Boeing ASB 767-57A0117: Revision 1, text

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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-57A0117 Original Issue: October 01, 2009 Revision 1: March 02, 2011 ATA System: 5700 SUBJECT: WINGS - Skins - Upper Wing Skin Panel at Front Spar Pitch Load Fitting Attachment

- Inspection and Repair 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 1 of 113

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Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 2 of 113 BOEING SERVICE BULLETIN 767-57A0117

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Table of Contents

Revision Transmittal Sheet5

Summary7

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

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 9 D. Description .............................................. 1 9 E. Compliance .............................................. 2 0 F. Approval ............................................... 6 9 G. Manpower .............................................. 7 0 H. Weight and Balance Changes .................................... 7 1 I. Electrical Load Data ......................................... 7 1 J. References .............................................. 7 1

1. Existing Data .......................................... 7 1

2. Data supplied with this Service Bulletin ............................ 7 1

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 7 1 K. Publications Affected ........................................ 7 2 L. Interchangeability and Intermixability of Parts ........................... 7 2

2. MATERIAL INFORMATION ........................................ 7 3 A. Material - Price and Availability ................................... 7 3 B. Industry Support Information .................................... 7 4 C. Parts Necessary For Each Airplane ................................. 7 4

1. Kits/Parts ............................................ 7 4

2. Parts and Materials Supplied by the Operator ........................ 7 5

3. Parts Modified and Reidentified ................................ 7 6

4. Parts Removed and Not Replaced .............................. 7 6 D. Parts Necessary to Change Spares ................................. 7 6 E. Special Tooling - Price and Availability ............................... 7 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 7 6

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 7 7 A. GENERAL INFORMATION ..................................... 7 7 B. WORK INSTRUCTIONS ....................................... 7 8 FIGURE 1: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD FITTING OF THE LEFT WING ................................ 8 2 FIGURE 2: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD FITTING OF THE RIGHT WING ................................ 8 4 FIGURE 3: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR PITCH LOAD FITTING OF THE LEFT WING ......................... 8 6 FIGURE 4: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR PITCH LOAD FITTING OF THE RIGHT WING ........................ 8 8 FIGURE 5: HOLE REPAIR ......................................... 9 0 FIGURE 6: FREEZE PLUG REPAIR .................................... 9 3 FIGURE 7: FASTENER REPLACEMENT, LEFT WING [Group 1-2, 4-5, 8] ............... 9 5 FIGURE 8: FASTENER REPLACEMENT, RIGHT WING [Group 1-2, 4-5, 8] ............. 1 0 0

Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 3 of 113 BOEING SERVICE BULLETIN 767-57A0117

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FIGURE 9: FASTENER REPLACEMENT, LEFT WING [Group 3, 6-7, 9] ............... 1 0 5 FIGURE 10: FASTENER REPLACEMENT, RIGHT WING [Group 3, 6-7, 9] ............... 1 0 9 APPENDIX A: SUPPLEMENTAL FASTENER REPLACEMENT (EXAMPLE) ............... 1 1 3

Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 4 of 113 BOEING SERVICE BULLETIN 767-57A0117

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Commercial Airplanes 767 Service Bulletin ALERT Revision Transmittal SheetNumber: 767-57A0117Original Issue: October 01, 2009 Revision 1: March 02, 2011 ATA System: 5700 SUBJECT: WINGS - Skins - Upper Wing Skin Panel at Front Spar Pitch Load Fitting Attachment

- Inspection and Repair This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) inspected or changed in accordance with the original issue of this service bulletin. However, the initial inspection threshold grace period for airplanes that have not accomplished the inspection in accordance with this service bulletin have been reduced and may require earlier inspections.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-217-AD, is related to this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2000-19-09 and AD 2004-16-12 are related to this service bulletin.

REASON FOR REVISION This revision is sent to revise the Compliance Tables to reduce the inspection grace period times due to inspection findings in the fleet.

These sections were changed:

1. In Summary, Background, added information about fleet inspection findings.

2. In Summary, Compliance, added NPRM and AD information.

3. In Paragraph 1.C., Reason, added information about fleet inspection findings.

4. In Paragraph 1.E., Compliance, added NPRM and AD information.

5. In Paragraph 1.E., Compliance, revised the compliance information in Table 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 and 14.

6. In Paragraph 1.E., Compliance, revised the description of the conditions in Table 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 and 14.

7. In Paragraph 1.F., Approval, added Alternate Method of Compliance statement.

Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 5 of 113

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8. In Paragraph 2.A., Material - Price and Availability, changed the table to apply effectivity.

9. In Paragraph 3.A., General Information, added notes about access and tool use.

10. In Paragraph 3.B., Accomplishment Instructions, revised the position of the slats.

11. In Paragraph 3.B., Accomplishment Instructions, revised the description of the conditions.

12. In Paragraph 3.B., Accomplishment Instructions, Figure 3, revised the reference for titanium fittings.

13. In Paragraph 3.B., Accomplishment Instructions, Figure 3, added a footnote about fastener removal.

14. In Paragraph 3.B., Accomplishment Instructions, Figure 4, revised the reference for titanium fittings.

15. In Paragraph 3.B., Accomplishment Instructions, Figure 4, added a footnote about fastener removal.

16. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised the 'Inspect' More Data column.

17. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised the 'Ream' More Data column.

18. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised footnote (a).

19. In Paragraph 3.B., Accomplishment Instructions, Figure 5, added a footnote (c) about fastener removal.

20. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised Table 1 and Table 2.

21. In Paragraph 3.B., Accomplishment Instructions, Figure 6, revised the 'Inspect' More Data column.

The data given in Information Notices 767-57A0117 IN-01, IN-02 and IN-03 is included in this revision.

