# Boeing Alert Service Bulletin 767-25A0505: No revision named

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- Title as filed: U.S. DOT/FAA - Service Bulletin - SB-767-25A0505-00--
- Pages: 60
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### Page 1

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-25A0505
Original Issue: January 14, 2011
ATA System: 2550
SUBJECT: EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water
Incursion Change
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 © 2011 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Unpublished Work - All Rights Reserved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.
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Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 7
A. Effectivity ................................................ 7
1. Airplanes ............................................. 7
2. Spares Affected ......................................... 7
B. Concurrent Requirements ....................................... 7
C. Reason ................................................. 8
D. Description ............................................... 8
E. Compliance .............................................. 8
F. Approval ................................................ 8
G. Manpower ............................................... 9
H. Weight and Balance Changes .................................... 1 0
I. Electrical Load Data ......................................... 1 0
J. References .............................................. 1 0
1. Existing Data .......................................... 1 0
2. Data supplied with this Service Bulletin ............................ 1 0
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 0
K. Publications Affected ........................................ 1 1
L. Interchangeability and Intermixability of Parts ........................... 1 1
2. MATERIAL INFORMATION ........................................ 1 3
A. Material - Price and Availability ................................... 1 3
B. Industry Support Information .................................... 1 3
C. Parts Necessary For Each Airplane ................................. 1 4
1. Kits/Parts ............................................ 1 4
2. Parts and Materials Supplied by the Operator ........................ 1 8
3. Parts Modified and Reidentified ................................ 1 8
4. Parts Removed and Not Replaced .............................. 1 8
D. Parts Necessary to Change Spares ................................. 1 9
E. Special Tooling - Price and Availability ............................... 1 9
F. Special Tooling Necessary to do this Service Bulletin ....................... 1 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1
A. GENERAL INFORMATION ..................................... 2 1
B. WORK INSTRUCTIONS ....................................... 2 2
FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE [Group 1] .................................... 2 4
FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD
SUPPORT ASSEMBLIES ................................... 2 8
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS ........................................... 3 1
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING
SUPPORTS AND INSTALL SUPPORT AT STATION 368 .................. 3 9
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING . . . 47
FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS [Group
1 ]  ................................................ 5 1
FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE [Group 2] .................................... 5 4
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FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND
RUB STRIP [Group 2] ..................................... 5 8
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Commercial 
Airplanes
767
Service Bulletin
ALERT
SummaryNumber: 767-25A0505Original Issue: January 14, 2011
ATA System: 2550
SUBJECT: EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water
Incursion Change
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 and a kit of parts provides retrofit instructions to improve water drainage in the lower lobe.
Water coming through the floor panels can accumulate up to 12 gallons in this location and typical aircraft
movement may not remove all the water. There is a potential for water to enter the electronic equipment bay.
Installation of parts assist in water drainage and will prevent water from getting into the electronic equipment
bay. If parts are not installed possible water damage could occur to electronic equipment which could result in
an electrical short and potential loss of several functions essential for safe flight.
Boeing Service Related Problem (SRP) 767-SRP-25-0290 is related to this service bulletin.
ACTION (PRR F06004-1RS)
Install 2 drains, dam and new support structure.
EFFECTIVITY
767-300 and 767-200 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE
Boeing recommends that operator accomplish the instructions provided in this bulletin within 24 months after
the Original Issue date on this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service
bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin
mandatory.
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INDUSTRY SUPPORT INFORMATION
Group 1:
