# Boeing Alert Service Bulletin 767-53A0139: No revision named - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2011-0993; AD 2012-09-08 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 767-53A0139](https://openairdocs.org/service-documents/boeing/767-53a0139.md) - Title as filed: U.S. DOT/FAA - Service Bulletin - Pages: 180 - PDF: https://openairdocs.org/files/sha256/7a/7c/7a7c33bc05d77328794b07706153a8bd1509fea031e88a5b49b8d9847bd1f461 - Page: https://openairdocs.org/service-documents/boeing/767-53a0139/file/7a7c33bc05d7 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0139 Original Issue: November 12, 2009 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 1 of 180 4.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 2 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Summary ...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A. Effectivity ................................................ 9 1. Airplanes ............................................. 9 2. Spares Affected ........................................ 1 1 B. Concurrent Requirements ...................................... 1 1 C. Reason ................................................ 1 1 D. Description .............................................. 1 2 E. Compliance .............................................. 1 2 F. Approval ............................................... 1 4 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 6 I. Electrical Load Data ......................................... 1 6 J. References .............................................. 1 6 1. Existing Data .......................................... 1 6 2. Data supplied with this Service Bulletin ............................ 1 7 3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 9 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 0 2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 1 C. Parts Necessary For Each Airplane ................................. 2 1 1. Kits/Parts ............................................ 2 1 2. Parts and Materials Supplied by the Operator ........................ 3 5 3. Parts Modified and Reidentified ................................ 3 6 4. Parts Removed and Not Replaced .............................. 3 6 D. Parts Necessary to Change Spares ................................. 3 6 E. Special Tooling - Price and Availability ............................... 3 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 8 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 0 FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION ................ 5 4 FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION [Group 2] ........... 5 9 FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS ............. 6 1 FIGURE 4: REMOVAL OF PRESSURE SEALS .............................. 6 5 FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL ..................... 6 8 FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION ................... 7 1 FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL .................. 7 4 FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL ........................ 7 7 FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL ........................ 8 5 FIGURE 10: AFT PRESSURE BULKHEAD PRESSURE RING FASTENER REMOVAL ......... 8 7 FIGURE 11: AFT PRESSURE BULKHEAD ATTACHMENT TO THE PRESSURE RING AT STA 1582 . 89 FIGURE 12: FORWARD SECTION 48 INSTALLATION .......................... 9 1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 3 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 4 FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION ................. 1 1 0 FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION ................ 1 2 2 FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION ...................... 1 3 4 FIGURE 16: PRESSURE SEAL INSTALLATION ............................. 1 3 9 FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS . . 142 FIGURE 18: BULKHEAD INSPECTIONS PRIOR TO REPLACEMENT ................. 1 4 7 FIGURE 19: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS ......... 1 5 0 FIGURE 20: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS ............... 1 6 0 FIGURE 21: STA 1582 FLOOR BEAM DETACHMENT .......................... 1 6 2 FIGURE 22: STA 1582 FLOOR BEAM SUPPORT ............................ 1 6 6 FIGURE 23: STA 1582 FLOOR BEAM ATTACHMENT .......................... 1 7 0 APPENDIX A: APU WIRING TEST PROCEDURE ............................. 1 7 5 APPENDIX B: ALIGNMENT PINS ...................................... 1 8 0 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 4 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 5 Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-53A0139Original Issue: November 12, 2009 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. CONCURRENT REQUIREMENTS None. BACKGROUND This service bulletin gives instructions for the removal and replacement of the STA 1582 aft pressure bulkhead. Service Bulletin 767-53A0026, "Fuselage - Section 48 - Body Station 1582 Pressure Bulkhead Inspection" was previously released to give instructions to inspect for cracks in the the STA 1582 aft pressure bulkhead radial web lap splices and tear strap splices. Aft pressure bulkhead radial web lap splice multiple site damage (MSD) cracks that are not found and repaired can link together and become large. This condition could result in rapid decompression of the passenger compartment and possible damage or interference with airplane control systems that penetrate the bulkhead, and consequent loss of controllability of the airplane. Operators have told Boeing that MSD fatigue cracks have been found in the STA 1582 aft pressure bulkhead radial web lap splices on multiple airplanes with 31,746 to 36,597 flight cycles. On four airplanes, the crack findings demonstrated MSD fatigue cracking common to the radial web lap splices. Design changes to improve the durability of the bulkhead were made in production at line number 176, and again at line number 424. Service Bulletin 767-53A0026 Revision 5 was released to give instructions to inspect for these types of cracks. Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the repeat inspections currently required by Boeing Service Bulletin 767-53A0026 and FAA Airworthiness Directive 2005-03-11. Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end the repeat inspections currently required by Boeing Service Bulletin 767-53A0087, "Fuselage - Section 48 - BS 1582 Aft Pressure Bulkhead Web Inspection at Web to Pressure Chord Joint" and FAA Airworthiness Directive 2004-05-16. Inspections of the replacement aft pressure bulkhead are to be done as specified in the Boeing Document D622T001 "767 Maintenance Planning Data" and Airworthiness Limitations - Structural Inspections as specified in Section 9 of Boeing Document D622T001, with threshold modifications identified in Paragraph 1.E., Compliance. Boeing Service Related Problem (SRP) 767-SRP-53-0228 is related to this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 5 of 180 ### Page 6 ACTION (PRR B12901-74S) Remove equipment for access to the forward and aft sides of the STA 1582 aft pressure bulkhead. Remove the vertical fin, the tail cone (with the APU installed), the left and right STA 1809.5 center bulkhead, and the horizontal stabilizer. Disconnect and remove the forward portion of Section 48 (with the aft pressure bulkhead attached) from Section 46 at STA 1582. Remove the aft pressure bulkhead from Section 48 and install a new aft pressure bulkhead in accordance with this service bulletin. Attach the modified forward part of Section 48 to Section 46 at STA 1582. Reinstall the horizontal stabilizer and reassemble the STA 1809.5 bulkhead. Reinstall the tail cone and the vertical fin. Install the equipment that was removed for access to the aft pressure bulkhead. Test disturbed systems in accordance with this service bulletin. EFFECTIVITY 767-200 and 767-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directive 2005-03-11 is related to this service bulletin. FAA Airworthiness Directive 2004-05-16 is affected by this service bulletin. Refer to Paragraph 1.E., Compliance. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin. MANPOWER Elapsed HoursTotal Task HoursAirplanes 265.51541All Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 6 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 7 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 8 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT BLANK PAGE ### Page 9 Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0139 Original Issue: November 12, 2009 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Replacement 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 PRRB12901-74S for data about this change Conversion Airplanes: If the aft pressure bulkhead replacement will be done on an affected airplane listed in this paragraph that has been modified by an approved "Boeing Converted Freighter Modification" of a 767-200 passenger airplane to a 767-200 Special Freighter (SF) airplane or of a 767-300 passenger airplane to a 767-300 Boeing Converted Freighter (BCF), contact Boeing for additional instructions. DESCRIPTIONCONFIGURATIONGROUP Airplanes line number 1 - 175 without a dual-loop APU fire detection system, except Group 3 airplanes. -1 Airplanes line number 1 - 175 with a dual-loop APU fire detection system. -2 Airplanes line number 158 and 165, which do not have a dual-loop APU fire detection system, but have been modified to include dedicated static pressure inputs to the elevator feel computer per PRRB11770. -3 Airplane Models: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 9 of 180 ### Page 10 767-200, 767-300 GroupVariable Number 1VA001 - VA020 1VA301 - VA315 1VA501 - VA526 1VA701 - VA712 