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 01, 2009Original Issue:

March 02, 2011Revision 1:

Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 6 of 113 BOEING SERVICE BULLETIN 767-57A0117

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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-57A0117Original Issue: October 01, 2009 Revision 1: March 02, 2011 ATA System: 5700 SUBJECT: WINGS - Skins - Upper Wing Skin Panel at Front Spar Pitch Load Fitting Attachment

- Inspection and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of this service bulletin will find possible cracks in the upper wing skin at the fastener holes common to the inboard and outboard front spar pitch load fittings. Undetected upper wing skin cracks at the fastener holes common to the inboard and outboard front spar pitch load fittings could result in the loss of the strut-to-wing upper link load path and possible separation of a strut and engine from the airplane during flight.

Multiple operators have reported a total of 36 cracks in the upper wing skin at the fastener holes common to the inboard and outboard front spar pitch load fittings. The reported airplanes had accumulated between 11,700 and 39,900 total flight-cycles and 28,700 and 83,100 total flight-hours. The reported crack lengths were between

0.016 and 0.140 inch. All cracks were found during accomplishment of the open hole high frequency eddy current (HFEC) inspections given in strut improvement service bulletins 767-54-0080, 767-54-0081 or 767-54-0082.

Further Boeing analysis has determined the cracks to be a result of fatigue due to higher than predicted fastener load and skin stress peaking along the aft fastener row.

Subsequent to the original issue of this service bulletin, one operator accomplishing this service bulletin reported finding a fastener hole with significant crack sizes of 0.53 inches and 0.31 inches on either side of the hole. The subject airplane had accumulated 18,900 flight cycles and 89,500 flight hours at the time of the inspection.

This service bulletin provides instructions to inspect the upper wing skin at the fastener holes common to the inboard and outboard front spar pitch load fittings for cracks and repair the holes if cracks are found. Inspection and repair will prevent undetected upper wing skin cracks at the fastener holes common to the inboard and outboard front spar pitch load fittings that could result in the loss of the strut-to-wing upper link load path and possible separation of a strut and engine from the airplane during flight.

Boeing Service Related Problem 767-SRP-57-0206 is related to this service bulletin.

Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 7 of 113

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ACTION Get access to the upper wing skin at the front spar pitch load fitting. Do a detailed and ultrasonic inspection or do a HFEC open hole inspection of the fastener holes common to the front spar pitch load fitting and wing skin for cracks. If any crack is found, repair the hole by oversizing the hole or installing a freeze plug. If no crack is found, continue to perform repeat inspections. If the crack is too large to repair, contact Boeing for repair instructions.

EFFECTIVITY All 767-200, -300, -300F and -400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-217-AD, is related to this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2000-19-09 and AD 2004-16-12 are related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection,and/or repair procedures given in this service bulletin.

MANPOWER For detailed Manhour estimates, refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 8 of 113 BOEING SERVICE BULLETIN 767-57A0117

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BOEING SERVICE BULLETIN 767-57A0117

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LEFT WING SHOWN (RIGHT WING OPPOSITE) 10 80

DO A DETAILED AND ULTRASONIC INSPECTION OR DO A HFEC OPEN HOLE INSPEC •TION OF THE

FASTENER HOL JES COMMON O THE FRONT SPAR

PITCH LOAD FI ING AND WING SKIN FOR CRACKS UPPER SKIN UPPER LINK

FRONT SPAR PITCH

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Original Issue: October 01, 2009 767-57A0117Revision 1: March 02, 2011 10 of 113 BOEING SERVICE BULLETIN 767-57A0117

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- Inspection and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes This service bulletin is for the airplanes shown below.

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

NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below is complete for airplanes through line number 1009. At least one airplane after line number 1009 is also affected by this service bulletin, and these airplanes are in Group(s) 3,6,7,9.

These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) \"get effectivity\" result when they are added to the MBF Fleet Profile Page.

DESCRIPTIONCONFIGURATIONGROUP 767-200, -300 and -300F Airplanes with Pratt and Whitney JT9D engines with line numbers 1-663.

-1 Airplanes that have not accomplished SB 767-54-0080.1 Airplanes that have accomplished SB 767-54-0080.2

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DESCRIPTIONCONFIGURATIONGROUP 767-200, -300 and -300F Airplanes with Pratt and Whitney PW4000 engines with line numbers 1-663.

-2 Airplanes that have not accomplished SB 767-54-0080.1 Airplanes that have accomplished SB 767-54-0080.2 767-200, -300 and -300F Airplanes with Pratt and Whitney engines with line numbers 664 and on.

-3 767 Airplanes with General Electric CF6-80A engines with line numbers 1-663.

-4 Airplanes that have not accomplished SB 767-54-0081.1 Airplanes that have accomplished SB 767-54-0081.2 767-200, -300 and -300F Airplanes with General Electric CF6-80C2 engines with line numbers 1-663.

-5 Airplanes that have not accomplished SB 767-54-0081.1 Airplanes that have accomplished SB 767-54-0081.2 767-200, -300 and -300F Airplanes with General Electric engines with line numbers 664 and on.

-6 767-400ER Airplanes with General Electric engines.-7 767-200, -300 and -300F Airplanes with Rolls Royce engines with line numbers 1-663.

-8 Airplanes that have not accomplished SB 767-54-0082.1 Airplanes that have accomplished SB 767-54-0082.2 767-200, -300 and -300F Airplanes with Rolls Royce engines with line numbers 664 and on.

-9 Airplane Models:

767-200, 767-300, 767-300F, 767-400ER GroupVariable Number 1VA001 - VA020 4VA301 - VA315

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