# Boeing Alert Service Bulletin 767-57A0095: Revision 2

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2010-0957; AD 2011-12-11 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 767-57A0095](https://openairdocs.org/service-documents/boeing/767-57a0095.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin (SB-767-57A0095-02)
- Pages: 60
- PDF: https://openairdocs.org/files/sha256/3a/50/3a50053256b4a3fdf837f51b5c26beca164ed18b818edf1a77a45a1039faa1f5
- Page: https://openairdocs.org/service-documents/boeing/767-57a0095/file/3a50053256b4

## Text

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### Page 1

Commercial 
Airplanes
767
Service Bulletin
Number: 767-57A0095
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
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 © 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Unpublished Work - All Rights Reserved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, 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
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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
1. PLANNING INFORMATION ........................................ 1 1
A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 1
B. Concurrent Requirements ...................................... 1 1
C. Reason ................................................ 1 2
D. Description .............................................. 1 4
E. Compliance .............................................. 1 4
F. Approval ............................................... 1 5
G. Manpower .............................................. 1 5
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 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6
K. Publications Affected ........................................ 1 6
L. Interchangeability and Intermixability of Parts ........................... 1 7
2. MATERIAL INFORMATION ........................................ 1 9
A. Material - Price and Availability ................................... 1 9
B. Industry Support Information .................................... 1 9
C. Parts Necessary For Each Airplane ................................. 1 9
1. Kits/Parts: ........................................... 1 9
2. Parts and Materials Supplied by the Operator: ........................ 2 0
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 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 6
FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE ..... 2 8
FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE ..... 3 2
FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE ....... 3 6
FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE ....... 4 0
FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL ......... 4 4
FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL ......... 4 9
Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS ...................... 5 4
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Commercial 
Airplanes
767
Service Bulletin
Revision Transmittal SheetNumber: 767-57A0095Original 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
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. The references to Federal Aviation
Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 are removed from the SB. In addition to these
changes, the term "as given in/as shown 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 shown in" to comply with latest SB standards.
The changes to this service bulletin are as follows:
– Summary - Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA
AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related to
this service bulletin is updated.
– Paragraph 1.E., Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive
FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related
to this service bulletin is updated.
– Paragraph 1.F., Approval - Alternative Method of Compliance (AMOC) approval paragraph removed.
– Paragraph 1.J.1., Existing Data - Reference to Federal Aviation Administration (FAA) Airworthiness Directive
FAA AD 2001-14-19 is removed.
– Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added.
– 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 - New footnotes (b) and (c) added.
– 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.
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– Figure 3 and Figure 4, Sheet 2, View A - Tolerance added to the 0.30 dimensions.
– Figure 3 and Figure 4, Step 7 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660
Optional)".
– Figure 3 and Figure 4, Footnote (e) - Dimension value 0.30 is added.
– Figure 5 and Figure 6, Step 3 - BMS 3-33 is added as an option to BMS 3-24.
– Figure 5 and Figure 6, Step 5 - BMS 3-33 is added as an option to BMS 3-24.
– Figure 5 and Figure 6, Step 21 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660
Optional)".
– Appendix A, Sheet 4 - A female 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.
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
June 02, 2005Original Issue:
December 19, 2006Revision 1:
December 17, 2009Revision 2:
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Commercial 
Airplanes
767
Service Bulletin
SummaryNumber: 767-57A0095Original 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
None.
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
re-routed drain tube with a flexible part, as given 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.
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, the change described in Boeing service bulletin 767-57A0094,
which is equivalent to the change given in this service bulletin, was completed on a 767-200ER airplane after
the initial release of service bulletin 767-57A0094. The change completed on the 767-200ER airplane is equivalent
to the change given in the release of Revision 1 of this service bulletin.
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ACTION (PRR B12901-53S)
Defuel the left and right wing main fuel tanks. Open the applicable left and right wing fuel 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
767-400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE
Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date of 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.
MANPOWER
Elapsed HoursTotal Task Hours
2043
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 767-57A0095
SEE A
FRONT SPAR
SLAT TRACK
HOUSING
RIB NO. 9
FWD <  INBD
REPLACE THE DRAIN TUBE
ASSEMBLY THAT HAS A
FLEXIBLE PART AT THE
NUMBER 5 AND NUMBER 8
LOWER  SLAT TRACK HOUSING, WITH
SKIN  AN ALUMINUM DRAIN TUBE
WITHOUT A FLEXIBLE PART.
(NUMBER 8 SLAT TRACK HOUSING OPPOSITE)  NUMBER 5 SLAT TRACK HOUSING SHOWN  423043
Original Issue: June 02, 2005
Revision 2: December 17, 2009  767-57A0095
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Commercial 
Airplanes
767
Service Bulletin
Number: 767-57A0095
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
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.
DESCRIPTIONCONFIGURATIONGROUP
767-400ER airplanes, Line Numbers 758 thru 878, 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 2 jumper
electrostatic bond configuration
-1
Airplane Models:
767-400ER
GroupVariable Number
1VQ001 - VQ021
1VQ071 - VQ086
2. Spares Affected
None.
B. Concurrent Requirements
None.
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C. Reason
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 re-routed drain tube with a flexible part, as given 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.
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, the change described in Boeing service bulletin
767-57A0094, which is equivalent to the change given in this service bulletin, was completed on a
767-200ER airplane after the initial release of service bulletin 767-57A0094. The change completed
on the 767-200ER airplane is equivalent to the change given in Revision 1 of this service bulletin.
Revision 1 of this service bulletin was sent to change the sequence of the work instructions and to
change the safety wire part number, as a result of the airplane validation. The validation found that the
step to close the main wing tank access panels was incorrectly located after the refuel step. The
validation also found that the minimum fuel quantity note was incorrectly located after the dry bay
inspection step. Special tools required to roller swage the drain tubes onto the ferrules, are specified
in this revision.
The changes to this service bulletin are as follows:
— The Summary, Background paragraph and Paragraph 1.C., Reason, are changed to include the
airplane validation data.
— The Summary, Compliance paragraph and Paragraph 1.E., Compliance, are revised to change
the recommended compliance time from 24 months after the initial release of this service bulletin,
to 24 months after the Revision 1 release of this service bulletin. The compliance time is changed
due to the special roller swage tools required to accomplish this service bulletin, and the difficulty
operators have experienced with special roller swage tool procurement.
— Paragraph 1.G., Manpower, is changed to agree with the resequenced steps to close the main
wing tank fuel bay access panels prior to the refuel step, in Paragraph 3.B., Work Instructions.
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— Paragraph 2.C.2., Parts and Materials Supplied by the Operator, is changed to correct the safety
wire part number from NASM20995AB32 to MS20995AB32, and to delete the BACT11SD08 tape.
— Paragraph 2.E., Special Tooling - Price and Availability, is changed to include the special roller
swage tools data.
— Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin, is changed to include the
special roller swage tools data.
— Paragraph 3.B., Work Instructions, for all airplane groups, are changed to resequence the steps
to close the main wing tank fuel bay access panels prior to the refuel step, and to move the minimum
fuel quantity note for the fuel leakage inspection to the refuel step.
— Figures 3 and 4 are changed to delete the BACT11SD08 tape and the reference to BAC5001.
— Figures 5 and 6 are changed to correct the safety wire part number from NASM20995AB32 to
MS0995AB32.
— Appendix A, Roller Swaging - Wiggins Type Ferrules, is changed to: switch the heading from Roller
Swaging - Wiggins Type Ferrules to Drain Tube Roller Swage Instructions; identify the required
special roller swage tools, add illustrations to depict special roller swage tools usage, and delete
the groove fill acceptance criteria.
Revision 2 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. The
references to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 are
removed from the SB. In addition to these changes, the term "as given in/as shown 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 shown in" to
comply with latest SB standards.
These sections were changed:
– Summary - Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive
FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive
related to this service bulletin is updated.
– Paragraph 1.E., Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness
Directive FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness
Directive related to this service bulletin is updated.
– Paragraph 1.F., Approval - Alternative Method of Compliance (AMOC) approval paragraph removed.
– Paragraph 1.J.1., Existing Data - Reference to Federal Aviation Administration (FAA) Airworthiness
Directive FAA AD 2001-14-19 is removed.
– Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added.
– 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 - New footnotes (b) and (c) added.
– 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.
– Figure 3 and Figure 4, Sheet 2, View A - Tolerance added to the 0.30 dimensions.
– Figure 3 and Figure 4, Step 7 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine
1600/1660 Optional)".
– Figure 3 and Figure 4, Footnote (e) - Dimension value 0.30 is added.
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– Figure 5 and Figure 6, Step 3 - BMS 3-33 is added as an option to BMS 3-24.
– Figure 5 and Figure 6, Step 5 - BMS 3-33 is added as an option to BMS 3-24.
– Figure 5 and Figure 6, Step 21 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine
1600/1660 Optional)".
– Appendix A, Sheet 4 - A female 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.
D. Description
Defuel the left and right wing main fuel tanks. Open the applicable left and right wing fuel 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.
Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this
service bulletin.
Revision 2 - No more work is necessary on airplanes changed in accordance with the original issue or
revision 1 of this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
532, 533, 632, 633767-400ER
E. Compliance
Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date
of 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.
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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 service bulletin 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 examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Elapsed HoursTask-HoursNumber of Per-
sons
Task
5.020.04Defuel
3.06.02Prepare for Fuel
Tank Access
1.02.02Open Panels
1.51.51FIGURE 1
1.51.51FIGURE 2
as necessaryFIGURE 3
as necessaryFIGURE 4
2.02.01FIGURE 5
2.02.01FIGURE 6
0.51.02Close Wing Main
Tank Panels
2.04.02Refuel
1.02.02Inspect
0.51.02Close Wing Dry Bay
Panels
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Elapsed HoursTask-HoursNumber of Per-
sons
Task
20.043.0TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR B12901-53S.
b. Service Related Problem (SRP) 767-SRP-57-0160.
c. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 12-11-01, 28-11-00, 28-26-00.
d. Boeing Standard Wiring Practices Manual (SWPM) 20-20-00.
e. Boeing Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-43-03, 20-50-02,
20-50-07, 20-50-10, 20-60-02.
f. Boeing Parts Standards Document D-590.
g. Boeing Drawing 012W6100.
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
DRAIN TUBE INSTL - SLAT TRACK HOUSING, WING112T2019
This drawing was used to prepare this service bulletin. This drawing is not necessary to make the
specified changes, and is not supplied with this service bulletin. This drawing may not be applicable
to all airplane configurations or operators.
K. Publications Affected
Chapter-SectionPublication
57-21767 Illustrated Parts Catalog
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1. 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 does not affect FCS, therefore DTIs are not necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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BLANK PAGE

