# Boeing Alert Service Bulletin 767-53A0100: Boeing - 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: Boeing - Service Bulletin - Pages: 310 - PDF: https://openairdocs.org/files/sha256/98/42/9842d987339bcd53f03dd5f3177585101cdaaa640cec24c6cdea42ca909c5871 - Page: https://openairdocs.org/service-documents/boeing/767-53a0100/file/9842d987339b ## Text Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 310 ALERT ALERT Commercial Airplane Group 767 ALERTALERT Service Bulletin Number: 767-53A0100 Date: September 26, 2002 Revision 2: January 15, 2010 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap - Inspection BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise. ### Page 2 BLANK PAGE September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BLANK PAGE ### Page 3 Table of Contents Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 33 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 34 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 34 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 55 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 56 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 FIGURE 1: LOGIC DIAGRAM (DELETED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FIGURE 2: STA 955 FAIL-SAFE STRAP INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 65 FIGURE 3: FASTENER/PART REMOVE/REPLACE - GROUP 1 AIRPLANES - LEFT SIDE. . . . . . 67 FIGURE 4: FASTENER/PART REMOVE/REPLACE - GROUP 1 AIRPLANES - RIGHT SIDE . . . . . 76 FIGURE 5: FASTENER/PART REMOVE/REPLACE - GROUP 2, 3, 10 AIRPLANES - LEFT SIDE . . 85 FIGURE 6: FASTENER/PART REMOVE/REPLACE- GROUP 2, 3, 10 AIRPLANES - RIGHT SIDE . . 95 FIGURE 7: FASTENER/PART REMOVE/REPLACE- GROUP 4, 7 AIRPLANES - LEFT SIDE. . . . . 105 FIGURE 8: FASTENER/PART REMOVE/REPLACE- GROUP 4, 7 AIRPLANES - RIGHT SIDE . . . . 115 FIGURE 9: FASTENER/PART REMOVE/REPLACE- GROUP 5 AIRPLANES - LEFT SIDE . . . . . . 125 FIGURE 10: FASTENER/PART REMOVE/REPLACE - GROUP 5 AIRPLANES - RIGHT SIDE . . . . 136 FIGURE 11: FASTENER/PART REMOVE/REPLACE- GROUP 6, 11 AIRPLANES - LEFT SIDE . . . 147 ### Page 4 Table of Contents Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT FIGURE 12: FASTENER/PART REMOVE/REPLACE - GROUP 6, 11 AIRPLANES - RIGHT SIDE . 158 FIGURE 13: TUBING - REMOVE/REPLACE - LEFT SIDE - GROUP 1-7, 10, 11 AIRPLANES . . . . 169 FIGURE 14: TUBING - REMOVE/REPLACE - RIGHT SIDE - GROUP 1-7, 10, 11 AIRPLANES . . . 172 FIGURE 15: FAIL-SAFE STRAP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 FIGURE 16: FASTENER/PART REMOVE/REPLACE- GROUP 8 - LEFT SIDE. . . . . . . . . . . . 180 FIGURE 17: FASTENER/PART REMOVE/REPLACE- GROUP 8 - RIGHT SIDE . . . . . . . . . . . 190 FIGURE 18: FASTENER/PART REMOVE/REPLACE- GROUP 9 - LEFT SIDE. . . . . . . . . . . . 200 FIGURE 19: FASTENER/PART REMOVE/REPLACE - GROUP 9 - RIGHT SIDE . . . . . . . . . . 211 FIGURE 20: TUBING - REMOVE/REPLACE - GROUP 8, 9 - LEFT SIDE. . . . . . . . . . . . . . . 222 FIGURE 21: TUBING - REMOVE/REPLACE - GROUP 8, 9 - RIGHT SIDE . . . . . . . . . . . . . . 226 FIGURE 22: JACK AND SUPPORT WORK - GROUP 1, 2, 5, 10 AIRPLANES . . . . . . . . . . . . 229 FIGURE 23: JACK AND SUPPORT WORK - GROUP 3, 4, 6 AIRPLANES . . . . . . . . . . . . . . 232 FIGURE 24: JACK AND SUPPORT WORK - GROUP 8,9 AIRPLANES. . . . . . . . . . . . . . . . 235 FIGURE 25: ACCESS AT WING/BODY INTERFACE - LEFT SIDE - GROUP 1-7, 10, 11 AIRPLANES . 238 FIGURE 26: ACCESS AT WING/BODY INTERFACE - RIGHT SIDE - GROUP 1-7, 10, 11 AIRPLANES 241 FIGURE 27: ACCESS AT WING/BODY INTERFACE - LEFT SIDE - GROUP 8, 9 AIRPLANES . . . 244 FIGURE 28: ACCESS AT WING/BODY INTERFACE - RIGHT SIDE - GROUP 8, 9 AIRPLANES . . 248 FIGURE 29: ACCESS AT WHEEL WELL/PRESSURE DECK - LEFT SIDE. . . . . . . . . . . . . . 252 FIGURE 30: ACCESS AT WHEEL WELL/PRESSURE DECK - RIGHT SIDE . . . . . . . . . . . . . 258 FIGURE 31: AILERON CONTROL CABLE PULL/STOW - LEFT SIDE . . . . . . . . . . . . . . . . 264 FIGURE 32: AILERON CONTROL CABLE PULL/STOW - RIGHT SIDE . . . . . . . . . . . . . . . 268 FIGURE 33: AILERON CONTROL CABLE RESTORE - LEFT SIDE . . . . . . . . . . . . . . . . . 273 FIGURE 34: AILERON CONTROL CABLE RESTORE - RIGHT SIDE . . . . . . . . . . . . . . . . 277 FIGURE 35: PRESSURE DECK RESTORE - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . 282 FIGURE 36: PRESSURE DECK RESTORE - RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . 289 FIGURE 37: SKIN PANEL REPAIR - REMOVAL OF FRETTING AND/OR CORROSION . . . . . . 296 FIGURE 38: SKIN PANEL REPAIR - MAKE/ASSEMBLE PARTS . . . . . . . . . . . . . . . . . . 302 FIGURE 39: JACK AND SUPPORT WORK - GROUP 7, 11 AIRPLANES. . . . . . . . . . . . . . . 308 ### Page 5 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 310 ALERT ALERT Commercial Airplanes 767 ALERTALERT Service Bulletin Number: 767-53A0100 Revision Transmittal Sheet Original Issue: September 26, 2002 Revision 2: January 15, 2010 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 airplanes changed as shown in Revision 1 of this service bulletin. Airplane VS729 was added to the effectivity of this service bulletin as a Group 6 airplane. Airplane VS729 was accidentally omitted from the effectivity of the previous release 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 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 which has been found on some airplanes when the fail-safe strap was trimmed in accordance with this service bulletin. Also, this revision 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, this revision is sent to give changed fastener data and changed instruction about how to support the airplane. These sections were changed: 1. Summary: Service history data has been added and manpower estimates have been adjusted. 2. 1.A., Effectivity: Airplane VS729 has been added as a Group 6 airplane. Created new groups 10 and 11 which contain airplanes moved from group 3 and group 6 respectively. These groups were created to separate airplanes that have different jacking/support instruction. In Group/Configuration table, created configurations for group 2 and group 4 airplanes with Special Freighter (SF) and Boeing Converted Freighter (BCF) modifications respectively. 3. 1.C., Reason: Service history data has been added. 4. 1.G., Manpower: Manpower estimates have been adjusted. ### Page 6 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 5. 2.A., Material - Price and Delivery: Data about replacement kits, supplemental kits, and replacement T- fittings has been added. 6. 2.C., Material - Parts Necessary For Each Airplane: Data about replacement and supplemental kits has been added. 7. 3.B., Work Instructions: Steps associated with access work and fretting and/or corrosion repair work have been added. Also, instruction to do an open hole HFEC inspection for cracks in adjacent structure has been added. Also, a note has been added to clarify that removal and replacement of certain fasteners identified in the figures is necessary only as required to accomplish the trim of the fail-safe strap without causing damage to the skin or the fail-safe strap. 8. Figures 3 -12, 16 - 19: Changes have been made to fastener data and a note has been added to clarify that removal and replacement of fasteners identified in the figure is necessary only as required to accomplish the trim of the fail-safe strap without causing damage. Where specified, fastener torque values have been changed to agree with standard ranges. 9. Figures 22 - 24: Changes have been made to the position of two body supports and instruction has been added to change the configuration of one of the body supports so that removal of certain wing/body fairing structure can be avoided. The jacking/support instructions for the airplanes now in group 10 have been changed. 10. Figures 25 - 28: Steps associated with more access work have been added to these figures. 11. Figures 29 - 36: These figures have been added to give more open/close access work instruction. 12. Figure 37, 38: These figures have been added to give instruction for repair of corrosion found on the inner surface of the skin panel. 