# Boeing Alert Service Bulletin 757-54A0047: Revision 4 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2011-0724; AD 2012-26-04 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 757-54A0047](https://openairdocs.org/service-documents/boeing/757-54a0047.md) - Title as filed: U.S. DOT/FAA - Service Bulletin -757-54A0047-04 - Pages: 62 - PDF: https://openairdocs.org/files/sha256/99/bc/99bc62dc6f37c4a9c96e17149eb838f64ea86d82a810d6eb8ec0df7e6a8f4c39 - Page: https://openairdocs.org/service-documents/boeing/757-54a0047/file/99bc62dc6f37 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 757 Service Bulletin ALERT Number: 757-54A0047 Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. 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 the Boeing livery 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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 1 of 62 3.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 2 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 7 1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1 1. Airplanes ............................................ 1 1 2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 8 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 3 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 2 5 I. Electrical Load Data ......................................... 2 6 J. References .............................................. 2 6 1. Existing Data: ......................................... 2 6 2. Data supplied with this Service Bulletin: ........................... 2 6 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 6 K. Publications Affected ........................................ 2 6 L. Interchangeability and Intermixability of Parts ........................... 2 7 2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 2 9 C. Parts Necessary For Each Airplane ................................. 2 9 1. Kits/Parts: ........................................... 2 9 2. Parts and Materials Supplied by the Operator: ........................ 2 9 3. Parts Modified and Reidentified: ............................... 3 0 4. Parts Removed and Not Replaced: .............................. 3 0 D. Parts Necessary to Change Spares ................................. 3 0 E. Special Tooling - Price and Availability ............................... 3 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 0 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1 A. GENERAL INFORMATION ..................................... 3 1 B. WORK INSTRUCTIONS ....................................... 3 2 FIGURE 1: ACCESS FOR INSPECTION ................................. 3 5 FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE .............. 3 8 FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD . . . 40 FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE ............ 4 3 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE .......... 4 6 FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE ........ 4 8 FIGURE 7: THIS FIGURE HAS BEEN DELETED ............................. 5 1 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND ..................... 5 2 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE ..................... 5 4 FIGURE 10: SEAL COVER PLATES .................................... 5 6 FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS ....... 5 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 3 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 4 FIGURE 12: NACELLE/PYLONS - ALTERNATIVE ACCESS TO THE CRITICAL HORIZONTAL FLANGE FASTENERS .......................................... 6 0 FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS . . 61 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 4 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 5 Commercial Airplanes 757 Service Bulletin ALERT Revision Transmittal SheetNumber: 757-54A0047Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2 or Revision 3 of this service bulletin. On airplanes without conclusive records of previous inspections, do a one time open hole High Frequency Eddy Current (HFEC) inspection or ultrasonic inspection of the four critical fastener holes in the horizontal flange as given in this service bulletin. No airplanes ware added or removed from this service bulletin effectivity. REASON FOR REVISION This revision is sent to revise the compliance information and to give an alternative method of accessing the critical fasteners at the strut-to-diagonal brace fitting. It is also sent to add more instructions for inspecting the aft torque bulkhead. The following sections were changed: 1. More information is added to the Background and Reason sections. 2. Paragraph 1.D., Description - Affected maintenance zones are added. 3. Paragraph 1.E., Compliance - The compliance information is revised. 4. Paragraph 1.F., Approval - An Alternative Method of Compliance (AMOC) statement is added, and the Federal Aviation Administration (FAA) Airworthiness Directives (AD) reference is changed. 5. Paragraph 1.G., Manpower - Added a new manpower table and changed manpower information. 6. Paragraph 1.J.1., Existing Data - Service Related Problem (SRP), Nondestructive Test (NDT) and the FAA (AD) reference is changed. 7. Paragraph 1.K., Publications Affected - A Damage Tolerance Based Structural Inspection statement is added. 8. Paragraph 3.A., General Information - Added new standard Note 1 and Note 7. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 5 of 62 ### Page 6 9. Paragraph 3.B., Work Instructions - More inspection instructions are added to Part II and Part IV. 10. FIGURE 3 - A new view and more inspection instructions are added. 11. FIGURE 12 and FIGURE 13 are added. The data given in Information Notice 757-54A0047 R03 IN-01 is included in this revision. 757-54A0047 R03 IN-01 was sent to inform operators about the Federal Aviation Administration (FAA) approval of an Alternative Method of Compliance (AMOC) to paragraph (g) of Airworthiness Directive (AD) 2007-16-13. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. REVISION HISTORY November 13, 2003Original Issue: March 24, 2005Revision 1: January 31, 2007Revision 2: June 27, 2007Revision 3: June 24, 2010Revision 4: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 6 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 7 Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-54A0047Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting 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 None. BACKGROUND This service bulletin gives the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and to do an inspection and repair of the four critical fastener holes on the horizontal flange. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. Service History ReportStrutCyclesHoursDate One bolt sheared in horizontal flange. Four bolts loose in vertical flange. -10,28429,45112/93 Four bolts loose in vertical flange of both struts.No. 1 & 29,35825,76811/96 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. No. 1 & 2--06/98 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. No. 1 & 221,74955,78911/99 Sixteen bolts loose in horizontal flange.No. 1 & 220,16146,45901/01 Two bolts loose in vertical flange.No. 113,66249,01909/01 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 7 of 62 ### Page 8 Service History ReportStrutCyclesHoursDate Two bolt heads cracked.