# Boeing Alert Service Bulletin 767-57A0100: Boeing - Service Bulletin

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### Page 1

Commercial 
Airplanes
767
Service Bulletin
Number: 767-57A0100
Original Issue: August 21, 2006
Revision 3: July 28, 2011
ATA System: 5720 2811
SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant
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 © 2006 The Boeing Company
Unpublished Work - All Rights Reserved
Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable
subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more
information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the
Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
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2.0

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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 7
B. Concurrent Requirements ...................................... 1 7
C. Reason ................................................ 1 7
D. Description .............................................. 1 8
E. Compliance .............................................. 1 9
F. Approval ............................................... 1 9
G. Manpower .............................................. 2 0
H. Weight and Balance Changes .................................... 2 1
I. Electrical Load Data ......................................... 2 1
J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2
K. Publications Affected ........................................ 2 2
L. Interchangeability and Intermixability of Parts ........................... 2 2
2. MATERIAL INFORMATION ........................................ 2 3
A. Material - Price and Availability ................................... 2 3
B. Industry Support Information .................................... 2 3
C. Parts Necessary For Each Airplane ................................. 2 3
1. Kits/Parts: ........................................... 2 3
2. Parts and Materials Supplied by the Operator: ........................ 2 3
3. Parts Modified and Reidentified: ............................... 2 4
4. Parts Removed and Not Replaced: .............................. 2 4
D. Parts Necessary to Change Spares ................................. 2 4
E. Special Tooling - Price and Availability ............................... 2 4
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 5
FIGURE 1: SEAL OF THE FASTENERS [Group 1-2; Group 3, Configuration 1] ............ 2 9
FIGURE 2: UPPER WING SKIN - LEFT MAIN TANK - LOCATION OF THE FASTENERS [Group 1-2; Group
3, Configuration 1] ....................................... 3 1
FIGURE 3: UPPER WING SKIN - RIGHT MAIN TANK - LOCATION OF THE FASTENERS [Group 1-2;
Group 3, Configuration 1] ................................... 3 3
FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS
[Group 2] ............................................ 3 5
FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE
FASTENERS [Group 2] .................................... 3 9
FIGURE 6: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - LEFT WING [Group
3 ]  ................................................ 4 3
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FIGURE 7: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - RIGHT WING [Group
3 ]  ................................................ 4 5
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Commercial 
Airplanes
767
Service Bulletin
Revision Transmittal SheetNumber: 767-57A0100Original Issue: August 21, 2006
Revision 3: July 28, 2011
ATA System: 5720 2811
SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant
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, Revision 1 or Revision
2 of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service bulletin.
REASON FOR REVISION
This revision is sent to correct the quantity of the fasteners specified in Figure 5. The figure incorrectly shows
15 fasteners that must be sealed at Rear Spar Station (RSS) 468.06. The correct fastener quantity for RSS
468.06 is 14. Also clarification was added to show that Figure 1 is a typical view of a fastener that was intended
to apply to rivets or bolts with collars.
These sections were changed:
1. In Figure 1, added the text rivet or bolt with a collar to the illustration and to footnotes (a), (c), (e), and (f).
2. In Figure 5, updated the illustration text to specify 14 locations at RSS 468.06 and update the total fastener
quantity in the table.
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
August 21, 2006Original Issue:
June 19, 2008Revision 1:
May 20, 2010Revision 2:
July 28, 2011Revision 3:
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Commercial 
Airplanes
767
Service Bulletin
SummaryNumber: 767-57A0100Original Issue: August 21, 2006
Revision 3: July 28, 2011
ATA System: 5720 2811
SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Accomplishment of the modifications within this service bulletin will help prevent possible ignition sources in the
main fuel tanks, and the surge tanks caused by a lightning strike on certain wing surfaces. An ignition source
in a fuel tank could result in a fire or an explosion.
