# Boeing Alert Service Bulletin 767-49A0035: Revision 2

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2005-22523; AD 2013-05-07 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 767-49A0035](https://openairdocs.org/service-documents/boeing/767-49a0035.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin - SB-767-49A0035-02
- Pages: 52
- PDF: https://openairdocs.org/files/sha256/77/de/77dec0bb22ffb4ed850f04676528ada299fd5dcd8f0fef2b7d62bc7b5a7b6c8d
- Page: https://openairdocs.org/service-documents/boeing/767-49a0035/file/77dec0bb22ff

## Text

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### Page 1

January 16, 2003
Revision 2:  June 02, 2006 767-49A0035
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 52
 
 
 
Commercial
Airplane
Group 767
Service Bulletin
Number: 767-49A0035
Date: January 16, 2003
Revision 2: June 02, 2006
ATA System: 4915
SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 
Modification
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Unpublished Work - All Rights Reserved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
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Revision 2:  June 02, 2006 767-49A0035
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BOEING SERVICE BULLETIN 767-49A0035
 
 
Table of Contents
Revision Transmittal Sheet .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 5
Summary .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 7
1. PLANNING INFORMATION .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  11
A. Effectivity .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  11
1. Airplanes   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  11
2. Spares Affected .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  22
B. Concurrent Requirements  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   .  22
C. Reason .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  22
D. Description .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  23
E. Compliance.  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   .  .  .  .  23
F. Approval .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  24
G. Manpower   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   .  .  .  .  24
H. Weight and Balance Changes  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  25
I. Electrical Load Data  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   .  .  .  25
J. References .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   .  .  .  .  25
1. Existing Data: .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  25
2. Data supplied with this Service Bulletin:   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  25
3. Installation Drawings Used in the Preparation of this Service Bulletin: .  .  .  .  .  .  .  .  .  .  25
K. Publications Affected .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  26
L. Interchangeability and Intermixability of Parts  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  26
2. MATERIAL INFORMATION .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  27
A. Material - Price and Availability.  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  27
B. Industry Support Information .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   .  27
C. Parts Necessary For Each Airplane  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  28
1. Kits/Parts: .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  28
2. Parts and Materials Supplied by the Operator:  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  30
3. Parts Modified and Reidentified:   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  30
4. Parts Removed and Not Replaced: .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  31
D. Parts Necessary to Change Spares  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  31
E. Special Tooling - Price and Availability.  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   31
F. Special Tooling Necessary to do this Service Bulletin .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  31
3. ACCOMPLISHMENT INSTRUCTIONS .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  33
A. GENERAL INFORMATION   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  33
B. WORK INSTRUCTIONS .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  34
FIGURE  1: Modify The Aft Air-intake Duct Assembly  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  35
FIGURE  2: Install Forward Brackets On The Aft Air-Intake Duct Assembly .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  38
FIGURE  3: Install Aft Brackets On The Aft Air-Intake Duct Assembly .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  42
FIGURE  4: Air-Intake Duct And Dripshield Installation   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  47
APPENDIX  A: WET POTTING OF INSERTS  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  5 1

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Table of Contents
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January 16, 2003
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 52
 
 
 
Commercial
Airplane
Group 767
Service Bulletin
Number: 767-49A0035 Revision Transmittal Sheet
Date: January 16, 2003
Revision 2: June 02, 2006
ATA System: 4915
SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 
Modification
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 previous revisions of this service bulletin.
REASON FOR REVISION
The data given in Information Notice 767-49-0035 IN 02 is included in this revision.  The Information Notice 
advised operators that it was unnecessary to remove the forward intake duct.  The steps to remove the forward 
intake duct have been removed from the Accomplishment Instructions and from Figure 1. 
Validation information has been added to the Reason and Background  paragraphs.  
The manpower required for the airplane rework has been reduced from 3.0 hours to 2.0 hours.  
A note has been added to Figure 1 to make it easier to remove the aft air-intake duct.
A note to show the reason for the large fastener holes has been added to Figure 2.
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.
REVISION HISTORY
Original Issue: January 16, 2003
Revision 1: December 11, 2003
Revision 2: June 2, 2006

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Commercial
Airplane
Group 767
Service Bulletin
Number: 767-49A0035 Summary
Date: January 16, 2003
Revision 2: June 02, 2006
ATA System: 4915
SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 
Modification
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Boeing Service Related Problem (SRP) 767-27-0147 is related to this service bulletin.
Incorporation of this change will prevent APU air intake duct water leakage from contributing to stiff operation 
of the elevator pitch control system and any other related pitch control issues.
Two instances of stiff operation of the elevator pitch control system have been reported. An investigation 
revealed that water can occasionally leak from the joint, in the air-intake duct for the Auxiliary Power Unit (APU), 
aft of Station 1809.5. The water can leak from the duct joint onto the elevator center-auto-pilot servo Linear 
Variable Differential Transducer (LVDT).   
 A dripshield can be installed under the aft air-intake duct to prevent water from reaching the LVDT.
As a part of a service bulletin validation program, this change was completed on airplane VN027 by Revision 
01 of this service bulletin. 
ACTION (PRR B12901-029S)
The 015T1729-8 Top Kits have been placed under management control, such that one 015T1729-8 Top Kit is 
available to each operator to use as a first incorporation unit in order to generate a spare unit for component 
rework. This will minimize airplane downtime and lessen the impact to maintenance operations.
Follow accomplishment instructions under “Component Work - Aft Air-Intake Duct Assembly Modification” to 
rework an existing Aft Air-intake Duct assembly into the equivalent production aft Air-intake Duct assembly. Use 
components from the 015T1729-7 Top Kit.
Follow accomplishment instructions under “Airplane Work - Duct Replacement And Dripshield Installation” to 
install a new Dripshield on either a new 353T0252-11 Aft Air-intake Duct, from a 015T1729-8 Top Kit, or a 
reworked Aft Air-intake Duct made from a 015T1729-7 Top Kit.

