# Boeing Alert Service Bulletin 767-57A0102: Boeing - Service Bulletin

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- Title as filed: Boeing - Service Bulletin
- Pages: 176
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## Text

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### Page 1

Commercial 
Airplanes
767
Service Bulletin
Number: 767-57A0102
Original Issue: October 25, 2006
Revision 4: September 20, 2011
ATA System: 5710 5720 2811
SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and
Change to Wire Bundle Clamps
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Unpublished Work - All Rights Reserved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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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 .............................................. 2 0
F. Approval ............................................... 2 0
G. Manpower .............................................. 2 1
H. Weight and Balance Changes .................................... 2 9
I. Electrical Load Data ......................................... 2 9
J. References .............................................. 2 9
1. Existing Data: ......................................... 2 9
2. Data supplied with this Service Bulletin: ........................... 3 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 0
K. Publications Affected ........................................ 3 0
L. Interchangeability and Intermixability of Parts ........................... 3 0
2. MATERIAL INFORMATION ........................................ 3 1
A. Material - Price and Availability ................................... 3 1
B. Industry Support Information .................................... 3 2
C. Parts Necessary For Each Airplane ................................. 3 2
1. Kits/Parts: ........................................... 3 2
2. Parts and Materials Supplied by the Operator: ........................ 3 4
3. Parts Modified and Reidentified: ............................... 3 5
4. Parts Removed and Not Replaced: .............................. 3 5
D. Parts Necessary to Change Spares ................................. 3 5
E. Special Tooling - Price and Availability ............................... 3 5
F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7
A. GENERAL INFORMATION ..................................... 3 7
B. WORK INSTRUCTIONS ....................................... 3 8
FIGURE 1: GROUP 1-2 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - POWER FEEDER WIRE
BUNDLES WITH AWG 1/0 AND LARGER WIRES IN THE UNPRESSURIZED AREA [Group
1-2] ............................................... 5 2
FIGURE 2: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH
A DIAMETER MORE THAN 1 INCH [Group 1-3] ....................... 5 5
FIGURE 3: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH
A DIAMETER OF 1 INCH OR LESS [Group 1-3] ....................... 5 8
FIGURE 4: GROUP 1 - FRONT SPAR STATION 143 TO STATION 616 - LEFT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 1] ........................... 6 1
FIGURE 5: GROUP 2 - FRONT SPAR STATION 143 TO STATION 616 - LEFT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 2] ........................... 6 6
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FIGURE 6: GROUP 3 - FRONT SPAR STATION 143 TO STATION 1063 - LEFT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 3] ........................... 7 1
FIGURE 7: GROUP 1 - FRONT SPAR STATION 616 TO STATION 1140 - LEFT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 1] ........................... 7 6
FIGURE 8: GROUP 2 - FRONT SPAR STATION 616 TO STATION 1140 - LEFT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 2] ........................... 8 2
FIGURE 9: GROUP 1 - FRONT SPAR STATION 143 TO STATION 616 - RIGHT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 1] ........................... 8 7
FIGURE 10: GROUP 2 - FRONT SPAR STATION 143 TO STATION 616 - RIGHT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 2] ........................... 9 2
FIGURE 11: GROUP 3 - FRONT SPAR STATION 143 TO STATION 1063 - RIGHT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 3] ........................... 9 7
FIGURE 12: GROUP 1 - FRONT SPAR STATION 616 TO STATION 1140 - RIGHT WING - LOCATION OF
THE WIRE BUNDLE CLAMPS [Group 1] .......................... 1 0 1
FIGURE 13: GROUP 2 - FRONT STATION 616 TO STATION 1140 - RIGHT WING - LOCATION OF THE
WIRE BUNDLE CLAMPS [Group 2] ............................. 1 0 7
FIGURE 14: GROUP 1 - FRONT SPAR - FORWARD CARGO COMPARTMENT - LOCATION OF THE WIRE
BUNDLE CLAMPS [Group 1] ................................. 1 1 3
FIGURE 15: GROUP 2 - FRONT SPAR - FORWARD CARGO COMPARTMENT - LOCATION OF THE WIRE
BUNDLE CLAMPS [Group 2] ................................. 1 1 5
FIGURE 16: GROUP 1-2 - REAR SPAR - MAIN WHEEL WELL - LOCATION OF THE WIRE BUNDLE
CLAMPS [Group 1-2] ..................................... 1 1 7
FIGURE 17: GROUP 1-3 - SEAL OF THE FASTENER [Group 1-3] ................... 1 1 9
FIGURE 18: GROUP 1 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS
[Group 1] ............................................ 1 2 1
FIGURE 19: GROUP 1 - FRONT SPAR - LEFT WING - SURGE TANK - LOCATION OF THE FASTENERS
[Group 1] ............................................ 1 2 8
FIGURE 20: GROUP 2 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS
[Group 2] ............................................ 1 3 1
FIGURE 21: GROUP 2 - FRONT SPAR - LEFT WING - SURGE TANK - LOCATION OF THE FASTENERS
[Group 2] ............................................ 1 4 0
FIGURE 22: GROUP 1 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE
FASTENERS [Group 1] .................................... 1 4 3
FIGURE 23: GROUP 1 - FRONT SPAR - RIGHT WING - SURGE TANK - LOCATION OF THE FASTENERS
[Group 1] ............................................ 1 5 0
FIGURE 24: GROUP 2 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE
FASTENERS [Group 2] .................................... 1 5 3
FIGURE 25: GROUP 2 - FRONT SPAR - RIGHT WING - SURGE TANK - LOCATION OF THE FASTENERS
[Group 2] ............................................ 1 6 2
FIGURE 26: GROUP 3 - FRONT SPAR - LEFT WING - MAIN FUEL TANK - LOCATION OF THE FASTENERS
[Group 3] ............................................ 1 6 5
FIGURE 27: GROUP 3 - FRONT SPAR - RIGHT WING - MAIN FUEL TANK - LOCATION OF THE
FASTENERS [Group 3] .................................... 1 6 8
FIGURE 28: GROUP 2 - CENTER BAY - AUXILIARY FUEL TANK - LOCATION OF THE FASTENERS
[Group 2] ............................................ 1 7 1
FIGURE 29: GROUP 1 - CENTER BAY - AUXILIARY FUEL TANK - LOCATION OF THE FASTENERS
[Group 1] ............................................ 1 7 4
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Commercial 
Airplanes
767
Service Bulletin
Revision Transmittal SheetNumber: 767-57A0102Original Issue: October 25, 2006
Revision 4: September 20, 2011
ATA System: 5710 5720 2811
SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and
Change to Wire Bundle Clamps
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Refer
to Work Packages 10, 11 and 12 for work instructions.
More work is necessary on airplanes changed in accordance with the original issue, Revision 1 or Revision 2
of this service bulletin. Refer to Work Package 13 for work instructions.
No more work is necessary on airplanes changed in accordance with Revision 3 of this service bulletin.
Airplane VV001 was added to Group 1 of this service bulletin effectivity.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service bulletin.
REASON FOR REVISION
This revision is sent to add VV001 to the service bulletin effectivity and to correct the quantity of the fasteners
in Figure 20 and Figure 24 view C-C. Also clarification was added to show that Figure 17 is a typical view of a
fastener that was intended to apply to rivets or bolts with collars.
These sections were changed:
1. In Manpower, added a table to Work Package 12 to have a table for Group 1 and another table for Group
2. Figure 24 was eliminated from Group 1 and Figure 22 was eliminated from Group 2.
2. In Manpower, added applicability for Work Package 13.
3. In the Parts and Materials Supplied by the Operator, added footnote (d) to all the tables to provide the pre
shrink diameter of the TFE-2X Standard Wall sleeve.
4. In Work Package 1, added the word left for clarification and consistency.
5. In Work Package 2, added the word right for clarification and consistency.
6. In Work Package 5, change access doors 532DB, 532EB, and 532FB to 533AB.
7. In Work Package 6, change access doors 632DB, 632EB, and 632FB to 633 AB.
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8. In Work Package 13, added applicability of Group 1-2.
9. In Figure 1, added footnote (a) to step 6. Also added the text each power feeder wire to footnotes (a) and
(b). The TFE-2X STANDARD WALL sleeve was added as an optional part for the 005W3281-() sleeve.
10. In Figure 2, added footnote (a) to step 4. The TFE-2X STANDARD WALL sleeve was added as an optional
part for the 005W3281-() sleeve.
11. In Figure 3, added footnote (a) to step 4. The TFE-2X STANDARD WALL sleeve was added as an optional
part for the 005W3281-() sleeve.
12. In Figure 17, added the text rivet or bolt with a collar to the illustration and to footnotes (a), (c), (d), and (e).
13. In Figure 20, updated the illustration text of view C-C to specify 16 locations and updated the total fastener
quantity in the table.
14. In Figure 24, updated the illustration text of view C-C to specify 16 locations and updated 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
October 25, 2006Original Issue:
November 27, 2007Revision 1:
January 07, 2010Revision 2:
December 02, 2010Revision 3:
September 20, 2011Revision 4:
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Commercial 
Airplanes
767
Service Bulletin
SummaryNumber: 767-57A0102Original Issue: October 25, 2006
Revision 4: September 20, 2011
ATA System: 5710 5720 2811
SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and
Change to Wire Bundle Clamps
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Accomplishment of the modifications within this service bulletin will help prevent possible ignition sources in the
auxiliary fuel tank, main fuel tanks, and surge tanks caused by a wiring short. An ignition source in a fuel tank
could result in a fire or an explosion.