A review by Boeing identified a certain fastener type in the fuel tank walls that have an insufficient bond to the
structure. If energy from lightning strike goes through these fasteners, arcing can occur at the ends of the
fasteners in the fuel tank. The ends of the fasteners in the fuel tank do not have sufficient electrical insulation
to contain the energy from the arcs.
This Service Bulletin gives the instructions to seal the end of certain fasteners in the fuel tank walls. These
changes make sure that the risk of an ignition source in the fuel tank from a lightning strike on the wing is kept
to a minimum.
This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank
System Fault Tolerance Evaluation Requirements".
ACTION (PRR B13421-10)
Group 1:
Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the fasteners on the
brackets that hold the vortex generators. Get access to the right main tank. Seal the ends of the fasteners on
the brackets that hold the vortex generators. Close access to the main fuel tanks.
Group 2:
Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the fasteners on the
brackets that hold the vortex generators. Seal the ends of fasteners on certain stiffeners on the rear spar. Get
access to the right main tank. Seal the ends of the fasteners on the brackets that hold the vortex generators.
Seal the ends of fasteners on certain stiffeners on the rear spar. Close access to the main fuel tanks.
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Group 3:
Get access to the outer surface of the upper wing panel on the left wing. Do a General Visual Inspection of the
specified vortex generators on the upper wing panel of the left wing. Get access to the outer surface of the upper
wing panel on the right wing. Do a General Visual Inspection of the specified vortex generators on the upper
wing panel on the right wing. If the vortex generators are attached with adhesive alone, no more work is necessary.
If the vortex generators are attached with fasteners, do the following steps: Prepare the main fuel tanks for entry.
Get access to the left main tank. Seal the ends of the fasteners on the brackets that hold the vortex generators.
Get access to the right main tank. Seal the ends of the fasteners on the brackets that hold the vortex generators.
Close access to the main fuel tanks.
Service Bulletin 767-57A0102 has similar access requirements as this bulletin and can be incorporated at the
same time or separately. Service Bulletin 767-57A0102 is separate from this bulletin because it makes
improvements to existing design and does not have warranty remedies.
EFFECTIVITY
767-200/-300/-300F/-400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service bulletin.
Boeing recommends that this service bulletin be incorporated within 60 months from the effective date of FAA
AD 2009-18-02.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are available for airplanes in warranty as of July 16, 2004. Please refer to Paragraph
2.B., Industry Support Information.
MANPOWER
Elapsed HoursTotal Task HoursAirplanes
10.0029.25Group 1
38.81143.24Group 2
10.0529.75Group 3, Config-
uration 1
0.500.50Group 3, Config-
uration 2
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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Commercial 
Airplanes
767
Service Bulletin
Number: 767-57A0100
Original Issue: August 21, 2006
Revision 3: July 28, 2011
ATA System: 5720 2811
SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent
production airplanes. Refer to PRRB13421-10 for data about this change.
Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP
767-200/300/300F airplanes-1
767-400ER airplanes-2
767-200/300 airplanes that have vortex fasteners installed with or
without fasteners
-3
Airplanes that have vortex generators installed with fasteners1
Airplanes that have vortex generators installed with adhesive alone2
Airplane Models:
767-200, 767-300, 767-300F, 767-400ER
GroupVariable Number
1VA001 - VA020
1VA301 - VA315
1VA501 - VA515
3VA516 - VA519
1VA520 - VA530
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GroupVariable Number
1VA701 - VA719
1VA801 - VA810
1VB001 - VB002
1VB051 - VB055
1VB101 - VB121
3VB122 - VB123
1VB124 - VB125
1VB201 - VB202
1VB251 - VB253
1VB281 - VB284
1VB301 - VB302
1VB321 - VB332
1VB371 - VB373
1VB401
1VB441 - VB444
1VE001 - VE003
1VE021 - VE023
3VE041
1VE042 - VE043
1VE061 - VE066
3VE067 - VE068
1VE069
1VE083 - VE086
1VE101
3VE102 - VE103
1VE104
3VE116 - VE117
1VE118
1VE121 - VE126
1VE141 - VE152
1VE171 - VE172
1VF001 - VF002
1VF041 - VF042
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GroupVariable Number
1VF051
1VF061 - VF062
1VF071 - VF072
1VF091 - VF093
1VF101 - VF102
1VF161 - VF162
1VF171 - VF172
1VF180 - VF184
1VF251
3VK001 - VK003
1VK004 - VK016
1VK021 - VK022
3VK031
1VK032 - VK056
1VK081 - VK113
1VK131 - VK133
1VK141 - VK148
1VK161 - VK164
1VK171
1VK181
1VK186
1VL001 - VL006
1VL011
1VL701 - VL703
1VL751 - VL755
1VL806 - VL807
1VL871 - VL873
1VL891 - VL900
1VL911 - VL914
1VL931 - VL932
1VL941
1VN001 - VN041
1VN051 - VN064
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GroupVariable Number
1VN081 - VN099
1VN111 - VN127
1VN130 - VN137
1VN151 - VN158
1VN163 - VN168
1VN171 - VN174
1VN191 - VN198
1VN211 - VN212
1VN221 - VN225
1VN231 - VN234
1VN241 - VN243
1VN251 - VN276
1VN291 - VN293
1VN301 - VN314
1VN371 - VN372
1VN376
1VN381 - VN388
1VN421 - VN427
1VN436
1VN471 - VN472
1VN491 - VN513
1VN531 - VN532
1VN536 - VN537
1VN541 - VN542
1VN546 - VN547
1VN551
1VN556 - VN557
1VN561 - VN562
1VN631 - VN638
1VN651 - VN658
1VN671 - VN672
1VN676
1VN681 - VN691
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GroupVariable Number
1VN731 - VN732
1VN751 - VN753
1VN791 - VN792
1VN811 - VN813
1VN921 - VN922
1VN931 - VN936
1VN951 - VN953
1VN966 - VN972
2VQ001 - VQ021
2VQ071 - VQ086
1VR051 - VR060
1VR081
1VR084
1VR086 - VR087
1VR106
1VR201 - VR211
1VR251
1VR256 - VR260
1VR401
1VR421 - VR423
1VR426
1VR441
1VR461
1VR471 - VR472
1VS051 - VS056
1VS061
1VS066 - VS070
1VS073 - VS078
1VS091 - VS104
1VS111 - VS113
1VS131 - VS133
1VS136 - VS137
1VS176 - VS177
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GroupVariable Number
1VS186 - VS187
1VS196 - VS203
1VS206 - VS208
1VS211
1VS216 - VS217
1VS231
1VS246 - VS248
1VS261 - VS263
1VS266 - VS274
1VS291 - VS293
1VS301 - VS303
1VS306 - VS311
1VS316
1VS321 - VS324
1VS331 - VS333
1VS336 - VS337
1VS366 - VS367
1VS381 - VS382
1VS391 - VS392
1VS401
1VS426 - VS428
1VS466 - VS472
1VS486
1VS496 - VS497
1VS506 - VS507
1VS526
1VS546 - VS549
1VS701 - VS712
1VS721 - VS732
1VS751 - VS759
1VS821 - VS825
1VS841 - VS844
1VS861
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GroupVariable Number
1VS881 - VS883
1VS891
1VS896
1VT501
1VT511
1VV001
1VW701 - VW721
1VW851
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Accomplishment of the modifications within this service bulletin will help prevent possible ignition
sources in the main fuel tanks, and the surge tanks caused by a lightning strike on certain wing surfaces.
An ignition source in a fuel tank could result in a consequent fire or explosion.
A review by Boeing identified a certain fastener type in the fuel tank walls that have an insufficient bond
to the structure. If energy from lightning strike goes through these fasteners, arcing can occur at the
ends of the fasteners in the fuel tank. The ends of the fasteners in the fuel tank do not have sufficient
electrical insulation to contain the energy from the arcs.
