# Boeing Alert Service Bulletin 767-53A0260: No revision named

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- Document: [Boeing Alert Service Bulletin 767-53A0260](https://openairdocs.org/service-documents/boeing/767-53a0260.md)
- Title as filed: U.S. DOT/FAA - SB-767-53A0260 R0
- Pages: 30
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## Text

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### Page 1

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0260
Original Issue: August 26, 2014
ATA System: 5315
SUBJECT: FUSELAGE - Section 41 - S-2R Skin Lap Splice, STA 368 TO STA 434 - Inspection
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 300-774). 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 © 2014 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and
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connection with this document unless provided in writing by Boeing.
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4.0

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Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
2. Spares Affected ........................................ 1 5
B. Concurrent Requirements ...................................... 1 5
C. Reason ................................................ 1 5
D. Description .............................................. 1 5
E. Compliance .............................................. 1 6
F. Approval ............................................... 1 8
G. Manpower .............................................. 1 9
H. Weight and Balance Changes .................................... 1 9
I. Electrical Load Data ......................................... 1 9
J. References .............................................. 1 9
1. Existing Data: ......................................... 1 9
2. Data Supplied with this Service Bulletin: ........................... 2 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 0
K. Publications Affected ........................................ 2 0
L. Interchangeability and Intermixability of Parts ........................... 2 0
M. Software Accomplishment Summary ................................ 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 ........................ 2 1
3. Parts Modified and Reidentified ................................ 2 1
4. Parts Removed and Not Replaced .............................. 2 1
D. Parts Necessary to Change Spares ................................. 2 1
E. Special Tooling - Price and Availability ............................... 2 1
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3
A. GENERAL INFORMATION ..................................... 2 3
B. WORK INSTRUCTIONS ....................................... 2 4
FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND
SURFACE HFEC INSPECTION ................................ 2 6
APPENDIX A: LOGIC DIAGRAM [Group 1] .................................. 2 9
APPENDIX B: LOGIC DIAGRAM [Group 2] .................................. 3 0
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Commercial 
Airplanes
767
Service Bulletin
ALERT
SummaryNumber: 767-53A0260Original Issue: August 26, 2014
ATA System: 5315
SUBJECT: FUSELAGE - Section 41 - S-2R Skin Lap Splice, STA 368 TO STA 434 - Inspection
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
The section 41, stringer S-2R skin lap splice from Body Station (STA) 368 to STA 434 has been determined to
be structure that is susceptible to Widespread Fatigue Damage (WFD). As a result of WFD analysis the S-2R
skin lap splice from STA 368 to STA 434 requires additional supplemental inspection beyond the inspections
given in 767 MPD. If fatigue cracking of the skin lap splice is not detected the cracking could grow which could
result in possible rapid decompression and loss of structural integrity.
This service bulletin gives inspection and repair instructions for cracking in the skin at S-2R skin lap splice from
Body Station (STA) 368 to STA 434.
The 767 MPD will be revised to give inspection requirements for 767-300 passenger airplanes after line number
1068.
Boeing Service Related Problem (SRP) 767-SRP-53-0449 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 767 FTD 53-13002 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
Paragraph 1.E., Compliance and Paragraph
1.F., Approval
YesAD Related
Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
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ReferenceAffectedPlanning Data
Paragraph 1.K., Publications AffectedYesPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsNoKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
NoOperator Supplied Parts/Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
Do an external detailed and surface High Frequency Eddy Current (HFEC) inspection of the outer skin for
cracking around fastener heads common to the inboard fastener row of the stringer S-2R skin lap splice from
Body Station (STA) 368 to STA 434. If any crack is found do an SRM repair.
EFFECTIVITY
767-200/-300/-400ER Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service
bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-18-10 is related to this service bulletin.
The effective date of AD 2003-18-10 is October 16, 2003.
This service bulletin affects SSI 53-10-I07A of MPD 622T001-9 Section 9, which is mandated by AD 2003-18-10.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service
bulletin.
MANPOWER
Elapsed HoursTotal Task HoursAirplanes
2.502.50All airplanes
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
None.
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BOEING SERVICE BULLETIN 767-53A0260
ALERT  ALERT
STA
434
BL O
STA
368
S-2R SKIN
LAP SPLICE
DO AN EXTERNAL DETAILED AND HFEC INSPECTION OF THE OUTER SKIN
FOR CRACKING AROUND FASTENER HEADS COMMON TO THE INBOARD
FASTENER ROW OF THE S-2R SKIN LAP SPLICE FROM STA 368 TO STA 434.
IF ANY CRACK IS FOUND, DO SRM REPAIR.
2312755
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### Page 9