### Page 19

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below.
If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More
kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date
Boeing gets the purchase order.
Unit Price thru
Dec 31/09
ROLT
(Weeks)
QTYDateNameKit Number
$1,117.00201Aug 18/04Top Kit - Slat Track
Housing - Drain Tube
Replacement
015T1772-1
25Oct 14/04
25Nov 11/04
25Dec 13/04
25Jan 19/05
25Feb 16/05
25Mar 16/05
25Apr 13/05
9May 11/05
The kits 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. Mail to:
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 changes 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.
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NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane.
Kit 015T1772
NotesExisting Part NumberNameQTYNew Part Number
-1
-Top Kit - Slat Track Housing
- Drain Tube Replacement
-015T1772-1
(a) (d)200-030-0001-501Tube2015T1772-2
AS1716D08Ferrule - Flexible4AS1716D08
AN735C8Clamp, Loop2AN735DC8
305B387S8Coupling - Flexible2AS1712D08
355B387S8Coupling - Half2AS1713D08
BACJ40AC44-6 or
BACJ40AC44-8
Bonding Jumper4BACJ40A20-8
BACN10YR3CDNut6BACN10YR3CD
(b)BACS12GU3K9Screw2BACS12HN3-9
(c)MS29513-114Packing, Preformed6MS29513-114
NAS1149D0316H or
NAS1149D0316J
Washer16NAS1149D0316H
-Washer - Plain2NAS1149D0332H
NAS1149D0363HWasher2NAS1149D0363H
(a) Discard the existing part.
(b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one
grip length longer than indicated. Also, if any fasteners part numbers listed are not
available or have been superseded, substitute fasteners may be supplied in kits.
Boeing Document D590 and Boeing Drawing 012W6100 are used to determine the
part numbers used as substitutes.
(c) There are more parts than are necessary.
(d) Optional to make drain tube, operators can make the drain tube from raw stock tubing
material 6061-T6 in accordance with WW-T-700/6 or AMS 4083 or AMS-T-7081, with
a nominal Outer Diameter of 0.5 inch, and a nominal wall thickness of 0.035 inch.
2. Parts and Materials Supplied by the Operator:
NotesNameQTYPart Number / Specification
(c)Chemical Conversion Coating1/2 pintAlodine 600 (Alodine 1600/1660 Option-
al)
(a)Corrosion Resistant Finish1/2 pintBMS 10-20, Type II
Safety Wire12 inchesMS20995AB32
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NotesNameQTYPart Number / Specification
(a)Grease1/4 pintBMS 3-24
(BMS 3-33 Optional)
Solvent1/2 pintDenatured Alcohol
(b)Lubricant1/4 pintSAE No. 10 Automotive Motor Oil (Mas-
terdraw B1767C Optional)
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for sup-
plier data.
(b) Any SAE "10W-xx" (10W-20, 10W-30, 10W-40, etc) automotive engine oil is an acceptable
substitute for SAE No.10 automotive engine oil.
(c) Refer to SOPM 20-43-03 as an accepted procedure for the application of Chemical Conversion
Coating.
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
The operator can supply the special tools shown in Paragraph 2.F., Special Tooling Necessary to do
this Service Bulletin. The special tools may be purchased from the suppliers shown below. Tool price
and availability data are not given.
NotesNameQTYTool Part Number
(b) (c)Wrench1ST2580-77A-5
(a) (b)
(c)
Frame1ST877W-F
(a) (b)
(c)
Die Block1ST877W-DF-D-08-1-1
(a) (b)
(c)
Die Block1ST877W-DF-D-08-1-2 (Optional)
(e) (h)Swage Block1DB6305H8 (Optional)
(a) (b)
(c)
Die Block Holder1ST877W-DH-1
(e) (g)Swage Block Holder1DH6305-1 (Optional)
(a) (d)Tube Expander1ST877W-E-8-035
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NotesNameQTYTool Part Number
(a) (f)Tube Expander1B9108-35 (Optional)
(e) (f)Tube Expander1B8308-35 (Optional)
(a) This tool can be purchased from: Monaghan & Associates, Inc. Elliot Tool Technologies 1760
Tuttle Avenue P.O. Box 1165-45401 Dayton, Ohio 45403-3428. Phone: 937-253-7706. Toll
Free: 800-332-0447. Fax: 937-259-9241. Contact: Ken MacDonald, Sales Engineer. Email:
sales@monaghaninc.com
(b) This tool can be purchased from: New Tech Industries, Inc. 7911 44th Avenue West Mukilteo,
Washington 98275. Phone: 425-778-1200. Fax: 425-743-3566. Contact: Tom Bigelow,
President. Email: tom@newtechind.com
(c) This tool can be purchased from: Precise Tool and Gage Co., Inc. 30540 S.E. 84th St., Unit
2 Preston, Washington 98050. Phone: 206-623-1120, 425-222-9567. Fax: 425-222-9568.
Contact: Brad Schulz, Sales Rep. Email: ptg@precisetoolco.com
(d) This tool can be purchased from: E.F. Bailey Company 5610 Fourth Avenue South Seattle,
Washington 98108. Phone: 206-607-4840. Fax: 206-607-5440. Contact: Ted McBurney, Sales
Rep.
(e) This tool can be purchased from: Adel Wiggins Group Transdigm, Inc. 5000 Triggs Street
Los Angeles, California 90022. Phone: 323-881-7654. Contact: Terri Roane, Boeing Account
Rep. Email: TRoane@AdelWiggins.com
(f) This tool is equivalent to the ST877W-E-8-035 Tube Expander.
(g) This tool is equivalent to the ST877W-DH-1 Die Block Holder.
(h) This tool is equivalent to the ST877W-DF-D-08-1-1 Die Block.
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 tools, a supply sequence is
given by Spares.
PURCHASE DATA:
NameBoeing Part Page Number (a)Tool Part Number
WrenchST2580-77A5ST2580-77A-5
FrameST877WFST877W-F
Die Block Holder
(Swage Block
Holder)
ST877WDH1 (DH6305-1Option-
al)
ST877W-DH-1
Die Block (Swage
Block)
ST877WDFD08-1-1
(ST877WDFD08-1-2 or
DB6305H8 Optional)
ST877W-DF-D-08-1-1
Tube ExpanderST877WE8-035 (B9108-35 or
B8308-35 Optional)
ST877W-E-8-035
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PURCHASE DATA:
NameBoeing Part Page Number (a)Tool Part Number
(a) Use the special Boeing part page number when ordering from the Boeing Part Page.
The Boeing Part Page only lets entries with dashes "-" between numbers be entered.
The user will be alerted to this, if the unmodified, tool part number is entered.
The Tools 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.
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. Mail to:
