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Commercial Airplanes 767 Service Bulletin ALERT Number: 767-57A0134 Original Issue: May 27, 2016 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Flap Outboard Support Assembly Number 3 and 6 - Inspection and Repair, Replacement or Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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:

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.

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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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: May 27, 2016 767-57A0134 1 of 61

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Original Issue: May 27, 2016 767-57A0134 2 of 61 BOEING SERVICE BULLETIN 767-57A0134

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Table of Contents

Summary5

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

2. Spares Affected10

B. Concurrent Requirements10

C. Reason10

D. Description10

E. Compliance11

F. Approval13

G. Manpower14

H. Weight and Balance Changes15

I. Electrical Load Data15

J. References15

1. Existing Data:15

2. Data Supplied with this Service Bulletin:16

3. Installation Drawings Used in the Preparation of this Service Bulletin:16

K. Publications Affected16

L. Interchangeability and Intermixability of Parts16

M. Software Accomplishment Summary17

2. MATERIAL INFORMATION19

A. Material - Price and Availability19

B. Industry Support Information19

C. Parts Necessary for Each Airplane19

1. Kits/Parts19

2. Parts and Materials Supplied by the Operator19

3. Parts Modified and Reidentified20

4. Parts Removed and Not Replaced20

D. Parts Necessary to Change Spares20

E. Special Tooling - Price and Availability20

F. Special Tooling Necessary to do this Service Bulletin20

3. ACCOMPLISHMENT INSTRUCTIONS21

A. GENERAL INFORMATION21

B. WORK INSTRUCTIONS23

FIGURE 1: LEFT WING INBOARD FLAP OUTBOARD SUPPORT - 6-9 DRIVE ARM ASSEMBLY GENERAL

VISUAL INSPECTION26

FIGURE 2: RIGHT WING INBOARD FLAP OUTBOARD SUPPORT - 6-9 DRIVE ARM ASSEMBLY GENERAL

VISUAL INSPECTION28

FIGURE 3: LEFT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM - INTERIM

BLEND REPAIR30

FIGURE 4: RIGHT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM -

INTERIM BLEND REPAIR32

FIGURE 5: LEFT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

ASSEMBLY REMOVAL34

FIGURE 6: RIGHT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

ASSEMBLY REMOVAL36

Original Issue: May 27, 2016 767-57A0134 3 of 61 BOEING SERVICE BULLETIN 767-57A0134

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FIGURE 7: LEFT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

DISASSEMBLY38

FIGURE 8: RIGHT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

DISASSEMBLY41

FIGURE 9: LEFT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

MODIFICATION44

FIGURE 10: RIGHT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

MODIFICATION49

FIGURE 11: LEFT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

INSTALLATION54

FIGURE 12: RIGHT WING INBOARD FLAP OUTBOARD SUPPORT - 4-5 ACTUATOR CRANK ARM

INSTALLATION56

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: GENERAL VISUAL INSPECTION OF THE 6-9 DRIVE ARM ASSEMBLY AND REPAIR, REPLACEMENT OR MODIFICATION OF THE 4-5 ACTUATOR CRANK ARM ASSEMBLY AT INBOARD FLAP

OUTBOARD SUPPORT NUMBER 3 AND 658

Original Issue: May 27, 2016 767-57A0134 4 of 61 BOEING SERVICE BULLETIN 767-57A0134

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Commercial Airplanes 767 Service Bulletin ALERT SummaryNumber: 767-57A0134Original Issue: May 27, 2016 ATA System: 5750 SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Flap Outboard Support Assembly Number 3 and 6 - Inspection and Repair, Replacement or Modification

THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND This Service Bulletin is sent to give instructions to inspect for damage caused by interference between the 6-9 drive arm assembly and the 4-5 actuator crank arm assembly on the inboard flap outboard support assembly number 3 and number 6. Instructions are also given for an interim blend repair, and modification or replacement of the 4-5 actuator crank arm assembly to terminate repeat inspections. If this service bulletin is not accomplished, interference between the 6-9 drive arm assembly and the 4-5 actuator crank arm assembly will cause a fatigue load on the 5-7 link which could result in failure of the 5-7 link and subsequent loss of the inboard flap, continued safe flight and landing could be affected after the departure of a flap during takeoff or landing.