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0260
Original Issue: August 26, 2014
ATA System: 5315
SUBJECT: FUSELAGE - Section 41 - S-2R Skin Lap Splice, STA 368 TO STA 434 - Inspection
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplane(s) shown below.
DESCRIPTIONCONFIGURATIONGROUP
767-200/-300 airplanes line number 1 - 1068-1
767-400ER airplanes line number 758 - 965-2
Airplane Models:
767-200, 767-300, 767-400ER
GroupVariable Number
1VA001 - VA020
1VA301 - VA315
1VA501 - VA530
1VA701 - VA719
1VA801 - VA810
1VB001 - VB002
1VB051 - VB055
1VB101 - VB125
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GroupVariable Number
1VB201 - VB202
1VB251 - VB253
1VB281 - VB284
1VB301 - VB302
1VB321 - VB332
1VB371 - VB373
1VB401
1VB441 - VB444
1VE001 - VE003
1VE021 - VE023
1VE041 - VE043
1VE061 - VE069
1VE083 - VE086
1VE101 - VE104
1VE116 - VE118
1VE121 - VE126
1VE141 - VE152
1VE171 - VE172
1VF001 - VF002
1VF041 - VF042
1VF051
1VF061 - VF062
1VF071 - VF072
1VF091 - VF093
1VF101 - VF102
1VF161 - VF162
1VF171 - VF172
1VF180 - VF184
1VF251
1VK001 - VK016
1VK021 - VK022
1VK031 - VK056
1VK081 - VK113
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GroupVariable Number
1VK131 - VK133
1VK141 - VK148
1VK161 - VK164
1VK171
1VK181
1VK186
1VL001 - VL006
1VL011
1VL701 - VL703
1VL751 - VL755
1VL806 - VL807
1VL871 - VL873
1VL891 - VL900
1VL911 - VL914
1VL931 - VL932
1VL941
1VN001 - VN041
1VN051 - VN064
1VN081 - VN099
1VN111 - VN127
1VN130 - VN137
1VN151 - VN158
1VN163 - VN168
1VN171 - VN174
1VN191 - VN198
1VN211 - VN212
1VN221 - VN225
1VN231 - VN234
1VN241 - VN243
1VN251 - VN276
1VN291 - VN293
1VN301 - VN314
1VN371 - VN372
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GroupVariable Number
1VN376
1VN381 - VN388
1VN421 - VN427
1VN436
1VN471 - VN472
1VN491 - VN513
1VN531 - VN532
1VN536 - VN537
1VN541 - VN542
1VN546 - VN547
1VN551
1VN556 - VN557
1VN561 - VN562
1VN631 - VN638
1VN651 - VN658
1VN671 - VN672
1VN676
1VN681 - VN691
1VN731 - VN732
1VN751 - VN753
1VN791 - VN792
1VN811 - VN813
1VN921 - VN922
1VN931 - VN936
1VN951 - VN953
1VN966 - VN972
2VQ001 - VQ021
2VQ071 - VQ086
2VQ111
1VR051 - VR060
1VR081
1VR084
1VR086 - VR089
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GroupVariable Number
1VR106 - VR109
1VR401
1VR421 - VR423
1VR426
1VR441
1VR461
1VR471 - VR472
1VS051 - VS056
1VS061
1VS066 - VS070
1VS073 - VS078
1VS091 - VS104
1VS111 - VS113
1VS131 - VS133
1VS136 - VS137
1VS176 - VS177
1VS186 - VS187
1VS196 - VS203
1VS206 - VS208
1VS211
1VS216 - VS217
1VS231
1VS246 - VS248
1VS261 - VS263
1VS266 - VS274
1VS291 - VS293
1VS301 - VS303
1VS306 - VS311
1VS316
1VS321 - VS324
1VS331 - VS333
1VS336 - VS337
1VS366 - VS367
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GroupVariable Number
1VS381 - VS382
1VS391 - VS392
1VS401
1VS426 - VS428
1VS466 - VS472
1VS486
1VS496 - VS497
1VS506 - VS507
1VS526
1VS546 - VS549
1VS701 - VS736
1VS751 - VS759
1VS821 - VS825
1VS841 - VS844
1VS861
1VS881 - VS883
1VS891
1VS896
1VS901 - VS912
1VS916
1VS921 - VS928
1VS931 - VS933
1VS941
1VS951 - VS954
1VS961 - VS969
1VS971 - VS977
1VS981 - VS984
1VT001 - VT013
1VT021
1VT031 - VT033
1VV001
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2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
The section 41, stringer S-2R skin lap splice from Body Station (STA) 368 to STA 434 has been
determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). As a result of
WFD analysis the S-2R skin lap splice from STA 368 to STA 434 requires additional supplemental
inspection beyond the inspections given in 767 MPD. If fatigue cracking of the skin lap splice is not
detected the cracking could grow which could result in possible rapid decompression and loss of
structural integrity.
This service bulletin gives inspection and repair instructions for cracking in the skin at S-2R skin lap
splice from Body Station (STA) 368 to STA 434.
The 767 MPD will be revised to give inspection requirements for airplanes after line number 1068.
Boeing Service Related Problem (SRP) 767-SRP-53-0449 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 767 FTD 53-13002 is related to this service bulletin.
D. Description
Do an external detailed and surface High Frequency Eddy Current (HFEC) inspection of the outer skin
for cracking around fastener heads common to the inboard fastener row of the stringer S-2R skin lap
splice from Body Station (STA) 368 to STA 434. If any crack is found do an SRM repair.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