Spares Customer Support - MC 36-65
Boeing Spares Department
P.O. Box 3707
Seattle, Washington 98124-2207 USA
(Service Bulletin 767-57A0095)
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.
NotesNameQTYTool Part Number
Wrench1ST2580-77A-5
(a)Frame1ST877W-F
(b)Die Block Holder
(Swage Block Holder)
1ST877W-DH-1
(DH6305-1 Optional)
(c)Die Block (Swage
Block)
1ST877W-DF-D-08-1-1
(ST877W-DF-D-08-1-2
or DB6305H8 Optional)
(d)Tube Expander1ST877W-E-8-035
(B9108-35 or B8308-35
Optional)
(a) This tool is optional. The ST877W-DH-1 die block holder (or DH6305-1swage block
holder) may be clamped in a securely mounted bench vise, for the roller swage process.
(b) A DH6305-1 swage block holder may be used in place of the ST877W-DH-1 die block
holder.
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NotesNameQTYTool Part Number
(c) Either a ST877W-DF-D-08-1-2 die block (no link installed) or a DB6305H8 swage block
may be used in place of the ST877W-DF-D-08-1-1 die block.
(d) Either a B9108-35 tube expander or a B8308-35 tube expander may be used in place
of the ST877W-E-8-035 tube expander.
NOTE: The above special tools are reusable. The special tools may be used to accomplish this service
bulletin on multiple airplanes, with proper use and care.
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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. 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
– Angular tolerance is plus or minus 2 degrees
– Torque limits to tighten nuts and bolts are in 767-400 Structural Repair Manual,
Chapter 51.
5. Use the approved fastener and process material substitutions in accordance with
767-400 Structural Repair Manual, Chapter 51. Alternate fasteners are listed in
767-400 Structural Repair Manual, Chapter 51 and Boeing Drawing 012W6100.
6. If the length of any fastener specified in this service bulletin does not meet the
installation standards in 767-400 Structural Repair Manual, Chapter 51, then a
fastener of the same specification, or an approved substitute, with a length which
meets the installation standards in 767-400 Structural Repair Manual, Chapter 51
may be used.
7. 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.
8. 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.
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B. WORK INSTRUCTIONS
WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR WEATHER RADAR
DURING THE DEFUEL PROCEDURES. THE OPERATION OF THE HF
COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN
EXPLOSION TO OCCUR.
1. Defuel the main tank of the left and right wing. Refer to 767 AMM 28-26-00 as an accepted
procedure.
WARNING: OBEY THE PURGING AND FUEL TANK ENTRY PRECAUTIONS. FAILURE TO OBEY
THE PURGING AND FUEL TANK ENTRY PRECAUTIONS CAN CAUSE SERIOUS
INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO EQUIPMENT.
2. Prepare to go into the main fuel tank, inboard of rib no.10, of the left and right wing. Refer to 767
AMM 28-11-00 as an accepted procedure.
WARNING: DO NOT USE AIRPLANE ELECTRICAL POWER WHEN FUEL TANK ACCESS DOORS
ARE REMOVED. A FIRE OR EXPLOSION CAN OCCUR IF FUEL VAPOR IS IGNITED
BY SPARK(S) FROM ELECTRICAL EQUIPMENT. A FIRE OR EXPLOSION CAN CAUSE
SERIOUS INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO
EQUIPMENT.
3. Open the left and right wing main tank and dry bay access panels listed below, to get access to
the number 5 and number 8 slat track housing drain tube assemblies. Refer to 767 AMM 06-44-00.
LocationPanel Number
LEFT WING DRY BAY533AB
RIGHT WING DRY BAY633AB
LEFT WING MAIN TANK532FB
RIGHT WING MAIN TANK632FB
4. Remove the existing drain tube assembly that has a flexible part at the number 5 slat track housing
in accordance with FIGURE 1.
5. Remove the existing drain tube assembly that has a flexible part at the number 8 slat track housing
in accordance with FIGURE 2.
6. Prepare the new drain tube for installation at the number 5 slat track housing in accordance with
FIGURE 3.
7. Prepare the new drain tube for installation at the number 8 slat track housing in accordance with
FIGURE 4.
8. Install the new drain tube at the number 5 slat track housing in accordance with FIGURE 5.
9. Install the new drain tube at the number 8 slat track housing in accordance with FIGURE 6.
10. Close the left and right wing main tank access panels listed below. Refer to 767 AMM 06-44-00.
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LocationPanel Number
LEFT WING MAIN TANK532FB
RIGHT WING MAIN TANK632FB
WARNING: DO NOT PUT GROUND EQUIPMENT UNDER THE WINGTIPS DURING THE REFUEL
PROCEDURES. THE WINGS MOVE DOWN UNDER THE WEIGHT OF THE FUEL AND
THE WINGTIPS MOVE THE MOST. BECAUSE THE FUEL TANKS ARE VENTED
THROUGH THE WINGTIPS, A DANGEROUS AND EXPLOSIVE MIXTURE AROUND
THE WINGTIPS CAN OCCUR.
WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR THE WEATHER RADAR
DURING THE REFUEL PROCEDURES. THE OPERATION OF THE HF
COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN
EXPLOSION TO OCCUR.
11. Refuel the main tank of the left and right wing. Refer to 767 AMM 12-11-01 as an accepted
procedure.
NOTE: A minimum of 4400 U.S. gallons of fuel is necessary in the main tanks to do a satisfactory
inspection for leakage.
12. Do a general visual inspection of the dry bay area in the left and right wing to make sure there is
no fuel leakage from the new drain tube installations.
13. Close the left and right wing dry bay access panels listed below. Refer to 767 AMM 06-44-00.
LocationPanel Number
LEFT WING DRY BAY533AB
RIGHT WING DRY BAY633AB
14. Put the airplane back to a serviceable condition.
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BOEING SERVICE BULLETIN 767-57A0095
SEE (A
FRONT SPAR  NUMBER 5
SLAT TRACK
HOUSING
RIB NO. 9
SEE ®
FWD •  INBD  SEE C
LOWER
SKIN  423044
FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE
(SHEET 1 OF 4)
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### Page 29

FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE
(SHEET 2 OF 4)
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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 the left wing.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1BACS12GU3K8ScrewRemove/Keep1
2BACN10YR3CDNutRemove/Keep2
one of the two types
of washer could be
installed.
3NAS1149D0316H or
NAS1149D0316J
WasherRemove/Keep3
2NAS1149D0363HWasherRemove/Keep4
1BACS12GU3K9ScrewRemove5
1BACN10YR3CMNutRemove6
3NAS1149D0316RWasherRemove7
2NAS1149D0363RWasherRemove8
FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE
(SHEET 3 OF 4)
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MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
one of the two types
of washer could be
installed.
1NAS1149D0316H or
NAS1149D0316J
WasherRemove9
1BACJ40AC44-6Bonding JumperRemove10
1BACJ40AC44-8Bonding JumperRemove11
1AN735C8Bonding ClampRemove12
1AN735DC8Bonding ClampRemove/Keep13
--LockwireRemove14
1355B387S8Coupling Assembly
--LockwireRemove15
1305B387S8Coupling Assembly
1200-030-0001-501Drain Tube AssemblyRemove16
FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE
(SHEET 4 OF 4)
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BOEING SERVICE BULLETIN 767-57A0095
SEE
FRONT SPAR
RIB NO. 9
NUMBER 8
SLAT TRACK
HOUSING
SEE B
UP
SEE
INBD  →FWD
LOWER
SKIN  423050
FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE
(SHEET 1 OF 4)
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### Page 33

FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE
(SHEET 2 OF 4)
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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 the right wing.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1BACS12GU3K8ScrewRemove/Keep1
2BACN10YR3CDNutRemove/Keep2
one of the two types
of washer could be
installed.
3NAS1149D0316H or
NAS1149D0316J
WasherRemove/Keep3
2NAS1149D0363HWasherRemove/Keep4
1BACS12GU3K9ScrewRemove5
1BACN10YR3CMNutRemove6
3NAS1149D0316RWasherRemove7
2NAS1149D0363RWasherRemove8
FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE
(SHEET 3 OF 4)
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MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
one of the two types
of washer could be
installed.
1NAS1149D0316H or
NAS1149D0316J
WasherRemove9
1BACJ40AC44-6Bonding JumperRemove10
1BACJ40AC44-8Bonding JumperRemove11
1AN735C8Bonding ClampRemove12
1AN735DC8Bonding ClampRemove/Keep13
--LockwireRemove14
1355B387S8Coupling Assembly
--LockwireRemove15
1305B387S8Coupling Assembly
1200-030-0001-501Drain Tube AssemblyRemove16
FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE
(SHEET 4 OF 4)
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Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
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35 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 36 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
FRONT WING SPAR
OFSS
428.683  NUMBER 5
SLAT TRACK
HOUSING
RIB NO. 9
SEE A
UP
FWD <  •INBD
LOWER WING
SKIN
FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE
(SHEET 1 OF 4)
Original issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  36 of 60

### Page 37 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
10.00 (REF)
- INBD
0.30
10.05
FERRULE  245091
DRAIN
. TUBE
(DRAIN TUBE SHOWN BENT)  0.30
+0.05
(Z LOCATIONS,
BEFORE SWAGE)
RIB NO.9
DRAIN TUBE ATTACHED TO
SLAT TRACK HOUSING
NEW  TYPICAL
DRAIN TUBE  DOUBLER
ASSEMBLY
0.300
0.050-
_ 0.170
0.050
FERRULE
0.205
0.085
0.335
0.085  FWD
NEW DRAIN TUBE
B-B  > INBD  C-C
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 the left wing.
FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE
(SHEET 2 OF 4)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  37 of 60

### Page 38

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
to make one end ful-
ly agree with the
drain tube attached
to the slat track
housing.
1015T1772-2Drain TubeAlign1
(a)-Measure
(b)-Bend2
(c)-Cut3
(d)-Deburr4
the outer surface to
remove oil and
grease. Refer to
SOPM 20-30-03 as
an accepted proce-
dure.
-Clean5
one on each end of
the drain tube as
shown.
2AS1716D08Ferrule - FlexibleInstall (New)6
the drain tube onto
each ferrule,in accor-
dance with Appendix
A.
-Roller Swage
to the inner and out-
er surface of the
drain tube. Refer to
SOPM 20-43-03 as
an accepted proce-
dure.
-Alodine 600 (Alodine
1600/1660 Optional)
Chemical Conversion
Coating
Apply7
(e)1 layerBMS 10-20, Type IICorrosion Resistant
Finish
Apply8
(f)-MarkingApply9
with a rubber stamp
to reidentify the
drain tube. Refer to
SOPM 20-50-10 as
an accepted proce-
dure.
-015T1772-3Part MarkApply10
(a) the bend angle necessary to make the other end of the drain tube fully agree with doubler at rib no. 9.
(b) with standard bend radius tools, to agree with the measurements. After the tube is bent, an end to end
distance tolerance of + or - 0.03 inches is permitted.
FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE
(SHEET 3 OF 4)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
38 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 39

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(c) to make one end parallel with the end of the drain tube attached to the slat track housing and one end
perpendicular with the doubler at rib no. 9. Cut the tube as necessary to keep the clearance dimensions
at each end of the tube as shown.
(d) Flat deburr and square both drain tube ends to within 0.005 inch. Radius all sharp edges to between 0.02
and 0.06 inch.
(e) to all of the inner surface, the specified area of the outer surface of the drain tube and each ferrule. Refer
to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures. Do not apply BMS 10-20, Type II to
the 0.30 dimension shown at the end of the each ferrule.
(f) Apply an arrow that points to rib no. 9, with a rubber stamp to the drain tube outer surface, to identify the
direction of flow. Refer to SOPM 20-50-10 as an accepted procedure.
FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE
(SHEET 4 OF 4)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
39 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 40 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
FRONT WING SPAR
OFSS
428.683
NUMBER 8
SLAT TRACK
HOUSING
RIB NO. 9
SEE A
UP
INBD
LOWER WING  423055
SKIN
FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE
(SHEET 1 OF 4)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  767-57A0095
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
10.00 (REF)
INBD
0.30
X457910  10.05
(DRAIN TUBE SHOWN BENT)
FERRULE
0.30
10.05  DRAIN
TUBE
D-D
TYPICAL  DOUBLER  RIB NO.9  BEFORE  (L LOCATIONS,  SWAGE)
ASSEMBLY
NEW
DRAIN TUBE
DRAIN TUBE ATTACHED TO
0.300  SLAT TRACK HOUSING
-0.050
0. 170
FWD  0.050
- FERRULE
INBD
0.205
0.335  0.085
-0.085
B-B  NEW DRAIN TUBE  C-C  423056
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 the right wing.
FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE
(SHEET 2 OF 4)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  41 of 60

