# Boeing Alert Service Bulletin 767-53A0263: No revision named

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- Document: [Boeing Alert Service Bulletin 767-53A0263](https://openairdocs.org/service-documents/boeing/767-53a0263.md)
- Title as filed: U.S. DOT/FAA - SB-767-53A0263-00
- Pages: 30
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## Text

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### Page 1

Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0263
Original Issue: January 12, 2015
ATA System: 5300
SUBJECT: FUSELAGE - Section 43 - Inspection of Skin and Splice Fittings at Stringer 29, Body
Station 786 Ring Chord
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 © 2015 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Unpublished Work.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
Boeing liveries 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.
Original Issue: January 12, 2015
767-53A0263
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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 6
E. Compliance .............................................. 1 6
F. Approval ............................................... 1 7
G. Manpower .............................................. 1 7
H. Weight and Balance Changes .................................... 1 8
I. Electrical Load Data ......................................... 1 8
J. References .............................................. 1 8
1. Existing Data: ......................................... 1 8
2. Data Supplied with this Service Bulletin: ........................... 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8
K. Publications Affected ........................................ 1 8
L. Interchangeability and Intermixability of Parts ........................... 1 9
M. Software Accomplishment Summary ................................ 1 9
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 5
FIGURE 1: LEFT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE
FITTINGS ............................................ 2 7
FIGURE 2: RIGHT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER
SPLICE FITTINGS ....................................... 2 9
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Commercial 
Airplanes
767
Service Bulletin
ALERT
SummaryNumber: 767-53A0263Original Issue: January 12, 2015
ATA System: 5300
SUBJECT: FUSELAGE - Section 43 - Inspection of Skin and Splice Fittings at Stringer 29, Body
Station 786 Ring Chord
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
While replacing a cracked underwing longeron fitting per service bulletin 767-57A0126, a crack indication was
found in the STA 786 ring chord at the tension bolt hole common to the wing front spar lower chord and the
internal bathtub fittings. There were two similar reports of these findings from two separate operators. The
airplanes in these reports had 14,367 and 18,354 flight cycles and had 90,389 and 96,826 flight hours, respectively.
The current Maintenance Planning Document (MPD) inspections are not sufficient to detect any possible fuselage
skin crack in the area adjacent to the ring chord at STA 786 before the crack extends to a critical length. The
fuselage skin in this area is hidden between the splice fittings on the external side of the fuselage and the bathtub
fittings on the internal side. This service bulletin specifies an external ultrasonic inspection of the skin hidden
by the upper and lower splice fittings on both sides of the fuselage to detect any fatigue crack in the fuselage
skin. It also specifies an external detailed inspection of the splice fittings and the adjacent visible fuselage skin
and structure for any crack, corrosion or other damage. If the service bulletin action is not accomplished, then
cracks in the fuselage skin in this hidden area could go undetected, potentially leading to a loss of a primary
load path between the fuselage and the wing box. The loss of the primary load path could adversely affect the
structural integrity of the airplane.
To date, there have been no reports of any fuselage skin cracks in the area that is inspected by this service
bulletin.
Boeing Service Related Problem (SRP) 767-53-0461 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 767 FTD 53-14001 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
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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
Paragraph 1.K., Publications AffectedNoPublications 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
Remove the wing-to-body access panels on the left and right sides of the airplane to open access to the splice
fittings on the fuselage adjacent and forward of the STA 786 ring chord. Do an initial external ultrasonic and
detailed inspection of the area on both sides of the fuselage. Do repeat inspections if no damage is found. If
damage is found, contact Boeing to get instructions for the repair for this service bulletin and do the work
instructed by Boeing, before further flight. Do the inspections in accordance with paragraph 1.E., Compliance.
EFFECTIVITY
767-200/-300/-300F/-400ER 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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER
Elapsed HoursTotal Task HoursAirplanes
4.608.60All Airplanes
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BOEING SERVICE BULLETIN 767-53A0263
ALERT  ALERT
MATERIAL INFORMATION
None.