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BOEING SERVICE BULLETIN 767-49A0035
 
 
EFFECTIVITY
All 767airplanes, line numbers 1 through 890, except 767-400ER airplanes.
COMPLIANCE
Boeing recommends incorporation of this service bulletin at a convenient opportunity when airplane and 
manpower are available, not to exceed 18 months after the receipt of revision one of this service bulletin.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are available for airplanes in warranty as of April 27, 2001.    Please refer to 
Paragraph 2.B., Industry Support Information.
MANPOWER
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Airplanes Total Task 
Hours
Elapsed 
Hours
Airplane Work - Duct 
Replacement And Dripshield 
Installation
2.0 2.0
Components Total Task 
Hours
Elapsed 
Hours
Component Work - Aft Air-
Intake Duct Assembly 
Modification
1.0 1.0

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FWD
DUCT ASSEMBLY
AFT AIR-INTAKE
REWORK AN EXISTING
EITHER REPLACE OR
STA
1843
INSTALL A NEW
DRIPSHIELD
SEE A
A
V86832

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Commercial
Airplane
Group 767
Service Bulletin
Number: 767-49A0035
Date: January 16, 2003
Revision 2: June 02, 2006
ATA System: 4915
SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 
Modification
1. PLANNING INFORMATION
A. Effectivity
1. Airplanes
Refer to Service Bulletin Index Document D6-24T001 Part 3 for Airplane Variable Number, Line 
Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent 
production airplanes. Refer to PRR B12901-29S for data about this change.
Airplane models:
767-200 767-300 767-300F
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
767 AIRCRAFT ONE, INC.  (ONI)
1 VA510–VA512
ABX AIR  (ABX)
1 VA301 VA304 VA803 VA807–VA809
VB101–VB123 VB125 VB302
AEROFLOT  (ARO)
1 VN471–VN472 VS216–VS217 VS321–VS324 VS392
AEROMEXICO  (AMX)
1 VF071–VF072 VF091 VF093 VS211
GROUP CONFIGURATION DESCRIPTION
1 - All 767airplanes, line numbers 1 through 890, 
except 767-400ER airplanes.

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AEROSVIT  (UKA)
1V N 1 5 5 V N 1 5 7
AEROTURBINE  (AUB)
1 VB051 VB054–VB055 VB321–VB322
AIR ALGERIE  (ALG)
1 VK131–VK133
AIR ATLANTA EUROPE LIMITED  (AUP)
1 VB326–VB327 VL011
AIR ATLANTA ICELANDIC  (AID)
1V N 1 5 3 V N 5 5 7
AIR CANADA  (ACN)
1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202
VN051–VN054 VN056–VN062 VN531 VN536
VN541–VN542 VN546–VN547 VN751–VN752 VN811–VN812
VN931–VN936 VS381–VS382 VS546–VS549
AIR CHINA  (BEJ)
1 VE064 VE083–VE086 VK161–VK164 VN388
VS206 VS208 VS274 VS307
AIR DO  (HIA)
1 VS176–VS177
AIR EUROPA  (ARE)
1 VN421 VS291–VS293
AIR GABON  (GBN)
1 VE021
AIR MADAGASCAR  (MAD)
1V N 1 6 7 V N 7 3 1
AIR MAURITIUS  (MAU)
1 VF001–VF002
AIR NEW ZEALAND  (ANZ)
1 VN652–VN658 VS112–VS113
AIR NIUGINI  (NIU)
1V N 6 5 1
AIR PACIFIC  (APC)
1V N 6 7 6
AIR SAHARA  (SAQ)
1V N 4 9 5

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AIR SEYCHELLES  (ASY)
1 VL941 VS526
AIR ZIMBABWE  (ZMB)
1 VF061–VF062
ALITALIA  (ALI)
1 VL701–VL702 VN422–VN427 VN732 VN813
VS366–VS367 VS401
ALL NIPPON AIRWAYS  (ANA)
1 VK081–VK113 VN191–VN198 VR401 VS721–VS727
VT501
AMERICAN AIRLINES  (AAL)
1 VA501–VA509 VA513–VA525 VA527–VA530 VN001–VN041
VS196–VS203
ANSETT AUSTRALIA  (ANS)
1V B 0 5 3
ARKEFLY  (HXL)
1 VN165 VN225
ASIANA AIRLINES  (AAR)
1 VK143–VK148 VR426 VW851
AUSTRALIAN AIRLINES  (AUF)
1 VN089–VN092 VS486
AUSTRIAN  (AUL)
1 VN242–VN243 VN671 VS301–VS303
AVIANCA  (AVI)
1 VE171–VE172 VF092 VF161 VN152
VN532
AVIATION COMPANY POLET  (PLF)
1V F 0 5 1
AWAS  (AWW)
1V B 3 2 5
BATAVIA AIR  (BTV)
1V A 8 0 6
BELAIR AIRLINES  (BLB)
1 VL932
BELLVIEW AIRLINES  (BEB)
1 VE125–VE126

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BLUE CITY HOLDING  (BCY)
1 VE069
BLUE PANORAMA AIRLINES  (BPA)
1 VL911 VN174 VN681 VS061
BOEING  (TBC)
1 VA001
BRA TRANSPORTES AEREOS  (BRW)
1V N 3 7 6
BRAVO AIRLINES  (BVA)
1 VE104
BRITISH AIRWAYS  (BAB)
1 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137
VS246–VS248
CAMEROON AIRLINES  (CAM)
1 VA801 VS308
CHINA EASTERN YUNNAN AIRLINES  (YUN)
1 VL871–VL873
CONDOR  (CDF)
1 VN683–VN691
CONTINENTAL AIRLINES  (CAL)
1 VR051–VR060
CONVIASA S.A.  (VSS)
1V N 5 0 0
DELTA AIR LINES  (DAL)
1 VA302–VA303 VA305–VA306 VA308–VA315 VK032
VK035–VK056 VL753 VN251–VN276 VN301–VN306
VR471–VR472 VS066–VS070 VS073–VS078 VS266–VS273
VS466–VS472
EL AL ISRAEL AIRLINES  (ELA)
1 VB281–VB284 VF101–VF102 VN682
ERITREAN AIR LINES  (ERJ)
1 VE066 VN211
ETHIOPIAN AIRLINES  (ETH)
1 VE002 VS306 VS506–VS507
ETIHAD AIRWAYS  (ETI)
1 VS391