The Boeing Company received a report from an operator that while inspecting the left wing, inboard flap, outboard support assembly number 3, it was seen that the extend overtravel stops on the 4-5 actuator crank arm assembly were touching the adjacent 6-9 drive arm assembly when the flaps were fully retracted. The cause of this problem occurred with the installation of 767-400ER flaps on 767-200 airplanes which have crank arms that have extend overtravel stops that are too large. The problem did not occur during the fitting of the 767-400ER flaps in production as the 4-5 actuator crank arm assembly had been redesigned.

Accomplishment of this service bulletin will prevent interference between the 6-9 drive arm assembly and the 4-5 actuator crank arm assembly.

Boeing Service Related Problem (SRP) 767-57-0282 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 57-16001 is related to this service bulletin.

Original Issue: May 27, 2016 767-57A0134 5 of 61

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This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR B12901-124RS) Get access to the inboard flap outboard support assembly at the number 3 and number 6 positions. Do a general visual inspection of the 6-9 drive arm assembly for any damage caused by interference with the 4-5 actuator crank arm assembly.

If any damage is found on the 6-9 drive arm assembly, do a repair of the 6-9 drive arm assembly, do an interim blend repair of the 4-5 actuator crank arm assembly, and do a repeat general visual inspection of the 6-9 drive arm assembly. As an option, replace or modify the 4-5 actuator crank arm assembly.

If no damage is found on the 6-9 drive arm assembly, repeat the general visual inspection of the 6-9 drive arm assembly, or do replacement or modification of the 4-5 actuator crank arm assembly.

EFFECTIVITY 767-200 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Refer to Paragraph 1.E., Compliance.

Original Issue: May 27, 2016 767-57A0134 6 of 61 BOEING SERVICE BULLETIN 767-57A0134

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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of August 12, 2015. Please refer to Paragraph

2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Operator Supplied Parts/Materials.

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

Original Issue: May 27, 2016 767-57A0134 7 of 61 BOEING SERVICE BULLETIN 767-57A0134

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BOEING SERVICE BULLETIN 767-57A0134

ALERT ALERT 4-5 ACTUATOR CRANK

ARM ASSEMBLY 6-9 DRIVE ARM 5-7 LINK DO A GENERAL VISUAL INSPECTION OF THE 6-9 DRIVE ARMS FOR ANY DAMAGE CAUSED BY INTERFERENCE WITH THE 4-5 ACTUATOR CRANK ARM ASSEMBLY

INBOARD FLAP, OUTBOARD SUPPORT ASSEMBLY (LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE) A-A 2481278 Original Issue: May 27, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 767-57A0134 Work - See page 1 for details. 8 of 61

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes This service bulletin is applicable to 767-200 Airplanes, line numbers 912, 930, 932, 941, 943, 952, 963 and 966 in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-124RS for data about this change.

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

DESCRIPTIONCONFIGURATIONGROUP 767-200 Tanker Transport Airplanes-1 Airplane Models:

Original Issue: May 27, 2016 767-57A0134 9 of 61

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2. Spares Affected Examine your spares supply for the parts or components identified below . If any parts or components are found, refer to Paragraph 3.B., Work Instructions for the recommended action.

Part Number 113T1227-29 113T1227-30 B. Concurrent Requirements None.

C. Reason This Service Bulletin is sent to give instructions to inspect for damage caused by interference between the 6-9 drive arm assembly and the 4-5 actuator crank arm assembly on the inboard flap outboard support assembly number 3 and number 6. Instructions are also given for an interim blend repair, and modification or replacement of the 4-5 actuator crank arm assembly to terminate repeat inspections.