2VA801 1VA802 2VA803 - VA804 1VA805 2VA806 - VA810 1VB001 - VB002 1VB051 - VB055 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB324 2VB371 - VB373 1VB401 1VE001 - VE002 1VE021 - VE023 1VE041 - VE043 2VE061 1VE062 2VE063 - VE064 1VE065 2VE066 - VE068 2VE083 - VE084 1VE101 - VE103 1VE116 - VE117 1VE121 - VE123 1VE141 - VE142 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 10 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 11 GroupVariable Number 2VK001 - VK004 1VK031 - VK037 3VL001 3VL011 2. Spares Affected None. B. Concurrent Requirements None. C. Reason This service bulletin gives instructions for the removal and replacement of the STA 1582 aft pressure bulkhead. Service Bulletin 767-53A0026, "Fuselage - Section 48 - Body Station 1582 Pressure Bulkhead Inspection" was previously released to give instructions to inspect for cracks in the the STA 1582 aft pressure bulkhead radial web lap splices and tear strap splices. Aft pressure bulkhead radial web lap splice multiple site damage (MSD) cracks that are not found and repaired can link together and become large. This condition could result in rapid decompression of the passenger compartment and possible damage or interference with airplane control systems that penetrate the bulkhead, and consequent loss of controllability of the airplane. Operators have told Boeing that MSD fatigue cracks have been found in the STA 1582 aft pressure bulkhead radial web lap splices on multiple airplanes with 31,746 to 36,597 flight cycles. On four airplanes, the crack findings demonstrated MSD fatigue cracking common to the radial web lap splices. Design changes to improve the durability of the bulkhead were made in production at line number 176, and again at line number 424. Service Bulletin 767-53A0026 Revision 5 was released to give instructions to inspect for these types of cracks. Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the repeat inspections currently required by Boeing Service Bulletin 767-53A0026 and FAA Airworthiness Directive 2005-03-11. Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end the repeat inspections currently required by Boeing Service Bulletin 767-53A0087, "Fuselage - Section 48 - BS 1582 Aft Pressure Bulkhead Web Inspection at Web to Pressure Chord Joint" and FAA Airworthiness Directive 2004-05-16. Inspections of the replacement aft pressure bulkhead are to be done as specified in the Boeing Document D622T001 "767 Maintenance Planning Data" and Airworthiness Limitations - Structural Inspections as specified in Section 9 of Boeing Document D622T001, with threshold modifications identified in Paragraph 1.E., Compliance. Boeing Service Related Problem (SRP) 767-SRP-53-0228 is related to this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 11 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 12 D. Description Remove equipment for access to the forward and aft sides of the STA 1582 aft pressure bulkhead. Remove the vertical fin, the tail cone (with the APU installed), the left and right STA 1809.5 center bulkhead, and the horizontal stabilizer. Disconnect and remove the forward portion of Section 48 (with the aft pressure bulkhead attached) from Section 46 at STA 1582. Remove the aft pressure bulkhead from Section 48 and install a new aft pressure bulkhead in accordance with this service bulletin. Attach the modified forward part of Section 48 to Section 46 at STA 1582. Reinstall the horizontal stabilizer and reassemble the STA 1809.5 bulkhead. Reinstall the tail cone and the vertical fin. Install the equipment that was removed for access to the ft pressure bulkhead. Test disturbed systems in accordance with this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1-2: Affected Maintenance Zones ZoneModel 165, 166, 251, 252, 253, 254, 311, 312, 313, 314, 315, 316, 321, 322, 323, 324, 325, 326, 331, 332, 333, 334, 335, 336, 337, 338, 341, 342, 343, 344, 345, 346, 347, 348 767-200, 767-300 Group 3: Affected Maintenance Zones ZoneModel 165, 166, 251, 252, 253, 254, 311, 312, 313, 314, 315, 316, 321, 322, 323, 324, 325, 326, 331, 332, 333, 334, 335, 336, 337, 338, 341, 342, 343, 344, 345, 346, 347, 348 767-300 E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directive 2005-03-11 is related to this service bulletin. FAA Airworthiness Directives 2004-05-16 is affected by this service bulletin. Boeing recommends that the aft pressure bulkhead replacement given in Paragraph 3.B., PART 2, PART 3, and PART 4 of this service bulletin be done when the airplane has flown 43,000 total flight-cycles, or within 5,000 flight-cycles after the original issue date on this service bulletin, whichever is later. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 12 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 13 Table 1: Inspection and Replacement of the STA 1582 Aft Pressure Bulkhead Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 5,000 flight-cycles af- ter the original issue date on this service bul- letin. Before 43,000 total flight-cy- cles. Replace the STA 1582 aft pressure bulkhead in ac- cordance with Accom- plishment Instructions PART 2 through PART 4. (a) (b) All airplanes. 1,600 flight-cycles. (d) Within 1,600 flight-cycles af- ter the last re- peat inspection done in accor- dance with Boe- ing Service Bul- letin 767- 53A0026. (d) Before 43,000 total flight-cy- cles. Do detailed, Low Frequen- cy Eddy Current (LFEC) and Mid Frequency Eddy Current (MFEC) inspec- tions of the STA 1582 aft pressure bulkhead for cracks in accordance with Accomplishment Instruc- tions PART 1. (b) (c) -Before further flight.Replace the STA 1582 aft pressure bulkhead in ac- cordance with Accom- plishment Instructions PART 2 through PART 4. (a) Any crack found. (a) After bulkhead replacement, the repeat inspections specified in Boeing Service Bulletins 767-53A0026 and 767-53A0087 are not necessary. (b) Bulkhead inspections are an interim alternative to aft pressure bulkhead replacement. (c) These inspections replace the repeat inspections specified in Boeing Service Bulletin 767-53A0026 during the compliance time. (d) But do the aft pressure bulkhead replacement within 5,000 flight-cycles after the original issue date on this service bulletin. After the aft pressure bulkhead has been replaced, continue to do the structural inspections of the aft pressure bulkhead as defined in Boeing Document D622T001 "767 Maintenance Planning Data". In addition, the inspections for Structural Significant Items (SSIs) 53-80-I01A, 53-80-I01B, 53-80-I01C, 53-80-I01D, and 53-80-I01E as defined in Section 9 of the Boeing Maintenance Planning Document, Boeing Document D622T001-9, Airworthiness Limitations - Structural Inspections (ALI) must begin at or before a threshold of 37,500 flight-cycles after the aft pressure bulkhead has been replaced. Repetitive inspections for these SSIs must follow DTR check forms contained in Boeing Document D622T001 Appendix B (will be D622T001-DTR) following the line number 424 and on configuration applicability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 13 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 14 F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspection defined in Figure 18 of this service bulletin as an alternative method of compliance to the requirements of paragraph (f) of AD 2005-03-11. All provisions of AD 2005-03-11 that are not specifically referenced in the above statement remain fully applicable and must be complied with. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the aft pressure bulkhead replacement modification defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (f) of AD 2005-03-11. All provisions of AD 2005-03-11 that are not specifically referenced in the above statement remain fully applicable and must be complied with. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the aft pressure bulkhead replacement modification defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (a), (b) and (f) of AD 2004-05-16. All provisions of AD 2004-05-16 that are not specifically referenced in the above statement remain fully applicable and must be complied with. G. Manpower The table below shows an estimate of the task hours necessary to do this change for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:  Time to adjust to the workplace  Time to schedule the work  Time to inspect the work  Time to cure the materials  Time to make the parts  Time to find the tools. NOTE: If the aft pressure bulkhead will not be replaced immediately, refer to Service Bulletin 767-53A0026 for an estimate of the task hours necessary to do the inspections described in Paragraph 3.B., Part 1. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 14 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 15 Aft Pressure Bulkhead Replacement Elapsed HoursTask HoursNumber of Per- sons Task 362Prepare the new bulkhead (Para- graph 3.B., Part 2) 382286Get Access (Paragraph 3.B., Part 3, through step 21) 362166Remove the vertical fin (Paragraph 3.B., Part 3, step 22) 14846Remove the tail cone (Paragraph 3.B., Part 3, steps 23 through 25) 19.51176Remove the horizontal stabilizer (Paragraph 3.B., Part 3, steps 26 through 29) 15906Remove the forward part of Section 48 (Paragraph 3.B., Part 3, step 30 through step 32) 3.25134Remove the aft pressure bulkhead from the forward part of Section 48 (Paragraph 3.B., Part 3, step 33) 3.25134Install the new aft pressure bulkhead in the forward part of Section 48 (Paragraph 3.B., Part 3, step 34) 15906Install the forward part of Section 48 (Paragraph 3.B., Part 3, step 35) 20.51236Install the horizontal stabilizer (Paragraph 3.B., Part 3, steps 36 through 41) 13.5816Install the tail cone (Paragraph 3.B., Part 3, steps 42 through 44) 362166Install the vertical fin (Paragraph 3.B., Part 3, step 45) 39.52376Restore Access (Paragraph 3.B., Part 3, step 46 through step 65) 9273Test disturbed systems (Paragraph 3.B., Part 4) 265.51541TOTAL FOR EACH AIRPLANE BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 15 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 16 H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +98084.0+62.0767-200 +106268.0+62.0767-300 I. Electrical Load Data Not changed. J. References 1. Existing Data a. Engineering Change Memo PRR B12901-74S b. Boeing Service Bulletins 767-25A0300, "Equipment/Furnishings - Insulation - Aft Bulkhead to Floor Insulation Blankets Modification", 767-53A0026, "Fuselage- Section 48 - Body Station 1582 Pressure Bulkhead Inspection", 767-53A0085, "Fuselage - Section 48 - Supports And Fittings - Vertical Fin Attachment Bolt And Barrel Nut Inspection And Replacement", 767-53A0078, "Fuselage - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and Modification", 767-53A0087, "Fuselage - Section 48 - BS 1582 Aft Pressure Bulkhead Web Inspection at Web to Pressure Chord Joint", 767-53-0118, "Fuselage - Section 48 - STA 1725.5 Aft Skin and Bulkhead Outer Chord Strap - Inspection and Repair", 767-53A0131, "Fuselage - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical Inner Chord, and External Skin - Inspection", 767-55-0006, "Stabilizers - Horizontal Stabilizer - Stabilizer Pivot Fittings - Bushing Modification" and 767-55-0008 "Stabilizers - Horizontal Stabilizer Pivot Fittings - Pivot Fitting Rework and Bearing Retainer Replacement" c. Boeing Service Letter 767-SL-51-008-B. d. Federal Aviation Administration (FAA) Airworthiness Directives 2004-05-16 and 2005-03-11 e. Standard Overhaul Practices Manual (SOPM) 20-50-19 f. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19 g. 767 Aircraft Maintenance Manual (AMM) 05-51-24, 07-11-03, 12-15-01, 12-15-02, 20-10-03, 20-10-04, 20-10-09, 22-10-00, 22-21-00, 23-11-00, 23-41-00, 24-22-00, 25-21-01, 25-21-05, 25-22-01, 25-22-02, 25-22-10, 25-25-01, 25-25-04, 25-27-02, 25-31-04, 25-41-04, 25-52-01, 25-52-03, 27-21-00, 27-21-11, 27-21-13, 27-23-00, 27-28-00, 27-31-00, 27-32-00, 27-41-00, 27-41-10, 27-48-00, 27-58-01, 28-25-05, 29-11-00, 31-31-00, 31-51-04, 32-00-20, 33-31-00, 33-45-00, 34-11-01, 36-11-01, 38-11-01, 38-32-11, 38-32-51, 53-01-01, 53-66-02, 53-80-70, 55-17-51 h. 767 Aircraft Recovery Document (ARD) i. 767 Non-Destructive Testing (NDT) Manual Part 6, 53-80-06, Part 6, 53-80-02 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 16 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 17 j. 767-200 Structural Repair Manual (SRM) 51-50-02, 53-80-08 k. 767-200SF Structural Repair Manual (SRM) 51-50-02 l. 767-300 Structural Repair Manual (SRM) 51-50-02, 53-80-08 m. 767-300BCF Structural Repair Manual (SRM) 51-50-02, 53-80-08 2. Data supplied with this Service Bulletin a. Drawings: ADCNDCN/REVSheetTitleDrawing No -J1Section 48/72 Integration100T3480 -CPSDL --1Mechanical Equipment Forward 48 Section Stand 2ME148T0200PBR --2 --1Mechanical Equipment Aft 48 Section Stand2ME148T0600PBR --2 --1Mechanical Equipment Strongback, Pres- sure Bulkhead Transportation and Installa- tion 2ME148T2610PBR --2 --3 --4 --5 --1Miscellaneous Tool Torque Multiplier and Adapter, Vertical Fin 2MIT100T3480PBR --2 --3 --4 --5 --6 --1Overhead Mechanical Equipment Vertical Fin Assembly Sling 2OHME100T3480PBR --1Mechanical Equip Sling & Strongback Fwd 48 Section Pressure Bulkhead R & R 3ME140T0140PBR --2 --3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 17 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 18 ADCNDCN/REVSheetTitleDrawing No --1Aft Pressure Bulkhead Parts Removal624T0020 -A10 --11 -A12 -A13 -A14 -A15 -A16 -A17 --2 --3 --4 --5 -A6 -A7 -A8 -A9 --1Mechanical Equipment Vertical Fin Lift Fit- tings ME100T3480PBR --1Mechanical Equipment Forward 48 Section Handling Fitting ME148T0200PBR --1Mechanical Equipment Aft 48 Section Han- dling Fitting ME148T0600PBR --1Mechanical Equipment Strongback Pressure Bulkhead Removal ME148T2610PBR --2 --3 --5 --1Mechanical Equipment Vert Fin Stand Floor Mounted ME170T0100PBR --2 --1Mechanical Equipment Floor Mounted Stand Horizontal Stabilizer ME180T0000PBR --1Mechanical Equipment Lift Fittings Front and Rear Spar Horizontal Stabilizer ME182T0000PBR --1Misc Tool Alignment Pins Vertical Fin Body Join MIT100T3480PBR BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 18 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 19 ADCNDCN/REVSheetTitleDrawing No --1Overhead Mech Equip Pressure Dome Sling Fwd 48 Section OHME148T2610PBR --2 --1Overhead Mech Equip Horizontal Stabilizer Complete OHME180T0100PBR --2 --1Portable Mechanical Equipment Forward 48 Section Internal Scaffolding PME148T0010PBR --2 --3 --4 --5 --6 --1Protective Equipment Pressure Bulkhead Cover PRE148T2610PBR --1Shipping Mech Equip Ground Transporta- tion Aft Pressure Bulkhead SME148T2610PBR --2 --3 --4 3. Installation Drawings Used in the Preparation of this Service Bulletin TitleDrawing Number Section 48/72 Integration100T3480 Monocoque Integration - Section 46/48140T0140 Floor System Integration Section 46 - 48140T0540 Seal Application Section 48 Integration140T4800 Stanchion Installation - Sect 46146T5500 Support Instl - Galley Tie Down Fittings, Sect 46146T5604 Fastener Instl Bulkhead Splice STA 1809.5148T0006 Fastener Instl148T0007 Fastener Instl - STA 1809.5 Splice, Sect 48148T0008 Frame Instl - Pivot Bulkhead148T1150 Bulkhead End Item - Center, Horiz Stab Pivot, STA 1809.5148T2740 Seal Instl - Pitot/Static Tubing Pressure Dome233T9112 Pressure Seal Instl - Pressure Dome STA 1582.0255T4821 Retainer Instl - Pressure Seal, Hydraulic Tubing272T4831 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 19 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 20 TitleDrawing Number Tubing Instl - APU Fuel Feed, Body Sections 45, 46 and 48346T0003 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 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. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 20 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 21 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. Kits/Parts availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. Unit Price thru Dec 31/09 ROLT (Weeks) NameKit or Part Number $27,650(a)Top Kit015T1812-1 $371,889(a)Pressure Bulkhead691T0103-1 (a) No Reorder Lead Time (ROLT) is provided. Boeing strongly recommends that operators contact Boeing and order parts at least 2 years prior to planned modification incorporation to ensure that parts can be made available. The kits and parts are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA B. Industry Support Information Boeing warranty remedies are not available for the configuration change given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One 691T0103-1 Pressure Bulkhead, one 015T1812-1 Top Kit, and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. The Top Kit is divided into Figure kits for each installation figure shown in the table below. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 21 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 22 Figure Kit 1413121161Top Kit 111111015T1812-1 Figure Kit 171615Top Kit 111015T1812-1 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 1413121161 QTY WASHER2140T0140-5 CLIP1140T0142-1 CLIP1140T0142-2 FITTING ASSY2140T0169-7 COVER PLATE1140T0345-1 SEAL BLOCK AS- SY 1140T0345-3 FILLER11148T0012-11 SHIM2148T0012-18 SHIM2148T0012-19 FILLER22148T0012-2 FILLER22148T0012-3 SHIM11148T0012-4 SHIM11148T0012-5 SPLICE-STRAP22148T0015-1 SEAL BLOCK AS- SY 1148T2629-2 washer148T2746-1 filler148T2746-2 TUBE ASSY233T9110-566 TUBE ASSEMBLY233T9110-665 PLATER RETAIN- ER 233T9113-4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 22 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 23 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 1413121161 QTY SEAL270T0004-1101 SEAL270T0004-1102 BRACKET ASSY-1272T4825-9 RETAINER-272T4830-1 RETAINER ASSY-272T4830-2 SEAL140345 (678782 op- tional) FITTING ASSY2412T3106-406 fitting assy1412T3106-408 SEAL-69B41314-6 BOLTBACB30LM3-3 BOLT, 12 PT HEAD BACB30LT5-12 BOLT, 12 PT HEAD BACB30LT7-12 BOLT, PROTRUD- ING HD 88BACB30MY10K10X BOLT TITANIUM O/S 1010BACB30MY10K3X BOLT, PROTRUD- ING HD 55BACB30MY10K5X BOLT, PROTRUD- ING HD 11BACB30MY10K6X BOLT, PROTRUD- ING HD 1111BACB30MY10K7X BOLT, PROTRUD- ING HD 1414BACB30MY10K8X BOLT, PROTRUD- ING HD 44BACB30MY12K10X BOLT, PROTRUD- ING HD 22BACB30MY12K6X BOLT, PROTRUD- ING HD 44BACB30MY12K7X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 23 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 24 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 1413121161 QTY BOLT, PROTRUD- ING HD 44BACB30MY12K8X BOLT, PROTRUD- ING HD 77BACB30MY8K10X BOLT, PROTRUD- ING HD 33BACB30MY8K11X BOLT, PROTRUD- ING HD 44BACB30MY8K12X BOLT, PROTRUD- ING HD 3535BACB30MY8K5X BOLT, PROTRUD- ING HD 11BACB30MY8K6X BOLT, PROTRUD- ING HD 6565BACB30MY8K7X BOLT, PROTRUD- ING HD 33BACB30MY8K8X BOLT, PROTRUD- ING HD 11BACB30MY8K9X BOLT, HEX HEAD8BACB30NM4K14 BOLT, 100 DEG HEX DR 44BACB30NW8K13X BOLT, 100 DEG HEX DR 22BACB30NW8K5X BOLT, 100 DEG HEX DR 22BACB30NW8K7X BOLT, 100 DEG HEX DR 44BACB30NW8K8X HEX DRIVE BOLTBACB30NX10K10 BOLT, PROTRUD- ING HD 44BACB30NX10K11X BOLT, PROTRUD- ING HD 44BACB30NX10K12X BOLTBACB30NX10K7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 24 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 25 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 1413121161 QTY BOLT, PROTRUD- ING HD 22BACB30NX10K8X BOLT, PROTRUD- ING HD 22BACB30NX10K9X BOLT, PROTRUD- ING HD 44BACB30NX12K12X BOLTBACB30NX14K16 BOLT, PROTRUD- ING HD 2BACB30NX6K10X BOLT, PROTRUD- ING HD 20BACB30NX6K4X BOLTBACB30NX6K5 BOLT, PROTRUD- ING HD 2BACB30NX6K5X HI LOKBACB30NX8K5 BOLT, HEX DRIVEBACB30NX8K7 BOLT, 12 PT HEAD BACB30US12K37 BOLT, 12 PT HEAD