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EUROATLANTIC AIRWAYS  (MAE)
1 VN151 VN551 VN561–VN562
EVA AIR  (EVA)
1 VN791–VN792
EVERGREEN AIR CENTER  (EAC)
1V E 0 6 1
FIRST CHOICE AIRWAYS  (ATZ)
1 VL751–VL752 VL754 VN921
FLYJET LIMITED  (FJE)
1V E 1 1 7
GE CAPITAL CORPORATION  (GEF)
1 VA307 VB443 VE123
GULF AIR  (GUL)
1 VL004–VL006 VN307–VN310 VN313–VN314
HAINAN AIRLINES  (HNA)
1 VS426 VS496–VS497
HAWAIIAN AIRLINES  (HWI)
1 VK031 VK033–VK034 VN171–VN173 VN381
VS309–VS311 VS821 VS841
ICELANDAIR  (ICE)
1 VN158 VN163 VN537
ITOCHU CORPORATION  (CIT)
1 VF181–VF184
JAL INTERNATIONAL  (JAL)
1 VB371–VB373 VK001–VK016 VK021–VK022 VK181
VK186 VR441 VR461 VS701–VS703
JET FREIGHT  (JFO)
1 VE067–VE068
KALAIR (BERMUDA)  (KLB)
1 VN311
KENYA AIRWAYS  (KEN)
1 VK141 VL003 VS331–VS333
KLM - ROYAL DUTCH AIRLINES  (KLM)
1 VL894–VL900 VS136–VS137
KRASAIR  (ZXD)
1 VE001 VE022–VE023

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LAB  (LAB)
1 VL001–VL002
LAM  (LAM)
1V F 1 6 2
LAN AIRLINES  (LAN)
1 VL703 VN063–VN064 VN166 VN168
VN753 VN966–VN971 VR251 VR256–VR260
VS111 VS131–VS133
LOT POLISH AIRLINES  (LOT)
1 VF041–VF042 VN233 VN291–VN293
MALEV HUNGARIAN AIRLINES  (HGA)
1 VF171–VF172
MARTINAIR HOLLAND  (MTH)
1 VN221–VN224 VN385 VN672
MAXJET AIRWAYS  (SLQ)
1 VB301 VE063
MEXICANA  (CMA)
1V N 1 5 4
MID EAST JET  (SKL)
1V F 2 5 1
MYTRAVEL AIRWAYS  (GUE)
1 VN951–VN953
NATIONWIDE AIRLINES  (NWR)
1V N 5 5 6
NEOS  (NEO)
1 VL892
NORTH AMERICAN AIRLINES  (NNA)
1 VL755 VN922 VS316
PB AIR  (PBJ)
1 VK142
PEGASUS AVIATION FINANCE  (PSF)
1V N 6 3 8
PHOENIX AIRCRAFT LEASING, INC.  (PLB)
1 VA810
PHOENIX AVIATION  (PHX)
1 VE041

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PLUNA  (PLU)
1 VN436
QANTAS  (QAN)
1 VN081–VN088 VN093–VN099 VN115–VN117 VN123
VN130–VN132 VS186–VS187
ROYAL AIR MAROC  (RAM)
1 VN636 VS336–VS337
ROYAL BRUNEI AIRLINES  (RBA)
1 VN372 VN382–VN384 VN386–VN387
SAS  (SAS)
1 VN156 VN164
SHANGHAI AIRLINES  (SHA)
1 VK171 VR421–VR423 VS207
SHEIKH MUSTAFA EDREES  (SME)
1V A 8 0 4
SKYMARK AIRLINES  (SKM)
1 VN637 VS231 VS261–VS263
STAR AIR  (SBJ)
1 VB323 VB328 VB441–VB442 VB444
VE101–VE103
STATE AIR COMPANY "BERKUT"  (ORE)
1 VR081
TAMPA CARGO  (TMP)
1 VE121–VE122 VE124
TEEBAH AIRLINES  (EBH)
1V A 7 1 0
THE SULTAN'S FLIGHT  (BWN)
1V F 1 8 0
THOMSONFLY  (BRI)
1 VB329–VB332 VL912–VL914 VS051–VS056
TRANSAERO AIRLINES  (TRX)
1 VE116 VE118 VE143 VN371
VN631–VN633
TUI AIRLINES BELGIUM  (TLB)
1 VN234

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UNITED AIRLINES  (UAL)
1 VA002–VA012 VA014–VA020 VN491–VN494 VN496–VN499
VN501–VN513 VS091–VS104
UPS  (UPS)
1 VR201–VR211 VW701–VW721
US AIRWAYS  (USA)
1 VE141–VE142 VE144–VE149 VE151–VE152
UZBEKISTAN AIRWAYS  (UZB)
1 VL806–VL807
VARIG AIRLINES  (VAR)
1 VN055 VN231–VN232
VIETNAM AIRLINES  (VIE)
1V N 9 7 2
VOLARE AIRLINES  (VLR)
1 VL931
YONA  (IOP)
1V N 3 1 2
ZOOM AIRLINES  (YFM)
1 VL891 VL893 VN634–VN635
IDENTIFICATION BY VARIABLE NUMBER
Variable  Group
VA001–VA020 1
VA301–VA315 1
VA501–VA530 1
VA701–VA719 1
VA801–VA810 1
VB001–VB002 1
VB051–VB055 1
VB101–VB125 1
VB201–VB202 1
VB251–VB253 1
VB281–VB284 1
VB301–VB302 1
VB321–VB332 1
VB371–VB373 1
VB401 1
VB441–VB444 1

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VE001–VE003 1
VE021–VE023 1
VE041–VE043 1
VE061–VE069 1
VE083–VE086 1
VE101–VE104 1
VE116–VE118 1
VE121–VE126 1
VE141–VE152 1
VE171–VE172 1
VF001–VF002 1
VF041–VF042 1
VF051 1
VF061–VF062 1
VF071–VF072 1
VF091–VF093 1
VF101–VF102 1
VF161–VF162 1
VF171–VF172 1
VF180–VF184 1
VF251 1
VK001–VK016 1
VK021–VK022 1
VK031–VK056 1
VK081–VK113 1
VK131–VK133 1
VK141–VK148 1
VK161–VK164 1
VK171 1
VK181 1
VK186 1
VL001–VL006 1
VL011 1
VL701–VL703 1
VL751–VL755 1
VL806–VL807 1
VL871–VL873 1
VL891–VL900 1
VL911–VL914 1
Variable  Group