Boeing warranty remedies are available for airplanes in warranty as of November 5, 2009. Please refer to
Paragraph 2.B., Industry Support Information.
Group 2:
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER
Group 1:
Elapsed HoursTotal Task HoursAirplanes
8.5016.00767-300BCF
Group 2:
Elapsed HoursTotal Task HoursAirplanes
8.5016.00767-200SF
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-25A0505
Original Issue: January 14, 2011
ATA System: 2550
SUBJECT: EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water
Incursion Change
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent
production airplanes. Refer to PRR F06004-1RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP
767-300BCF for VN191-VN195-1
767-200SF for VA511-2
Airplane Models:
767-200, 767-300
GroupVariable Number
2VA511
1VN191 - VN195
2. Spares Affected
None.
B. Concurrent Requirements
None.
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C. Reason
This service bulletin and a kit of parts provides retrofit instructions to improve water drainage in the
lower lobe. Water coming through the floor panels can accumulate up to 12 gallons in this location and
typical aircraft movement may not remove all the water. There is a potential for water to enter the
electronic equipment bay. Installation of parts assist in water drainage and will prevent water from
getting into the electronic equipment bay. If parts are not installed possible water damage could occur
to electronic equipment which could result in an electrical short and potential loss of several functions
essential for safe flight.
Boeing Service Related Problem (SRP) 767-SRP-25-0290 is related to this service bulletin.
D. Description
Installs 2 drains, dam and new support structure.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
119, 121, 122767-300
Group 2:
Affected Maintenance Zones
ZoneModel
119, 121, 122767-200
E. Compliance
Boeing recommends that operator accomplish the instructions provided in this bulletin within 24 months
after the Original Issue date on this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to
this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this
service bulletin mandatory.
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 for all 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.
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.
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G. Manpower
The table below shows an estimate of the task hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
 Time to adjust to the workplace
 Time to schedule the work
 Time to inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
Group 1:
Elapsed HoursTask HoursNumber of PersonsTask
0.500.501Open Access
1.503.002Figure 1
0.501.002Figure 2
1.503.002Figure 3
1.252.502Figure 4
1.252.502Figure 5
1.503.002Figure 6
0.500.501Close Access
8.5016.00TOTAL FOR EACH AIRPLANE
Group 2:
Elapsed HoursTask HoursNumber of PersonsTask
0.500.501Open Access
1.503.002Figure 7
0.501.002Figure 2
1.503.002Figure 3
1.252.502Figure 4
1.252.502Figure 5
1.503.002Figure 8
0.500.501Close Access
8.5016.00TOTAL FOR EACH AIRPLANE
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H. Weight and Balance Changes
Group 1:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
+408.0+2.6767-300BCF
Group 2:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
+902.0+3.5767-200SF
I. Electrical Load Data
Not changed.
J. References
1. Existing Data
a. Engineering Change Memo PRR F06004-1RS
b. Boeing Service Related Problem (SRP) 767-SRP-25-0290
c. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-50-01, 20-50-19
d. 767 Aircraft Maintenance Manual (AMM) 25-52-02
e. 767-200SF Structural Repair Manual (SRM) 51-40-02
f. 767-300BCF Structural Repair Manual (SRM) 51, 51, 51-40-02, 51-40-08
2. Data supplied with this Service Bulletin
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin
TitleDrawing Number
SUPP0RT INSTALLATION - END LINING, STA 355,453T1104
LINING INSTL - CEILING, FWD LWR CARGO COMPT, MOD657T4640
SUPPORT INSTL - CEILING, FWD LWR CARGO COMPT, MOD657T4641
LINING INSTL - CEILING, LWR CARGO COMPT, MOD845T3108
SUPPORT INSTL - CEILING, LWR CARGO COMPT (MOD)845T3109
STA 355 ENDWALL ASSY - REWORK INSTL845T3154
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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:
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 does not affect FCS, therefore DTIs are not necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are
encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The
kit is subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR REORDER LEAD TIME (ROLT) AND THE LATEST PRICE INFORMATION
Unit Price as of the original
issue date of this Service
Bulletin (US Dollars)
QTYNameKit Number
$27,077.001767-300BCF Water Management
Retrofit Kit
880T0026-1
$26,844.001767-200SF Water Management Retrofit
Kit
880T0026-2
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing Part Page
2. Fax to (206) 662-7145
B. Industry Support Information
Group 1:
Boeing warranty remedies are available for 767 airplanes in warranty as of November 5, 2009. For
task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing
Commercial Airplanes Group - Warranties. The kit for airplanes in warranty as of that date will be
supplied at no charge. Send a purchase order for the kit to Boeing Spares. Please refer to this service
