# Boeing Alert Service Bulletin 767-78A0089: Revision 5

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- Document: [Boeing Alert Service Bulletin 767-78A0089](https://openairdocs.org/service-documents/boeing/767-78a0089.md)
- Title as filed: U.S. DOT/FAA - Service Information
- Pages: 66
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## Text

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### Page 1

Commercial        
Airplane
Group 
 767
Service Bulletin
ALERT
Number: 767-78A0089
Date: July 19, 2001
Revision 5: June 09, 2009
ATA System: 7831
SUBJECT: EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser
Deactivation Pin Modification
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 © 2001 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Unpublished Work - All Rights Reserved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, 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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July 19, 2001
767-78A0089Revision 5: June 09, 2009
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3.0

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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ..................................................... 7
1. PLANNING INFORMATION ........................................ 1 1
A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 2
B. Concurrent Requirements ...................................... 1 2
C. Reason ................................................ 1 2
D. Description .............................................. 1 3
E. Compliance .............................................. 1 4
F . Approval ............................................... 1 4
G. Manpower .............................................. 1 5
H. Weight and Balance Changes .................................... 1 5
I. Electrical Load Data ......................................... 1 5
J. References .............................................. 1 6
1. Existing Data: .......................................... 1 6
2. Data supplied with this Service Bulletin: ........................... 1 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6
4. Process Data: ......................................... 1 6
K. Publications Affected ......................................... 1 6
L. Interchangeability and Intermixability of Parts ........................... 1 6
2. MATERIAL INFORMATION ........................................ 1 7
A. Material - Price and Availability ................................... 1 7
B. Industry Support Information .................................... 1 8
C. Parts Necessary For Each Airplane ................................. 1 8
1. Kits/Parts: ............................................ 1 8
2. Parts and Materials Supplied by the Operator: ........................ 2 1
3. Parts Modified and Reidentified: ................................ 2 2
4. Parts Removed and Not Replaced: .............................. 2 3
D. Parts Necessary to Change Spares ................................. 2 3
E. Special Tooling - Price and Availability ............................... 2 4
F . Special Tooling Necessary to do this Service Bulletin ....................... 2 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 5
FIGURE 1: SHOP AID HOLDER - INNER INSERT ............................ 2 8
FIGURE 2: SHOP AID SPANNER - OUTER INSERT ........................... 3 0
FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT ...... 3 2
FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING [Group 1] ............... 3 5
FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE ...................... 4 0
FIGURE 6: NEW INSERT FIT CHECK ................................... 4 3
FIGURE 7: INSERT INSTALLATION .................................... 4 9
FIGURE 8: RECONNECTION OF LINEAR ACTUATOR ......................... 5 4
FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN
REPLACEMENT ........................................ 5 6
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FIGURE 10: MARK THRUST REVERSER ID PLATE WITH SERVICE BULLETIN NUMBER ...... 6 0
FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING  [Group 2] ............... 6 2
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Commercial        
Airplane
Group 
 767
Service Bulletin
ALERT
Revision Transmittal SheetNumber: 767-78A0089Date: July 19, 2001
Revision 5: June 09, 2009
ATA System: 7831
SUBJECT: EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser
Deactivation Pin Modification
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Group 1:
No more work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4 of this
service bulletin.
Group 2:
More work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4 of this service
bulletin. Airplanes that delivered with the 315T3222-3 bushing need to replace the 315T3222-3 bushing with
the 315T3221-1 bushing. If Group 2 operators previously replaced the 315T3222-3 bushing with the 315T3222-10
bushing, the 315T3222-10 bushing must be replaced by the 315T3221-1 bushing due to inadequate edge margin.
Federal Aviation Administration (FAA) Airworthiness Directive 2002-19-11, is related to this service bulletin.
REASON FOR REVISION
This revision is sent to add the 315T3221-1 bushing installation for airplanes delivered with the 315T3222-3
bushing. Revision 4 of this service bulletin added the 315T3222-3 bushing configuration. However, Boeing
received a report from an operator that the 315T3222-3 bushing could not be replaced by the 315T3222-10
bushing due to inadequate edge margin. Therefore, this revision replaces the 315T3222-3 bushing with a new
315T3221-1 bushing that will provide adequate edge margin.
These sections were changed:
1. In Effectivity - Airplanes, paragraph 1.A.1., airplanes that delivered with the 315T3222-3 bushing configuration
were moved to a new Group 2.
2. In Material - Price and Availability, paragraph 2.A., price and ROLT data is added for the new 015T1838-1
and 015T1838-2 kits. Also, notes are added to clarify the correlation of the new kits to the old kits for Group
2 airplanes.
3. In Kits/Parts, paragraph 2.C.1., a table was added for the new 015T1838-1 and 015T1838-2 kits.
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4. In Work Instructions, paragraph 3.B., Step 4 was added to Work Package 2 for Group 2 airplanes.
