# Boeing Alert Service Bulletin 767-51A0027: Revision 1 - 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 767-51A0027](https://openairdocs.org/service-documents/boeing/767-51a0027.md) - Title as filed: U.S. DOT/FAA - Service Bulletin - SB-767-51A0027-01 - Pages: 62 - PDF: https://openairdocs.org/files/sha256/5f/12/5f12caff705fd12273155fa338c6117ea64c0d348dbd8a0eca216b00323b824f - Page: https://openairdocs.org/service-documents/boeing/767-51a0027/file/5f12caff705f ## Text Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 62 Commercial Airplane Group 767 Service Bulletin Number: 767-51A0027 Date: December 09, 2004 Revision 1: October 12, 2006 ATA System: 5141 SUBJECT: STRUCTURES - Airframe Drainage - Horizontal Stabilizer Center Section - Gutter Installation BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. ### Page 2 BLANK PAGE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 62 BOEING SERVICE BULLETIN 767-51A0027 BLANK PAGE ### Page 3 Table of Contents December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 62 BOEING SERVICE BULLETIN 767-51A0027 Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 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: . . . . . . . . . . . . . . . . . . . . . . . . . 26 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 26 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: . . . . . . . . . . . . . . . . . . . . . . 29 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 30 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 1: GUTTER PREPARATION AND PROTECTION . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 2: REWORK SIDE BRACE FITTINGS - HORIZONTAL STABILIZER CENTER SECTION . . 36 FIGURE 3: GUTTER INSTALLATION - UPPE R SURFACE, HORIZONTAL STABILIZER CENTER SECTION - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FIGURE 4: GUTTER INSTALLATION - UPPE R SURFACE, HORIZONTAL STABILIZER CENTER SECTION - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION. . . . . . . . 45 FIGURE 6: DISCONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION . . 50 FIGURE 7: GUTTER PREPARATION - LOCATOR IDENTIFICATION . . . . . . . . . . . . . . . . . 52 FIGURE 8: GUTTER INSTALLATION - UPPE R SURFACE, HORIZONTAL STABILIZER CENTER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 ### Page 4 Table of Contents December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 9: GUTTER SEALING - HORIZONTAL STABILIZER CENTER SECTION. . . . . . . . . . . 59 FIGURE 10: CONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION . . . 61 ### Page 5 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 62 Commercial Airplane Group 767 Service Bulletin Number: 767-51A0027 Revision Transmittal Sheet Date: December 09, 2004 Revision 1: October 12, 2006 ATA System: 5141 SUBJECT: STRUCTURES - Airframe Drainage - Horizontal Stabilizer Center Section - Gutter Installation 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 initial release of this service bulletin. Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2005-NM-058-AD is related to this service bulletin. REASON FOR REVISION This revision is sent to improve the work instructions as a result of access restrictions found during the service bulletin validation. Additionally, based on one other operator report revision 1 is sent to provide instructions to install the gutter as a one piece assembly. Instructions throughout the service bulletin are changed to provide two options to install the gutter as one piece or as two pieces. As a part of a service bulletin validation program, this change was completed on airplane VN097 by Service Bulletin 767-51A0027 before the release of Revision 1 of this service bulletin. In the validation the gutter was installed in two pieces. The change completed on airplane VN097 by Service Bulletin 767-51A0027 is equivalent to the release of Revision 1 of this service bulletin. Changes to this service bulletin include: – References to a FAA Notice of Proposed Rule Making are added throughout the service bulletin. – Material Information - A new 180T3250-9 gutter assembly is added. The 180T3250-4 gutter assembly is optional to the 180T3250-9 gutter assembly. The Boeing drawing number and parts modified and reidentified are changed. The quantity of optional rivets supplied by the operator is reduced. – Accomplishment Instructions - An additional access door is added. Maintenance manual references to test the elevator control system, elevator power control actuator and autopilot systems are added. A stabilizer tool reference has been removed as it is acceptable to use another lock tool. A maintenance manual reference to install the service platform is changed. – Figure 1 is changed to add a dimension for the gutter assembly cut location. – Figure 2 is changed to give rework instructions if cracks are found and to add an alternative high frequency eddy current inspection for cracks. The two possible side brace fittings installed after the rework are identified. – Figures 3 and 4 are changed to remove the option to install rivets and to change the quantity of hi loks used to install the gutter assembly at each hydraulic bracket. – Figure 6 is added to disconnect and move the hydraulic lines at the hydraulic control brackets. ### Page 6 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 62 BOEING SERVICE BULLETIN 767-51A0027 – Figure 7 is added to identify a locator mark on the gutter when installing the gutter as one piece. – Figure 8 is added to install the gutter as one piece. – Figure 9 is added to apply sealant between the upper spar chord and gutter when installing the gutter as one piece. – Figure 10 is added to connect the hydraulic lines at the hydraulic control brackets. 