A safety assessment by Boeing identified a certain type of fastener that penetrates the fuel tank wall and has
an insufficient electrical bond to the fuel tank structure. These fasteners can be a path for electrical energy to
enter the fuel tank if a wiring short occurs in a wire bundle installed along the fuel tank boundary structure. The
electrical energy from the wiring short can go through these fasteners because they have an insufficient bond
to the fuel tank structure. This energy can be sufficient to cause arcing at the ends of these fasteners in the fuel
tank. If arcing occurs it can be an ignition source in a fuel tank.
This Service Bulletin makes these changes where a high energy short can occur and certain fasteners are
installed: Installs a polytetraflouroethylene (TFE) sleeve on the wire bundles where the wire bundle clamp is
installed to give more protection from chafing, replaces the wire bundle clamps with a different design that has
better protection on its metal edges, and seals the ends of the fasteners in the fuel tanks to contain the electrical
energy from a wiring short. These changes make sure that the risk of an ignition source in the fuel tank from a
short 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 B13421-11)
This service bulletin is divided into work packages that are related to the different areas of the airplane.
Work Package 1 - Get access to the left front spar of the outer wing and change the clamp configurations at the
specified locations.
Work Package 2 - Get access to the right front spar of the outer wing and change the clamp configurations at
the specified locations.
Work Package 3 - Get access to the front spar of the center wing in the forward cargo area and change the
clamp configurations at the specified locations.
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Work Package 4 - Get access to the rear spar of the center wing in the main wheel well on the right side and
change the clamp configurations at the specified locations.
Work Package 5 - Prepare the main fuel tank and surge tank in the left wing for entry. Get access to the fasteners
and seal the fasteners and certain stiffeners at the specified locations in the fuel tank. Close access to the main
fuel tank and the surge tank.
Work Package 6 - Prepare the main fuel tank and surge tank in the right wing for entry. Get access to the
fasteners and seal the fasteners and certain stiffeners at the specified locations in the fuel tank. Close access
to the main fuel tank and the surge tank.
Work Package 7 - Prepare the center bay of the auxiliary fuel tank for entry. Get access to the fasteners and
seal the fasteners at the specified locations in the fuel tank. Close access to the auxiliary fuel tank.
Work Package 8 - Get access to the main fuel tank in the left wing. Get access to the fasteners and seal the
fasteners and certain stiffeners at the specified locations in the fuel tank. Close access to the main fuel tank.
Work Package 9 - Prepare the main fuel tank in the right wing. Get access to the fasteners and seal the fasteners
and certain stiffeners at the specified locations in the fuel tank. Close access to the main fuel tank.
Work Package 10 - Prepare the center bay of the auxiliary fuel tank for entry. Get access to the fasteners on
the rear spar at the specified locations. Do a General Visual Inspection of the fasteners at the specified locations.
If the fasteners are not sealed, seal the fasteners at the specified locations. Close access to the auxiliary fuel
tank.
Work Package 11 - Prepare the left main fuel tank for entry. Get access to the fasteners at rib 28. Do a General
Visual Inspection of the fasteners for sealant. If the fasteners are not sealed, seal the fasteners at the specified
locations at rib 28. Close access to the left main fuel tank.
Work Package 12 - Prepare the right main fuel tank for entry. Get access to the fasteners at rib 28. Do a General
Visual Inspection of the fasteners at the specified locations. If the fasteners are not sealed, seal the fasteners
at the specified locations at rib 28. Close access to the right main fuel tank.
Work Package 13 - Get access to the right wheel well. Do a General Visual Inspection of the clamp location on
the rear spar. If a TFE sleeve is not installed between the clamp and the plastic convoluted tubing, install a TFE
sleeve between the clamp and the plastic convoluted tubing. Close access to the right wheel well.
Return the airplane to a serviceable condition.
Service bulletin 767-57A0100 has common access and defuel requirements. This bulletin can be incorporated
at the same time or separately. Service Bulletin 767-57A0100 is separate from this bulletin because it corrects
a design deficiency and has 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 FAA AD 2009-18-02 is related to this service
bulletin.
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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 not available for the configuration changes given in this service bulletin.
MANPOWER
Elapsed HoursTotal Task HoursAirplanes
110.87330.88Group 1
277.66969.76Group 2
26.4149.97Group 3
15.3225.07Group 1, Configuration 2
24.0238.27Group 2, Configuration 2
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Commercial 
Airplanes
767
Service Bulletin
Number: 767-57A0102
Original Issue: October 25, 2006
Revision 4: September 20, 2011
ATA System: 5710 5720 2811
SUBJECT: WINGS - Center Wing - Outer Wing - Change to Fasteners in Fuel Tank Walls and
Change to Wire Bundle Clamps
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 PRRB13421-11 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, 767-300, 767-300F-1
767-200/300/300F airplanes that have not accomplished the original
issue of Boeing Service Bulletin 767-57A0102
1
767-200/300/300F airplanes that have accomplished the original
issue of Boeing Service Bulletin 767-57A0102
2
767-400ER-2
767-400ER airplanes that have not accomplished the original issue
of Boeing Service Bulletin 767-57A0102
1
767-400ER airplanes that have accomplished the original issue of
Boeing Service Bulletin 767-57A0102
2
767-300 airplanes that need wire bundle clamp changes at limited
locations on the front spar of the wings and sealant applied at limited
locations in the main fuel tanks
-3
Airplane Models:
767-200, 767-300, 767-300F, 767-400ER
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GroupVariable Number
1VA001 - VA020
1VA301 - VA315
1VA501 - VA530
1VA701 - VA719
1VA801 - VA810
1VB001 - VB002
1VB051 - VB055
1VB101 - VB125
1VB201 - VB202
1VB251 - VB253
1VB281 - VB284
1VB301 - VB302
1VB321 - VB332
1VB371 - VB373
1VB401
1VB441 - VB444
1VE001 - VE003
1VE021 - VE023
1VE041 - VE043
1VE061 - VE069
1VE083 - VE086
1VE101 - VE104
1VE116 - VE118
1VE121 - VE126
1VE141 - VE152
1VE171 - VE172
1VF001 - VF002
1VF041 - VF042
1VF051
1VF061 - VF062
1VF071 - VF072
1VF091 - VF093
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GroupVariable Number
1VF101 - VF102
1VF161 - VF162
1VF171 - VF172
1VF180 - VF184
1VF251
1VK001 - VK016
1VK021 - VK022
1VK031 - VK056
1VK081 - VK113
1VK131 - VK133
1VK141 - VK148
1VK161 - VK164
1VK171
1VK181
1VK186
1VL001 - VL006
1VL011
1VL701 - VL703
1VL751 - VL755
1VL806 - VL807
1VL871 - VL873
1VL891 - VL900
1VL911 - VL914
1VL931 - VL932
1VL941
1VN001 - VN041
1VN051 - VN064
1VN081 - VN099
1VN111 - VN127
1VN130 - VN137
1VN151 - VN158
1VN163 - VN168
1VN171 - VN174
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GroupVariable Number
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
1VN731 - VN732
1VN751 - VN753
1VN791 - VN792
1VN811 - VN813
1VN921 - VN922
1VN931 - VN936
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GroupVariable Number
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
1VS186 - VS187
1VS196 - VS203
1VS206 - VS208
1VS211
1VS216 - VS217
1VS231
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GroupVariable Number
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
3VS713 - VS714
1VS721 - VS732
1VS751 - VS759
1VS821 - VS825
1VS841 - VS844
1VS861
1VS881 - VS883
1VS891
1VS896
1VT501
3VT511 - VT512
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GroupVariable Number
3VT521 - VT522
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 auxiliary fuel tank, main fuel tanks, and surge tanks caused by a wiring short. An ignition
source in a fuel tank could result in a fire or an explosion.
A safety assessment by Boeing identified a certain type of fastener that penetrates the fuel tank wall
and has an insufficient electrical bond to the fuel tank structure. These fasteners can be a path for
electrical energy to enter the fuel tank if a wiring short occurs in a wire bundle installed along the fuel
tank boundary structure. The electrical energy from the wiring short can go through these fasteners
because they have an insufficient bond to the fuel tank structure. This energy can be sufficient to cause
arcing at the ends of these fasteners in the fuel tank. If arcing occurs it can be an ignition source in a
fuel tank.
This Service Bulletin makes these changes where a high energy wiring short can occur and certain
fasteners are installed: Installs a polytetraflouroethylene (TFE) sleeve on the wire bundles where the
wire bundle clamp is installed to give more protection from chafing, replaces the wire bundle clamps
with a different design that has better protection on its metal edges, and seals the ends of the fasteners
in the fuel tanks to contain the electrical energy from a wiring short. These changes make sure that
the risk of an ignition source in the fuel tank from a short 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 correct the specified location of fasteners that must be sealed on the rear spar in
the auxiliary fuel tank, correct the specified location of fasteners that must be sealed at rib 28 on the
front spar, add Work Packages for airplanes that accomplished the original issue of this service bulletin,
add references to more access doors that are necessary to get access to the fuel tanks and to specify
permitted alternative fuel tank sealants.
New Work Packages are necessary because the original issue of this service bulletin specified the
incorrect locations for certain fasteners on the rear spar of the auxiliary fuel tank and the front spar of
the main wing. The new Work Packages do a general visual inspection of certain fasteners in the fuel
tanks for sealant and seals the fasteners if they are not sealed already. If the correct fasteners are not