5. In Figure 4, Step 5 was added to inspect for cracks, and Step 11 was changed to wet install the fasteners.
6. Figure 11 was added for Group 2 airplanes.
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
July 19, 2001Original Issue:
May 30, 2002Revision 1:
March 13, 2003Revision 2:
December 18, 2003Revision 3:
March 06, 2008Revision 4:
June 09, 2009Revision 5:
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Commercial        
Airplane
Group 
 767
Service Bulletin
ALERT
SummaryNumber: 767-78A0089Date: July 19, 2001
Revision 5: June 09, 2009
ATA System: 7831
SUBJECT: EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser
Deactivation Pin Modification
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
The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation
of this service bulletin.
This service bulletin provides modification instructions to improve the thrust reverser deactivation pin's structural
integrity. This modification will ensure non-deployment of a deactivated thrust reverser.
Four partial deployments of improperly deactivated thrust reversers have been reported by operators with
PW4000 engines. These occurred during landing, with up to 12 inches of the reverser deployed. Investigation
of these events found that the, motorized isolation valve was not locked-out, as required by the 767 Dispatch
Deviations Guide. This allowed hydraulic pressure to be available to the actuators when the reverser levers
were activated on landing. The pin insert, located on each reverser sleeve, did not completely resist the
deployment loads and twisted out of place allowing movement of the deactivated thrust reverser. The JT9D
thrust reverser design is similar to the PW4000 thrust reverser design.
Further investigation and analysis by Boeing has also found that the current deactivation pin arrangement may
not always restrain a reverser against a full powered deployment.
The improved deactivation pin modification consists of: (1) replacing the pin insert with one that has increased
load carrying capability, (2) the bushing in the aft cascade ring is replaced with one that allows clearance for
the new insert and (3) the deactivation pin is replaced with a longer one which will engage the cascade bushing
despite any tolerances in the reverser.
Boeing Service Related Problem (SRP) 767-SRP-78-0042 is related to this service bulletin.
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ACTION (PRR B13498-R)
For each reverser half, replace the aft cascade bushing, sleeve insert, and the deactivation pin with new
components.
EFFECTIVITY
All JT9D powered 767 airplanes.
COMPLIANCE
Boeing recommends incorporation of this service bulletin within 24 months after November 5, 2002.
Federal Aviation Administration (FAA) Airworthiness Directive 2002-19-11, Amendment 39-12891, is related to
this service bulletin.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the changes given in this service bulletin.
MANPOWER
Total Man-hours - 17 Hours for each engine
Elapsed Time - 8.5 Hours
MATERIAL INFORMATION
Boeing Supplied Kits. Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
ON EACH LEFT AND
RIGHT THRUST REVERSER
SLEEVE REPLACE:
POTTED INSERT
BUSHING
DEACTIVATION PIN
WITH NEW COMPONENTS.
POTTED INSERT
(BUSHING LOCATED
UNDERNEATH)
THRUST REVERSER
(LEFT SLEEVE SHOWN
RIGHT SLEEVE SIMILAR)
....
1500
LEFT SLEEVE
THRUST REVERSER
DEACTIVATION PIN
RIGHT SLEEVE  STOWAGE
THRUST REVERSER  UP
DEACTIVATION PIN  STOWAGE  V43978
July 19, 2001
Revision 5: June 09, 2009  767-78A0089
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ALERTALERT
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Commercial        
Airplane
Group 
 767
Service Bulletin
ALERT
Number: 767-78A0089
Date: July 19, 2001
Revision 5: June 09, 2009
ATA System: 7831
SUBJECT: EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser
Deactivation Pin Modification
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
Refer to Service Bulletin Index Document D624T001, Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP
767 airplanes with JT9D engines with 315T3222-4, 315T3222-5, or
315T3222-6 bushings as part of the aft cascade ring
-1
767 airplanes with JT9D engines with 315T3222-3 bushings as part
of the aft cascade ring
-2
Airplane Models:
767-200, 767-300
GroupVariable Number
2VA001 - VA011
1VA012 - VA020
2VA701
1VA702 - VA719
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GroupVariable Number
2VA801
1VA802 - VA810
2VB001
1VB002
1VB201 - VB202
1VB281 - VB284
1VB301 - VB302
1VB371 - VB373
1VE001 - VE003
1VE021 - VE023
1VE041 - VE043
1VE061 - VE069
1VE083 - VE084
1VK001 - VK011
1VK021 - VK022
2. Spares Affected
None
B. Concurrent Requirements
None
C. Reason
The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires
incorporation of this service bulletin.
This service bulletin provides modification instructions to improve the thrust reverser deactivation pin's
structural integrity. This modification will ensure non-deployment of a deactivated thrust reverser.
Four partial deployments of improperly deactivated thrust reversers have been reported by operators
with PW4000 engines. These occurred during landing, with up to 12 inches of the reverser deployed.