### Page 42

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
to make one end ful-
ly agree with the
drain tube attached
to the slat track
housing.
1015T1772-2Drain TubeAlign1
(a)-Measure
(b)-Bend2
(c)-Cut3
(d)-Deburr4
the outer surface to
remove oil and
grease. Refer to
SOPM 20-30-03 as
an accepted proce-
dure.
-Clean5
one on each end of
the drain tube as
shown.
2AS1716D08Ferrule - FlexibleInstall (New)6
the drain tube onto
each ferrule,in accor-
dance with Appendix
A.
-Roller Swage
to the inner and out-
er surface of the
drain tube. Refer to
SOPM 20-43-03 as
an accepted proce-
dure.
-Alodine 600 (Alodine
1600/1660 Optional)
Chemical Conversion
Coating
Apply7
(e)1 layerBMS 10-20, Type IICorrosion Resistant
Finish
Apply8
(f)-MarkingApply9
with a rubber stamp
to reidentify the
drain tube. Refer to
SOPM 20-50-10 as
an accepted proce-
dure.
-015T1772-3Part MarkApply10
(a) the bend angle necessary to make the other end of the drain tube fully agree with doubler at rib no. 9.
(b) with standard bend radius tools, to agree with the measurements. After the tube is bent, an end to end
distance tolerance of + or - 0.03 inches is permitted.
FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE
(SHEET 3 OF 4)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
42 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 43

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(c) to make one end parallel with the end of the drain tube attached to the slat track housing and one end
perpendicular with the doubler at rib no. 9. Cut the tube as necessary to keep the clearance dimensions
at each end of the tube as shown.
(d) Flat deburr and square both drain tube ends to within 0.005 inch. Radius all sharp edges to between 0.02
and 0.06 inch.
(e) to all of the inner surface, the specified area of the outer surface of the drain tube and each ferrule. Refer
to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures. Do not apply BMS 10-20, Type II to
the 0.30 dimension shown at the end of the each ferrule.
(f) Apply an arrow that points to rib no. 9, with a rubber stamp to the drain tube outer surface, to identify the
direction of flow. Refer to SOPM 20-50-10 as an accepted procedure.
FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE
(SHEET 4 OF 4)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
43 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 44 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
FRONT WING SPAR
OFSS
428.683  NUMBER 5
SLAT TRACK
HOUSING
RIB NO. 9
SEE M
SEE
FUD TIMEO
LOWER WING
SKIN
423057
FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL
(SHEET 1 OF 5)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  44 of 60

### Page 45 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
DOUBLER
ASSEMBLY  STIFFENER
FWD
UP
FUD PRIMBO
RETAINING
WASHERS
423058
FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL
(SHEET 2 OF 5)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  45 of 60

### Page 46 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
GAGE 0.59
0.47
RETAINER
RETAINING
WASHER  NEW DRAIN
TUBE
RETAINING
WASHER
COUPLING
NUT
COUPLING
BODY
DRAIN TUBE
ATTACHED TO
SLAT TRACK
HOUSING
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 the left wing.
FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL
(SHEET 3 OF 5)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  46 of 60

### Page 47

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)1015T1772-3Drain TubeAlign1
(b)Install (New)
(c)1MS29513-114Packing, PreformedInstall (New)2
(d)-BMS 3-24 (BMS 3-33
optional)
GreaseApply3
Engage the coupling
nut and tighten by
hand.
1AS1713D08Coupling Assembly,
Half
Install (New)
(c)2MS29513-114Packing, PreformedInstall (New)4
(e)-BMS 3-24 (BMS 3-33
optional)
GreaseApply5
(f)1AS1712D08Coupling AssemblyInstall (New)
to safety each cou-
pling. Refer to
SOPM 20-50-02 as
an accepted proce-
dure.
-MS20995AB32WireInstall (New)6
(g)-FinishRemove7
(h)1AN735DC8Bonding ClampInstall (New)
1BACJ40A20-8Bonding JumperInstall (New)8
1BACJ40A20-8Bonding JumperInstall (New)9
4NAS1149D0316HWasherInstall (New)10
1NAS1149D0332HWasherInstall (New)11
1NAS1149D0363HWasherInstall (New)12
1BACS12HN3-9ScrewInstall (New)13
1BACN10YR3CDNutInstall (New)14
1AN735DC8Bonding ClampInstall (Kept)15
3NAS1149D0316H or
NAS1149D0316J
WasherInstall (Kept)16
2NAS1149D0363HWasherInstall (Kept)17
1BACS12GU3K8ScrewInstall (Kept)18
2BACN10YR3CDNutInstall (Kept)19
(i)-Designated Bond
(Electrostatic)
Electrical ResistanceMeasure20
FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL
(SHEET 4 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
47 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 48