13. Figure 39: This figure has been added to give revised jacking/support instruction for freighter (group 7, 11) airplanes. As a part of a service bulletin validation program, this change was completed on airplane VK089 by Service Bulletin 767-53A0100, Revision 1. Airplane VK089 has the configuration of a Group 3 airplane. 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. Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. REVISION HISTORY Original Issue: September 26, 2002 Revision 1: August 11, 2006 Revision 2: January 15, 2010 ### Page 7 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 310 ALERT ALERT Commercial Airplanes 767 ALERTALERT Service Bulletin Number: 767-53A0100 Summary Original Issue: September 26, 2002 Revision 2: January 15, 2010 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap - Inspection THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. CONCURRENT REQUIREMENTS None. BACKGROUND 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. ### Page 8 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. 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. 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. Flight Cycles Flight Hours Damage Comments 13,472 37,634 Corrosion left and right side, cracks left and right side. Straps had extreme corrosion. 16,403 55,609 Crack left side. Crack may have started from damage in strap surface. 18,061 72,706 Crack left side. Crack started at area of small gouging and fretting on strap surface. 15,694 71,643 Corrosion on left side Strap had extreme corrosion 18,545 62,360 Corrosion and cracks right side Fastener hole elongation 23,337 63,549 Corrosion on left side Strap had extreme corrosion 23,987 74,823 Corrosion on right side Strap had extreme corrosion 31,809 66,467 Crack right side Fretting, fastener hole elongation 36,635 51,129 Crack right side Strap repaired with trim-out repair given in this service bulletin. ### Page 9 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. 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 Refer to paragraph 1.E for compliance information. Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 R1 is related to this service bulletin. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin. MANPOWER MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. Airplanes Total Task Hours Elapsed Hours Group 1-10 4.0 2.0 Airplanes Total Task Hours Elapsed Hours Group 1-7, 10 295 85 Group 8, 9 297 86 ### Page 10 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT TYPICAL CORROSION FWD FWD T-FITTING DO ULTRASONIC INSPECTION OF THE AREA OF THE FAILSAFE STRAP UNDER THE T-FITTING DO A DETAILED INSPECTION AND A SURFACE HFEC INSPECTION OF ACCESSABLE AREAS OF FAILSAFE STRAP T- FITTING STA 955 A SEE A RIGHT SIDE OPPOSITE LEFT SIDE SHOWN, INSPECTION FITTING BULKHEAD REAR SPAR STA 955 AREA FAILSAFE STRAP TYPICAL CRACK IN FAILSAFE STRAP V88417 ### Page 11 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 310 ALERT ALERT Commercial Airplanes 767 ALERTALERT Service Bulletin Number: 767-53A0100 Original Issue: September 26, 2002 Revision 2: January 15, 2010 ATA System: 5350 SUBJECT: FUSELAGE - Section 45 - STA 955 Rear Spar Bulkhead Side Fittings - Fail-safe Strap - Inspection THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. 1. PLANNING INFORMATION A. Effectivity 1. Airplanes 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. GROUP CONFIGURATION DESCRIPTION 1 - 767-200 with longeron splice installation 145T0083-7/-8, -9/-10, -11/-12 1 Not modified to Boeing Approved Special Freighter configuration 2 767-200 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 3 - 767-300 with longeron splice installation 145T0083-13/-14 ### Page 12 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT Airplane models: 767-200 767-300 767-300F 767-400ER IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AA 767 LLC (SVX) 1 VE067 4 - 767-300 with longeron splice installation 145T0083-21/-22, -25/-26, -33/-34 1 Not modified to Boeing Converted Freighter (BCF) configuration 2 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 3 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 4 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 5 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 6 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 5 - 767-200 with longeron splice installation 145T0083-41/-42 6 - 767-300 with longeron splice installation 145T0083-45/-46, -47/-48 7 - 767-300F with longeron splice installation 145T0083-25/-26, -27/-28, -37/-38 8 - 767-400ER with longeron splice installation 145T0083-31/-32 9 - 767-400ER with longeron splice installation 145T0083-43/-44 10 - 767-200 with longeron splice installation 145T0083-13/-14 11 - 767-300F with longeron splice installation 145T0083-49/-50 GROUP CONFIGURATION DESCRIPTION ### Page 13 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT ABX AIR (ABX) 1 VA301 VA304–VA305 VA309–VA312 VA314–VA315 VA509 VA803 VA807–VA809 VB101–VB123 VB125 VB302 AEROFLOT (ARO) 4 VL896–VL897 VN471–VN472 VS216–VS217 VS321–VS324 VS392 AEROMEXICO (AMX) 2 VF071 VF093 VF162 4 VN531 VS211 AEROSVIT (UKA) 4 VN154–VN155 VN157 VS206 AEROTURBINE (AUB) 1 VB051 VB054–VB055 VB321 VB331–VB332 AIR ALGERIE (ALG) 4 VK131–VK133 AIR ASTANA (AKZ) 4 VL899–VL900 AIR CANADA (ACN) 1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202 4 VN051–VN054 VN056–VN062 VN541 VN546–VN547 VN751–VN752 VN811–VN812 VN931–VN936 VS381–VS382 VS546–VS549 AIR CHINA (BEJ) 1V E 0 8 5 3 VK161–VK164 4V S 2 0 8 V S 2 7 4 AIR DO (HIA) 4 VS176–VS177 AIR EUROPA (ARE) 4 VS292–VS293 AIR ITALY (RIT) 2 VF001–VF002 4 VL913 AIR MADAGASCAR (MAD) 4 VN167 VN556 AIR NEW ZEALAND (ANZ) 4 VN653 VN655–VN658 ### Page 14 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT AIR PACIFIC (APC) 4V N 6 7 6 AIR SEYCHELLES (ASY) 1 VB301 VE104 4 VL941 VS136 VS526 AIR TRANSPORT INTERNATIONAL (TIN) 1 VA313 VA511–VA512 AIR ZIMBABWE (ZMB) 2 VF061–VF062 ALITALIA COMPAGNIA AEREA ITALIANA SPA (ILQ) 4 VL701–VL702 VN426 VN732 VN813 VS367 ALL NIPPON AIRWAYS (ANA) 11 VT501 3 VK081–VK113 VR401 4 VN191–VN198 6 VS721–VS732 AMERICAN AIRLINES (AAL) 1 VA501–VA505 VA514–VA523 VA525 VA527–VA530 4 VN001–VN041 VS196–VS203 6 VS751–VS759 AMERIJET INTERNATIONAL (AMJ) 1 VA303 VA306 ARAMCO ASSOCIATED COMPANY (RAS) 5V R 0 8 4 ARKEFLY (HXL) 4 VN156 VN164–VN165 ASIANA AIRLINES (AAR) 3 VK143–VK148 VR426 7V W 8 5 1 AUSTRIAN AIRLINES AG (AUL) 4 VN242–VN243 VN671 VS301–VS303 AVIANCA (AVI) 1 VE171 2V F 0 7 2 V F 1 6 1 4 VN152 VN500 VN532 AWAS (AWW) 1 VB325 VE172 2V F 0 9 2 4V N 6 5 1 ### Page 15 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BELAIR AIRLINES (BLB) 4 VL932 BELLVIEW AIRLINES (BEB) 1 VE125–VE126 BLUE CITY HOLDING (BCY) 1V E 0 6 9 BLUE PANORAMA AIRLINES (BPA) 4 VN174 VN225 VN681 VS061 BOEING (TBC) 1V A 0 0 1 BOEING CAPITAL CORPORATION (ZMF) 1V E 1 1 7 BRISTOL AIR LIMITED (BMD) 1V A 8 0 4 BRITISH AIRWAYS (BAB) 4 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137 VS246–VS248 BTM CAPITAL CORPORATION (BTO) 1V E 0 2 2 CARGOJET AIRWAYS LTD. (WNT) 1V A 5 1 0 V A 5 1 3 CHILEAN AIR FORCE (CHF) 4 VN561 CHINA EASTERN AIRLINES (CEA) 4 VL871–VL873 COLOMBIAN AIR FORCE (CLB) 1V E 0 8 6 CONDOR (CDF) 4 VN683–VN691 CONTINENTAL AIRLINES (CAL) 2 VR051–VR060 8 VQ071–VQ082 9 VQ083–VQ086 CROCUS CORPORATION (CCS) 6V S 8 2 5 CSDS AVIATION (CSO) 1 VA506–VA507 ### Page 16 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT DELTA AIR LINES (DAL) 1 VA302 3 VK036 VK039–VK056 VR471–VR472 4 VL753 VN251–VN276 VN301–VN306 VS066–VS070 VS073–VS078 VS266–VS273 VS466–VS472 8 VQ001–VQ019 9 VQ020–VQ021 DNIPROAVIA (DNE) 4V N 4 9 5 EL AL ISRAEL AIRLINES (ELA) 1 VB283–VB284 10 VF101–VF102 4 VN537 VN682 VN972 ERITREAN AIR LINES (ERJ) 1 VE066 ETHIOPIAN AIRLINES (ETH) 4 VL898 VN388 VS306 VS496–VS497 VS506–VS507 6 VS881–VS882 EUROATLANTIC AIRWAYS (MAE) 4 VN055 VN151 VN551 VN562 EVERGREEN MAINTENANCE CENTER (EAC) 1 VE061 FIRST AIR (BRS) 1 VA508 FLYGLOBESPAN.COM (FGS) 4 VL891 VN654 VS112–VS113 GA TELESIS (GTG) 3 VK002–VK003 GABON AIRLINES (GBO) 1 VA017–VA018 GENERIC CUSTOMER/SUPPLIER (XXX) 1 VA005 VE002 VE023 VE041 VE063 4 VN221–VN222 VN310 VN314 GOL AIRLINES (GOT) 2V F 1 7 1 4 VN163 VN557 VN637 VN753 VS307 ### Page 17 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT GUGGENHEIM AVIATION PARTNERS (GPR) 4 VN153 HAINAN AIRLINES (HNA) 6 VS426–VS428 HAWAIIAN AIRLINES (HWI) 3 VK031–VK034 4 VN171–VN173 VN381 VS309–VS311 6 VS821–VS824 