Investigation of these events found that the, motorized isolation valve was not locked-out, as required
by the 767 Dispatch Deviations Guide. This allowed hydraulic pressure to be available to the actuators
when the reverser levers were activated on landing. The pin insert, located on each reverser sleeve,
did not completely resist the deployment loads and twisted out of place allowing movement of the
deactivated thrust reverser. The JT9D thrust reverser design is similar to the PW4000 thrust reverser
design.
Further investigation and analysis by Boeing has also found that the current deactivation pin arrangement
may not always restrain a reverser against a full powered deployment.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 19, 2001
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The improved deactivation pin modification consists of: (1) replacing the pin insert with one that has
increased load carrying capability, (2) the bushing in the aft cascade ring is replaced with one that
allows clearance for the new insert and (3) the deactivation pin is replaced with a longer one which will
engage the cascade bushing despite any tolerances in the reverser.
Boeing Service Related Problem (SRP) 767-SRP-78-0042 is related to this service bulletin.
Revision 2 is sent to add a stowage bracket for the thrust reverser deactivation pin.
Revision 3 is sent to add instructions to add instructions for part marking the thrust reverser ID plate
with the service bulletin number and to correct the existing part nomenclature in the Parts Modified and
Reidentified table (formerly Existing Parts Accountability).
Revision 4 is sent to include missing configuration for 315T3222-3 bushing replacement in the aft
cascade ring.
Revision 5 is sent to add the 315T3221-1 bushing installation for airplanes delivered with the 315T3222-3
bushing. Revision 4 of this service bulletin added the 315T3222-3 bushing configuration. However,
Boeing received a report from an operator that the 315T3222-3 bushing could not be replaced by the
315T3222-10 bushing due to inadequate edge margin.Therefore, this revision replaces the 315T3222-3
bushing with a new 315T3221-1 bushing that will provide adequate edge margin.
These sections were changed:
1. In Effectivity - Airplanes, paragraph 1.A.1., airplanes that delivered with the 315T3222-3 bushing
configuration were moved to a new Group 2.
2. In Material - Price and Availability, paragraph 2.A., price and ROLT data is added for the new
015T1838-1 and 015T1838-2 kits. Also, notes are added to clarify the correlation of the new kits
to the old kits for Group 2 airplanes.
3. In Kits/Parts, paragraph 2.C.1., a table was added for the new 015T1838-1 and 015T1838-2 kits.
4. In Work Instructions, paragraph 3.B., Step 4 was added to Work Package 2 for Group 2 airplanes.
5. In Figure 4, Step 5 was added to inspect for cracks, and Step 11 was changed to wet install the
fasteners.
6. Figure 11 was added for Group 2 airplanes.
D. Description
For each reverser half, replace the aft cascade bushing, sleeve insert, and the deactivation pin with
new components.
The changes in this service bulletin will not change the Engine Indication and Crew Alerting System
(EICAS).
Revision 4 - No more work is necessary on airplanes changed as shown in the initial release and
Revision 1, Revision 2 or Revision 3 of this service bulletin.
Revision 5 -
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Group 1:
No more work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4
of this service bulletin.
Group 2:
More work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4 of
this service bulletin. Airplanes that delivered with the 315T3222-3 bushing need to replace the
315T3222-3 bushing with the 315T3221-1 bushing. If Group 2 operators previously replaced the
315T3222-3 bushing with the 315T3222-10 bushing, the 315T3222-10 bushing must be replaced by
the 315T3221-1 bushing due to inadequate edge margin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
425, 426767-200, 767-300
Group 2:
Affected Maintenance Zones
ZoneModel
425, 426767-200
E. Compliance
Boeing recommends incorporation of this service bulletin within 24 months after November 5, 2002.
Federal Aviation Administration (FAA) Airworthiness Directive 2002-19-11, Amendment 39-12891, is
related to this service bulletin.
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.
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This service bulletin has been approved by the FAA. 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 (a) of AD 2002-19-11. All
provisions of AD 2002-19-11 that are not specifically referenced in the above statement remain fully
applicable and must be complied with.
Before using this AMOC, notify your appropriate principal inspector (PI) in the FAA Flight Standards
District Office (FSDO), or lacking a PI, your local FSDO.
This approval is subject to the following condition: If in the future the Seattle Aircraft Certification Office
(SACO) determines that this AMOC does not provide an acceptable level of safety, the SACO may
revoke or revise the terms of the AMOC following notice to the requester and a seven-day opportunity
for the requester to comment on the revocation or proposed revision.