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: December 09, 2004 Revision 1: October 12, 2006 ### Page 7 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 62 Commercial Airplane Group 767 Service Bulletin Number: 767-51A0027 Summary Date: December 09, 2004 Revision 1: October 12, 2006 ATA System: 5141 SUBJECT: STRUCTURES - Airframe Drainage - Horizontal Stabilizer Center Section - Gutter Installation CONCURRENT REQUIREMENTS None. BACKGROUND This service bulletin gives instructions to install a gutter on the horizontal stabilizer center section. This gutter will channel water that enters Section 48 at the side of body seals away from the elevator control system components aft of the horizontal stabilizer. This will make it less likely that ice can accumulate on the elevator control system components. Ice on the elevator systems can restrict elevator movement which limits the ability of the flight crew to make elevator control inputs, resulting in reduced controllability of the airplane. Boeing has received three reports of stiff or jammed elevator controls. Analysis of all three reports indicated that ice had formed on the elevator control components aft of the horizontal stabilizer, which restricted the movement of the elevator controls. Water was found to get into Section 48 of the airplane through the fairing panels at the side of the body. The ice then formed from water that had accumulated on the horizontal stabilizer center section. In one case, the water accumulated due to a leak in the Auxiliary Power Unit (APU) inlet duct. In another case, the water came from a leak in a galley water drain line. Airplane line numbers 1 through 110 have side of body seal doors that do not allow water to enter Section 48 and therefore, are not subject to this service bulletin. After line number 921, a gutter is installed on the horizontal stabilizer center section in production. Accomplishment of the modification shown in this service bulletin will make it less likely that movement of the elevator control system will be restricted due to the accumulation of ice on the elevator control system components aft of the horizontal stabilizer center section. As a part of a service bulletin validation program, this change was completed on airplane VN097 by Service Bulletin 767-51A0027 before the release of Revision 1 of this service bulletin. The change completed on airplane VN097 by Service Bulletin 767-51A0027 is equivalent to the release of Revision 1 of this service bulletin. The related 767-400ER Boeing service bulletin is 767-51A0028. Boeing Service Related Problem (SRP) 767-SRP-27-0147 is related to this service bulletin. ### Page 8 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 62 ACTION (PRR B12901-51S) Get access to the horizontal stabilizer center section through the service doors 312AR and 313AL. Disconnect 6 hydraulic lines. Rework the horizontal stabilizer side brace fittings to enlarge the drain holes. Option 1: Install the gutter as two pieces along the rear spar upper chord of the horizontal stabilizer center section, on the controls brackets. Seal the gap between the gutter sections. Install two splices to re-join the gutter sections using shims between mating surfaces. Apply sealant between the gutter, the rear upper spar chord and splices. Option 2: Install the gutter as one piece along the rear spar upper chord of the horizontal stabilizer center section, on the controls brackets. Apply sealant between the gutter and the rear upper spar chord. Do system tests of the elevator control system, elevator power control actuator and autopilot systems. EFFECTIVITY 767-200, 767-300 and 767-300F airplanes line number 111 through 921. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. COMPLIANCE Boeing recommends that operators accomplish the modifications shown in this bulletin within five years after the issue date of initial release of this service bulletin. FAA Notice of Proposed Rule Making 2005-NM-058-AD is related to 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. 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 Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. ### Page 9 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 62 BOEING SERVICE BULLETIN 767-51A0027 STABILIZER CENTER SECTION TO THE HORIZONTAL INSTALL GUTTER ASSEMBLY FWD UP 422228 ### Page 10 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 62 BOEING SERVICE BULLETIN 767-51A0027 BLANK PAGE ### Page 11 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 62 Commercial Airplane Group 767 Service Bulletin Number: 767-51A0027 Date: December 09, 2004 Revision 1: October 12, 2006 ATA System: 5141 SUBJECT: STRUCTURES - Airframe Drainage - Horizontal Stabilizer Center Section - Gutter Installation 1. PLANNING INFORMATION A. Effectivity 1. Airplanes Refer to Service Bulletin Index Document D624T001 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 B12901-51S for data about this change. Airplane models: 767-200 767-300 767-300F IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AA 767 LLC (SVX) 1V E 0 6 7 ABX AIR (ABX) 1 VB117–VB123 VB125 AEROFLOT (ARO) 1 VL896 VN471–VN472 VS216–VS217 VS321–VS324 VS392 AEROMEXICO (AMX) 1 VF071 VF093 VS211 GROUP CONFIGURATION DESCRIPTION 1 - 767-200, 767-300 and 767-300F airplanes, line number 111 through 921. ### Page 12 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 62 AEROSVIT (UKA) 1 VN155 VN157 AIR ALGERIE (ALG) 1 VK131–VK133 AIR ATLANTA EUROPE LIMITED (AUP) 1 VB326–VB327 VL011 AIR ATLANTA ICELANDIC (AID) 1 VN153 AIR CANADA (ACN) 1 VA713–VA719 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 VN638 VS291–VS293 AIR MADAGASCAR (MAD) 1 VN167 VN731 AIR MAURITIUS (MAU) 1 VF001–VF002 AIR NEW ZEALAND (ANZ) 1 VN653–VN658 VS113 AIR NIUGINI (NIU) 1 VN651 AIR PACIFIC (APC) 1 VN676 AIR SAHARA (SAQ) 1 VN495 AIR SEYCHELLES (ASY) 1 VL941 VS526 AIR TRANSPORT INTERNATIONAL (TIN) 1 VA512–VA513 AIR ZIMBABWE (ZMB) 1 VF061–VF062 ### Page 13 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 62 ALITALIA (ALI) 1 VL701–VL702 VN422–VN427 VN732 VN813 VS366–VS367 VS401 ALL NIPPON AIRWAYS (ANA) 1 VK081–VK113 VN191–VN198 VR401 VS721–VS730 VT501 AMERICAN AIRLINES (AAL) 1 VA514–VA525 VA527–VA530 VN001–VN041 VS196–VS203 VS751–VS759 ARAMCO ASSOCIATED COMPANY (RAS) 1 VR084 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 AVE.COM (PHX) 1V E 0 4 1 AVIANCA (AVI) 1 VE171–VE172 VF072 VF092 VF161 VN152 VN532 AVIATION COMPANY POLET (PLF) 1V F 0 5 1 AWAS (AWW) 1V B 3 2 5 BELAIR AIRLINES (BLB) 1 VL932 BELLVIEW AIRLINES (BEB) 1 VE125–VE126 BLUE CITY HOLDING (BCY) 1V E 0 6 9 BLUE PANORAMA AIRLINES (BPA) 1 VL911 VN174 VN681 VS061 ### Page 14 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 62 BOEING SERVICE BULLETIN 767-51A0027 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 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 VK035–VK056 VL753 VN251–VN276 VN301–VN306 VR471–VR472 VS066–VS070 VS073–VS078 VS266–VS273 VS466–VS472 EL AL ISRAEL AIRLINES (ELA) 1 VF101–VF102 VN537 VN682 ERITREAN AIR LINES (ERJ) 1 VE066 ETHIOPIAN AIRLINES (ETH) 1 VS306 VS506–VS507 VS881 ETIHAD AIRWAYS (ETI) 1 VS391 EUROATLANTIC AIRWAYS (MAE) 1 VN151 VN551 VN561–VN562 EVA AIR (EVA) 1 VN791–VN792 EVERGREEN AIR CENTER (EAC) 1 VE061 EXCEL AIRWAYS (SBE) 1V N 5 5 7 ### Page 15 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIRST CHOICE AIRWAYS (ATZ) 1 VL751–VL752 VL754 VN921 FLYGLOBESPAN.COM (FGS) 1V S 1 1 2 FLYJET LIMITED (FJE) 1V E 1 1 7 GE CAPITAL CORPORATION (GEF) 1V E 1 2 3 GLOBAL JET LUXEMBOURG (SIQ) 1V S 8 2 5 GULF AIR (GUL) 1 VL004–VL006 VN307–VN310 VN313–VN314 HAINAN AIRLINES (HNA) 1 VS426–VS428 VS496–VS497 HAWAIIAN AIRLINES (HWI) 1 VK031–VK034 VN171–VN173 VN381 VS309–VS311 VS821–VS824 VS841–VS843 ICELANDAIR (ICE) 1 VN158 VN163 VN211 ITALIAN AIR FORCE (ZSV) 1 VR086 ITOCHU CORPORATION (CIT) 1 VF181–VF184 JAL INTERNATIONAL (JAL) 1 VB371–VB373 VK001–VK016 VK021–VK022 VK181 VK186 VR441 VR461 VS701–VS709 JET FREIGHT (JFO) 1V E 0 6 8 KALAIR (BERMUDA) (KLB) 1 VN311 KENYA AIRWAYS (KEN) 1 VK141 VL003 VN421 VS331–VS333 KLM - ROYAL DUTCH AIRLINES (KLM) 1 VL897–VL900 VS136–VS137 LAM (LAM) 1V F 1 6 2 ### Page 16 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 62 BOEING SERVICE BULLETIN 767-51A0027 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 VN652 MALEV HUNGARIAN AIRLINES (HGA) 1 VF171–VF172 MARTINAIR HOLLAND (MTH) 1 VN221–VN224 VN385 VN672 MAXJET AIRWAYS (SLQ) 1 VE063 MEXICANA (CMA) 1 VL001–VL002 VN154 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 VL894 NORTH AMERICAN AIRLINES (NNA) 1 VL755 VL895 VN922 VS316 PLUNA (PLU) 1V N 4 3 6 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) 1V N 1 5 6 V N 1 6 4 SHANGHAI AIRLINES (SHA) 1 VK171 VR421–VR423 VS207 ### Page 17 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 62 BOEING SERVICE BULLETIN 767-51A0027 SKYMARK AIRLINES (SKM) 1 VN637 VS231 VS261–VS263 VS861 STAR AIR (SBJ) 1 VB328 VB441–VB444 VE101–VE103 STATE AIR COMPANY "BERKUT" (ORE) 1 VR081 TAMPA CARGO (TMP) 1 VE121–VE122 VE124 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 UNITED AIRLINES (UAL) 1 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 VS844 VARIG AIRLINES (VAR) 1 VN055 VN231–VN232 VIETNAM AIRLINES (VIE) 1 VN972 VIVA MACAU (VMC) 1 VF091 VK142 VOLARE AIRLINES (VLR) 1 VL931 YONA (IOP) 1 VN312 ### Page 18 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 62 BOEING SERVICE BULLETIN 767-51A0027 ZOOM AIRLINES (YFM) 1 VL891 VL893 VN634–VN635 IDENTIFICATION BY VARIABLE NUMBER Variable Group VA512–VA530 1 VA713–VA719 1 VB117–VB125 1 VB324–VB332 1 VB371–VB373 1 VB401 1 VB441–VB444 1 VE003 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 ### Page 19 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 62 BOEING SERVICE BULLETIN 767-51A0027 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 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 Variable Group ### Page 20 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 62 BOEING SERVICE BULLETIN 767-51A0027 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 VN791–VN792 1 VN811–VN813 1 VN921–VN922 1 VN931–VN936 1 VN951–VN953 1 VN966–VN972 1 VR051–VR060 1 VR081 1 VR084 1 VR086 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 Variable Group ### Page 21 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 62 2. Spares Affected None. 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 VS321–VS324 1 VS331–VS333 1 VS336–VS337 1 VS366–VS367 1 VS381–VS382 1 VS391–VS392 1 VS401 1 VS426–VS428 1 VS466–VS472 1 VS486 1 VS496–VS497 1 VS506–VS507 1 VS526 1 VS546–VS549 1 VS701–VS709 1 VS721–VS730 1 VS751–VS759 1 VS821–VS825 1 VS841–VS844 1 VS861 1 VS881 1 VT501 1 VW701–VW721 1 VW851 1 Variable Group ### Page 22 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 62 B. Concurrent Requirements None. C. Reason This service bulletin gives instructions to install a gutter on the horizontal stabilizer center section. This gutter will channel water that enters Section 48 at the side of body seals away from the elevator control system components aft of the horizontal stabilizer. This will make it less likely that ice can accumulate on the elevator control system components. Ice on the elevator systems can restrict elevator movement which limits the ability of the flight crew to make elevator control inputs, resulting in reduced controllability of the airplane. Boeing has received three reports of stiff or jammed elevator controls. Analysis of all three reports indicated that ice had formed on the elevator control components aft of the horizontal stabilizer, which restricted the movement of the elevator controls. Water was found to get into Section 48 of the airplane through the fairing panels at the side of the body. The ice then formed from water that had accumulated on the horizontal stabilizer center section. In one case, the water accumulated due to a leak in the Auxiliary Power Unit (APU) inlet duct. In another case, the water came from a leak in a galley water drain line. Airplane line numbers 1 through 110 have side of body seal doors that do not allow water to enter Section 48 and therefore, are not subject to this service bulletin. After line number 921, a gutter is installed on the horizontal stabilizer center section in production. Accomplishment of the modification shown in this service bulletin will make it less likely that movement of the elevator control system will be restricted due to the accumulation of ice on the elevator control system components aft of the horizontal stabilizer center section. The related 767-400ER Boeing service bulletin is 767-51A0028. Boeing Service Related Problem (SRP) 767-SRP-27-0147 is related to this service bulletin. Revision 1 is sent to improve the work instructions as a result of access restrictions found during the service bulletin validation. Additionally, based on one other operator report revision 1 is sent to provide instructions to install the gutter as a one piece assembly. Instructions throughout the service bulletin are changed to provide two options to install the gutter as one piece or as two pieces. As a part of a service bulletin validation program, this change was completed on airplane VN097 by Service Bulletin 767-51A0027 before the release of Revision 1 of this service bulletin. In the validation the gutter was installed in two pieces. The change completed on airplane VN097 by Service Bulletin 767-51A0027 is equivalent to the release of Revision 1 of this service bulletin. Changes to this service bulletin include: – References to a FAA Notice of Proposed Rule Making are added throughout the service bulletin. – Material Information - A new 180T3250-9 gutter assembly is added. The 180T3250-4 gutter assembly is optional to the 180T3250-9 gutter assembly. The Boeing drawing number and parts modified and reidentified are changed. The quantity of optional rivets supplied by the operator is reduced. – Accomplishment Instructions - An additional access door is added. Maintenance manual references to test the elevator control system, elevator power control actuator and autopilot systems are added. A