VS841–VS843 HEWA BORA AIRWAYS (EXD) 1V E 0 2 1 HIS MAJESTY THE SULTAN'S FLIGHT (BWN) 2V F 1 8 0 ICELANDAIR (ICE) 4 VN158 VN211 ILFC (ILF) 2V F 0 5 1 4V S 4 0 1 INTEGRATED DEFENSE SYSTEMS (BAC) 1V A 8 0 6 ITALIAN AIR FORCE (ZSV) 5 VR086–VR087 ITOCHU CORPORATION (CIT) 2 VF181–VF184 JAL INTERNATIONAL (JAL) 1 VB371–VB373 3 VK001 VK004–VK016 VK021–VK022 VK181 VK186 VR441 VR461 6 VS701–VS712 JETAIRFLY (TLB) 4 VN234 VS231 JORDAN AVIATION (JOR) 1 VB327 VB329–VB330 KALAIR (BERMUDA) (KLB) 4 VN311 KAM AIR (KMC) 1V A 0 1 9 ### Page 18 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT KENYA AIRWAYS (KEN) 3 VK141 VL003 4 VN421 VS331–VS333 LAN AIRLINES (LAN) 4 VL703 VN063–VN064 VN168 VN966–VN971 VS111 VS131–VS133 7 VR251 VR256–VR260 LOT POLISH AIRLINES (LOT) 4 VL893 VN233 VN291–VN293 VN652 LUZAIR TRANSPORTES AEREOS S.A. (LUZ) 4V N 7 3 1 MALEV HUNGARIAN AIRLINES LTD. (HGA) 2V F 1 7 2 MARTINAIR HOLLAND (MTH) 4 VN223–VN224 VN385 VN672 MEXICANA (CMA) 2 VF041–VF042 3 VL001–VL002 MID EAST JET (SKL) 2V F 2 5 1 NEOS (NEO) 4 VL892 VL894 NORTH AMERICAN AIRLINES (NNA) 4 VL755 VL895 VL911 VN634 VN922 VS316 OMNI AIR INTERNATIONAL (OAE) 4 VN424 VN427 VN635 PACE AIRLINES (PIE) 1 VB053 PHOENIX AIRCRAFT LEASING, INC. (PLB) 1 VA810 PRESIDENTIAL FLIGHT (ABD) 4 VS391 PRIVATAIR (PTS) 4 VS137 PTC AEROSPACE (PTE) 1 VB282 ### Page 19 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT QANTAS (QAN) 4 VN081–VN099 VN115–VN117 VN123 VN130–VN132 VS186–VS187 VS486 ROSSIYA RUSSIAN AIRLINES (STG) 4 VS261–VS263 ROYAL AIR MAROC (RAM) 4 VN636 VS291 VS336–VS337 VS366 ROYAL BRUNEI AIRLINES (RBA) 4 VN372 VN382–VN384 VN386–VN387 RYAN INTERNATIONAL AIRLINES (RYN) 3 VK035 VK038 VL011 4 VN166 VN376 S7 AIRLINES (SBR) 4 VN436 VN638 SAFI AIRWAYS (FFI) 1V E 0 8 4 SALAMIS AVIATION (LMV) 1V E 0 6 8 SHANGHAI AIRLINES (SHA) 3 VK171 VR421–VR423 4V S 2 0 7 SKY HOLDING COMPANY (PSH) 4 VL931 SKY KING (SKN) 1V E 0 6 4 SKYMARK AIRLINES, INC. (SKM) 6V S 8 6 1 SKYSTAR (SYW) 1 VA008 VA011–VA012 VA020 SMARTLYNX AIRLINES (LCH) 4 VN536 VN542 SOJITZ CORPORATION (SOJ) 4 VN231–VN232 STAR AIR (SBJ) 1 VA307–VA308 VB323 VB328 VB441–VB444 VE101–VE103 ### Page 20 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT STATE AIR COMPANY "BERKUT" (ORE) 2V R 0 8 1 STATE OF CAMEROON (RCF) 4 VS308 TAA (TNL) 1 VA002–VA004 VA007 VA014–VA015 TAM (TPR) 4 VN422–VN423 VN425 TAMPA CARGO (TMP) 1 VE121–VE124 TEEBAH AIRLINES (EBH) 1 VA710 THOMAS COOK AIRLINES UK (JMA) 4 VN951–VN953 THOMSON AIRWAYS (BRI) 4 VL751–VL752 VL754 VL914 VN791–VN792 VN921 VS051–VS056 TRANSAERO AIRLINES (TRX) 1 VE116 VE118 VE143 4 VN307–VN309 VN313 VN371 VN631–VN633 TRANSATLANTIC INTL AIRLINES (TIB) 1 VA016 TUIFLY NORDIC (TNS) 4 VL912 TURKMENISTAN AIRLINES (TUE) 6 VS891 UNITED AIR LINES (UAL) 4 VN491–VN494 VN496–VN499 VN501–VN513 VS091–VS104 UPS (UPS) 7 VR201–VR211 VW701–VW721 US AIRWAYS (USA) 1 VE141–VE142 VE144–VE149 VE151–VE152 UT FINANCE CORPORATION (ZZJ) 1 VE001 UZBEKISTAN AIRWAYS (UZB) 4 VL806–VL807 6 VS844 VS896 ### Page 21 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT VISION AIR (VEG) 1 VA006 VA009–VA010 VIVA MACAU (VMC) 2V F 0 9 1 3V K 1 4 2 WELLS FARGO (FSB) 3 VL004–VL006 WEST DOVER LLC (WDR) 3V K 0 3 7 YONA (IOP) 4 VN312 IDENTIFICATION BY VARIABLE NUMBER Variable Group VA001–VA020 1 VA301–VA315 1 VA501–VA530 1 VA701–VA719 1 VA801–VA810 1 VB001–VB002 1 VB051–VB055 1 VB101–VB125 1 VB201–VB202 1 VB251–VB253 1 VB281–VB284 1 VB301–VB302 1 VB321–VB332 1 VB371–VB373 1 VB401 1 VB441–VB444 1 VE001–VE003 1 VE021–VE023 1 VE041–VE043 1 VE061–VE069 1 VE083–VE086 1 VE101–VE104 1 VE116–VE118 1 VE121–VE126 1 VE141–VE152 1 ### Page 22 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT VE171–VE172 1 VF001–VF002 2 VF041–VF042 2 VF051 2 VF061–VF062 2 VF071–VF072 2 VF091–VF093 2 VF101–VF102 10 VF161–VF162 2 VF171–VF172 2 VF180–VF184 2 VF251 2 VK001–VK016 3 VK021–VK022 3 VK031–VK056 3 VK081–VK113 3 VK131–VK133 4 VK141–VK148 3 VK161–VK164 3 VK171 3 VK181 3 VK186 3 VL001–VL006 3 VL011 3 VL701–VL703 4 VL751–VL755 4 VL806–VL807 4 VL871–VL873 4 VL891–VL900 4 VL911–VL914 4 VL931–VL932 4 VL941 4 VN001–VN041 4 VN051–VN064 4 VN081–VN099 4 VN111–VN127 4 VN130–VN137 4 VN151–VN158 4 VN163–VN168 4 Variable Group ### Page 23 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT VN171–VN174 4 VN191–VN198 4 VN211–VN212 4 VN221–VN225 4 VN231–VN234 4 VN241–VN243 4 VN251–VN276 4 VN291–VN293 4 VN301–VN314 4 VN371–VN372 4 VN376 4 VN381–VN388 4 VN421–VN427 4 VN436 4 VN471–VN472 4 VN491–VN513 4 VN531–VN532 4 VN536–VN537 4 VN541–VN542 4 VN546–VN547 4 VN551 4 VN556–VN557 4 VN561–VN562 4 VN631–VN638 4 VN651–VN658 4 VN671–VN672 4 VN676 4 VN681–VN691 4 VN731–VN732 4 VN751–VN753 4 VN791–VN792 4 VN811–VN813 4 VN921–VN922 4 VN931–VN936 4 VN951–VN953 4 VN966–VN972 4 VQ001–VQ019 8 VQ020–VQ021 9 VQ071–VQ082 8 Variable Group ### Page 24 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT VQ083–VQ086 9 VR051–VR060 2 VR081 2 VR084 5 VR086–VR087 5 VR201–VR211 7 VR251 7 VR256–VR260 7 VR401 3 VR421–VR423 3 VR426 3 VR441 3 VR461 3 VR471–VR472 3 VS051–VS056 4 VS061 4 VS066–VS070 4 VS073–VS078 4 VS091–VS104 4 VS111–VS113 4 VS131–VS133 4 VS136–VS137 4 VS176–VS177 4 VS186–VS187 4 VS196–VS203 4 VS206–VS208 4 VS211 4 VS216–VS217 4 VS231 4 VS246–VS248 4 VS261–VS263 4 VS266–VS274 4 VS291–VS293 4 VS301–VS303 4 VS306–VS311 4 VS316 4 VS321–VS324 4 VS331–VS333 4 VS336–VS337 4 Variable Group ### Page 25 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. VS366–VS367 4 VS381–VS382 4 VS391–VS392 4 VS401 4 VS426–VS428 6 VS466–VS472 4 VS486 4 VS496–VS497 4 VS506–VS507 4 VS526 4 VS546–VS549 4 VS701–VS712 6 VS721–VS732 6 VS751–VS759 6 VS821–VS825 6 VS841–VS844 6 VS861 6 VS881–VS882 6 VS891 6 VS896 6 VT501 11 VW701–VW721 7 VW851 7 Variable Group ### Page 26 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. 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. 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. Flight Cycles Flight Hours Damage Comments 13,472 37,634 Corrosion left and right side, cracks left and right side. Straps had extreme corrosion. 16,403 55,609 Crack left side. Crack may have started from damage in strap surface. 18,061 72,706 Crack left side. Crack started at area of small gouging and fretting on strap surface. 15,694 71,643 Corrosion on left side Strap had extreme corrosion 18,545 62,360 Corrosion and cracks right side Fastener hole elongation 23,337 63,549 Corrosion on left side Strap had extreme corrosion 23,987 74,823 Corrosion on right side Strap had extreme corrosion 31,809 66,467 Crack right side Surface wear, fastener hole elongation 36,635 51,129 Crack right side Strap repaired with trim-out repair given in this service bulletin. ### Page 27 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. 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 ATENTION: 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. ### Page 28 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. ### Page 29 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT E. Compliance 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. Condition Action Compliance Time (Whichever Occurs Last) Repeat Interval (Not to Exceed) Group 1-7 airplanes Group 10 airplanes Group 11 airplanes Do a detailed and a surface HFEC inspection of the fail- safe strap for cracks and corrosion in accordance with Accomplishment Instruction 3.B. Before 15,000 total flight-cycles Within 3,000 flight-cycles after Nov. 1, 2004 (effective date of AD 2004-19-06, R1). 6,000 flight-cycles or 36 months, whichever occurs first. (a) Group 1-7 airplanes Group 10 airplanes Group 11 airplanes Do an ultrasonic inspection of the fail- safe strap for cracks in accordance with Accomplishment Instruction 3.B. Before 15,000 total flight-cycles Within 3,000 flight-cycles after the revision 1 date of this service bulletin. 6,000 flight-cycles or 36 months, whichever occurs first. (a) Group 8 airplanes Group 9 airplanes Do a detailed and a surface HFEC inspection of the fail- safe strap for cracks and corrosion and an ultrasonic inspection of the fail-safe strap for cracks in accordance with Accomplishment Instruction 3.B. Before 15,000 total flight-cycles Within 3,000 flight-cycles after the revision 1 date of this service bulletin. 