-14,63323,42301/02 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. No. 1 & 212,49316,60104/02 Migrated shim between bulkhead and vertical flange of fitting. No. 1 & 215,52243,82205/02 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. No. 215,90046,75806/02 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. No. 120,09049,80712/02 Two loose bolts in vertical flange.-22,11150,84104/03 Three loose bolts in vertical flange.No. 19,99130,07209/03 Migrated shims between bulkhead and vertical flange of fitting. No. 1 & 226,91460,71509/03 Three loose bolts in vertical flange.No. 215,00444,98510/03 Three loose bolts in vertical flange.No. 27,92212,36801/04 Four loose bolts in vertical flange.No. 17,59212,11902/04 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. No. 113,08344,42304/06 In addition, one operator found a strut torque bulkhead fitting with loose fasteners and cracks at the joint common to the strut diagonal brace fitting on two airplanes with the Strut Improvement Program (SIP) incorporated during production. One airplane had been inspected for loose fasteners in 2006 per service bulletin 75-54A0047 Revision 01 with no findings. Since that inspection, the airplane had accumulated less than 3000 flight cycles. The loose fasteners and cracks were found during an engine change while the area was exposed. Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130 are related to this service bulletin. ACTION Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 8 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 9 Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A borescope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection and repair of the four critical fastener holes on the horizontal flange. As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. EFFECTIVITY 757-200/-200CB and -200PF airplanes line numbers 1 thru 1048, powered by Rolls Royce engines. COMPLIANCE Refer to paragraph 1.E., Compliance for compliance information. Federal Aviation Administration (FAA) Airworthiness Directives (AD) 2004-12-07 and 2008-05-10, are related to this service bulletin. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin. MANPOWER Elapsed HoursTotal Task HoursAirplanes 22.0 (a)44.0 (a)All (a) Inspections only. Does not include time to make repairs if loose fasteners or cracks are found. MATERIAL INFORMATION Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 9 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 10 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT INSPECT FASTENERS IN HORIZONTAL FLANGE OF FITTING (16 LOCATIONS). FWD A-A INSPECT THE ACCESS DOOR CUTOUT FOR FWD ‹ CRACKING. INSPECT SHIM INSPECT FASTENERS INSTALLATION. IN VERTICAL FLANGE OF FITTING (4 LOCATIONS) . INSPECT THE BULKHEAD FOR CRACKING. W38926 Original Issue: November 13, 2003 Revision 4: June 24, 2010 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 62 ### Page 11 Commercial Airplanes 757 Service Bulletin ALERT Number: 757-54A0047 Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting 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 Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. DESCRIPTIONCONFIGURATIONGROUP 757-200/-200CB/-200PF airplanes line number 1 thru 735, powered by Rolls Royce engines. -1 Airplanes without SB 757-54-0035 incorporation.1 Airplanes with SB 757-54-0035 incorporation.2 757-200/-200PF airplanes line number 736 thru 1048, powered by Rolls Royce engines. -2 Airplane Models: 757-200, 757-200CB, 757-200PF GroupVariable Number 1NA002 - NA028 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 11 of 62 ### Page 12 GroupVariable Number 1NA191 - NA199 1NA201 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 1NA401 - NA408 1NA441 - NA447 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB201 - NB204 1NB221 - NB225 2NB226 - NB228 2NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 2NB571 2NB581 - NB583 1NC058 - NC061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 12 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 13 GroupVariable Number 2NC062 1NC936 - NC950 1NC971 - NC974 1ND001 - ND007 1ND011 - ND059 1ND111 - ND113 1ND161 - ND199 1ND201 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND317 2ND318 - ND322 2ND401 1ND891 1ND895 2NJ001 - NJ004 2NJ031 - NJ032 2NN001 - NN002 2NN051 - NN052 1NS601 - NS610 2NS611 - NS616 2NT001 - NT009 2NT201 - NT202 2NT231 - NT234 2NT237 - NT240 2NT242 2NT245 - NT248 2NT281 - NT289 2NT381 - NT386 2NT401 - NT409 2NT411 - NT412 2NT426 - NT427 2NT431 - NT432 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 13 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 14 GroupVariable Number 2NT436 - NT438 2NT446 2NT731 - NT769 2NT861 - NT862 2NT901 - NT916 2NT971 - NT985 2. Spares Affected None. B. Concurrent Requirements None. C. Reason This service bulletin gives the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and do an inspection and repair of the four critical fastener holes on the horizontal flange. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. Service History ReportStrutCyclesHoursDate One bolt sheared in horizontal flange. Four bolts loose in vertical flange. -10,28429,45112/93 Four bolts loose in vertical flange of both struts.No. 1 & 29,35825,76811/96 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. No. 1 & 2--06/98 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. No. 1 & 221,74955,78911/99 Sixteen bolts loose in horizontal flange.No. 1 & 220,16146,45901/01 Two bolts loose in vertical flange.No. 113,66249,01909/01 Two bolt heads cracked.-14,63323,42301/02 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. No. 1 & 212,49316,60104/02 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 14 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 15 Service History ReportStrutCyclesHoursDate Migrated shim between bulkhead and vertical flange of fitting. No. 1 & 215,52243,82205/02 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. No. 215,90046,75806/02 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. No. 120,09049,80712/02 Two loose bolts in vertical flange.-22,11150,84104/03 Three loose bolts in vertical flange.No. 19,99130,07209/03 Migrated shims between bulkhead and vertical flange of fitting. No. 1 & 226,91460,71509/03 Three loose bolts in vertical flange.No. 215,00444,98510/03 Three loose bolts in vertical flange.No. 27,92212,36801/04 Four loose bolts in vertical flange.No. 17,59212,11902/04 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. No. 11308344,42304/06 In addition, one operator found a strut torque bulkhead fitting with loose fasteners and cracks at the joint common to the strut diagonal brace fitting on two airplanes with the Strut Improvement Program (SIP) incorporated during production. One airplane had been inspected for loose fasteners in 2006 per service bulletin 75-54A0047 Revision 01 with no findings. Since that inspection, the airplane had accumulated less than 3000 flight cycles. The loose fasteners and cracks were found during an engine change while the area was exposed. Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130 are related to this service bulletin. Revision 01 is sent to give migration limits for the shims in the diagonal brace load path. The inspection given in the initial release of this service bulletin made it necessary to repair a loose shim before an airplane could be put back in service. With these new migration limits, an airplane can be put back in service with a migrated shim if the inspection finds that it is in the permitted limits. The bulkhead crack repair as given in the initial release has been deleted. If cracks are found, they will be reviewed on a case-by-case basis. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 15 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 16 A new repair is added for the shims in the diagonal brace load path. There are now 4 repairs and 1 repair that has been deleted. For identification, they are referred to as Interim Repairs I, II, III, IV and V. Interim Repair I is almost the same as the one given in the initial release and replaces the two shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Interim Repairs II and III are the same as those given in the initial release. Interim Repair II installs oversize fasteners in the vertical flange of the fitting, and Interim Repair III installs oversize fasteners in the horizontal flange of the fitting. Interim Repair IV is the same bulkhead crack repair given in the initial release and has been deleted. Interim Repair V is new and gives the instructions to cut and remove the exposed plies of the shims as a repair for shim migration of 0.50, or less These sections of the service bulletin were changed with revision 01: — Compliance - Decreased repeat inspection thresholds to address additional in service reports where loose fasteners were found on airplanes with less than 12,000 flight cycles. Also, added compliance information for airplanes line numbers 736 thru 1048 to address additional reports of loose fasteners on airplanes with the latest configuration. — Reason and Description - Add six reports to the service history table. — Effectivity - Added 757-200/-200CB and 200PF airplanes with RB211 engines, Line numbers 736 thru 1048. — Work Instructions, Part I, Step 2 - Add shim migration limits to show the necessary work if shim migration is found during the inspection. — Figure 2 - Add instructions to measure and record the distance a shim has moved from the installed position, if the shim shows signs of movement during the inspection. — Figure 4 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair I. — Make corrections to the illustration and instructions to show the replacement of two shims. One on the left flange of the fitting and one on the right flange of the fitting. — Add a step is to apply sealant around the outer edge of the shim. — Add a step to increase the hole diameter after shim is in place. — Removed repair instructions for cracks. — Figure 5 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair II. — Removed repair instructions for cracks. — Figure 6 - Make changes to the figure as follows: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 16 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 17 — Change the figure title to show that it is Interim Repair III. — Removed repair instructions for cracks. — Figure 7 - Deleted. — Figure 9 - Add this new figure to give the instructions for Interim Repair V. — Figure 10 - Added this new figure to give instructions for sealing removed parts. Revision 02 is sent to give revised inspection schedule and repair requirements. Instructions are added to inspect for cracking at four critical horizontal flange fasteners holes if one or more loose fasteners is found. Also, do a one-time inspection and repair of the four critical faster holes on the horizontal flange. Figure 11, Interim Repair VI is new and gives location and instruction for the four critical horizontal flange fastener locations. These sections of the service bulletin are changed with revision 02: — Summary - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Action section. Added one report to the Service History in Background section. — Planning - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Description section. Added one report to the Service History in the Reason section. Added Manpower hours for Part IV inspection. — Accomplishment Instructions - Revised access instructions. Added inspections, critical fastener identification, locations, compliance requirement Notes and Part IV inspection. — Figure 6 - Added HFEC inspections to aluminum bulkhead and steel web with NDT references. — Figure 11 - Added, for critical horizontal flange fastener locations, HFEC inspections to aluminum bulkhead and steel web with NDT references. — All references to AD 2004-12-07 are changed to AD 2005-12-04. Revision 03 is sent to give revised inspection compliance times and replace the phrase "one time inspection" with "inspection" when referring to the Part IV inspection of the critical fastener holes on the horizontal flange . These sections of the service bulletin are changed with revision 03: — Summary - Compliance information is deleted from the Compliance section. — Paragraph 1.E., Compliance - Compliance times are revised and presented in a tabular format. — Summary, Planning Information, Work Instructions: replaced the words "one time inspection" with "inspection". Revision 04 is sent to revise the compliance information and to give an alternative method of accessing the critical fasteners at the strut-to-diagonal brace fitting. It is also sent to add more instructions for inspecting the aft torque bulkhead. The following sections were changed: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 17 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 18 1. More information is added to the Background and Reason sections. 2. Paragraph 1.D., Description - Affected maintenance zones are added. 3. Paragraph 1.E., Compliance - The compliance information is revised. 4. Paragraph 1.F., Approval - An Alternative Method of Compliance (AMOC) statement is added, and the Federal Aviation Administration (FAA) Airworthiness Directives (AD) reference is changed. 5. Paragraph 1.G., Manpower - Added a new manpower table and changed manpower information. 6. Paragraph 1.J.1., Existing Data - Service Related Problem (SRP), Nondestructive Test (NDT) and the FAA (AD) reference is changed. 7. Paragraph 1.K., Publications Affected - A Damage Tolerance Based Structural Inspection statement is added. 8. Paragraph 3.A., General Information - Added new standard Note 1 and Note 7. 9. Paragraph 3.B., Work Instructions - More inspection instructions are added to Part II and Part IV. 10. FIGURE 3 - A new view and more inspection instructions are added. 11. FIGURE 12 and FIGURE 13 are added. D. Description Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs. Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A borescope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection of the four critical fastener holes on the horizontal flange. As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. Revision 01 - More work is necessary on airplanes changed as shown in the initial release of this service bulletin. Repeat inspections are required for airplanes that have incorporated Service Bulletin 757-54-0035. Revision 02 - More work is necessary on airplanes changed as shown in the initial release and revision 01 of this service bulletin. Instructions are added to do a one-time inspection and repair of the four critical fastener holes on the horizontal flange. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 18 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 19 Revision 03 - No more work is necessary on airplanes changed as shown in the Original issue, Revision 1, or Revision 2 of this service bulletin, however the conditions and the compliance time for doing the inspection of the four critical fasteners on the horizontal flange have changed. Revision 04 - More work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2 or Revision 3 of this service bulletin. On airplanes without conclusive records of previous inspections, do a one time open hole High Frequency Eddy Current (HFEC) inspection or ultrasonic inspection of the four critical fastener holes in the horizontal flange as given in this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1: Affected Maintenance Zones ZoneModel 433, 443757-200, 757-200CB, 757- 200PF Group 2: Affected Maintenance Zones ZoneModel 433, 443757-200, 757-200PF BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 19 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 20 E. Compliance Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque Bulkhead . Repeat IntervalCompliance Time (Whichever Occurs later)ActionCondition --Within 90 days of the date of Revision 4 of this service bulletin. Inspect the four critical fasteners in the horizon- tal flange in accordance with Part IV unless al- ready accomplished in accordance with Revi- sion 2 or Revision 3 of this service bulletin. All airplane struts that had findings on the horizontal or vertical fasten- ers or the shims which lead to a rejec- tion while do- ing Revision 1 or the original release of this service bul- letin, and all airplanes that had equivalent findings prior to the original re- lease of this service bul- letin. (a) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 20 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 21 Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque Bulkhead . Repeat IntervalCompliance Time (Whichever Occurs later)ActionCondition 1800 flight cycles.1800 flight cycles from the last inspec- tion for loose fasten- ers and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin. Inspect the shim instal- lation in accordance with Part I, Step 3. In- spect all four fasteners in the vertical flange in accordance with Part I, Step 5. Inspect the fas- teners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection of the bulkhead in accor- dance with Part II, Step 3. Group 1 Config- uration 1 OR 3000 flight cycles.1800 flight cycles from the last inspec- tion for loose fasten- ers and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin. Inspect the shim instal- lation in accordance with Part I, Step 3. In- spect all four fasteners in the vertical flange in accordance with Part I, Step 5. Inspect the fas- teners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection and an ultrasonic in- spection of the bulk- head in accordance with Part II, Step 3. 3000 flight cycles.3,000 flight cycles from the last inspec- tion for loose fasten- ers and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin. Inspect the shim instal- lation in accordance with Part I, Step 3. In- spect all four fasteners in the vertical flange in accordance with Part I, Step 5. Inspect the fas- teners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection of the bulkhead in accor- dance with Part II, Step 3. Group 1 Config- uration 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 21 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 22 Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque Bulkhead . Repeat IntervalCompliance Time (Whichever Occurs later)ActionCondition 3000 flight cycles.3,000 flight cycles from the last inspec- tion for loose fasten- ers and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin. Inspect the shim instal- lation in accordance with Part I, step 3. In- spect all four fasteners in the vertical flange in accordance with Part I, Step 5. Inspect the fas- teners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection of the bulkhead in accor- dance with Part II, Step 3. Group 2 --Within 90 days of the date of Revision 04 of this service bulletin. Do an open hole High Frequency Eddy Cur- rent (HFEC) inspection at the critical fastener location in accordance with Work Instructions Part IV, Step 2.a. Airplanes with- out conclusive records of pre- vious inspec- tion. OR --Within 90 days of the date of Revision 04 of this service bulletin. Do an ultrasonic inspec- tion of the critical fasten- er holes in the horizon- tal flange in accordance with Work Instructions Part IV, Step 2.b. --Before further flight after completing all inspections. Repair in accordance with Part I, Step 4.a. Total cumula- tive shim movement equal to or less than 0.50 inch. --Before further flight after completing all inspections. Repair in accordance with Part I, Step.4.b. Total cumula- tive shim movement more than 0.50 inch. --Before further flight after completing all inspections. Repair in accordance with Part I, Step 5.a.(2) AND Inspect and repair in accordance with Part I, Step 5.a.(3) Rejected fas- tener in the vertical flange. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 22 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 23 Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque Bulkhead . Repeat IntervalCompliance Time (Whichever Occurs later)ActionCondition --Before further flight after completing all inspections. Repair in accordance with Part II, Step 2.a.(2) AND Inspect and repair in accordance with Part II, Step 2.a.(3) Rejected fas- tener in the horizontal flange. --Before further flight.Contact Boeing for re- pair instructions and do the repair. Any crack found in the bulkhead flange or the vertical stiffen- ers or the ac- cess door cutout edge. --Before further flight.Contact Boeing for re- pair instructions and do the repair. Any crack found in any critical fastener hole. (a) Findings on Group 1, Configuration 2 airplane struts prior to service bulletin 757-54-0035 incorporation are excluded from this condition. Federal Aviation Administration (FAA) Airworthiness Directives (AD) 2004-12-07 and 2008-05-10 are related to this service bulletin. 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 changes. The Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the inspection methods and fastener replacements specified in Table 1 under paragraph 1.E., "Compliance," of Service Bulletin 757-54A0047, Revision 4, as an AMOC to the inspection methods and modifications specified in SB 757-54-0035, Revision 1, dated April 15, 1999; or Revision 2, dated June 13, 2002, as required by paragraphs (b) and (d) of AD 2004-12-07. All provisions of AD 2004-12-07, including the compliance times, that are not specifically referenced in the preceding sentence remain fully applicable and must be complied with. In addition, the manager of the SACO approves the inspection methods, and modifications specified in Table 1 under paragraph 1.E., "Compliance," of Service Bulletin 757-54A0047, Revision 4, including Part IV, Option 2 - Ultrasonic Inspection, as an AMOC to the inspections and modifications in accordance with SB 757-54A0047 Revision 3, dated June 27, 2007 specified by paragraphs (g) and (l) of AD 2008-05-10. All provisions of AD 2008-05-10, including the compliance times, that are not specifically referenced in the preceding sentence remain fully applicable and must be complied with. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 23 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 24 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 inspection and repair for each strut. 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 examine the work. — Time to cure the materials. — Time to make the parts. — Time to find the tools. Part I - Inspection - Fasteners and Shim - Vertical Flange Elapsed HoursTask-HoursNumber of Per- sons Task 6.012.02Open Access 1.02.02Inspect ---Repair (a) 7.014.02Close Access 14.028.0TOTAL FOR EACH STRUT (a) An estimate for the task-hours necessary to do the repair is not given. Part II - Inspection - Fasteners - Horizontal Flange Elapsed HoursTask-HoursNumber of Per- sons Task 1.02.02Open Access 6.012.02Inspect ---Repair (a) 1.02.02Close Access 8.016.0TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) More time can be necessary for the removal of the engine, diagonal brace, and precooler. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 24 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 25 Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Engine Removed) Elapsed HoursTask-HoursNumber of Per- sons Task 2.510.04Open Access (En- gine Removed) 1.02.02.0Inspect Option 1 2.04.02.0Inspect Option 2 ---Repair (a) 3.012.04Close Access (En- gine Removed) 3.06.03Trim and Check En- gine 8.5 (b)28.0 (b)TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) Total does not include inspection estimate. Add inspection estimate for option used to total shown to arrive at revised total. Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Common Nozzle Exhaust Removed) Elapsed HoursTask-HoursNumber of Per- sons Task 3.57.02Open Access (Common Nozzle Exhaust Removed) 1.02.02.0Inspect Option 1 2.04.02.0Inspect Option 2 ---Repair (a) 3.57.02Close Access (Common Nozzle Exhaust Removed) 7.0 (b)14.0 (b)TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) Total does not include inspection estimate. Add inspection estimate for option used to total shown to arrive at revised total. H. Weight and Balance Changes None. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 25 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 26 I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130. b. 757 Aircraft Maintenance Manual (AMM) 54-51-02, 54-53-01, 54-53-02, 71-00-02, 71- 00-02, 71-11-07, 78-11-04 and 78-31-00. c. 757 Structural Repair Manual (SRM) Chapter 51. d. 757 Non-Destructive Testing (NDT) Manual Part 4, 54-50-02, Part 6, 51-00-14, Part 6, 51-00-16 and Part 6, 51-00-17. e. Standard Overhaul Practices Manual (SOPM) 20-43-03, 20-50-19 f. Boeing Service Bulletin 757-54-0035, 'NACELLES/PYLONS Rolls Royce RB211 Powered Airplanes - Nacelle Strut and Wing Structure Improvement'. g. FAA Airworthiness Directives AD 2004-12-07 and 2008-05-10. h. Boeing Parts Standards Document D-590. i. Boeing Drawing 65-88700. 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Spar Installation - Lower Nacelle Strut311N5042 Torque Bulkhead Installation311N5045 Seal Application - Nacelle Strut311N5062 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 26 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 27 None. 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 affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 27 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 28 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 28 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT BLANK PAGE ### Page 29 2. MATERIAL INFORMATION A. Material - Price and Availability None. B. Industry Support Information Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: NotesNameQTYPart Number / Speci- fication (a)Chemical Conversion Treatment 4 oz.Type 2, Class A (c)Primer8 oz.BMS 10-11, Type 1 (c)Sealant1 pt.BMS 5-63 (d)Primer8 oz.DAPCO 1-400 (e)Primer8 oz.DC 1200 -Sealant1 pt.DC 93-006 -Leveling Compound1 qt.DC 3110 (f)--RTV 560 (f)--RTV 3 (f)--RTV 60 2.50 x 2.50 x 0.080 (g)CRES Plate-301 SS 1/2 Hard (h)Bolt-BACB30* -Collar-BACC30* (i) BACS40R015C027F optionalShim, Laminated2BACS40R015B027F (j)Filler, Radius2BACF3H10JT010HG (a) Can be necessary if you make the radius filler shown in Figure 6. Refer to SOPM 20- 43-03 for data about the Chemical Conversion Treatment. (b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) Alternative to DC 93-006. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 29 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 30 NotesNameQTYPart Number / Speci- fication (d) Primer is necessary if BMS 5-63 is applied over rubber/silicon substrates. (e) Use with DC 93-006 and DC 3110. (f) Alternative to DC 3110. (g) Can be necessary if a crack is found in the aft bulkhead that cannot be repaired with the installation of an oversize fastener. (h) See the Paragraph 3.B., Work Instructions, Figures 4, 5, 6, and 7, for the oversize bolt/collars that can be necessary if the inspections find a loose shim and/or damaged fasteners. (i) Can be necessary if loose shims are found during the inspection. (j) Can be necessary if oversize fasteners are installed as shown in Figure 6. Instructions are also given to make the filler from 0.063 thick 2024-T3, T4, T42, or 7075-T6 Bare Aluminum Sheet. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin A borescope, or other inspection aids, can be necessary to do the inspection of the fasteners in the horizontal flange of the strut-to-diagonal brace fitting. Also, 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 30 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 31 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. The instructions in Paragraph 3.B., Work Instructions, and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions in the specified manual sections. 4. 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 are in 757 SRM, Chapter 51. — Torque limits to tighten nuts and bolts are in 757 SRM, Chapter 51. 5. For approved fastener and process material substitutions, refer to 757 SRM, Chapter 51, Alternate fasteners are in 757 SRM Chapter 51 and Boeing Drawing 65-88700. 6. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 7. Inspections, used in the service bulletin, are defined as follows: Detailed Inspection: An intensive visual examination of a specific structural area, system, 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 by the inspector. Inspection aids such as mirrors, magnifying lenses, etc. may be used. Surface cleaning and elaborate access procedures may be required. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 31 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 32 Non-Destructive Testing (NDT) inspections are used to examine all subsurface damage and most small cracks. NDT is also used in areas where a visual inspection is not sufficient to find the dimensions of damage. 