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VL931–VL932 1
VL941 1
VN001–VN041 1
VN051–VN064 1
VN081–VN099 1
VN111–VN127 1
VN130–VN137 1
VN151–VN158 1
VN163–VN168 1
VN171–VN174 1
VN191–VN198 1
VN211–VN212 1
VN221–VN225 1
VN231–VN234 1
VN241–VN243 1
VN251–VN276 1
VN291–VN293 1
VN301–VN314 1
VN371–VN372 1
VN376 1
VN381–VN388 1
VN421–VN427 1
VN436 1
VN471–VN472 1
VN491–VN513 1
VN531–VN532 1
VN536–VN537 1
VN541–VN542 1
VN546–VN547 1
VN551 1
VN556–VN557 1
VN561–VN562 1
VN631–VN638 1
VN651–VN658 1
VN671–VN672 1
VN676 1
VN681–VN691 1
VN731–VN732 1
VN751–VN753 1
Variable  Group

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VN791–VN792 1
VN811–VN813 1
VN921–VN922 1
VN931–VN936 1
VN951–VN953 1
VN966–VN972 1
VR051–VR060 1
VR081 1
VR201–VR211 1
VR251 1
VR256–VR260 1
VR401 1
VR421–VR423 1
VR426 1
VR441 1
VR461 1
VR471–VR472 1
VS051–VS056 1
VS061 1
VS066–VS070 1
VS073–VS078 1
VS091–VS104 1
VS111–VS113 1
VS131–VS133 1
VS136–VS137 1
VS176–VS177 1
VS186–VS187 1
VS196–VS203 1
VS206–VS208 1
VS211 1
VS216–VS217 1
VS231 1
VS246–VS248 1
VS261–VS263 1
VS266–VS274 1
VS291–VS293 1
VS301–VS303 1
VS306–VS311 1
VS316 1
Variable  Group

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2. Spares Affected
Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts 
Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for 
the recommended use.
B. Concurrent Requirements
None.
C. Reason
Boeing Service Related Problem (SRP) 767-27-0147 is related to this service bulletin.
Incorporation of this change will prevent APU air intake duct water leakage from contributing to stiff 
operation of the elevator pitch control system and any other related pitch control issues.
Two instances of stiff operation of the elevator pitch control system have been reported. An 
investigation revealed that water can occasionally leak from the joint, in the air-intake duct for the 
Auxiliary Power Unit (APU), aft of Station 1809.5. The water can leak from the duct joint onto the 
elevator center-auto-pilot servo Linear Variable Differential Transducer (LVDT).     
A dripshield can be installed under the aft air-intake duct to prevent water from reaching the LVDT.
VS321–VS324 1
VS331–VS333 1
VS336–VS337 1
VS366–VS367 1
VS381–VS382 1
VS391–VS392 1
VS401 1
VS426 1
VS466–VS472 1
VS486 1
VS496–VS497 1
VS506–VS507 1
VS526 1
VS546–VS549 1
VS701–VS703 1
VS721–VS727 1
VS821 1
VS841 1
VT501 1
VW701–VW721 1
VW851 1
Variable  Group

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Revision 1 is sent to prevent an interference condition found on a production airplane. New kits, 
provided by this revision, allow the dripshield to be installed further away from an adjacent hydraulic 
tube. None of the original Top kits 015T1729-1 and -2 were shipped to operators. Top kits 015T1729-
1 and -2 have been replaced by Top kits 015T1729-7 and -8 respectively. The dripshield 353T0263-
1, contained in the original top kits, has been replaced by dripshield 353T0263-2.
The compliance time was changed to add "not to exceed 18 months after the receipt of revision one 
of this service bulletin."
This revision also provides after rework part numbers for existing Aft Air-intake ducts that are 
reworked by this service bulletin and do not have a production equivalent after rework part number.
Revision 2 is sent to incorporate the intent of 767-49A0035R01, IN02.  The steps to remove the 
forward intake duct have been removed from the Accomplishment Instructions and from Figure 1. 
Validation information has been added to the Reason and Background  paragraphs.  The manpower 
required for the airplane rework has been reduced from 3.0 hours to 2.0 hours.  A note has been 
added to Figure 1 to make it easier to remove the aft air-intake duct.  A note to show the reason for 
the large fastener holes has been added to Figure 2.
As a part of a service bulletin validation program, this change was completed on airplane VN027 by 
Revision 01 of this service bulletin. 
D. Description
The 015T1729-8 Top Kits have been placed under management control, such that one 015T1729-8 
Top Kit is available to each operator to use as a first incorporation unit in order to generate a spare 
unit for component rework. This will minimize airplane downtime and lessen the impact to 
maintenance operations.
Follow accomplishment instructions under “Component Work - Aft Air-Intake Duct Assembly 
Modification” to rework an existing Aft Air-intake Duct assembly into the equivalent production aft Air-
intake Duct assembly. Use components from the 015T1729-7 Top Kit.
Follow accomplishment instructions under “Airplane Work - Duct Replacement And Dripshield 
Installation” to install a new Dripshield on either a new 353T0252-11 Aft Air-intake Duct, from a 
015T1729-8 Top Kit, or a reworked Aft Air-intake Duct made from a 015T1729-7 Top Kit.   
Revision 1 - No more work is necessary because no parts were available to make the change on 
airplanes shown in the initial release of this service bulletin.
Revision 2 - No more work is necessary on airplanes changed as shown in the previous revisions of 
this service bulletin.
E. Compliance
Boeing recommends incorporation of this service bulletin at a convenient opportunity when airplane 
and manpower are available, not to exceed 18 months after the receipt of revision one of this service 
bulletin.