6,000 flight-cycles or 36 months, whichever occurs first. (a) Corrosion found Make a repair in accordance with Accomplishment Instruction 3.B. Before further flight - ### Page 30 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT Crack found Make a repair in accordance with Accomplishment Instruction 3.B. Also, do Detailed and open hole HFEC inspections of adjacent structure for cracks and corrosion in accordance with Accomplishment Instruction 3.B. Repair adjacent structure as necessary in accordance with Accomplishment Instruction 3.B. Before further flight - Fail-safe strap trim repair accom- plished. (b) - - Fail-safe strap replaced and the replacement strap has the revised edge configuration. (c) (d) - - Fail-safe strap is replaced and the replacement strap does not have the revised edge configuration. (c) Do a detailed and a surface HFEC inspection of the fail- safe strap for cracks and corrosion and an ultrasonic inspection of the fail-safe strap for cracks in accor- dance with Accom- plishment Instruction 3.B. Before 12,000 flight-cycles after the replacement fail-safe strap is installed. (e) 6,000 flight-cycles or 36 months, whichever occurs first. (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 corro- sion 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. Table 1: Inspection of the Fail-Safe Strap for Cracks and Corrosion - Group 1-11 Airplanes. Condition Action Compliance Time (Whichever Occurs Last) Repeat Interval (Not to Exceed) ### Page 31 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT Federal Aviation Administration (FAA) Airworthiness Directive 2004-19-06 R1, Amendment 39-13800 is related to this service bulletin. 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 revision 2 of 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. 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. (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 accor- dance with this service bulletin will no longer be necessary on the side of the airplane where the replace- ment is accomplished. (e) For this condition, the "whichever occurs last" statement in the heading of the table does not apply. Table 1: Inspection of the Fail-Safe Strap for Cracks and Corrosion - Group 1-11 Airplanes. Condition Action Compliance Time (Whichever Occurs Last) Repeat Interval (Not to Exceed) ### Page 32 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. H. Weight and Balance Changes None. Inspection Manpower - Group 1-11 Airplanes Task Number of Persons Task-Hours Elapsed Hours Open Access 2 1.0 0.5 Examine 2 2.0 1.0 Close Access 2 1.0 0.5 TOTAL FOR EACH AIRPLANE 4.0 2.0 Repair Manpower - Group 1-7, 10, 11 Airplanes Task Number of Persons Task-Hours Elapsed Hours Open Access 4 133.0 33.25 Examine 2 2.0 1.0 Repair (a) 1 12.0 12.0 Test (b) 2 7.0 3.5 Close Access 4 141.0 35.25 TOTAL FOR EACH AIRPLANE 295.0 85.0 (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 Task Number of Persons Task-Hours Elapsed Hours Open Access 4 133.0 33.25 Examine 2 2.0 1.0 Repair (a) 1 12.0 12.0 Test (b) 2 9.0 4.5 Close Access 4 141.0 35.25 TOTAL FOR EACH AIRPLANE 297.0 86.0 (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. ### Page 33 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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 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. ### Page 34 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 3. Installation Drawings Used in the Preparation of this Service Bulletin: These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. 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. Drawing Number Title 145T0083 Splice Installation - Longeron at Rear Spar Bulkhead 145T8752 Closure Panel Assembly - Pressure Deck, Section 45 145T8800 Wheel Well Longeron Installation 100T1430 Monoque Integration - Wing to Body 145T0010 Monoque Integration - Section 45 100T1482 Integration - Section 45 Crown to Keel Beam & Pressure Deck 145T3321 Skin Panel - Machined, STA 785.9 to STA 1065, S-17L to Wing 278T4572 Tubing Installation Main Wheel Well RH, STA 955 - STA 1065 278T4563 Tubing Installation Main Wheel Well LH, STA 955 thru STA 1065 278T1373 Tubing Installation Inboard Rear Spar and Trailing Edge LH, BBL 97.42 to RSS 608.7 278T1374 Tubing Installation Inboard Rear Spar and Trailing Edge RH, BBL 97.42 to RSS 608.7 113T1621 Panel Support Installation - Wing T.E. 100T1482 Integration - Section 45 - Crown to Keel Beam & Pressure Deck 251T1000 Control Installation - Lateral 140T4500 Seal Application - Section 45 ### Page 35 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. Kit Number (a) Name Date QTY ROLT (Weeks) Unit Price thru Oct 31/06 015T1788-1 (b) Kit - Group 1 Airplanes 1/17/07 10 64 $11,331.00 015T1788-1 (b) Kit - Group 1 Airplanes 2/28/07 10 64 $11,331.00 015T1788-1 (b) Kit - Group 1 Airplanes 3/28/07 10 64 $11,331.00 015T1788-1 (b) Kit - Group 1 Airplanes 4/25/07 10 64 $11,331.00 (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-51. Kit Number (a) Name Date QTY ROLT (Weeks) Unit Price thru Oct 31/06 015T1788-2 (b) Kit - Group 2, 3, 10 Airplanes 8/14/06 2 64 $15,033.00 015T1788-2 (b) Kit - Group 2, 3, 10 Airplanes 9/13/06 30 64 $15,033.00 (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-52. Kit Number (a) Name Date QTY ROLT (Weeks) Unit Price thru Oct 31/06 015T1788-3 (b) Kit - Group 4, 7 Airplanes 11/28/06 5 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 1/4/07 5 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 2/1/07 5 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 3/1/07 10 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 3/29/07 15 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 4/26/07 15 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 5/24/07 15 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 6/22/07 15 65 $9,103.00 015T1788-3 (b) Kit - Group 4, 7 Airplanes 7/23/07 15 65 $9,103.00 (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-53. ### Page 36 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT Kit Number (a) Name Date QTY ROLT (Weeks) Unit Price thru Oct 31/06 015T1788-4 (b) Kit - Group 5 Airplanes 7/9/07 2 64 $15,837.00 (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-54. Kit Number (a) Name Date QTY ROLT (Weeks) Unit Price thru Oct 31/06 015T1788-5 (b) Kit - Group 6, 11 Airplanes 2/5/07 5 65 $9,054.00 015T1788-5 (b) Kit - Group 6, 11 Airplanes 3/5/07 5 65 $9,054.00 (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-55. Kit Number (a) Name Date QTY ROLT (Weeks) Unit Price thru Oct 31/06 015T1788-6 (b) Kit - Group 8 Airplanes 7/31/07 2 65 $32,593.00 (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-56. Kit Number (a) Name Date QTY ROLT (Weeks) Unit Price thru Oct 31/06 015T1788-7 (b) Kit - Group 9 Airplanes 7/31/07 2 65 $32,727.00 (a) Kit can be used to make a right side or left side repair. (b) Not available for procurement. Superseded by 015T1788-57. Kit Number Name ROLT (weeks) Unit Price 015T1788-51 (a) (b) Kit - Group 1 Airplanes 69 $21,098 015T1788-52 (a) (c) Kit - Group 2, 3, 10 Airplanes 105 $25,518 015T1788-53 (a) (d) Kit - Group 4, 7 Airplanes 72 $16,842 015T1788-54 (a) (e) Kit - Group 5 Airplanes 105 $26,085 015T1788-55 (a) (f) Kit - Group 6, 11 Airplanes 70 $17,218 015T1788-56 (a) (g) Kit - Group 8 Airplanes 105 $27,239 015T1788-57 (a) (h) Kit - Group 9 Airplanes 105 $27,803 (a) Kit can be used to make a right side or left side repair. (b) Replaces 015T1788-1 (c) Replaces 015T1788-2 (d) Replaces 015T1788-3 (e) Replaces 015T1788-4 (f) Replaces 015T1788-5 (g) Replaces 015T1788-6 (h) Replaces 015T1788-7 ### Page 37 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B. Industry Support Information Boeing warranty remedies are not available for the inspection or repair/modification given in this service bulletin. Kit Number Name ROLT (weeks) Unit Price 015T1788-61 (a) Supplemental Kit - Group 1 Airplanes (h) $698 015T1788-62 (b) Supplemental Kit - Group 2, 3, 10 Airplanes (h) $1,816 015T1788-63 (c) Supplemental Kit - Group 4, 7 Airplanes (h) $1,434 015T1788-64 (d) Supplemental Kit - Group 5 Airplanes (h) $2,168 015T1788-65 (e) Supplemental Kit - Group 6, 11 Airplanes (h) $1,756 015T1788-66 (f) Supplemental Kit - Group 8 Airplanes (h) $2,467 015T1788-67 (g) Supplemental Kit - Group 9 Airplanes (h) $2,790 (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 Part Number Name ROLT (Weeks) Unit Price 100T1440U3 (a) "T" Fitting (left side) (b) $2,899 100T1440U4 (a) "T" Fitting (right side) (b) $2,899 (a) Replacement part for group 1 airplanes. (b) Contact Boeing for delivery data. Part Number Name ROLT (Weeks) Unit Price 145T1929U9 (a) "T" Fitting (left side) (b) $4,894 145T1929U10 (a) "T" Fitting (right side) (b) $4,894 (a) Replacement part for group 2-11 airplanes (b) Contact Boeing for delivery data. ### Page 38 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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 New Part Number QTY Name Existing Part Number Notes-6 -5 -4 -3 -2 -1 0 1 5 T 1 7 8 8 - 1 0 ..... 