stabilizer tool reference has been removed as it is acceptable to use another lock tool. A maintenance manual reference to install the service platform is changed. ### Page 23 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 62 – Figure 1 is changed to add a dimension for the gutter assembly cut location. – Figure 2 is changed to give rework instructions if cracks are found and to add an alternative high frequency eddy current inspection for cracks. The two possible side brace fittings installed after the rework are identified. – Figures 3 and 4 are changed to remove the option to install rivets and to change the quantity of hi loks used to install the gutter assembly at each hydraulic bracket. – Figure 6 is added to disconnect and move the hydraulic lines at the hydraulic control brackets. – Figure 7 is added to identify a locator mark on the gutter when installing the gutter as one piece. – Figure 8 is added to install the gutter as one piece. – Figure 9 is added to apply sealant between the upper spar chord and gutter when installing the gutter as one piece. – Figure 10 is added to connect the hydraulic lines at the hydraulic control brackets. D. Description Get access to the horizontal stabilizer center section through the service doors 312AR and 313AL. Disconnect 6 hydraulic lines. Rework the horizontal stabilizer side brace fittings to enlarge the drain holes. Option 1: Install the gutter as two pieces along the rear spar upper chord of the horizontal stabilizer center section, on the controls brackets. Seal the gap between the gutter sections. Install two splices to re-join the gutter sections using shims between mating surfaces. Apply sealant between the gutter, the rear upper spar chord and splices. Option 2: Install the gutter as one piece along the rear spar upper chord of the horizontal stabilizer center section, on the controls brackets. Apply sealant between the gutter and the rear upper spar chord. Do system tests of the elevator control system, elevator power control actuator and autopilot systems. NOTE: Boeing Service Bulletins 767-25A0322, 767-27A0192 and 767-49A0035 are also related to 767-SRP-27-0147. Boeing recommends that operators accomplish these service bulletins, and this service bulletin, to make it less likely that movement of the elevator control system will be restricted due to the accumulation of ice on the elevator control system components aft of the horizontal stabilizer center section. Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this service bulletin. E. Compliance Boeing recommends that operators accomplish the modifications shown in this bulletin within five years after the issue date of initial release of this service bulletin. FAA Notice of Proposed Rule Making 2005-NM-058-AD is related to 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. ### Page 24 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 62 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 modification 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. Option 1 - Two Piece Gutter Installation Task Number of Persons Task-Hours Elapsed Hours Open Access 1 0.50 0.50 Figure 1 1 0.25 0.25 Figure 2 1 0.75 0.75 Figure 3 1 3.00 3.00 Figure 4 1 3.00 3.00 Figure 5 1 2.00 2.00 Figure 6 1 2.50 2.50 Figure 10 1 2.50 2.50 Close Access 1 0.50 0.50 TOTAL FOR EACH AIRPLANE 15 15 Option 2 - One Piece Gutter Installation Task Number of Persons Task-Hours Elapsed Hours Open Access 1 0.50 0.50 Figure 2 1 0.75 0.75 Figure 6 1 2.50 2.50 Figure 7 1 0.25 0.25 ### Page 25 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 62 BOEING SERVICE BULLETIN 767-51A0027 H. Weight and Balance Changes I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR B12901-51S b. Service Related Problem (SRP) 767-SRP-27-0147 c. 767 Aircraft Maintenance Manual (AMM) 06-42-00/201, 20-10-09, 20-10-10, 22-10-00/501, 27-31-00/501, 27-31-05/601, 27-41-10/401, 29-11-00/201, 52-48-00 d. 767-200 Structural Repair Manual (SRM) 51-20-11 e. 767-300 Structural Repair Manual (SRM) 51-20-11 f. 767-300F Structural Repair Manual (SRM) 51-20-11 g. 767 Non-Destructive Testing (NDT) Manual, Part 6, 51-00-04, Part 6, 51-00-11, Part 6, 51-00-16 h. Boeing Service Bulletin 767-25A0322, "EQUIPMENT/FURNISHINGS - Buffet/Galley - Aft Galley - A2 Galley Drain Leak Inspection"; 767-27A0192, "FLIGHT CONTROLS - Elevator Control System - Seal Block Hole Addition" and 767-49A0035, "AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield Modification" i. Boeing Standard Overhaul Practices Manual (SOPM) Subject 20-20-02, 20-41-02, 20-43-01, 20-43-03, 20-50-10, 20-50-19 and 20-50-20 Figure 8 1 4.00 4.00 Figure 9 1 0.50 0.50 Figure 10 1 2.50 2.50 Close Access 1 0.50 0.50 TOTAL FOR EACH AIRPLANE 11.5 11.5 Airplane Change in Weight (Pounds) Change in Moment (Pound-Inches) 767-200 Airplanes +3.2 +5800.0 767-300 Airplanes +3.2 +6222.0 767-300F Airplanes +3.2 +6222.0 Option 2 - One Piece Gutter Installation Task Number of Persons Task-Hours Elapsed Hours ### Page 26 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 62 BOEING SERVICE BULLETIN 767-51A0027 j. Boeing Parts Standards Document D-590 k. Boeing Drawing 012W6100 l. FAA Notice of Proposed Rule Making 2005-NM-058-AD 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. K. Publications Affected None. L. Interchangeability and Intermixability of Parts Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information. ### Page 27 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 62 BOEING SERVICE BULLETIN 767-51A0027 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown below. If there is a limit to the quantity (QTY) of available 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 kit is 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. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA 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/parts for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits/parts to Boeing Spares. Please refer to this service bulletin number and reference the airplane variable number(s) in your purchase order. Kit Number Name Date QTY ROLT (Days) Unit Price thru Dec 31/06 015T1770-1 Top Kit 07/26/04 1 80 $ 1,902.00 09/21/04 22 10/19/04 22 11/16/04 22 12/16/04 22 01/24/05 22 02/21/05 22 03/21/05 22 04/18/05 22 05/16/05 22 06/14/05 22 ### Page 28 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 62 BOEING SERVICE BULLETIN 767-51A0027 C. Parts Necessary For Each Airplane 1. Kits/Parts: To get the kit 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. Kit 015T1770 New Part Number QTY Name Existing Part Number Notes-1 180T3250-9 (180T3250-4 optional) 1 GUTTER ASSY 180T3251-2 1 SPLICE (c) 180T3251-3 1 SPLICE (c) BACB30VT5HK3 24 BOLT, PROTRUDING HD (a) (b) BACB30VT5HK4 9 BOLT, PROTRUDING HD (a) (b) BACC30BL5 33 COLLAR, SHEAR (a) BACS40R006C025F 4 SHIM, LAMINATED (a) BACS40R007C046F 1 SHIM, LAMINATED (a) BACS40R007D046F 2 SHIM,LAMINATED (a) BACS40R009B015F 6 SHIM,LAMINATED (a) BACS40R015B020F 2 SHIM, LAMINATED (a) (a) There are more parts than are necessary. (b) 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 012W6100 are used to determine the part numbers used as substitutes. (c) This part is only necessary for option 1, two piece gutter installation. ### Page 29 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. Part Number / Specification QTY Name Notes BACR15BB5AD 16 Rivet (a) BACR15BB5D 16 Rivet (a) BACR15FT5AD 16 Rivet (a) BACR15FT5D 16 Rivet (a) BMS 10-11 1/2 pint Primer (b) BMS 5-95, Type 1, Class B-1/2 1/2 pint Sealant (b) Dye 1 ounce Dye Penetrant (b) Alodine 1200, Type 2, Class A 1/2 pint Chemical Conversion Coating (b) (a) This part is optional to BACB30VT5HK3 and BACB30VT5HK4 supplied in Kit 015T1770-1. (b) 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 182T1330-1 2 Side Brace Fitting 182T1330-3 (a) (b) (c) (d) 182T1330-2 2 Side Brace Fitting 182T1330-4 (a) (b) (c) (d) (a) Make the change given in this service bulletin. (b) This is the part number after the change given in this service bulletin. (c) This part is used in production. (d) The 182T1330-2 side brace fitting is optional to the 182T1330-1 side brace fitting. ### Page 30 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. ### Page 31 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. 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 — Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual, Chapter 51. 4. 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 012W6100. 5. 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. B. WORK INSTRUCTIONS 1. Lock the horizontal stabilizer. Refer to 767 AMM 27-41-10/401. 2. Remove pressure from the Left, Right and Center hydraulic systems as shown in 767 AMM 29-11-00/201 or equivalent approved procedure. 3. Put these switches on the right side panel, P61, in the off position and attach DO-NOT-OPERATE tags: GRID SWITCH S2 RIGHT TAIL HYD SHUT OFF VALVE SWITCH S4 CENTER TAIL HYD SHUT OFF VALVE SWITCH S6 LEFT TAIL HYD SHUT OFF VALVE SWICH ### Page 32 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 62 BOEING SERVICE BULLETIN 767-51A0027 4. Open these circuit breakers on the overhead circuit breaker panel, P11, and attach DO-NOT-CLOSE tags: WARNING: BEFORE YOU BEGIN TO WORK, MAKE SURE THAT THERE IS NO MOVEMENT OF THE HORIZONTAL STABILIZER. WARNING: STAY OFF THE SERVICE ACCESS DOOR 312AR, AND THE ACCESS DOOR FOR THE CONTROLS BAY 313AL. YOUR WEIGHT CAN CAUSE THE SPRING-LOADED LATCHES TO RELEASE. IF YOU FALL THROUGH THE DOOR, INJURY CAN OCCUR. 5. Get access to the horizontal stabilizer center section through access doors 312AR and 313AL as shown in 767 AMM 06-42-00/201 or equivalent approved procedure. WARNING: MAKE SURE THE SERVICE PLATFORM IS INSTALLED ABOVE THE SERVICE ACCESS DOOR OPENING. IF YOU DO NOT INSTALL THE SERVICE PLATFORM, YOU CAN FALL THROUGH THE SERVICE ACCESS DOOR OPENING AND INJURY CAN OCCUR. 6. Install the service platform above the opening of the service access door as shown in 767 AMM 52-48-00 or equivalent approved procedure. WARNING: REMOVE ALL PRESSURE FROM THE SYSTEM AS SPECIFIED IN THE APPLICABLE MAINTENANCE INSTRUCTIONS BEFORE YOU START THE REMOVAL OF THE FLARELESS TUBING ASSEMBLY. A PRESSURIZED SYSTEM CAN CAUSE INJURY. WARNING: MAKE SURE EACH TUBE AND THE PORT FITTING HAVE TAGS TO IDENTIFY THE CORRECT INSTALLATION LOCATION. IF YOU DO NOT PUT TAGS ON THE TUBES AND PORT FITTINGS, CROSS-CONNECTION OF THE TUBES CAN OCCUR DURING INSTALLATION. IF THIS OCCURS, UNINTENDED OPERATION OR MALFUNCTION OF AIRPLANE SYSTEMS CAN RESULT AND CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. CAUTION: PUT CAPS ON THE HYDRAULIC LINES AND FITTINGS. UNWANTED MATERIAL CAN CAUSE CONTAMINATION OF HYDRA ULIC LINES, DAMAGE TO SYSTEM COMPONENTS, AND LEAKAGE OF HYDRAULIC FLUID. CAUTION: DO NOT LET HYDRAULIC FLUID LEAKAGE COLLECT. REMOVE IT IMMEDIATELY. HYDRAULIC FLUID CAN CAUSE DAMAGE. CAUTION: PUT CAPS ON THE HOSES AND FITTING S. UNWANTED MATERIAL CAN CAUSE CONTAMINATION OF HOSES, DAMAGE TO SYSTEM COMPONENTS, AND LEAKAGE OF HYDRAULIC FLUID. REMO VE ALL HYDRAULIC FLUID LEAKAGE. HYDRAULIC FLUID CAN CAUSE CORROSION OR OTHER DAMAGE. 7. Remove the hydraulic lines as given in Figure 6. GRID CIRCUIT BREAKER H17 FLT CONT SHUTOFF TAIL LEFT H18 FLT CONT SHUTOFF TAIL CENTER H27 FLT CONT SHUTOFF TAIL RIGHT ### Page 33 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 62 BOEING SERVICE BULLETIN 767-51A0027 8. Do Option 1 to install the Gutter in two pieces OR do Option 2 to install the gutter as one piece. OPTION 1 - TWO PIECE GUTTER INSTALLATION a. Cut the gutter into two sections and finish the cut edges as given in Figure 1. b. Rework the horizontal stabilizer side brace fittings as given in Figure 2. c. Install left gutter section as given in Figure 3. d. Install right gutter section as given in Figure 4. e. Splice the gutter sections as given in Figure 5. OPTION 2 - ONE PIECE GUTTER INSTALLATION a. Rework the horizontal stabilizer side brace fittings as given in Figure 2. b. Identity a locator mark on the gutter as given in Figure 7. c. Install the gutter as given in Figure 8. d. Seal the gutter as given in Figure 9. CAUTION: ALWAYS KEEP THE CLAMPS TIGHT. TIGHT CLAMPS KEEP THE AREA BETWEEN THE TUBE AND THE CLAMP SURFACES FREE OF UNWANTED MATERIALS AND CONTAMINATION. IF SURFACES ARE NOT CLEAN, DAMAGE BY FRICTION CAN OCCUR. CAUTION: USE THE INDEX LINE ON THE SIDE OF THE HOSE TO MAKE SURE THE HOSE IS NOT TWISTED. IF THE HOSE IS TWISTE D, HOSE FAILURE OR HOSE COUPLING LEAKAGE CAN OCCUR BEFORE THE USUAL TIME. 9. Install the hydraulic lines as given in Figure 10. 10. Remove the service platform and close access doors 312AR and 313AL as shown in 767 AMM 06-42-00/201 or equivalent approved procedure. 11. Close these circuit breakers on the overhead circuit breaker panel, P11, and remove DO-NOT-CLOSE tags: GRID CIRCUIT BREAKER H17 FLT CONT SHUTOFF TAIL LEFT H18 FLT CONT SHUTOFF TAIL CENTER H27 FLT CONT SHUTOFF TAIL RIGHT ### Page 34 December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 62 BOEING SERVICE BULLETIN 767-51A0027 12. Put these switches on the right side panel, P61, in the ON position and remove DO-NOT-OPERATE tags: 13. Restore pressure to the Left, Right and Center hydraulic systems as shown in 767 AMM 29-11-00/201 or equivalent approved procedure. 