BACB30US12K40 BOLT, 12 PT HEAD 26BACB30US5K16 BOLT, 12 PT HEAD 58BACB30US5K17 BOLT, 12 PT HEAD 40BACB30US5K18 BOLT, 12 PT HEAD 24BACB30US5K19 BOLT, 12 PT HEAD 10BACB30US5K21 BOLT, 12 PT HEAD 6BACB30US5K25 BOLT, 12 PT HEAD 4BACB30US6K31 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 25 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 26 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 1413121161 QTY BOLT, 12 PT HEAD 40BACB30US6K33 BOLT, 12 PT HEAD 32BACB30US6K34 BOLT, 12 PT HEAD 8BACB30US6K35 BOLT, 12 PT HEAD 8BACB30US6K36 BOLT, 12 PT HEAD BACB30US7K24 BOLT, 12 PT HEAD BACB30US7K26 BOLT, 12 PT HEAD BACB30US7K27 BOLT, 12 PT HEAD BACB30US7K28 BOLT, 12 PT HEAD 20BACB30US7K35 BOLT, 12 PT HEAD 12BACB30US7K39 BOLT, 12 PT HEAD 16BACB30US7K40 BOLT, 12 PT HEAD BACB30US8K30 BOLT, 12 PT HEAD BACB30US8K31 BOLT, 12 PT HEAD 16BACB30US8K42 CLAMP, LOOPBACC10DK6 COLLAR1414BACC30BH10 COLLAR44BACC30BH12 COLLAR, PRELOAD BACC30BH14 COLLAR24BACC30BH6 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 26 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 27 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 1413121161 QTY COLLARBACC30BH8 COLLAR4949BACC30M10 COLLAR1414BACC30M12 COLLAR145145BACC30M8 SELF-LOCKING NUT BACN10HR12CD NUT156BACN10HR5CD SELF-LOCKING NUT 92BACN10HR6CD NUT44BACN10HR7CD NUT16BACN10HR8CD NUTBACN10JC3CD SELF-LOCKING NUT BACN10JC7CD NUT, SELF-LOCK15BACN11AG3 NUTBACN11Z5CD RIVET, UNIVER- SAL HD 50BACR15FT5D7C RIVET, UNIVER- SAL HD 5BACR15FT6D8C RIVET8BACR15FT6KE7C RIVET55BACR15FV7KE7 RIVET11BACR15FV7KE8 BOLT15BACS12HN3-7 BOLTBACS12HN3-9 SHIM, LAMINAT- ED 2BACS40R011B012F SHIM,LAMINATED22BACS40R011B027F SHIM, LAMINAT- ED 22BACS40R012B027F SHIM, LAMINAT- ED 11BACS40R016B098F BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 27 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 28 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 1413121161 QTY SHIM, LAMINAT- ED 11BACS40R027C030F WASHER, PLAINBACW10BP12CD WASHER, PLAINBACW10BP12DP CSK WASHER156BACW10BP5CD WASHER-PLAIN154BACW10BP5DP WASHER, PLAIN92BACW10BP6CD WASHER92BACW10BP6DP WASHER44BACW10BP7CD WASHER44BACW10BP7DP WASHER16BACW10BP8CD WASHER16BACW10BP8DP WASHER8NAS1149D0316J WASHER30NAS1149D0332J WASHER, FLAT5NAS1149D0363J RIVET, BLIND31NAS1399D6A10 SPACERS FOR RIVETS 1NAS42DD3-44FC SPACERS FOR RIVETS 1NAS42DD3-48FC SPACERS FOR RIVETS 1NAS42DD3-64FC ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY WASHER140T0140-5 CLIP140T0142-1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 28 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 29 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY CLIP140T0142-2 FITTING ASSY140T0169-7 COVER PLATE140T0345-1 SEAL BLOCK AS- SY 140T0345-3 FILLER148T0012-11 SHIM148T0012-18 SHIM148T0012-19 FILLER148T0012-2 FILLER148T0012-3 SHIM148T0012-4 SHIM148T0012-5 SPLICE-STRAP148T0015-1 SEAL BLOCK AS- SY 148T2629-2 washer2148T2746-1 filler2148T2746-2 TUBE ASSY1233T9110-566 TUBE ASSEMBLY1233T9110-665 PLATER RETAIN- ER 2233T9113-4 SEAL3270T0004-1101 SEAL1270T0004-1102 BRACKET ASSY-272T4825-9 RETAINER-1272T4830-1 RETAINER ASSY-1272T4830-2 SEAL40345 (678782 op- tional) FITTING ASSY412T3106-406 fitting assy412T3106-408 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 29 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 30 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY SEAL-169B41314-6 BOLT16BACB30LM3-3 BOLT, 12 PT HEAD 10BACB30LT5-12 BOLT, 12 PT HEAD 8BACB30LT7-12 BOLT, PROTRUD- ING HD BACB30MY10K10X BOLT TITANIUM O/S BACB30MY10K3X BOLT, PROTRUD- ING HD BACB30MY10K5X BOLT, PROTRUD- ING HD BACB30MY10K6X BOLT, PROTRUD- ING HD BACB30MY10K7X BOLT, PROTRUD- ING HD BACB30MY10K8X BOLT, PROTRUD- ING HD BACB30MY12K10X BOLT, PROTRUD- ING HD BACB30MY12K6X BOLT, PROTRUD- ING HD BACB30MY12K7X BOLT, PROTRUD- ING HD BACB30MY12K8X BOLT, PROTRUD- ING HD BACB30MY8K10X BOLT, PROTRUD- ING HD BACB30MY8K11X BOLT, PROTRUD- ING HD BACB30MY8K12X BOLT, PROTRUD- ING HD BACB30MY8K5X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 30 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 31 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY BOLT, PROTRUD- ING HD BACB30MY8K6X BOLT, PROTRUD- ING HD BACB30MY8K7X BOLT, PROTRUD- ING HD BACB30MY8K8X BOLT, PROTRUD- ING HD BACB30MY8K9X BOLT, HEX HEADBACB30NM4K14 BOLT, 100 DEG HEX DR BACB30NW8K13X BOLT, 100 DEG HEX DR BACB30NW8K5X BOLT, 100 DEG HEX DR BACB30NW8K7X BOLT, 100 DEG HEX DR BACB30NW8K8X HEX DRIVE BOLT44BACB30NX10K10 BOLT, PROTRUD- ING HD BACB30NX10K11X BOLT, PROTRUD- ING HD BACB30NX10K12X BOLT54BACB30NX10K7 BOLT, PROTRUD- ING HD BACB30NX10K8X BOLT, PROTRUD- ING HD BACB30NX10K9X BOLT, PROTRUD- ING HD BACB30NX12K12X BOLT8BACB30NX14K16 BOLT, PROTRUD- ING HD BACB30NX6K10X BOLT, PROTRUD- ING HD BACB30NX6K4X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 31 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 32 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY BOLT8BACB30NX6K5 BOLT, PROTRUD- ING HD BACB30NX6K5X HI LOK8BACB30NX8K5 BOLT, HEX DRIVE76BACB30NX8K7 BOLT, 12 PT HEAD 4BACB30US12K37 BOLT, 12 PT HEAD 4BACB30US12K40 BOLT, 12 PT HEAD BACB30US5K16 BOLT, 12 PT HEAD BACB30US5K17 BOLT, 12 PT HEAD BACB30US5K18 BOLT, 12 PT HEAD BACB30US5K19 BOLT, 12 PT HEAD BACB30US5K21 BOLT, 12 PT HEAD BACB30US5K25 BOLT, 12 PT HEAD BACB30US6K31 BOLT, 12 PT HEAD BACB30US6K33 BOLT, 12 PT HEAD BACB30US6K34 BOLT, 12 PT HEAD BACB30US6K35 BOLT, 12 PT HEAD BACB30US6K36 BOLT, 12 PT HEAD 22BACB30US7K24 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 32 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 33 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY BOLT, 12 PT HEAD 2BACB30US7K26 BOLT, 12 PT HEAD 4BACB30US7K27 BOLT, 12 PT HEAD 32BACB30US7K28 BOLT, 12 PT HEAD BACB30US7K35 BOLT, 12 PT HEAD BACB30US7K39 BOLT, 12 PT HEAD BACB30US7K40 BOLT, 12 PT HEAD 2BACB30US8K30 BOLT, 12 PT HEAD 4BACB30US8K31 BOLT, 12 PT HEAD BACB30US8K42 CLAMP, LOOP10BACC10DK6 COLLAR107BACC30BH10 COLLARBACC30BH12 COLLAR, PRELOAD 8BACC30BH14 COLLAR8BACC30BH6 COLLAR84BACC30BH8 COLLARBACC30M10 COLLARBACC30M12 COLLARBACC30M8 SELF-LOCKING NUT 8BACN10HR12CD NUTBACN10HR5CD SELF-LOCKING NUT BACN10HR6CD BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 33 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 34 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY NUT60BACN10HR7CD NUT4BACN10HR8CD NUT18BACN10JC3CD SELF-LOCKING NUT 8BACN10JC7CD NUT, SELF-LOCKBACN11AG3 NUT10BACN11Z5CD RIVET, UNIVER- SAL HD BACR15FT5D7C RIVET, UNIVER- SAL HD BACR15FT6D8C RIVETBACR15FT6KE7C RIVETBACR15FV7KE7 RIVETBACR15FV7KE8 BOLTBACS12HN3-7 BOLT24BACS12HN3-9 SHIM, LAMINAT- ED BACS40R011B012F SHIM,LAMINATEDBACS40R011B027F SHIM, LAMINAT- ED BACS40R012B027F SHIM, LAMINAT- ED BACS40R016B098F SHIM, LAMINAT- ED BACS40R027C030F WASHER, PLAIN8BACW10BP12CD WASHER, PLAIN8BACW10BP12DP CSK WASHER10BACW10BP5CD WASHER-PLAIN12BACW10BP5DP WASHER, PLAINBACW10BP6CD WASHERBACW10BP6DP BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 34 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 35 ALL KIT 015T1812-1 NOTES Existing Part NumberName Figure New Part Number 171615 QTY WASHER68BACW10BP7CD WASHER68BACW10BP7DP WASHERBACW10BP8CD WASHER4BACW10BP8DP WASHER24NAS1149D0316J WASHERNAS1149D0332J WASHER, FLATNAS1149D0363J RIVET, BLINDNAS1399D6A10 SPACERS FOR RIVETS NAS42DD3-44FC SPACERS FOR RIVETS NAS42DD3-48FC SPACERS FOR RIVETS NAS42DD3-64FC 2. Parts and Materials Supplied by the Operator NotesNameQTYPart Number/ Specification Sealant-BMS 5-95 Bolt8BACB30NM4K4 Epoxy Adhesive2 OzBMS5-25 Bolt8NAS6603-3 Sealant-BMS 5-142 Plate1A Plate1B Angle6C Angle2D Angle2E Bolt120BACB30NX6K5 Collar138BACC30BH6SW Bolt18BACB30NX6K8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 35 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 36 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 Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the date the tools will be used. If there is a limit in the quantity of available rental tools, a supply sequence is given by Spares. Monthly PriceDaily Price thru Dec 31/09 NameTool Kit Number Not Available$500Forward 48 Section Internal Scaffolding PME148T0010PBR Not Available$220Pressure Bulkhead CoverPRE148T2610PBR Not Available$200Vertical Fin Alignment PinsMIT100T3480PBR Not Available$240Vertical Fin Floor StandME170T0100PBR Not Available$380Pressure Dome SlingOHME148T2610PBR Not Available$240Vertical Fin Lift Sling2OHME100T3480PBR Not Available$260Vertical Fin Lift FittingsME100T3480PBR Not Available$200Horizontal Stabilizer Lift FittingsME182T0000PBR Not Available$360Horizontal Stabilizer Lift SlingOHME180T0100PBR Not Available$240Forward 48 Section Sling and Strongback 3ME140T0140PBR Not Available$500Vertical Fin Torque Multiplier and Adapter 2MIT100T3480PBR Not Available$460Aft 48 Section Lift Sling and At- tach Fittings ME148T0600PBR Not Available(a)Pressure Bulkhead Removal Strongback ME148T2610PBR Not Available$380Horizontal Stabilizer Floor StandME180T0000PBR Not Available$360Aft 48 Section Stand2ME148T0600PBR Not Available$420Forward 48 Section Attach Fit- tings ME148T0200PBR BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 36 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 37 Monthly PriceDaily Price thru Dec 31/09 NameTool Kit Number Not Available$360Forward 48 Section Stand2ME148T0200PBR A $150.00 handling fee is added to all tool rentals. (a) Rental price data for this tool was not available at the time this service bulletin was issued. Purchase Data: Unit Price thru Dec 31/09 NameTool Kit Number $151,600Forward 48 Section Internal Scaffolding PME148T0010PBR $19,320Pressure Bulkhead CoverPRE148T2610PBR $10,120Vertical Fin Alignment PinsMIT100T3480PBR $21,400Vertical Fin Floor StandME170T0100PBR $63,250Pressure Dome SlingOHME148T2610PBR $22,400Vertical Fin Lift Sling2OHME100T3480PBR $25,300Vertical Fin Lift FittingsME100T3480PBR $10,120Horizontal Stabilizer Lift FittingsME182T0000PBR $50,600Horizontal Stabilizer Lift SlingOHME180T0100PBR $20,400Forward 48 Section Sling and Strongback 3ME140T0140PBR $151,800Vertical Fin Torque Multiplier and Adapter 2MIT100T3480PBR $124,000Aft 48 Section Lift Sling and At- tach Fittings ME148T0600PBR (a)Pressure Bulkhead Removal Strongback ME148T2610PBR $69,576Horizontal Stabilizer Floor StandME180T0000PBR $50,600Aft 48 Section Stand2ME148T0600PBR $83,200Forward 48 Section Attach Fit- tings ME148T0200PBR $50,600Forward 48 Section Stand2ME148T0200PBR (a) Purchase price data for this tool was not available at the time this ser- vice bulletin was issued. