# Boeing Alert Service Bulletin 767-53A0100: U.S. DOT/FAA - Service Bulletin - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2011-0044; AD 2012-09-04 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 767-53A0100](https://openairdocs.org/service-documents/boeing/767-53a0100.md) - Title as filed: U.S. DOT/FAA - Service Bulletin - Pages: 309 - PDF: https://openairdocs.org/files/sha256/31/9b/319b03ce3c01735b908c884d42500877e5823ccf7f1515772590424ed361cdd2 - Page: https://openairdocs.org/service-documents/boeing/767-53a0100/file/319b03ce3c01 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 767 Service Bulletin Number: 767-53A0100 Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap - Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 1 of 309 4.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 2 of 309 BOEING SERVICE BULLETIN 767-53A0100 BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 7 1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1 1. Airplanes ............................................ 1 1 2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 2 0 E. Compliance .............................................. 2 1 F. Approval ............................................... 2 3 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 2 5 I. Electrical Load Data ......................................... 2 5 J. References .............................................. 2 5 1. Existing Data: ......................................... 2 5 2. Data supplied with this Service Bulletin: ........................... 2 6 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 6 K. Publications Affected ........................................ 2 7 L. Interchangeability and Intermixability of Parts ........................... 2 7 2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 3 2 C. Parts Necessary For Each Airplane ................................. 3 2 1. Kits/Parts: ........................................... 3 2 2. Parts and Materials Supplied by the Operator: ........................ 5 1 3. Parts Modified and Reidentified: ............................... 5 2 4. Parts Removed and Not Replaced: .............................. 5 2 D. Parts Necessary to Change Spares ................................. 5 2 E. Special Tooling - Price and Availability ............................... 5 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 2 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 3 A. GENERAL INFORMATION ..................................... 5 3 B. WORK INSTRUCTIONS ....................................... 5 4 FIGURE 1: LOGIC DIAGRAM (DELETED) ................................ 6 1 FIGURE 2: STA 955 FAIL-SAFE STRAP INSPECTION ......................... 6 2 FIGURE 3: FASTENER/PART REMOVE/REPLACE - GROUP 1 AIRPLANES - LEFT SIDE [Group 1] . 64 FIGURE 4: FASTENER/PART REMOVE/REPLACE - GROUP 1 AIRPLANES - RIGHT SIDE [Group 1] . 73 FIGURE 5: FASTENER/PART REMOVE/REPLACE - GROUP 2, 3, 10 AIRPLANES - LEFT SIDE [Group 2-3, 10] ............................................. 8 2 FIGURE 6: FASTENER/PART REMOVE/REPLACE- GROUP 2, 3, 10 AIRPLANES - RIGHT SIDE [Group 2-3, 10] ............................................. 9 2 FIGURE 7: FASTENER/PART REMOVE/REPLACE- GROUP 4, 7 AIRPLANES - LEFT SIDE [Group 4, 7] ................................................. 1 0 2 FIGURE 8: FASTENER/PART REMOVE/REPLACE- GROUP 4, 7 AIRPLANES - RIGHT SIDE [Group 4, 7 ] ................................................ 1 1 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 3 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 4 FIGURE 9: FASTENER/PART REMOVE/REPLACE- GROUP 5 AIRPLANES - LEFT SIDE [Group 5] . 122 FIGURE 10: FASTENER/PART REMOVE/REPLACE - GROUP 5 AIRPLANES - RIGHT SIDE [Group 5] . 133 FIGURE 11: FASTENER/PART REMOVE/REPLACE- GROUP 6, 11 AIRPLANES - LEFT SIDE [Group 6, 11] ............................................... 1 4 4 FIGURE 12: FASTENER/PART REMOVE/REPLACE - GROUP 6, 11 AIRPLANES - RIGHT SIDE [Group 6, 11] ............................................... 1 5 5 FIGURE 13: TUBING - REMOVE/REPLACE - LEFT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ............................................. 1 6 6 FIGURE 14: TUBING - REMOVE/REPLACE - RIGHT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ............................................. 1 6 9 FIGURE 15: FAIL-SAFE STRAP REPAIR/MODIFICATION ....................... 1 7 2 FIGURE 16: FASTENER/PART REMOVE/REPLACE- GROUP 8 - LEFT SIDE [Group 8] ....... 1 7 7 FIGURE 17: FASTENER/PART REMOVE/REPLACE- GROUP 8 - RIGHT SIDE [Group 8] ...... 1 8 7 FIGURE 18: FASTENER/PART REMOVE/REPLACE- GROUP 9 - LEFT SIDE [Group 9] ....... 1 9 7 FIGURE 19: FASTENER/PART REMOVE/REPLACE - GROUP 9 - RIGHT SIDE [Group 9] ...... 2 0 8 FIGURE 20: TUBING - REMOVE/REPLACE - GROUP 8, 9 - LEFT SIDE [Group 8-9] ......... 2 1 9 FIGURE 21: TUBING - REMOVE/REPLACE - GROUP 8, 9 - RIGHT SIDE [Group 8-9] ........ 2 2 3 FIGURE 22: JACK AND SUPPORT WORK - GROUP 1, 2, 5, 10 AIRPLANES [Group 1, Configuration 1; Group 2, 5, 10] ........................................ 2 2 6 FIGURE 23: JACK AND SUPPORT WORK - GROUP 3, 4, 6 AIRPLANES [Group 3; Group 4, Configuration 1; Group 6] .......................................... 2 2 9 FIGURE 24: JACK AND SUPPORT WORK - GROUP 8,9 AIRPLANES [Group 8-9] .......... 2 3 2 FIGURE 25: ACCESS AT WING/BODY INTERFACE - LEFT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ........................................... 2 3 5 FIGURE 26: ACCESS AT WING/BODY INTERFACE - RIGHT SIDE - GROUP 1-7, 10, 11 AIRPLANES [Group 1-7, 10-11] ....................................... 2 3 9 FIGURE 27: ACCESS AT WING/BODY INTERFACE - LEFT SIDE - GROUP 8, 9 AIRPLANES [Group 8-9] ................................................. 2 4 3 FIGURE 28: ACCESS AT WING/BODY INTERFACE - RIGHT SIDE - GROUP 8, 9 AIRPLANES [Group 8-9] ................................................. 2 4 7 FIGURE 29: ACCESS AT WHEEL WELL/PRESSURE DECK - LEFT SIDE ............... 2 5 1 FIGURE 30: ACCESS AT WHEEL WELL/PRESSURE DECK - RIGHT SIDE .............. 2 5 7 FIGURE 31: AILERON CONTROL CABLE PULL/STOW - LEFT SIDE ................. 2 6 3 FIGURE 32: AILERON CONTROL CABLE PULL/STOW - RIGHT SIDE ................ 2 6 7 FIGURE 33: AILERON CONTROL CABLE RESTORE - LEFT SIDE ................... 2 7 2 FIGURE 34: AILERON CONTROL CABLE RESTORE - RIGHT SIDE .................. 2 7 6 FIGURE 35: PRESSURE DECK RESTORE - LEFT SIDE ........................ 2 8 1 FIGURE 36: PRESSURE DECK RESTORE - RIGHT SIDE ....................... 2 8 8 FIGURE 37: SKIN PANEL REPAIR - REMOVAL OF FRETTING AND/OR CORROSION ....... 2 9 5 FIGURE 38: SKIN PANEL REPAIR - MAKE/ASSEMBLE PARTS .................... 3 0 1 FIGURE 39: JACK AND SUPPORT WORK - GROUP 7, 11 AIRPLANES [Group 7, 11] ........ 3 0 7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 4 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 5 Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-53A0100Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap - Inspection This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with Revision 2 of this service bulletin. Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 R1 is related to this service bulletin. REASON FOR REVISION This revision is sent to give less restrictive instruction for the access and restore work associated with the repair/modification given in this service bulletin. This revision is also sent to make the work instruction more clear. These sections were changed: 1. Paragraph 1.C., Reason: Updated service history. 2. Paragraph 1.D., Description: Added maintenance zone data. 3. Paragraph 1.E., Compliance: Added statement regarding a possible new AD due to existing AD worksheet. 4. Paragraph 3.A., General Information: Added notes numbered 5, 9-13. Note 11 is added to give flexibility regarding access work. 5. Paragraph 3.B., Work Instructions: Added note to steps 9-12, 23, 24, 26 to give flexibility regarding the sequence of work. 6. Figure 15: Added a note to the step table to clarify the necessary work when the trim modification is accomplished on a crack-free strap. 7. Figures 22-24, 39: Changed instruction to recommend (vs. require) that all jacks be locked by mechanical means. 8. Figure 25-28: Changed the reference given for the installation and check of the bonding fastener. Also added alternative fastener data in fastener table. 9. Figure 28: Added a fastener code (B) that was inadvertantly omitted from sheet 1 graphic. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 5 of 309 ### Page 6 10. Figure 29, 30: Revised sheet 3 graphic to give a more accurate depiction. 11. Figure 32, 34: Revised cable identification labels on sheet 2, 3 graphics. 12. Figure 35,36: Revised sheet 3 graphic to give a more accurate depiction. 13. Figure 37: Changed skin thickness allowable for group 5 airplanes from 0.360 to 0.324 in. 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 September 26, 2002Original Issue: August 11, 2006Revision 1: January 15, 2010Revision 2: February 06, 2012Revision 3: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 6 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 7 Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-53A0100Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap - Inspection CONCURRENT REQUIREMENTS None. BACKGROUND The inspections specified in this service bulletin are necessary to make sure that cracks and/or corrosion in a fail-safe strap will be found and repaired before the damage can have an effect on flight safety. The fail-safe strap is held/attached between the rear spar bulkhead side fitting and the body skin at body station 955 on both sides of the airplane. If the airplane is operated with a crack and/or corrosion in the fail-safe strap, a difficult repair that requires removal of the fail-safe strap could become necessary. Also, the damage in the strap could cause cracks in the body skin and other adjacent structure which then could be unable to sustain regulatory loads, possibly resulting in a loss of structural integrity. It is anticipated that cracks and/or corrosion in the fail-safe strap will be found with the inspections given in this service bulletin before there is damage in the body skin and other adjacent structure, and before it is necessary to replace the strap. The repair specified in this service bulletin requires only a fraction of the work and down time required to replace the fail-safe strap. Before the release of revision 1 of this service bulletin there were ten reports of cracks and/or corrosion in the fail-safe strap on nine airplanes as shown in the table below. All but one of the damaged