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Commercial Airplanes 767 Service Bulletin Number: 767-57A0094 Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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BLANK PAGE Original Issue: June 02, 2005 Revision 2: December 17, 2009 767-57A0094 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 141 BOEING SERVICE BULLETIN 767-57A0094

BLANK PAGE

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Table of Contents Original Issue: June 02, 2005 Revision 2: December 17, 2009 767-57A0094 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 141 BOEING SERVICE BULLETIN 767-57A0094

Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 33

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 33 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 33

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 36

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 39

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 1 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 2 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 FIGURE 3: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 3 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 FIGURE 4: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 4 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 FIGURE 5: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 1 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 FIGURE 6: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 2

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Table of Contents Original Issue: June 02, 2005 Revision 2: December 17, 2009 767-57A0094 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 141 BOEING SERVICE BULLETIN 767-57A0094

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 FIGURE 7: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 FIGURE 8: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 FIGURE 9: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 FIGURE 10: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 135

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Commercial Airplanes 767 Service Bulletin Number: 767-57A0094 Revision Transmittal Sheet Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2001-14-19, is related to this service bulletin.

No more work is necessary on airplanes changed in accordance with the original issue or revision 1 of this service bulletin.

REASON FOR REVISION This revision is sent to add the option for operators to make their own drain tubes and add some optional materials to the service bulletin. A cross reference table is added to the special tooling section to show the equivalent part numbers for operators who want to order special tools from the Boeing Parts Page. This revision also adds a female 3/8 inch square drive socket as an alternative to the wrench. In addition to these changes, the term "as given in" is changed to "Refer to, as an accepted procedure" to comply with the latest SB standards on non-FAA approved manuals. Figure references are also updated to say "in accordance with" instead of "as given in" to comply with latest SB standards.

The changes to this service bulletin are as follows:

— Summary - Compliance - Information related to the future release of Airworthiness Directive related to this service bulletin is updated.

— Paragraph 1.E., Compliance - Information related to the future release of Airworthiness Directive related to this service bulletin is updated.

— Paragraph 1.F., Approval - FAA Approval statement updated.

— Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added.

— Paragraph 1.B., Concurrent Requirements - Second last sentence deleted from the paragraph for Group 3 Instructions.

— Paragraph 2.A., Material - Price and Availability - Pricing information updated.

— Paragraph 2.C.1., Kits/Parts - New footnote (d) is added to 015T1772-2 drain tube in top kit table to give operators the option to make the drain tube.

— Paragraph 2.C.2., Parts and Materials Supplied by the Operator - BMS 3-33 is added as an option to BMS

3-24. Also the name for "MIL-C-5541 Class 1A (Alodine 600)" changed to "Alodine 600 (Alodine 1600/1660 Optional)" — Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Footnote (b) is added to show optional automotive engine oils to SAE No 10.

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— Paragraph 2.E., Special Tooling - Price and Availability - Special tooling cross-reference chart added to show the required special tooling part numbers to use when ordering from Boeing Part Page.

— Paragraph 3.A., General Information, Step 10 - Last sentence deleted from the paragraph for Group 3 airplanes.

— Figure 9 and Figure 10, Sheet 2, View A - Tolerance added to the 0.30 dimensions.

— Figure 9 and Figure 10, Step 7 - "MIL-C-5541, Class 1A" changed to "Alodine 600 (Alodine 1600/1660 Optional)".

— Figure 9 and Figure 10, Note (e) - Note updated by adding "0.30".

— Figure 11 thru Figure 18, Step 3 and 5 - BMS 3-33 is added as an optional to BMS 3-24.

— Figure 11 thru Figure 18, Step 22 - "MIL-C-5541, Class 1A" changed to "Alodine 600 (Alodine 1600/1660 Optional)".

— Figure 18, Step 22 changed to step 21 which was previously a typo.

— Appendix A, Sheet 4 - A 3/8 inch square drive socket is added to the illustration.

— Appendix A, Sheet 5 - Wrench P/N is changed from ST877W-77A-5 to ST2580-77A-5 in the special tooling table and footnote (e) is added to give tool compatibility information.