8. These work instructions refer to procedures included on 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. B. WORK INSTRUCTIONS PART I - INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE - ALL AIRPLANES 1. Refer to 757 AMM 78-31-00 and do the Thrust Reverser Deactivation for Ground Maintenance. WARNING: DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENT THE OPERATION OF THE THRUST REVERSER. THE ACCIDENTAL OPERATION OF THE THRUST REVERSER CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 2. Get access for the inspection of the fasteners and shim in the vertical flange in accordance with FIGURE 1. 3. Do the inspection of the shim installation between the vertical flange and bulkhead in accordance with FIGURE 2: a. For Group 1 and Group 2 airplanes: If the shim installation shows signs of movement and is rejected: Continue with Step 4, below. NOTE: All Part I and Part II inspections can be accomplished before repairs are done. b. If the shim installation is satisfactory: Continue with the inspection of the four fasteners in the vertical flange in accordance with step 5, below. 4. Do repairs to the shim installation between the vertical flange and the bulkhead as given below: a. If the shim(s) Total cumulative movement is 0.50 or less: Do Interim Repair V in accordance with FIGURE 9. Record the amount of total shim movement and save for future inspections. b. If the shim(s) Total cumulative movement is more than 0.50: Remove the engine. Refer to 757 AMM 71-00-02 as an accepted procedure and do Interim Repair I in accordance with FIGURE 4. Also, do the inspection and repair of the four critical fastener holes on the horizontal flange in accordance with Part IV. 5. Do the inspection of the four fasteners in the vertical flange in accordance with FIGURE 2: a. If one or more of the four fasteners are rejected: (1) Remove the engine. Refer to 757 AMM 71-00-02 as an accepted procedure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 32 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 33 NOTE: All Part I and Part II inspections can be accomplished before repairs are done. (2) At the locations where fasteners are rejected in the vertical flange: Remove the fastener, increase the hole diameter and install oversize fasteners as shown for Interim Repair II in accordance with FIGURE 5. (3) Do the inspection and repair of the four critical fastener holes on the horizontal flange in accordance with Part IV. PART II - INSPECTION - FASTENERS - HORIZONTAL FLANGE - ALL AIRPLANES 1. Get more access, and removal of the leveling compound, for the inspection of the fasteners in the horizontal flange in accordance with FIGURE 1. 2. Do the inspection of the sixteen fasteners that hold the strut to the horizontal flange of the strut-to-diagonal brace fitting in accordance with FIGURE 3: a. If one or more of the sixteen fasteners are rejected: (1) Remove the engine. Refer to 757 AMM 71-00-02 as an accepted procedure. NOTE: All Part I and Part II inspections can be accomplished before repairs are done. (2) Remove the rejected fastener, inspect the fastener hole for cracking, increase the hole diameters and install oversize fasteners as shown for Interim Repair III in accordance with FIGURE 6. (3) Do the inspection and repair of the four critical horizontal flange fastener holes on the horizontal flange in accordance with Part IV. 3. Inspect the bulkhead in the area around the access door cutout and around the critical fasteners in the horizontal flange in accordance with FIGURE 3, and do an optional ultrasonic inspection of the bulkhead around the fasteners in the horizontal flange in accordance with FIGURE 13. a. If any crack is found in the bulkhead or the access door cutout edge, contact Boeing for repair instructions and do the repair. b. If no crack is found in the bulkhead or the access door cutout edge, do repeat inspections in accordance with Paragraph 1.E., Compliance. PART III - CLOSE ACCESS - ALL AIRPLANES 1. Apply new sealant in accordance with FIGURE 8. 2. Apply the leveling compound in accordance with FIGURE 8. 3. Install and seal the covers in accordance with FIGURE 10. 4. Install the remaining components that were removed to get access for the inspection. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 33 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 34 5. If necessary, install the engine. Refer to 757 AMM 71-00-02 as an accepted procedure. 6. Put the airplane back to a serviceable condition. 7. Schedule the airplane for the repeat inspection at the time in accordance with Paragraph 1.E., Compliance. PART IV - INSPECTION - CRITICAL FASTENER HOLES ON THE HORIZONTAL FLANGE 1. If not already done get access in accordance with FIGURE 1. 2. Inspect the critical fastener holes in the horizontal flange using one of the options that follow: a. Option 1 - High Frequency Eddy Current (HFEC) inspection. (1) Get additional access by removing the engine, if not already done. Refer to 757 AMM 71- 00-02 as an accepted procedure, or remove the common exhaust in accordance with FIGURE 12. (2) Remove the fasteners and do an HFEC inspection in accordance with FIGURE 11. (a) If any crack is found, contact Boeing for repair instructions and do the repair. (3) At locations where the critical fastener hole was rejected, increase the hole size and install an oversize fastener in accordance with FIGURE 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener in accordance with FIGURE 11. (4) At locations where the fastener hole was not rejected, install the same size fastener as was removed in accordance with FIGURE 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener in accordance with FIGURE 11. b. Option 2 - Ultrasonic Inspection: (1) Do an ultrasonic inspection in accordance with FIGURE 13. (a) If any crack is found, contact Boeing for repair instructions and repair. (b) If no crack is found, do the repeat inspections in accordance with Paragraph 1.E., Compliance. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4: June 24, 2010 34 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 35 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT SEE (A FWD LEFT SHOWN RIGHT ALMOST THE SAME (3) FWD • SEE LEFT WING/STRUT SHOWN W39396 RIGHT WING/STRUT THE SAME FIGURE 1: ACCESS FOR INSPECTION (SHEET 1 OF 3) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 35 of 62 ### Page 36 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT LEFT SHOWN RIGHT OPPOSITE EXISTING COMPOUND - A-A W39439 FIGURE 1: ACCESS FOR INSPECTION (SHEET 2 OF 3) Original Issue: November 13, 2003 Revision 4 June 24, 2010 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 62 ### Page 37 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut. NOTESQTYREFERENCESNAMETASKSTEP -1Refer to 757 AMM 54-53-02. Access DoorOpen or Remove1 -1-ClampLoosen2 -1-Boot SealMove3 -1-CoverRemove4 -1Refer to 757 AMM 54-53-01. Cover PlateRemove5 Remove the seal between the strut and the common nozzle fairing. 