fail-safe straps were replaced. One fail-safe strap was repaired with the trim-out repair given in this service bulletin. CommentsDamageFlight HoursFlight Cycles Straps had extreme corrosion.Corrosion left and right side, cracks left and right side. 37,63413,472 Crack may have started from damage in strap surface. Crack left side.55,60916,403 Crack started at area of small gouging and fretting on strap sur- face. Crack left side.72,70618,061 Strap had extreme corrosionCorrosion on left side71,64315,694 Fastener hole elongationCorrosion and cracks right side62,36018,545 Strap had extreme corrosionCorrosion on left side63,54923,337 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 7 of 309 ### Page 8 CommentsDamageFlight HoursFlight Cycles Strap had extreme corrosionCorrosion on right side74,82323,987 Fretting, fastener hole elongationCrack right side66,46731,809 Strap repaired with trim-out repair given in this service bulletin. Crack right side51,12936,635 Crack growth in the fail-safe strap is not due to classical tensile fatigue. Boeing has found that the fatigue is due to residual tension in the fail-safe strap. This tension is from locally high compressive stress yielding the part. The fatigue occurs when the yielded section of the fail-safe strap repeatedly goes through cyclic loading. The 767 fatigue test aircraft was tested for 100,000 flight cycles and cracks were found in the fail-safe strap on both the right and left sides of the test airplane. At the release of revision 2 of this service bulletin, cracks have been found in 51 fail-safe straps on 41 airplanes. Of these cases, 42 fail-safe straps were repaired in accordance with this service bulletin and nine fail-safe straps were not repairable and were replaced. Fail-safe straps were repaired on 33 airplanes with flight-cycles ranging from 9,250 to 38,490 and flight-hours ranging from 39,886 to 89,236. Fail-safe straps were replaced on nine airplanes with flight-cycles ranging from 12,565 to 31,809 and flight-hours ranging from 48,704 to 93,212. Also, four fail-safe straps have been replaced due to corrosion damage only (no cracks) on four airplanes with flight-cycles ranging from 12,540 to 23,987 and flight-hours ranging from 37,634 to 74,823. At the release of revision 2 of this service bulletin, there has also been one report of a crack found in the "T" fitting which connects the fail-safe strap and the pressure deck. The cracked "T" fitting was found at 13,449 flight-cycles / 74,008 flight-hours and the crack was located at the lower of the three fastener holes common to the fail-safe strap. As a result of this finding, instruction to do an open hole HFEC inspection of the "T" fitting has been added to this service bulletin. As of the release of revision 3 of this service bulletin, cracks have been found in 108 fail-safe straps on 79 airplanes. Of these cases, 94 fail-safe straps were repaired in accordance with this service bulletin and 14 fail-safe straps were not repairable and were replaced. Fail-safe straps have been repaired on airplanes with flight-cycles ranging from 8,214 to 41,120, and fail-safe straps have been replaced on 14 airplanes with flight-cycles ranging from 12,565 to 40,421. Also, seven fail-safe straps have been replaced due to corrosion damage only (no cracks) on seven airplanes with flight-cycles ranging from 12,540 to 25, 867. Also, two fail-safe straps have been repaired (in place) to remove corrosion from the tab area. See Boeing Fleet Team Digest Article Number 767-FTD-53-02004 for pictures and more information of cracks that have been found in-service on the fail-safe strap. Boeing Service Related Problem (SRP) 767-SRP-53-0180 is related to this service bulletin. Boeing Structural Item Interim Advisory (SIIA) 767-21 is related to this service bulletin. The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin for group 1-7, 10, 11 airplanes. ACTION (PRR B12901-63S) A detailed and HFEC inspection for corrosion and crack damage are to be done over the visible surface of the fail-safe strap on each side of the airplane. Also, an ultrasonic inspection is to be done to find if there is a crack in the area of the fail-safe strap under (covered by) the "T" fitting which is connected to the fail-safe strap and to the outboard edge of the sloping pressure deck. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 8 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 9 If no corrosion or cracks are found with the inspections, repeat inspections are to be made at regular intervals. If cracks and/or corrosion are found, a repair must be made before more flights. If crack damage has not extended outside the tab part of the strap where the "T" fitting is attached, the fail-safe strap repair given in this service bulletin is to be made. If crack damage extends outside the specified area, it will be necessary to replace the strap. Boeing plans to release service bulletin 767-53-0116 at a later date with instructions to install a replacement strap. NOTE: The change made to the airplane with the fail-safe strap repair given in this service bulletin can be made at any time to end the need for more inspections per this service bulletin at the side of the airplane that has the repair. EFFECTIVITY 767-200/-300/-300F/-400ER airplanes. Refer to paragraph 1.A.1 for effectivity. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 R1 is related to this service bulletin. The Federal Aviation Administration (FAA) will possibly release a new Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory for all the airplanes affected by this service bulletin. Refer to Paragraph 1.E., Compliance. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin. MANPOWER Elapsed HoursTotal Task HoursAirplanes 2.04.0Group 1-10 Elapsed HoursTotal Task HoursAirplanes 85295Group 1-7, 10 86297Group 8, 9 MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 9 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 10 (OCR) BOEING SERVICE BULLETIN 767-53A0100 STA 955 FAILSAFE STRAP T-FITTING REAR SPAR BULKHEAD FITTING SEE DO ULTRASONIC INSPECTION OF THE AREA OF THE FAILSAFE STRAP UNDER THE T-FITTING INSPECTION AREA T- FITTING , FWD TYPICAL CRACK IN FAILSAFE LEFT SIDE SHOWN, STRAP RIGHT SIDE OPPOSITE DO A DETAILED INSPECTION AND A SURFACE HFEC INSPECTION OF TYPICAL V88417 ACCESSABLE AREAS OF FAILSAFE STRAP CORROSION Original Issue: September 26, 2002 Revision 3: February 06, 2012 BOEING PROPRIETARY - 767-53A0100 Copyright © Unpublished Work - See page 1 for details. 10 of 309 ### Page 11 Commercial Airplanes 767 Service Bulletin Number: 767-53A0100 Original Issue: September 26, 2002 Revision 3: February 06, 2012 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap - Inspection 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 B12901-63S for data about this change. DESCRIPTIONCONFIGURATIONGROUP 767-200 with longeron splice installation 145T0083-7/-8, -9/-10, -11/-12 -1 Not modified to Boeing Approved Special Freighter configuration1 767-200 with longeron splice installation 145T0083-11/-12 and Special Freighter modification which is given in Boeing service bulletin 767-53-0125 and is applicable to VA511 only 2 767-200 with longeron splice installation 145T0083-19/-20-2 767-300 with longeron splice installation 145T0083-13/-14-3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 11 of 309 ### Page 12 DESCRIPTIONCONFIGURATIONGROUP 767-300 with longeron splice installation 145T0083-21/-22, -25/-26, -33/-34 -4 Not modified to Boeing Converted Freighter (BCF) configuration1 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0140 and is applicable to VN191 only 2 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0148 and is applicable to VN192 only 3 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0150 and is applicable to VN 193 only 4 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0154 and is applicable to VN194 only 5 Longeron splice installation 145T0083-21/-22 and BCF modification which is given in Boeing service bulletin 767-53-0157 and is applicable to VN195 - VN197 only 6 767-200 with longeron splice installation 145T0083-41/-42-5 767-300 with longeron splice installation 145T0083-45/-46, -47/-48-6 767-300F with longeron splice installation 145T0083-25/-26, -27/-28, -37/-38 -7 767-400ER with longeron splice installation 145T0083-31/-32-8 767-400ER with longeron splice installation 145T0083-43/-44-9 767-200 with longeron splice installation 145T0083-13/-14-10 767-300F with longeron splice installation 145T0083-49/-50-11 Airplane Models: 767-200, 767-300, 767-300F, 767-400ER GroupVariable Number 1VA001 - VA020 1VA301 - VA315 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 12 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 13 GroupVariable Number 1VA501 - VA530 1VA701 - VA719 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB332 1VB371 - VB373 1VB401 1VB441 - VB444 1VE001 - VE003 1VE021 - VE023 1VE041 - VE043 1VE061 - VE069 1VE083 - VE086 1VE101 - VE104 1VE116 - VE118 1VE121 - VE126 1VE141 - VE152 1VE171 - VE172 2VF001 - VF002 2VF041 - VF042 2VF051 2VF061 - VF062 2VF071 - VF072 2VF091 - VF093 10VF101 - VF102 2VF161 - VF162 2VF171 - VF172 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 13 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 14 GroupVariable Number 2VF180 - VF184 2VF251 3VK001 - VK016 3VK021 - VK022 3VK031 - VK056 3VK081 - VK113 4VK131 - VK133 3VK141 - VK148 3VK161 - VK164 3VK171 3VK181 3VK186 3VL001 - VL006 3VL011 4VL701 - VL703 4VL751 - VL755 4VL806 - VL807 4VL871 - VL873 4VL891 - VL900 4VL911 - VL914 4VL931 - VL932 4VL941 4VN001 - VN041 4VN051 - VN064 4VN081 - VN099 4VN111 - VN127 4VN130 - VN137 4VN151 - VN158 4VN163 - VN168 4VN171 - VN174 4VN191 - VN198 4VN211 - VN212 4VN221 - VN225 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 14 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 15 GroupVariable Number 4VN231 - VN234 4VN241 - VN243 4VN251 - VN276 4VN291 - VN293 4VN301 - VN314 4VN371 - VN372 4VN376 4VN381 - VN388 4VN421 - VN427 4VN436 4VN471 - VN472 4VN491 - VN513 4VN531 - VN532 4VN536 - VN537 4VN541 - VN542 4VN546 - VN547 4VN551 4VN556 - VN557 4VN561 - VN562 4VN631 - VN638 4VN651 - VN658 4VN671 - VN672 4VN676 4VN681 - VN691 4VN731 - VN732 4VN751 - VN753 4VN791 - VN792 4VN811 - VN813 4VN921 - VN922 4VN931 - VN936 4VN951 - VN953 4VN966 - VN972 8VQ001 - VQ019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 15 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 16 GroupVariable Number 9VQ020 - VQ021 8VQ071 - VQ082 9VQ083 - VQ086 2VR051 - VR060 2VR081 5VR084 5VR086 - VR087 7VR201 - VR211 7VR251 7VR256 - VR260 3VR401 3VR421 - VR423 3VR426 