— Appendix A, Step 11 - A note is added to show optional automotive engine oils to SAE No 10.

— Appendix A, Step 15 - A female 3/8 inch square drive socket is added as an alternative to the wrench.

— Appendix A, Step 16 - A female 3/8 inch square drive socket is added as an alternative to the wrench.

The data given in Information Notice 767-57A0094 IN-01, IN-02 and IN-03 is included in this revision Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY Original Issue: June 02, 2005 Revision 1: December 19, 2006 Revision 2: December 17, 2009

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Commercial Airplanes 767 Service Bulletin Number: 767-57A0094 Summary Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement

CONCURRENT REQUIREMENTS Group 1-2: You cannot make the changes in accordance with this service bulletin unless the changes in accordance with Part III - Terminating Action of either Boeing service bulletin 767-57A0060 Revision 1, dated December 31, 1998, or 767-57A0060 Revision 2, dated January 31, 2002, are made. Part III - Terminating Action of either Boeing service bulletin 767-57A0060 Revision 1 or 767-57A0060 Revision 2, provides instructions to install new number 5 and number 8 slat track housing drain tube assemblies, to prevent possible fuel leakage near an engine or exhaust nozzle, when the airplane is on the ground.

Group 2: You cannot make the changes in accordance with this service bulletin unless the changes in accordance with Part IV - Additional Work of either Boeing service bulletin 767-57A0060 Revision 1, dated December 31, 1998, or 767-57A0060 Revision 2, dated January 31, 2002, are made. Part IV - Additional Work installs an additional electrostatic bond path for the number 5 and 8 inboard slat track drain tube assemblies.

Group 3: You cannot make the changes in accordance with this service bulletin unless the changes in accordance with Boeing service bulletin 767-57-0068 Revision 1, dated May 09, 2002, are made. Service bulletin 767-57-0068 Revision 1, dated May 09, 2002, gives instructions to make a better electrostatic bond for the number 5 and number 8 slat track housing drain tube assemblies.

Group 4: These airplanes are not affected by either Boeing service bulletin 767-57A0060 or 767-57-0068.

Refer to service bulletin Paragraph 1.B., Concurrent Requirements, for more information.

BACKGROUND Accomplishment of this service bulletin prevents cracks in the number 5 and number 8 slat track housing drain tubes. Cracks in these drain tubes could let fuel drain from the main fuel tanks into the dry bay area of the wings.

Fuel from the dry bay areas could subsequently drain on to hot Main Landing Gear (MLG) brakes and possibly result in a fire.

One operator told Boeing of a fuel leak on to the MLG as a result of a cracked drain tube at the number 8 slat track housing, no fire was reported. The crack was in a drain tube on a 767 airplane that had incorporated a rerouted drain tube with a flexible part, in accordance with Boeing service bulletin 767-57A0060. An investigation by Boeing found that the drain tube with a flexible part had cracked as a result of a high intensity engine vibration, which was more than the design of the tube permitted.

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Boeing was told of a second occurrence of a cracked drain tube at the number 8 slat track housing. The crack in the flexible part of the drain tube was found after an airplane had a high intensity engine vibration. During flight, an airplane had vibration from the number 2 engine (Pratt & Whitney PW4000) as a result of a second stage turbine blade failure. The engine was subsequently shut-down and the airplane was diverted. After the airplane had landed fuel leakage was seen from the pylon area by maintenance personnel.

This problem affects airplane line numbers 1 thru 921. Airplanes after line number 921 have a production design change which installs the new drain tube without a flexible part.

This service bulletin gives instructions to replace a drain tube assembly which has a flexible part with a new aluminum drain tube without a flexible part, at the number 5 and number 8 slat track housing. Boeing tests have shown that the new aluminum drain tubes are stronger and more resistant to damage during high intensity engine vibrations.

Boeing Service Related Problem (SRP) 767-SRP-57-0160 is related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane VR084 after the initial release of this service bulletin. The change completed on airplane VR084 is equivalent to the change given in Revision 1 of this service bulletin. Airplane VR084 has the configuration of a Group 4 airplane.