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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.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected 
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency 
approval before incorporating this service bulletin.
G. Manpower
The table below shows an estimate of the task-hours necessary to do this change for each airplane.  
This estimate is for direct labor only, done by an experienced crew.  Adjust the estimate with operator 
task-hour data if necessary.  The estimate does not include lost time.  These are some examples of 
lost time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Airplane Work - Duct Replacement And Dripshield Installation
Component Work - Aft Air-Intake Duct Assembly Modification
Task
Number of 
Persons Task-Hours Elapsed Hours
Access 1 0.50 0.50
Replace Duct 1 1.0 1.0
Install Dripshield 1 0.5 0.5
Total per Airplane 2.00 2.00
Task
Number of 
Persons Task-Hours Elapsed Hours
Change Duct 1 1.0 1.0
Total per Airplane 1.0 1.0

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H. Weight and Balance Changes
I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. Engineering Change Memo PRR B12901-29S
b. Service Related Problem (SRP) 767-SRP-27-0147
c. 767 Maintenance Manual (AMM) Subject 49-15-01
d. BSOPM 20-50-10
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
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.
Top Kit Airplane Model
Change in 
Weight (Pounds)
Change in 
Moment (Pound-
Inches)
015T1729-7 767-200 +1.9 +3438.0
767-300 +1.9 +3688.9
015T1729-8 767-200 +1.7 +3076.0
767-300 +1.7 +3300.5
Drawing Number Title
353T0252 INLET DUCT ASSY TRANSITION - AUX POWER SYSTEM
353T0200 INTAKE DUCT INSTL - AUXILIARY POWER SYSTEM

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K. Publications Affected
L. Interchangeability and Intermixability of Parts
Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability 
information.
Publication Chapter-Section
767 Maintenance Manual 49-15-01
767 Illustrated Parts Catalog 49-15-01

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2. MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane and 
Paragraph 2.D., Parts Necessary to Change Spares as shown below.  If there is a limit in the quantity 
(QTY) of kits, a supply sequence is given by Spares.  More kits become available as shown in the 
Reorder Lead Time (ROLT).  ROLT is calculated from the date Boeing gets the purchase order
The kits are subject to the terms and conditions of the Boeing standard purchase order 
acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States 
dollars. Terms: Net 30 days.
NOTE:The 015T1729-8 Top Kits have been placed under management control, such that one 
015T1729-8 Top Kit is available to each operator to use as a first incorporation unit in order to 
generate a spare unit for component rework. This will minimize airplane downtime and lessen 
the impact to maintenance operations.
B. Industry Support Information
Boeing warranty remedies are available for 767 airplanes in warranty as of April 27, 2001. For man-
hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing 
Commercial Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be 
supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service 
bulletin number and reference the airplane variable numbers in your purchase order.
 Number Name Date QTY
ROLT 
(Weeks)
Unit Price thru
March 01, 2004
015T1729-7 Top Kit, Duct Rework 
Installation
3/25/04 14 20 $1462.00
4/08/04 10 20 $1462.00
4/22/04 10 20 $1462.00
5/06/04 10 20 $1462.00
5/20/04 10 20 $1462.00
6/04/04 10 20 $1462.00
6/18/04 10 20 $1462.00
7/02/04 10 20 $1462.00
7/19/04 10 20 $1462.00
8/02/04 10 20 $1462.00
8/16/04 12 20 $1462.00
015T1729-8 Top Kit, Duct 
Replacement 
Installation
3/25/04 10 19 $18985.00
4/08/04 10 19 $18985.00
4/22/04 10 19 $18985.00
5/06/04 5 19 $18985.00

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C. Parts Necessary For Each Airplane
1. Kits/Parts:
To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE:The 015T1729-8 Top Kits have been placed under management control, such that one 
015T1729-8 Top Kit is available to each operator to use as a first incorporation unit in order 
to generate a spare unit for component rework. This will minimize airplane downtime and 
lessen the impact to maintenance operations
NOTE:One 015T1729-8 top kit is necessary for the first airplane in each operators’ fleet, and one 
015T1729-7 top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied 
by the Operator, are necessary for all remaining airplanes in each operators’ fleet.
015T1729 KIT, INTAKE DUCT, DRIPSHIELD CONVERSON - AUX. PWR. SYS.
New Part 
Number
QTY
Name
Existing Part 
Number Notes-8 -7
015T1729-7 . - Top Kit, Duct 
Rework Installation
-( f )
015T1729-8 - . Top Kit, Duct 
Replacement 
Installation
-( f )
015T1729-3 - 1 Subkit, Intake Duct, 
Drip Shield 
Conversion
--
353T0263-2 1 1 Dripshield - (b) (g)
353T0252-11 1 - Aft Air-intake Duct 
Assembly
353T0252-() (a) (b) 
(c) (e)
BACB30NM3K2 4 4 Bolt - (d)
NAS1149D0316J 4 4 Washer - (d)
(a) Discard or rework the existing part. 
(b) The 353T0252-11 part is used in production.
(c) You can not use the existing part to replace the new or changed part without 
rework.
(d) If grip length shown is not available at Boeing, fasteners supplied in kits may 
be one grip length longer than indicated. Also, if any fasteners part numbers 
listed are not available or have been superseded, substitute fasteners may be 
supplied in kits. Boeing Document D-590 and Boeing Drawing 012T2100 are 
used to determine the part numbers used as substitutes.
(e) There is no production part number for the reworked Aft Air-intake Duct 
assembly. Use the new retrofit part numbers shown in Paragraph 2.C.3. “Parts 
Modified and Re-identified” to identify on the duct that it has been reworked by 
this service bulletin. Use BSOPM 20-50-10 part marking procedure.
(f) Revision 1 replaced Top Kits 015T1729-1 and -2 with Top Kits 015T1729-7 
and -8 respectively.
(g) Revision 1 replaced dripshield 353T0263-1 with dripshield 353T0263-2.

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015T1729-3 SUBKIT, INTAKE DUCT, DRIPSHIELDCONVERSION - AUX. 
PWR. SYS.
New Part 
Number
QTY
Name
Existing Part 
Number Notes-3
015T1729-3 - Subkit, Intake Duct, 
Drip Shield 
Conversion
--
015T1729-6 1 Mylar Template - -
015T1729-4 2 Bracket Assembly 353T0256-2 (a)
353T0256-6 2 Bracket Assembly - (b)
BACB30NM3K2 4 Bolt - (c)
BACB30NX5HK3 4 Bolt - (c)
BACC30AB5C 4 Collar - (c)
BACI12AC3CD 4 Insert, Blind - (c)
NAS1149C0332R 4 Washer - (c)
(a) Discard the existing part. 
(b) This part is used in production.
(c) If grip length shown is not available at Boeing, fasteners supplied in kits 
may be one grip length longer than indicated. Also, if any fasteners part 
numbers listed are not available or have been superseded, substitute 
fasteners may be supplied in kits. Boeing Document D-590 and Boeing 
Drawing 012T1200 are used to determine the part numbers used as 
substitutes.