3VR441 3VR461 3VR471 - VR472 4VS051 - VS056 4VS061 4VS066 - VS070 4VS073 - VS078 4VS091 - VS104 4VS111 - VS113 4VS131 - VS133 4VS136 - VS137 4VS176 - VS177 4VS186 - VS187 4VS196 - VS203 4VS206 - VS208 4VS211 4VS216 - VS217 4VS231 4VS246 - VS248 4VS261 - VS263 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 16 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 17 GroupVariable Number 4VS266 - VS274 4VS291 - VS293 4VS301 - VS303 4VS306 - VS311 4VS316 4VS321 - VS324 4VS331 - VS333 4VS336 - VS337 4VS366 - VS367 4VS381 - VS382 4VS391 - VS392 4VS401 6VS426 - VS428 4VS466 - VS472 4VS486 4VS496 - VS497 4VS506 - VS507 4VS526 4VS546 - VS549 6VS701 - VS712 6VS721 - VS732 6VS751 - VS759 6VS821 - VS825 6VS841 - VS844 6VS861 6VS881 - VS882 6VS891 6VS896 11VT501 7VW701 - VW721 7VW851 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 17 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 18 2. Spares Affected None. B. Concurrent Requirements None. C. Reason The inspections specified in this service bulletin are necessary to make sure that cracks and/or corrosion in a fail-safe strap will be found and repaired before the damage can have an effect on flight safety. The fail-safe strap is held/attached between the rear spar bulkhead side fitting and the body skin at body station 955 on both sides of the airplane. If the airplane is operated with a crack and/or corrosion in the fail-safe strap, a difficult repair that requires removal of the fail-safe strap could become necessary. Also, the damage in the strap could cause cracks in the body skin and other adjacent structure which then could be unable to sustain regulatory loads, possibly resulting in a loss of structural integrity. It is anticipated that cracks and/or corrosion in the fail-safe strap will be found with the inspections given in this service bulletin before there is damage in the body skin and other adjacent structure, and before it is necessary to replace the strap. The repair specified in this service bulletin requires only a fraction of the work and down time required to replace the fail-safe strap. Before the release of revision 1 of this service bulletin there were ten reports of cracks and/or corrosion in the fail-safe strap on nine airplanes as shown in the table below. All but one of the damaged fail-safe straps were replaced. One fail-safe strap was repaired with the trim-out repair given in this service bulletin. CommentsDamageFlight HoursFlight Cycles Straps had extreme corrosion.Corrosion left and right side, cracks left and right side. 37,63413,472 Crack may have started from damage in strap surface. Crack left side.55,60916,403 Crack started at area of small gouging and fretting on strap sur- face. Crack left side.72,70618,061 Strap had extreme corrosionCorrosion on left side71,64315,694 Fastener hole elongationCorrosion and cracks right side62,36018,545 Strap had extreme corrosionCorrosion on left side63,54923,337 Strap had extreme corrosionCorrosion on right side74,82323,987 Surface wear, fastener hole elon- gation Crack right side66,46731,809 Strap repaired with trim-out repair given in this service bulletin. Crack right side51,12936,635 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 18 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 19 The crack growth in the fail-safe strap is not due to classical tensile fatigue. Boeing has found that the fatigue is due to residual tension in the fail-safe strap. This tension is from locally high compressive stress yielding the part. The fatigue occurs when the yielded section of the fail-safe strap repeatedly goes through cyclic loading. The 767 fatigue test aircraft was tested for 100,000 flight cycles and cracks were found in the fail-safe strap on both the right and left sides of the test airplane. As of the release of revision 2 of this service bulletin, cracks have been found in 51 fail-safe straps on 41 airplanes. Of these cases, 42 fail-safe straps were repaired in accordance with this service bulletin and nine fail-safe straps were not repairable and were replaced. Fail-safe straps were repaired on 33 airplanes with flight-cycles ranging from 9,250 to 38,490 and flight-hours ranging from 39,886 to 89,236. Fail-safe straps were replaced on nine airplanes with flight-cycles ranging from 12,565 to 31,809 and flight-hours ranging from 48,704 to 93,212. Also, four fail-safe straps have been replaced due to corrosion damage (no cracks) on four airplanes with flight-cycles ranging from 12,540 to 23,987 and flight-hours ranging from 37,634 to 74,823. At the release of revision 2 of this service bulletin, there has also been one report of a crack found in the "T" fitting which connects the fail-safe strap and the pressure deck. The cracked "T" fitting was found at 13,449 flight-cycles / 74,008 flight-hours and the crack was located at the lower of the three fastener holes common to the fail-safe strap. As a result of this finding, instruction to do an open hole HFEC inspection of the "T" fitting has been added to this service bulletin. As of the release of revision 3 of this service bulletin, cracks have been found in 108 fail-safe straps on 79 airplanes. Of these cases, 94 fail-safe straps were repaired in accordance with this service bulletin and 14 fail-safe straps were not repairable and were replaced. Fail-safe straps have been repaired on airplanes with flight-cycles ranging from 8,214 to 41,120, and fail-safe straps have been replaced on 14 airplanes with flight-cycles ranging from 12,565 to 40,421. Also, seven fail-safe straps have been replaced due to corrosion damage only (no cracks) on seven airplanes with flight-cycles ranging from 12,540 to 25, 867. Also, two fail-safe straps have been repaired (in place) to remove corrosion from the tab area. See Boeing Fleet Team Digest Article Number 767-FTD-53-02004 for pictures and more information of cracks that have been found in-service on the fail-safe strap. Boeing Service Related Problem (SRP) 767-SRP-53-0180 is related to this service bulletin. Boeing Structural Item Interim Advisory (SIIA) 767-21 is related to this service bulletin. The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin for group 1-7, 10, 11 airplanes. Revision 1 is sent to give instruction for an expanded inspection and also for a repair that can be made if the damage found with the inspection is contained inside a specified area of the fail-safe strap. Also, the inspections requirements given in this service bulletin are extended to model 767-400ER airplanes. Revision 2 is sent to give more instruction about how to get access to the repair/modification area and also to give instruction about how to repair skin fretting and/or corrosion. Also, revision 2 is sent to give instruction to inspect adjacent structure in cases where a crack is indicated in the fail-safe strap with the ultrasonic inspection. Also, revision 2 is sent to give revised fastener data and revised instruction about how to support the airplane. Revision 3 is sent to give clarification to and add flexibility to the work instruction. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 19 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 20 D. Description A detailed and HFEC inspection for corrosion and crack damage are to be done over the visible surface of the fail-safe strap on each side of the airplane. Also, an ultrasonic inspection is to be done to find if there is a crack in the area of the fail-safe strap under (covered by) the "T" fitting which is connected to the fail-safe strap and to the outboard edge of the sloping pressure deck. If no corrosion or cracks are found with the inspections, repeat inspections are to be made at regular intervals. If cracks and/or corrosion are found, a repair must be made before more flights. If crack damage has not extended outside the tab part of the strap where the "T" fitting is attached, the fail-safe strap repair given in this service bulletin is to be made. If crack damage extends outside the specified area, it will be necessary to replace the strap. Boeing plans to release service bulletin 767-53-0116 with instructions to install a replacement strap. NOTE: The change made to the airplane with the fail-safe strap repair given in this service bulletin can be made at any time to stop the need for more of the inspections given in this service bulletin. PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. REPORT IF CRACKS ARE FOUND ALSO SEND A REPORT IF NO CRACKS ARE FOUND. Send your report to: BOEING COMMERCIAL AIRPLANES GROUP ATTENTION: MANAGER, AIRLINE SUPPORT The airplane effectivity is divided into 11 groups due to differences in the parts that are used to make the repair. Revision 1 - No more work is necessary on group 1-7 airplanes inspected as shown in the initial release of this service bulletin; however, the inspections given in revision 1 to this service bulletin are necessary by the times given in paragraph 1.E Compliance. NOTE: The group 1-7 airplanes identified in Revision 1 are contained in groups 1-7 plus group 10 and group 11 in Revision 2. Revision 2 - No more work is necessary on airplanes inspected and/or changed in accordance with revision 1 of this service bulletin. Revision 3 - No more work is necessary on airplanes inspected and/or changed in accordance with revision 2 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1-2, 5, 10: Affected Maintenance Zones ZoneModel 131, 132, 141, 142, 241, 242, 551, 651767-200 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 20 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 21 Group 3-4, 6: Affected Maintenance Zones ZoneModel 131, 132, 141, 142, 241, 242, 551, 651767-300 Group 7, 11: Affected Maintenance Zones ZoneModel 131, 132, 141, 142, 241, 242, 551, 651767-300F Group 8-9: Affected Maintenance Zones ZoneModel 131, 132, 141, 142, 241, 242, 551, 651767-400ER E. Compliance Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 R1, Amendment 39-13800 is related to this service bulletin. The Federal Aviation Administration (FAA) will possibly release a new Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory for all the airplanes affected by this service bulletin. NOTE: For group 1-7 and group 10, 11 airplanes that have not been inspected in accordance with the initial release of this service bulletin, Boeing recommends that the initial inspection include the detailed, surface HFEC and ultrasonic inspections of the fail-safe strap given in Accomplishment Instruction 3.B.5. Thereafter, the inspections are to be repeated at the intervals given below. Table 1: Inspection of the Fail-Safe Strap for Cracks and Corrosion - Group 1-11 Airplanes. Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Last) ActionCondition 6,000 flight-cycles or 36 months, whichever occurs first. Within 3,000 flight-cycles after Nov. 1, 2004 (effec- tive date of AD 2004-19- 06, R1). Before 15,000 total flight-cycles Do a detailed and a surface HFEC inspec- tion of the fail-safe strap for cracks and corrosion in accor- dance with Accom- plishment Instruction 3.B. Group 1-7 airplanes Group 10 airplanes Group 11 airplanes (a) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 21 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 22 Table 1: Inspection of the Fail-Safe Strap for Cracks and Corrosion - Group 1-11 Airplanes. Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Last) ActionCondition 6,000 flight-cycles or 36 months, whichever occurs first. Within 3,000 flight-cycles after the revision 1 date of this service bulletin. Before 15,000 total flight-cycles Do an ultrasonic in- spection of the fail- safe strap for cracks in accordance with Accomplishment In- struction 3.B. Group 1-7 airplanes Group 10 airplanes Group 11 airplanes (a) 6,000 flight-cycles or 36 months, whichever occurs first. Within 3,000 flight-cycles after the revision 1 date of this service bulletin. Before 15,000 total flight-cycles Do a detailed and a surface HFEC inspec- tion of the fail-safe strap for cracks and corrosion and an ultra- sonic inspection of the fail-safe strap for cracks in accordance with Accomplishment Instruction 3.B. Group 8 airplanes Group 9 airplanes (a) -Before further flightMake a repair in accor- dance with Accom- plishment Instruction 3.B. Corrosion found -Before further flightMake a repair in accor- dance with Accom- plishment Instruction 3.B. Also, do Detailed and open hole HFEC inspections of adja- cent structure for cracks and corrosion in accordance with Accomplishment In- struction 3.B. Repair adjacent structure as necessary in accor- dance with Accom- plishment Instruction 3.B. Crack found --(b)Fail-safe strap trim repair accomplished. --(d)Fail-safe strap re- placed and the re- placement strap has the revised edge configuration. (c) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 22 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 23 Table 1: Inspection of the Fail-Safe Strap for Cracks and Corrosion - Group 1-11 Airplanes. Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Last) ActionCondition 6,000 flight-cycles or 36 months, whichever occurs first. Before 12,000 flight-cycles after the replace- ment fail-safe strap is installed. (e) Do a detailed and a surface HFEC inspec- tion of the fail-safe strap for cracks and corrosion and an ultra- sonic inspection of the fail-safe strap for cracks in accordance with Accomplishment Instruction 3.B. Fail-safe strap is re- placed and the re- placement strap does not have the revised edge config- uration. (c) (a) Accomplishment of the fail-safe strap trim repair given in this service bulletin terminates the repeat inspection requirement on the side of the airplane where the repair has been accomplished. The fail-safe strap trim repair can be accomplished as a modification on a fail-safe strap that has no crack and/or corrosion damage as an alternative to repeat inspections. (b) After the fail-safe strap trim repair given in this service bulletin is accomplished, inspection in accordance with this service bulletin will no longer be necessary on the side of the airplane where the repair was accom- plished. (c) The revised edge configuration does not include the tab for the three bolt connection between the fail-safe strap and the T-fitting. With the revised edge configuration the T-fitting is not connected to the fail-safe strap. The revised (no tab) edge configuration is equivalent to the post-repair configuration after the fail-safe strap trim repair given in this service bulletin is accomplished. (d) If a replacement fail-safe strap that has the revised edge configuration is installed, inspection in accordance with this service bulletin will no longer be necessary on the side of the airplane where the replacement is accomplished. (e) For this condition, the "whichever occurs last" statement in the heading of the table does not apply. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. The jacking and support instruction given in this service bulletin is not approved for Group 1, configuration 2 airplanes or Group 4, configuration 2 thru 6 airplanes. For these airplanes, special instruction based on the actual configuration of the airplane will be required for approval. 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 23 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 24 This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service bulletin as an alternative method of compliance to the corresponding requirements of paragraphs (f) and (g) of AD 2004-19-06 R1. All provisions of AD 2004-19-06 R1 that are not specifically referenced in the above statement remain fully applicable and must be complied with. G. Manpower The first table below gives an estimate of the task-hours necessary to do the inspection given in figure 2 for each airplane. The second table below gives an estimate of the task-hours necessary to do the repair work on one side of the airplane after a crack is found with the inspection. These estimates are 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. Inspection Manpower - Group 1-11 Airplanes Elapsed HoursTask-HoursNumber of Per- sons Task 0.51.02Open Access 1.02.02Examine 0.51.02Close Access 2.04.0TOTAL FOR EACH AIRPLANE NOTE: The estimate given for the "examine" step in the tables below is the estimate for added inspection that must be done when the repair is made. Repair Manpower - Group 1-7, 10, 11 Airplanes Elapsed HoursTask-HoursNumber of Per- sons Task 33.25133.04Open Access 1.02.02Examine 12.012.01Repair (a) 3.57.02Test (b) 35.25141.04Close Access 85.0295.0TOTAL FOR EACH AIRPLANE BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 24 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 25 Repair Manpower - Group 1-7, 10, 11 Airplanes Elapsed HoursTask-HoursNumber of Per- sons Task (a) Time to accomplish the work given in figures 37 and 38 is not included in the estimate. If the work given in figures 37 and 38 is necessary, more time will be necessary. (b) Leak tests done after hydraulic tubes are installed per AMM 20-10-09. Repair Manpower - Group 8,9 Airplanes Elapsed HoursTask-HoursNumber of Per- sons Task 33.25133.04Open Access 1.02.02Examine 12.012.01Repair (a) 4.59.02Test (b) 35.25141.04Close Access 86.0297.0TOTAL FOR EACH AIRPLANE (a) Time to accomplish the work given in figures 37 and 38 is not included in the estimate. If the work given in figures 37 and 38 is necessary, more time will be necessary. (b) Leak tests done after hydraulic tubes are installed per AMM 20-10-09. H. Weight and Balance Changes None. I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR B12901-63S b. 767-200 Structural Repair Manual (SRM) 51, 51-10-02, 51-40-05, 51-50-02 c. 767-200SF Structural Repair Manual (SRM) 51, 51-10-02, 51-40-05 d. 767-300 Structural Repair Manual (SRM) 51, 51-10-02, 51-40-05, 51-50-02 e. 767-300BCF Structural Repair Manual (SRM) 51, 51-10-02, 51-40-05 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 25 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 26 f. 767-300F Structural Repair Manual (SRM) 51, 51-10-02, 51-40-05, 51-50-02 g. 767-400 Structural Repair Manual (SRM) 51, 51-10-02, 51-40-05, 51-50-02 h. 767 Aircraft Maintenance Manual (AMM) 07-11-01, 07-11-03, 12-15-01, 12-15-02, 20-10-09, 25-21-01, 25-24-00, 25-25-01, 25-27-01, 25-52-00, 27-11-00, 27-11-08, 27-11-34, 27-11-36, 28-26-00, 29-11-00, 32-00-15, 32-00-20, 53-01-01 i. 767 Non-Destructive Testing (NDT) Manual, Part 4, 51-00-10, Part 4, 53-50-05, Part 6, 51-00-01, Part 6, 51-00-19, Part 6, Subject 51-00-16, Part 6, Subject 51-00-19 j. 767 Structural Item Interim Advisory (SIIA) 767-21 k. Boeing Drawing 012W6100 l. Boeing Fleet Team Digest Article Number 767-FTD-53-02004 m. Boeing Parts Standards Document D-590 n. Boeing Service Bulletin 767-53-0116 o. FAA Airworthiness Directive 2004-19-06 R1, Amendment 39-13800 p. Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 q. Service Related Problem (SRP) 767-SRP-53-0180 r. Standard Overhaul Practices Manual (SOPM) 20-00-00, 20-11-03, 20-41-02, 20-43-03, 20-50-11, 20-50-19 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Splice Installation - Longeron at Rear Spar Bulkhead145T0083 Closure Panel Assembly - Pressure Deck, Section 45145T8752 Wheel Well Longeron Installation145T8800 Monoque Integration - Wing to Body100T1430 Monoque Integration - Section 45145T0010 Integration - Section 45 Crown to Keel Beam & Pressure Deck100T1482 Skin Panel - Machined, STA 785.9 to STA 1065, S-17L to Wing145T3321 Tubing Installation Main Wheel Well RH, STA 955 - STA 1065278T4572 Tubing Installation Main Wheel Well LH, STA 955 thru STA 1065278T4563 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 26 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 27 TitleDrawing Number Tubing Installation Inboard Rear Spar and Trailing Edge LH, BBL 97.42 to RSS 608.7 278T1373 Tubing Installation Inboard Rear Spar and Trailing Edge RH, BBL 97.42 to RSS 608.7 278T1374 Panel Support Installation - Wing T.E.113T1621 Integration - Section 45 - Crown to Keel Beam & Pressure Deck100T1482 Control Installation - Lateral251T1000 Seal Application - Section 45140T4500 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 27 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 28 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 28 of 309 BOEING SERVICE BULLETIN 767-53A0100 BLANK PAGE ### Page 29 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. Unit Price thru Oct 31/06 ROLT (Weeks) QTYDateNameKit Number (a) $11,331.0064101/17/07Kit - Group 1 Airplanes015T1788-1 (b) $11,331.0064102/28/07Kit - Group 1 Airplanes015T1788-1 (b) $11,331.0064103/28/07Kit - Group 1 Airplanes015T1788-1 (b) $11,331.0064104/25/07Kit - Group 1 Airplanes015T1788-1 (b) (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-51. Unit Price thru Oct 31/06 ROLT (Weeks) QTYDateNameKit Number (a) $15,033.006428/14/06Kit - Group 2, 3, 10 Airplanes015T1788-2 (b) $15,033.0064309/13/06Kit - Group 2, 3, 10 Airplanes015T1788-2 (b) (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-52. Unit Price thru Oct 31/06 ROLT (Weeks) QTYDateNameKit Number (a) $9,103.0065511/28/06Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.006551/4/07Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.006552/1/07Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.0065103/1/07Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.0065153/29/07Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.0065154/26/07Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.0065155/24/07Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.0065156/22/07Kit - Group 4, 7 Airplanes015T1788-3 (b) $9,103.0065157/23/07Kit - Group 4, 7 Airplanes015T1788-3 (b) (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-53. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 29 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 30 Unit Price thru Oct 31/06 ROLT (Weeks) QTYDateNameKit Number (a) $15,837.006427/9/07Kit - Group 5 Airplanes015T1788-4 (b) (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-54. Unit Price thru Oct 31/06 ROLT (Weeks) QTYDateNameKit Number (a) $9,054.006552/5/07Kit - Group 6, 11 Airplanes015T1788-5 (b) $9,054.006553/5/07Kit - Group 6, 11 Airplanes015T1788-5 (b) (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-55. Unit Price thru Oct 31/06 ROLT (Weeks) QTYDateNameKit Number (a) $32,593.006527/31/07Kit - Group 8 Airplanes015T1788-6 (b) (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-56. Unit Price thru Oct 31/06 ROLT (Weeks) QTYDateNameKit Number (a) $32,727.006527/31/07Kit - Group 9 Airplanes015T1788-7 (b) (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-57. Unit PriceROLT (weeks) NameKit Number $21,09869Kit - Group 1 Airplanes015T1788-51 (a) (b) $25,518105Kit - Group 2, 3, 10 Airplanes015T1788-52 (a) (c) $16,84272Kit - Group 4, 7 Airplanes015T1788-53 (a) (d) $26,085105Kit - Group 5 Airplanes015T1788-54 (a) (e) $17,21870Kit - Group 6, 11 Airplanes015T1788-55 (a) (f) $27,239105Kit - Group 8 Airplanes015T1788-56 (a) (g) $27,803105Kit - Group 9 Airplanes015T1788-57 (a) (h) (a) Kit can be used to make a right side or left side repair. (b) Replaces 015T1788-1 (c) Replaces 015T1788-2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 30 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 31 Unit PriceROLT (weeks) NameKit Number (d) Replaces 015T1788-3 (e) Replaces 015T1788-4 (f) Replaces 015T1788-5 (g) Replaces 015T1788-6 (h) Replaces 015T1788-7 Unit PriceROLT (weeks) NameKit Number $698(h)Supplemental Kit - Group 1 Airplanes015T1788-61 (a) $1,816(h)Supplemental Kit - Group 2, 3, 10 Airplanes015T1788-62 (b) $1,434(h)Supplemental Kit - Group 4, 7 Airplanes015T1788-63 (c) $2,168(h)Supplemental Kit - Group 5 Airplanes015T1788-64 (d) $1,756(h)Supplemental Kit - Group 6, 11 Airplanes015T1788-65 (e) $2,467(h)Supplemental Kit - Group 8 Airplanes015T1788-66 (f) $2,790(h)Supplemental Kit - Group 9 Airplanes015T1788-67 (g) (a) 015T1788-61 plus 015T1788-1 is equivalent to 015T1788-51 (b) 015T1788-62 plus 015T1788-2 is equivalent to 015T1788-52 (c) 015T1788-63 plus 015T1788-3 is equivalent to 015T1788-53 (d) 015T1788-64 plus 015T1788-4 is equivalent to 015T1788-54 (e) 015T1788-65 plus 015T1788-5 is equivalent to 015T1788-55 (f) 015T1788-66 plus 015T1788-6 is equivalent to 015T1788-56 (g) 015T1788-67 plus 015T1788-7 is equivalent to 015T1788-57 (h) Contact Boeing for delivery data Unit PriceROLT (Weeks) NamePart Number $2,899(b)"T" Fitting (left side)100T1440U3 (a) $2,899(b)"T" Fitting (right side)100T1440U4 (a) (a) Replacement part for group 1 airplanes. (b) Contact Boeing for delivery data. Unit PriceROLT (Weeks) NamePart Number $4,894(b)"T" Fitting (left side)145T1929U9 (a) $4,894(b)"T" Fitting (right side)145T1929U10 (a) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 31 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 32 Unit PriceROLT (Weeks) NamePart Number (a) Replacement part for group 2-11 airplanes (b) Contact Boeing for delivery data. B. Industry Support Information Boeing warranty remedies are not available for the inspection or repair/modification given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts: NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each side of the airplane. To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 --FILLER1.....015T1788-10 --FILLER.11111140T0145-35 --SHIM1.....145T0083-5 --SHIM1.....145T0083-6 --SHIM.11111145T0083-16 --SHIM.11111145T0083-17 (a)-BOLT, HEX DRIVE3.....BACB30LX14A22 (a)-BOLT, HEX DRIVE3.....BACB30LX14A23 (a)-BOLT, HEX DRIVE5.....BACB30LX16A24 (a)-BOLT, HEX DRIVE1.....BACB30LX16A26 (a)-BOLT, HEX DRIVE.2.2..BACB30LX16A43 (a)-BOLT, HEX DRIVE..2.22BACB30LX16A46 (a)-BOLT, PROTRUDING HD 66666.BACB30MY10K11X (a)-BOLT, PROTRUDING HD .6666.BACB30MY10K12X (a)-BOLT, PROTRUDING HD 2.....BACB30MY8K6X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 32 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 33 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 (a)-BOLT, PROTRUDING HD 5.....BACB30MY8K8X (a)-BOLT444444444435BACB30NN3K7 (a)-BOLT, 100 DEG HEX DR 9.....BACB30NW10K12X (a)-BOLT, 100 DEG HEX DR 29999.BACB30NW10K14X (a)-BOLT, 100 DEG HEX DR .....9BACB30NW10K15X (a)-BOLT, 100 DEG HEX DR .2222.BACB30NW10K16X (a)-BOLT, 100 DEG HEX DR .....2BACB30NW10K17X (a)-BOLT, 100 DEG HEX DR 21111.BACB30NW10K20X (a)-BOLT, 100 DEG HEX DR 211111BACB30NW10K21X (a)BOLT, 100 DEG HEX DR .....1BACB30NW10K22X (a)-BOLT, 100 DEG HEX DR .4.4..BACB30NW10K23X (a)-BOLT, HEX DRIVE..4.4.BACB30NW10K24X (a)-BOLT, 100 DEG HEX DR .11114BACB30NW10K25X (a)-BOLT, HEX DRIVE.1.1..BACB30NW10K26X (a)-BOLT, HEX DRIVE..1.11BACB30NW10K27X (a)-BOLT O/S.....1BACB30NW10K28X (a)-BOLT, 100 DEG HEX DR .33331BACB30NW12K16X (a)-BOLT, 100 DEG HEX DR .22222BACB30NW12K17X (a)-BOLT, 100 DEG HEX DR 311112BACB30NW12K18X (a)-BOLT, 100 DEG HEX DR 311111BACB30NW12K19X (a)-BOLT, 100 DEG HEX DR 6....1BACB30NW12K20X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 33 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 34 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 (a)-BOLT, 100 DEG HEX DR 2.....BACB30NW12K21X (a)-BOLT TITANIUM O/S.1111.BACB30NW12K22X (a)-BOLT, 100 DEG HEX DR 1....1BACB30NW12K23X (a)-BOLT, 100 DEG HEX DR 1.....BACB30NW12K24X (a)-BOLT, 100 DEG HEAD .1.1..BACB30NW12K25X (a)-BOLT TITANIUM O/S.1111.BACB30NW12K26X (a)-BOLT, HEX DRIVE1.1.1.BACB30NW12K27X (a)-BOLT, HEX DRIVE1....1BACB30NW12K28X (a)-BOLT, HEX DRIVE.1.1.1BACB30NW12K29X (a)-BOLT, HEX DRIVE.1.1..BACB30NW12K30X (a)-BOLT, HEX DRIVE..1.1.BACB30NW12K32X (a)-BOLT, HEX DRIVE..1.11BACB30NW12K33X (a)-BOLT, HEX DRIVE.....1BACB30NW12K34X (a)-BOLT, HEX DRIVE.4.4..BACB30NW14K21X (a)-BOLT, 100 DEG HEX DR .2424.BACB30NW14K22X (a)-BOLT, 100 DEG HEX DR .62624BACB30NW14K23X (a)-BOLT, 100 DEG HEX DR .16162BACB30NW14K24X (a)-BOLT, HEX DRIVE.....3BACB30NW14K25X (a)-BOLT, 100 DEG HEX DR ..1.1.BACB30NW14K26X (a)-BOLT, HEX DRIVE.....1BACB30NW14K27X (a)-BOLT, HEX DRIVE.....2BACB30NW14K28X (a)-BOLT, HEX DRIVE.....1BACB30NW14K29X (a)-BOLT, 100 DEG HEX DR .11111BACB30NW8K11X (a)-BOLT, 100 DEG HEX DR 444444BACB30NW8K12X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 34 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 35 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 (a)-BOLT, 100 DEG HEX DR 888888BACB30NW8K13X (a)-BOLT, 100 DEG HEX DR 766666BACB30NW8K9X (a)-BOLT, PROTRUDING HD .....12BACB30NX10K12X (a)-BOLT, PROTRUDING HD 1.....BACB30NX16K24X (a)-BOLT, PROTRUDING HD 1.....BACB30NX16K32X (a)-BOLT, PROTRUDING HD 222222BACB30NX6K10X (a)-BOLT, PROTRUDING HD .....2BACB30NX6K12X (a)-BOLT, PROTRUDING HD 1010101010.BACB30NX6K5X (a)-BOLT, PROTRUDING HD 6666612BACB30NX6K6X (a)-BOLT, PROTRUDING HD 222222BACB30NX6K7X (a)-BOLT, PROTRUDING HD 844444BACB30NX6K8X (a)-BOLT, PROTRUDING HD 266668BACB30NX6K9X (a)-BOLT, 100 DEG HEX DR 1.....BACB30NY14K20X (a)-BOLT, HEX DRIVE1.....BACB30NY14K21X (a)-BOLT, 100 DEG HEX DR 1.....BACB30NY14K22X (a)-BOLT, 100 DEG HEX DR 133333BACB30NY14K26X (a)-BOLT, HEX DRIVE133333BACB30NY14K27X (a)-BOLT, 100 DEG HEX DR 5.....BACB30NY14K28X (a)-BOLT, HEX DRIVE.2.2..BACB30NY16K22X (a)-BOLT, 100 DEG HD.1.1..BACB30NY16K23X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 35 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 36 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 (a)-BOLT, 100 DEG HEX DR 2.2.2.BACB30NY16K24X (a)-BOLT, 100 DEG HEX DR ..1.1.BACB30NY16K26X (a)-BOLT, 100 DEG HEX DR .33333BACB30NY16K28X (a)-BOLT, HEX DRIVE.22224BACB30NY16K29X (a)-BOLT, 100 DEG HEX DR 2....1BACB30NY16K30X (a)-BOLT, HEX DRIVE.11111BACB30NY16K31X (a)-BOLT, 100 DEG HEX DR 17.7..BACB30NY16K32X (a)-BOLT, HEX DRIVE..7.7.BACB30NY16K35X (a)-BOLT, HEX DRIVE1.....BACB30NY16K37X (a)-BOLT, HEX DRIVE.....7BACB30NY16K39X (a)-BOLT, HEX DRIVE.4.4..BACB30NY18K33X (a)-BOLT, HEX DRIVE..4.44BACB30NY18K35X (a)-BOLT, HEX DRIVE4.....BACB30NY18K37X (a)-HI-LOK.....4BACB30NZ6K5 (a)-HI-LOK888884BACB30NZ6K6 (a)-BOLT, 100 DEG HEX DR 555555BACB30NZ8K7 (a)-BOLT, HEX DRIVE.4.4..BACB30YM20K43X (a)-BOLT, 100 DEG HEX DR ....4.BACB30YM20K46 (a)-BOLT..4..4BACB30YM20K46X --COLLAR ASSEMBLY4.....BACC30AG10 --COLLAR ASSEMBLY18.....BACC30AG12 --COLLAR.8...6BACC30BH10 --COLLAR.12....BACC30BH12 --COLLAR, PRELOAD1519196619BACC30BH14 --COLLAR, SHEAR..8..19BACC30BL10 --COLLAR..12..12BACC30BL12 --COLLAR.....6BACC30BM10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 36 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 37 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 --COLLAR, PRELOAD.44444BACC30CP20C --COLLAR1723232323.BACC30M10 --COLLAR383638383838BACC30M6 --COLLAR312424242424BACC30M8 --COLLAR1417176617BACC30X16 --COLLAR, PRELOAD444..4BACC30X18 --NUT...88.BACN10YR5CD --SELF-LOCKING NUT...1212.BACN10YR6CD --NUT, SELF-LOCK, HEX ...1313.BACN10YT7CD --NUT, SELF-LOCK, HEX ...1212.BACN10YT8CD --NUT1.....BACN11Z7CD --NUT.11..1BACN11Z8CD --NUT...44.BACN11Z9CD --RIVET, 100 DEG646464646469BACR15BA6AD8C --WASHER...88.NAS1149D0532J --WASHER...1616.NAS1149D0563J --WASHER, PLAIN...1212.NAS1149D0632J --WASHER...2424.NAS1149D0663J --WASHER1.....NAS1149D0763J --WASHER, PLAIN.11..1NAS1149D0863J --WASHER, PLAIN...44.NAS1149E0932P --WASHER, PLAIN...88.NAS1149E0963P --RIVET, BLIND313131313131NAS1399D6A7 --RIVET, BLIND111112NAS1399MW6A4 (a) 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 deter- mine the part numbers used as substitutes. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 37 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 38 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -7 --FILLER1140T0145-35 --SHIM1145T0083-16 --SHIM1145T0083-17 (a)-BOLT, HEX DRIVE2BACB30LX16A46 (a)-BOLT35BACB30NN3K7 (a)-BOLT, 100 DEG HEX DR9BACB30NW10K15X (a)-BOLT, 100 DEG HEX DR2BACB30NW10K17X (a)-BOLT, 100 DEG HEX DR1BACB30NW10K21X (a)-BOLT, 100 DEG HEX DR1BACB30NW10K22X (a)-BOLT, 100 DEG HEX DR4BACB30NW10K25X (a)-BOLT, HEX DRIVE1BACB30NW10K27X (a)-BOLT, HEX DRIVE1BACB30NW10K28X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K16X (a)-BOLT, 100 DEG HEX DR2BACB30NW12K17X (a)-BOLT, 100 DEG HEX DR2BACB30NW12K18X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K19X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K20X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K23X (a)-BOLT, HEX DRIVE1BACB30NW12K28X (a)-BOLT, HEX DRIVE1BACB30NW12K29X (a)-BOLT, HEX DRIVE1BACB30NW12K33X (a)-BOLT, HEX DRIVE1BACB30NW12K34X (a)-BOLT, 100 DEG HEX DR4BACB30NW14K23X (a)-BOLT, 100 DEG HEX DR2BACB30NW14K24X (a)-BOLT, HEX DRIVE3BACB30NW14K25X (a)-BOLT, HEX DRIVE1BACB30NW14K27X (a)-BOLT, HEX DRIVE2BACB30NW14K28X (a)-BOLT, HEX DRIVE1BACB30NW14K29X (a)-BOLT, 100 DEG HEX DR1BACB30NW8K11X (a)-BOLT, 100 DEG HEX DR4BACB30NW8K12X (a)-BOLT, 100 DEG HEX DR8BACB30NW8K13X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 38 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 39 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -7 (a)-BOLT, 100 DEG HEX DR6BACB30NW8K9X (a)-BOLT, PROTRUDING HD12BACB30NX10K12X (a)-BOLT, PROTRUDING HD2BACB30NX6K10X (a)-BOLT, PROTRUDING HD2BACB30NX6K12X (a)-BOLT, PROTRUDING HD12BACB30NX6K6X (a)-BOLT, PROTRUDING HD2BACB30NX6K7X (a)-BOLT, PROTRUDING HD4BACB30NX6K8X (a)-BOLT, PROTRUDING HD8BACB30NX6K9X (a)-BOLT, 100 DEG HEX DR3BACB30NY14K26X (a)-BOLT, HEX DRIVE3BACB30NY14K27X (a)-BOLT, 100 DEG HEX DR3BACB30NY16K28X (a)-BOLT, HEX DRIVE4BACB30NY16K29X (a)-BOLT, 100 DEG HEX DR1BACB30NY16K30X (a)-BOLT, HEX DRIVE1BACB30NY16K31X (a)-BOLT, HEX DRIVE7BACB30NY16K39X (a)-BOLT, HEX DRIVE4BACB30NY18K35X (a)-HI-LOK4BACB30NZ6K5 (a)-HI-LOK4BACB30NZ6K6 (a)-BOLT, 100 DEG HEX DR5BACB30NZ8K7 (a)-BOLT4BACB30YM20K46X --COLLAR6BACC30BH10 --COLLAR, PRELOAD6BACC30BH14 --COLLAR, SHEAR11BACC30BL10 --COLLAR6BACC30BM10 --COLLAR, PRELOAD4BACC30CP20C --COLLAR38BACC30M6 --COLLAR24BACC30M8 --COLLAR6BACC30X16 --NUT8BACN10YR5CD --SELF-LOCKING NUT12BACN10YR6CD --NUT, SELF-LOCK, HEX13BACN10YT7CD BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 39 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 40 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -7 --NUT, SELF-LOCK, HEX12BACN10YT8CD --NUT4BACN11Z9CD --RIVET, 100 DEG69BACR15BA6AD8C --WASHER8NAS1149D0532J --WASHER16NAS1149D0563J --WASHER, PLAIN12NAS1149D0632J --WASHER24NAS1149D0663J --WASHER, PLAIN4NAS1149E0932P --WASHER, PLAIN8NAS1149E0963P --RIVET, BLIND31NAS1399D6A7 (a) 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. Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -51-52-53-54-55-56 --KIT-.....015T1788-51 --KIT.-....015T1788-52 --KIT..-...015T1788-53 --KIT...-..015T1788-54 --KIT....-.015T1788-55 --KIT.....-015T1788-56 --FILLER1.....015T1788-10 --FILLER.11111140T0145-35 --SHIM1.....145T0083-5 --SHIM1.....145T0083-6 --SHIM.11111145T0083-16 --SHIM.11111145T0083-17 (a)-BOLT, HEX DRIVE3.....BACB30LX14A22 (a)-BOLT, HEX DRIVE3.....BACB30LX14A23 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 40 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 41 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -51-52-53-54-55-56 (a)-BOLT, HEX DRIVE5.....BACB30LX16A24 (a)-BOLT, HEX DRIVE1.....BACB30LX16A26 (a)-BOLT, HEX DRIVE.2.2..BACB30LX16A43 (a)-BOLT, HEX DRIVE..2.22BACB30LX16A46 (a)-BOLT, PROTRUDING HD 66666.BACB30MY10K11X (a)-BOLT, PROTRUDING HD .6666.BACB30MY10K12X (a)-BOLT, PROTRUDING HD 2.....BACB30MY8K6X (a)-BOLT, PROTRUDING HD 5.....BACB30MY8K8X (a)-BOLT444444444435BACB30NN3K7 (a)-BOLT, 100 DEG HEX DR 9.....BACB30NW10K12X (a)-BOLT, 100 DEG HEX DR 29999.BACB30NW10K14X (a)-BOLT, 100 DEG HEX DR .....9BACB30NW10K15X (a)-BOLT, 100 DEG HEX DR .2222.BACB30NW10K16X (a)-BOLT, 100 DEG HEX DR .....2BACB30NW10K17X (a)-BOLT, 100 DEG HEX DR 21111.BACB30NW10K20X (a)-BOLT, 100 DEG HEX DR 211111BACB30NW10K21X (a)BOLT, 100 DEG HEX DR .....1BACB30NW10K22X (a)-BOLT, 100 DEG HEX DR .4.4..BACB30NW10K23X (a)-BOLT, HEX DRIVE..4.4.BACB30NW10K24X (a)-BOLT, 100 DEG HEX DR .11114BACB30NW10K25X (a)-BOLT, HEX DRIVE.1.1..BACB30NW10K26X (a)-BOLT, HEX DRIVE..1.11BACB30NW10K27X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 41 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 42 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -51-52-53-54-55-56 (a)-BOLT O/S.....1BACB30NW10K28X (a)-BOLT, 100 DEG HEX DR .33331BACB30NW12K16X (a)-BOLT, 100 DEG HEX DR .22222BACB30NW12K17X (a)-BOLT, 100 DEG HEX DR 311112BACB30NW12K18X (a)-BOLT, 100 DEG HEX DR 311111BACB30NW12K19X (a)-BOLT, 100 DEG HEX DR 6....1BACB30NW12K20X (a)-BOLT, 100 DEG HEX DR 2.....BACB30NW12K21X (a)-BOLT TITANIUM O/S.1111.BACB30NW12K22X (a)-BOLT, 100 DEG HEX DR 1....1BACB30NW12K23X (a)-BOLT, 100 DEG HEX DR 1.....BACB30NW12K24X (a)-BOLT, 100 DEG HEAD .1.1..BACB30NW12K25X (a)-BOLT TITANIUM O/S.1111.BACB30NW12K26X (a)-BOLT, HEX DRIVE1.1.1.BACB30NW12K27X (a)-BOLT, HEX DRIVE1....1BACB30NW12K28X (a)-BOLT, HEX DRIVE.1.1.1BACB30NW12K29X (a)-BOLT, HEX DRIVE.1.1..BACB30NW12K30X (a)-BOLT, HEX DRIVE..1.1.BACB30NW12K32X (a)-BOLT, HEX DRIVE..1.11BACB30NW12K33X (a)-BOLT, HEX DRIVE.....1BACB30NW12K34X (a)-BOLT, HEX DRIVE.4.4..BACB30NW14K21X (a)-BOLT, 100 DEG HEX DR .2424.BACB30NW14K22X (a)-BOLT, 100 DEG HEX DR .62624BACB30NW14K23X (a)-BOLT, 100 DEG HEX DR .16162BACB30NW14K24X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 42 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 43 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -51-52-53-54-55-56 (a)-BOLT, HEX DRIVE.....3BACB30NW14K25X (a)-BOLT, 100 DEG HEX DR ..1.1.BACB30NW14K26X (a)-BOLT, HEX DRIVE.....1BACB30NW14K27X (a)-BOLT, HEX DRIVE.....2BACB30NW14K28X (a)-BOLT, HEX DRIVE.....1BACB30NW14K29X (a)-BOLT, 100 DEG HEX DR .11111BACB30NW8K11X (a)-BOLT, 100 DEG HEX DR 444444BACB30NW8K12X (a)-BOLT, 100 DEG HEX DR 888888BACB30NW8K13X (a)-BOLT, 100 DEG HEX DR 766666BACB30NW8K9X (a)-BOLT, PROTRUDING HD .....12BACB30NX10K12X (a)-BOLT, PROTRUDING HD 2.....BACB30NX16K24X (a)-BOLT, PROTRUDING HD 1.....BACB30NX16K32X (a)-BOLT, PROTRUDING HD 222222BACB30NX6K10X (a)-BOLT, PROTRUDING HD .....2BACB30NX6K12X (a)-BOLT, PROTRUDING HD 1010101010.BACB30NX6K5X (a)-BOLT, PROTRUDING HD 6666612BACB30NX6K6X (a)-BOLT, PROTRUDING HD 222222BACB30NX6K7X (a)-BOLT, PROTRUDING HD 844444BACB30NX6K8X (a)-BOLT, PROTRUDING HD 266668BACB30NX6K9X (a)-BOLT, 100 DEG HEX DR 1.....BACB30NY14K20X (a)-BOLT, HEX DRIVE1.....BACB30NY14K21X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 43 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 44 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -51-52-53-54-55-56 (a)-BOLT, 100 DEG HEX DR 1.....BACB30NY14K22X (a)-BOLT, 100 DEG HEX DR 133333BACB30NY14K26X (a)-BOLT, HEX DRIVE133333BACB30NY14K27X (a)-BOLT, 100 DEG HEX DR 2.....BACB30NY14K28X (a)-BOLT, HEX DRIVE.2.2..BACB30NY16K22X (a)-BOLT, 100 DEG HD.1.1..BACB30NY16K23X (a)-BOLT, 100 DEG HEX DR 2.2.2.BACB30NY16K24X (a)-BOLT, 100 DEG HEX DR ..1.1.BACB30NY16K26X (a)-BOLT, 100 DEG HEX DR .33333BACB30NY16K28X (a)-BOLT, HEX DRIVE.32324BACB30NY16K29X (a)-BOLT, 100 DEG HEX DR 21.1.1BACB30NY16K30X (a)-BOLT, HEX DRIVE.11111BACB30NY16K31X (a)-BOLT, 100 DEG HEX DR 14141.BACB30NY16K32X (a)-BOLT, 100 DEG HEX DR ..1.1.BACB30NY16K33X (a)-BOLT, HEX DRIVE..4.4.BACB30NY16K35X (a)-BOLT, HEX DRIVE.....1BACB30NY16K36X (a)-BOLT, HEX DRIVE1....1BACB30NY16K37X (a)-BOLT, HEX DRIVE.....4BACB30NY16K39X (a)-BOLT, HEX DRIVE.4.4..BACB30NY18K33X (a)-BOLT, HEX DRIVE..4.44BACB30NY18K35X (a)-BOLT, HEX DRIVE4.....BACB30NY18K37X (a)-HI-LOK.....5BACB30NZ6K5 (a)-HI-LOK888888BACB30NZ6K6 (a)-BOLT, 100 DEG HEX DR 555555BACB30NZ8K7 (a)-BOLT, HEX DRIVE3.....BACB30YM14K28X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 44 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 45 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -51-52-53-54-55-56 (a)-BOLT, HEX DRIVE.3.3..BACB30YM16K32X (a)-BOLT, HEX DRIVE..3.3.BACB30YM16K35X (a)-BOLT, HEX DRIVE.....3BACB30YM16K39X (a)-BOLT, HEX DRIVE.4.4..BACB30YM20K43X (a)-BOLT..4.44BACB30YM20K46X --COLLAR ASSEMBLY4.....BACC30AG10 --COLLAR ASSEMBLY18.....BACC30AG12 --COLLAR.....6BACC30BH10 --COLLAR......BACC30BH12 --COLLAR, PRELOAD1366666BACC30BH14 --COLLAR.....6BACC30BM10 --COLLAR, PRELOAD.44444BACC30CP20C --COLLAR173131232319BACC30M10 --COLLAR.1212..12BACC30M12 --COLLAR.1313..13BACC30M14 --COLLAR383638383838BACC30M6 --COLLAR312424242424BACC30M8 --COLLAR1415156615BACC30X16 --COLLAR, PRELOAD444..4BACC30X18 --NUT...88.BACN10YR5CD --SELF-LOCKING NUT...1212.BACN10YR6CD --NUT, SELF-LOCK, HEX ...1313.BACN10YT7CD --NUT, SELF-LOCK, HEX ...99.BACN10YT8CD --NUT3.....BACN11Z7CD --NUT.33333BACN11Z8CD --NUT...44.BACN11Z9CD --RIVET, 100 DEG646464646469BACR15BA6AD8C --RIVET, BLIND313131313131NAS1399D6A7 --RIVET, BLIND111112NAS1399MW6A4 --SEAL111111145T8008-5 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 45 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 46 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -51-52-53-54-55-56 --SEAL111111145T8008-6 --RIVET6767676767.BACR15BA7AD8C --SHIM111111BACS40R009B027F --SHIM111111BACS40R015B015F --SHIM111111BACS40R016B017F --SHIM111111BACS40R017B032F --WASHER, PLAIN...88.BACW10BP51DP --WASHER, PLAIN...88.BACW10BP51NDP --WASHER, PLAIN...1212.BACW10BP61DP --WASHER, PLAIN...1212.BACW10BP61NDP --WASHER, PLAIN6.....BACW10BP71DP --WASHER, PLAIN.66666BACW10BP81DP --WASHER, PLAIN...88.BACW10BP91DP --RIVET323232323232NAS1398D6A3 (a) 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 deter- mine the part numbers used as substitutes. Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -57 --KIT-015T1788-57 --FILLER1140T0145-35 --SHIM1145T0083-16 --SHIM1145T0083-17 (a)-BOLT, HEX DRIVE2BACB30LX16A46 (a)-BOLT35BACB30NN3K7 (a)-BOLT, 100 DEG HEX DR9BACB30NW10K15X (a)-BOLT, 100 DEG HEX DR2BACB30NW10K17X (a)-BOLT, 100 DEG HEX DR1BACB30NW10K21X (a)-BOLT, 100 DEG HEX DR1BACB30NW10K22X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 46 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 47 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -57 (a)-BOLT, 100 DEG HEX DR4BACB30NW10K25X (a)-BOLT, HEX DRIVE1BACB30NW10K27X (a)-BOLT, HEX DRIVE1BACB30NW10K28X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K16X (a)-BOLT, 100 DEG HEX DR2BACB30NW12K17X (a)-BOLT, 100 DEG HEX DR2BACB30NW12K18X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K19X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K20X (a)-BOLT, 100 DEG HEX DR1BACB30NW12K23X (a)-BOLT, HEX DRIVE1BACB30NW12K28X (a)-BOLT, HEX DRIVE1BACB30NW12K29X (a)-BOLT, HEX DRIVE1BACB30NW12K33X (a)-BOLT, HEX DRIVE1BACB30NW12K34X (a)-BOLT, 100 DEG HEX DR4BACB30NW14K23X (a)-BOLT, 100 DEG HEX DR2BACB30NW14K24X (a)-BOLT, HEX DRIVE3BACB30NW14K25X (a)-BOLT, HEX DRIVE1BACB30NW14K27X (a)-BOLT, HEX DRIVE2BACB30NW14K28X (a)-BOLT, HEX DRIVE1BACB30NW14K29X (a)-BOLT, 100 DEG HEX DR1BACB30NW8K11X (a)-BOLT, 100 DEG HEX DR4BACB30NW8K12X (a)-BOLT, 100 DEG HEX DR8BACB30NW8K13X (a)-BOLT, 100 DEG HEX DR6BACB30NW8K9X (a)-BOLT, PROTRUDING HD12BACB30NX10K12X (a)-BOLT, PROTRUDING HD2BACB30NX6K10X (a)-BOLT, PROTRUDING HD2BACB30NX6K12X (a)-BOLT, PROTRUDING HD12BACB30NX6K6X (a)-BOLT, PROTRUDING HD2BACB30NX6K7X (a)-BOLT, PROTRUDING HD4BACB30NX6K8X (a)-BOLT, PROTRUDING HD8BACB30NX6K9X (a)-BOLT, 100 DEG HEX DR3BACB30NY14K26X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 47 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 48 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -57 (a)-BOLT, HEX DRIVE3BACB30NY14K27X (a)-BOLT, 100 DEG HEX DR3BACB30NY16K28X (a)-BOLT, HEX DRIVE4BACB30NY16K29X (a)-BOLT, 100 DEG HEX DR1BACB30NY16K30X (a)-BOLT, HEX DRIVE1BACB30NY16K31X (a)-BOLT, HEX DRIVE1BACB30NY16K36X (a)-BOLT, HEX DRIVE1BACB30NY16K37X (a)-BOLT, HEX DRIVE4BACB30NY16K39X (a)-BOLT, HEX DRIVE4BACB30NY18K35X (a)-HI-LOK5BACB30NZ6K5 (a)-HI-LOK8BACB30NZ6K6 (a)-BOLT, 100 DEG HEX DR5BACB30NZ8K7 (a)-BOLT3BACB30YM16K39X (a)-BOLT4BACB30YM20K46X --COLLAR6BACC30BH10 --COLLAR, PRELOAD6BACC30BH14 --COLLAR, SHEAR11BACC30M10 --COLLAR6BACC30BM10 --COLLAR, PRELOAD4BACC30CP20C --COLLAR38BACC30M6 --COLLAR24BACC30M8 --COLLAR6BACC30X16 --NUT8BACN10YR5CD --SELF-LOCKING NUT12BACN10YR6CD --NUT, SELF-LOCK, HEX13BACN10YT7CD --NUT, SELF-LOCK, HEX9BACN10YT8CD --NUT3BACN11Z8CD --NUT4BACN11Z9CD --RIVET, 100 DEG69BACR15BA6AD8C --WASHER, PLAIN8BACW10BP51DP --WASHER, PLAIN8BACW10BP51NDP BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 48 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 49 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -57 --WASHER, PLAIN12BACW10BP61DP --WASHER, PLAIN12BACW10BP61NDP --WASHER, PLAIN6BACW10BP81DP --WASHER, PLAIN8BACW10BP91DP --RIVET, BLIND31NAS1399D6A7 --RIVET32NAS1398D6A3 --RIVET, BLIND2NAS1399MW6A4 --SEAL1145T8008-5 --SEAL1145T8008-6 --SHIM1BACS40R009B027F --SHIM1BACS40R015B015F --SHIM1BACS40R016B017F --SHIM1BACS40R017B032F (a) 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. Kit 015T1788 NotesExisting Part Num- ber NameQTYNew Part Number -61-62-63-64-65-66 --KIT - SUPPLEMENTAL-.....015T1788-61 --KIT - SUPPLEMENTAL.-....015T1788-62 --KIT - SUPPLEMENTAL..-...015T1788-63 --KIT - SUPPLEMENTAL...-..015T1788-64 --KIT - SUPPLEMENTAL....-.015T1788-65 --KIT - SUPPLEMENTAL.....-015T1788-66 (a)-BOLT,PROTRUD HD1.....BACB30NX16K24X (a)-BOLT, HEX DRIVE.1.1..BACB30NY16K29X (a)-BOLT, 100 DEG HEX DR.1.1..BACB30NY16K30X (a)-BOLT, 100 DEG HEX DR..1.1.BACB30NY16K32X (a)-BOLT, 100 DEG HEX DR..1.1.BACB30NY16K33X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 49 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 50 Kit 015T1788 NotesExisting Part Num- ber NameQTYNew Part Number -61-62-63-64-65-66 (a)-BOLT, HEX DRIVE.....1BACB30NY16K36X (a)-BOLT, HEX DRIVE.....1BACB30NY16K37X (a)-HI-LOK.....5BACB30NZ6K5 (a)-BOLT, HEX DRIVE3.....BACB30YM14K28X (a)-BOLT, HEX DRIVE.3.3..BACB30YM16K32X (a)-BOLT, HEX DRIVE..3.3.BACB30YM16K35X (a)-BOLT, HEX DRIVE.....3BACB30YM16K39X --COLLAR.88..19BACC30M10 --COLLAR.1212..12BACC30M12 --COLLAR.1313..13BACC30M14 --NUT3.....BACN11Z7CD --NUT.33333BACN11Z8CD --SEAL111111145T8008-5 --SEAL111111145T8008-6 --RIVET6767676767.BACR15BA7AD8C --SHIM111111BACS40R009B027F --SHIM111111BACS40R015B015F --SHIM111111BACS40R016B017F --SHIM111111BACS40R017B032F --WASHER, PLAIN...88.BACW10BP51DP --WASHER, PLAIN...88.BACW10BP51NDP --WASHER, PLAIN...1212.BACW10BP61DP --WASHER, PLAIN...1212.BACW10BP61NDP --WASHER, PLAIN6.....BACW10BP71DP --WASHER, PLAIN.66666BACW10BP81DP --WASHER, PLAIN...88.BACW10BP91DP --RIVET323232323232NAS1398D6A3 (a) 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 de- termine the part numbers used as substitutes. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 50 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 51 Kit 015T1788 NotesExisting Part Number NameQTYNew Part Number -67 --KIT - SUPPLEMENTAL-015T1788-67 (a)-BOLT, HEX DRIVE1BACB30NY16K36X (a)-BOLT, HEX DRIVE1BACB30NY16K37X (a)-HI-LOK5BACB30NZ6K5 (a)-BOLT, HEX DRIVE3BACB30YM16K39X --COLLAR, SHEAR11BACC30M10 --NUT3BACN11Z8CD --WASHER, PLAIN8BACW10BP51DP --WASHER, PLAIN8BACW10BP51NDP --WASHER, PLAIN12BACW10BP61DP --WASHER, PLAIN12BACW10BP61NDP --WASHER, PLAIN6BACW10BP81DP --WASHER, PLAIN8BACW10BP91DP --RIVET32NAS1398D6A3 --SEAL1145T8008-5 --SEAL1145T8008-6 --SHIM1BACS40R009B027F --SHIM1BACS40R015B015F --SHIM1BACS40R016B017F --SHIM1BACS40R017B032F (a) 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. 2. Parts and Materials Supplied by the Operator: NotesNameQTYPart Number / Specification (a)Sealant1 gal.BMS 5-95 Type 1, Class B-2 (a)Primer1 gal.BMS 10-11, Type I (a)Leveling Compound1 gal.BMS 5-125, Type III (a)Aerodynamic Filler1 qt.BMS 5-142 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 51 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 52 NotesNameQTYPart Number / Specification (a) These materials are for the fail-safe strap trim repair. See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. In addition to the above materials, replacement fasteners for removed pressure deck panels are to be supplied by the operator. The quantity and specification of the fasteners that will be needed to restore the pressure deck can be determined when the pressure deck panels are removed to get access to the repair area. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the inspection 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 52 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 53 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 – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in SRM Chapter 51 4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. 6. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 7. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 53 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 54 9. Boeing Service Letter 767-SL-51-036, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 10. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 11. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. Work that is identified as access or restore work can be done in a different sequence than the specified sequence relative to other work that is identified as access or restore work respectively. 12. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 13. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. B. WORK INSTRUCTIONS 1. Install the main and nose landing gear downlocks. Refer to 767 AMM 32-00-20. WARNING: MAKE SURE THERE ARE NO PERSONS OR EQUIPMENT IN THE WHEEL WELL AREA BEFORE YOU MOVE THE GROUND RELEASE LEVER FOR THE DOOR. THE DOORS OPEN AND CLOSE QUICKLY AND CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 2. Open the Main Landing Gear (MLG) doors. Refer to 767 AMM 32-00-15. WARNING: MAKE SURE YOU INSTALL THE DOOR LOCKS CORRECTLY. THE DOORS OPEN AND CLOSE QUICKLY AND CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 3. Install the MLG Door locks. Refer to 767 AMM 32-00-15. 4. Remove hydraulic power. Refer to 767 AMM 29-11-00. 5. Do a detailed inspection, a surface HFEC inspection, and an ultrasonic inspection of the fail-safe strap on the right and left side of the airplane as given in figure 2. If a crack is indicated by the ultrasonic inspection, do an open hole HFEC inspection at the lower of the three fastener holes common to the fail-safe strap and the "T" fitting. Do this inspection in accordance with 767 NDT, Part 6, 51-00-16 and inspect all the parts in the stackup at that location (longeron splice plate, skin panel, fail-safe strap and "T" fitting). BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 54 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 55 NOTE: The specified ultrasonic inspection procedure includes instruction to do an open hole HFEC inspection to verify a crack indication. In addition to possible verification of a crack in the fail-safe strap, the open hole HFEC inspection above is to include all parts in the stackup. If a crack is found, a repair must be made in accordance with Paragraph 1.E., Compliance and instruction given below. It is possible that a crack in the failsafe strap will not be indicated by the open hole HFEC inspection. 6. If no crack or corrosion is found, put the airplane back to a serviceable condition and do repeat inspections as given in paragraph 1.E., Compliance. NOTE: If the trim repair/modification given in this service bulletin is accomplished, the inspections given in this service bulletin will no longer be necessary on the side of the airplane where the repair/modification is accomplished. The trim repair/modification given in this service bulletin can be accomplished as an alternative to the repeated inspections at any time immediately after all the inspections given in figure 2 are accomplished. With a fail-safe strap that is crack-free, the trim modification is accomplished in accordance with the same instruction given for the crack repair, except that specified steps associated with crack removal are not necessary. 7. If corrosion is found on the visible/accessible part of the fail-safe strap, try to find the limits of the area(s) with corrosion and then contact Boeing for repair instruction. Unless instructed by Boeing to do otherwise, after the corrosion is removed, apply chemical conversion coating and BMS 10-11, Type 1 primer to all bare surfaces of the strap. Apply chemical conversion coating per SOPM 20-43-03. Apply primer per SOPM 20-41-02. Apply a top finish to match surrounding surfaces. Put the airplane back to a serviceable condition and do repeat inspections as given in paragraph 1.E., Compliance. If a crack is indicated in the fail-safe strap by any inspection given above, accomplish the trim repair in accordance with the steps below. If a crack is also found in the "T" fitting, a replacement "T" fitting is to be installed concurrent with the trim repair. If a crack or corrosion is found in structure adjacent to the fail-safe strap, contact Boeing for repair instructions. CAUTION: THE STRUCTURE COULD BE DAMAGED WHEN IT IS DISASSEMBLED IF A JACK/SUPPORT PROCEDURE OTHER THAN THE RECOMMENDED PROCEDURE IS USED. 8. Defuel and jack/support the airplane. Refer to 767 AMM 28-26-00 for defueling instructions. Jack/support the airplane in accordance with the figure identified in the table below or contact Boeing to get special jack/support instruction if necessary. NOTE: The jack and support loads given in the figures are based on OEW configuration. For other than OEW configuration, including 767-200 and -300 model airplanes modified to Boeing approved freighter configuration, contact Boeing and give the airplane weight, center of gravity, and configuration changes to get adjusted jack