224767-200, 767-300
Group 2:
Affected Maintenance Zones
ZoneModel
224767-400ER
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E. Compliance
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to
this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-18-10 is related to this service
bulletin. The effective date of AD 2003-18-10 is October 16, 2003.
This service bulletin affects SSI 53-10-I07A of MPD 622T001-9 Section 9, which is mandated by AD
2003-18-10. All other MPD inspections outside of the affected area, including SSI 53-10-I07B, are not
affected and must continue.
Boeing recommends that the inspection and repair given in this service bulletin be done in accordance
with Paragraph 1.E., Compliance, Table 1.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
Group 1:
Table 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 3,000
flight cycles af-
ter the original
issue date of
this service bul-
letin
Before 43,000
total flight cycles
Do PART 1: SECTION 41
- S-2R SKIN LAP
SPLICE, STA 368 TO
STA 434 - DETAILED IN-
SPECTION AND SUR-
FACE HFEC INSPEC-
TION (a)
All airplanes
9,000 flight cycles-Repeat PART 1: SEC-
TION 41 - S-2R SKIN
LAP SPLICE, STA 368
TO STA 434 - DETAILED
INSPECTION AND SUR-
FACE HFEC INSPEC-
TION (a)
CONDITION 1: NO
CRACK IS FOUND
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Group 1:
Table 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Before further flightCONDITION 2 (ACTION
1):
CONDITION 2: ANY
CRACK IS FOUND
Do PART 2: SECTION 41
- S-2R SKIN LAP
SPLICE, STA 368 TO
STA 434 - REPAIR
9,000 flight cycles-CONDITION 2 (ACTION
2):
Repeat PART 1: SEC-
TION 41 - S-2R SKIN
LAP SPLICE, STA 368
TO STA 434 - DETAILED
INSPECTION AND SUR-
FACE HFEC INSPEC-
TION (a)
(a) If any existing external repair is found in the inspection area, then Part 1 inspection is not required in the
area hidden by the repair, provided that the repair was previously approved by the FAA or by a Boeing
Authorized Representative or installed in accordance with 767 SRM 53-00-01 (as specified in PART 2).
Part 1 inspections remain applicable in areas not hidden by the repair.
Group 2:
Table 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3,000
flight cycles af-
ter the original
issue date of
this service bul-
letin
Before 40,000
total flight cycles
Do PART 1: SECTION 41
- S-2R SKIN LAP
SPLICE, STA 368 TO
STA 434 - DETAILED IN-
SPECTION (a)
All airplanes
9,000 flight cycles-Repeat PART 1: SEC-
TION 41 - S-2R SKIN
LAP SPLICE, STA 368
TO STA 434 - DETAILED
INSPECTION AND SUR-
FACE HFEC INSPEC-
TION (a)
CONDITIONS 1: NO
CRACK IS FOUND
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Group 2:
Table 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before further flightCONDITION 2 (ACTION
1):
CONDITIONS 2: ANY
CRACK IS FOUND
Do PART 2: SECTION 41
- S-2R SKIN LAP
SPLICE, STA 368 TO
STA 434 - REPAIR
9,000 flight cycles-CONDITION 2 (ACTION
2):
Repeat PART 1: SEC-
TION 41 - S-2R SKIN
LAP SPLICE, STA 368
TO STA 434 - DETAILED
INSPECTION AND SUR-
FACE HFEC INSPEC-
TION (a)
(a) If any existing external repair is found in the inspection area, then Part 1 inspection is not required in the
area hidden by the repair, provided that the repair was previously approved by the FAA or by a Boeing
Authorized Representative or installed in accordance with 767 SRM 53-00-01 (as specified in PART 2).
Part 1 inspections remain applicable in areas not hidden by the repair.
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.
In addition, the Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the
accomplishment of the inspections per this service bulletin (SB) along with the corresponding compliance
times specified in paragraph 1.E., "Compliance," of SB 767-53A0260, Original issue as an alternative
method of compliance (AMOC) to the inspections, defined in D622T001-DTR Structural Significant
Item 53-10-I07A and Section 9 of the Maintenance Planning Document D622T001-9, required by
paragraphs (c) and (d) of Airworthiness Directive (AD) 2003-18-10. This AMOC only applies to the
areas inspected in accordance with this service bulletin. When this SB specifies contacting Boeing for
repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph
(e) of the AD. All provisions of AD 2003-18-10 that are not specifically referenced in this paragraph
remain fully applicable and must be complied with accordingly.
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### Page 19