This Service Bulletin gives the instructions to seal the end of certain fasteners in the fuel tank walls.
These changes make sure that the risk of an ignition source in the fuel tank from a lightning strike on
the wing is kept to a minimum.
This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel
Tank System Fault Tolerance Evaluation Requirements".
Revision 1 is sent to to give instructions to do a General Visual Inspection of the vortex generators on
certain airplanes. Before work is done, the vortex generators on certain airplanes must be inspected
to determine if the vortex generators are installed with fasteners or adhesive alone. An operator reported
that the vortex generators on some 767 airplanes are attached with adhesive alone. If fasteners are
not used to install the vortex generators it is not necessary to apply sealant at these locations. A review
of the engineering drawing for the upper wing inspar panel installation confirms that some airplanes in
a certain line number range were delivered with vortex generators that are attached by adhesive alone.
The data given in Information Notice 767-57A0100 IN 01 is included in this revision.
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Revision 2 is sent to correct a typographical error in the quantity of fasteners specified in certain figures.
Figure 4 and Figure 5 correctly shows 10 fasteners that must be sealed at Rear Spar Station (RSS)
916.70 and the text after the circle note specifies a quantity of 9 locations. Also this revision corrects
discrepancies in references and specifies alternative fuel tank sealants.
The data given in Information Notice 767-57A0100 IN 02 is included in this revision.
Revision 3 is sent to correct the quantity of the fasteners specified in Figure 5. The figure incorrectly
shows 15 fasteners that must be sealed at Rear Spar Station (RSS) 468.06. The correct fastener
quantity for RSS 468.06 is 14. Also clarification was added to show that Figure 1 is a typical view of a
fastener that was intended to apply to rivets or bolts with collars.
D. Description
Group 1:
Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the fasteners
on the brackets that hold the vortex generators. Get access to the right main tank. Seal the ends of
the fasteners on the brackets that hold the vortex generators. Close access to the main fuel tanks.
Group 2:
Prepare the main fuel tanks and surge tanks for entry. Get access to the left main tank. Seal the ends
of the fasteners on the brackets that hold the vortex generators. Seal the ends of fasteners on certain
stiffeners on the rear spar. Get access to the right main tank. Seal the ends of the fasteners on the
brackets that hold the vortex generators. Seal the ends of fasteners on certain stiffeners on the rear
spar. Close access to the main fuel tanks.
Group 3:
Get access to the outer surface of the upper wing panel on the left wing. Do a General Visual Inspection
of the specified vortex generators on the upper wing panel of the left wing. Get access to the outer
surface of the upper wing panel on the right wing. Do a General Visual Inspection of the specified vortex
generators on the upper wing panel on the right wing. If the vortex generators are attached with adhesive
alone, no more work is necessary. If the vortex generators are attached with fasteners, do the following
steps: Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the
fasteners on the brackets that hold the vortex generators. Get access to the right main tank. Seal the
ends of the fasteners on the brackets that hold the vortex generators. Close access to the main fuel
tanks.
Service Bulletin 767-57A0102 has similar access requirements as this bulletin and can be incorporated
at the same time or separately. Service Bulletin 767-57A0102 is separate from this bulletin because it
makes improvements to existing design and does not have warranty remedies.
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
and Revision 1 of this service bulletin.
Revision 3 - No more work is necessary on airplanes changed in accordance with the original issue,
Revision1, and Revision 2 of this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
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Group 1:
Affected Maintenance Zones
ZoneModel
541, 641767-200, 767-300, 767-300F
Group 2:
Affected Maintenance Zones
ZoneModel
541, 542, 641, 642767-400ER
Group 3:
Affected Maintenance Zones
ZoneModel
541, 641767-200, 767-300
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service
bulletin.