UPPER SPLICE
FITTING
S-29
• LOWER SPLICE
FITTING
INBD
DO AN INITIAL ULTRASONIC AND DETAILED INSPECTION OF
THE FUSELAGE SKIN AT THE SPLICE FITTINGS. DO A REPEAT
INSPECTION IF NO DAMAGE IS FOUND. IF DAMAGE IS FOUND,
DO THE REPAIR BEFORE FURTHER FLIGHT.  2365367
Original Issue: January 12, 2015
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Commercial 
Airplanes
767
Service Bulletin
ALERT
Number: 767-53A0263
Original Issue: January 12, 2015
ATA System: 5300
SUBJECT: FUSELAGE - Section 43 - Inspection of Skin and Splice Fittings at Stringer 29, Body
Station 786 Ring Chord
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 applicable to all 767-200/-300/-300F/-400ER airplanes, line numbers 1-9999
in one (1) Group. The Variable Numbers and Group Information for the applicable airplanes is
given below.
Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and
Serial Number data.
NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1093.
Affected airplanes after Line Number 1093 will be added to the service bulletin's
MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet
Profile Page.
DESCRIPTIONCONFIGURATIONGROUP
All 767 Airplanes, line numbers 1-9999-1
Airplane Models:
767-200, 767-300, 767-300F, 767-400ER
GroupVariable Number
1VA001 - VA020
1VA301 - VA315
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GroupVariable Number
1VA501 - VA530
1VA701 - VA719
1VA801 - VA810
1VB001 - VB002
1VB051 - VB055
1VB101 - VB125
1VB201 - VB202
1VB251 - VB253
1VB281 - VB284
1VB301 - VB302
1VB321 - VB332
1VB371 - VB373
1VB401
1VB441 - VB444
1VE001 - VE003
1VE021 - VE023
1VE041 - VE043
1VE061 - VE069
1VE083 - VE086
1VE101 - VE104
1VE116 - VE118
1VE121 - VE126
1VE141 - VE152
1VE171 - VE172
1VF001 - VF002
1VF041 - VF042
1VF051
1VF061 - VF062
1VF071 - VF072
1VF091 - VF093
1VF101 - VF102
1VF161 - VF162
1VF171 - VF172
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GroupVariable Number
1VF180 - VF184
1VF251
1VK001 - VK016
1VK021 - VK022
1VK031 - VK056
1VK081 - VK113
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
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GroupVariable Number
1VN231 - VN234
1VN241 - VN243
1VN251 - VN276
1VN291 - VN293
1VN301 - VN314
1VN371 - VN372
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
1VQ001 - VQ021
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GroupVariable Number
1VQ071 - VQ086
1VQ111
1VR051 - VR060
1VR081
1VR084
1VR086 - VR089
1VR106 - VR109
1VR201 - VR211
1VR251
1VR256 - VR260
1VR266 - VR292
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
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GroupVariable Number
1VS261 - VS263
1VS266 - VS274
1VS291 - VS293
1VS301 - VS303
1VS306 - VS311
1VS316
1VS321 - VS324
1VS331 - VS333
1VS336 - VS337
1VS366 - VS367
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
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GroupVariable Number
1VS951 - VS954
1VS961 - VS969
1VS971 - VS977
1VS981 - VS984
1VT001 - VT013
1VT021
1VT031 - VT033
1VT501
1VT511 - VT513
1VT521 - VT523
1VT531 - VT533
1VT541 - VT546
1VT551 - VT552
1VT556 - VT581
1VV001
1VW701 - VW721
1VW851
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
While replacing a cracked underwing longeron fitting per service bulletin 767-57A0126, a crack indication
was found in the STA 786 ring chord at the tension bolt hole common to the wing front spar lower chord
and the internal bathtub fittings. There were two similar reports of these findings from two separate
operators. The airplanes in these reports had 14,367 and 18,354 flight cycles and had 90,389 and
96,826 flight hours, respectively. The current Maintenance Planning Document (MPD) inspections are
not sufficient to detect any possible fuselage skin crack in the area adjacent to the ring chord at STA
786 before the crack extends to a critical length. The fuselage skin in this area is hidden between the
splice fittings on the external side of the fuselage and the bathtub fittings on the internal side. This
service bulletin specifies an external ultrasonic inspection of the skin hidden by the upper and lower
splice fittings on both sides of the fuselage to detect any fatigue crack in the fuselage skin. It also
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specifies an external detailed inspection of the splice fittings and the adjacent visible fuselage skin and
structure for any crack, corrosion or other damage. If the service bulletin action is not accomplished,
then cracks in the fuselage skin in this hidden area could go undetected, potentially leading to a loss
of a primary load path between the fuselage and the wing box. The loss of the primary load path could
adversely affect the structural integrity of the airplane.