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgement. After the Price date, new price data is applicable. Prices are in United States dollars. Terms: Net 30 days. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 37 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 38 Reference this service bulletin number and submit purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA (Service Bulletin 767-53A0139) F. Special Tooling Necessary to do this Service Bulletin To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available. NameTool Kit Number Forward 48 Section Internal Scaffolding PME148T0010PBR Pressure Bulkhead CoverPRE148T2610PBR Vertical Fin Alignment PinsMIT100T3480PBR Vertical Fin Floor StandME170T0100PBR Pressure Dome SlingOHME148T2610PBR Pressure Dome Removal Strongback ME148T2610PBR Vertical Fin Lift Sling2OHME100T3480PBR Vertical Fin Lift FittingsME100T3480PBR Horizontal Stabilizer Lift FittingsME182T0000PBR Horizontal Stabilizer Lift SlingOHME180T0100PBR Forward 48 Section Sling and Strongback 3ME140T0140PBR Vertical Fin Torque Multiplier and Adapter 2MIT100T3480PBR Aft 48 Section Lift Sling and At- tach Fittings ME148T0600PBR Horizontal Stabilizer Floor StandME180T0000PBR Aft 48 Section Stand2ME148T0600PBR Forward 48 Section Attach Fit- tings ME148T0200PBR Forward 48 Section Stand2ME148T0200PBR BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 38 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 39 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are given in 767-200 or 767-300 SRM, Chapter 51 – Torque limits to tighten nuts and bolts are given in 767-200 or 767-300 SRM, Chapter 51 5. Use the approved fastener and process material substitutions in accordance with 767-200 or 767-300 SRM, Chapter 51 and Boeing Drawing 012W6100. Alternate fasteners are also listed in 767-200 or 767-300 SRM Chapter 51 and Boeing Drawing 012W6100. Note that the substitution of BACR15BB( ) rivets as substitutes for BACR15FT( ) rivets is not acceptable at certain locations that require repeated surface High Frequency Eddy Current (HFEC) inspections, due to reduced crack detectability around the BACR15BB( ) rivet's larger manufactured head. Contact Boeing if substitutes for the specified BACR15FT( ) rivets are necessary. 6. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements. 7. If the length of any fastener specified in this service bulletin does not meet the installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. 8. Boeing recommends that the work that follows be done with the airplane indoors. If the airplane is not indoors, the work instructions that follow are not complete. Additional instructions will be necessary to prevent damage to the airplane and injury to personnel. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 39 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 40 9. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "as given in" or "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 10. These work instructions refer to procedures included in other Boeing documents. When the words "is shown in" are included in the instructions, the procedure in the Boeing document is similar, but must be adjusted to compensate for differences. 11. 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. B. WORK INSTRUCTIONS PART 1 - BULKHEAD INSPECTIONS PRIOR TO REPLACEMENT 1. At the time given in Paragraph 1.E., Compliance, start to do inspections of the aft pressure bulkhead as given in Figure 18. NOTE: 1. If there are any existing repairs in the inspection areas, continue to inspect the repaired areas as given in the repair instructions provided with the applicable repair. If inspection instructions were not provided with the repair instructions, contact Boeing for special inspection instructions. 2. As an alternative to inspection, replace the aft pressure bulkhead as given in PART 2, PART 3, and PART 4. 2. If cracks are found, repair as given in 767-200 SRM 53-80-08, 767-300 SRM 53-80-08, 767-300BCF SRM 53-80-08, ask Boeing for repair data, or replace the aft pressure bulkhead as given in PART 2, PART 3, and PART 4. 3. Put the airplane back to a serviceable condition. Do the inspections in PART 1 again at the time given in Paragraph 1.E., Compliance. Replace the aft pressure bulkhead as given in PART 2, PART 3, and PART 4 at the time given in Paragraph 1.E., Compliance. PART 2 - BULKHEAD PREPARATION 1. Prepare the new aft pressure bulkhead assembly as given in Figure 1. 2. Group 2: Do additional preparation of the new aft pressure bulkhead assembly as given in Figure 2. 3. Continue to PART 3. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 40 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 41 PART 3 - BULKHEAD REPLACEMENT 1. Supply airplane electrical power. Refer to 767 AMM 24-22-00 as an accepted procedure. 2. Pressurize the center hydraulic system. Refer to 767 AMM 29-11-00 as an accepted procedure. 3. Use the STAB TRIM levers or switches to move the horizontal stabilizer to the neutral position (2 units of trim on the position indicator). 4. Remove the pressure from the center, right, and left hydraulic systems. Refer to 767 AMM 29-11-00 as an accepted procedure. 5. Set the C, R, and L STAB TRIM switches on the P10 Panel to the CUTOUT position and attach DO-NOT-OPERATE tags. 6. On the P61 right side panel, put these switches in the OFF position and attach DO-NOT-OPERATE tags: S2 RIGHT TAIL HYD SHUT OFF VALVE SWITCH S4 CENTER TAIL HYD SHUT OFF VALVE SWITCH S6 LEFT TAIL HYD SHUT OFF VALVE SWITCH 7. Open the following circuit breakers and attach DO-NOT-CLOSE tags: a. On the P11 Overhead Circuit Breaker Panel: (1) For the APU Fuel System: 11B36, APU START 11D34, FUEL DC PUMP PWR 11D35, FUEL DC PUMP CONT 11M25, FUEL PUMPS L FWD R AFT (2) For the horizontal stabilizer ballscrew and pivot pins: 11A36, ALT STAB TRIM (if installed) 11C12, STAB TRIM SHUTOFF L 11C13, STAB TRIM SHUTOFF CENTER 11H17, FLT CONT SHUTOFF TAIL LEFT 11H18, FLT CONT SHUTOFF TAIL CENTER 11H27, FLT CONT SHUTOFF TAIL RIGHT 11D29, ENG HYD PUMP L SUPPLY BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 41 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 42 11D30, ENG HYD. PUMP R SUPPLY 11L25, HYD ELEC PUMP L 11L16, HYD ELEC PUMP R 11L15, ELEC HYD PUMP C 111L18, HYD SYS C PRESS 11D31, AIR HYD PUMP b. On the P6 Main Power Distribution Panel: 6E3, APU FUEL VALVES 8. Remove airplane electrical power. Refer to 767 AMM 24-22-00 as an accepted procedure. 9. Support and jack the airplane indoors as follows: a. Install nose and main landing gear down locks. Refer to 767 AMM 32-00-20 as an accepted procedure. b. Deflate the nose gear and pump oil into the nose gear. Simultaneously deflate both main gears and pump oil into the main gears. When the oil flow is free of nitrogen bubbles close the valves. Pump additional oil into both the nose and main landing gear oleos to achieve one inch of chrome showing. Refer to 767 AMM 12-15-01 and 767 AMM 12-15-02 as accepted procedures. c. Partially support the airplane with nose and main landing gear/axial jacks at all five axle jack points. Refer to 767 AMM 07-11-03 as an accepted procedure. Apply a a 10,000 - 12,000 pound load at each axial jack location. Install wheel chocks and chains at each main landing gear. NOTE: Parking brake can remain set. d. Mechanically lock all five axle jacks. 10. Disassemble and remove (or shift forward) equipment from the aft part of the passenger compartment for access to the Aft Pressure Bulkhead joint at STA 1582. This includes: a. Passenger seats. Refer to 767 AMM 25-25-01 as an accepted procedure. b. Partitions. Refer to 767 AMM 25-25-04 as an accepted procedure. c. Aft Galley Complex A1, A4, or A1-A3. Refer to 767 AMM 25-31-04 as an accepted procedure. d. Lavatories. Refer to 767 AMM 25-41-04 as an accepted procedure. e. Sidewall Panels. Refer to 767 AMM 25-21-01 as an accepted procedure. f. Ceiling panels. Refer to 767 AMM 25-22-01, 767 AMM 25-22-02, and/or 767 AMM 25-22-10 as accepted procedures. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 42 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 43 g. Sidewall and Ceiling Insulation. Refer to 767 AMM 25-21-05 as an accepted procedure. h. Doorway/Galley Floor Covering. Refer to 767 AMM 25-27-02 as an accepted procedure. i. Floor Panels. Refer to 767 AMM 53-01-01 as an accepted procedure. 11. Disassemble and remove (or shift forward) equipment from the aft end of the bulk cargo compartment for access to the Aft Pressure Bulkhead joint at STA 1582. This includes: a. Bulk Cargo Compartment Aft Lining. Refer to 767 AMM 25-52-01 as an accepted procedure. b. Bulk Cargo Compartment Sidewall Lining, for access to the pitot-static tubes on the left side from the aft pressure bulkhead to the bulk cargo door aft frame at STA 1461. Refer to 767 AMM 25-52-01 as an accepted procedure. c. Potable Water Tanks. Refer to 767 AMM 38-11-01 as an accepted procedure. d. Vacuum Lavatory Waste Tanks. Refer to 767 AMM 38-32-11 as an accepted procedure. e. Sidewall Insulation, which includes insulation blankets and capstrips from the sidewall, ceiling, and aft pressure bulkhead. Refer to 767 AMM 25-52-03 as an accepted procedure. NOTE: Boeing Service Bulletin 767-25A0300, "Equipment/Furnishings - Insulation - Aft Bulkhead to Floor Insulation Blankets Modification", which is mandated by FAA AD 2003-13-03, requires replacement of aft pressure bulkhead insulation blankets. 