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2. Parts and Materials Supplied by the Operator:
3. Parts Modified and Reidentified:
The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the 
number of parts changed on each airplane.
Part Number / 
Specification QTY Name Notes
BMS 5-28, Type 
18 (a)
4 Oz. Potting Compound -
BMS 5-28, Type 
19, 20 or 30 (a)
- Optional Potting Compound -
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for 
supplier data.
Existing Part 
Number QTY Name New Part Number Notes
353T0252- 1 1 Aft Air-intake Duct 
Assembly
015T1729-9 (a) (b) (c)
353T0252- 5 1 Aft Air-intake Duct 
Assembly
015T1729-10 (a) (b) (c)
353T0252- 6 1 Aft Air-intake Duct 
Assembly
015T1729-11 (a) (b) (c)
353T0252- 8 1 Aft Air-intake Duct 
Assembly
015T1729-12 (a) (b) (c)
353T0252- 9 1 Aft Air-intake Duct 
Assembly
015T1729-13 (a) (b) (c)
(a) Make the change given in this service bulletin.
(b) The 015T1729-( ) retrofit part numbers shown are the new part numbers after the duct is 
reworked by the change given in this service bulletin. Use BSOPM 20-50-10 part marking 
procedure.
(c) The 353T0252-11 duct part number is used in production.

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4. Parts Removed and Not Replaced:
D. Parts Necessary to Change Spares
To get the kit shown below, refer to Paragraph 2.A., Material - Price and Availability.
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 except Mylar 
Template 015T1729-6, provided in subkit 015T1729-3, and 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.
Existing 
Part Number Name QTY Notes
353T0256-2 Bracket Assembly 2 -
Part Number Name QTY
015T1729-3 Subkit, Intake Duct, 
Drip Shield 
Conversion
1

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BLANK PAGE

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3. ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
NOTE:
1. Use sufficient precautions to make sure that the system components, airplane electrical 
wires and structures, are not damaged by drills, metal shavings and other contamination 
while you do work. Metal shavings or contamination left in the airplane can touch wire 
bundles and cause chafing damage to electrical wires. Chafed wires can cause arcing 
damage.
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. The work instructions are divided into work packages. Task-Hours and Elapsed-Hours for 
each package are given in Paragraph 1.G., Manpower. You can do each work package 
independently.
5. Unless shown differently, these dimensions and tolerances are used:
— Linear dimensions are in inches
— Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or 
minus 0.03 inch.
— Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
— Hole dimensions for standard solid rivets are given in 767 Structural Repair Manual, 
Chapter 51
— Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual, 
Chapter 51.
6. For approved fastener and process material substitutions, refer to 767 Structural Repair 
Manual, Chapter 51, Alternate fasteners are given in 767 Structural Repair Manual 
Chapter 51 and Boeing Drawing 012T2100.
7. 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
8. The 015T1729-8 Top Kits have been placed under management control, such that one 
015T1729-8 Top Kit is available to each operator to use as a first incorporation unit in order 
to generate a spare unit for component rework. This will minimize airplane downtime and 
lessen the impact to maintenance operations.
9. The work instructions are divided into two instruction packages: The “Airplane Work - Duct 
Replacement and Dripshield Installation” and the “Component Work - Aft Air-Intake Duct 
Assembly Modification” instructions.
Follow accomplishment instructions under “Component Work - Aft Air-intake Duct 
Assembly Modification” to rework an existing Aft Air-intake Duct assembly into the 
equivalent production aft Air-intake Duct assembly. Use components from the 015T1729-
7 Top Kit.

### Page 34

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BOEING SERVICE BULLETIN 767-49A0035
 
 
Follow accomplishment instructions under “Airplane Work - Duct Replacement And 
Dripshield Installation” to install a new Dripshield on either a new 353T0252-11 Aft Air-
intake Duct, from a 015T1729-8 Top Kit, or a reworked Aft Air-intake Duct made from a 
015T1729-7 Top Kit.
B. WORK INSTRUCTIONS
Airplane Work - Duct Replacement And Dripshield Installation
1. Get access and remove the aft Air-intake duct components from the airplane:
a. On the first airplane in each operators’ fleet, use 767 AMM 49-15-01 instructions to get 
access and remove the aft Air-intake duct components from the airplane. 
b. On all remaining airplanes in each operators’ fleet, get access and remove the aft Air-intake 
duct components from the airplane as shown in Figure 1.
2. Install an aft Air-intake Duct assembly and a Dripshield on the airplane as shown in Figure 4:
a. On the first airplane in each operators’ fleet, install a new aft Air-intake Duct assembly 
352T0252-11, from the 015T1729-8 Top Kit. 
b. On all remaining airplanes in each operators’ fleet, install a reworked aft Air-intake Duct 
assembly, made from a 015T1729-7 Top Kit. 
Rework the aft Air-intake Duct assembly by following the “Component Work - Aft Air-Intake 
Duct Assembly Modification” instructions below.
Component Work - Aft Air-Intake Duct Assembly Modification 
1. Replace the two forward brackets, located on the bottom of the aft Air-intake Duct assembly, as 
shown in Figure 2.
2. Install two aft brackets, on the bottom of the aft Air-intake Duct assembly, as shown in Figure 3.

### Page 35

FIGURE 1: Modify The Aft Air-intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
FIGURE  1: Modify The Aft Air-intake Duct Assembly
AFT AIR-INTAKE
DUCT ASSEMBLY
SLIP RING
(6 LOCATIONS)
FASTENER
SLIP RING
A
A
1
31
1
UP
FWD
SEE A
A
V86901
(SHEET 1 OF 3)

### Page 36

FIGURE 1: Modify The Aft Air-intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
(2 LOCATIONS)
BRACKET
(4 LOCATIONS)
FASTENER
A-A
SLIP RING
DUCT ASSEMBLY
AFT AIR-INTAKE
FASTENER
FASTENERFASTENER
B-B
(2 LOCATIONS)
FASTENER
BRACKET
SLIP RING
B
B
2
2
UP
FWD
3
3
33
2
3
2
3
V86909
FWD
(SHEET 2 OF 3)