To date, there have been no reports of any fuselage skin cracks in the area that is inspected by this
service bulletin.
Boeing Service Related Problem (SRP) 767-53-0461 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 767 FTD 53-14001 is related to this service bulletin.
D. Description
Remove the wing-to-body access panels on the left and right sides of the airplane to open access to
the splice fittings on the fuselage adjacent and forward of the STA 786 ring chord. Do an initial external
ultrasonic and detailed inspection of the area on both sides of the fuselage. Do repeat inspections if
no damage is found. If damage is found, contact Boeing to get instructions for the repair for this service
bulletin and do the work instructed by Boeing, before further flight. Do the inspections in accordance
with paragraph 1.E., Compliance.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
193, 194767-200, 767-300, 767-300F,
767-400ER
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.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
Table 1: Inspection For Damage At The Splice Fitting Locations
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3000
flight cycles or
24 months, after
the original is-
sue date of this
service bulletin
(whichever oc-
curs first)
Before 37,500
total flight cycles
or 87,500 total
flight hours
(whichever oc-
curs first)
Do PART 1: EXTERNAL
ULTRASONIC AND DE-
TAILED INSPECTION AT
THE SPLICE FITTINGS
All airplanes
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Table 1: Inspection For Damage At The Splice Fitting Locations
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
6,000 flight cycles
or 18,000 flight
hours(whichever
occurs first)
--Repeat PART 1: EXTER-
NAL ULTRASONIC AND
DETAILED INSPECTION
AT THE SPLICE FIT-
TINGS
CONDITION 1: No crack,
corrosion or other damage
found
--Before further
flight
Contact Boeing to get in-
structions for the repair
for this service bulletin
and do the work instruct-
ed by Boeing.
CONDITION 2: Any crack,
corrosion or other damage
found
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
G. Manpower
The table below shows an estimate of the task hours necessary to do this 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
0.300.301Open Access
Inspect
2.004.002...Left - FIGURE 1
2.004.002...Right - FIGURE 2
0.300.301Close Access
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Elapsed HoursTask HoursNumber of PersonsTask
4.608.60TOTAL FOR EACH AIRPLANE
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) 767-53-0461
c. Service Bulletin Index D624T001
d. Standard Overhaul Practices Manual (SOPM) 20-50-01
e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19
f. 767 Aircraft Maintenance Manual (AMM) 53-52-01
g. 767 Fleet Team Digest (FTD) 53-14001
h. 767 Non-Destructive Testing (NDT) Manual [Part 4, 53-30-02]
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
MONOCOQUE INTEGRATION - SECTION 43 TO 45140T0120
INTEGRATION INSTL - FWD OF FRONT SPAR FAIRING140T0720
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:
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None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. 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 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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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. The work instructions are divided into work packages. Task Hours and Elapsed Hours
for each package are given in Paragraph 1.G., Manpower. You can do each work
package independently.
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 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
Aircraft 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
Aircraft Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
5. Use the approved fastener, process and material substitutions in accordance with
SRM Chapter 51.
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, as accepted procedures.
7. The necessary conditions for selection of clamp type and size are included in SWPM
20-10-12. If any wire bundle support clamp specified in this service bulletin does not
make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted
procedure to select a clamp that fits correctly.
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8. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate
full threaded fasteners (screws) needed for installation in this service bulletin.
9. 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.
10. A General Visual Inspection is defined as: A visual examination of an interior or
exterior area, installation or assembly to detect obvious damage, failure or irregularity.
This level of inspection is made from within touching distance unless otherwise
specified. A mirror may be necessary to enhance visual access to all exposed surfaces
in the inspection area. This level of inspection is made under normally available
lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may
require removal or opening of access panels or doors. Stands, ladders or platforms
may be required to gain proximity to the area being checked.
11. 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.
12. 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.
13. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
14. 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.
15. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
16. If shading is used, shaded areas in Figures are to separate the non-critical and
non-authoritative information from the critical and authoritative information.
17. Use of colors in Figures is based on guidance from the ATA e-Business Program
(ATA) iSpec 2200.
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18. 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.
19. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
20. The CONDITIONS, ACTIONS and OPTIONS shown apply to each area on the
fuselage (left and right sides) where the splice fittings are located independently.