1 F I L L E R - - 1 4 0 T 0 1 4 5 - 3 5 11111 . F I L L E R - - 1 4 5 T 0 0 8 3 - 5 ..... 1 S H I M - - 1 4 5 T 0 0 8 3 - 6 ..... 1 S H I M - - 1 4 5 T 0 0 8 3 - 1 6 11111 . S H I M - - 1 4 5 T 0 0 8 3 - 1 7 11111 . S H I M - - B A C B 3 0 L X 1 4 A 2 2 ..... 3 B O L T , H E X D R I V E - ( a ) B A C B 3 0 L X 1 4 A 2 3 ..... 3 B O L T , H E X D R I V E - ( a ) B A C B 3 0 L X 1 6 A 2 4 ..... 5 B O L T , H E X D R I V E - ( a ) B A C B 3 0 L X 1 6 A 2 6 ..... 1 B O L T , H E X D R I V E - ( a ) BACB30LX16A43 . . 2 . 2 . BOLT, HEX DRIVE - (a) BACB30LX16A46 2 2 . 2 . . BOLT, HEX DRIVE - (a) B A C B 3 0 M Y 1 0 K 1 1 X . 66666 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 M Y 1 0 K 1 2 X . 6666 . B O L T , P R O T RUDING HD -( a ) B A C B 3 0 M Y 8 K 6 X ..... 2 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 M Y 8 K 8 X ..... 5 B O L T , P R O T RUDING HD -( a ) BACB30NN3K7 35 44 44 44 44 44 BOLT - (a) B A C B 3 0 N W 1 0 K 1 2 X ..... 9 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 4 X . 99992 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 5 X 9 ..... B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 6 X . 2222 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 7 X 2 ..... B O L T , 1 0 0 D E G H E X DR -( a ) ### Page 39 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B A C B 3 0 N W 1 0 K 2 0 X . 11112 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 2 1 X 111112 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 2 2 X 1 ..... B O L T , 1 0 0 D E G H E X DR (a) BACB30NW10K23X . . 4 . 4 . BOLT, 100 DEG HEX DR -( a ) BACB30NW10K24X . 4 . 4 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N W 1 0 K 2 5 X 41111 . B O L T , 1 0 0 D E G H E X DR -( a ) BACB30NW10K26X . . 1 . 1 . BOLT, HEX DRIVE - (a) BACB30NW10K27X 1 1 . 1 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N W 1 0 K 2 8 X 1 ..... B O L T O / S - ( a ) B A C B 3 0 N W 1 2 K 1 6 X 13333 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 1 7 X 22222 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 1 8 X 211113 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 1 9 X 111113 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 0 X 1 .... 6 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 1 X ..... 2 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 2 X . 1111 . B O L T T I T A N I U M O / S - ( a ) B A C B 3 0 N W 1 2 K 2 3 X 1 .... 1 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 4 X ..... 1 B O L T , 1 0 0 D E G H E X DR -( a ) BACB30NW12K25X . . 1 . 1 . BOLT, 100 DEG HEAD -( a ) B A C B 3 0 N W 1 2 K 2 6 X . 1111 . B O L T T I T A N I U M O / S - ( a ) B A C B 3 0 N W 1 2 K 2 7 X .1.1.1 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 2 K 2 8 X 1 .... 1 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 2 K 2 9 X 1.1.1. B O L T , H E X D R I V E - ( a ) BACB30NW12K30X . . 1 . 1 . BOLT, HEX DRIVE - (a) BACB30NW12K32X . 1 . 1 . . BOLT, HEX DRIVE - (a) BACB30NW12K33X 1 1 . 1 . . BOLT, HEX DRIVE - (a) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-6 -5 -4 -3 -2 -1 ### Page 40 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B A C B 3 0 N W 1 2 K 3 4 X 1 ..... B O L T , H E X D R I V E - ( a ) BACB30NW14K21X . . 4 . 4 . BOLT, HEX DRIVE - (a) B A C B 3 0 N W 1 4 K 2 2 X . 4242 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 4 K 2 3 X 42626 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 4 K 2 4 X 26161 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 4 K 2 5 X 3 ..... B O L T , H E X D R I V E - ( a ) BACB30NW14K26X . 1 . 1 . . BOLT, 100 DEG HEX DR -( a ) B A C B 3 0 N W 1 4 K 2 7 X 1 ..... B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 4 K 2 8 X 2 ..... B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 4 K 2 9 X 1 ..... B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 8 K 1 1 X11111 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 8 K 1 2 X444444 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 8 K 1 3 X888888 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 8 K 9 X 666667 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N X 1 0 K 1 2 X 1 2 ..... B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 1 6 K 2 4 X ..... 1 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 1 6 K 3 2 X ..... 1 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 6 K 1 0 X 222222 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 6 K 1 2 X2 ..... B O L T , P R O T RUDING HD -( a ) BACB30NX6K5X . 10 10 10 10 10 BOLT, PROTRUDING HD -( a ) B A C B 3 0 N X 6 K 6 X 1 2 66666 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 6 K 7 X 222222 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 6 K 8 X 444448 B O L T , P R O T RUDING HD -( a ) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-6 -5 -4 -3 -2 -1 ### Page 41 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B A C B 3 0 N X 6 K 9 X 866662 B O L T , P R O T R U D I N G HD -( a ) B A C B 3 0 N Y 1 4 K 2 0 X ..... 1 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 4 K 2 1 X ..... 1 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 4 K 2 2 X ..... 1 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 4 K 2 6 X 333331 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 4 K 2 7 X 333331 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 4 K 2 8 X ..... 5 B O L T , 1 0 0 D E G H E X DR -( a ) BACB30NY16K22X . . 2 . 2 . BOLT, HEX DRIVE - (a) BACB30NY16K23X . . 1 . 1 . BOLT, 100 DEG HD - (a) BACB30NY16K24X . 2 . 2 . 2 BOLT, 100 DEG HEX DR -( a ) BACB30NY16K26X . 1 . 1 . . BOLT, 100 DEG HEX DR -( a ) B A C B 3 0 N Y 1 6 K 2 8 X 33333 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 6 K 2 9 X 42222 . B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 6 K 3 0 X 1 .... 2 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 6 K 3 1 X 11111 . B O L T , H E X D R I V E - ( a ) BACB30NY16K32X . . 7 . 7 1 BOLT, 100 DEG HEX DR -( a ) BACB30NY16K35X . 7 . 7 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N Y 1 6 K 3 7 X ..... 1 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 6 K 3 9 X 7 ..... B O L T , H E X D R I V E - ( a ) BACB30NY18K33X . . 4 . 4 . BOLT, HEX DRIVE - (a) BACB30NY18K35X 4 4 . 4 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N Y 1 8 K 3 7 X ..... 4 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Z 6 K 5 4 ..... H I - L O K - ( a ) B A C B 3 0 N Z 6 K 6 488888 H I - L O K - ( a ) B A C B 3 0 N Z 8 K 7 555555 B O L T , 1 0 0 D E G H E X DR -( a ) BACB30YM20K43X . . 4 . 4 . BOLT, HEX DRIVE - (a) B A C B 3 0 Y M 2 0 K 4 6. 4 .... B O L T , 1 0 0 D E G H E X DR -( a ) BACB30YM20K46X 4 . . 4 . . BOLT - (a) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-6 -5 -4 -3 -2 -1 ### Page 42 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B A C C 3 0 A G 1 0 ..... 4 C O L L A R A S S E M B L Y - - B A C C 3 0 A G 1 2 ..... 1 8 C O L L A R A S S E M B L Y - - BACC30BH10 6 . . . 8 . COLLAR - - B A C C 3 0 B H 1 2 .... 1 2 . C O L L A R - - BACC30BH14 19 6 6 19 19 15 COLLAR, PRELOAD - - BACC30BL10 19 . . 8 . . COLLAR, SHEAR - - BACC30BL12 12 . . 12 . . COLLAR - - B A C C 3 0 B M 1 0 6 ..... C O L L A R - - B A C C 3 0 C P 2 0 C 44444 . C O L L A R , P R E L O A D - - BACC30M10 . 23 23 23 23 17 COLLAR - - B A C C 3 0 M 6 3 83 83 83 83 63 8 C O L L A R - - B A C C 3 0 M 8 2 42 42 42 42 43 1 C O L L A R - - BACC30X16 17 6 6 17 17 14 COLLAR - - BACC30X18 4 . . 4 4 4 COLLAR, PRELOAD - - BACN10YR5CD . 8 8 . . . NUT - - BACN10YR6CD . 12 12 . . . SELF-LOCKING NUT - - BACN10YT7CD . 13 13 . . . NUT, SELF-LOCK, HEX -- BACN10YT8CD . 