### Page 37

FIGURE 1: Modify The Aft Air-intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 
numbers shown below are the total number of parts necessarily for each step.
STEP TASK NAME PART NUMBER QTY NOTES
1
Remove Aft Air-intake Duct 
Assembly
             - 1 keep. Use 767 AMM 49-
15-01
Slip Ring              - 1 keep
Slip Ring Fastener              - 6 keep
NOTE:  Remove the fasteners and sealant from the aft end of the duct.  Remove the 6 fasteners that 
connect the aft air-intake duct to the slip ring.  Push the slip ring slightly forward.  Shake the aft duct until 
it becomes loose and drops down.  
2 Bracket 253T0256-2 2 discard
Bracket Fastener              - 2 keep
3
Re-install Slip Ring              - 1 kept
Slip Ring Fastener - 4 of 6 kept. Keep remain-
ing two slip ring fasten-
ers for installation later.
(SHEET 3 OF 3)

### Page 38

FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
FIGURE  2: Install Forward Brackets On The Aft Air-Intake Duct Assembly
A
A
UP
FWD
SEE A
A
V86938
(SHEET 1 OF 4)

### Page 39

FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
RING
SLIP
RING
SLIP
(4 LOCATIONS)
FASTENER
(2 LOCATIONS)
FASTENER
BRACKET
(2 LOCATIONS)
A-A
AFT AIR-INTAKE
DUCT ASSEMBLY
DUCT ASSEMBLY
AFT AIR-INTAKE
B
B
UP
FWD
UP
FWD
7
7
642
7531
531
B
BSEE
V86939
(SHEET 2 OF 4)

### Page 40

FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
Revision 2:  June 02, 2006 767-49A0035
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 52
BOEING SERVICE BULLETIN 767-49A0035
 
 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 
numbers shown below are the total number of parts necessary for each step.
NOTE:Use components from the 015T1729-7 Top Kit.
STEP TASK NAME PART NUMBER QTY NOTES
1
Install Bracket Assembly 015T1729-4 2 on Slip Ring
Slip Ring Fastener              - 2 kept
2
Mark Fastener Hole              - 4 locations on brackets. 
Use holes in aft air-
intake duct as a guide
3 Remove Bracket Assembly 015T1729-4 2 temporarily and keep
Slip Ring Fastener              - 2 temporarily and keep
4
Drill Fastener Hole              - 4 0.192 to 0.202 inch 
diameter. Two in each 
bracket.  These fastener 
holes are larger then 
normal.  The larger hole 
allows for some 
adjustment of the 
bracket.
5 Install Bracket Assembly 015T1729-4 2 loose on Slip Ring
Slip Ring Fastener              - 2 kept
B-B
BRACKET
BRACKET
FASTENER
FASTENER
(6 LOCATIONS)
FASTENER
DUCT ASSEMBLY
AFT AIR-INTAKESLIP RING
SLIP RING
FASTENER
SLIP RING
FASTENER
SLIP RING
15 3
15 3
513
513
62 4
62 4
7
7
V86940
FWD
(SHEET 3 OF 4)

### Page 41

FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
6
Install Bolt BACB30NX5HK3 4                 -
Collar BACC30AB5C 4                 -
7 Remove Slip Ring              - 1 keep 
Slip Ring Fastener              - 6 keep 
STEP TASK NAME PART NUMBER QTY NOTES
(SHEET 4 OF 4)

### Page 42

FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
FIGURE  3: Install Aft Brackets On The Aft Air-Intake Duct Assembly
A-A
BRACKETS
FORWARD
ASSEMBLY
AIR-INTAKE DUCT
BOTTOM OF AFT
BRACKETS
NEW AFT
A
A
B
B
UP
FWD
6
5
SEE A
V86941
FWD
(SHEET 1 OF 5)

### Page 43

FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
B-B
TEMPLATE
MYLAR
FOR INSERTS
HOLE LOCATION
AIR-INTAKE DUCT
BOTTOM OF AFT
ASSEMBLY
BRACKETS
AGAINST THE FORWARD
WILL BE USED TO BUTT
THIS TRIMMED EDGE
NEW FORWARD
BRACKET
NEW FORWARD
BRACKET
MARK
ALIGNMENT
HOLE LOCATION
FOR INSERTS
ALIGNMENT
MARK
C
C
UP
FWD
1
BSEE
43 5
BSEE
2
2
43 5
BSEE
V86945
(SHEET 2 OF 5)

### Page 44

FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
BRACKETSINSERT
INSERT
C-C
ALIGNMENT
HOLE LOCATION
TEMPLATE
MYLAR
NOT SAG IN THIS AREA
MYLAR TEMLATE SHOULD TEMPLATE
MYLAR
D-D
D
D
A 6
3 4 5
53 4
FWD
UP
2
SEE B FWD
UP
SEE B
UP
V86961
(SHEET 3 OF 5)

### Page 45

FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
Revision 2:  June 02, 2006 767-49A0035
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BOEING SERVICE BULLETIN 767-49A0035
 
 
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 
numbers shown below are the total number of parts necessary for each step.
MYLAR TEMPLATE
BRACKET HOLES
FROM CENTER OF
USE TO LOCATE
BRACKET HOLES
FROM CENTER OF
USE TO LOCATE
FOR INSERTS
HOLE LOCATION
HOLE LOCATION
FOR INSERTS
BRACKETS
BUTT AGAINST THE
WILL BE USED TO
THIS TRIMMED EDGE
FWD
B
53 4
53 4
2
2
V86960
(SHEET 4 OF 5)

### Page 46

FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
NOTE:Use components from the 015T1729-7 Top Kit.
STEP TASK NAME PART NUMBER QTY NOTES
1 Place Mylar Template 015T1729-6 1 on the bottom of the Air- intake duct
2
Align Marks - 2 on the Mylar Template 
with holes in the two 
forward brackets
NOTE: Make sure the edge of the Mylar Template butts up against the aft surface of the two 
forward brackets, and make sure the mylar does not sag.
3
Transfer Hole Locations - 4 from template to aft Air-
intake duct
Remove Mylar Template 015T1729-6 1 -
4 Install Insert BACI12AC3CD 4 Use instructions in Appendix A
5
Install Bracket Assembly 353T0256-6 2 -
Bolt BACB30NM3K2 4 -
Washer NAS1149C0332R 4 -
6
Change Part 
Number
Aft Air-intake Duct 
Assembly
- 1 as shown in Paragraph 
2.C.3 “Parts Modified 
and Reidentified”
(SHEET 5 OF 5)