bulletin number and reference the airplane variable number in your purchase order.
Group 2:
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
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C. Parts Necessary For Each Airplane
1. Kits/Parts
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane.
Group 1:
Kit 880T0026-1
NotesExisting Part NumberNameQTYNew Part Number
767-300BCF Water Manage-
ment Retrofit Kit
-880T0026-1
845T3108-11CEILING LINER1845T3108-21
845T3108-12CEILING LINER1845T3108-22
845T3108-13CEILING LINER1845T3108-23
845T3108-12CEILING LINER1845T3108-32
845T3109-29SUPPORT ASSY1845T3109-41
657T1137-1SUPPORT ASSY1845T3109-42
Or
IDR-767-25-0406-0065-5
Or
IDR-767-25-0420-0010-5
Or
IDR-767-25-0424-0017-5
Or
IDR-767-25-0433-0002-5
SUPPORT4845T3109-47
TUBE1845T3109-48
TUBE1845T3109-49
SUPPORT ASSY1845T3109-51
SPUD ASSY2845T3109-52
CLOSURE BLOCK DETAIL1845T3109-53
CLOSURE BLOCK DETAIL1845T3109-58
845T3109-25LEFT SUPPORT ASSY1845T3109-61
SUPPORT ASSY1845T3109-62
845T3109-25RIGHT SUPPORT ASSY1845T3109-64
SUPPORT ASSY1845T3109-70
SUPPORT ASSY1845T3109-71
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Group 1:
Kit 880T0026-1
NotesExisting Part NumberNameQTYNew Part Number
453T1541-1SUPPORT ASSY1845T3109-73
SUPPORT ASSY1845T3109-75
SUPPORT ASSY2845T3154-14
453T1602-6SUPPORT ASSY1845T3154-15
453T1602-7SUPPORT ASSY1845T3154-16
453T1602-8SUPPORT ASSY1845T3154-17
(a)BOLT, PAN HD, CROSS10BACB30NT3K2
(a)BOLT, PROTRUDING HD4BACB30VT5HK3
(a)BOLT20BACB30VT6K5
(a)CLAMP, LOOP12BACC10D616A
(a)CLAMP, LOOP6BACC10DK16
(a)CLAMP, HOSE4BACC10JB022C040
(a)NUT7BACN10JC3CD
(a)NUT14BACN10YR08CM
(a)NUT16BACN10YR3CM
(a)NUT4BACN10ZV08
(a)NUT20BACN10ZV3
(a)RIVET, UNIVERSAL HEAD12BACR15BB4D5C
(a)RIVET20BACR15BB5D5C
(a)RIVET, UNIVERSAL HD10BACR15BB5D6C
(a)SCREW, 100 DEG HEAD36BACS12ER3K6
(a)SCREW4BACS12FA08K15
(a)SCREW, WASHER HEAD4BACS12FA08K22
(a)FAIRING SCREWS10BACS12FA3K10
(a)SCREW, WASHER HEAD50BACS12FA3K14
(a)SCREW, WASHER HEAD212BACS12FA3K8
(a)SCREW6BACS12GU3K10
(a)SCREW4BACS12GX08A16
(a)SCREW4BACS12GX08A22
(a)SCREW11BACS12GX3A8
(a)SCREW10BACS12HJ3K6
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Group 1:
Kit 880T0026-1
NotesExisting Part NumberNameQTYNew Part Number
(a)STRAP4BACS38K1
(a)SHIM,LAMINATED6BACS40R008D010F
(a)SHIM,LAMINATED8BACS40R008D012F
(a)WASHER10BACW10P136AL
(a)WASHER, PLAIN10BACW10P151AL
(a)WASHER, PLAIN4BACW10P183AL
(a)WASHER13NAS1149D0332J
(a) There are more parts than are necessary.
Group 2:
Kit 880T0026-2
NotesExisting Part NumberNameQTYNew Part Number
767-200SF Water Management
Retrofit Kit
-880T0026-2
657T4640-7CEILING LINER1657T4640-41
657T4640-32CEILING LINER1657T4640-42
657T4640-29CEILING LINER1657T4640-43
657T4640-32CEILING LINER1657T4640-44
SUPPORT ASSY1845T3109-41
657T1137-4SUPPORT ASSY1845T3109-42
SUPPORT4845T3109-47
TUBE1845T3109-48
TUBE1845T3109-49
SUPPORT ASSY1845T3109-51
SPUD ASSY2845T3109-52
CLOSURE BLOCK DETAIL1845T3109-53
CLOSURE BLOCK DETAIL1845T3109-58
845T3109-25LEFT SUPPORT ASSY1845T3109-61
657T4661-12SUPPORT ASSY1845T3109-62
657T4661-13RIGHT SUPPORT ASSY1845T3109-64
SUPPORT ASSY1845T3109-70
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Group 2:
Kit 880T0026-2
NotesExisting Part NumberNameQTYNew Part Number
SUPPORT ASSY1845T3109-71
453T1541-1SUPPORT ASSY1845T3109-73
SUPPORT ASSY1845T3109-75
SUPPORT ASSY2845T3154-14
453T1602-6SUPPORT ASSY1845T3154-15
453T1602-7SUPPORT ASSY1845T3154-16
453T1602-8SUPPORT ASSY1845T3154-17
(a)BOLT, PAN HD, CROSS10BACB30NT3K2
(a)BOLT, PROTRUDING HD4BACB30VT5HK3
(a)BOLT20BACB30VT6K5
(a)CLAMP, LOOP12BACC10D616A
(a)CLAMP, LOOP6BACC10DK16
(a)CLAMP, HOSE4BACC10JB022C040
(a)NUT7BACN10JC3CD
(a)NUT14BACN10YR08CM
(a)NUT16BACN10YR3CM
(a)NUT4BACN10ZV08
(a)NUT20BACN10ZV3
(a)RIVET, UNIVERSAL HEAD12BACR15BB4D5C
(a)RIVET20BACR15BB5D5C
(a)RIVET, UNIVERSAL HD10BACR15BB5D6C
(a)SCREW, 100 DEG HEAD36BACS12ER3K6
(a)SCREW4BACS12FA08K15
(a)SCREW, WASHER HEAD4BACS12FA08K22
(a)FAIRING SCREWS10BACS12FA3K10
(a)SCREW, WASHER HEAD50BACS12FA3K14
(a)SCREW, WASHER HEAD212BACS12FA3K8
(a)SCREW6BACS12GU3K10
(a)SCREW4BACS12GX08A16
(a)SCREW4BACS12GX08A22
(a)SCREW11BACS12GX3A8
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Group 2:
Kit 880T0026-2
NotesExisting Part NumberNameQTYNew Part Number
(a)SCREW10BACS12HJ3K6
(a)STRAP4BACS38K1
(a)SHIM,LAMINATED6BACS40R008D010F
(a)SHIM,LAMINATED8BACS40R008D012F
(a)WASHER10BACW10P136AL
(a)WASHER, PLAIN10BACW10P151AL
(a)WASHER, PLAIN4BACW10P183AL
(a)WASHER13NAS1149D0332J
(a) There are more parts than are necessary.
2. Parts and Materials Supplied by the Operator
NotesNameQTYPart Number /
Specification
(a) (b)TAPE - SEALING1 Roll657T4640-101
Equivalent to BMS 5-146, Class 1,
Type I, Grade A.
(a) (c)TAPE - DOUBLEBACK1 Roll657T4640-102
Equivalent to BMS 5-133, Class 1,
Type IV.
(d)Sealant1
Quart
Pro-Seal 870
BMS 5-95, Class B.
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
(b) Can be procured from 3M Company, 1425 Stokke Parkway, Menomonie, WI 54751.
(c) Can be procured from Orcon Corporation, 1570 Atlantic Street, Union City, CA 94587–3299
(d) Can be procured from PRC-DeSoto International, Incorporated, Post Office Box 1800,
Sylmar, CA 91342-3728
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
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D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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BLANK PAGE