G. Manpower
The table below shows an estimate of the man-hours necessary to do this modification for each engine.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
man-hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Elapsed Time (Hours)Man-HoursNumber of PersonsTask
1.02.02Open
6.513.02Modification
1.02.02Close
8.517.0TOTAL FOR EACH ENGINE
H. Weight and Balance Changes
Change in MomentChange in Weight
(Pound-Inches)(Pounds)Airplane
+ 330.0+ 0.4All
I. Electrical Load Data
Not changed
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J. References
1. Existing Data:
a. Service Related Problem (SRP) 767-SRP-78-0042
b. Engineering Change Memo PRR B13498-R
c. 767 Maintenance Planning Data (MPD) Section 4 "Access Doors and Panels"
d. Component Maintenance Manual (CMM) 71-11-31, 78-31-14
e. Standard Overhaul Practices Manual (SOPM) 20-20-02, 20-50-10, 20-50-19
f. 767 Aircraft Maintenance Manual (AMM) 27-62-00, 51-31-01, 71-11-04, 78-31-00
g. FAA Airworthiness Directive 2002-19-11
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None
4. Process Data:
None
K. Publications Affected
Chapter-SectionPublication
71-11, 78-31767 Component Maintenance Manual
78-31767 Illustrated Parts Catalog
L. Interchangeability and Intermixability of Parts
Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability
information.
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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, and Paragraph
2.D., Parts Necessary to Change Spares, as shown below. Kit availability is shown in the Reorder Lead
Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.
Group 1:
Unit Price thru Sep
30/01
ROLT
(weeks)
NameKit Number
No Longer Available-Top Kit - 767315T4026-9
No Longer Available-C - Duct Kit - Spares Only315T4026-8
$7,32224C - Duct Kit - Spares Only315T4026-25
$14,64424Top Kit - 767315T4026-26
$1,26821Supplemental315T4026-27
Group 1:
NOTE: For future purchase orders, Top Kit 315T4026-25 replaces Top Kit 315T4026-8 and Top Kit
315T4026-26 replaces Top Kit 315T4026-9. For previous purchase orders, Supplemental Top
Kit 315T4026-27 is needed to complete Top Kits 315T4026-8 and 315T4026-9.
Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary for Each Airplane, and
Paragraph 2.D., Parts Necessary to Change Spares, 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 2:
Unit Price thru
DEC 31, 2009
ROLT
(Weeks)
QTYDateNameKit Number
$9,986.003010July 1,
2009
Top Kit - (JT9D Engine)
Thrust Reverser
Deactivation Pin Change
015T1838-1
$3,523.00304June 4,
2009
Supplemental Kit -
Thrust Reverser
Deactivation Pin -
Bushing Replacement
015T1838-2
Group 2:
NOTE: The 015T1838-1 Top Kit replaces the 315T4026-25 or 315T4026-26 Top Kits.The 015T1838-1
Top Kit provides the parts necessary for each engine.
Group 2:
NOTE: If operators previously purchased the 315T4026-25 Top Kit, one 015T1838-2 Supplemental
Kit can be purchased to provide the parts needed for each engine.
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Group 2:
NOTE: If operators previously purchased the 315T4026-26 Top Kit, two 015T1838-2 Supplemental
Kits can be purchased to provide the parts needed for each airplane.
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.
Send purchase orders and letters about the supply data to the Director of Spares and refer to this
service bulletin number.
B. Industry Support Information
Boeing warranty remedies are not available for the changes given in this service bulletin.
C. Parts Necessary For Each Airplane
1. Kits/Parts:
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
Group 1:
NOTE: One 315T4026-26 top kit and the items shown in Paragraph 2.C.2., Parts and Materials
Supplied by the Operator, are necessary for each airplane.
Group 2:
NOTE: One 015T1838-1 top kit and the items shown in Paragraph 2.C.2., Parts and Materials
Supplied by the Operator, are necessary for each engine.
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Group 1:
Kit 315T4026
NotesExisting Part
Number
NameQTYNew Part Number
-5-6-7-8-9-27
(d) (f)Top Kit - 767....-.315T4026-9
(e) (f)Engine Kit - Spares
Only
...-..315T4026-8
(f)Supplemental Top
Kit
.....-315T4026-27
Pin Installation..-24.315T4026-7
Insert Installation.-.24.315T4026-6
Bushing Installation-..24.315T4026-5
315T1604-1,
315T1604-2,
315T1604-3,
315T1604-4 or
315T1604-5
Pin..1...315T1604-6
315T3222-4,
315T3222-5 or
315T3222-6
Bushing1.....315T3222-10
(a) (b)315T3563-1Insert Assembly.1....315T4027-1
(c)Blind Rivet4.....MS90353-0603
Kit, Deactivation Pin
- Right T/R
.....1015T0196-2
Kit, Deactivation Pin
- Left T/R
.....1015T0196-3
(a) The outer insert part number is 315T4027-2.
(b) The inner insert part number is 315T4027-4.
(c) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers listed are not available or have been superseded,
substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 012W6100
are used to determine the part numbers used as substitutes.
(d) The Top Kit 315T4026-9 has been replaced by Top Kit 315T4026-26.
(e) The Spares Top Kit 315T4026-8 has been replaced by Spares Top Kit 315T4026-25.