12 12 . . . NUT, SELF-LOCK, HEX -- B A C N 1 1 Z 7 C D ..... 1 N U T - - BACN11Z8CD 1 . . 1 1 . NUT - - BACN11Z9CD . 4 4 . . . NUT - - BACR15BA6AD8C 69 64 64 64 64 64 RIVET, 100 DEG - - NAS1149D0532J . 8 8 . . . WASHER - - NAS1149D0563J . 16 16 . . . WASHER - - NAS1149D0632J . 12 12 . . . WASHER, PLAIN - - NAS1149D0663J . 24 24 . . . WASHER - - N A S 1 1 4 9 D 0 7 6 3 J ..... 1 W A S H E R - - NAS1149D0863J 1 . . 1 1 . WASHER, PLAIN - - NAS1149E0932P . 4 4 . . . WASHER, PLAIN - - NAS1149E0963P . 8 8 . . . WASHER, PLAIN - - NAS1399D6A7 31 31 31 31 31 31 RIVET, BLIND - - N A S 1 3 9 9 M W 6 A 4 211111 R I V E T , B L I N D - - (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 New Part Number QTY Name Existing Part Number Notes-6 -5 -4 -3 -2 -1 ### Page 43 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-7 140T0145-35 1 FILLER - - 145T0083-16 1 SHIM - - 145T0083-17 1 SHIM - - BACB30LX16A46 2 BOLT, HEX DRIVE - (a) BACB30NN3K7 35 BOLT - (a) BACB30NW10K15X 9 BOLT, 100 DEG HEX DR - (a) BACB30NW10K17X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW10K21X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW10K22X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW10K25X 4 BOLT, 100 DEG HEX DR - (a) BACB30NW10K27X 1 BOLT, HEX DRIVE - (a) BACB30NW10K28X 1 BOLT, HEX DRIVE - (a) BACB30NW12K16X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K17X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW12K18X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW12K19X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K20X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K23X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K28X 1 BOLT, HEX DRIVE - (a) BACB30NW12K29X 1 BOLT, HEX DRIVE - (a) BACB30NW12K33X 1 BOLT, HEX DRIVE - (a) BACB30NW12K34X 1 BOLT, HEX DRIVE - (a) BACB30NW14K23X 4 BOLT, 100 DEG HEX DR - (a) BACB30NW14K24X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW14K25X 3 BOLT, HEX DRIVE - (a) BACB30NW14K27X 1 BOLT, HEX DRIVE - (a) BACB30NW14K28X 2 BOLT, HEX DRIVE - (a) BACB30NW14K29X 1 BOLT, HEX DRIVE - (a) BACB30NW8K11X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW8K12X 4 BOLT, 100 DEG HEX DR - (a) BACB30NW8K13X 8 BOLT, 100 DEG HEX DR - (a) BACB30NW8K9X 6 BOLT, 100 DEG HEX DR - (a) BACB30NX10K12X 12 BOLT, PROTRUDING HD - (a) BACB30NX6K10X 2 BOLT, PROTRUDING HD - (a) BACB30NX6K12X 2 BOLT, PROTRUDING HD - (a) BACB30NX6K6X 12 BOLT, PROTRUDING HD - (a) BACB30NX6K7X 2 BOLT, PROTRUDING HD - (a) ### Page 44 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BACB30NX6K8X 4 BOLT, PROTRUDING HD - (a) BACB30NX6K9X 8 BOLT, PROTRUDING HD - (a) BACB30NY14K26X 3 BOLT, 100 DEG HEX DR - (a) BACB30NY14K27X 3 BOLT, HEX DRIVE - (a) BACB30NY16K28X 3 BOLT, 100 DEG HEX DR - (a) BACB30NY16K29X 4 BOLT, HEX DRIVE - (a) BACB30NY16K30X 1 BOLT, 100 DEG HEX DR - (a) BACB30NY16K31X 1 BOLT, HEX DRIVE - (a) BACB30NY16K39X 7 BOLT, HEX DRIVE - (a) BACB30NY18K35X 4 BOLT, HEX DRIVE - (a) BACB30NZ6K5 4 HI-LOK - (a) BACB30NZ6K6 4 HI-LOK - (a) BACB30NZ8K7 5 BOLT, 100 DEG HEX DR - (a) BACB30YM20K46X 4 BOLT - (a) BACC30BH10 6 COLLAR - - BACC30BH14 6 COLLAR, PRELOAD - - BACC30BL10 11 COLLAR, SHEAR - - BACC30BM10 6 COLLAR - - BACC30CP20C 4 COLLAR, PRELOAD - - BACC30M6 38 COLLAR - - BACC30M8 24 COLLAR - - BACC30X16 6 COLLAR - - BACN10YR5CD 8 NUT - - BACN10YR6CD 12 SELF-LOCKING NUT - - BACN10YT7CD 13 NUT, SELF-LOCK, HEX - - BACN10YT8CD 12 NUT, SELF-LOCK, HEX - - BACN11Z9CD 4 NUT - - BACR15BA6AD8C 69 RIVET, 100 DEG - - NAS1149D0532J 8 WASHER - - NAS1149D0563J 16 WASHER - - NAS1149D0632J 12 WASHER, PLAIN - - NAS1149D0663J 24 WASHER - - NAS1149E0932P 4 WASHER, PLAIN - - Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-7 ### Page 45 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT NAS1149E0963P 8 WASHER, PLAIN - - NAS1399D6A7 31 RIVET, BLIND - - (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 New Part Number QTY Name Existing Part Number Notes- 5 6- 5 5- 5 4- 5 3- 5 2- 5 1 0 1 5 T 1 7 8 8 - 5 1 .....-K I T - - 0 1 5 T 1 7 8 8 - 5 2 ....-.K I T - - 0 1 5 T 1 7 8 8 - 5 3 ...-..K I T - - 015T1788-54 . . - . . . KIT - - 015T1788-55 . - . . . . KIT - - 0 1 5 T 1 7 8 8 - 5 6 -.....K I T - - 0 1 5 T 1 7 8 8 - 1 0 ..... 1 F I L L E R - - 1 4 0 T 0 1 4 5 - 3 5 11111 . F I L L E R - - 1 4 5 T 0 0 8 3 - 5 ..... 1 S H I M - - 1 4 5 T 0 0 8 3 - 6 ..... 1 S H I M - - 1 4 5 T 0 0 8 3 - 1 6 11111 . S H I M - - 1 4 5 T 0 0 8 3 - 1 7 11111 . S H I M - - B A C B 3 0 L X 1 4 A 2 2 ..... 3 B O L T , H E X D R I V E - ( a ) B A C B 3 0 L X 1 4 A 2 3 ..... 3 B O L T , H E X D R I V E - ( a ) B A C B 3 0 L X 1 6 A 2 4 ..... 5 B O L T , H E X D R I V E - ( a ) B A C B 3 0 L X 1 6 A 2 6 ..... 1 B O L T , H E X D R I V E - ( a ) BACB30LX16A43 . . 2 . 2 . BOLT, HEX DRIVE - (a) BACB30LX16A46 2 2 . 2 . . BOLT, HEX DRIVE - (a) B A C B 3 0 M Y 1 0 K 1 1 X . 66666 B O L T , P R O T R U D I N G HD -( a ) B A C B 3 0 M Y 1 0 K 1 2 X . 6666 . B O L T , P R O T R U D I N G HD -( a ) B A C B 3 0 M Y 8 K 6 X ..... 2 B O L T , P R O T R U D I N G HD -( a ) B A C B 3 0 M Y 8 K 8 X ..... 5 B O L T , P R O T R U D I N G HD -( a ) BACB30NN3K7 35 44 44 44 44 44 BOLT - (a) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-7 ### Page 46 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B A C B 3 0 N W 1 0 K 1 2 X ..... 9 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 4 X . 99992 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 5 X 9 ..... B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 6 X . 2222 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 1 7 X 2 ..... B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 2 0 X . 11112 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 2 1 X 111112 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 0 K 2 2 X 1 ..... B O L T , 1 0 0 D E G H E X DR (a) BACB30NW10K23X . . 4 . 4 . BOLT, 100 DEG HEX DR -( a ) BACB30NW10K24X . 4 . 4 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N W 1 0 K 2 5 X 41111 . B O L T , 1 0 0 D E G H E X DR -( a ) BACB30NW10K26X . . 1 . 1 . BOLT, HEX DRIVE - (a) BACB30NW10K27X 1 1 . 1 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N W 1 0 K 2 8 X 1 ..... B O L T O / S - ( a ) B A C B 3 0 N W 1 2 K 1 6 X 13333 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 1 7 X 22222 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 1 8 X 211113 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 1 9 X 111113 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 0 X 1 .... 6 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 1 X ..... 2 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 2 X . 1111 . B O L T T I T A N I U M O / S - ( a ) B A C B 3 0 N W 1 2 K 2 3 X 1 .... 1 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 2 K 2 4 X ..... 1 B O L T , 1 0 0 D E G H E X DR -( a ) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes- 5 6- 5 5- 5 4- 5 3- 5 2- 5 1 ### Page 47 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BACB30NW12K25X . . 1 . 1 . BOLT, 100 DEG HEAD -( a ) B A C B 3 0 N W 1 2 K 2 6 X . 1111 . B O L T T I T A N I U M O / S - ( a ) B A C B 3 0 N W 1 2 K 2 7 X .1.1.1 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 2 K 2 8 X 1 .... 1 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 2 K 2 9 X 1.1.1. B O L T , H E X D R I V E - ( a ) BACB30NW12K30X . . 1 . 1 . BOLT, HEX DRIVE - (a) BACB30NW12K32X . 1 . 1 . . BOLT, HEX DRIVE - (a) BACB30NW12K33X 1 1 . 1 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N W 1 2 K 3 4 X 1 ..... B O L T , H E X D R I V E - ( a ) BACB30NW14K21X . . 4 . 4 . BOLT, HEX DRIVE - (a) B A C B 3 0 N W 1 4 K 2 2 X . 4242 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 4 K 2 3 X 42626 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 4 K 2 4 X 26161 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 1 4 K 2 5 X 3 ..... B O L T , H E X D R I V E - ( a ) BACB30NW14K26X . 1 . 1 . . BOLT, 100 DEG HEX DR -( a ) B A C B 3 0 N W 1 4 K 2 7 X 1 ..... B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 4 K 2 8 X 2 ..... B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 1 4 K 2 9 X 1 ..... B O L T , H E X D R I V E - ( a ) B A C B 3 0 N W 8 K 1 1 X11111 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 8 K 1 2 X444444 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 8 K 1 3 X888888 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N W 8 K 9 X 666667 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N X 1 0 K 1 2 X 1 2 ..... B O L T , P R O T R U D I N G HD -( a ) B A C B 3 0 N X 1 6 K 2 4 X ..... 