### Page 21

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 identified 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 given 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 767-300BCF SRM 51 Structural
Repair Manual (SRM) 51
– Torque limits to tighten nuts and bolts are in 767-300BCF SRM 51.
5. Use the approved fastener and process material substitutions in accordance with
767-300BCF SRM 51. Alternate fasteners are listed in 767-300BCF SRM 51 and
Boeing Drawing 012W6100.
6. If the length of any fastener specified in this service bulletin does not meet the
installation standards in 767-300BCF SRM 51, then a fastener of the same
specification, or an approved substitute, with a length which meets the installation
standards in 767-300BCF SRM 51 may be used.
7. Fay surface seal the lower surface of z-support bracket assy and the upper surface
of drain fitting using BMS 5-95. Within the sealant's application time, apply sealant
to upper surface of the fitting. Apply sealant to the surface with sufficient thickness
required to fill the assembled faying surfaces and to give continuous and visible
squeeze-out at the faying surface joints. Refer to SOPM 20-50-19 as an accepted
procedure.
8. Apply BMS 5-95, Class "C" sealant to fasteners using method 2. Extruded sealant
shall be continuous to indicate adequate sealing. Do not remove sealant from fastener
threads prior to nut installation. Apply Class "B" sealant fillet around fastener after
installation. Apply sealant so as to form a visually uniform coating which completely
covers the fastener. Application to be completed within application time of sealant.
Refer to SOPM 20-50-19 as an accepted procedure.
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9. Proper routing for right side hose into the bilge shall be determined by mock-up.
Extra length of tubing was provided by design. Trim the excess as required when
proper routing is accomplished. If required, usage of two extra plastic straps
BACS38K1 is acceptable.
10. Proper routing for left side hose shall be determined by mock-up. The supports
brackets shall be installed to the cargo bulkhead approximately 16 inches apart, with
a tolerance of +/- 2.50 inches. Horizontal adjustment of about 0.6 inches is permitted
by support bracket design. Extra length of tubing was provided by design - trim the
excess as required when proper routing is accomplished. If required, usage of extra
two plastic straps BACS38K1 is acceptable.
11. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
B. WORK INSTRUCTIONS
Group 1:
1. Gain access to forward side of cargo bulkhead through door 119AL.
2. Gain access to aft side of cargo bulkhead through the forward cargo door.
3. Remove ceiling liners and structure in accordance with FIGURE 1.
4. Install cargo bulkhead support in accordance with FIGURE 2.
5. Install right side ceiling supports in accordance with FIGURE 3.
6. Install left side ceiling supports and install support (secondary dam) at station 368 in accordance
with FIGURE 4.
7. Install drain tubing in accordance with FIGURE 5.
8. Install ceiling panels in accordance with FIGURE 6.
9. Put the airplane back to a serviceable condition.
Group 2:
1. Gain access to forward side of cargo bulkhead through door 119AL.
2. Gain access to aft side of cargo bulkhead through the forward cargo door.
3. Remove ceiling liners and structure in accordance with FIGURE 7.
4. Install cargo bulkhead support in accordance with FIGURE 2.
5. Install right side ceiling supports in accordance with FIGURE 3.
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6. Install left side ceiling supports and install support (secondary dam) at station 368 in accordance
with FIGURE 4.
7. Install drain tubing in accordance with FIGURE 5.
8. Install ceiling panels in accordance with FIGURE 8.
9. Put the airplane back to a serviceable condition.
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BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
This Figure applies only to: Group 1.
STA
355
FORWARD CARGO COMPARTMENT
LOOKING FORWARD
(TYPICAL)
FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 1 OF 4)
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### Page 25 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
STA  STA  STA  STA  STA  STA
355  368  390  412  434  456
B
RBL
64.50
RBL
37.44
LBL
10.38
LBL
67.50
FWD
A-A  1987635
FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 2 OF 4)
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### Page 26 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
LBL  LBL
67.50  13.257
BL
0.00
RBL  RBL
13.78  64.50
BL
0.00
• WL
192.43
LOOKING FORWARD  B-B  1985914
FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 3 OF 4)
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### Page 27

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 each airplane..
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)1845T3108-11CEILING LINERRemove1
(a) (b)1845T3108-12CEILING LINERRemove2
(a) (b)1845T3108-13CEILING LINERRemove3
(c) For VN1912IDR-767-25-0406-0087-
3
SUPPORT BRACKETRemove4
(c) For VN1922IDR-767-25-0420-0081-
3
SUPPORT BRACKETRemove
(c) For VN1932IDR-767-25-0424-0065-
3
SUPPORT BRACKETRemove
(c) For VN1942IDR-767-25-0433-0044-
3
SUPPORT BRACKETRemove
(c) For VN1952657T4664-1SUPPORT BRACKETRemove
For VN1911IDR-767-25-0406-0065-
5
STABILIZATION
STRAP ASSY
Remove5
For VN1921IDR-767-25-0420-0010-
5
STABILIZATION
STRAP ASSY
Remove
For VN1931IDR-767-25-0424-0017-
5
STABILIZATION
STRAP ASSY
Remove
For VN1941IDR-767-25-0433-0002-
5
STABILIZATION
STRAP ASSY
Remove
For VN195.1657T1137-4STABILIZATION
STRAP ASSY
Remove
1845T3109-25SUPPORT ASSYRemove6
1845T3109-29SUPPORT ASSYRemove7
1453T1602-6SUPPORTRemove8
1453T1602-7SUPPORTRemove9
1453T1602-8SUPPORTRemove10
(a) Refer to 767 AMM 25-52-02 as an accepted procedure.
(b) Panel can be used as a template to layout cut-outs in the new panels.
(c) Plug any open holes left by removing the support brackets with AD rivet. Refer to 767-300BCF SRM 51-
40-02 as an accepted procedure.
FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 4 OF 4)
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BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
STA  67.50  LBL  19.97  LBL  0,00  BL
355
0.00  BL  47.159  RBL  64.50  RBL
WL
191.93
B
(3 LOCATIONS)
FORWARD CARGO COMPARTMENT  A-A  1988456
LOOKING FORWARD
FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT
ASSEMBLIES
(SHEET 1 OF 3)
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### Page 29 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
(4 LOCATIONS)
FWD
INBD
B-B
(2 LOCATIONS)
C-C
LOOKING UP
LOOKING UP  D-D  1988487
FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT
(SHEET 2 OF 3)
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### Page 30