sealed, there is a risk that arcing from a short can enter the fuel tank and be an ignition source.
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Revision 2 is sent to make the installation of a polyamide spacer with power feeder wire bundles more
clear. Some airplanes do not have spacers at the clamp locations. Also, this revision corrects errors
in the access door numbers, corrects the preparation instructions for the work in the main fuel tanks,
and corrects other discrepancies.
The data given in Information Notices 767-57A0102 IN 03, 767-57A0102 IN 04, and 767-57A0102 IN
05 is included in this revision.
Revision 3 is sent to correct a discrepancy in the number of fastener locations specified in Figure 24
and Figure 25. The reason is that sealed fasteners are required to correct the unsafe condition. This
revision is also sent to specify more work to install a polytetraflouroethylene (TFE) sleeve at a clamp
location in the right wheel well. If a TFE sleeve is not installed at this location, this revision gives
instructions to install a TFE sleeve. The reason is that a TFE sleeve is required to correct the unsafe
condition. Also this revision makes clarifications in accomplishment instructions and figures.
The data given in Information Notice 767-57A0102 IN06 is included in this revision.
Revision 4 revision is sent to add VV001 to the service bulletin effectivity and to correct the quantity of
the fasteners in Figure 20 and Figure 24 view C-C. Also clarification was added to show that Figure
17 is a typical view of a fastener that was intended to apply to rivets or bolts with collars.
D. Description
This service bulletin is divided into work packages that are related to the different areas of the airplane.
Group 1-3:
Work Package 1 - Get access to the left front spar of the outer wing and change the clamp configurations
at the specified locations.
Group 1-3:
Work Package 2 - Get access to the right front spar of the outer wing and change the clamp
configurations at the specified locations.
Group 1-2:
Work Package 3 - Get access to the front spar of the center wing in the forward cargo area and change
the clamp configurations at the specified locations.
Group 1-2:
Work Package 4 - Get access to the rear spar of the center wing in the main wheel well on the right
side and change the clamp configurations at the specified locations.
Group 1-2:
Work Package 5 - Prepare the main fuel tank and surge tank in the left wing for entry. Get access to
the fasteners and seal the fasteners and certain stiffeners at the specified locations in the fuel tank.
Close access to the main fuel tank and the surge tank.
Group 1-2:
Work Package 6 - Prepare the main fuel tank and surge tank in the right wing for entry. Get access to
the fasteners and seal the fasteners and certain stiffeners at the specified locations in the fuel tank.
Close access to the main fuel tank and the surge tank.
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Group 1-2:
Work Package 7 - Prepare the center bay of the auxiliary fuel tank for entry. Get access to the fasteners
and seal the fasteners at the specified locations in the fuel tank. Close access to the auxiliary fuel tank.
Group 3:
Work Package 8 - Get access to the main tank in the left wing. Get access to the fasteners and seal
the fasteners at the specified locations in the fuel tank. Close access to the main fuel tank.
Group 3:
Work Package 9 - Get access to the main fuel tank in the right wing. Get access to the fasteners and
seal the fasteners at the specified locations in the fuel tank. Close access to the main fuel tank.
Group 1-2, Configuration 2:
Work Package 10 - Prepare the center bay of the auxiliary fuel tank for entry. Get access to the fasteners
on the rear spar at the specified locations. Do a General Visual Inspection of the fasteners at the
specified locations. If the fasteners are not sealed, seal the fasteners at the specified locations. Close
access to the auxiliary fuel tank.
Group 1, Configuration 2:
Work Package 11 - Prepare the left main fuel tank for entry. Get access to the fasteners at rib 28. Do
a General Visual Inspection of the fasteners for sealant. If the fasteners are not sealed, seal the fasteners
at the specified locations at rib 28. Close access to the left main fuel tank.
Group 1-2, Configuration 2:
Work Package 12 - Prepare the right main fuel tank for entry. Get access to the fasteners at rib 28. Do
a General Visual Inspection of the fasteners at the specified locations. If the fasteners are not sealed,
seal the fasteners at the specified locations at rib 28. Close access to the right main fuel tank.
Work Package 13 - Get access to the right wheel well. Do a General Visual Inspection of the clamp
location on the rear spar. If a TFE sleeve is not installed between the clamp and the plastic convoluted
tubing, install a TFE sleeve between the clamp and the plastic convoluted tubing. Close access to the
right wheel well.
Service bulletin 767-57A0100 has common access and defuel requirements. This bulletin can be
incorporated at the same time or separately. Service Bulletin 767-57A0100 is separate from this bulletin
because it corrects a design deficiency and has warranty remedies.
Revision 1 - More work is necessary on airplanes changed as shown in the original issue of this service
bulletin. Refer to Work Package 10, 11, and 12 for work instructions.
Revision 2 - No more work is necessary on airplanes changed as shown in the original issue and
Revision 1 of this service bulletin.
Revision 3 - More work is necessary on airplanes changed in accordance with the original issue of this
service bulletin. Refer to Work Packages 10, 11 and 12 for work instructions.
Revision 3 - More work is necessary on airplanes changed in accordance with with the original issue,
Revision 1, or Revision 2 of this service bulletin. Refer to Work Package 13 for work instructions.
Revision 4 - No more work is necessary on airplanes changed in accordance with Revision 3 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
511, 521, 531, 541, 542, 611, 621, 631, 641, 642767-200, 767-300, 767-300F
Group 2:
Affected Maintenance Zones
ZoneModel
511, 521, 531, 541, 542, 611, 621, 631, 641, 642767-400ER
Group 3:
Affected Maintenance Zones
ZoneModel
511, 521, 531, 611, 621, 631767-300, 767-300F
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive FAA 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 (g) of FAA AD 2009-18-02. All provisions of FAA 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 work
package. 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:
Work Package 1 - Front Spar - Left Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
2.254.502Open Access
2.875.752Figure 1, 3 and 4
3.757.502Figure 2, 3 and 7
2.374.752Close Access
11.2522.50Total per Airplane
Group 1:
Work Package Number 2, 3, 4, 5, 6, 7 can be done at the same time as Work Package 1.
Group 2:
Work Package 1 - Front Spar - Left Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
2.254.502Open Access
2.875.752Figure 1, 3, and 5
3.126.252Figure 2, 3 and 8
2.374.752Close Access
10.6121.25Total per Airplane
Group 2:
Work Package Number 2, 3, 4, 5, 6, 7 can be done at the same time as Work Package 1.
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Group 3:
Work Package 1 - Front Spar - Left Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
2.254.502Open Access
1.753.502Figure 2, 3 and 6
2.374.752Close Access
6.3712.75Total per Airplane
Group 3:
Work Package Number 2, 8, 9 can be done at the same time as Work Package 1.
Group 1:
Work Package 2 - Front Spar - Right Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
2.254.502Open Access
2.875.752Figure 1, 3 and 9
3.877.752Figure 2, 3 and 12
2.374.752Close Access
11.3722.75Total per Airplane
Group 1:
Work Package Number 1, 3, 4, 5, 6, 7 can be done at the same time as Work Package 2.
Group 2:
Work Package 2 - Front Spar - Right Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
2.254.502Open Access
3.126.252Figure 1, 3 and 10
2.875.752Figure 2, 3 and 13
2.374.752Close Access
10.6721.25Total per Airplane
Group 2:
Work Package Number 1, 3, 4, 5, 6, 7 can be done at the same time as Work Package 2.
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Group 3:
Work Package 2 - Front Spar - Right Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
2.254.502Open Access
1.252.502Figure 2, 3 and 11
2.374.752Close Access
5.8711.75Total per Airplane
Group 3:
Work Package Number 1, 8, 9 can be done at the same time as Work Package 2.
Group 1:
Work Package 3 - Front Spar - Center Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.500.501Open Access
0.640.641Figure 2 and 14
0.750.751Close Access
1.891.89Total per Airplane
Group 1:
Work Package Number 1, 2, 4, 5, 6, 7 can be done at the same time as Work Package 3.
Group 2:
Work Package 3 - Front Spar - Center Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.500.501Open Access
0.640.641Figure 2 and 15
0.750.751Close Access
1.891.89Total per Airplane
Group 2:
Work Package Number 1, 2, 4, 5, 6, 7 can be done at the same time as Work Package 3.
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Group 1-2:
Work Package 4 - Rear Spar - Center Wing - Change of the Wire Bundle Clamps
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.650.651Open Access
0.320.321Figure 3 and 16
0.900.901Close Access
1.871.87Total per Airplane
Group 1-2:
Work Package Number 1, 2, 3, 5, 6, 7 can be done at the same time as Work Package 4.
Group 1:
Work Package 5 - Front Spar - Left Wing - Main Fuel Tank and Surge Tank - Seal of the
Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
6.5013.002Open Access
25.50102.004Figure 17 and 18
3.006.002Figure 17 and 19
3.8115.254Close Access
41.81142.25Total per Airplane
Group 1:
Work Package Number 1, 2, 3, 4, 6, 7 can be done at the same time as Work Package 5.
Group 2:
Work Package 5 - Front Spar - Left Wing - Main Fuel Tank and Surge Tank - Seal of the
Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
6.5013.002Open Access
102.00408.004Figure 17 and 20
6.7513.502Figure 17 and 21
3.8115.254Close Access
122.06455.75Total per Airplane
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Group 2:
Work Package Number 1, 2, 3, 4, 6, 7 can be done at the same time as Work Package 5.
Group 1:
Work Package 6 - Front Spar - Right Wing - Main Fuel Tank and Surge Tank - Seal of
the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
6.5013.002Open Access
25.50102.004Figure 17 and 22