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(j)-Alodine 600 (Alodine
1600/1660 Optional)
Chemical Conversion
Coating
Apply21
(k)1 layerBMS 10-20, Type IICorrosion Resistant
Finish
(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where it aligns
with the drain tube attached to the slat track housing and the doubler.
(b) Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube attached
to the slat track housing and the ferrule of the new drain tube, before the coupling is installed.
(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the same config-
uration as shown.
(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) before
installation. Refer to SOPM 20-50-07 as an accepted procedure.
(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the coupling as-
sembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.
(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your hand. A
correctly tightened coupling will agree with gage tolerance shown.
(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 20-20-00
as an accepted procedure.
(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an accepted
procedure.
(i) between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is attached
to the slat track housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches
away from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. Refer
to SWPM 20-20-00 as an accepted procedure.
(j) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation
of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-43-03 as an accepted
procedure.
(k) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation
of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-41-02 and SOPM
20-60-02 as accepted procedures.
FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL
(SHEET 5 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
48 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 49 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
FRONT WING SPAR
OFSS
NUMBER 8  428.683
SLAT TRACK
HOUSING
RIB NO. 9
SEE A
SEE ®
LOWER WING
SKIN
UP
INBD  > FWD  423060
FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL
(SHEET 1 OF 5)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  49 of 60

### Page 50 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
DOUBLER
STIFFENER  ASSEMBLY
10 19)
FWD
UP
INBD  FWD
RETAINING
WASHERS
FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL
(SHEET 2 OF 5)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  BOEING PROPRIETARY -  767-57A0095
Copyright © Unpublished Work - See page 1 for details.  50 of 60

### Page 51 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
0.59 GAGE
0.47
RETAINER
RETAINING
NEW DRAIN  WASHER
TUBE
RETAINING
WASHER
COUPLING
NUT
COUPLING
BODY
DRAIN TUBE
ATTACHED TO SLAT
TRACK HOUSING
423063
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 the right wing.
FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL
(SHEET 3 OF 5)
Original Issue: June 02, 2005
Revision 2 December 17, 2009  767-57A0095
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  51 of 60

### Page 52

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)1015T1772-3Drain TubeAlign1
(b)Install (New)
(c)1MS29513-114Packing, PreformedInstall (New)2
(d)-BMS 3-24 (BMS 3-33
optional)
GreaseApply3
Engage the coupling
nut and tighten by
hand.
1AS1713D08Coupling Assembly,
Half
Install (New)
(c)2MS29513-114Packing, PreformedInstall (New)4
(e)-BMS 3-24 (BMS 3-33
optional)
GreaseApply5
(f)1AS1712D08Coupling AssemblyInstall (New)
to safety each cou-
pling. Refer to
SOPM 20-50-02 as
an accepted proce-
dure.
-MS20995AB32WireInstall6
(g)-FinishRemove7
(h)1AN735DC8Bonding ClampInstall (New)
1BACJ40A20-8Bonding JumperInstall (New)8
1BACJ40A20-8Bonding JumperInstall (New)9
4NAS1149D0316HWasherInstall (New)10
1NAS1149D0332HWasherInstall (New)11
1NAS1149D0363HWasherInstall (New)12
1BACS12HN3-9ScrewInstall (New)13
1BACN10YR3CDNutInstall (New)14
1AN735DC8Bonding ClampInstall (Kept)15
3NAS1149D0316H or
NAS1149D0316J
WasherInstall (Kept)16
2NAS1149D0363HWasherInstall (Kept)17
1BACS12GU3K8ScrewInstall (Kept)18
2BACN10YR3CDNutInstall (Kept)19
(i)-Designated Bond
(Electrostatic)
Electrical ResistanceMeasure20
FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL
(SHEET 4 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
52 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 53

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(j)-Alodine 600 (Alodine
1600/1660 Optional)
Chemical Conversion
Coating
Apply21
(k)1 layerBMS 10-20, Type IICorrosion Resistant
Finish
(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where it aligns
with the drain tube attached to the slat track housing and the doubler.
(b) Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube attached
to the slat track housing and the ferrule of the new drain tube, before the coupling is installed.
(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the same config-
uration as shown.
(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) before
installation. Refer to SOPM 20-50-07 as an accepted procedure.
(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the coupling as-
sembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.
(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your hand. A
correctly tightened coupling will agree with gage tolerance shown.
(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 20-20-00
as an accepted procedure.
(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an accepted
procedure.
(i) between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is attached
to the slat track housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches
away from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. Refer
to SWPM 20-20-00 as an accepted procedure.
(j) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation
of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-43-03 as an accepted
procedure.
(k) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation
of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-41-02 and SOPM
20-60-02 as accepted procedures.
FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL
(SHEET 5 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
53 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 54

Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS
(SHEET 1 OF 7)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
54 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 55

Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS
(SHEET 2 OF 7)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
55 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 56

Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS
(SHEET 3 OF 7)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
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56 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 57 (OCR)

BOEING SERVICE BULLETIN 767-57A0095
WRENCH
WRENCH  FLATS
DIE BLOCK (OR SWAGE BLOCK) HOLDER  DIE BLOCK (OR SWAGE BLOCK)  FERRULE  TUBE EXPANDER
TAPERED  MANDREL
DRAIN  TUBE  FRAME  1315671
Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS
(SHEET 4 OF 7)
Original Issue: June 02, 2005
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Copyright © Unpublished Work - See page 1 for details.  57 of 60