14. Unlock the horizontal stabilizer. Refer to 767 AMM 27-41-10/401. 15. Do an operational test of the elevator control system as shown in 767 AMM 27-31-00/501 or equivalent approved procedure and make sure that there is no leakage of hydraulic fluid. 16. Do a check of the Elevator Power Control Actuator as shown in 767 AMM 27-31-05/601 or equivalent approved procedure. 17. Do a systems test of the autopilot system as shown in 767 AMM 22-10-00/501 or equivalent approved procedure. 18. Put the airplane back to a serviceable condition. GRID SWITCH S2 RIGHT TAIL HYD SHUT OFF VALVE SWITCH S4 CENTER TAIL HYD SHUT OFF VALVE SWITCH S6 LEFT TAIL HYD SHUT OFF VALVE SWICH ### Page 35 FIGURE 1: GUTTER PREPARATION AND PROTECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 1: GUTTER PREPARATION AND PROTECTION 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. NOTE: This figure applies to option 1, two piece gutter installation. STEP TASK NAME PART NUMBER QTY NOTES 1 Cut Gutter Assy 180T3250-9 (180T3250-4 optional) 1( a ) 2 Apply Chemical Conversion Coating Type 2, Class A 2 layers To all bare aluminum surfaces. As given in SOPM 20-43-01. 3 Apply Primer BMS 10-11, Type 1 2 layers To all bare aluminum surfaces. As given in SOPM 20-41-02. (a) Break all sharp edges, 0.015R to 0.03R. 34.0 + 0.050- 36.0 + 0.050- 1 2 3 422232 (SHEET 1 OF 1) ### Page 36 FIGURE 2: REWORK SIDE BRACE FITTINGS - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 2: REWORK SIDE BRACE FITTINGS - HORIZONTAL STABILIZER CENTER SECTION A A B B 4.05 1.00 SIDE BRACE FITTING UP FWD FWD INBD A-A 4.05 1.00 SIDE BRACE FITTING B-B 1 2 3 4 5 6 1 2 3 4 56 INBD FWD 423658 (SHEET 1 OF 2) ### Page 37 FIGURE 2: REWORK SIDE BRACE FITTINGS - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Drill Drain Hole - 2 (a) 2 Deburr Drain Hole - 2 3 Inspect Drain Hole Dye Penetrant 2 (b) (c) (d) 4 Apply Chemical Conversion Coating, Type 2, Class A Type 2, Class A - To all bare aluminum surfaces. As given in SOPM 20-43-03. 5 Apply Primer BMS 10-11, Type 1 - To all bare aluminum surfaces. As given in SOPM 20-41-02. 6 Identify Side Brace Fitting - Horizontal Stabilizer 182T1330-1 2 Part mark as 182T1330-3 as shown in SOPM 20-50-10. (e) OR 182T1330-2 2 Part mark as 182T1330-4 as shown in SOPM 20-50-10. (e) (a) Enlarge the existing drain hole to a 0.500 - 0.504 inch diameter. Blend around the hole after drilling to provide a smooth transition into the radius of the fitting. (b) Inspect drain hole for cracks. Refer to SOPM 20-20-02. (c) It is optional to do a high frequency eddy current inspection for cracks as shown in 767 NDT, Part 6, 51-00-04 or 767 NDT, Part 6, 51-00-11 or 767 NDT, Part 6, 51-00-16, instead of a dye penetrant inspection. (d) If cracks or damage are found oversize the hole to remove the crack or damage. Hole size up to 0.625 inches in diameter is acceptable. If damage still remains at a hole size of 0.625 inches contact Boeing with details of the damage for further rework instructions. (e) The 182T1330-2 side brace fitting is optional to the 182T1330-1 side brace fitting. (SHEET 2 OF 2) ### Page 38 FIGURE 3: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION - LEFT SIDE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 3: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SECTION - LEFT SIDE 0.02 0.08 LEFT GUTTER 1.65 RIGHT GUTTER OF GAP CENTER LINE BRACKET HYDRAULIC B B D D A A C C INBD FWD UP 1 21 (3 LOCATIONS) HYDRAULIC BRACKET 422233 A-A (SHEET 1 OF 4) ### Page 39 FIGURE 3: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION - LEFT SIDE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 62 BOEING SERVICE BULLETIN 767-51A0027 INBD BRACKET HYDRAULIC BRACKET CONTROLS GUTTER C-C B-B FWD 33 4 5 7 8 6 4 5 434135 (SHEET 2 OF 4) ### Page 40 FIGURE 3: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION - LEFT SIDE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. NOTE: This figure applies to option 1, two piece gutter installation. STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Align Gutter Sections (Left and Right) 180T3250-9 (180T3250-4 optional) 2( a ) 2 Remove / Keep Gutter Section (Right) 180T3250-9 (180T3250-4 optional) 1 3 Align Shim, Laminated BACS40R006C025F 2 (c) 4 Drill Controls bracket - 1 (b) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R006C025F 2 Gutter Section (Left) 180T3250-9 (180T3250-4 optional) 1 5 Install Gutter Section (Left) 180T3250-9 (180T3250-4 optional) 1 Shim, Laminated BACS40R006C025F 2 Bolt BACB30VT5HK3 4 Collar BACC30BL5 4 6 Align Shim, Laminated BACS40R007D046F 1 (c) HYDRAULIC BRACKET GUTTER D-D 10 119 422836 (SHEET 3 OF 4) ### Page 41 FIGURE 3: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION - LEFT SIDE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 62 BOEING SERVICE BULLETIN 767-51A0027 7 Drill Hydraulic Bracket - 1 (b) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R007D046F 1 Gutter Section (Left) 180T3250-9 (180T3250-4 optional) 1 8 Install Shim, Laminated BACS40R007D046F 1 (d) Gutter Section (Left) 180T3250-9 (180T3250-4 optional) 1 Bolt BACB30VT5HK4 2 Collar BACC30BL5 2 9 Align Shim, Laminated BACS40R007C046F 1 (c) 10 Drill Hydraulic Bracket - 1 (b) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R007C046F 1 Gutter Section (Left) 180T3250-9 (180T3250-4 optional) 1 11 Install Shim, Laminated BACS40R007C046F 1 (d) Gutter Section (Left) 180T3250-9 (180T3250-4 optional) 1 Bolt BACB30VT5HK4 2 Collar BACC30BL5 2 (a) Align the 36 inch section on the left side and the 34 inch section on the right side with an equal clearance on either end from the stabilizer hinges, and a gap of 0.08 +/- 0.02 inches between the left and right gutter sections. (b) Make sure there is a minimum 2 D edge margin at fastener locations. Deburr all sharp edges. (c) Shim gaps greater than 0.010 inches prior to installation. Remove 0.003 inch laminations as required. Refer to SOPM 20-50-20 and 767-200 SRM 51-20-11 OR 767-300 SRM 51-20-11 OR 767-300F SRM 51-20-11. Optional solid shim stock and multiple shims can be used to prevent bending the bracket and gutter flanges during installation. (d) Install collars on the upper surface of the gutter. This is to prevent interference between the bolts and hydraulic lines. STEP TASK NAME IDENTIFICATION QTY MORE DATA (SHEET 4 OF 4) ### Page 42 FIGURE 4: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION - RIGHT SIDE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 4: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SECTION - RIGHT SIDE BB A A C