3.006.002Figure 17 and 23
3.8115.254Close Access
41.81142.25Total per Airplane
Group 1:
Work Package Number 1, 2, 3, 4, 5, 7 can be done at the same time as Work Package 6.
Group 2:
Work Package 6 - Front Spar - Right Wing - Main Fuel Tank and Surge Tank - Seal of
the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
6.5013.002Open Access
102.00408.004Figure 17 and 24
6.7513.502Figure 17 and 25
6.7513.504Close Access
122.06455.75Total per Airplane
Group 2:
Work Package Number 1, 2, 3, 4, 5, 7 can be done at the same time as Work Package 6.
Group 2:
Work Package 7 - Center Bay - Auxiliary Fuel Tank - Seal of the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
0.751.502Open Access
3.006.002Figure 17 and 28
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Group 2:
Work Package 7 - Center Bay - Auxiliary Fuel Tank - Seal of the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
1.753.502Close Access
8.5017.00Total per Airplane
Group 2:
Work Package Number 1, 2, 3, 4, 5, 6 can be done at the same time as Work Package 7.
Group 1:
Work Package 7 - Center Bay - Auxiliary Fuel Tank - Seal of the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
0.751.502Open Access
3.006.002Figure 17 and 29
1.753.502Close Access
8.5017.00Total per Airplane
Group 1:
Work Package Number 1, 2, 3, 4, 5, 6 can be done at the same time as Work Package 7.
Group 3:
Work Package 8 - Front Spar - Left Wing - Main Fuel Tank - Seal of the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.500.501Open Access
5.5011.002Figure 17 and 26
1.252.502Close Access
7.2514.00Total per Airplane
Group 3:
Work Package Number 1, 2, 9 can be done at the same time as Work Package 8.
Group 3:
Work Package 9 - Front Spar - Right Wing - Main Fuel Tank - Seal of the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.500.501Open Access
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Group 3:
Work Package 9 - Front Spar - Right Wing - Main Fuel Tank - Seal of the Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
4.308.602Figure 17 and 27
1.252.502Close Access
6.0511.60Total per Airplane
Group 3:
Work Package Number 1, 2, 8 can be done at the same time as Work Package 9.
Group 2, Configuration 2:
Work Package 10 - Center Bay - Auxiliary Fuel Tank - Inspection and Seal of Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
0.751.502Open Access
0.100.101Inspect
1.501.501Figure 17 and 28
1.753.502Close Access
7.1012.60Total per Airplane
Group 1, Configuration 2:
Work Package 10 - Center Bay - Auxiliary Fuel Tank - Inspection and Seal of Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
0.751.502Open Access
0.100.101Inspect
1.501.501Figure 17 and 29
1.753.502Close Access
7.1012.60Total per Airplane
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Group 1, Configuration 2:
Work Package 11 - Front Spar - Left Wing - Main Fuel Tank - Inspection and Seal of
Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
1.001.001Open Access
0.200.201Inspect
1.501.501Figure 17 and 18
1.503.002Close Access
7.2011.70Total per Airplane
Group 1, Configuration 2:
Work Package 12 - Front Spar - Right Wing - Main Fuel Tank - Inspection and Seal of
Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
0.500.502Open Access
1.501.501Figure 17 and 22
0.100.101Inspect
1.252.502Close Access
6.3510.60Total per Airplane
Group 2, Configuration 2:
Work Package 12 - Front Spar - Right Wing - Main Fuel Tank - Inspection and Seal of
Fasteners
Elapsed HoursTask-HoursNumber of Per-
sons
Task
3.006.002Prepare
0.500.502Open Access
1.501.501Figure 17 and 24
0.100.101Inspect
1.252.502Close Access
6.3510.60Total per Airplane
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Group 1-2:
Work Package 13 - Rear Spar - Center Wing - More Work
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.650.651Open Access
0.320.321Figure 3 and 16
0.900.901Close Access
1.871.87Total per Airplane
H. Weight and Balance Changes
Group 1:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+8140+8.8Group 1
Group 2:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+16,465+17.8Group 2
Group 3:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+10171.1Group 3
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR B13421-11
b. Standard Overhaul Practices Manual (SOPM) 20-30-93
c. Boeing Service Bulletin 767-57A0100
d. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12
e. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 24-22-00, 25-52-01, 27-81-00, 28-11-00,
28-11-01, 28-11-02, 28-11-03, 28-11-06, 28-26-00, 32-00-15, 32-00-20
f. Federal Aviation Administration (FAA) Airworthiness Directive 2009-18-02
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2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Wire Bundle Installation 14 Sect L.H. Front Spar & L.E., IFSS 143.5-OFSS 616.0288T1487
Wire Bundle Installation 14 Sect R.H. Front Spar & L.E., IFSS 143.5-OFSS 616.0288T1488
Wire Bundle Installation 14 Sect L.H. Front Spar & L.E., IFSS 616.0-OFSS 1140.0288T1489
Wire Bundle Installation 14 Sect R.H. Front Spar & L.E., IFSS 616.0-OFSS 1140.0288T1490
Wire Bundle Installation 45 Section Front Spar Bulkhead STA. 785.9288T4539
Wire Bundle Installation 45 Sect - R. Wheel Well Area STA. 955-1065288T4570
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:
Chapter-SectionPublication
24-00767 Illustrated Parts Catalog
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
Boeing can supply the kits 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.
Group 1:
Unit Price thru
Sep 30/06
ROLT
(Weeks)
QTYDateNameKit Number
$1,632151005/31/06Top Kit015T1793-1
$1,632151006/14/06Top Kit015T1793-1
$1,632151006/28/06Top Kit015T1793-1
$1,632151007/13/06Top Kit015T1793-1
$1,632151007/27/06Top Kit015T1793-1
$1,632151008/17/06Top Kit015T1793-1
$1,632152509/14/06Top Kit015T1793-1
$1,632152510/12/06Top Kit015T1793-1
$1,632152511/09/06Top Kit015T1793-1
Group 2:
Unit Price thru
Sep 30/06
ROLT
(Weeks)
QTYDateNameKit Number
$1,30415503/30/06Top Kit015T1793-2
Group 3:
Unit Price thru
Sep 30/06
ROLT
(Weeks)
QTYDateNameKit Number
$33816105/31/06Top Kit015T1793-3
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. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle,
Washington 98124-2207 USA
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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 shown below, refer to Paragraph 2.A., Material - Price and Availability.
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.
Group 1:
Kit 015T1793
NotesNameQTYNew Part Number
-1
(a)Sleeve - 5/8 inch I.D (As
supplied 0.93 inch I.D)
3005W3281-4
(a)Sleeve - 1 inch I.D. (As
supplied 1.5 inch I.D.)
6005W3281-5
(a)(b)WIRE BUNDLE CLAMP30BACC10JU105
(a)(b)WIRE BUNDLE CLAMP30BACC10JU106
(a)(b)WIRE BUNDLE CLAMP26BACC10JU107
(a)(b)WIRE BUNDLE CLAMP2BACC10JU109
(a)(b)WIRE BUNDLE CLAMP19BACC10JU110
(a)(b)WIRE BUNDLE CLAMP9BACC10JU111
(a)(b)WIRE BUNDLE CLAMP4BACC10JU113
(a)(b)CLAMP, LOOP2BACC10JU114
(a)(b)CLAMP, LOOP2BACC10KL105R
(a) There are more parts than are necessary.
(b) Some part numbers may not be needed to complete the
change.
Group 2:
Kit 015T1793
NotesNameQTYNew Part Number
-2
(a)Sleeve - 5/8 inch I.D (As
supplied 0.93 inch I.D)
2005W3281-4
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Group 2:
Kit 015T1793
NotesNameQTYNew Part Number
-2
(a)Sleeve - 1 inch I.D. (As
supplied 1.5 inch I.D.)
5005W3281-5
(a)(b)WIRE BUNDLE CLAMP2BACC10JU103
(a)(b)WIRE BUNDLE CLAMP25BACC10JU105
(a)(b)WIRE BUNDLE CLAMP24BACC10JU106
(a)(b)WIRE BUNDLE CLAMP15BACC10JU107
(a)(b)WIRE BUNDLE CLAMP2BACC10JU109
(a)(b)WIRE BUNDLE CLAMP6BACC10JU110
(a)(b)WIRE BUNDLE CLAMP8BACC10JU111
(a)(b)WIRE BUNDLE CLAMP3BACC10JU112
(a)(b)WIRE BUNDLE CLAMP13BACC10JU113
(a)(b)CLAMP, LOOP1BACC10JU114
(a) There are more parts than are necessary.
(b) Some part numbers may not be needed to complete the
change.
Group 3:
Kit 015T1793
NotesNameQTYNew Part Number
-3
(a)Sleeve - 5/8 inch I.D (As
supplied 0.93 inch I.D)
1005W3281-4
(a)Sleeve - 1 inch I.D. (As
supplied 1.5 inch I.D.)
1005W3281-5
(a)(b)WIRE BUNDLE CLAMP17BACC10JU105
(a)(b)WIRE BUNDLE CLAMP3BACC10JU113
(a)(b)CLAMP, LOOP2BACC10JU114
(a) There are more parts than are necessary.
(b) Some part numbers may not be needed to complete the
change.
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2. Parts and Materials Supplied by the Operator:
Group 1:
NotesNameQTYPart Number / Specification
(a)(c)(d)Sleeve3 inchesTFE-2X Standard Wall
(a)(b)LACING TAPE100 ft.BMS 13-54, TYPE III, CLASS 1, FINISH C, WHITE
(a)(b)SOLVENT24 fluid ozBMS 11-7 (SOLVENTS in SOPM 20-30-93 optional)
(a)(b)WIPER50BMS 15-5
(a)(b)SEALANT12 fluid ozBMS 5-45, CLASS A-2 (PERMITTED ALTERNATIVE
FUEL TANK SEALANTS IN 767 AMM 28-11-00, 801
optional)
(a)(b)SEALANT50 fluid ozBMS 5-45, CLASS B-2 (PERMITTED ALTERNATIVE
FUEL TANK SEALANTS IN 767 AMM 28-11-00, 801
optional)
(a) Quantity is approximate.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
(c) Chemplast or Zeus Industrial Products
(d) The pre shrink diameter is 1.5 inches.
Group 2:
NotesNameQTYPart Number / Specification
(a)(c)(d)Sleeve3 inchesTFE-2X Standard Wall
(a)(b)LACING TAPE200 ft.BMS 13-54, TYPE III, CLASS 1, FINISH C, WHITE
(a)(b)SOLVENT48 fluid ozBMS 11-7 (SOLVENTS in SOPM 20-30-93 optional)
(a)(b)WIPER140BMS 15-5
(a)(b)SEALANT42 fluid ozBMS 5-45, CLASS A-2 (PERMITTED ALTERNATIVE
FUEL TANK SEALANTS IN 767 AMM 28-11-00, 801
optional)
(a)(b)SEALANT168 fluid ozBMS 5-45, CLASS B-2 (PERMITTED ALTERNATIVE
FUEL TANK SEALANTS IN 767 AMM 28-11-00, 801
optional)
(a) Quantity is approximate.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier
data.
(c) Chemplast or Zeus Industrial Products
(d) The pre shrink diameter is 1.5 inches.
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Group 3:
NotesNameQTYPart Number / Specification
(a)(c)(d)Sleeve3 inchesTFE-2X Standard Wall
(a)(b)LACING TAPE50 ft.BMS 13-54, TYPE III, CLASS 1, FINISH C, WHITE
(a)(b)SOLVENT4 fluid ozBMS 11-7 (SOLVENTS in SOPM 20-30-93 optional)
(a)(b)WIPER10BMS 15-5
(a)(b)SEALANT3 fluid ozBMS 5-45, CLASS A-2 (PERMITTED ALTERNATIVE
FUEL TANK SEALANTS IN 767 AMM 28-11-00, 801
optional)
(a)(b)SEALANT12 fluid ozBMS 5-45, CLASS B-2 (PERMITTED ALTERNATIVE
FUEL TANK SEALANTS IN 767 AMM 28-11-00, 801
optional)
(a) Quantity is approximate.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier
data.
(c) Chemplast or Zeus Industrial Products
(d) The pre shrink diameter is 1.5 inches.
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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BLANK PAGE