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 each airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1845T3154-15SUPPORT ASSYInstall (New)1
1845T3154-16SUPPORT ASSYInstall (New)2
1845T3154-17SUPPORT ASSYInstall (New)3
2845T3154-14SUPPORT ASSYInstall (New)4
(a)8BACS12ER3K6SCREW, 100 DEG
HEAD
Install (New)5
8BACS12ER3K6SCREW, 100 DEG
HEAD
Install (New)6
(a)2BACS12ER3K6SCREW, 100 DEG
HEAD
Install (New)7
(a)1BACS12ER3K6SCREW, 100 DEG
HEAD
Install (New)8
(a)2BACS12ER3K6SCREW, 100 DEG
HEAD
Install (New)9
(a)6BACS12ER3K6SCREW, 100 DEG
HEAD
Install (New)10
(a) Drill 0.2180 - 0.2290 diameter hole from hole in existing structure. Countersink 0.2610 - 0.2710 X 100
degree (near side). Refer to 767-300BCF SRM 51-40-08 as an accepted procedure.
FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT
ASSEMBLIES
(SHEET 3 OF 3)
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
STA
355
STA
412
60
STA
390
A-A
DIG
STA
355  1988559
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 1 OF 8)
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### Page 32 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
1.2700
1000
°00  000
RBL
•O‹  37.44
°00
6) SUPPOR  ASSEMBL
BOLT  RIVET
(2 LOCATIONS)  (4 LOCATIONS)
SHIM
(2 LOCATIONS)
FLOOR
RIVET  BEAM
ASSY
SUPPORT
ASSEMBLY
BOLT
INBD  WASHER
NUT
C-C
LOOKING AFT
1988579
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 2 OF 8)
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### Page 33 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
E
SCREW
• NUT
(4 LOCATIONS)
SPUD
ASSEMBLY
LOOKING INBOARD  1989254
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 3 OF 8)
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### Page 34 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
(4 LOCATIONS)
12
RBL
46.0
13)
E-E
(15
RBL
46.0
F-F  1989274
LOOKING UP
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 4 OF 8)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
GAP
TRANSITION
SEALANT
FROM FILLET
SEAL TO
GAP SEAL
GAP
_ GAP
G
LOOKING UP
1989289
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 5 OF 8)
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### Page 36

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 each airplane..
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1453T1541-1SUPPORT ASSYRemove1
Gap to be 0.1500 +/-
0.0100 between
Support Assemblies.
1845T3109-42SUPPORT ASSYInstall (New)2
Fay seal mating sur-
faces of cargo bulk-
head support assem-
bly with BMS 5-95.
Refer to SOPM 20-
50-19 as an accept-
ed procedure.
Gap to be 0.1500 +/-
0.0100 between
Support Assemblies.
1845T3109-62SUPPORT ASSYInstall (New)3
(a)2BACB30NT3K2BOLT, PAN HD,
CROSS
Install (New)4
(b)1845T3109-51SUPPORT ASSYInstall (New)5
Drill 0.1610 / 0.1640
diameter holes from
pilot holes in Sup-
port Assy.
2BACB30VT5HK3BOLT, PROTRUDING
HD
Install (New)
2BACN10ZV08NUTInstall (New)
2BACW10P183ALWASHER, PLAINInstall (New)
1845T3109-64RIGHT SUPPORT AS-
SY
Install (New)6
(c)2BACS40R008D012FSHIM,LAMINATEDInstall (New)
(a)2BACB30NT3K2BOLT, PAN HD,
CROSS
Install (New)
Drill holes from pilot
holes in Support As-
sy.
4BACR15BB5D6CRIVET, UNIVERSAL
HD
Install (New)
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 6 OF 8)
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### Page 37

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1845T3109-73SUPPORT ASSYInstall (New)7
Drill from holes in
existing structure.
2BACR15BB5D5CRIVETInstall (New)
1BACB30VT6K5BOLTInstall (New)
Install under head of
bolt.
1BACW10P151ALWASHER, PLAINInstall (New)
(d)1BACN10ZV3NUTInstall (New)
4BACB30VT6K5BOLTInstall (New)8
Install under head of
bolt.
4BACW10P151ALWASHER, PLAINInstall (New)
(d)4BACN10ZV3NUTInstall (New)
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 7 and 8.
1845T3109-52SPUD ASSYInstall (New)9
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 7 and 8.
4BACS12HJ3K6SCREWInstall (New)
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 7 and 8.
4BACN10YR3CMNUTInstall (New)
(e) (f)1845T3109-58CLOSURE BLOCK
DETAIL
Install (New)10
(f)1845T3109-70SUPPORT ASSYInstall (New)11
4BACS12FA3K8SCREW, WASHER
HEAD
Install (New)12
(g)1BACS12FA08K15SCREWInstall (New)13
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 8.
1BACN10YR08CMNUTInstall (New)
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 7 OF 8)
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### Page 38