### Page 58

The following special tooling is required to roller swage the 015T1772-2 drain tube onto the AS1716D08 ferrules:
NotesDescriptionPart NumberQuantity
(a)FrameST877W-F1
(c)Die Block Holder (Swage
Block Holder)
ST877W-DH-1 (DH6305-
1 Optional)
1
(b)Die Block (Swage Block)ST877W-DF-D-08-1-1
(ST877W-DF-D-08-1-2 or
DB6305H8 Optional)
1
(d)Tube ExpanderST877W-E-8-035 (B9108-
35 or B8308-35 Optional)
1
(e)WrenchST2580-77A-51
(a) The use of the ST877W-F Frame is optional. The ST877W-DH-1 die block holder
(or the DH6305-1swage block holder) may be installed in a sturdy bench vise,
instead of in the ST877W-F Frame.
(b) Either a ST877W-DF-D-08-1-2 die block (no link installed) or a DB6305H8 swage
block may be used in place of the ST877W-DF-D-08-1-1 die block.
(c) A DH6305-1 swage block holder may be used in place of the ST877W-DH-1 die
block holder.
(d) Either a B9108-35 tube expander or a B8308-35 tube expander may be used in
place of the ST877W-E-8-035 tube expander.
(e) This tool is only compatible with the ST877W-E-8-035 and the B9108-35 tube
expander. A female 3/8 inch square drive socket can be used for the B8308-35
tube expander.
1. Make sure the AS1716D08 ferrule internal swage grooves are free of debris and/or lubricant.
2. Make sure the outside surface of the 015T1772-2 drain tube is free of scratches and/or gouges in the
swaging areas. Scratches and/or gouges on the drain tube outside surface swaging areas are not acceptable.
If the drain tube outside surface has a scratch and/or gouge in the swaging area that is deeper than 0.001
inch after polishing, the part must be replaced.
3. Make sure the outside surface of the 015T1772-2 drain tube is free of debris and/or lubricant in the swaging
areas.
4. Attach the ST877W-F frame to a sturdy workbench, if the ST877W-DH-1 die block holder will be installed
in the frame. Refer to Item 5 below.
5. Install the ST877W-DH-1 die block holder on the ST877W-F frame. Two 0.5000-13 x (length required) steel
fasteners (operator supplied) are required to secure the die block holder to the frame. Optional to secure
the die block holder in a sturdy bench vise, instead of on the ST877W-F frame. The 0.5000-13 x (length
required) steel fasteners are not required if the die block holder is secured in a bench vise, instead of the
frame.
Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS
(SHEET 5 OF 7)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
58 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 59

6. Clean the ST877W-DF-D-08-1-1 die block halves using Denatured Alcohol and a clean cloth, to ensure the
die block halves ferrule cavities are free of debris and/or lubricant.
7. Insert the AS1716D08 ferrule into the ST877W-DF-D-08-1-1 die block half cavity and close the die block
halves.
8. Install the ST877W-DF-D-08-1-1 die block halves (and AS1716D08 ferrule) into the ST877W-DH-1 die
block holder. The flanged end of the AS1716D08 ferrule must be located adjacent to the die block stop in
the die block holder. Align the die block split lines approximately perpendicular to the die block holder split
line.
9. Torque the ST877W-DH-1 die block holder clamping fastener to 100 foot-pounds. Make sure the
ST877W-DF-D-08-1-1 die block halves are fully against the die block holder stop, prior to torque application.
10. Clean the rollers and to the tapered mandrel of the ST877W-E-8-035 tube expander, using Denatured
Alcohol solvent and a clean cloth.
11. Apply SAE No. 10 automotive engine oil lubricant to the rollers and to the tapered end of the ST877W-E-8-035
tube expander. Optional to use Masterdraw B1767C lubricant.
NOTE: Any SAE "10W-xx" (10W-20, 10W-30, 10W-40, etc) automotive engine oil is an acceptable substitute
for SAE No.10 automotive engine oil.
12. Insert the 015T1772-2 drain tube into the AS1716D08 ferrule until it contacts the ferrule tube stop. Hold the
drain tube squarely against the ferrule tube stop until the swage process is completed.
13. Insert the ST877W-E-8-035 tube expander into ST877W-DF-D-08-1-1 die block, opposite the 015T1772-2
drain tube.
14. Push the exposed end of the mandrel towards the ST877W-E-8-035 tube expander body and rotate the
mandrel by hand clockwise, to start the tube expander self-feeding action.
15. Install the ST2580-77A-5 wrench or a female 3/8 inch square drive socket (as applicable), on the end of
the tube expander mandrel.
16. Torque the ST2580-77A-5 wrench (or female 3/8 inch square drive socket) to 16 - 20 inch-pounds. The
mandrel end will advance into the tube expander body as it rotates. Ten or more complete turns of the
wrench may be necessary to reach the required torque.
17. Rotate the mandrel counterclockwise to loosen and remove the ST877W-E-8-035 tube expander.
18. Loosen the ST877W-DH-1 die block holder clamping fastener to remove the ST877W-DF-D-08-1-1 die
block and swaged drain tube/ferrule.
19. Remove the swaged drain tube/ferrule from the ST877W-DF-D-08-1-1 die block halves.
20. Remove lubricant residue from the swaged drain tube/ferrule with a clean cloth.
Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS
(SHEET 6 OF 7)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
59 of 60
BOEING SERVICE BULLETIN 767-57A0095

### Page 60

21. Do a General Visual Inspection of the swaged joint, to check for die parting-line welts on the external
AS1716D08 ferrule surfaces. External die parting-line welts exceeding 0.002 inch height on O-ring sealing
areas, or 0.004 inch height in non-seal areas, are not acceptable and the parts must be replaced.
22. Do a General Visual Inspection of the swaged joint, to check for 015T1772-2 drain tube extrusion beyond
the AS1716D08 ferrule flange end face. Drain tube extrusion beyond the ferrule flange end face is not
acceptable and the parts must be replaced.
23. Do a General Visual Inspection of the swaged joint, to check for signs of AS1716D08 ferrule flange shearing,
due to linear tubing expansion from the roller swage process. Ferrule flange shearing is not acceptable and
the parts must be replaced.
24. Do a General Visual Inspection of the swaged joint, to check for scratches and/or die marks on the
AS1716D08 ferrule flange. Scratches and/or die marks on the ferrule flange are not acceptable and the
parts must be replaced.
25. Do a General Visual Inspection of the swaged joint, to check for visible gaps between the AS1716D08
ferrule tube stop and the end of the 015T1772-2 drain tube. Visible gaps between the ferrule stop and the
end of the drain tube are not acceptable and the parts must be replaced.
26. Do a General Visual Inspection of the swaged joint, to check for longitudinal AS1716D08 ferrule cracks.
Longitudinal ferrule cracks are not acceptable and the parts must be replaced.
Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS
(SHEET 7 OF 7)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 02, 2005
767-57A0095Revision 2 December 17, 2009
60 of 60
BOEING SERVICE BULLETIN 767-57A0095

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