### Page 37

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. The work instructions are divided into work packages. Task Hours and Elapsed Hours
for each package are given in Paragraph 1.G., Manpower. You can do each work
package independently.
4. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets are in Structural Repair Manual (SRM)
Chapter 51
– Torque limits to tighten nuts and bolts are in SRM Chapter 51
5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,
and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.
6. 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.
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7. 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.
8. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
9. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
The removed part can be discarded if a new or serviceable part is installed.
B. WORK INSTRUCTIONS
WORK PACKAGE 1 - Front Spar - Left Wing - Change of the Wire Bundle Clamp
1. Deactivate the leading edge slats. Refer to 767 AMM 27-81-00 as an accepted procedure.
2. Remove electrical power from the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
3. Group 1-2:
Get access to the left front spar inboard of the nacelle strut. Remove and keep the access panels
511PT, 511FB, 511KB, and 511NB on the wing leading edge. Refer to 767 AMM 06-44-00 as an
accepted procedure.
NOTE: If it is necessary to get better access, other panels on the wing leading edge can be
removed.
4. Group 3:
Get access to the left front spar. Remove and keep the access panels 511PT, 511FB, 511KB, and
511NB, 521TB, and 521AFB on the wing leading edge. Refer to 767 AMM 06-44-00 as an accepted
procedure.
NOTE: If it is necessary to get better access, other panels on the wing leading edge can be
removed.
5. Group 1-2:
Get access to the left front spar outboard of the nacelle strut. Remove and keep the access panels
521BB, 521ANB, 521EB, 521HB, 521JB, 521SB, 521QB, 521RB, 521TB, 521YB, 521ZB and
521AFB on the wing leading edge. Refer to 767 AMM 06-44-00 as an accepted procedure.
NOTE: On some airplanes, access panel 521SB has been divided into three access panels
521PB, 521QB, and 521RB.
NOTE: If it is necessary to get better access, other panels on the wing leading edge can be
removed.
6. Group 1:
Change the wire bundle clamp configuration on the left front spar, at the locations from Front Spar
Station 260 to Front Spar Station 607 as given in:
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— Figure 1 for power feeder wire bundles with American Wire Gauge (AWG) 1/0 and larger wires
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 4 for the locations of the clamp changes.
7. Group 2:
Change the wire bundle clamp configuration on the left front spar, at the locations from Front Spar
Station 260 to Front Spar Station 607 as given in:
— Figure 1 for power feeder wire bundles with AWG 1/0 and larger wires
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 5 for the locations of the clamp changes.
8. Group 3:
Change the wire bundle clamp configuration on the left front spar, at the locations from Front Spar
Station 260 to Front Spar Station 1063 as given in:
— Figure 2 for the wire bundles with a diameter more than 1 inch
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 6 for the locations of the clamp changes.
9. Group 1:
Change the wire bundle clamp configuration at the remaining locations on the left front spar as
given in:
— Figure 2 for the wire bundles with a diameter more than 1 inch
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 7 for the locations of the clamp changes.
10. Group 2:
Change the wire bundle clamp configuration at the remaining locations on the left front spar as
given in:
— Figure 2 for the wire bundles with a diameter more than 1 inch
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 8 for the locations of the clamp changes.
11. Group 1-2:
Close access to the left front spar. Install the access panels that were removed. Refer to 767 AMM
06-44-00 as an accepted procedure.
12. Group 3:
Close access to the left front spar. Install the access panels that were removed. Refer to 767 AMM
06-44-00 as an accepted procedure.
13. Activate the leading edge slats. Refer to 767 AMM 27-81-00 as an accepted procedure.
14. Restore electrical power to the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
15. Put the airplane back to a serviceable condition.
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WORK PACKAGE 2 - Front Spar - Right Wing - Change of the Wire Bundle Clamp
1. Deactivate the leading edge slats. Refer to 767 AMM 27-81-00 as an accepted procedure.
2. Remove electrical power from the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
3. Group 1-2:
Get access to the right front spar inboard of the nacelle strut. Remove and keep the access panels
611PT, 611FB, 611KB, and 611NB on the wing leading edge. Refer to 767 AMM 06-44-00 as an
accepted procedure.
NOTE: If it is necessary to get better access, other panels on the wing leading edge can be
removed.
4. Group 3:
Get access to the right front spar. Remove and keep the access panels 611PT, 611FB, 611KB,
611NB, and 621AFB on the wing leading edge. Refer to 767 AMM 06-44-00 as an accepted
procedure.
NOTE: If it is necessary to get better access, other panels on the wing leading edge can be
removed.
5. Group 1-2:
Get access to the right front spar outboard of the nacelle strut. Remove and keep the access
panels 621BB, 621ANB, 621EB, 621HB, 621JB, 621SB, 621QB, 621RB, 621TB, 621YB, 621ZB,
and 621AFB on the wing leading edge. Refer to 767 AMM 06-44-00 as an accepted procedure.
NOTE: On some airplanes, access panel 621SB has been divided into three access panels
621PB, 621QB, and 621RB.
NOTE: If it is necessary to get better access, other panels on the wing leading edge can be
removed.
6. Group 1:
Change the wire bundle clamp configuration on the right front spar, at the locations from Front
Spar Station 143 to Front Spar Station 616 as given in:
— Figure 1 for the power feeder wire bundles with AWG 1/0 and larger wires
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 9 for the locations of the clamp changes.
7. Group 2:
Change the wire bundle clamp configuration on the right front spar, at the locations from Front
Spar Station 143 to Front Spar Station 616 as given in:
— Figure 1 for the power feeder wire bundles with AWG 1/0 and larger wires
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 10 for the locations of the clamp changes.
8. Group 3:
Change the wire bundle clamp configuration on the right front spar, at the locations from Front
Spar Station 260 to Front Spar Station 1063 as given in:
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— Figure 2 for the wire bundles with a diameter more than 1 inch
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 11 for the locations of the clamp changes.
9. Group 1:
Change the wire bundle clamp configuration at the remaining locations on the right front spar as
given in:
— Figure 2 for the wire bundles with a diameter more than 1 inch
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 12 for the locations of the clamp changes.
10. Group 2:
Change the wire bundle clamp configuration at the remaining locations on the right front spar as
given in:
— Figure 2 for the wire bundles with a diameter more than 1 inch
— Figure 3 for the wire bundles with a diameter less than 1 inch
— Figure 13 for the locations of the clamp changes.
11. Group 1-2:
Close access to the right front spar. Install the access panels that were removed. Refer to 767
AMM 06-44-00 as an accepted procedure.
12. Group 3:
Close access to the right front spar. Install the access panels that were removed. Refer to 767
AMM 06-44-00 as an accepted procedure.
13. Activate the leading edge slats. Refer to 767 AMM 27-81-00 as an accepted procedure.
14. Restore electrical power to the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
15. Put the airplane back to a serviceable condition.
Group 1-2:
WORK PACKAGE 3 - Front Spar - Center Wing - Change of the Wire Bundle Clamp
1. Remove electrical power from the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
2. Group 1-2:
Get access to the forward cargo compartment and open the right and left side of the endwall curtain
to get access to the power feeder bundles. Refer to 767 AMM 25-52-01 as an accepted procedure.
3. Group 1:
Change the wire bundles clamp configuration on the forward bulkhead of the center fuel tank as
given in:
— Figure 2
— Figure 14 for the locations of the clamp changes.
4. Group 2:
Change the wire bundles clamp configuration on the forward bulkhead of the center fuel tank as
given in:
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— Figure 2
— Figure 15 for the locations of the clamp changes.
5. Group 1-2:
Close the endwall curtain. Refer to 767 AMM 25-52-01 as an accepted procedure.
6. Group 1-2:
Put the airplane back to a serviceable condition.
Group 1-2:
WORK PACKAGE 4 - Rear Spar - Center Wing - Change of the Wire Bundle Clamp
1. Remove electrical power from the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
2. Group 1-2:
Install the downlocks on the nose and main landing gear. Refer to 767 AMM 32-00-20 as an
accepted procedure.
3. Group 1-2:
Install the door locks on the nose and main landing gear. Refer to 767 AMM 32-00-15 as an
accepted procedure.
4. Group 1-2:
Get access to the rear spar at the main wheel well on the right side of the airplane.
5. Group 1-2:
Change the wire bundle clamp configuration as given in:
— Figure 3
— Figure 16 for the location of the clamp change.
6. Group 1-2:
Remove the door locks on the nose and main landing gear. Refer to 767 AMM 32-00-15 as an
accepted procedure.
7. Group 1-2:
Remove the downlocks on the nose and main landing gear. Refer to 767 AMM 32-00-20 as an
accepted procedure.
8. Restore electrical power to the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
9. Group 1-2:
Put the airplane back to a serviceable condition.
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Group 1-2:
WORK PACKAGE 5 - Front Spar - Left Wing - Main Fuel Tank and Surge Tank - Seal of the
Fasteners
1. Group 1-2:
Defuel the left main fuel tank. Refer to 767 AMM 28-26-00 as an accepted procedure.
2. Group 1-2:
Prepare the fuel tank for entry. Refer to 767 AMM 28-11-00 as an accepted procedure.
3. Group 1-2:
Get access to the left main fuel tank and the surge tank. Remove and keep the left main fuel tank
and surge tank access doors as shown in the table below. Refer to 767 AMM 28-11-01 and 767
AMM 28-11-03 as accepted procedures.
Gives Access to Fastener Loca-
tions Between Ribs
Access Door
Ribs 4 and 5532AZ
Ribs 5 and 6532BB
Ribs 6 and 7533AB
Ribs 7 and 8533AB
Ribs 8 and 9533AB
Ribs 10 and 11541AB
Ribs 11 and 12541BB
Ribs 12 and 13541CB
Ribs 13 and 14541DB
Ribs 14 and 15541EB
Ribs 15 and 16541FB
Ribs 17 and 18541HB
Ribs 18 and 19541JB
Ribs 19 and 20541KB
Ribs 20 and 21541LB
Ribs 21 and 22541MB
Ribs 22 and 23541NB
Ribs 23 and 24541PB
Ribs 24 and 25541QB
Ribs 25 and 26541SB
Ribs 26 and 27541TB
Ribs 27 and 28541UB
Ribs 28 and 29541VB
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Gives Access to Fastener Loca-
tions Between Ribs
Access Door
Ribs 31 and 32542AB
Ribs 32 and 33542BB
Ribs 33 and 34542CB
4. Group 1:
Find and seal the fasteners for the support brackets on the front spar in the main tank as given in:
— Figure 17 for the seal of the fastener
— Figure 18 for the location of the fasteners.
5. Group 1:
Find and apply a fillet seal to certain stiffeners and apply injection seals to injection channels on
the front spar in the main tank as given in Figure 18.
6. Group 1:
Find and seal the fasteners for the support brackets on the front spar in the surge tank as given
in:
— Figure 17 for the seal of the fastener
— Figure 19 for the location of the fasteners.
7. Group 2:
Find and seal the fasteners for the support brackets on the front spar in the main tank as given in:
— Figure 17 for the seal of the fastener
— Figure 20 for the location of the fasteners.
8. Group 2:
Find and apply a fillet seal to certain stiffeners on the front spar in the main tank as given in Figure
20.
9. Group 2:
Find and seal the fasteners for the support brackets on the front spar in the surge tank as given
in:
— Figure 17 for the seal of the fastener
— Figure 21 for the location of the fasteners.
10. Group 1-2:
Close access to the left main fuel tank and surge tank. Install the access doors that were removed
in Step 3. Refer to 767 AMM 28-11-01 and 767 AMM 28-11-03 as accepted procedures.
11. Group 1-2:
Put the airplane back to a serviceable condition.
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Group 1-2:
WORK PACKAGE 6 - Front Spar - Right Wing - Main Fuel Tank and Surge Tank - Seal of the
Fasteners
1. Group 1-2:
Defuel the right main fuel tank. Refer to 767 AMM 28-26-00 as an accepted procedure.
2. Group 1-2:
Prepare the fuel tank for entry. Refer to 767 AMM 28-11-00 as an accepted procedure.
3. Group 1-2:
Get access to the right main tank and the surge tank. Remove and keep the right main fuel tank
and surge tank access doors as shown in the table below. Refer to 767 AMM 28-11-01 and 767
AMM 28-11-03 as accepted procedures.
Gives Access to Fastener Loca-
tions Between Ribs
Access Door
Ribs 4 and 5632AZ
Ribs 5 and 6632BB
Ribs 6 and 7633AB
Ribs 7 and 8633AB
Ribs 8 and 9633AB
Ribs 10 and 11641AB
Ribs 11 and 12641BB
Ribs 12 and 13641CB
Ribs 13 and 14641DB
Ribs 14 and 15641EB
Ribs 15 and 16641FB
Ribs 17 and 18641HB
Ribs 18 and 19641JB
Ribs 19 and 20641KB
Ribs 20 and 21641LB
Ribs 21 and 22641MB
Ribs 22 and 23641NB
Ribs 23 and 24641PB
Ribs 24 and 25641QB
Ribs 25 and 26641SB
Ribs 26 and 27641TB
Ribs 27 and 28641UB
Ribs 28 and 29641VB
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Gives Access to Fastener Loca-
tions Between Ribs
Access Door
Ribs 31 and 32642AB
Ribs 32 and 33642BB
Ribs 33 and 34642CB
4. Group 1:
Find and seal the fasteners for the support brackets on the front spar in the main tank as given in:
— Figure 17 for the seal of the fastener
— Figure 22 for the location of the fasteners.
5. Group 1:
Find and apply a fillet seal to certain stiffeners and apply injection seals to injection channels on
the front spar in the main tank as given in Figure 22.
6. Group 1:
Find and seal the fasteners for the support brackets on the front spar in the surge tank as given
in:
— Figure 17 for the seal of the fastener
— Figure 23 for the location of the fasteners.
7. Group 2:
Find and seal the fasteners for the support brackets on the front spar in the main tank as given in:
— Figure 17 for the seal of the fastener
— Figure 24 for the location of the fasteners.
8. Group 2:
Find and apply a fillet seal to certain stiffeners on the front spar in the main tank as given in Figure
24.
9. Group 2:
Find and seal the fasteners for the support brackets on the front spar in the surge tank as given
in:
— Figure 17 for the seal of the fastener
— Figure 25 for the location of the fasteners.
10. Group 1-2:
Close access to the right main fuel tank and surge tank. Install the access panels that were removed
in Step 3. Refer to 767 AMM 28-11-01 and 767 AMM 28-11-03 as accepted procedures.
11. Group 1-2:
Put the airplane back to a serviceable condition.
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### Page 47

Group 1-2:
WORK PACKAGE 7 - Center Bay - Auxiliary Fuel Tank - Seal of the Fasteners
1. Group 1-2:
Defuel the auxiliary fuel tank. Refer to 767 AMM 28-26-00 as an accepted procedure.
NOTE: Some airplanes have a dry center bay in the auxiliary fuel tank. The fasteners in the
center bay must be sealed on all airplanes.
NOTE: If the center bay of the auxiliary fuel tank is dry, it is not necessary to defuel the center
auxiliary fuel tank to seal the fasteners.
2. Group 1-2:
Prepare the center bay of the fuel tank for entry. Refer to 767 AMM 28-11-00 as an accepted
procedure.
3. Group 1-2:
Open the pressure relief door 194HR. Refer to 767 AMM 28-11-02 as an accepted procedure.
4. Group 1-2:
Get access to the center bay of the auxiliary fuel tank. Remove and keep the access door 136KZ
and baffle doors 134BZ, 134CZ, 134DZ, 134EZ, 134FZ, and 134GZ. Refer to 767 AMM 28-11-02
as an accepted procedure.
5. Group 2:
Find and seal the fasteners for the support brackets in the fuel tank as given in:
— Figure 17 for the seal of the fastener
— Figure 28 for the location of the fasteners.
6. Group 1:
Find and seal the fasteners for the support brackets in the fuel tank as given in:
— Figure 17 for the seal of the fastener
— Figure 29 for the location of the fasteners.
7. Group 1-2:
Close access to the center bay of the center bay of the auxiliary fuel tank. Install the 134BZ, 134CZ,
134DZ, 134EZ, 134FZ, and 134GZ baffle doors and access door 136KZ. Refer to 767 AMM
28-11-02 as an accepted procedure.
8. Group 1-2:
Put the airplane back to a serviceable condition.
Group 3:
WORK PACKAGE 8 - Front Spar - Left Wing - Main Fuel Tank - Seal of the Fasteners
1. Group 3:
Get access to the dry bay in the left main tank. Remove and keep the access door as shown in
the table below. Refer to 767 AMM 28-11-06 as an accepted procedure.
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### Page 48