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(g)1BACS12FA08K22SCREW, WASHER
HEAD
Install (New)14
1BACN10YR08CMNUTInstall (New)
(g) (h)1BACS12GX08A16SCREWInstall (New)15
1BACN10YR08CMNUTInstall (New)
(g) (h)1BACS12GX08A22SCREWInstall (New)16
1BACN10YR08CMNUTInstall (New)
(i)1BACS12GX3A8SCREWInstall (New)17
(j)-PRO-SEAL 870SEALANTApply18
(a) Leave a 0.005-0.010 clearance between bolt head and support structure.
(b) Locate support assy Fwd/Aft, by mock-up. A good location shall perfectly nest the two small structural
supports and shall clear all other structural parts and adjacent fasteners. If needed, it is acceptable to lo-
cally trim this support assy, along the edge, without compromising the edge margins. Trim area shall not
be more than 0.1 inch from the part trimline and shall not exceed 0.5 inches in length.
(c) Strip .003 laminations if and as required. Install shims wet and finish cut edges with BMS 10-11, type 1
yellow primer. Refer to SOPM 20-41-02 as an accepted procedure.
(d) Torque nut to 20-25 In-Lbs. Refer to SOPM 20-50-01 as an accepted procedure.
(e) The aft face of cargo bulkhead support assembly and the aft face of closure block detail need to be flush.
(f) Fay seal all mating surfaces with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure.
(g) Drill hole through mating parts from hole in 845T3109-58 to 0.1920 - 0.2030 diameter.
(h) Countersink near side 0.332 - 0.319 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted
procedure.
(i) Countersink near side 0.385 - 0.371 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted
procedure.
(j) Fillet seal all visible edges and gap seal all gaps with BMS 5-95. Refer to SOPM 20-50-19 as an accepted
procedure.
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING
SUPPORTS
(SHEET 8 OF 8)
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### Page 39 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
STA
355
STA
412
.6000
STA
390
A-A
• 1.00
16.00  0.50
- 16.50
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 1 OF 8)
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### Page 40 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
1.2700
1°00  60°
LBL
10.38  7000
ASSEMBLY 2  SUPPORT
RIVET  BOLT
(4 LOCATIONS)  (2 LOCATIONS)
SHIM
(2 LOCATIONS)
FWD
1989466
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 2 OF 8)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
D
5)
NUT  SCREW
(4 LOCATIONS)  4) SPUD  ' ASSEMBLY
EL
FWD
LOOKING INBOARD  1989454
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 3 OF 8)
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### Page 42 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
(5 LOCATIONS)
RBL
19.0
D-D
LBL
19.0
E-E  1989470
LOOKING UP
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 4 OF 8)
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### Page 43

FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 5 OF 8)
BOEING PROPRIETARY -
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ALERTALERT

### 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 each airplane..
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Gap to be 0.1500 +/-
0.0100 between
Support Assemblies.
1845T3109-41SUPPORT ASSYInstall (New)1
1845T3109-61LEFT SUPPORT ASSYInstall (New)2
(a)2BACS40R008D012FSHIM,LAMINATEDInstall (New)
(b)2BACB30NT3K2BOLT, PAN HD,
CROSS
Install (New)
Drill holes from pilot
holes in Support As-
sy.
4BACR15BB5D6CRIVET, UNIVERSAL
HD
Install (New)
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 6 OF 8)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
44 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 45

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1BACB30VT6K5BOLTInstall (New)3
Install under head of
bolt.
1BACW10P136ALWASHERInstall (New)
(c)1BACN10ZV3NUTInstall (New)
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 7 and 8.
1845T3109-52SPUD ASSYInstall (New)4
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 7 and 8.
4BACS12HJ3K6SCREWInstall (New)
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 7 and 8.
4BACN10YR3CMNUTInstall (New)
(d) (e)1845T3109-53CLOSURE BLOCK
DETAIL
Install (New)5
(e)1845T3109-71SUPPORT ASSYInstall (New)6
4BACS12FA3K8SCREW, WASHER
HEAD
Install (New)7
(f)1BACS12FA08K15SCREWInstall (New)8
Install in accordance
with Accomplish-
ment Instructions,
General Information
Note 8.
1BACN10YR08CMNUTInstall (New)
(f)1BACS12FA08K22SCREW, WASHER
HEAD
Install (New)9
1BACN10YR08CMNUTInstall (New)
(f) (g)1BACS12GX08A16SCREWInstall (New)10
1BACN10YR08CMNUTInstall (New)
(f) (g)1BACS12GX08A22SCREWInstall (New)11
1BACN10YR08CMNUTInstall (New)
(h)1BACS12GX3A8SCREWInstall (New)12
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 7 OF 8)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
45 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 46