and support loads. Adjusted jack and support loads will also be required for non-freighter airplanes originally delivered as zero occupancy. Jack/Support FigureGroup 221, 2, 5, 10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 55 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 56 Jack/Support FigureGroup 233, 4, 6 248, 9 397, 11 9. Get access to the upper surface of the sloping pressure deck from body station 950-980 at the side of body by removing the sidewall panel and the floor panel over this area. Remove interior components as necessary to remove the sidewall and floor panels. Refer to the manual sections given in the table below as necessary. For left side repair only, remove left side floor panel near the side of body to get access to the center turn buckles for aileron control cables A1A and A1B which are at body station 709 and 687 respectively. Alternatively, the turn buckles can be accessed from the forward cargo compartment by removing the ceiling lining. For right side repair only, remove right side floor panel near the side of body to get access to the center turn buckles for aileron control cables A2A and A2B which are at body station 687 and 709 respectively. Alternatively, the turn buckles can be accessed from the forward cargo compartment by removing ceiling lining. Reference AMMComponent 767 AMM 25-25-01, 767-400 AMM 25-25-01 passenger seats 767 AMM 25-24-00, 767-400 AMM 25-24-00 closets and partitions 767 AMM 25-27-01, 767-400 AMM 25-27-01 floor covering 767 AMM 53-01-01, 767-400 AMM 53-01-01 floor panel (passenger) 767 AMM 53-01-06floor panel (freighter) 767 AMM 25-21-01, 767-400 AMM 25-21-01 sidewall lining (passenger) 767 AMM 25-59-00sidewall lining (freighter) 767 AMM 25-52-02, 767-400 AMM 25-52-02 cargo compartment ceiling lining NOTE: The work given in this step is access work that can be accomplished before the airplane is jacked/supported. 10. Remove parts as necessary to get external access at the wing/body interface. Refer to the applicable figure identified in the table below. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 56 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 57 Access Figure - Right Side Access Figure - Left Side Group 26251-7, 10, 11 28278, 9 NOTE: The work given in this step is access work that can be accomplished before the airplane is jacked/supported. 11. Remove/keep hydraulic tubes as necessary to get clear access to the repair area. Refer to the applicable figure identified in the table below. Figure - Hydraulic Tube Removal - Right Side Figure - Hydraulic Tube Removal - Left Side Group 14131-7, 10, 11 21208, 9 NOTE: The work given in this step is access work that can be accomplished before the airplane is jacked/supported. 12. Pull and stow the aileron control cables that go through the pressure deck. Refer to the applicable figure identified in the table below. Figure - Control Cable Pull/Stow - Right Side Figure - Control Cable Pull/Stow - Left Side Group 3231All NOTE: The work given in this step is access work that can be accomplished before the airplane is jacked/supported. 13. Remove parts from the pressure deck. Refer to the applicable figure identified in the table below. Figure - Pressure Deck Disassembly - Right Side Figure - Pressure Deck Disassembly - Left Side Group 3029All 14. Remove the "T" fitting connected to the fail-safe strap. Refer to the applicable figure identified in the table below. NOTE: The figure given in the table below shows more than how to remove the "T" fitting. For the work given in this step, refer to this figure only to remove the "T" fitting. Figure - Right SideFigure - Left SideGroup 431 652, 3, 10 874, 7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 57 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 58 Figure - Right SideFigure - Left SideGroup 1095 12116, 11 17168 19189 15. Do open hole and surface HFEC inspections of the fail-safe strap as given in figure 15. 16. If the cracks in the fail-safe strap are thought to be shorter than the limit given in figure 15, remove fasteners/parts identified in the applicable figure given in step 14 above as necessary to install a protective shim between the skin and the fail-safe strap in accordance with figure 15. NOTE: Fasteners identified in the figures given above in step 14 must be removed/replaced as necessary to remove/reinstall the "T"-fitting. The remaining fasteners identified in the figures must be removed/replaced only as is necessary to accomplish all the work steps given in figure 15 (and, if necessary, all the work steps given in figure 37) without causing damage to the skin or other structure. 17. Remove crack damage from the fail-safe strap in accordance with figure 15. If there is a crack in the fail-safe strap that cannot be repaired with the work given in figure 15, contact Boeing to get instruction to install a replacement fail-safe strap. NOTE: Boeing plans to release service bulletin 767-53-0116 to give instruction to install a replacement fail-safe strap. 18. Do a detailed inspection of the removed "T" fitting for fretting and corrosion damage. If damage is found on the "T" fitting around any of the holes for the three fasteners that connect the "T" fitting to the fail-safe strap, it will be necessary to install a replacement "T" fitting when the structure is reassembled. Also do an open hole inspection for cracks in the "T" fitting at the locations of the three fasteners that connect the "T" fitting to the fail-safe strap. Do this inspection in accordance with 767 NDT, Part 6, 51-00-16. If there is a crack in the "T" fitting, it will be necessary to install a replacement "T" fitting when the structure is reassembled. 19. Do a detailed inspection of the internal surface of the skin panel for fretting and corrosion damage in the area where the "T" fitting was installed. If damage is found in this area, do the repair work given in figure 37 as necessary to remove the damage from the skin. If the skin damage cannot be fully removed with the repair given in figure 37, contact Boeing for special instruction. 20. Make a disk filler in accordance with figure 38 for each repair spotface that has been made in the skin. If necessary, do more work in the repaired area of the skin in accordance with figure 37 to satisfy the clearance, angularity and other assembly requirements given in figure 38. Keep disk filler(s) for installation at the same spotface in a later work step. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 58 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 59 21. Install new and removed/kept parts as given in the applicable figure identified in the table below. If spotface(s) have been made in the skin, install disk filler(s) at the spotface(s) and make sure that the clearance, angularity and other assembly requirements are satisfied in accordance with figure 38. If necessary, do more work in the repaired area of the skin in accordance with figure 37 to satisfy the fit requirements. NOTE: Fasteners identified in the figures given in the table below must be removed/replaced as necessary to install a protective shim in accordance with figure 15 (and, if necessary, all the work steps given in figure 37) without causing damage to the skin or other structure. The oversize replacement fasteners identified in the figures given in the table below must be installed where the initial fasteners have been removed. Figure - Right SideFigure - Left SideGroup 431 652, 3, 10 874, 7 1095 12116, 11 17168 19189 22. Install the parts that were removed from the pressure deck. Refer to the applicable figure identified in the table below. Figure - Pressure Deck Re- store - Right Side Figure - Pressure Deck Re- store - Left Side Group 3635All 23. Restore the aileron control cables that go through the pressure deck. Refer to the applicable figure identified in the table below. Figure - Control Cable Pull/Stow - Right Side Figure - Control Cable Pull/Stow - Left Side Group 3433All NOTE: The work given in this step is restore work that can be accomplished after the airplane is lowered off the jacks. 24. Do a pressure leak test at the reinstalled pressure deck panels. Refer to AMM 05-51-24 for leak test procedure or use operators preferred alternative test procedure. NOTE: The work given in this step can be accomplished at any time between the work given in the previous step and the final step below. 25. Install the removed/kept tubes as given in the applicable figure identified in the table below. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 59 of 309 BOEING SERVICE BULLETIN 767-53A0100 ### Page 60 Hydraulic Tube Replace - Right Side Hydraulic Tube Replace - Left Side Group 14131-7, 10, 11 21208, 9 26. Install parts removed to get external access at the wing/body interface. Refer to the applicable figure identified in the table below. Figure - Right SideFigure - Left SideGroup 26251-7, 10, 11 28278, 9 NOTE: The work given in this step is restore work that can be accomplished after the airplane is lowered off the jacks. 27. Restore hydraulic power. Refer to 767 AMM 29-11-00. 28. Do a leak check on all hydraulic tubes disconnected during the repair procedure. Refer to 767 AMM 20-10-09, or use operators preferred alternative test procedure. 29. Remove the main landing gear door locks and close the main landing gear doors. Refer to 767 AMM 32-00-15. WARNING: THE DOORS OPEN AND CLOSE QUICKLY AND CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 30. Remove the body and wing supplemental supports and the nose gear axle jack. Lower the airplane off the jacks and service the nose and main gear struts. Refer to 767 AMM 07-11-01. 31. Remove the main and nose landing gear downlocks. Refer to 767 AMM 32-00-20. 32. Do functional checks of the aileron control system mechanisms affected by the pull/stow of the control cables. Refer to the manual identified in the table below for instruction, or use operator's equivalent check procedures. Functional Check ReferenceMechanism 767 AMM 27-11-08Lateral Control Feel, Centering, and Trim Mechanism 767 AMM 27-11-36Aileron Control Override Mechanism 767 AMM 27-11-34Right Aileron Control Output Quadrant Refer to 767 AMM 27-11-00 for Aileron and Aileron Trim Control System - Adjustment/Test procedures. 33. Put the airplane back to a serviceable condition. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 26, 2002 767-53A0100Revision 3: February 06, 2012 60 of 309 BOEING SERVICE BULLETIN 767-53A0100 The text continues at https://openairdocs.org/service-documents/boeing/767-53a0100/file/319b03ce3c01.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.