C UP FWD INBDA-A 22 1 1 (3 LOCATIONS) HYDRAULIC BRACKET 422841 (SHEET 1 OF 3) ### Page 43 FIGURE 4: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION - RIGHT SIDE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 62 BOEING SERVICE BULLETIN 767-51A0027 BRACKET HYDRAULIC BRACKET CONTROLS GUTTER HYDRAULIC BRACKET GUTTERGUTTER 3 4 6 7 5 8 INBD FWD 3 4 430161 B-B C-C (SHEET 2 OF 3) ### Page 44 FIGURE 4: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION - RIGHT SIDE December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. NOTE: This figure applies to option 1, two piece gutter installation. STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Align Gutter Section (Left and Right) 180T3250-9 (180T3250-4 optional) 2( a ) 2 Align Shim, Laminated BACS40R006C025F 2 (c) 3 Drill Controls bracket - 1 (b) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R006C025F 2 Gutter Section (Right) 180T3250-9 (180T3250-4 optional) 1 4 Install Gutter Section (Right) 180T3250-9 (180T3250-4 optional) 1 Shim, Laminated BACS40R006C025F 2 Bolt BACB30VT5HK3 4 Collar BACC30BL5 4 5 Align Shim, Laminated BACS40R007D046F 1 (c) 6 Drill Hydraulic Bracket - 1 (b) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R007D046F 1 Gutter Section (Right) 180T3250-9 (180T3250-4 optional) 1 7 Install Shim, Laminated BACS40R007D046F 1 (d) Gutter Section (Right) 180T3250-9 (180T3250-4 optional) 1 Bolt BACB30VT5HK4 2 Collar BACC30BL5 2 8 Apply Sealant BMS 5-95 - Completely fill the gap between gutter sections. Refer to SOPM 20-50-19. (a) Align the right gutter section with a gap of 0.08 +/- 0.02 inches between the left and right gutter sections. Make sure that the distance between the left gutter and left stabilizer hinge is equal to the distance between the right gutter and right stabilizer hinge. (b) Make sure there is a minimum 2 D edge margin at fastener locations. Deburr all sharp edges. (c) Shim gaps greater than 0.010 inches prior to installation. Remove 0.003 inch laminations as required. Refer to SOPM 20-50-20 and 767-200 SRM 51-20-11 OR 767-300 SRM 51-20-11 OR 767-300F SRM 51-20-11. Optional solid shim stock and multiple shims can be used to prevent bending the bracket and gutter flanges during installation. (d) Install collars on the upper surface of the gutter. This is to prevent interference between the bolts and hydraulic lines. (SHEET 3 OF 3) ### Page 45 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION B B A A UP FWD A-A 0.1500 +0.0500-0.1000 BRACKET HYDRAULIC GUTTER BRACKET CONTROL 1 (3 LOCATIONS) HYDRAULIC BRACKET 430159 (SHEET 1 OF 5) ### Page 46 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 62 BOEING SERVICE BULLETIN 767-51A0027 E E C C FWD DD 8C-C HYDRAULIC BRACKET GUTTER 5 6 7 6 7 429834 B-B (SHEET 2 OF 5) ### Page 47 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 62 BOEING SERVICE BULLETIN 767-51A0027 HYDRAULIC BRACKET GUTTER GUTTER 2 3 2 4 3 4 3 4 422239 E-E D-D (SHEET 3 OF 5) ### Page 48 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. NOTE: This figure applies to option 1, two piece gutter installation. STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION: DO NOT ALLOW THE SEALANT TO CREATE HIGH SPOTS OR RIDGES THAT WILL TRAP WATER ONTO THE UPPER SKIN. 1 Apply Sealant BMS 5-95 - (a) 2 Align (New) Splice 180T3251-2 1 Align splice and shims to Gutter Assembly. Shim, Laminated BACS40R015B020F 2 On the vertical edge of the gutter. (c) Shim, Laminated BACS40R009B015F 2 On the lower edge of the gutter. (c) 3 Drill Splice 180T3251-2 1 (b) (c) 0.164 - 0.168 inch hole diameter. Shim, Laminated BACS40R015B020F 2 Shim, Laminated BACS40R009B015F 2 Gutter Section (left and Right) 180T3250-9 (180T3250-4 optional) 2 4 Install Splice 180T3251-2 1 (c) (e) Shim, Laminated BACS40R015B020F 2 Shim, Laminated BACS40R009B015F 2 Bolt BACB30VT5HK3 or 12 Rivet BACR15BB5AD (optional) or Rivet BACR15BB5D (optional) or Rivet BACR15FT5AD (optional) or Rivet BACR15FT5D (optional) Collar BACC30BL5 12 5 Align (New) Splice 180T3251-3 1 Align splice to Gutter Assembly. 6 Drill Splice 180T3251-3 1 (b) (c) 0.164 - 0.168 inch hole diameter. Gutter Section (left and Right) 180T3250-9 (180T3250-4 optional) 2 7 Install Splice 180T3251-3 1 (c) (e) Bolt BACB30VT5HK3 or 4 Rivet BACR15BB5AD (optional) or Rivet BACR15BB5D (optional) or Rivet BACR15FT5AD (optional) or Rivet BACR15FT5D (optional) Collar BACC30BL5 4 8 Apply Sealant BMS 5-95 - (d) (SHEET 4 OF 5) ### Page 49 FIGURE 5: SPLICE INSTALLATION - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 62 BOEING SERVICE BULLETIN 767-51A0027 (a) Inject sealant BMS 5-95 per SOPM 20-50-19 to fill void created beneath the three hydraulic brackets and the upper spar chord. Apply BMS 5-95 sealant per SOPM 20-50-19 at final installation of gutter to completely fill faying surfaces between upper spar chord and gutter, and to fair the upper skin to the forward flange of the gutter the entire length of the gutter. Allow sealant to dry for 2 hours. (b) Make sure there is a minimum 2 D edge margin at fastener locations. Deburr all sharp edges. (c) Shim gaps greater than 0.010 inches prior to installation. Remove 0.003 inch laminations as required. Refer to SOPM 20-50-20 and 767-200 SRM 51-20-11 OR 767-300 SRM 51-20-11 OR 767-300F SRM 51-20-11. Optional solid shim stock and multiple shims can be used to prevent bending the bracket and gutter flanges during installation. (d) Inject sealant BMS 5-95 per SOPM 20-50-19 to fill void between gutter and splice. (e) It is acceptable to use solid rivets instead of bolts and collars. Install rivets in a 0.159 - 0.171 inch hole diameter. STEP TASK NAME IDENTIFICATION QTY MORE DATA (SHEET 5 OF 5) ### Page 50 FIGURE 6: DISCONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 6: DISCONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION 41.5 RBBL 41.5 LBBL 0 BBL UP FWD 1 3 7 9 5 2 4 6 8 12 10 11 J73146 (SHEET 1 OF 2) ### Page 51 FIGURE 6: DISCONNECT HYDRAULIC LINES - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 62 BOEING SERVICE BULLETIN 767-51A0027 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. STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Remove/Keep Hydraulic tube 272T8200-188 1 Refer to 767 AMM 20-10-09 or equivalent approved procedure. 2 Disconnect Hydraulic hose AS115-06D0274 1 (a) 3 Remove/Keep Hydraulic tube 272T8200-187 1 Refer to 767 AMM 20-10-09 or equivalent approved procedure. 4 Disconnect Hydraulic hose AS115-08D0280 1 (a) 5 Remove/Keep Hydraulic tube 272T8200-202 1 Refer to 767 AMM 20-10-09 or equivalent approved procedure. 