(f) The Supplemental Top Kit 315T4026-27 is needed to complete Top Kits 315T4026-8 and 315T4026-9.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Group 1:
Kit 315T4026
NotesExisting Part
Number
NameQTYNew Part Number
-25-26
(a)Top Kit - 767.-315T4026-26
(b)Engine Kit - Spares Only-.315T4026-25
Pin Installation24315T4026-7
Insert Installation24315T4026-6
Bushing Installation24315T4026-5
Kit, Deactivation Pin -
Right T/R
12015T0196-2
Kit, Deactivation Pin -
Left T/R
12015T0196-3
(a) The Top Kit 315T4026-9 has been replaced by Top Kit 315T4026-26
(b) The Spares Top Kit 315T4026-8 has been replaced by Spares Top Kit
315T4026-25.
Group 1:
Kit 015T0196
NotesExisting Part
Number
NameQTYNew Part Number
-2-3
Kit, Deactivation Pin -
Right T/R
-.015T0196-2
Kit, Deactivation Pin -
Left T/R
.-015T0196-3
Bracket Assy1.015T0196-4
Bracket Assy.1015T0196-5
Hi-Lok44BACB30NX6K3X
Collar44BACC30M6
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Group 2:
Kit 015T1838
NotesExisting Part
Number
NameQTYNew Part Number
-1-2
Group
2
airplanes
(a)
Supplemental Kit -
Thrust Reverser
Deactivation Pin -
Bushing Replacement
.-015T1838-2
Group
2
airplanes
(a)
Top Kit - (JT9D Engine)
Thurst Reverser
Deactivation Pin Change
-.015T1838-1
Bracket Assy1.015T0196-4
Bracket Assy1.015T0196-5
315T1604-1,
315T1604-2,
315T1604-3,
315T1604-4 or
315T1604-5
Pin2.315T1604-6
315T3222-3Bushing Plate22315T3221-1
(b) (c)315T3563-1Insert Assembly2.315T4027-1
Hi-Lock8.BACB30NX6K3X
Bolt, Blind88BACB30VX6A03U
Collar8.BACC30M6
(a) One kit provides the quantity of parts needed for each engine.
(b) The outer insert part number is 315T4027-2.
(c) The inner insert part number is 315T4027-4.
2. Parts and Materials Supplied by the Operator:
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NotesNameQTYPart Number /
Specification
(a) (b)Screw2NAS1351-01-6
(c)Screw2NAS1351-02-4
(f)Cotter Pin12MS24665-153
(k)Antisieze Lubricant16 ozBMS 3-28 or BAC
5008 Type 7-3
(e)Adhesive (Liquid Shim)4 ozBMS 5-141
(d)Sealant16 ozBMS 5-26 Type 1
or Type 2
(e)Potting Compound8 ozBMS 5-28, Type 6
(e)Thread Adhesive4 ozLoctite 242
(d)Transfer Punch515156
(b)Vacuum Bag Sealant Tape12 inAP200Y or
GS43MR
(a) NAS1351-02-6 may be substituted for the part listed.
(b) This part is used in FIGURE 1.
(c) This part is used in FIGURE 2.
(d) This part is used in FIGURE 4  and FIGURE 11 .
(e) This part is used in FIGURE 7.
(f) This part is used in FIGURE 8.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
(h) Pacific Distributing Inc. (206340), 7118 Beacon Ave. South, Seattle, WA 98108.
(i) Airtech International, 5700 Skylab Rd., Huntington Beach, CA 92647.
(j) Other similar "clay type adhesive" or Thick Double Back Tape may be substituted.
(k) This part is used in the Accomplishment Instructions during preassembly to lubricate the
pin or helicoil threads.
3. Parts Modified and Reidentified:
The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the
number of parts changed on each airplane.
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NotesNew Part NumberNameQTYExisting Part
Number
(a) (b)315T3204-21Aft Cascade Ring Assy2315T3204-5
(a) (b)315T3204-22Aft Cascade Ring Assy2315T3204-6
(a) (b)315T3204-21Aft Cascade Ring Assy2315T3204-7
(a) (b)315T3204-22Aft Cascade Ring Assy2315T3204-8
(a) (c)315T4026-17T/R Sleeve Assy2315T3500-1
(a) (c)315T4026-18T/R Sleeve Assy2315T3500-2
(a) (c)315T4026-19T/R Sleeve Assy2315T3500-21
(a) (c)315T4026-20T/R Sleeve Assy2315T3500-22
(a) (c)315T4026-21T/R Sleeve Assy2315T3500-23
(a) (c)315T4026-22T/R Sleeve Assy2315T3500-24
(a) (c)315T4026-23T/R Sleeve Assy2315T3500-27
(a) (c)315T4026-24T/R Sleeve Assy2315T3500-28
(a) Make the change given in this service bulletin.
(b) This is the part number for the new equivalent or replacement part.
(c) This is the part number after the change given in this service bulletin
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.