2 B O L T , P R O T R U D I N G HD -( a ) B A C B 3 0 N X 1 6 K 3 2 X ..... 1 B O L T , P R O T R U D I N G HD -( a ) B A C B 3 0 N X 6 K 1 0 X 222222 B O L T , P R O T R U D I N G HD -( a ) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes- 5 6- 5 5- 5 4- 5 3- 5 2- 5 1 ### Page 48 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B A C B 3 0 N X 6 K 1 2 X2 ..... B O L T , P R O T RUDING HD -( a ) BACB30NX6K5X . 10 10 10 10 10 BOLT, PROTRUDING HD -( a ) B A C B 3 0 N X 6 K 6 X 1 2 66666 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 6 K 7 X 222222 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 6 K 8 X 444448 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N X 6 K 9 X 866662 B O L T , P R O T RUDING HD -( a ) B A C B 3 0 N Y 1 4 K 2 0 X ..... 1 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 4 K 2 1 X ..... 1 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 4 K 2 2 X ..... 1 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 4 K 2 6 X 333331 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 4 K 2 7 X 333331 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 4 K 2 8 X ..... 2 B O L T , 1 0 0 D E G H E X DR -( a ) BACB30NY16K22X . . 2 . 2 . BOLT, HEX DRIVE - (a) BACB30NY16K23X . . 1 . 1 . BOLT, 100 DEG HD - (a) BACB30NY16K24X . 2 . 2 . 2 BOLT, 100 DEG HEX DR -( a ) BACB30NY16K26X . 1 . 1 . . BOLT, 100 DEG HEX DR -( a ) B A C B 3 0 N Y 1 6 K 2 8 X 33333 . B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 N Y 1 6 K 2 9 X 42323 . B O L T , H E X D R I V E - ( a ) BACB30NY16K30X 1 . 1 . 1 2 BOLT, 100 DEG HEX DR -( a ) B A C B 3 0 N Y 1 6 K 3 1 X 11111 . B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 6 K 3 2 X . 14141 B O L T , 1 0 0 D E G H E X DR -( a ) BACB30NY16K33X . 1 . 1 . . BOLT, 100 DEG HEX DR -( a ) BACB30NY16K35X . 4 . 4 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N Y 1 6 K 3 6 X 1 .....B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 6 K 3 7 X 1 .... 1 B O L T , H E X D R I V E - ( a ) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes- 5 6- 5 5- 5 4- 5 3- 5 2- 5 1 ### Page 49 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT B A C B 3 0 N Y 1 6 K 3 9 X 4 ..... B O L T , H E X D R I V E - ( a ) BACB30NY18K33X . . 4 . 4 . BOLT, HEX DRIVE - (a) BACB30NY18K35X 4 4 . 4 . . BOLT, HEX DRIVE - (a) B A C B 3 0 N Y 1 8 K 3 7 X ..... 4 B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Z 6 K 5 5 ..... H I - L O K - ( a ) B A C B 3 0 N Z 6 K 6 888888 H I - L O K - ( a ) B A C B 3 0 N Z 8 K 7 555555 B O L T , 1 0 0 D E G H E X DR -( a ) B A C B 3 0 Y M 1 4 K 2 8 X ..... 3 B O L T , H E X D R I V E - ( a ) BACB30YM16K32X . . 3 . 3 . BOLT, HEX DRIVE - (a) BACB30YM16K35X . 3 . 3 . . BOLT, HEX DRIVE - (a) B A C B 3 0 Y M 1 6 K 3 9 X 3 ..... B O L T , H E X D R I V E - ( a ) BACB30YM20K43X . . 4 . 4 . BOLT, HEX DRIVE - (a) BACB30YM20K46X 4 4 . 4 . . BOLT - (a) B A C C 3 0 A G 1 0 ..... 4 C O L L A R A S S E M B L Y - - B A C C 3 0 A G 1 2 ..... 1 8 C O L L A R A S S E M B L Y - - B A C C 3 0 B H 1 0 6 ..... C O L L A R - - B A C C 3 0 B H 1 2 ...... C O L L A R - - B A C C 3 0 B H 1 4 66666 1 3 C O L L A R , P R E L O A D - - B A C C 3 0 B M 1 0 6 ..... C O L L A R - - B A C C 3 0 C P 2 0 C 44444 . C O L L A R , P R E L O A D - - BACC30M10 19 23 23 31 31 17 COLLAR - - BACC30M12 12 . . 12 12 . COLLAR - - BACC30M14 13 . . 13 13 . COLLAR - - B A C C 3 0 M 6 3 83 83 83 83 63 8 C O L L A R - - B A C C 3 0 M 8 2 42 42 42 42 43 1 C O L L A R - - BACC30X16 15 6 6 15 15 14 COLLAR - - BACC30X18 4 . . 4 4 4 COLLAR, PRELOAD - - BACN10YR5CD . 8 8 . . . NUT - - BACN10YR6CD . 12 12 . . . SELF-LOCKING NUT - - BACN10YT7CD . 13 13 . . . NUT, SELF-LOCK, HEX -- BACN10YT8CD . 9 9 . . . NUT, SELF-LOCK, HEX -- B A C N 1 1 Z 7 C D ..... 3 N U T - - B A C N 1 1 Z 8 C D 33333 . N U T - - BACN11Z9CD . 4 4 . . . NUT - - Kit 015T1788 New Part Number QTY Name Existing Part Number Notes- 5 6- 5 5- 5 4- 5 3- 5 2- 5 1 ### Page 50 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BACR15BA6AD8C 69 64 64 64 64 64 RIVET, 100 DEG - - NAS1399D6A7 31 31 31 31 31 31 RIVET, BLIND - - N A S 1 3 9 9 M W 6 A 4 211111 R I V E T , B L I N D - - 1 4 5 T 8 0 0 8 - 5 111111S E A L - - 1 4 5 T 8 0 0 8 - 6 111111S E A L - - B A C R 1 5 B A 7 A D 8 C . 6 76 76 76 76 7R I V E T - - B A C S 4 0 R 0 0 9 B 0 2 7 F 111111S H I M - - B A C S 4 0 R 0 1 5 B 0 1 5 F 111111S H I M - - B A C S 4 0 R 0 1 6 B 0 1 7 F 111111S H I M - - B A C S 4 0 R 0 1 7 B 0 3 2 F 111111S H I M - - B A C W 1 0 B P 5 1 D P .8 8 ...W A S H E R , P L A I N- - B A C W 1 0 B P 5 1 N D P .8 8 ...W A S H E R , P L A I N- - B A C W 1 0 B P 6 1 D P .1 2 1 2 ...W A S H E R , P L A I N- - B A C W 1 0 B P 6 1 N D P .1 2 1 2 ...W A S H E R , P L A I N- - B A C W 1 0 B P 7 1 D P .....6 W A S H E R , P L A I N- - B A C W 1 0 B P 8 1 D P 66666. W A S H E R , P L A I N - - B A C W 1 0 B P 9 1 D P .8 8 ...W A S H E R , P L A I N- - NAS1398D6A3 32 32 32 32 32 32 RIVET - - (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 New Part Number QTY Name Existing Part Number Notes-57 015T1788-57 - KIT - - 140T0145-35 1 FILLER - - 145T0083-16 1 SHIM - - 145T0083-17 1 SHIM - - BACB30LX16A46 2 BOLT, HEX DRIVE - (a) BACB30NN3K7 35 BOLT - (a) BACB30NW10K15X 9 BOLT, 100 DEG HEX DR - (a) BACB30NW10K17X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW10K21X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW10K22X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW10K25X 4 BOLT, 100 DEG HEX DR - (a) BACB30NW10K27X 1 BOLT, HEX DRIVE - (a) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes- 5 6- 5 5- 5 4- 5 3- 5 2- 5 1 ### Page 51 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BACB30NW10K28X 1 BOLT, HEX DRIVE - (a) BACB30NW12K16X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K17X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW12K18X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW12K19X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K20X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K23X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW12K28X 1 BOLT, HEX DRIVE - (a) BACB30NW12K29X 1 BOLT, HEX DRIVE - (a) BACB30NW12K33X 1 BOLT, HEX DRIVE - (a) BACB30NW12K34X 1 BOLT, HEX DRIVE - (a) BACB30NW14K23X 4 BOLT, 100 DEG HEX DR - (a) BACB30NW14K24X 2 BOLT, 100 DEG HEX DR - (a) BACB30NW14K25X 3 BOLT, HEX DRIVE - (a) BACB30NW14K27X 1 BOLT, HEX DRIVE - (a) BACB30NW14K28X 2 BOLT, HEX DRIVE - (a) BACB30NW14K29X 1 BOLT, HEX DRIVE - (a) BACB30NW8K11X 1 BOLT, 100 DEG HEX DR - (a) BACB30NW8K12X 4 BOLT, 100 DEG HEX DR - (a) BACB30NW8K13X 8 BOLT, 100 DEG HEX DR - (a) BACB30NW8K9X 6 BOLT, 100 DEG HEX DR - (a) BACB30NX10K12X 12 BOLT, PROTRUDING HD - (a) BACB30NX6K10X 2 BOLT, PROTRUDING HD - (a) BACB30NX6K12X 2 BOLT, PROTRUDING HD - (a) BACB30NX6K6X 12 BOLT, PROTRUDING HD - (a) BACB30NX6K7X 2 BOLT, PROTRUDING HD - (a) BACB30NX6K8X 4 BOLT, PROTRUDING HD - (a) BACB30NX6K9X 8 BOLT, PROTRUDING HD - (a) BACB30NY14K26X 3 BOLT, 100 DEG HEX DR - (a) BACB30NY14K27X 3 BOLT, HEX DRIVE - (a) BACB30NY16K28X 3 BOLT, 100 DEG HEX DR - (a) BACB30NY16K29X 4 BOLT, HEX DRIVE - (a) BACB30NY16K30X 1 BOLT, 100 DEG HEX DR - (a) BACB30NY16K31X 1 BOLT, HEX DRIVE - (a) BACB30NY16K36X 1 BOLT, HEX DRIVE - (a) BACB30NY16K37X 1 BOLT, HEX DRIVE - (a) BACB30NY16K39X 4 BOLT, HEX DRIVE - (a) Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-57 ### Page 52 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BACB30NY18K35X 4 BOLT, HEX DRIVE - (a) BACB30NZ6K5 5 HI-LOK - (a) BACB30NZ6K6 8 HI-LOK - (a) BACB30NZ8K7 5 BOLT, 100 DEG HEX DR - (a) BACB30YM16K39X 3 BOLT - (a) BACB30YM20K46X 4 BOLT - (a) BACC30BH10 6 COLLAR - - BACC30BH14 6 COLLAR, PRELOAD - - BACC30M10 11 COLLAR, SHEAR - - BACC30BM10 6 COLLAR - - BACC30CP20C 4 COLLAR, PRELOAD - - BACC30M6 38 COLLAR - - BACC30M8 24 COLLAR - - BACC30X16 6 COLLAR - - BACN10YR5CD 8 NUT - - BACN10YR6CD 12 SELF-LOCKING NUT - - BACN10YT7CD 13 NUT, SELF-LOCK, HEX - - BACN10YT8CD 9 NUT, SELF-LOCK, HEX - - BACN11Z8CD 3 NUT - - BACN11Z9CD 4 NUT - - BACR15BA6AD8C 69 RIVET, 100 DEG - - BACW10BP51DP 8 WASHER, PLAIN - - BACW10BP51NDP 8 WASHER, PLAIN - - BACW10BP61DP 12 WASHER, PLAIN - - BACW10BP61NDP 12 WASHER, PLAIN - - BACW10BP81DP 6 WASHER, PLAIN - - BACW10BP91DP 8 WASHER, PLAIN - - NAS1399D6A7 31 RIVET, BLIND - - NAS1398D6A3 32 RIVET - - NAS1399MW6A4 2 RIVET, BLIND - - 145T8008-5 1 SEAL - - 145T8008-6 1 SEAL - - BACS40R009B027F 1 SHIM - - BACS40R015B015F 1 SHIM - - Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-57 ### Page 53 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT BACS40R016B017F 1 SHIM - - BACS40R017B032F 1 SHIM - - (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 New Part Number QTY Name Existing Part Number Notes-66 -65 -64 -63 -62 -61 0 1 5 T 1 7 8 8 - 6 1 .....