Boeing recommends that this service bulletin be incorporated within 60 months from the effective date
of FAA AD 2009-18-02.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection
or modification) defined in this service bulletin as an alternative method of compliance to the requirements
of paragraph (f) of AD 2009-18-02. All provisions of AD 2009-18-02 that are not specifically referenced
in the above statement remain fully applicable and must be complied with.
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G. Manpower
The table below shows an estimate of the task-hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task-hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Group 1:
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.2513.004Prepare
1.503.002Open Access
3.006.002Figure 1 and Figure
2
1.807.254Close Access
8.7529.25TOTAL FOR EACH AIRPLANE
Group 2:
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.2513.004Prepare
3.006.002Open Access
3.006.002Figure 1 and Figure
3
13.5054.004Figure 1 and Figure
4
13.5054.004Figure 1 and Figure
5
2.5610.254Close Access
38.81143.25TOTAL FOR EACH AIRPLANE
Group 3, Configuration 1:
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.500.501Inspect - Figure 6
and Figure 7
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Group 3, Configuration 1:
Elapsed HoursTask HoursNumber of Per-
sons
Task
3.2513.004Prepare
1.503.002Open Access
3.006.002Figure 1 and Figure
2
1.807.254Close Access
10.0529.75TOTAL FOR EACH AIRPLANE
Group 3, Configuration 2:
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.500.501Inspect - Figure 6
and Figure 7
0.500.50TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
Group 1; Group 3, Configuration 1:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+152.6+0.14Group 1
Group 2:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+1526+1.4Group 2
Group 3, Configuration 2:
None.
I. Electrical Load Data
Not changed.
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J. References
1. Existing Data:
a. Engineering Change Memo PRR B13421-10
b. 767 Aircraft Maintenance Manual (AMM) 28-11-00, 28-11-01, 28-11-02, 28-11-03, 28-26-00
c. Boeing Service Bulletin 767-57A0102
d. Boeing Standard Overhaul Practices Manual SOPM 20-30-93
e. Federal Aviation Administration (FAA) Airworthiness Directive 2009-18-02
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Rear Spar Inst - Wing112T1901
Panel Installation, Inspar Wing, Upper112T3000
These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary For Each
Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin
does not show the Boeing price and supply data.
B. Industry Support Information
Boeing warranty remedies are available for 767 airplanes in warranty as of July 16, 2004. For man-hour
and material reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing
Commercial Airplanes Group - Warranties.
C. Parts Necessary For Each Airplane
1. Kits/Parts:
None.
2. Parts and Materials Supplied by the Operator:
Group 1-2; Group 3, Configuration 1:
NotesNameQTYPart Number /
Specification
(a) (b)SOLVENT10 fl. oz.BMS 11-7 (SOL-
VENTS IN SOPM
20-30-93optional)
(a) (b)SEALANT7 fl. oz.BMS 5-45, CLASS
A-2, GRADE
1(PERMITTED AL-
TERNATIVE FUEL
TANK SEALANTS
IN 767 AMM 28-
11-01 optional)
(a) (b)SEALANT28 fl. oz.BMS 5-45, CLASS
B-2 (PERMITTED
ALTERNATIVE
FUEL TANK
SEALANTS IN 767
AMM 28-11-01 op-
tional)
(a)WIPER, ABSORBENT-BMS 15-5
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
(b) Quantity is approximate.
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Group 3, Configuration 2:
None.
3. Parts Modified and Reidentified:
None.
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. 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 ensure visual access to all surfaces in the
inspection area. This level of inspection is made under normal 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.
4. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "as
given in" are included in the instruction, the procedure in the Boeing document must
be used.
B. WORK INSTRUCTIONS
WARNING: KEEP PERSONS AND EQUIPMENT AWAY FROM ALL CONTROL SURFACES WHEN
HYDRAULIC POWER IS SUPPLIED. AILERONS, ELEVATORS, RUDDER, FLAPS,
SLATS, SPOILERS, AND STABILIZER ARE FULLY POWERED SURFACES. INJURY
TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC
POWER IS SUPPLIED.