ACTION (PRR B12901-53S) Defuel the left and right wing main tanks. Open the applicable left and right wing main tank access panels to get access to the number 5 and number 8 slat track housing drain tubes. Remove the existing drain tube assemblies that have a flexible part. Prepare and install new aluminum drain tubes without a flexible part at the two locations. Close the left and right wing main tank fuel bay access panels. Refuel the left and right wing main tanks. Inspect the left and right wing main tank dry bay to make sure there is no fuel leakage from the new drain tube installations. Close the left and right wing main tank dry bay access panels.

EFFECTIVITY 767-200/300/300F Airplanes. Refer to service bulletin Paragraph 1.A.1 for effectivity.

COMPLIANCE Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date of this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2001-14-19 is related to this service bulletin.

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.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

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MANPOWER

MATERIAL INFORMATION Boeing Supplied Kits.

Refer to Paragraph 2.A., Material - Price and Availability.

Airplanes Total Task Hours Elapsed Hours Group 1 and Group 2 45 22 Group 3 and Group 4 43 20

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FWD INBD UP WITHOUT A FLEXIBLE PART.

AN ALUMINUM DRAIN TUBE

SLAT TRACK HOUSING, WITH NUMBER 5 AND NUMBER 8

FLEXIBLE PART AT THE

ASSEMBLY THAT HAS A

REPLACE THE DRAIN TUBE (NUMBER 8 SLAT TRACK HOUSING OPPOSITE) TYPICAL NUMBER 5 SLAT TRACK HOUSING SHOWN RIB NO. 9 LOWER SKIN

HOUSING

SLAT TRACK

FRONT SPAR A ASEE 383964

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-53S for data about this change.

GROUP CONFIGURATION DESCRIPTION 1 - 767-200/300/300F airplanes, Line Numbers 1 thru 671, that have a drain tube with a flexible part installed at the no.5 and no.8 slat track housing. Two doublers are installed at rib no.9 and there is a 3 jumper electrostatic bond configuration.

2 - 767-200 airplane, Variable Number VE066, that has a drain tube with a flexible part installed at the no.5 and no.8 slat track housing. One doubler is installed at rib no.9 and there is a 3 jumper electrostatic bond configuration.

3 - 767-300/300F airplanes, Line Numbers 672 thru 757, that have a drain tube with a flexible part installed at the no.5 and no.8 slat track housing.

One doubler is installed at rib no.9 and there is a 2 jumper electrostatic bond configuration.

4 - 767-200/300/300F airplanes, Line Numbers 759 thru 921, that have a drain tube with a flexible part installed at the no.5 and no.8 slat track housing. Two doublers are installed at rib no.9 and there is 2 jumper electrostatic bond configuration.

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Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AA 767 LLC (SVX) 1 VE067

ABX AIR (ABX) 1 VA301 VA303–VA306 VA309–VA315 VA508 VA803 VA807–VA809 VB101–VB123 VB125 VB302 VE064

AEROFLOT (ARO) 1 VL896–VL897 VN471–VN472 3 VS216 4 VS217 VS321–VS324 VS392

AEROMEXICO (AMX) 1 VF071 VF093 VF162 VN166 VN531 3 VS211

AEROSVIT (UKA) 1 VN154–VN155 VN157 3 VS206

AEROTURBINE (AUB) 1 VB051 VB054–VB055 VB321 VB331–VB332

AIR ALGERIE (ALG) 1 VK131–VK133

AIR ASTANA (AKZ) 1 VL899–VL900

AIR CANADA (ACN) 1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202 VN051–VN054 VN056–VN062 VN541 VN546–VN547 VN751–VN752 VN811–VN812 VN931–VN936 4 VS381–VS382 VS546–VS549

AIR CHINA (BEJ) 1 VE085–VE086 VK161–VK164 4 VS208 VS274

AIR DO (HIA) 3 VS176–VS177

AIR EUROPA (ARE) 4 VS292–VS293

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