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(i)-845T3109SEALApply13
1845T3109-75SUPPORT ASSYInstall (New)14
Install near side.4BACR15BB5D5CRIVETInstall (New)15
(a) Strip .003 laminations if and as required. Install shims wet and finish cut edges with BMS 10-11, type 1
yellow primer. Refer to SOPM 20-41-02 as an accepted procedure.
(b) Leave a 0.005-0.010 clearance between bolt head and support structure.
(c) Torque nut to 20-25 In-Lbs. Refer to SOPM 20-50-01 as an accepted procedure.
(d) The aft face of cargo bulkhead support assembly and the aft face of closure block detail need to be flush.
(e) Fay seal all mating surfaces with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure.
(e) Drill hole through mating parts from hole in 845T3109-58 to 0.1920 - 0.2030 diameter.
(e) Countersink near side 0.332 - 0.319 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted
procedure.
(h) Countersink near side 0.385 - 0.371 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted
procedure.
(i) Fillet seal all visible edges and gap seal all gaps with BMS 5-95. Refer to SOPM 20-50-19 as an accepted
procedure.
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS
AND INSTALL SUPPORT AT STATION 368
(SHEET 8 OF 8)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
46 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 47 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
STA
355
RBL  LBL
46.0  19.0
8) (4 LOCATIONS)
(4 LOCATIONS)
A-A  1989305
I LOOKING AFT
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING
(SHEET 1 OF 4)
Original issue: January 14, 2011
767-25A0505
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  • 47 of 60

### Page 48 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
FWD
FWD
):0:0
nar
B-B  06861
LOOKING INBOARD
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING
(SHEET 2 OF 4)
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Copyright © Unpublished Work - See page 1 for details.  48 of 60

### Page 49 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
C-C
LOOKING DOWN
FWD
LOOKING DOWN  E-E  1989336
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING
(SHEET 3 OF 4)
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Copyright © Unpublished Work - See page 1 for details.  49 of 60

### Page 50

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 each airplane..
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1845T3109-48TUBEInstall (New)1
1BACC10JB022C040CLAMP, HOSEInstall (New)2
Remove existing
clamps.
5BACC10D616ACLAMP, LOOPInstall (New)3
5BACS12GX3A8SCREWInstall (New)
5NAS1149D0332JWASHERInstall (New)
5BACN10JC3CDNUTInstall (New)
Route tube in accor-
dance with Accom-
plishment Instruc-
tions, General Infor-
mation Note 9.
1845T3109-48TUBERoute4
1BACS38K1STRAPInstall (New)
1845T3109-49TUBEInstall (New)5
1BACC10JB022C040CLAMP, HOSEInstall (New)6
Install brackets in
accordance with Ac-
complishment In-
structions, General
Information Note 10.
4845T3109-47SUPPORTInstall (New)7
8BACR15BB4D5CRIVET, UNIVERSAL
HEAD
Install (New)
4BACC10DK16CLAMP, LOOPInstall (New)8
4BACS12GU3K10SCREWInstall (New)
4NAS1149D0332JWASHERInstall (New)
4BACN10YR3CMNUTInstall (New)
Route tube in accor-
dance with Accom-
plishment Instruc-
tions, General Infor-
mation Note 10.
1845T3109-49TUBERoute9
1BACS38K1STRAPRoute
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING
(SHEET 4 OF 4)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
50 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 51 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
This Figure applies only to: Group 1.
STA  STA
STA  355  456
355
RBL
64.50
RBL
37.44
LBL
10.38
LBL
67.50
FORWARD CARGO CEILING  LOOKING DOWN  1989589
(TYPICAL)
FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS
(SHEET 1 OF 3)
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Copyright © Unpublished Work - See page 1 for details.  51 of 60

### Page 52

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 each airplane..
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Drill 0.1920 - 0.1980
diameter holes from
holes in existing
structure.
1845T3109-51SUPPORT ASSYDrill1
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1845T3108-21CEILING LINERInstall (New)2
(d)
(a) (b)51BACS12FA3K8SCREW, WASHER
HEAD
Install (New)
-657T4640-101TAPE - SEALINGInstall (New)
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1845T3108-32CEILING LINERInstall (New)3
(c) (d)
-657T4640-101TAPE - SEALINGInstall (New)
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1845T3108-22CEILING LINERInstall (New)4
(d)
(a) (b)58BACS12FA3K8SCREW, WASHER
HEAD
Install (New)
-657T4640-101TAPE - SEALINGInstall (New)
2BACS12FA3K10FAIRING SCREWSInstall (New)5
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1845T3108-23CEILING LINERInstall (New)6
(c) (d)
(a) (b)33BACS12FA3K8SCREW, WASHER
HEAD
Install (New)
All locations except
those designated for
a different fastener.
-657T4640-101TAPE - SEALINGInstall (New)
(a) (b)23BACS12FA3K14SCREW, WASHER
HEAD
Install (New)7
(a) Drill 0.29 - 0.30 diameter hole through liner from center of existing slotted hole in structure. Refer to 767
AMM 25-52-02 as an accepted procedure.
FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS
(SHEET 2 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
52 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 53