12. Disconnect the elevator (E1A/E1B/E2A/E2B), stabilizer trim (ST1A/ST1B/ ST2A/ST2B) and rudder (RA/RB) control cables. Refer to 767 AMM 20-10-03 as an accepted procedure. a. Install cable clamps. b. Disconnect the cables at any turnbuckle aft of the aft pressure bulkhead. c. Remove and salvage any air seals where the cable penetrates the aft pressure bulkhead. d. Move and coil the cable ends forward and aft of the aft pressure bulkhead. 13. Remove and salvage the control cable air seals and fasteners for the elevator (E1A/E1B/E2A/E2B), stabilizer trim (ST1A/ST1B/ ST2A/ST2B) and rudder (RA/RB) control cables. Refer to 767 AMM 20-10-04 as an accepted procedure. The salvaged air seals will be installed on the new aft pressure bulkhead assembly when the control cables are reinstalled. 14. Disconnect and remove auxiliary pitot tubes and seals as given in Figure 3. 15. Disconnect and remove auxiliary static system tubes (if installed) and hydraulic lines as follows. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 43 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 44 a. Group 3: Disconnect the auxiliary static system (AS1 and AS2) tubes at the junctions between STA 1605.5 and STA 1629, between stringers S-31L and S-32L. Cap the open ends of all tubes. Refer to 767 AMM 20-10-09 as an accepted procedure. b. Disconnect and cap the hydraulic lines at or near STA 1809. c. Disconnect and cap the hydraulic lines forward of the aft pressure bulkhead. d. Remove and discard the pressure seals at the aft pressure bulkhead as given in Figure 4. e. Remove hydraulic lines between the aft pressure bulkhead and STA 1809. f. Group 3: Move the auxiliary static system (AS1 and AS2) tubes forward of STA 1582. 16. Disconnect the electrical connectors from the altitude pressure switches. Refer to 767 AMM 38-32-51 as an accepted procedure. 17. Disconnect electrical systems, including: a. Lights b. APU Power c. High Frequency Communications d. Stall Warning Systems e. Interphone f. Autopilot g. Yaw Damper h. Rudder Trim Actuator i. Rudder Ratio Changer j. Rudder and Elevator Shutoff Valves k. Rudder Position Indicator l. Stabilizer Trim Control System m. Flap/Stabilizer Position Module n. Flight Recorder Systems o. APU Fire Detection System 18. Disassemble and remove and keep all seal components where wires penetrate the aft pressure bulkhead. Move all loose wires forward or aft, as necessary. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 44 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 45 19. Disconnect and remove the APU Air Supply Duct. Refer to 767 AMM 36-11-01 as an accepted procedure. 20. Disconnect the APU fuel line at the aft pressure bulkhead as follows: a. In the aft end of the bulk cargo compartment, disconnect the shroud and APU fuel line at the aft pressure bulkhead fitting. Salvage all bolts, nuts, and washers. Refer to the task "Remove the APU Fuel Line and Shroud Between the Center Compartment of the Auxiliary Fuel Tank and the Pressure Bulkhead for the Aft Cargo Compartment" in 767 AMM 28-25-05 as an accepted procedure. b. Remove the APU fuel line between the aft pressure bulkhead the the APU firewall. Refer to the task "Remove the APU Fuel Line and Shroud Between the Pressure Bulkhead for the Aft Cargo Compartment and the APU Firewall Bulkhead" in 767 AMM 28-25-05 as an accepted procedure. c. Remove and keep the APU fuel line bulkhead fitting as given in Figure 5. d. Install the APU fuel line bulkhead fitting on the new aft pressure bulkhead as given in Figure 6. 21. Remove the Dorsal Fin. Refer to 767 AMM 53-66-02 as an accepted procedure. CAUTION: SLOWLY LIFT AND REMOVE LARGE STRUCTURAL COMPONENTS TO PREVENT DAMAGE TO THE AIRPLANE OR TO PERSONS. 22. Remove the Vertical Fin. A vertical fin removal procedure is shown in 767 ARD 2-60-2. (This procedure has similarities that can be used as a guideline): a. Install internal scaffolding PME148T0010PBR inside Section 48. b. Attach vertical fin lift fittings ME100T3480PBR to the vertical fin. c. Attach vertical fin lift sling 2OHME100T3480PBR to the vertical fin and apply 1,000 pounds upward prelift tension to the sling. d. Disconnect the fin-to-body link at the leading edge of the fin. Remove the 16 tension bolts and 156 lock bolts that attach the vertical fin to the aft body. Use torque tool 2MIT100T3480PBR as necessary when removing the tension bolts. Lift the vertical fin off the body. A vertical fin removal procedure is shown in 767 ARD 2-60-2 for airplane recovery purposes. e. Without a rotating fixture, the vertical fin must be stored in an upright position. Use fin stand ME170T0100PBR or create a tool to act as a base to support the vertical fin by attaching to the four corner tension bolt locations. The vertical fin should be stored indoors. NOTE: All H-11 hardware should have been replaced at fin to body joint per Boeing Service Bulletin 767-53A0085 and FAA AD 2003-10-11 by July 1, 2006. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 45 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 46 CAUTION: THE TRAP LOCKING DEVICES MUST BE REMOVED FROM THE HORIZONTAL STABILIZER PIVOTS ON BOTH THE LEFT AND RIGHT SIDES TO DO THE PIN ROTATION CHECK. 23. Support the horizontal stabilizer with 767 SRM Horizontal Stabilizer supplementary supports as given in 767-200 SRM 51-50-02, 767-200SF SRM 51-50-02, 767-300 SRM 51-50-02, or 767-300BCF SRM 51-50-02 Detail IV on the left and right sides. Load four jacks approximately uniform until the horizontal stabilizer pivot fittings begin to move vertically relative to the airplane Section 48 structure (refer to 767 AMM 55-17-51) and check that the outer pin can be rotated freely. NOTE: The sum of all four jack loads should not exceed 5,000 pounds. 24. Remove the horizontal stabilizer seal fairings. Refer to 767 AMM 53-80-70 as an accepted procedure. CAUTION: INSUFFICIENT OR EXCESSIVE LIFT FORCE CAN RESULT IN STRUCTURAL DAMAGE AND A SAFETY HAZARD. 25. Support the tail cone between STA 1809 and STA 1952 with lift fittings and sling ME148T0600PBR. The APU will remain in place. Remove the fasteners that attach the tail cone to the STA 1809 bulkhead as given in Figure 7. Remove and store the tail cone on stand 2ME148T0600PBR. 26. Attach horizontal stabilizer lift fittings ME182T0000PBR and lift sling OHME180T0100PBR to the horizontal stabilizer and make the sling cable assembly tight. 27. Disconnect the stabilizer trim ballscrew from the horizontal stabilizer center section. Refer to 767 AMM 27-41-10 as an accepted procedure. 28. Do not remove the horizontal stabilizer pivot pins. Make sure the horizontal stabilizer sling cable assembly is still tight. With the horizontal stabilizer vertically balanced as described in Steps 23 and 26, complete the disassembly of the STA 1809.5 bulkhead as given in Figure 8 to allow the horizontal stabilizer to be removed. The left and right STA 1809.5 center bulkhead assemblies will remain attached to the horizontal stabilizer at the pivot pins. CAUTION: THE LEFT AND RIGHT STA 1809.5 BULKHEAD OUTER CHORDS WILL NO LONGER BE CONNECTED TO THE SURROUNDING STRUCTURE AFTER COMPLETION OF THE FASTENER REMOVALS GIVEN IN FIGURES 7 AND 8. TO PREVENT DAMAGE TO THE OUTER CHORDS, USE CARE TO REMOVE THE OUTER CHORDS WHILE THE HORIZONTAL STABILIZER (WITH THE STA 1809.5 CENTER BULKHEAD ASSEMBLIES ATTACHED) ARE REMOVED. 29. Use the horizontal stabilizer lift sling to vertically lift the horizontal stabilizer a small amount to unload the 767 SRM Horizontal Stabilizer supplementary supports, then remove the supplementary supports. Remove the left and right STA 1809.5 bulkhead outer chords, which are trapped between the STA 1809.5 center bulkhead assemblies and the forward part of section 48 that remains. Move the horizontal stabilizer aft until it is clear of the STA 1809.5 bulkhead. Set the horizontal stabilizer down on a storage fixture similar to ME180T0000PBR. 30. Make and install temporary STA 1809.5 bulkhead stabilizing tools as given in Figure 19. CAUTION: INSUFFICIENT OR EXCESSIVE LIFT FORCE CAN RESULT IN STRUCTURAL DAMAGE AND A SAFETY HAZARD. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 46 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 47 LEAVING THE PME148T0010PBR INTERNAL SCAFFOLDING INSIDE THE FORWARD PART OF SECTION 48 DURING THE OVERHEAD REMOVAL PROCESS RESULTS IN A FORWARD SHIFT IN THE CENTER OF GRAVITY OF THE FORWARD PART OF SECTION 48 THAT MAY CAUSE SEPARATION DIFFICULTIES. 31. Support the forward part of Section 48 (STA 1582 to STA 1809) with lift fittings and sling 3ME140T0140PBR and handling fittings ME148T0200PBR. Remove fasteners, clips, and fittings as given in Figure 9. Detach the STA 1582 floor beam as given in Figure 21. Remove the forward part of Section 48 (the aft pressure bulkhead will remain attached to the forward part of Section 48 at this time). Remove and store the forward part of Section 48 (which includes the aft pressure bulkhead) on stand 2ME148T0200PBR. WARNING: UNTIL THE STA 1582 FLOOR BEAM TEMPORARY SUPPORTS ARE INSTALLED, DO NOT PLACE EXCESSIVE WEIGHT ON THE MAIN DECK FLOOR STRUCTURE AFT OF STA 1562. THE MAIN DECK FLOOR AFT OF STA 1562 IS NOT SUPPORTED. DO THIS TO PREVENT INJURY TO PERSONNEL AND DAMAGE TO THE FLOOR STRUCTURE. WARNING: INSTALL APPROPRIATE SAFETY BARRICADES OR SIMILAR TO BLOCK THE END OF THE MAIN DECK FLOOR AFT OF STA 1582. DO THIS TO PREVENT INJURY TO PERSONNEL. 