Boeing ASB 757-54A0047: Revision 3, text

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ALERT ALERT Commercial Airplane Group 757

ALERTALERT Service Bulletin Number: 757-54A0047 Date: November 13, 2003 Revision 3: June 27, 2007 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

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 26 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 29

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 30

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 FIGURE 1: ACCESS FOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE . . . . . . . . . . . . . . 37 FIGURE 3: INSPECTION - FASTENERS - HORIZONTAL FLANGE . . . . . . . . . . . . . . . . . . 39 FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE . . . . . . . . . . . . 41 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE . . . . . . . . . . 43 FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE . . . . . . . . 45 FIGURE 7: THIS FIGURE HAS BEEN DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND . . . . . . . . . . . . . . . . . . . . 49 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE. . . . . . . . . . . . . . . . . . . . . 51 FIGURE 10: SEAL COVER PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS . . . . . . 55

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ALERT ALERT

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ALERT ALERT Commercial Airplane Group 757

ALERTALERT Service Bulletin Number: 757-54A0047 Revision Transmittal Sheet Date: November 13, 2003 Revision 3: June 27, 2007 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 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 in the horizontal flange have changed.

Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-12-04, is related to this service bulletin.

REASON FOR REVISION Revision 03 is sent to give revised inspection compliance times and replace the phrase "one time inspection" with "inspection" when refering 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".

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

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.

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ALERT ALERT

REVISION HISTORY Original Issue: November 13, 2003 Revision 01: March 24, 2005 Revision 02: January 31, 2007 Revision 03: June 27, 2007

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ALERT ALERT Commercial Airplane Group 757

ALERTALERT Service Bulletin Number: 757-54A0047 Summary Date: November 13, 2003 Revision 3: June 27, 2007 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-todiagonal 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 Date Hours Cycles Strut Report 12/93 29,451 10,284 - One bolt sheared in horizontal flange. Four bolts loose in vertical flange.

11/96 25,768 9,358 No. 1 & 2 Four bolts loose in vertical flange of both struts.

06/98 - - No. 1 & 2 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2.

11/99 55,789 21,749 No. 1 & 2 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.

01/01 46,459 20,161 No. 1 & 2 Sixteen bolts loose in horizontal flange.

09/01 49,019 13,662 No. 1 Two bolts loose in vertical flange.

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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 and 757-SRP-54-0118 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.

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 boroscope, 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.

01/02 23,423 14,633 - Two bolt heads cracked.

04/02 16,601 12,493 No. 1 & 2 Two bolts loose in horizontal flange of Strut No. 1.

Three bolts loose in horizontal flange of Strut No. 2.

05/02 43,822 15,522 No. 1 & 2 Migrated shim between bulkhead and vertical flange of fitting.

06/02 46,758 15,900 No. 2 Four bolts loose in vertical flange. Five bolts loose in horizontal flange.

12/02 49,807 20,090 No. 1 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations.

04/03 50,841 22,111 - Two loose bolts in vertical flange.

09/03 30,072 9,991 No. 1 Three loose bolts in vertical flange.

09/03 60,715 26,914 No. 1 & 2 Migrated shims between bulkhead and vertical flange of fitting.

10/03 44,985 15,004 No. 2 Three loose bolts in vertical flange.

01/04 12,368 7,922 No. 2 Three loose bolts in vertical flange.

02/04 12,119 7,592 No. 1 Four loose bolts in vertical flange.

04/06 44,423 13,083 No. 1 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.

Service History Date Hours Cycles Strut Report

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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 Directive (AD) 2005-12-04, is 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

(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.

Airplanes Total Task Hours Elapsed Hours All 34 (a) 17 (a)

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ALERT ALERT

HORIZONTAL FLANGE OF FITTING (16 LOCATIONS)

INSPECT FASTENERS IN

INSTALLATION

INSPECT SHIM

INSPECT FASTENERS

IN VERTICAL FLANGE (4 LOCATIONS)

OF FITTING A A FWD FWD A-A W38926

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ALERT ALERT Commercial Airplane Group 757

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.

Airplane models:

757-200 757-200CB 757-200PF

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AEROTURBINE (AUB) 1 NA023 NA395

GROUP CONFIGURATION DESCRIPTION 1 - All 757-200 airplanes line number 1 thru 735, powered by Rolls Royce engines.

1 Airplanes without SB 757-54-0035 incorporation 2 Airplanes with SB 757-54-0035 incorporation 2 - All 757-200 airplanes line number 736 thru 1048, powered by Rolls Royce engines.

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ALERT ALERT

AIR ASTANA (AKZ) 1N B 5 6 1 2 NT231 NT411–NT412

AIR CHINA SOUTHWEST BRANCH (XIN) 1 NB291–NB295 NB297–NB299 NB301–NB302 NB327 2 NT201–NT202

AIR FINLAND (FNL) 1 NB221 NB239 NB454

AIR GREENLAND AS (GRL) 1N A 3 5 0

AMERICA WEST AIRLINES (AMW) 1 NA018–NA020 NB021–NB023 NB036–NB041

AMERICAN AIRLINES (AAL) 1 ND011–ND044 ND046–ND059 ND111–ND113 ND161–ND166 ND168–ND199 2 NT731–NT750 NT971–NT985 ASTRAEUS, LTD. (AUA) 1 NA442 NB131 NB134 NB142 2 ND401 ATA AIRLINES, INC. (AAT) 1 NC058 NC061 2 NC062 NT281–NT283

ATLASJET AIRLINES (ABE) 1 NA025–NA026 NA196 2 NT910–NT911

AVIANCA (AVI) 1 NA341 NA347 NA351 NA406 NA444 NB324 NB326

AZERBAIJAN AIRLINES (AHY) 1 ND248 2 NT437–NT438

BABCOCK & BROWN A/C MANAGEMENT (BBB) 1N A 4 4 7

BELAIR AIRLINES (BLB) 2 NT426–NT427

BRITISH AIRWAYS (BAB) 1 NA237–NA239 NA303–NA305 NA398 2 NB581–NB583 NT401–NT403

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