1Refer to 757 AMM 71-11-07. SealRemove6 As necessary, remove the level- ing compound from the area around the fasteners. --Leveling Com- pound Remove7 FIGURE 1: ACCESS FOR INSPECTION (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 37 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 38 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT FASTENER (4 LOCATIONS) FWD< 12) SHIM SHIM SHIM SHOWN VERTICAL IN MIGRATED VERTICAL MEASUREMENT POSITION MEASUREMENT HORIZONTAL (2) MEASUREMENT ® MASUREMENT FITTING W39458 A-A FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE (SHEET 1 OF 2) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 38 of 62 ### Page 39 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTESPROCEDURENAMETASKSTEP (a)Detailed InspectionShim Installation (left shim)Inspect1 (b)-Shim Migration (left shim)Measure/Record2 (a)Detailed InspectionShim Installation (right shim)Inspect3 (b)-Shim Migration (right shim)Measure/Record4 (c) Four locationsDetailed InspectionFastenerInspect5 (a) Look for signs of damaged sealant around the outer edge of the shim. Look for signs that show movement of the shim. Reject a shim that shows signs of movement. (b) Measure and record the horizontal movement and the vertical movement of the shim from the installed position. Add the movement in each direction together to obtain the total movement of the shim at this inspection. This movement must be added to all previous measurements to obtain total cumulative movement of the shim(s). This data is used during the repeat inspection and to make decisions about repairs. Data necessary for the repeat inspection and to make decisions about repairs are: (i) The shims have not moved from the installed position. (ii) The shim total cumulative movement is 0.50, or less. (iii)The shim total cumulative movement is more than 0.50. (c) Look at the two sides of the fastener installation for signs of damaged sealant. Remove the sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar. FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 39 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 40 FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD (SHEET 1 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 40 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 41 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT TORQUE BULKHEAD FWD VIEW LOOKING AFT 1856468 FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD (SHEET 2 OF 3) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 62 ### Page 42 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. NOTESPROCEDURENAMETASKSTEP (a)(b)Detailed InspectionFastenerInspect1 Eight locations. (a)(b)Detailed InspectionFastenerInspect2 Eight locations. (c)Detailed InspectionAccess Door Cutout Inspect3 (d)Detailed InspectionBulkheadInspect4 (a) Use a borescope, or other inspection aids if necessary, to view the lower surface of the fasteners instal- lation. (b) Look at the two sides of the fastener installation for signs of damaged paint and/or sealant. Remove the paint and/or sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar. (c) Do a detailed inspection of the edge of the access door cutout for cracking at the forward and aft side of the cutout. (d) Do a detailed inspection of the bulkhead for cracking in the area shown. FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 42 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 43 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT FWDS FITTING D350 450 4 LOCATIONS A-A W40524 FIGURE 4: INTERIM REPAIR T- SHIM REPLACEMENT - VERTICAL FLANGE (SHEET 1 OF 3) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 43 of 62 ### Page 44 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for the replacement of one shim. NOTESQTYPART NUMBERNAMETASKSTEP (left bolts and/or right bolts).2-FastenerRemove1 (left shim and/or right shim).1-ShimRemove2 (a)2-Fastener HoleInspect3 --ClearanceMeasure4 (b) BACS40R015C027F is option- al. (c) 1BACS40R015B027FShimAdjust Drill holes in shim to agree with hole diameters in fitting. 2-HolesDrill --ShimClean/Deburr To mating surfaces.-DC93-006SealantApply --ShimInstall Increase diameter by 0.01562-HolesReam5 See Code A1 and A2.2-FastenerInstall6 Do an eddy current inspection of the holes through the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT Part 6, 51-00-16. (a) If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. Remove laminations to adjust the shim thickness. Remove all sharp edges. The maximum clearance permitted with the shim in position is 0.005. (b) Alternative: Make a solid shim from 2024-T3, or 2024-T4, -T81, T861, or 7075-T6. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 for data about the chemical conversion treatment. (c) The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes. NOTESHOLE DIAPART NUMBERNAMECODE Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4526 - 0.4536BACB30NX14K10XBoltA1 -BACC30BH14SCollar FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE (SHEET 2 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 44 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 45 NOTESHOLE DIAPART NUMBERNAMECODE Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4682 - 0.4692BACB30NX14K10YBoltA2 -BACC30AC14SCollar FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 45 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 46 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT FWD S FITTING 3 45o 4 LOCATIONS A-A W40549 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE (SHEET 1 OF 2) Original Issue: November 13, 2003 Revision 4 June 24, 2010 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 62 ### Page 47 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for strut. NOTESQTYPART NUMBERNAMETASKSTEP ---FastenerRemove1 (a)--Fastener HoleInspect2 See Codes A1 and A2.--FastenerInstall3 Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT Part 6, 51-00-16. (a) If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes. NOTESHOLE DIAPART NUMBERNAMECODE Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4526 - 0.4536BACB30NX14K10XBoltA1 -BACC30BH14SCollar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4682 - 0.4692BACB30NX14K10YBoltA2 -BACC30AC14SCollar FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 47 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 48 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT 1.00 1.00 0.063 0.35 RADIUS OR LARGER FADE RADIUS FILLER FITTING 1 1118 LOCATIONS SEE ·$ FWD 6 LOCATIONS W40801 A—A FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE (SHEET 1 OF 3) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 48 of 62 ### Page 49 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut. NOTESQTYPART NUMBERNAMETASKSTEP ---FastenerRemove1 (a)--Fastener HoleInspect See Codes B1 and B2--FastenerInstall ---FastenerRemove2 (a)--Fastener HoleInspect See Codes C1 and C2--FastenerInstall ---FastenerRemove3 (a)--Fastener HoleInspect (b)--Radius FillerMake/Install See Codes D1 and D2--FastenerInstall Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT, Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, in accordance with 757 NDT, Part 6, 51-00-17: (a) If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions. If necessary, make and install a radius filler below the seal retainer at these fastener locations. Install Radius Filler BACF3H10JT010HG, or make the filler from 0.063 