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Group 1:
NamePart NumberQuantity
Engine Kit - Spares Only315T4026-251
Group 2:
NamePart NumberQuantity
Top Kit - (JT9D Engine) Thurst
Reverser Deactivation Pin
Change
015T1838-11
E. Special Tooling - Price and Availability
Boeing can supply the tools shown in Paragraph 2.F ., Special Tooling Necessary to do this Service
Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the
date the tools will be used.
If there is a limit in the quantity of available rental tools, a supply sequence is given by Spares.
Purchase Data:
Price thru DEC
31, 2009
NameTool Kit Number
$7,500.00Hole Saw with PilotMIT315T4500
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
After the Price date, new price data is applicable. Prices are in United States dollars. Terms: Net 30
days.
F. Special Tooling Necessary to do this Service Bulletin
To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability.
Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be
necessary. Examine operator tool supply to make sure all necessary tools are available.
NameTool Kit Number
Hole Saw with PilotMIT315T4500
Note: An operator approved equivalent tool or tools may be used
instead of the tool(s) called for in this bulletin. The alternate tool(s)
must produce the same or better end item affect to the modified
part.
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3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
NOTE: 1. The paragraphs identified with a letter give the general work instructions. The
instructions identified with numbers on the figures give the recommended sequence
of steps.
2. 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 given in 767 Structural Repair
Manual, Chapter 51
— Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual,
Chapter 51.
3. In this service bulletin, all references to Boeing airplane documentation (i.e. AMM,
BSOPM, etc.) imply the use of your equivalent procedure(s) to these references as
acceptable, unless otherwise stated.
4. Alternative fasteners are given in 767 Structural Repair Manual, Chapter 51.
5. Obey all of the warnings and cautions given in the specified manual sections.
6. An operator approved equivalent tool or tools may be used instead of a tool called
for in this bulletin. The alternate tool(s) must produce the same or better end item
affect to the modified part.
B. WORK INSTRUCTIONS
WORK PACKAGE I - Pre-Modification Preparation
1. Make the shop aid tools shown in FIGURE 1, "Holder - Inner Insert" and FIGURE 2, "Spanner -
Outer Insert". These are required to install the new two piece insert.
2. Test install the pin, part number 315T4026-7, into the insert, part number 315T4026-6 (tighten
until the pin head is seated against the insert). This will test its function and reduce the initial tear
torque.The initial check is necessary to eliminate the possibility of dislodging the insert after it has
been potted into the thrust reverser sleeve. An antisieze lubricant may be added to the threads of
the pin or helicoil to ease installation of the pin into the insert.
WORK PACKAGE II - Modification procedures for a thrust reverser that is installed on an airplane
1. Do the Thrust Reverser Deactivation procedures, for all engines, as follows:
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WARNING: DO THE DEACTIVATION PROCEDURE FOR THE AUTOMATIC SPEED BRAKE
CONTROL SYSTEM. IF YOU DO NOT DO THIS, THE AUTOMATIC SPEED BRAKES
CAN MOVE QUICKL Y WHEN YOU MOVE THE THRUST LEVERS. THIS CAN
CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.
a. Make sure the forward thrust levers are in the idle position and attach the DO-NOT -OPERATE
tags.
b. Make sure the reverse thrust levers are in the fully stowed position and attach the
DO-NOT -OPERATE tags.
c. Deactivate the Isolation Valve for ground maintenance as shown in 767 AMM 78-31-00, "Thrust
Reverser Deactivation and Activation For Ground Maintenance". However, since the T/R
sleeve will be manually translated in FIGURE 3, do not install the deactivation pin in the side
of the T/R sleeve.
2. To get access to the AFT cascade ring and reverser sleeve insert, translate the reverser by your
hand as shown in FIGURE 3.
3. Group 1:
Replace the pin bushing square, in the aft cascade ring, as shown in FIGURE 4.
4. Group 2:
Replace the pin bushing square in the aft cascade ring, as shown in FIGURE 11.
5. Remove the insert as shown in FIGURE 5.
6. Do a fit check of the new two piece insert (without liquid shim and potting) as shown in FIGURE
6.
7. Install the new two piece insert (with liquid shim and potting) as shown in FIGURE 7.
8. After the potting and liquid shim have cured, reconnect the linear actuators as shown in FIGURE
8.
9. Install the new deactivation pin. Be sure it can be installed all the way; then remove the deactivation
pin.
10. Install the screw plug, part number BACB30VF8K2 (part number AIC1195-8-2 is optional but not
preferred), into the hole of the outer insert (where the deactivation pin was inserted) and tighten
the screw plug to 120-150 pound-inches (13.6-17.0 newton-meters).
11. Open the fan cowl as shown in 767 AMM 71-11-04. Install a new stowage bracket and replace
the stowed deactivation pin as shown in FIGURE 9.
12. Mark the service bulletin number on each thrust reverser ID plate as shown in FIGURE 10.
13. Manually Extend and Retract the reverser as shown in 767 AMM 78-31-00 (Manual Method) to
check the thrust reverser operation and the rod end gap of the center locking actuator.