### Page 47

FIGURE 4: Air-Intake Duct And Dripshield Installation
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
FIGURE  4: Air-Intake Duct And Dripshield Installation
AFT AIR-INTAKE(REFERENCE)
DUCT ASSEMBLY
FORWARD AIR-INTAKE
SLIP RING
DUCT ASSEMBLY
SEE A
UP
FWD
1
1
1
A
BSEE
V86963
(SHEET 1 OF 4)

### Page 48

FIGURE 4: Air-Intake Duct And Dripshield Installation
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
DUCT ASSEMBLY
AFT AIR-INTAKE
DRIPSHIELD
FASTENERS
UP
FWD
B
2
2
DSEE
SEE C
V86971
(SHEET 2 OF 4)

### Page 49

FIGURE 4: Air-Intake Duct And Dripshield Installation
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
(2 LOCATIONS)
FASTENER
DRIPSHIELD
(2 LOCATIONS)
FASTENER
DRIPSHIELD
(6 LOCATIONS)
SLIP RING FASTENER
FWD
FWD
RING
SLIP
C
2
2
D
2
2
1
1
V86967
(SHEET 3 OF 4)

### Page 50

FIGURE 4: Air-Intake Duct And Dripshield Installation
January 16, 2003
Revision 2:  June 02, 2006 767-49A0035
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BOEING SERVICE BULLETIN 767-49A0035
 
 
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 
numbers shown below are the total number of parts necessary for each step.
STEP TASK NAME PART NUMBER QTY NOTES
1
Install Slip Ring - 1 kept
Slip Ring Fastener - 6 kept
Forward Air-intake 
Duct
- 1 kept. Use 767 AMM 49-
15-01
Aft Air-intake Duct - 1 new or reworked. Use 
767 AMM 49-15-01
2
Install Dripshield 
Assembly
353T0263-2 1 -
Bolt BACB30NM3K2 4 -
Washer NAS1149D0316J 4 -
(SHEET 4 OF 4)

### Page 51

APPENDIX A: WET POTTING OF INSERTS
January 16, 2003
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BOEING SERVICE BULLETIN 767-49A0035
 
 
APPENDIX  A: WET POTTING OF INSERTS
NOTE:THE PROCESS INFORMATION THAT IS SUPPLIED WITH THIS SERVICE BULLETIN IS IN A 
SHORTENED FORM AND WAS UP-T0-DATE WHEN THIS SERVICE BULLETIN WAS PREPARED. 
THE PROCESS INFORMATION SUPPLIED WILL NOT BE KEPT UP-TO-DATE. FOR MORE 
INFORMATION, REFER TO THE APPLICABLE BAC PROCESS AND MATERIAL SPECIFICATIONS.
PROCESS FOR POTTING INSERTS AND EDGES INTO SANDWHICH PANELS (BAC5583)
1. BAC5583 METHOD B - WET POTTING OF INSERTS
A. Locate and drill a 0.686 to 0.691 inch diameter hole in the panel. The hole should be down to, but not 
in contact with the opposite face. Hole depth shall be at least 0.250 inch greater that the insert length.
B. Remove loose particles, including dust from the hole using a suitable method such as vacuuming or 
blow out with clean, dry air.
WARNING: COMPRESSED AIR SHALL NOT BE USED FOR CLEANING PURPOSES EXCEPT
WHERE REDUCED TO LESS THAN 30 PSI AND THEN ONLY WITH EFFECTIVE CHIP
GUARDING AND PERSONAL PROTECTION EQUIPMENT.
C. Do not clean the inserts unless they are contaminated with oil, grease, of similar bond inhibiting 
substances or particles which would prevent bonding of the insert.
D. Profile holes with enough potting compound to ensure that when the insert is installed the bottom of 
the insert will be immersed into the potting.
E. Before the initial gel time is achieved (see Table I, Cure Schedules), push the insert into the hole by 
applying even pressure across the insert-tab until it is flush with the surface (see Detail I).)
F. Inject potting compound into the hole of the insert tab until approximately a.0.25 inch uninterrupted 
stream of potting compound is expelled through the other hole.
G. Inject potting compound into the opposite insert tab hole until approximately a 0.25 inch uninterrupted 
stream of potting compound is expelled through the other hole.
H. Examine the insert to ensure that it is flush (+0.02/-0.02 inch) with panel surface and that the surfaces 
are clean of potting compound. 
I. Remove the excess potting material. Solvent clean in accordance with BSOPM 20-30-03 or operator’s 
equivalent procedure. An approved solvent may be used on fiberglass or paperbase laminate 
surfaces for removing trace potting material. Decorative laminate surfaces should be protected from 
contamination by masking tape, and solvent cleaning if needed.
J. Cure the potting compound as in Table I, Cure Schedules.
K. After initial cure (cure to permit further processing from Table I), remove alignment tabs, protective 
tape, etc. No load (such as torque or pullout for an insert) may be applied until potting is fully cured.
2. PREPARATION OF POTTING COMPOUND

### Page 52

APPENDIX A: WET POTTING OF INSERTS
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BOEING SERVICE BULLETIN 767-49A0035
 
 
A. Combine 50 grams of BMS 5-28, Type 18 (BMS 5-28, Type 19, 20 or 30 Optional) Part A with the 
appropriate amount of Part B in accordance with the manufacturer’s recommendations. Thoroughly 
blend the two components within 6 minutes of mixing. The working life of the mixed potting compound 
at Room Temperature (65 to 85 F) is 12 to 25 minutes.
TABLE I: CURE SCHEDULES
BMS 5-28 
TYPE
GEL TIME 
(minutes)
CURE TO PREMIT 
FURTHER PROCESSING
FULL CURE
18 12-25 3 hours minimum at room 
temperature (b)
5 hours at 125 F (a)
7 days at room temperature (b)
(a) +/- 10 F
(b) 65 to 85 F
COMPOUND
POTTING
INSTALLATION, PROVIDED POTTING FLOWS UNDER INSERT
CORE MAY BE CRUSHED ON INSTALLATION TO INSURE FLUSH
INSERT
PORTS
POTTING
TAB (NAS1837)
PANEL
DETAIL I
1
1
V87042

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