1. Group 3:
Get access to the outer surface of the upper wing panel on the left wing.
2. Group 3:
Do a General Visual Inspection of the specified vortex generators on the upper wing panel on the
left wing as given in FIGURE 6.
WARNING: KEEP PERSONS AND EQUIPMENT AWAY FROM ALL CONTROL SURFACES WHEN
HYDRAULIC POWER IS SUPPLIED. AILERONS, ELEVATORS, RUDDER, FLAPS,
SLATS, SPOILERS, AND STABILIZER ARE FULLY POWERED SURFACES. INJURY
TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC
POWER IS SUPPLIED.
3. Group 3:
Get access to the outer surface of the upper wing panel on the right wing.
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4. Group 3:
Do a General Visual Inspection of the specified vortex generators on the upper wing panel on the
right wing as given in FIGURE 7.
5. Group 3:
If the vortex generators are attached with adhesive alone, no more work is necessary. If the vortex
generators are attached with fasteners, go to the next step.
NOTE: Airplanes with vortex generators that are attached with fasteners are in Group 3,
Configuration 1.
NOTE: Airplanes with vortex generators that are attached with adhesive alone are in Group 3,
Configuration 2.
6. Group 1-2; Group 3, Configuration 1:
Defuel the left and right main fuel tank. Refer to 767 AMM 28-26-00, Page Block 201 as an accepted
procedure.
7. Group 1; Group 3, Configuration 1:
Prepare the left and right main fuel tanks for entry. Refer to 767 AMM 28-11-00 Page Block 201
as an accepted procedure.
8. Group 2:
Prepare the left and right main fuel tanks and surge tanks for entry. Refer to 767 AMM 28-11-00
Page Block 201 as an accepted procedure.
9. Group 1; Group 3, Configuration 1:
Get access to the left main fuel tank. Remove and keep the access doors as shown in the table
below. Refer to 767 AMM 28-11-01 as an accepted procedure.
Gives Access to Rear or Front Spar
Area between Rib Number
Access Door
Ribs 10 and 11541AB
Ribs 11 and 12541BB
Ribs 12 and 13541CB
10. Group 1; Group 3, Configuration 1:
Get access to the right main fuel tank. Remove and keep the access doors as shown in the table
below. Refer to 767 AMM 28-11-01 as an accepted procedure.
Gives Access to Rear or Front Spar
Area between Rib Number
Access Door
Ribs 10 and 11641AB
Ribs 11 and 12641BB
Ribs 12 and 13641CB
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11. Group 2:
Get access to the left main fuel tank and the surge tank. Remove and keep the access doors as
shown in the table below. Refer to 767 AMM 28-11-01 and 767 AMM 28-11-03 as an accepted
procedure.
Gives Access to Rear or Front Spar
Area between Rib Number
Access Door
Ribs 11 and 12541BB
Ribs 12 and 13541CB
Ribs 28 and 29541VB
Ribs 30 and 31541XB
Ribs 32 and 33542BB
12. Group 2:
Get access to the right main fuel tank and the surge tank. Remove and keep the access doors as
shown in the table below. Refer to 767 AMM 28-11-01 and 767 AMM 28-11-03 as an accepted
procedure.
Gives Access to Rear or Front Spar
Area between Rib Number
Access Door
Ribs 11 and 12641BB
Ribs 12 and 13641CB
Ribs 28 and 29641VB
Ribs 30 and 31641XB
Ribs 32 and 33642BB
13. Group 1-2; Group 3, Configuration 1:
Find and seal the fasteners for the brackets that hold the vortex generators on the upper wing skin
in the main tank in as given in:
— FIGURE 1 for the seal of the fastener
— FIGURE 2 for the location of the fasteners in the left main tank
— FIGURE 3 for the location of the fasteners in the right main tank.
14. Group 2:
Find and seal the fasteners for the stiffeners on the rear spar in the main tank and the surge tank
as given in:
— FIGURE 1 for the seal of the fastener
— FIGURE 4 for the location of the fasteners in the left main tank and surge tank
— FIGURE 5 for the location of the fasteners in the right main tank and surge tank.