14. Do the following Thrust Reverser Activation procedures as follows:
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a. Activate the Isolation Valve for ground maintenance as shown in 767 AMM 78-31-00, "Thrust
Reverser Deactivation and Activation For Ground Maintenance".
b. Do the activation procedure for the speed brake control system as shown in 767 AMM 27-62-00.
c. Remove the DO-NOT -OPERATE tags from the reverse thrust levers and the forward thrust
levers.
15. Extend and retract the thrust reverser three times with hydraulic power to make sure it operates
correctly and the flight compartment indications are correct as shown in 767 AMM 78-31-00.
16. Return the airplane to service condition.
WORK PACKAGE III - Modification procedures for a spare thrust reverser
1. If not previously made, make the shop aid tools shown in FIGURE 1, "Holder - Inner Insert" and
FIGURE 2, "Spanner - Outer Insert". These are required to install the new two piece insert.
2. To get access to the AFT cascade ring and reverser sleeve insert, translate the reverser by your
hand as shown in FIGURE 3.
3. Replace the pin bushing square, in the aft cascade mounding ring, as shown in FIGURE 4.
4. Remove the insert as shown in FIGURE 5.
5. Do a fit check of the new two piece insert (without liquid shim and potting) as shown in FIGURE
6.
6. Install the new two piece insert (with liquid shim and potting) as shown in FIGURE 7.
7. After the potting and liquid shim have cured, reconnect the linear actuators as shown in FIGURE
8.
8. Install the new deactivation pin. Be sure it can be installed all the way; then remove the deactivation
pin.
9. Install the screw plug, part number BACB30VF8K2 (part number AIC1195-8-2 is optional but not
preferred), into the hole of the outer insert (where the deactivation pin was inserted) and tighten
the screw plug to 120-150 pound-inches (13.6-17.0 newton-meters).
10. Install a new stowage bracket and replace the stowed deactivation pin as shown in FIGURE 9.
11. Mark the service bulletin number on each thrust reverser ID plate as shown in FIGURE 10.
12. Do the following thrust reverser tests as shown in the CMM 78-31-14:
a. Manually Extend and Retract the reverser to check the thrust reverser operation and the rod
end gap of the center locking actuator.
b. Extend and retract the thrust reverser three times with hydraulic power to make sure it operates
correctly.
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BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
(2 LOCATIONS)
(2 LOCATIONS)
0.250
0.250
- 16.30  2.00
0.50-  10.45 -  1.96
0.45  10.40  2.00-
-A-
0.125 R  Ł SYMM •-
(4 LOCATIONS)
1.50  0.9688  0.90
0.9375  0.87
© 0.010 A
1.500
‡ .005
FIGURE 1: SHOP AID HOLDER - INNER INSERT
(SHEET 1 OF 2)
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### Page 29

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts associated with the shop aid tool.
NOTESQTYMATERIALNAMETASKSTEP
Thickness is 0.112 - 0.100.12024 orStockLayout1
7075 or
Other Suitable
Aluminum Alloy
1- -HoleDrill2
or other steel alloy screw or pin
with a diameter of 0.073 - 0.0695
and a final length as shown.
(Threads are not required.)
2NAS1351-01-6ScrewInstall3
or other steel alloy screw or pin
with a diameter of 0.0860 -
0.0822. Final length as shown.
(Threads are not required.)
(NAS1351-02-6
optional)
So that inner insert will adhear to
tool. (Approx. area each location
is 1/4 X 1/2 X 1/16 to 1/8.)
2GS43MR orVacuum Bag Sealant
Tape
Install4
(AP200Y or
any other type)
as: "PW4000/JT9D T/R (767-78A0080, 767-78A0089, or
747-78A2165) Holder - Inner Insert"
Shop Aid ToolIdentify5
FIGURE 1: SHOP AID HOLDER - INNER INSERT
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
0.250
20°
4.00  1.5
0.9857
1.50  ‡0.015
0.125 R
(4 LOCATIONS)
(2 LOCATIONS)
FIGURE 2: SHOP AID SPANNER - OUTER INSERT
(SHEET 1 OF 2)
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### Page 31

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts associated with the shop aid tool.
NOTESQTYMATERIALNAMETASKSTEP
Thickness is 0.112 - 0.100.12024 orStockLayout /
Cut
1
7075 or
Other Suitable
Aluminum Alloy
or other steel alloy screw or pin,
diameter of 0.0860 - 0.0822, with
a final length as shown. (Threads
are not required.)