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(b) Maintain 0.60 inch edge margin for fasteners.
(c) Align new ceiling panel with previously removed ceiling panel to layout cut-outs and do cuts. Refer to 767
AMM 25-52-02 as an accepted procedure.
(d) Apply tape to cover all joints and seams in ceiling liner and shrouds. At panel edges tape shall extend to
seal edge joint. Centerline of tape to coincide approximately with the centerline of lining attaching fasteners.
Once installed, tape shall not be reused. Splice in new tape if tape is removed for any reason. Refer to
767 AMM 25-52-02 as an accepted procedure.
FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS
(SHEET 3 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
53 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 54 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
This Figure applies only to: Group 2.
STA
355
FORWARD CARGO COMPARTMENT
LOOKING FORWARD
(TYPICAL)
FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 1 OF 4)
Original Issue: January 14, 2011
BOEING PROPRIETARY -  767-25A0505
Copyright © Unpublished Work - See page 1 for details.  54 of 60

### Page 55 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
STA  STA  STA  STA  STA  STA
355  368  390  412  434  456
B
RBL
64.50
RBL
37.44
LBL
10.38
LBL
67.50
B  FWD
A-A  1989960
FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 2 OF 4)
Original Issue: January 14, 2011
BOEING PROPRIETARY -  767-25A0505
Copyright © Unpublished Work - See page 1 for details.  55 of 60

### Page 56 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
LBL  LBL
67.50  13.257
BL
0.00
RBL  RBL
13.78  64.50
BL
0.00
WL
192.43
LOOKING FORWARD  B-B  1989974
FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 3 OF 4)
Original Issue: January 14, 2011
BOEING PROPRIETARY -  767-25A0505
Copyright © Unpublished Work - See page 1 for details.  56 of 60

### 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 each airplane..
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1657T4640-30RUB STRIPRemove / Keep1
(a)1657T4640-7CEILING LINERRemove2
(a) (b)1657T4640-29CEILING LINERRemove3
(a) (b)1657T4640-32CEILING LINERRemove4
(c)3657T4664-1SUPPORT BRACKETRemove5
1657T1137-4STABILIZATION
STRAP ASSY
Remove6
1845T3109-25SUPPORT ASSYRemove7
1845T3109-29SUPPORT ASSYRemove8
1453T1602-6SUPPORTRemove9
1453T1602-7SUPPORTRemove10
1453T1602-8SUPPORTRemove11
(a) Refer to 767 AMM 25-52-02 as an accepted procedure.
(b) Panel can be used as a template to layout cut-outs in the new panels.
(c) Plug any open holes left by removing the support brackets with AD rivets. Refer to 767-200SF SRM 51-
40-02 as an accepted procedure.
FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND
STRUCTURE
(SHEET 4 OF 4)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
57 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 58 (OCR)

BOEING SERVICE BULLETIN 767-25A0505
ALERT  ALERT
This Figure applies only to: Group 2.
A
STA  STA
STA  355  456
355
RBL
64.50
RBL
37.44
LBL
10.38
LBL
67.50
FORWARD CARGO CEILING  LOOKING DOWN  1990000
(TYPICAL)
FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB
STRIP
(SHEET 1 OF 3)
Original Issue: January 14, 2011
767-25A0505
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  58 of 60

### 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 each airplane..
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Drill 0.1920 - 0.1980
diameter holes from
holes in existing
structure.
1845T3109-51SUPPORT ASSYDrill1
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1657T4640-41CEILING LINERInstall (New)2
(d)
(a) (b)51BACS12FA3K8SCREW, WASHER
HEAD
Install (New)
-657T4640-101TAPE - SEALINGInstall (New)
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1657T4640-44CEILING LINERInstall (New)3
(c) (d)
-657T4640-101TAPE - SEALINGInstall (New)
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1657T4640-42CEILING LINERInstall (New)4
(d)
(a) (b)58BACS12FA3K8SCREW, WASHER
HEAD
Install (New)
-657T4640-101TAPE - SEALINGInstall (New)
3BACS12FA3K10FAIRING SCREWSInstall (New)5
Refer to 767 AMM
25-52-02 as an ac-
cepted procedure.
1657T4640-43CEILING LINERInstall (New)6
(c) (d)
(a) (b)33BACS12FA3K8SCREW, WASHER
HEAD
Install (New)
All locations except
those designated for
a different fastener.
-657T4640-101TAPE - SEALINGInstall (New)
(a) (b)23BACS12FA3K14SCREW, WASHER
HEAD
Install (New)7
1657T4640-30RUB STRIPInstall (Kept)8
(e)-657T4640-102TAPE - DOUBLEBACKInstall (New)
FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB
STRIP
(SHEET 2 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
59 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

### Page 60

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a) Drill 0.29 - 0.30 diameter hole through liner from center of existing slotted hole in structure. Refer to 767
AMM 25-52-02 as an accepted procedure.
(b) Maintain 0.60 inch edge margin for fasteners.
(c) Align new ceiling panel with previously removed ceiling panel to layout cut-outs and do cuts. Refer to 767
AMM 25-52-02 as an accepted procedure.
(d) Apply tape to cover all joints and seams in ceiling liner and shrouds. At panel edges tape shall extend to
seal edge joint. Centerline of tape to coincide approximately with the centerline of lining attaching fasteners.
Once installed, tape shall not be reused. Splice in new tape if tape is removed for any reason. Refer to
767 AMM 25-52-02 as an accepted procedure.
(e) Install doubleback tape between ceiling liner and rub strip along entire periphery of rub strip. Doubleback
tape overlap splices allowed.
FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB
STRIP
(SHEET 3 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2011
767-25A0505
60 of 60
BOEING SERVICE BULLETIN 767-25A0505
ALERTALERT

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