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15. Group 1; Group 3, Configuration 1:
Close access to the fuel tanks. Install the access doors that were removed. Refer to 767 AMM
28-11-01 as an accepted procedure.
16. Group 2:
Close access to the fuel tanks. Install the access doors that were removed. Refer to 767 AMM
28-11-01 and 767 AMM 28-11-03 as an accepted procedure.
17. Group 1-2; Group 3, Configuration 1:
Put the airplane back to a serviceable condition.
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This Figure applies only to: Group 1-2; Group 3, Configuration 1.
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Make sure that the
debris around the
areas to be sealed
is removed.
--DEBRISRemove1
Use a BMS 15-5
wiper wet with sol-
vent. (a)
-BMS 11-7  (SOL-
VENTS IN BSOPM 20-
30-93 optional)
SOLVENTApply2
Use a non-metallic
brush.
--FASTENERSClean
The remaining sol-
vent must be re-
moved while wet
with a clean, dry
BMS 15-5 wiper. (b)
--SOLVENTRemove
Use a BMS 15-5
wiper wet with sol-
vent. (a)(c)
-BMS 11-7  (SOL-
VENTS IN BSOPM 20-
30-93 optional)
SOLVENTApply3
Use a non-metallic
brush.
--FASTENERSClean
The remaining sol-
vent must be re-
moved while wet
with a clean, dry
BMS 15-5 wiper.(b)
--SOLVENTRemove
FIGURE 1: SEAL OF THE FASTENERS
(SHEET 1 OF 2)
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MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Precoat sealant.
(d)(e)
-BMS 5-45, CLASS A-2,
GRADE 1  (PERMIT-
TED ALTERNATIVE
FUEL TANK
SEALANTS IN 767
AMM 28-11-00 option-
al)
SEALANTApply4
Fillet sealant. (d)(f)-BMS 5-45, CLASS B-2,
GRADE 1  (PERMIT-
TED ALTERNATIVE
FUEL TANK
SEALANTS IN 767
AMM 28-11-00 option-
al)
SEALANTApply5
(a) Make sure that an area approximately 0.5 inch from the base of the fastener (rivet or bolt with a collar) is
clean. The cleaned area must be larger than the area that has sealant.
(b) Make sure that the wiper has no visible soil remaining after the area is cleaned.
(c) It is not necessary to apply solvent, clean the fasteners (rivets or bolts with collars) and remove the solvent
again if Step 2 is done immediately before the precoat sealant is applied.
(d) Make sure to use the sealants specified in this table or specified alternatives.
(e) Make sure to apply the precoat sealant on the fastener (rivet or bolt with a collar). Refer to 767 AMM 28-
11-00 as an accepted procedure.
(f) Make sure to apply the fillet sealant on the fastener (rivet or bolt with a collar). Refer to 767 AMM 28-11-
00 as an accepted procedure.
FIGURE 1: SEAL OF THE FASTENERS
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 1-2; Group 3, Configuration 1.
VORTEX
GENERATOR
- RIB 11
12 LOCATIONS
RIB 12
STRINGER
NO. 25
• RIB 13
2 LOCATIONS
2 LOCATIONS 1
FWD
A—A
INBD
2 LOCATIONS 1
FIGURE 2: UPPER WING SKIN - LEFT MAIN TANK - LOCATION OF THE FASTENERS
(SHEET 1 OF 2)
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### Page 32

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Get access. Find the location of
the fasteners that must be
sealed.
8-FASTENERSLocate1
FIGURE 2: UPPER WING SKIN - LEFT MAIN TANK - LOCATION OF THE FASTENERS
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 1-2; Group 3, Configuration 1.