32. Install temporary supports for the STA 1582 floor beam as given in Figure 22. Prior to installation of the supports, make sure that the floor grid is level, and not deflected down or up. 33. Attach removal strongback ME148T2610PBR and lifting fixture OHME148T2610PBR to the existing aft pressure bulkhead in the forward part of Section 48. Remove the rivets that attach the aft pressure bulkhead to the Section 48 pressure ring as given in Figure 10. Remove the old aft pressure bulkhead from the forward part of Section 48. NOTE: Some rivets will need to be removed just prior to installation of the strongback due to the rivet location being hidden under the strongback attach location. 34. Attach lifting fixture OHME148T2610PBR to installation strongback 2ME148T2610PBR (this strongback is shipped already attached to the new aft pressure bulkhead) and lift the new bulkhead into position in the forward part of Section 48. Install fasteners to attach the new aft pressure bulkhead to the Section 48 (STA 1582) pressure ring as given in Figure 11. Remove the aft pressure bulkhead lifting fixture. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 47 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 48 WARNING: WITH THE STA 1582 FLOOR BEAM TEMPORARY SUPPORTS REMOVED, DO NOT PLACE EXCESSIVE WEIGHT ON THE MAIN DECK FLOOR STRUCTURE AFT OF STA 1562. THE MAIN DECK FLOOR AFT OF STA 1562 IS NOT SUPPORTED. DO THIS TO PREVENT INJURY TO PERSONNEL AND DAMAGE TO THE FLOOR STRUCTURE. CAUTION: JUST PRIOR TO FINAL POSITIONING OF THE FORWARD PART OF SECTION 48, REMOVE THE STA 1582 FLOOR BEAM TEMPORARY SUPPORTS. DO THIS TO PREVENT DAMAGE TO THE NEW AFT PRESSURE BULKHEAD FROM THE FLOOR BEAM SUPPORT FASTENERS. 35. Lift the forward part of Section 48 (STA 1582 to STA 1809, including the new aft pressure bulkhead) into position from the storage stand with lift fittings and sling 3ME140T0140PBR and handling fittings ME148T0200PBR. Install fasteners as given in Figure 12 to attach the new aft pressure bulkhead and the forward part of Section 48 to Section 46 at STA 1582. Attach the STA 1582 floor beam as given in Figure 23. Remove the sling, handling fittings, and lift fittings. 36. Remove the temporary STA 1809.5 bulkhead stabilizing tools as given in Figure 20. 37. Lift the horizontal stabilizer (with the left and right STA 1809.5 center bulkheads attached at the hinge pins) from the storage fixture and move it near its final position using the lift sling and lift fittings. Before moving the horizontal stabilizer into its final position, position the previously removed left and right STA 1809.5 bulkhead outer chords between the forward part of Section 48 and the STA 1809.5 center bulkhead assemblies. The final position is set by alignment of the left and right center bulkhead fastener patterns. 38. Support the horizontal stabilizer with 767 SRM Horizontal Stabilizer supplementary supports as given in 767-200 SRM 51-50-02, 767-200SF SRM 51-50-02, 767-300 SRM 51-50-02, or 767-300BCF SRM 51-50-02 Detail IV on the left and right sides. Load four jacks uniformly until the supports have taken the load off the horizontal stabilizer lift sling. Do not yet remove the horizontal stabilizer lift sling or lift fittings. NOTE: The sum of all four jack loads should not exceed 5,000 pounds. 39. Attach the left and right STA 1809.5 center bulkheads as given in Figure 13 and Figure 14. Use care to prevent excessive loading of the stabilizer hinge joints. 40. Connect the stabilizer trim ballscrew to the horizontal stabilizer center section. Refer to 767 AMM 27-41-10 as an accepted procedure. 41. Remove the horizontal stabilizer lift sling and lift fittings. Reinstall the production fasteners at the lift fitting attach points. 42. Lift the tail cone into position with the sling and lift fittings. Install the fasteners as given in Figure 15, to attach the tail cone to the STA 1809 bulkhead. Remove the sling and lift fittings. NOTE: Accomplishment of Part 3 Step 38 (horizontal stabilizer support), Step 39 (align and attach STA 1809.5 center bulkheads), Step 40 (stabilizer trim ballscrew attachment), Step 41 (removal of lift sling and fittings), and Step 42 (attach tail cone) should return the horizontal stabilizer to the position initially given in Step 23. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 48 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 49 43. The horizontal stabilizer is now supported by suitable means, with trap lock devices removed. Check that the right and left horizontal stabilizer pivot pins can be rotated freely with an applied torque of 400 in-lb or less. If necessary, remove and reinstall both the left and right pivot pins. Refer to 767 AMM 55-17-51 as an accepted procedure. 44. Install the horizontal stabilizer seal fairings. Refer to 767 AMM 53-80-70 as an accepted procedure. 45. Install the Vertical Fin. Refer to Boeing Drawing 100T3480 and the vertical fin removal procedure that is shown in 767 ARD 2-60-2 for guidance. The vertical fin installation procedure is described in General Note 2 on Sheet PSDL of Drawing 100T3480. a. If not already installed, install internal scaffolding PME148T0010PBR inside Section 48. b. Lift the vertical fin off the storage fixture into position using the vertical fin lift fittings and lift sling. c. Install the 16 tension bolts and 156 lock bolts that attach the vertical fin to the aft body. Use torque tool 2MIT100T3480PBR and alignment pins MIT100T3480PBR. NOTE: 1. All H-11 hardware should have been replaced at fin to body joint per Boeing Service Bulletin 767-53A0085 and FAA AD 2003-10-11 by July 1, 2006. 2. Reusing BACB30US*K* tension bolts and BACN11B* barrel nuts is acceptable. Excess sealant should be removed from parts (in a manner that does not damage the parts), and a detailed inspection of the parts should be done to ensure that there is no damage. Ensure that the self-locking feature of BACN11B* barrel nuts is operable. d. Connect the fin-to-body link at the leading edge of the fin. e. Remove the internal scaffolding PME148T0010PBR from inside Section 48. f. Remove the vertical fin lift fittings and sling. 46. Finish all bare aluminum with chemical film treatment and two coats of BMS 10-11, Type I primer. Apply corrosion inhibiting compound to both the forward and aft sides of the aft pressure bulkhead. Refer to 767 AMM 51-24-09 as an accepted procedure. 47. Install the Dorsal Fin. Refer to 767 AMM 53-66-02 as an accepted procedure. 48. Install the APU fuel line between the aft pressure bulkhead the the APU firewall. Refer to the task "Install the APU Fuel Line and Shroud Between the Pressure Bulkhead for the Aft Cargo Compartment and the APU Firewall Bulkhead" in 767 AMM 28-25-05 as an accepted procedure. 49. In the aft end of the bulk cargo compartment, attach the APU fuel line and shroud to the aft pressure bulkhead fitting. Refer to the task "Install the APU Fuel Line and Shroud Between the Center Compartment of the Auxiliary Fuel Tank and the Pressure Bulkhead for the Aft Cargo Compartment" in 767 AMM 28-25-05 as an accepted procedure. 50. Install the APU Air Supply Duct. Refer to 767 AMM 36-11-01 as an accepted procedure. 51. Connect electrical systems, including: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 49 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 50 a. Lights b. APU Power c. High Frequency Communications d. Stall Warning Systems e. Interphone f. Autopilot g. Yaw Damper h. Rudder Trim Actuator i. Rudder Ratio Changer j. Rudder and Elevator Shutoff Valves k. Rudder Position Indicator l. Stabilizer Trim Control System m. Flap/Stabilizer Position Module n. Flight Recorder Systems o. APU Fire Detection System 52. Install salvaged pressure seals where wires penetrate the aft pressure bulkhead. 53. Connect the electrical connectors for the altitude pressure switches. Refer to 767 AMM 38-32-51 as an accepted procedure. 54. Install the hydraulic lines that were removed earlier that pass through the aft pressure bulkhead. 55. Group 3: Install the auxiliary static system tubes that were removed earlier that pass through the aft pressure bulkhead. 56. Install pressure seals at the aft pressure bulkhead as given in Figure 16. 57. Install auxiliary pitot tubes and seals as given in Figure 17. 58. Reconnect the stabilizer trim (ST1A/ST1B/ ST2A/ST2B), elevator (E1A/E1B/E2A/E2B), and rudder (RA/RB) control cables. Refer to 767 AMM 20-10-03 as an accepted procedure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 50 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 51 a. Connect the cable ends (coiled forward and aft of the aft pressure bulkhead) through the aft pressure bulkhead at the appropriate turnbuckle. b. Install new or salvaged air seals and fasteners where cables penetrate the aft pressure bulkhead. Refer to 767 AMM 20-10-04 as an accepted procedure. c. Remove cable clamps. 59. Adjust the Stabilizer Trim System. Refer to 767 AMM 27-41-00 as an accepted procedure. 60. Adjust the Elevator System. Refer to 767 AMM 27-31-00 as an accepted procedure. 61. Adjust the Rudder System. Refer to 767 AMM 27-21-00 as an accepted procedure. 62. Install equipment in the aft end of the bulk cargo compartment that was removed for access. This includes: a. Potable Water Tanks. Refer to 767 AMM 38-11-01 as an accepted procedure. b. Vacuum Lavatory Waste Tanks. Refer to 767 AMM 38-32-11 as an accepted procedure. c. Sidewall Insulation. Refer to 767 AMM 25-52-03 as an accepted procedure. d. Bulk Cargo Compartment Aft Lining. Refer to 767 AMM 25-52-01 as an accepted procedure. e. Bulk Cargo Compartment Sidewall Lining, for access to the pitot-static tubes on the left side from the aft pressure bulkhead to the bulk cargo door aft frame at STA 1461. Refer to 767 AMM 25-52-01 as an accepted procedure. 