thick 2024-T3, -T4, -T42, or 7075-T6 Bare Aluminum Sheet as shown. Apply a Chemical Conversion Treatment, Type 2, Class A, and one layer of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 for data about the chemical conversion treatment. Install the filler with Sealant BMS 5-63 or Dow Corning 93-006. (b) The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes. NOTESHOLE DIAPART NUMBERNAMECODE Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911BACB30YK12K11XBoltB1 -BACC30CP12CCollar FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE (SHEET 2 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 49 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 50 NOTESHOLE DIAPART NUMBERNAMECODE Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067BACB30YK12K11YBoltB2 -BACC30CP12CYCollar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911BACB30MC12A6UBoltC1 -BACC30BH12SCollar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067BACB30MD12A6UBoltC2 -BACC30AC12SCollar (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911BACB30FP12A11UBoltD1 -BACC30AB12SYCollar (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067BACB30KK12A11UBoltD2 -BACC30AC12SCollar (a) If the installation of the radius filler is necessary, fasteners with longer grip lengths will also be necessary. FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE (SHEET 3 OF 3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 50 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 51 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT THIS FIGURE IS DELETED. 1328539 FIGURE 7: THIS FIGURE HAS BEEN DELETED (SHEET 1 OF 1) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 51 of 62 ### Page 52 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT SEE Q FNDE EXAMPLE-FASTENER LOCATIONS EXISTING COMPOUND - A-A W42540 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND (SHEET 1 OF 2) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 52 of 62 ### Page 53 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut. NOTESQTYPART NUMBERNAMETASKSTEP (a) (b) If the shim was replaced during the repair procedures, apply primer and a fillet seal around the outer edge of the shim/fitting flange. -Dow Corning 1200PrimerApply1 Dow Corning 93-006Sealant (a) (b) Apply to all locations where sealant was removed for the inspections and/or fastener replacement. -Dow Corning 1200PrimerApply2 -Dow Corning 93-006Sealant (c) (d)-Dow Corning 1200PrimerApply3 Optional compound is RTV560, RTV3 or RTV60. -Dow Corning 3110Leveling Compound (a) Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Primer DAPCO 1-400 and Sealant BMS 5-63, Type II is optional. Before Sealant BMS 5-63 is applied let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours. (c) Before the Dow Corning 3110 compound is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (d) You can mix solvent BMS 3-2, Type II, with the leveling compound to make it more liquid. The maximum quantity of solvent permitted in the mixture is 20 percent when measured by weight. FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 53 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 54 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP CAUTION: DO NOT INSTALL A NEW COLLAR OR TRY TO TIGHTEN EXISTING COLLAR IN AN AT- TEMPT TO TIGHTEN THE JOINT BETWEEN THE FITTING AND BULKHEAD AS STRUCTURAL DAMAGE MAY OCCUR. ---Exposed plies (left shim)Cut1 --BMS 10-11, Type 1PrimerApply2 (a)-DAPCO 1-400PrimerApply3 (b) Seal edges-BMS 5-63SealantApply4 ---Exposed plies (right shim)Cut5 --BMS 10-11, Type 1PrimerApply6 (a)DAPCO 1-400PrimerApply7 (b) Seal edges-BMS 5-63, Type IISealantApply8 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE (SHEET 1 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 54 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 55 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (a) Dow Corning 93-006 sealant and Dow Corning 1200 primer are optional for this application. Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Before Sealant BMS 5-63 is applied let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours. FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 55 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 56 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT SEE A FWD LEFT SHOWN RIGHT ALMOST THE SAME FWDS LEFT WING/STRUT SHOWN RIGHT WING/STRUT THE SAME FIGURE 10: SEAL COVER PLATES (SHEET 1 OF 2) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 56 of 62 ### Page 57 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut NOTESREFERENCEQTYNAMETASKSTEP --1CoverInstall1 (a)Refer to SOPM 20-50-19.--Primer DC 1200 Sealant DC93-006 Apply2 -Refer to 757 AMM 54-53- 01. 1Cover PlateInstall3 (b)-1Boot SealMove4 Tighten Clamp-1ClampAdjust5 (a) Apply Intermediate liquid control fillet seal around entire periphery of the cover. Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Move the Boot Seal back to the original position as necessary. FIGURE 10: SEAL COVER PLATES (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 57 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 58 (OCR) BOEING SERVICE BULLETIN 757-54A0047 ALERT ALERT FADE FITTING B14 LOCATIONS FWD 1335626 A—A FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS (SHEET 1 OF 2) Original Issue: November 13, 2003 Revision 4 June 24, 2010 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 58 of 62 ### Page 59 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut. MORE DATAQTYPART NUMBERNAMETASKSTEP ---FastenerRemove1 (a) (b)4-Fastener HoleInspect2 Refer to Codes B0, B1 and B2--FastenerInstall3 (a) Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT, Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accor- dance with 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, in accordance with 757 NDT, Part 6, 51-00-17. (b) Measure the hole diameter. If the hole is true and round, and the diameter is within the limits allowed for installation of the same size fastener, do not increase the hole size. Otherwise, increase the hole size to remove damage The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes. NOTESHOLE DIAPART NUMBERNAMECODE Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3745 - 0.3755BACB30YK12K11BoltB0 -BACC30CP12CCollar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911BACB30YK12K11XBoltB1 -BACC30CP12CCollar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067BACB30YK12K11YBoltB2 -BACC30CP12CYCollar FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 59 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT ### Page 60 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut. MORE DATAQTYPART NUMBERNAMETASKSTEP Refer to 757 AMM 78-11-04 as an accepted procedure. 1-Common Nozzle Exhaust Remove1 (a)1-(Diagonal Brace) Load Release2 (a) Remove the load from the diagonal brace. Refer to 757 AMM 54-51-02 as an accepted procedure. FIGURE 12: NACELLE/PYLONS - ALTERNATIVE ACCESS TO THE CRITICAL HORIZONTAL FLANGE FASTENERS (SHEET 1 OF 1) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047Revision 4 June 24, 2010 60 of 62 BOEING SERVICE BULLETIN 757-54A0047 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/757-54a0047/file/99bc62dc6f37.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.