G. Manpower
The table below shows an estimate of the task hours necessary to do this inspection 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.
Elapsed HoursTask HoursNumber of PersonsTask
2.502.501FIGURE 1
(a)(a)(a)Repair
2.502.50TOTAL FOR EACH AIRPLANE (a)
(a) Manpower estimates for the repair are not included.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Boeing Service Letter 767-SL-51-036
b. Boeing Service Related Problem (SRP) 767-SRP-53-0449
c. 767 Fleet Team Digest (FTD) 53-13002
d. 767 Maintenance Planning Data (MPD)
e. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01
f. 767-200 Structural Repair Manual (SRM) 53-00-01
g. 767-200SF Structural Repair Manual (SRM) 53-00-01
h. 767-300 Structural Repair Manual (SRM) 53-00-01
i. 767-300BCF Structural Repair Manual (SRM) 53-00-01
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### Page 20

j. 767-400 Structural Repair Manual (SRM) 53-00-01
k. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-18-10
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
MONOCOQUE INTEGRATION - SECTION 41/43140T0110
SKIN SPLICE INTEGRATION INSTL - STRINGERS 2R, 26L AND
26R
141T0016
The table above lists applicable drawings used to prepare this service bulletin. The drawings are
not necessary to make the specified changes, and are not supplied with this service bulletin. The
drawings may not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
Chapter-SectionPublication
Section 9 (D622T001-9)767 Maintenance Planning Data
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. 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.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
None.
B. Industry Support Information
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this
service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts
None.
2. Parts and Materials Supplied by the Operator
None.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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### Page 23

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque Values:
— Values for structural fasteners are given in 767 Structural Repair Manual,
Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 767
Airplane Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of
Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 767
Airplane Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
4. 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.
5. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
6. Boeing Service Letter 767-SL-51-036, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
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### Page 24

7. Refer to Appendix A and Appendix B for logic diagram(s). Logic diagrams are provided
as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information in Paragraph 3.B., Work Instructions is the
primary source for tasks required for compliance.
8. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
9. If shading is used, shaded areas in Figures are to separate the non-critical and
non-authoritative information from the critical and authoritative information.
10. Use of colors in Figures is based on guidance from the ATA e-Business Program
(ATA) iSpec 2200.
11. When more than one OPTION is given for a CONDITION, do only one of the OPTION
numbers. When more than one ACTION is given for a CONDITION number or an
OPTION number, do all of the ACTION numbers for that CONDITION number or
OPTION number.
12. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
13. Some steps in the Work Instructions are identified as Required for Compliance (RC).
If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps
identified as RC must be done to comply with the AD. Alternative procedures for
steps not identified with RC can be used if the RC steps can still be done as specified,
and the airplane can be put back in a serviceable condition. An Alternative Method
of Compliance (AMOC) is not necessary for deviations to steps that are not identified
as RC.
B. WORK INSTRUCTIONS
1. Do PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED
INSPECTION AND SURFACE HFEC INSPECTION
CONDITION 1: NO CRACK IS FOUND
a. Repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED
INSPECTION AND SURFACE HFEC INSPECTION at the time given in Paragraph 1.E.,
Compliance.
NOTE: It is not necessary to repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA
368 TO STA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION
in areas that are covered by a repair that was previously approved by the FAA or by
a Boeing Authorized Representative or installed in accordance with 767 SRM 53-00-01
(as specified in PART 2).
CONDITION 2: ANY CRACK IS FOUND
a. CONDITION 2 (ACTION 1): Do PART 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368
TO STA 434 - REPAIR
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b. CONDITION 2 (ACTION 2): Repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA
368 TO STA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION at the time
given in Paragraph 1.E., Compliance.
NOTE: It is not necessary to repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA
368 TO STA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION
in areas that are covered by a repair that was previously approved by the FAA or by
a Boeing Authorized Representative or installed in accordance with 767 SRM 53-00-01
(as specified in PART 2).
PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION
AND SURFACE HFEC INSPECTION
1. RC - Do an external detailed and surface High Frequency Eddy Current (HFEC) inspection of the
outer skin for cracking around fastener heads common to the inboard fastener row of the stringer
S-2R skin lap splice from Body Station (STA) 368 to STA 434 in accordance with FIGURE 1.
2. Put airplane back to a serviceable condition.
PART 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - REPAIR
1. Repair cracking in accordance with 767-200 SRM 53-00-01, 767-200SF SRM 53-00-01, 767-300
SRM 53-00-01, 767-300BCF SRM 53-00-01, 767-400 SRM 53-00-01.
2. Put airplane back to a serviceable condition.
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### Page 26 (OCR)