If this service bulletin is not accomplished, interference between the 6-9 drive arm assembly and the 4-5 actuator crank arm assembly will cause a fatigue load on the 5-7 link which could result in failure of the 5-7 link and subsequent loss of the inboard flap, continued safe flight and landing could be affected after the departure of a flap during takeoff or landing.

If no damage is found on the 6-9 drive arm assembly, repeat the general visual inspection of the 6-9 drive arm assembly, or do replacement or modification of the 4-5 actuator crank arm assembly.

Boeing Service Related Problem (SRP) 767-57-0282 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 57-16001 is related to this service bulletin.

D. Description Get access to the inboard flap outboard support assembly at the number 3 and number 6 positions.

Do a general visual inspection of the 6-9 drive arm assembly for any damage caused by interference with the 4-5 actuator crank arm assembly.

If no damage is found on the 6-9 drive arms, repeat the general visual inspection of the 6-9 drive arms, or do replacement or modification of the 4-5 actuator crank arm assembly.

Original Issue: May 27, 2016 767-57A0134 10 of 61 BOEING SERVICE BULLETIN 767-57A0134

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The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones ZoneModel 571, 671767-200 E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX A.

When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.

Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

Table 1: General Visual Inspection of the 6-9 Drive Arm Assembly and Repair, Replacement or Modification of the 4-5 Actuator Crank Arm Assembly at Inboard Flap Outboard Support Number 3 and 6 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 36 months after the original issue date of this service bulletin.

Before 5,000 total flight cycles.

Do PART 1: 6-9 DRIVE

ARM ASSEMBLY GENER-

AL VISUAL INSPECTION for any damage caused by interference with the 4-5 actuator crank arm assembly.

Original Issue: May 27, 2016 767-57A0134 11 of 61 BOEING SERVICE BULLETIN 767-57A0134

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Table 1: General Visual Inspection of the 6-9 Drive Arm Assembly and Repair, Replacement or Modification of the 4-5 Actuator Crank Arm Assembly at Inboard Flap Outboard Support Number 3 and 6 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.OPTION 1 (ACTION 1):CONDITION 1: ANY DAMAGE FOUND ON 6- 9 DRIVE ARM ASSEM- BLY Do PART 2: 4-5 ACTUA-

TOR CRANK ARM ASSEM-

BLY INTERIM BLEND RE- PAIR on the crank arms associated with the damaged 6-9 drive arm assembly.

-Before further flight.OPTION 1 (ACTION 2):

Do PART 3: 6-9 DRIVE ARM ASSEMBLY REPAIR.

2,500 flight cycles. (b) -OPTION 1 (ACTION 3):

Repeat PART 1: 6-9 DRIVE

ARM ASSEMBLY GENER-

AL VISUAL INSPECTION for any damage caused by interference with the 4-5 actuator crank arm assembly.

(a) -Before further flight.OPTION 2 (ACTION 1):

Do PART 3: 6-9 DRIVE ARM ASSEMBLY REPAIR.

-Before further flight.OPTION 2 (ACTION 2):

Do PART 4: 4-5 ACTUA-

TOR CRANK ARM ASSEM-

BLY REPLACEMENT (TERMINATING ACTION) on the crank arms associated with the damaged 6-9 drive arm assembly.

-Before further flight.OPTION 3 (ACTION 1):

Do PART 3: 6-9 DRIVE ARM ASSEMBLY REPAIR.

-Before further flight.OPTION 3 (ACTION 2):

Do PART 5: 4-5 ACTUA-

TOR CRANK ARM ASSEM-

BLY MODIFICATION (TER- MINATING ACTION) on the crank arms associated with the damaged 6-9 drive arm assembly.

Original Issue: May 27, 2016 767-57A0134 12 of 61 BOEING SERVICE BULLETIN 767-57A0134

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