information between "RC Start" and "RC End" in the SB are identical to the information in the same sections (Compliance, Work Instructions...) of the RB which the SB refers to as the related document.
3. The compliance times for the actions in WORK INSTRUCTIONS are in Compliance.
4. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided.
5. 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 Values:
— Values for structural fasteners are given in 757 Structural Repair Manual, Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 757 Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).
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— Values for engine maintenance tasks are included in Chapter 70 of 757 Aircraft Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the applicable installation step.
6. 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.
7. 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.
8. 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.
9. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.
10. 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. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin.
B. WORK INSTRUCTIONS Actions Required for Compliance:
1. Requirements:
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: April 01, 2024 757-27A0160 RB 12 of 33 REQUIREMENTS BULLETIN 757-27A0160