6 Disconnect Hydraulic hose AS115-06D0274 1 (a) 7 Remove/Keep Hydraulic tube 272T8200-203 1 Refer to 767 AMM 20-10-09 or equivalent approved procedure. 8 Disconnect Hydraulic hose AS115-08D0274 1 (a) 9 Remove/Keep Hydraulic tube 272T8200-186 1 Refer to 767 AMM 20-10-09 or equivalent approved procedure. 10 Disconnect Hydraulic hose AS115-06D0274 1 (a) 11 Remove/Keep Hydraulic tube 272T8200-185 1 Refer to 767 AMM 20-10-09 or equivalent approved procedure. 12 Disconnect Hydraulic hose AS115-08D0280 1 (a) (a) Refer to 767 AMM 20-10-10 or equivalent approved procedure. Move the hydraulic line away from the modification area. (SHEET 2 OF 2) ### Page 52 FIGURE 7: GUTTER PREPARATION - LOCATOR IDENTIFICATION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 7: GUTTER PREPARATION - LOCATOR IDENTIFICATION 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 this figure. NOTE: This figure applies to option 2, one piece gutter installation. STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Identify Locator Mark - 1 As a reference for subsequent installation alignment. (a) (a) Use a method that does not damage the gutter or surface finish on the gutter. 34.35 + 0.050- 1 U73538 (SHEET 1 OF 1) ### Page 53 FIGURE 8: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 8: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SECTION GUTTER BRACKET HYDRAULIC B B D D A A C C E E F F INBD FWD UP 1 1 (3 LOCATIONS) HYDRAULIC BRACKET U73539 A-A (SHEET 1 OF 6) ### Page 54 FIGURE 8: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 62 BOEING SERVICE BULLETIN 767-51A0027 INBD BRACKET HYDRAULIC BRACKET CONTROLS GUTTER C-C B-B FWD 22 3 4 8 9 7 3 4 U73540 (SHEET 2 OF 6) ### Page 55 FIGURE 8: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 62 BOEING SERVICE BULLETIN 767-51A0027 HYDRAULIC BRACKET GUTTER D-D INBDE-E 11 1210 22 U73541 (SHEET 3 OF 6) ### Page 56 FIGURE 8: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 62 BOEING SERVICE BULLETIN 767-51A0027 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 this figure. NOTE: This figure applies to option 2, one piece gutter installation. STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION: DO NOT TO DAMAGE THE GUTTER AND ADJACENT STRUCTURE. MORE WORK WILL BE NECESSARY FOR REPAIRS IF THE GUTTER OR ADJACENT STRUCTURE IS DAMAGED. 1 Align Gutter Assembly 180T3250-9 (180T3250-4 optional) 2( a ) 2 Align Shim, Laminated BACS40R006C025F 4 (b) 3 Drill Controls bracket - 1 (c) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R006C025F 2 Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 4 Install Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 Shim, Laminated BACS40R006C025F 2 Bolt BACB30VT5HK3 4 Collar BACC30BL5 4 5 Drill Controls bracket - 1 (c) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R006C025F 2 Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 BRACKET HYDRAULIC BRACKET CONTROLS GUTTER 5 6 INBD FWD 5 6 14 15 13 U73542 F-F (SHEET 4 OF 6) ### Page 57 FIGURE 8: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 62 BOEING SERVICE BULLETIN 767-51A0027 6 Install Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 Shim, Laminated BACS40R006C025F 2 Bolt BACB30VT5HK3 4 Collar BACC30BL5 4 7 Align Shim, Laminated BACS40R007D046F 1 (b) 8 Drill Hydraulic Bracket - 1 (c) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R007D046F 1 Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 9 Install Shim, Laminated BACS40R007D046F 1 (d) Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 Bolt BACB30VT5HK4 2 Collar BACC30BL5 2 10 Align Shim, Laminated BACS40R007C046F 1 (b) 11 Drill Hydraulic Bracket - 1 (c) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R007C046F 1 Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 12 Install Shim, Laminated BACS40R007C046F 1 (d) Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 Bolt BACB30VT5HK4 2 Collar BACC30BL5 2 13 Align Shim, Laminated BACS40R007D046F 1 (b) 14 Drill Hydraulic Bracket - 1 (c) 0.164 - 0.168 inch hole diameter.Shim, Laminated BACS40R007D046F 1 Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 15 Install Shim, Laminated BACS40R007D046F 1 (d) Gutter Assembly 180T3250-9 (180T3250-4 optional) 1 Bolt BACB30VT5HK4 2 Collar BACC30BL5 2 (a) Align the locator mark to the right side edge of the hydraulic bracket when looking forward. STEP TASK NAME IDENTIFICATION QTY MORE DATA (SHEET 5 OF 6) ### Page 58 FIGURE 8: GUTTER INSTALLATION - UPPER SURFACE, HORIZONTAL STABILIZER CENTER SEC- TION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 62 BOEING SERVICE BULLETIN 767-51A0027 (b) Shim gaps greater than 0.010 inches prior to installation. Remove 0.003 inch laminations as required. Refer to SOPM 20-50-20 and 767-200 SRM 51-20-11 OR 767-300 SRM 51-20-11 OR 767-300F SRM 51-20-11. Optional solid shim stock and multiple shims can be used to prevent bending the bracket and gutter flanges during installation. (c) Make sure there is a minimum 2 D edge margin at fastener locations. Deburr all sharp edges. (d) Install collars on the upper surface of the gutter. This is to prevent interference between the bolts and hydraulic lines. STEP TASK NAME IDENTIFICATION QTY MORE DATA (SHEET 6 OF 6) ### Page 59 FIGURE 9: GUTTER SEALING - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 62 BOEING SERVICE BULLETIN 767-51A0027 FIGURE 9: GUTTER SEALING - HORIZONTAL STABILIZER CENTER SECTION A A UP FWD A-A 0.1500 +0.0500-0.1000 BRACKET HYDRAULIC GUTTER BRACKET CONTROL 1 U73543 (SHEET 1 OF 2) ### Page 60 FIGURE 9: GUTTER SEALING - HORIZONTAL STABILIZER CENTER SECTION December 09, 2004 Revision 1: October 12, 2006 767-51A0027 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 62 BOEING SERVICE BULLETIN 767-51A0027 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 this figure. NOTE: This figure applies to option 2, one piece gutter installation. STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION: DO NOT ALLOW THE SEALANT TO CREATE HIGH SPOTS OR RIDGES THAT WILL TRAP WATER ONTO THE UPPER SKIN. 1 Apply Sealant BMS 5-95 - (a) (a) Inject sealant BMS 5-95 per SOPM 20-50-19 to fill void created beneath the three hydraulic brackets and the upper spar chord. Apply BMS 5-95 sealant per SOPM 20-50-19 at final installation of gutter to completely fill faying surfaces between upper spar chord and gutter, and to fair the upper skin to the forward flange of the gutter the entire length of the gutter. Allow sealant to dry for 2 hours. (SHEET 2 OF 2) The text continues at https://openairdocs.org/service-documents/boeing/767-51a0027/file/5f12caff705f.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. 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