Gives Access to Fastener Loca-
tions Between Ribs
Access Door
Ribs 7 and 8533AB
2. Group 3:
Find and seal the fasteners for the support brackets and apply injection seals to injection channels
on the front spar in the main tank as given in:
— Figure 17 for the seal of the fastener
— Figure 26 for the location of the fasteners.
3. Group 3:
Install the access panel that was removed. Refer to 767 AMM 28-11-06 as an accepted procedure.
4. Group 3:
Put the airplane back to a serviceable condition.
Group 3:
WORK PACKAGE 9 - Front Spar - Right Wing - Main Fuel Tank - Seal of the Fasteners
1. Group 3:
Get access to the dry bay in the right main tank. Remove and keep access door as shown in the
table below. Refer to 767 AMM 28-11-06 as an accepted procedure.
Gives Access to Fastener Loca-
tions Between Ribs
Access Door
Ribs 7 and 8633AB
2. Group 3:
Find and seal the fasteners for the support brackets and apply injection seals to injection channels
on the front spar in the main tank as given in:
— Figure 17 for the seal of the fastener
— Figure 27 for the location of the fasteners.
3. Group 3:
Install the access panel that was removed. Refer to 767 AMM 28-11-06 as an accepted procedure.
4. Group 3:
Put the airplane back to a serviceable condition.
Group 1-2, Configuration 2:
WORK PACKAGE 10 - Center Bay - Auxiliary Fuel Tank - Inspection and Seal of Fasteners
1. Group 1-2, Configuration 2:
Defuel the auxiliary fuel tank. Refer to 767 AMM 28-26-00 as an accepted procedure.
NOTE: Some airplanes have a dry center bay in the auxiliary fuel tank. The fasteners in the
center bay must be sealed on all airplanes.
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Original Issue: October 25, 2006
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### Page 49

NOTE: If the center bay of the auxiliary fuel tank is dry, it is not necessary to defuel the center
auxiliary fuel tank to inspect the fasteners.
2. Group 1-2, Configuration 2:
Prepare the center bay of the auxiliary fuel tank for entry. Refer to 767 AMM 28-11-00 as an
accepted procedure.
3. Group 1-2, Configuration 2:
Open the pressure relief door 194HR. Refer to 767 AMM 28-11-02 as an accepted procedure.
4. Group 1-2, Configuration 2:
Get access to the center bay of the auxiliary fuel tank. Remove and keep the access door 136KZ
and baffle doors 134BZ, 134CZ, 134DZ, 134EZ, 134FZ, and 134GZ. Refer to 767 AMM 28-11-02
as an accepted procedure.
5. Group 2, Configuration 2:
Do a General Visual Inspection of the two fasteners for the support bracket between Right Body
Buttock Line (RBBL) 10 and RBBL 18.25 in the fuel tank. Refer to:
— Figure 17 for the correct configuration of the sealed fastener
— Figure 28 for the location of the fasteners (quantity of 2).
a. If the fasteners are not sealed as given in Figure 17, seal the fasteners as given in Figure 17.
b. If the fasteners are sealed as given in Figure 17, no more work is necessary.
6. Group 1, Configuration 2:
Do a General Visual Inspection of the two fasteners for the support bracket between Right Body
Buttock Line (RBBL) 10 and RBBL 18.25 in the fuel tank. Refer to:
— Figure 17 for the correct configuration of the sealed fastener
— Figure 29 for the location of the fasteners (quantity of 2).
a. If the fasteners are not sealed as given in Figure 17, seal the fasteners as given in Figure 17.
b. If the fasteners are sealed as given in Figure 17, no more work is necessary.
7. Group 1-2, Configuration 2:
Close access to the center bay of the auxiliary fuel tank. Install the 134BZ, 134CZ, 134DZ, 134EZ,
134FZ, and 134GZ baffle doors and access door 136KZ. Refer to 767 AMM 28-11-02 as an
accepted procedure.
8. Group 1-2, Configuration 2:
Put the airplane back to a serviceable condition.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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### Page 50

Group 1, Configuration 2:
WORK PACKAGE 11 - Front Spar - Left Wing - Main Fuel Tank - Inspection and Seal of Fasteners
1. Group 1, Configuration 2:
Defuel the left main fuel tank. Refer to 767 AMM 28-26-00 as an accepted procedure.
2. Group 1, Configuration 2:
Prepare the left main fuel tank for entry. Refer to 767 AMM 28-11-00 as an accepted procedure.
3. Group 1, Configuration 2:
Get access to the left main tank. Remove and keep the 541UB access door. Refer to 767 AMM
28-11-01 and 767 AMM 28-11-03 as accepted procedures.
4. Group 1, Configuration 2:
Do a General Visual Inspection of the fasteners at rib 28 in the fuel tank. Refer to:
— Figure 17 for the correct configuration of the sealed fastener
— Figure 18 for the location of the two fasteners at rib 28 (quantity of 2).
a. If the fasteners are not sealed as given in Figure 17, seal the fasteners as given in Figure 17.
b. If the fasteners are sealed as given in Figure 17, no more work is necessary.
5. Group 1, Configuration 2:
Close access to the left main fuel tank. Install the access panels that were removed. Refer to 767
AMM 28-11-01 and 767 AMM 28-11-03 as accepted procedures.
6. Group 1, Configuration 2:
Put the airplane back to a serviceable condition.
Group 1-2, Configuration 2:
WORK PACKAGE 12 - Front Spar - Right Wing - Main Fuel Tank - Inspection and Seal of Fasteners
1. Group 1-2, Configuration 2:
Defuel the right main fuel tank. Refer to 767 AMM 28-26-00 as an accepted procedure.
2. Group 1-2, Configuration 2:
Prepare the right main fuel tank for entry. Refer to 767 AMM 28-11-00 as an accepted procedure.
3. Group 1-2, Configuration 2:
Get access to the right main fuel tank. Remove and keep the 641UB access door. Refer to 767
AMM 28-11-01 and 767 AMM 28-11-03 as accepted procedures.
4. Group 1, Configuration 2:
Do a General Visual Inspection of the fasteners at rib 28 in the fuel tank. Refer to:
— Figure 17 for the correct configuration of the sealed fastener
— Figure 22 for the location of the fasteners at rib 28 (quantity of 2).
a. If the fasteners are not sealed as given in Figure 17, seal the fasteners as given in Figure 17.
b. If the fasteners are sealed as given in Figure 17, no more work is necessary.
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Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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### Page 51

5. Group 2, Configuration 2:
Do a General Visual Inspection of the fasteners at rib 28 in the fuel tank. Refer to:
— Figure 17 for the correct configuration of the sealed fastener
— Figure 24 for the location of the fasteners at rib 28 (quantity of 2).
a. If the fasteners are not sealed as given in Figure 17, seal the fasteners as given in Figure 17.
b. If the fasteners are sealed as given in Figure 17, no more work is necessary.
6. Group 1-2, Configuration 2:
Close access to the right main fuel tank. Install the access panels that were removed. Refer to
767 AMM 28-11-01 and 767 AMM 28-11-03 as accepted procedures.
7. Group 1-2, Configuration 2:
Put the airplane back to a serviceable condition.
Group 1-2:
WORK PACKAGE 13 - Rear Spar - Center Wing - More Work
1. Remove electrical power from the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
2. Install the downlocks on the nose and main landing gear. Refer to 767 AMM 32-00-20 as an
accepted procedure.
3. Install the door locks on the main landing gear. Refer to 767 AMM 32-00-15 as an accepted
procedure.
4. Get access to the rear spar at the main wheel well on the right side of the airplane.
5. Do a General Visual Inspection of the clamp to find if a TFE sleeve is installed between the clamp
and the plastic convoluted tube. Refer to:
— Figure 3 for configuration of the the TFE sleeve and clamp
— Figure 16 for the location of the clamp.
a. If a TFE sleeve is not installed between the clamp and the plastic convoluted tubing, install a
TFE sleeve as given in Figure 3.
b. If a TFE sleeve is installed between the clamp and the plastic convoluted tubing as given in
Figure 3, no more action is necessary.
6. Remove the door locks on the main landing gear. Refer to 767 AMM 32-00-15 as an accepted
procedure.
7. Remove the downlocks on the nose and main landing gear. Refer to 767 AMM 32-00-20 as an
accepted procedure.
8. Restore electrical power to the airplane. Refer to 767 AMM 24-22-00 as an accepted procedure.
9. Put the airplane back to a serviceable condition.
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Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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### Page 52 (OCR)

BOEING SERVICE BULLETIN 767-57A0102
This Figure applies only to: Group 1-2.
SUPPORT BRACKET
SO SEE A
- 0.25
• 0.50
0.25 -
0.50
3.00 MINIMUM
0.5 INCH  TYPICAL SINGLE CLAMP INSTALLATION
OVERLAP
MINIMUM
POWER FEEDER
SLEEVE
WRAPPING
DIRECTION
POWER FEEDER
LONGITUDINAL
AXIS
SLEEVE
J60315
FIGURE 1: GROUP 1-2 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - POWER FEEDER WIRE
BUNDLES WITH AWG 1/0 AND LARGER WIRES IN THE UNPRESSURIZED AREA
(SHEET 1 OF 3)
Original Issue: October 25, 2006
Revision 4 September 20, 2011  BOEING PROPRIETARY -  767-57A0102
Copyright © Unpublished Work - See page 1 for details.  52 of 176