63. Install equipment in the aft part of the passenger compartment that was removed for access. This includes: a. Floor Panels. Refer tor 767 AMM 53-01-01 as an accepted procedure. b. Doorway/Galley Floor Covering. Refer to 767 AMM 25-27-02 as an accepted procedure. c. Sidewall and Ceiling Insulation. Refer to 767 AMM 25-21-05 as an accepted procedure. d. Ceiling panels. Refer to 767 AMM 25-22-01, 767 AMM 25-22-02, and/or 767 AMM 25-22-10 as accepted procedures. e. Sidewall Panels. Refer to 767 AMM 25-21-01 as an accepted procedure. f. Aft Galley Complex A1, A4, or A1-A3. Refer to 767 AMM 25-31-04 as an accepted procedure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 51 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 52 g. Lavatories. Refer to 767 AMM 25-41-04 as an accepted procedure. h. Partitions. Refer to 767 AMM 25-25-04 as an accepted procedure. i. Passenger seats. Refer to 767 AMM 25-25-01 as an accepted procedure. 64. Dejack the airplane. Service the nose and main landing gears and put them in serviceable condition. 65. Do the systems tests given in PART 4. PART 4- SYSTEMS TESTS 1. Bleed the hydraulic system. Refer to 767 AMM 29-11-00 as an accepted procedure. Do a leak check of the hydraulic lines that were removed and reinstalled. Refer to 767 AMM 20-10-09 as an accepted procedure. 2. Do a leak test of the new pitot-static tubes. Refer to 767 AMM 34-11-01 as an accepted procedure. 3. Do a test of the Autopilot. Refer to the task "AFDS Operational Test" in 767 AMM 22-10-00 as an accepted procedure. 4. Do a test of the Yaw Damper System. Refer to the task "Operational Test - Yam Damper System" in 767 AMM 22-21-00 an accepted procedure. 5. Test the left and right High Frequency Communications Systems. Refer to the task "Operational Test - HF Communication System" in 767 AMM 23-11-00 as an accepted procedure. 6. Do a test of the Interphone system. Refer to the task "Operational Test - Service Interphone System" in 767 AMM 23-41-00 as an accepted procedure. 7. Do a test of the Stick Nudger. Refer to steps 2.A., 2.B., 2.C., 2.D., 2.G., and 2.H. in the task "Operational Test - Stall Warning System" in 767 AMM 27-32-00 as an accepted procedure. 8. Test the Horizontal Stabilizer Trim Control System. Refer to the task "Operational Test" in 767 AMM 27-41-00 as an accepted procedure. 9. Test the Stabilizer Trim System. Refer to the "Manual-Mechanical Stabilizer Trim Control Operational Test", the "Lever Force Test" and the "Horizontal Stabilizer Trim Control System Operational Test" in 767 AMM 27-41-00 as an accepted procedure. 10. Test the Elevator System. Refer to the task "System Test - Elevator Controls" in 767 AMM 27-31-00 as an accepted procedure. It is acceptable to not perform the "Elevator Position Indication Test", the "Elevator Power Control Actuators Test", the "Elevator Feel System Test", the "Stick Nudger Test", and the "Elevator Autopilot Servo Rods Test" tasks within the Systems Test. 11. Do an operational test of the Elevator Control System. Refer to the task "Operational Test - Elevator Control System" in 767 AMM 27-31-00 as an accepted procedure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 52 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 53 12. Test the Rudder System. Refer to the task "System Test - Rudder and Rudder Trim Control" in 767 AMM 27-21-00. It is acceptable to not perform the "Test Rudder Pedal Adjustment Mechanism Travel", the "Test Captain's Rudder Pedal Travel", the "Test First Officer's Pedal Travel", the "Test Single Hydraulic System and PCA", the "Test Rudder Ratio-Changer System", the "Test Rudder Ration Flight Deck Annunciation", the "Test the Left RRCM", the "Test the Right RRCM", and the "Rudder Trim Authority and Rate Test" tasks within the System Test. 13. Test the Rudder Trim Actuator. Refer to the task "Rudder Trim Actuator - Test" in 767 AMM 27-21-11 as an accepted procedure. 14. Test the Rudder Ratio Changer. Refer to the task "Rudder Ratio Changer Mechanism - Test" in 767 AMM 27-21-13 as an accepted procedure. 15. Test the Rudder and Elevator Shutoff Valves. Refer to the task "Rudder and Elevator Shutoff Valves - System Test" in 767 AMM 27-23-00 as an accepted procedure. 16. Test the Rudder Position Indicator. Refer to the task "Rudder Position Indication - Operational Test" in 767 AMM 27-28-00 as an accepted procedure. 17. Test the Position Indicating System. Refer to the task "Operational Test - Position Indicating System" in 767 AMM 27-48-00 as an accepted procedure. 18. Test the Flap/Stabilizer Position Module. Refer to the task "Test for the FSPM" in 767 AMM 27-58-01 as an accepted procedure. 19. Test the Takeoff Configuration Warning Card Module. Refer to steps 4.A., 4.B., 4.C., 4.I., and 4.J. in the task "Warning Electronics Unit (WEU) Card Module Test" in 767 AMM 31-51-04 as an accepted procedure. 20. Test the Flight Data Recorder. Refer to the task "Flight Data Recorder Operational Test" in 767 AMM 31-31-00 as an accepted procedure. 21. Test the service lights. Refer to the task "Service Lights - Operational Test" in 767 AMM 33-31-00 as an accepted procedure. 22. Test the logo lights. Refer to the task "Logo Lights - Operational Test" in 767 AMM 33-45-00 as an accepted procedure. 23. Test the altitude pressure switches. Refer to 767 AMM 38-32-51 as an accepted procedure. 24. Test the APU wiring as given in Appendix A. 25. Do a cabin pressure leakage test. Refer to 767 AMM 05-51-24 as an accepted procedure. 26. Put the airplane back to a serviceable condition. At the time given in Paragraph 1.E., Compliance, start to do after-replacement inspections of the new aft pressure bulkhead. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 53 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 54 (OCR) BOEING SERVICE BULLETIN 767-53A0139 ALERT ALERT VIEW IN THE FORWARD DIRECTION FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 1 OF 5) Original Issue: November 12, 2009 BOEING PROPRIETARY - 767-53A0139 Copyright © Unpublished Work - See page 1 for details. 54 of 180 ### Page 55 (OCR) BOEING SERVICE BULLETIN 767-53A0139 ALERT ALERT 2 3 21 LOCATIONS 3.78 2 3) SEAL BLOCK 2.42 4(6) 18 LOCATIONS 2.47 SEAL BLOCK (4) PRESSURE BULKHEAD ASSEMBLY FWD 1664002 FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 2 OF 5) Original Issue: November 12, 2009 767-53A0139 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 180 ### Page 56 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each new aft pressure bulkhead. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP -4-FastenerRemove1 1.19 - 1.21 inch di- ameter, normal to the bulkhead sur- face. 125 microinch or better surface fin- ish. 4-HoleDrill / Ream Break sharp edges and apply chemical film treatment and two coats of BMS 10-11, Type I primer to the bare edges of the holes. --FinishApply --148T2629-2SEAL BLOCK ASSYLocate2 -21-Rivet HoleDrill / Ream FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 3 OF 5) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 56 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 57 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Apply a pressure faying surface seal to the entire mating surface of the seal block assembly. -BMS 5-95SealantApply3 -1148T2629-2SEAL BLOCK ASSYInstall (New) -21BACR15FT5D7CRIVET, UNIVERSAL HD Install (New) -4-FastenerRemove4 --140T0345-3SEAL BLOCK ASSYLocate -22-Rivet HoleDrill / Ream Apply a pressure faying surface seal to the entire mating surface of the seal block assembly. -BMS 5-95SealantApply5 -1140T0345-3SEAL BLOCK ASSYInstall (New) -18BACR15FT5D7CRIVET, UNIVERSAL HD Install (New)6 -4BACR15FT5D7CRIVET, UNIVERSAL HD Install (New)7 Optional, if oversize rivets are necessary. 4BACR15FT6D8CRIVET, UNIVERSAL HD Install (New) Apply a pressure faying surface seal to the entire mating surface of the cover plate and pressure pan. -BMS 5-95SealantApply8 -1140T0345-1COVER PLATEInstall (New) -14BACS12HN3-7BOLTInstall (New)9 Under screw head.14NAS1149D0332JWASHERInstall (New) Under nut.14NAS1149D0332JWASHERInstall (New) -14BACN11AG3NUT, SELF-LOCKInstall (New) Fillet seal all screw heads, nuts, and washers. -BMS 5-95SealantApply10 The parts shown in the table below are provided as extra parts for this figure. FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 4 OF 5) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 57 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 58 MORE DATAQTYIDENTIFICATIONNAME 8BACB30NM4K14BOLT, HEX HEAD -1BACN11AG3NUT, SELF-LOCK -7BACR15FT5D7CRIVET, UNIVERSAL HD -1BACR15FT6D8CRIVET, UNIVERSAL HD 8BACR15FT6KE7CRIVET -1BACS12HN3-7BOLT -2NAS1149D0332JWASHER 5NAS1149D0363JWASHER, FLAT 1NAS42DD3-44FCSPACERS FOR RIV- ETS 1NAS42DD3-48FCSPACERS FOR RIV- ETS 1NAS42DD3-64FCSPACERS FOR RIV- ETS FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 5 OF 5) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 58 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT ### Page 59 (OCR) BOEING SERVICE BULLETIN 767-53A0139 ALERT ALERT This Figure applies only to: Group 2. VIEW IN THE FORWARD DIRECTION 1664714 FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 1 OF 2) Original Issue: November 12, 2009 Copyright © Unpublished Work - See page 1 for details. BOEING PROPRIETARY - 767-53A0139 59 of 180 ### Page 60 The step numbers shown below agree with the numbers shown in the circle symbols in the figure.. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP 0.530 - 0.539 inch diameter, normal to the doubler. 125 mi- croinch or better surface finish. 1-HoleDrill / Ream1 Break sharp edges and apply chemical film treatment and two coats of BMS 10-11, Type I primer to the bare edges of the holes. --FinishApply FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 12, 2009 767-53A0139 60 of 180 BOEING SERVICE BULLETIN 767-53A0139 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/767-53a0139/file/7a7c33bc05d7.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.