VORTEX
GENERATOR
RIB 11
2 LOCATIONS
RIB 12
NO. 25
RIB 13  1 2 LOCATIONS
FWD
A-A  → INBD
1 2 LOCATIONS
1 2 LOCATIONS
J68736
FIGURE 3: UPPER WING SKIN - RIGHT MAIN TANK - LOCATION OF THE FASTENERS
(SHEET 1 OF 2)
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### Page 34

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Get access. Find the location of
the fasteners that must be
sealed.
8-FASTENERSLocate1
FIGURE 3: UPPER WING SKIN - RIGHT MAIN TANK - LOCATION OF THE FASTENERS
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 2.
-- WS 0
SEE A
RIB 1
RIB  10
RIB  11
RIB 12
RIB 13
FWD D  REAR SPAR
RIB 28
RIB 29
RIB 30
RIB 31
RIB 32
RIB 33
FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS
(SHEET 1 OF 4)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN 767-57A0100
RSS
RIB 11  468.06
UP
INBD  1 15 LOCATIONS
A-A
RSS
508.06  RIB 13
12 LOCATIONS 1
UP
INBD <  J69170
B~B
FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS
(SHEET 2 OF 4)
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### Page 37 (OCR)

BOEING SERVICE BULLETIN 767-57A0100
9 LOCATIONS 1_
RSS
RIB 28  916.70
UP
9 LOCATIONS 1  1) 10 LOCATIONS
INBD <
RSS
RIB 30  9 LOCATIONS 1  975.60
+ "
UP
INBD
D-D
FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS
(SHEET 3 OF 4)
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### Page 38

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Get access. Find the location of
the fasteners that must be
sealed.
72-FASTENERSLocate1
FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS
(SHEET 4 OF 4)
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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 2.
WS 0-
SEE A
O
RIB 10
RIB 11
• RIB 12
- RIB 13
REAR SPAR  aFWD
RIB 28
RIB 29
RIB 30
RIB 31
RIB 32
RIB 33
J69955
FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE
FASTENERS
(SHEET 1 OF 4)
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### Page 40 (OCR)

BOEING SERVICE BULLETIN 767-57A0100
RSS
468.06  RIB 11
14 LOCATIONS 1
UP
— INBD  A-A
RSS
RIB 13  508.06
112 LOCATIONS
UP
→ INBD  B—B
FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE
FASTENERS
(SHEET 2 OF 4)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 767-57A0100
RSS
916.70  1 9 LOCATIONS  RIB 28
10 LOCATIONS 1  UP
1 9 LOCATIONS
> INBD
C-C
RSS
975.60  RIB 30
1 9 LOCATIONS
UP
—INBD
D-D
FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE
FASTENERS
(SHEET 3 OF 4)
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### Page 42

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Get access. Find the location of
the fasteners that must be
sealed.
71-FASTENERSLocate1
FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE
FASTENERS
(SHEET 4 OF 4)
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### Page 43 (OCR)

BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 3.
VORTEX
GENERATOR
RIB 13
RIB 12
INBD
•RIB 11  FWD
A—A
1545427
FIGURE 6: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - LEFT WING
(SHEET 1 OF 2)
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### Page 44

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
4-VORTEX GENERA-
TOR
Locate1
(a)4-VORTEX GENERA-
TOR
Inspect
(a) Do a General Visual Inspection to find if the vortex generator is installed with fasteners or adhesive alone.
FIGURE 6: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - LEFT WING
(SHEET 2 OF 2)
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### Page 45 (OCR)

BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 3.
VORTEX
GENERATOR
RIB 13
RIB 12
› INBD
FWD  RIB 11
A-A
FIGURE 7: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - RIGHT WING
(SHEET 1 OF 2)
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### Page 46

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
4-VORTEX GENERA-
TOR
Locate1
(a)4-VORTEX GENERA-
TOR
Inspect
(a) Do a General Visual Inspection to find if the vortex generator is installed with fasteners or adhesive alone.
FIGURE 7: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - RIGHT WING
(SHEET 2 OF 2)
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