21. 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 the PART 1: EXTERNAL ULTRASONIC AND DETAILED INSPECTION AT THE SPLICE
FITTINGS within the compliance time in Paragraph 1.E., Compliance.
a. CONDITION 1: NO CRACK, CORROSION, OR OTHER DAMAGE FOUND
(1) Repeat PART 1: EXTERNAL ULTRASONIC AND DETAILED INSPECTION AT THE
SPLICE FITTINGS within the compliance time in Paragraph 1.E., Compliance.
b. CONDITION 2: ANY CRACK, CORROSION, OR OTHER DAMAGE FOUND
(1) Contact Boeing to get instructions for the repair for this service bulletin and do the work
instructed by Boeing, before further flight.
PART 1: EXTERNAL ULTRASONIC AND DETAILED INSPECTION AT THE SPLICE FITTINGS
1. Remove the wing-to-body access panel to open access to the splice fittings. Refer to 767 AMM
53-52-01 as an accepted procedure.
RightLeft
194CR193CL
2. RC - Do an external ultrasonic and detailed inspection at the upper and lower splice fittings area
adjacent to the ring chord in accordance with the figures below:
RightLeft
FIGURE 2FIGURE 1
3. Install the wing-to-body access panel to close access to the splice fittings. Refer to 767 AMM
53-52-01 as an accepted procedure.
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RightLeft
194CR193CL
4. Return the airplane to a serviceable condition.
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BOEING SERVICE BULLETIN 767-53A0263
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UPPER SPLICE 12  STA  UNDERWING
FITTING  786  LONGERON
FITTING
ASSEMBLIES
SKIN (
S-29
6.20
6.00
(TYPICAL)
LOWER SPLICE U2
FITTING
INSPECTION
AREA  INBD
FIGURE 1: LEFT SIDE OF FUSELAGE - EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE
FITTINGS
(SHEET 1 OF 2)
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### Page 28

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
Do an ultrasonic in-
spection of the skin
hidden by the upper
and lower splice fit-
tings for any
crack.(a) (c)
--Splice FittingsInspect1
Do a detailed inspec-
tion of the upper and
lower splice fittings
for any crack, corro-
sion, or other dam-
age, including dis-
placed fasteners.(b)
(c)
--Splice FittingsInspect2
Do a detailed inspec-
tion of the skin sur-
face for any crack,
corrosion, or other
damage, including
displaced fasten-
ers.(b) (c)
--SkinInspect3
(a) Do the inspection in accordance with 767 NDT Manual [Part 4, 53-30-02].
(b) It is only necessary to do the detailed inspection of the exposed skin and exposed surfaces of splice fittings
not covered by permanently attached structure. The fitting assemblies that are depicted on the illustration
exist only on some airplanes and are shown as examples of structure that does not need to be removed.
(c) It is not necessary to remove any fasteners to do the inspection.
FIGURE 1: LEFT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE
FITTINGS
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN 767-53A0263
ALERT  ALERT
UNDERWING  SIA  12 FITTING  UPPER SPLICE
LONGERON  786  3 SKIN
FITTING
• ASSEMBLY
BRACKET
•ASSEMBLY
- S-29
6.20
6.00
(TYPICAL)
INSPECTION  INBD  2365366
AREA
FIGURE 2: RIGHT SIDE OF FUSELAGE - EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE
FITTINGS
(SHEET 1 OF 2)
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### Page 30

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure
More DataQtyIdentificationNameTaskStep
Do an ultrasonic in-
spection of the skin
hidden by the upper
and lower splice fit-
tings for any
crack.(a) (c)
--Splice FittingsInspect1
Do a detailed inspec-
tion of the upper and
lower splice fittings
for any crack, corro-
sion, or other dam-
age, including dis-
placed fasteners.(b)
(c)
--Splice FittingsInspect2
Do a detailed inspec-
tion of the skin sur-
face for any crack,
corrosion, or other
damage, including
displaced fasten-
ers.(b) (c)
--SkinInspect3
(a) Do the inspection in accordance with 767 NDT Manual [Part 4, 53-30-02].
(b) It is only necessary to do the detailed inspection of the exposed skin and exposed surfaces of splice fittings
not covered by permanently attached structure. The fitting and bracket assemblies that are depicted on
the illustration exist only on some airplanes and are shown as examples of structure that does not need
to be removed.
(c) It is not necessary to remove any fasteners to do the inspection.
FIGURE 2: RIGHT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE
FITTINGS
(SHEET 2 OF 2)
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