-K I T - S U P P L E M E N T A L - - 0 1 5 T 1 7 8 8 - 6 2 ....-.K I T - S U P P L E M E N T A L - - 0 1 5 T 1 7 8 8 - 6 3 ...-..K I T - S U P P L E M E N T A L - - 0 1 5 T 1 7 8 8 - 6 4 ..-...K I T - S U P P L E M E N T A L - - 0 1 5 T 1 7 8 8 - 6 5 .-....K I T - S U P P L E M E N T A L - - 0 1 5 T 1 7 8 8 - 6 6 -.....K I T - S U P P L E M E N T A L - - B A C B 3 0 N X 1 6 K 2 4 X .....1 B O L T , P R O T RUD HD - (a) BACB30NY16K29X . . 1 . 1 . BOLT, HEX DRIVE - (a) BACB30NY16K30X . . 1 . 1 . BOLT, 100 DEG HEX DR -( a ) BACB30NY16K32X . 1 . 1 . . BOLT, 100 DEG HEX DR -( a ) BACB30NY16K33X . 1 . 1 . . BOLT, 100 DEG HEX DR -( a ) B A C B 3 0 N Y 1 6 K 3 6 X 1 .....B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Y 1 6 K 3 7 X 1 ..... B O L T , H E X D R I V E - ( a ) B A C B 3 0 N Z 6 K 5 5 ..... H I - L O K - ( a ) B A C B 3 0 Y M 1 4 K 2 8 X ..... 3 B O L T , H E X D R I V E - ( a ) BACB30YM16K32X . . 3 . 3 . BOLT, HEX DRIVE - (a) BACB30YM16K35X . 3 . 3 . . BOLT, HEX DRIVE - (a) B A C B 3 0 Y M 1 6 K 3 9 X 3 ..... B O L T , H E X D R I V E - ( a ) BACC30M10 19 . . 8 8 . COLLAR - - BACC30M12 12 . . 12 12 . COLLAR - - BACC30M14 13 . . 13 13 . COLLAR - - B A C N 1 1 Z 7 C D ..... 3 N U T - - B A C N 1 1 Z 8 C D 33333 . N U T - - 1 4 5 T 8 0 0 8 - 5 111111S E A L - - Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-57 ### Page 54 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 145T8008-6 111111S E A L - - B A C R 1 5 B A 7 A D 8 C . 6 76 76 76 76 7R I V E T - - B A C S 4 0 R 0 0 9 B 0 2 7 F 111111S H I M - - B A C S 4 0 R 0 1 5 B 0 1 5 F 111111S H I M - - B A C S 4 0 R 0 1 6 B 0 1 7 F 111111S H I M - - B A C S 4 0 R 0 1 7 B 0 3 2 F 111111S H I M - - B A C W 1 0 B P 5 1 D P .8 8 ...W A S H E R , P L A I N - - B A C W 1 0 B P 5 1 N D P .8 8 ...W A S H E R , P L A I N - - B A C W 1 0 B P 6 1 D P .1 2 1 2 ...W A S H E R , P L A I N - - B A C W 1 0 B P 6 1 N D P .1 2 1 2 ...W A S H E R , P L A I N - - B A C W 1 0 B P 7 1 D P .....6 W A S H E R , P L A I N - - B A C W 1 0 B P 8 1 D P 66666. W A S H E R , P L A I N - - B A C W 1 0 B P 9 1 D P .8 8 ...W A S H E R , P L A I N - - N A S 1 3 9 8 D 6 A 3 3 23 23 23 23 23 2R I V E T - - (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 New Part Number QTY Name Existing Part Number Notes-67 015T1788-67 - KIT - SUPPLEMENTAL - - BACB30NY16K36X 1 BOLT, HEX DRIVE - (a) BACB30NY16K37X 1 BOLT, HEX DRIVE - (a) BACB30NZ6K5 5 HI-LOK - (a) BACB30YM16K39X 3 BOLT, HEX DRIVE - (a) BACC30M10 11 COLLAR, SHEAR - - BACN11Z8CD 3 NUT - - BACW10BP51DP 8 WASHER, PLAIN - - BACW10BP51NDP 8 WASHER, PLAIN - - BACW10BP61DP 12 WASHER, PLAIN - - BACW10BP61NDP 12 WASHER, PLAIN - - BACW10BP81DP 6 WASHER, PLAIN - - BACW10BP91DP 8 WASHER, PLAIN - - NAS1398D6A3 32 RIVET - - 145T8008-5 1 SEAL - - Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-66 -65 -64 -63 -62 -61 ### Page 55 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 2. Parts and Materials Supplied by the Operator: 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. 145T8008-6 1 SEAL - - BACS40R009B027F 1 SHIM - - BACS40R015B015F 1 SHIM - - BACS40R016B017F 1 SHIM - - BACS40R017B032F 1 SHIM - - (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. Part Number / Specification QTY Name Notes BMS 5-95 Type 1, Class B-2 1 gal. Sealant (a) BMS 10-11, Type I 1 gal. Primer (a) BMS 5-125, Type III 1 gal. Leveling Compound (a) BMS 5-142 1 qt. Aerodynamic Filler (a) (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. Kit 015T1788 New Part Number QTY Name Existing Part Number Notes-67 ### Page 56 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. ### Page 57 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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 are given in 767-200 SRM 51, 767-300 SRM 51, 767-300F SRM 51, or 767-400 SRM 51as applicable. — Torque limits to tighten nuts and bolts are given in 767-200 SRM 51, 767-300 SRM 51, 767-300F SRM 51, or 767-400 SRM 51 as applicable. 4. For approved fastener and process material substitutions, refer to 767-200 SRM 51, 767-300 SRM 51, 767-300F SRM 51, 767-400 SRM 51, 767-200SF SRM 51, or 767-300BCF SRM 51 as applicable. 5. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 6. 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. 7. These work instructions refer to procedures included on 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 “as given in” or "in accordance with " are included in the instruction, the procedure in the Boeing document must be used. B. WORK INSTRUCTIONS 1. Install the main and nose landing gear downlocks. Refer to 767 AMM 32-00-20. ### Page 58 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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 QUICKLEY 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). 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 with any of the above inspections, a repair must be made in accordance with Paragraph 1.E., Compliance and instruction given below. 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. 7. If corrosion is found on the visible/accessible part of the fail-safe strap, remove corrosion as given in 767-200 SRM 51-10-02, 767-300 SRM 51-10-02, 767-300F SRM 51-10-02, 767-400 SRM 51-10-02, 767-200SF SRM 51-10-02, or 767-300BCF SRM 51-10-02 as applicable. 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 found in the fail-safe strap, 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 is found in other/adjacent structure, contact Boeing for repair instructions. ### Page 59 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 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. 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. 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. Group Jack/Support Figure 1, 2, 5, 10 22 3, 4, 6 23 8, 9 24 7, 11 39 Component Reference 767 AMM passenger seats 767 AMM 25-25-01 closets and partitions 767 AMM 25-24-00 floor covering 767 AMM 25-27-01 floor panel 767 AMM 53-01-01 sidewall lining (passenger) 767 AMM 25-21-01 sidewall lining (freighter) 767 AMM 25-52-00 ### Page 60 Original Issue: September 26, 2002 Revision 2: January 15, 2010 767-53A0100 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 310 BOEING SERVICE BULLETIN 767-53A0100 ALERT ALERT 10. Remove parts as necessary to get external access at the wing/body interface. Refer to the applicable figure identified in the table below. 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. 12. Pull and stow the aileron control cables that go through the pressure deck. Refer to the applicable figure identified in the table below. 13. Remove parts from the pressure deck. Refer to the applicable figure identified in the table below. 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. 15. Do open hole and surface HFEC inspections of the fail-safe strap as given in figure 15. Group Access Figure - Left Side Access Figure - Right Side 1-7, 10, 11 25 26 8, 9 27 28 Group Figure - Hydraulic Tube Removal - Left Side Figure - Hydraulic Tube Removal - Right Side 1-7, 10, 11 13 14 8, 9 20 21 Group Figure - Control Cable Pull/Stow - Left Side Figure - Control Cable Pull/Stow - Right Side All 31 32 Group Figure - Pressure Deck Disassembly - Left Side Figure - Pressure Deck Disassembly - Right Side All 29 30 Group Figure - Left Side Figure - Right Side 13 4 2, 3, 10 5 6 4, 7 7 8 59 1 0 6, 11 11 12 81 6 1 7 91 8 1 9 The text continues at https://openairdocs.org/service-documents/boeing/767-53a0100/file/9842d987339b.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.