BOEING SERVICE BULLETIN 767-53A0260
ALERT  ALERT
STA
434
STA
368  BL O
S-2R SKIN
LAP SPLICE
- A
2312743
FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND
SURFACE HFEC INSPECTION
(SHEET 1 OF 3)
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### Page 27 (OCR)

BOEING SERVICE BULLETIN 767-53A0260
ALERT  ALERT
S-2R
STA 368 -
(TYPICAL) 125-  OUTER  INNER
SKIN  SKIN
STA 434 -
TEDETAILED
JINSPECTION AREA
T SURFACE HFEC
INSPECTION AREA  NBD  2312758
TYPICAL
• REFERENCE FASTENER  A-A
FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND
SURFACE HFEC INSPECTION
(SHEET 2 OF 3)
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### Page 28

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataQtyIdentificationNameTaskStep
(a)--OUTER SKINInspect1
(b)--OUTER SKINInspect2
(a) Do an external detailed inspection for cracks.
(b) Do an external surface HFEC inspection of the outer skin for cracking around fastener heads common
to the inboard fastener row of the S-2R skin lap splice from STA 368 to STA 434 in accordance with 767
NDT Manual Part 6, 51-00-01 or 767 NDT Manual Part 6, 51-00-19.
FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND
SURFACE HFEC INSPECTION
(SHEET 3 OF 3)
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### Page 29 (OCR)

BOEING SERVICE BULLETIN 767-53A0260
ALERT  ALERT
This Appendix applies only to: Group 1.
BEFORE 43,000 TOTAL FLIGHT CYCLES, OR WITHIN 3,000 FLIGHT CYCLES AFTER THE
ORIGINAL ISSUE DATE OF THIS SERVICE BULLETIN, WHICHEVER OCCURS LATER.
DO PART 1:
SECTION 41-S-2R SKIN LAP
SPLICE, STA 368 TO STA 434 -
DETAILED INSPECTION AND
SURFACE HFEC INSPECTION.
CONDITION 1:  CONDITION 2:
VO CRACK IS FOUND.  ANY CRACK IS FOUND.
DO PART 2:
SECTION 41-S-2R SKIN LAP
SPLICE, STA 368 TO STA 434 -
REPAIR.
REPEAT PART 1:
SECTION 41-S-2R SKIN LAP SPLICE,
STA 368 TO STA 434 - DETAILED
INSPECTION AND SURFACE HFEC
INSPECTION. AT INTERVALS NOT
TO EXCEED 9,000 FLIGHT CYCLES.
2337142
APPENDIX A: LOGIC DIAGRAM
(SHEET 1 OF 1)
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### Page 30 (OCR)

BOEING SERVICE BULLETIN 767-53A0260
ALERT  ALERT
This Appendix applies only to: Group 2.
BEFORE 40,000 TOTAL FLIGHT CYCLES, OR WITHIN 3,000 FLIGHT CYCLES AFTER THE
ORIGINAL ISSUE DATE OF THIS SERVICE BULLETIN, WHICHEVER OCCURS LATER.
DO PART 1:
SECTION 41-S-2R SKIN LAP
SE PACE HE BRECHION
CONDITION 1:  CONDITION 2:
NO CRACK IS FOUND.  ANY CRACK IS FOUND.
DO PART 2:
SECTION 41-S-2R SKIN LAP
SPLICE, STA 368 TO STA 434 -
REPAIR.
REPEAT PART 1:
SECTION 41-S-2R SKIN LAP SPLICE,
STA 368 TO STA 434 - DETAILED
INSPECTION AND SURFACE HFEC
INSPECTION. AT INTERVALS NOT
TO EXCEED 9,000 FLIGHT CYCLES
2337122
APPENDIX B: LOGIC DIAGRAM
(SHEET 1 OF 1)
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