### Page 53

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 location.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1-SCREWRemove/Keep1
If a washer is installed. Some
configurations do not have a
washer.
1-WASHERRemove/Keep
If a spacer is installed.1-SPACERRemove/Keep
It is not necessary to remove
the nut if it is fastened to the
bracket.
1-NUTRemove/Keep
The clamp size should be
recorded before it is discarded
to help select the new clamp
size.
1-CLAMPRemove2
The wire harness ties that hold
the spacer must be removed.
2-LACING TAPERemove3
The spacer between the power
feeder wires, if a spacer is in-
stalled.
1-SPACER,
POLYAMIDE
Remove/Keep4
A 3 inch minimum length of
sleeve is necessary. (a)
1005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVECut5
Cut the sleeve longitudinally for
installation on the wire bundle.
1005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVECut
A sleeve must be installed on
each power feeder wire. (a) (b)
(c)
3005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVEInstall (New)6
(d)2BMS 13-54, TYPE
III, CLASS 1, FIN-
ISH C, WHITE
LACING TAPEInstall (New)7
If a spacer was removed. Some
configurations do not have a
spacer.
1-SPACER,
POLYAMIDE
Install (Kept)8
A wire harness tie must be as-
sembled on one end of the
spacer to hold it in its position.
It is not necessary for the lacing
tape tie to engage the detent of
the spacer. (d)
1BMS 13-54, TYPE
III, CLASS 1, FIN-
ISH C, WHITE
LACING TAPEInstall (New)9
FIGURE 1: GROUP 1-2 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - POWER FEEDER WIRE
BUNDLES WITH AWG 1/0 AND LARGER WIRES IN THE UNPRESSURIZED AREA
(SHEET 2 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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53 of 176
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### Page 54

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(e) (f) (g)1BACC10JU()
(TA027063()P op-
tional)
WIRE BUNDLE
CLAMP
Install (New)10
If a washer was installed before.1-WASHERInstall (Kept)11
1-SCREWInstall (Kept)
If a spacer was installed before.1-SPACERInstall (Kept)
If a nut was removed.1-NUTInstall (Kept)
(a) The sleeve must have the sufficient length to make a 50 percent minimum overlap when it is fully wrapped
around each power feeder wire.
(b) The edge of the sleeve must make a 50 percent minimum overlap when it is fully wrapped around each
power feeder wire.
(c) The center of the sleeve must be aligned with the center of the clamp.
(d) The string tie can be placed anywhere between 0.25 inch from the edge of the sleeve and 0.50 inch
maximum from the edge of the sleeve. Refer to SWPM 20-10-11 as an accepted procedure to assemble a
wire harness tie.
(e) Use the clamp size recorded in Step 2 to get the approximate size of the new clamp.
(f) Refer to SWPM 20-10-12 as an accepted procedure for installation of wire bundle support clamps.
(g) A BACC10KL() clamp is a satisfactory alternative if the wire bundle has three power feeder wires.
FIGURE 1: GROUP 1-2 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - POWER FEEDER WIRE
BUNDLES WITH AWG 1/0 AND LARGER WIRES IN THE UNPRESSURIZED AREA
(SHEET 3 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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54 of 176
BOEING SERVICE BULLETIN 767-57A0102

### Page 55 (OCR)

BOEING SERVICE BULLETIN 767-57A0102
This Figure applies only to: Group 1-3.
SUPPORT BRACKET
WIRE BUNDLE,  1 34 SEE A
- 0.25
0.50
0.25 -
10.50
3.00 MINIMUM
0.5 INCH  TYPICAL SINGLE CLAMP INSTALLATION
OVERLAP
MINIMUM
WIRE BUNDLE
SLEEVE
WRAPPING /
DIRECTION
WIRE BUNDLE
LONGITUDINAL
AXIS
SLEEVE
J60352
FIGURE 2: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A
DIAMETER MORE THAN 1 INCH
(SHEET 1 OF 3)
Original Issue: October 25, 2006
Revision 4 September 20, 2011  767-57A0102
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  55 of 176

### Page 56

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 location.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1-SCREWRemove /
Keep
1
If a washer is installed. Some
configurations do not have a
washer.
1-WASHERRemove /
Keep
If a spacer is installed.1-SPACERRemove /
Keep
It is not necessary to remove
the nut if it is fastened to the
bracket.
1-NUTRemove /
Keep
Record the clamp size before it
is discarded to help select the
new clamp size.
1-CLAMPRemove2
A 3 inch minimum length of
sleeve is necessary.(a)
-005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVECut3
Cut the sleeve longitudinally for
installation on the wire bundle.
1005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVECut
(a) (b) (c) (d) (g)1005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVEInstall (New)4
(e)1BACC10JU()CLAMPInstall (New)5
If a washer was installed before.1-WASHERInstall (Kept)6
If a spacer was installed before.1-SPACERInstall (Kept)
1-SCREWInstall (Kept)
If a nut was removed.1-NUTInstall (Kept)
(h)2BMS 13-54, TYPE
III, CLASS 1, FIN-
ISH C, WHITE
LACING TAPEInstall (New)7
(a) The sleeve must have the sufficient length to make a 50 percent minimum overlap when it is fully wrapped
around the bundle.
(b) The direction of the wrap must be along the longitudinal axis of the sleeve.
(c) The sleeve must make a 50 percent minimum overlap when it is fully wrapped around the bundle.
(d) The center of the sleeve must be aligned with the center of the clamp.
FIGURE 2: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A
DIAMETER MORE THAN 1 INCH
(SHEET 2 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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56 of 176
BOEING SERVICE BULLETIN 767-57A0102

### Page 57

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(e) Use the clamp size recorded in Step 2 to get the approximate size of the new clamp.
(f) Refer to SWPM 20-10-12 as an accepted procedure for installation of wire bundle support clamps.
(g) Make sure that the curled edges are pointed away from the wire bundle.
(h) The string tie can be placed anywhere between 0.25 inch from the edge of the sleeve and 0.50 inch
maximum from the edge of the sleeve. Refer to SWPM 20-10-11 as an accepted procedure to assemble a
wire harness tie.
FIGURE 2: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A
DIAMETER MORE THAN 1 INCH
(SHEET 3 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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57 of 176
BOEING SERVICE BULLETIN 767-57A0102

### Page 58 (OCR)

BOEING SERVICE BULLETIN 767-57A0102
This Figure applies only to: Group 1-3.
SUPPORT BRACKET,
WIRE BUNDLE,
0.25
— 0.50
0.25 -
0.50
3.00 MINIMUM
TYPICAL SINGLE CLAMP INSTALLATION
WIRE BUNDLE
SEE NOTES
FOR MINIMUM
OVERLAP
SLEEVE
J60557
FIGURE 3: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A
DIAMETER OF 1 INCH OR LESS
(SHEET 1 OF 3)
Original Issue: October 25, 2006
Revision 4 September 20, 2011  BOEING PROPRIETARY -  767-57A0102
Copyright © Unpublished Work - See page 1 for details.  58 of 176

### Page 59

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 each location.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
1-SCREWRemove/Keep1
If a washer is installed. Some
configurations do not have a
washer.
1-WASHERRemove/Keep
If a spacer is installed.1-SPACERRemove/Keep
It is not necessary to remove
the nut if it is fastened to the
bracket.
1-NUTRemove/Keep
Record the clamp size before it
is discarded to help select the
new clamp size.
1-CLAMPRemove2
A 3 inch minimum length of
sleeve is necessary.(a)
1005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVECut3
Cut the sleeve longitudinally for
installation on the wire bundle.
1005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVECut
(a) (b) (c)1005W3281-() (TFE-
2X STANDARD
WALL optional)
SLEEVEInstall (New)4
(d) (e)1BACC10JU()CLAMPInstall (New)5
If a washer was installed before.1-WASHERInstall (Kept)6
1-SCREWInstall (Kept)
If a spacer was installed before.1-SPACERInstall (Kept)
If a nut was removed.1-NUTInstall (Kept)
(f)2BMS 13-54, TYPE
III, CLASS 1, FIN-
ISH C, WHITE
LACING TAPEInstall (New)7
(a) The sleeve must have the sufficient length to make a 50 percent minimum overlap when it is fully wrapped
around the bundle.
(b) The edges of the sleeve must make a 50 percent minimum overlap when it is fully wrapped around the
bundle.
(c) The center of the sleeve must be aligned with the center of the clamp.
(d) Use the clamp size recorded in Step 2 to get the approximate size of the new clamp.
(e) Refer to SWPM 20-10-12 as an accepted procedure for installation of wire bundle support clamps.
FIGURE 3: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A
DIAMETER OF 1 INCH OR LESS
(SHEET 2 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
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59 of 176
BOEING SERVICE BULLETIN 767-57A0102

### Page 60

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(f) The string tie can be placed anywhere between 0.25 inch from the edge of the sleeve and 0.50 inch
maximum from the edge of the sleeve. Refer to SWPM 20-10-11 as an accepted procedure to assemble a
wire harness tie.
FIGURE 3: GROUP 1-3 - WIRE BUNDLE CLAMP CONFIGURATION CHANGE - WIRE BUNDLES WITH A
DIAMETER OF 1 INCH OR LESS
(SHEET 3 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 25, 2006
767-57A0102Revision 4 September 20, 2011
60 of 176
BOEING SERVICE BULLETIN 767-57A0102

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