2NAS1351-02-4ScrewInstall2
as: "PW4000/JT9D T/R (767-78A0080, 767-78A0089, or
747-78A2165) Spanner - Outer Insert"
Shop Aid ToolIdentify3
FIGURE 2: SHOP AID SPANNER - OUTER INSERT
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
SEE AO
LEFT SIDE SHOWN
(RIGHT SIDE OPPOSITE)
THRUST
REVERSER  HYDRAULIC
SLEEVE  ACTUATOR
HYDRAULIC  1 BOLT  ACCESS PANEL  (3 LOCATIONS)
ACTUATOR  2 WASHER  SEE ®
(2) BUSHING
2 WASHER
1 HYDRAULIC ACTUATOR
ACCESS PANEL
2 NUT AND
COTTER PIN
FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT
(SHEET 1 OF 3)
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### Page 33

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts associated with one reverser sleeve.
FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT
(SHEET 2 OF 3)
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NOTESQTYPART NUMBERNAMETASKSTEP
WARNING: FAILURE TO FOLLOW THE DEACTIVATION PROCEDURES GIVEN IN THE GENERAL
ACCOMPLISHMENT INSTRUCTIONS MAY RESULT IN SERIOUS INJURY AND/OR DAMAGE TO THE
THRUST REVERSER.
Reference 767 MPD
Section 4, and 767
AMM 78-31-00.
3415CL (left engine outboard)Upper Hydraulic
Actuator Access
Panel:
Remove /
Keep
1
416CR (left engine inboard)
426CR (right engine outboard)
425CL (right engine inboard)
415DL (left engine outboard)Middle Hydraulic
Actuator Access
Panel: 416DR (left engine inboard)
426DR (right engine outboard)
425DL (right engine inboard)
415EL (left engine outboard)Lower Hydraulic
Actuator Access
Panel: 416ER (left engine inboard)
426ER (right engine outboard)
425EL (right engine inboard)
3MS24665-153Cotter PinRemove2
3BACN10JD105NutRemove /
Keep 6AN960-516Washer
3NAS6705D18Bolt
3NAS74A5E006PBushing
by hand, all the way to
the deploy position.
1- -Reverser SleeveTranslate3
FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT
(SHEET 3 OF 3)
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BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
This Figure applies only to: Group 1.
LEFT SIDE SHOWN
(RIGHT SIDE OPPOSITE)
SEE  УвУС
CASCADE
RING
FWD '  V43998
FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING
(SHEET 1 OF 5)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
90
3) CHAMFER
0.03-0.04
BY 45°
CASCADE
RING
4568
(4 LOCATIONS)
FWD &
A-A
B
CASCADE (12)
RING
FWD
FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING
(SHEET 2 OF 5)
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### Page 37

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts necessary for one reverser sleeve.
FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING
(SHEET 3 OF 5)
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### Page 38

NOTESQTYPART NUMBERNAMETASKSTEP
CAUTION: PRIOR TO MAKING ANY CHANGES TO THE THRUST REVERSER, TEST INSTALL THE NEW
DEACTIVATION PIN INTO THE HELICOIL OF THE NEW OUTER INSERT (TIGHTEN UNTIL THE PIN
HEAD IS SEATED AGAINST THE INSERT).THIS WILL CHECK ITS FUNCTION AND REDUCE THE INITIAL
TEAR TORQUE.THE INITIAL CHECK IS NECESSARY TO ELIMINATE THE POSSIBILITY OF DISLODGING
THE INSERT AFTER IT HAS BEEN POTTED INTO THE THRUST REVERSER SLEEVE. AN ANTISIEZE
LUBRICANT MAY BE ADDED TO THE THREADS OF THE PIN OR HELICOIL TO EASE INSTALLATION
OF THE PIN INTO THE INSERT.
slowly, by your hand, towards
stow until the cascade bushing
square (which receives the end
of the deactivation pin) is
centered as shown.
1- -Reverser SleeveMove1
by drilling out countersunk rivet
heads.
1315T3222-4, -5, or -6Bushing SquareRemove2
Note: To ensure complete rivet removal, it is recommended to apply a tape or putty to the back side
of rivet to contain it while it is tapped out of the hole. Remove the tape/putty with rivet thru the
deactivation pin hole.
1- -HoleChamfer3
to a diameter of 0.199 - 0.201.4- -Rivet HolesOversize4
Dye penetrant inspect for cracks.
Refer to SOPM 20-20-02 as an
accepted procedure. (a)
4- -Rivet HolesInspect5
into the rivet holes.415156Transfer PunchPut6
in PROPER orientation as shown
to transfer the center mark of the
transfer punch to the bushing
plate.
1315T3222-10Bushing PlateMount7
from cascade ring.1315T3222-10Bushing PlateRemove
into bushing plate. Diameter is
0.199 - 0.202.
4- -Rivet HolesDrill
415156Transfer PunchRemove8
on cascade ring of any previous
sealant in the area the bushing
plate will cover. Ref. 767 AMM
51-31-01.
-- -SurfaceClean9
to cascade ring. The area for the
bushing plate. Ref. 767 AMM
51-31-01.
-BMS5-26Fay SealApply10
in PROPER orientation as shown.1315T3222-10Bushing PlateInstall11
Wet install with BMS5-26. Refer4MS90353-0603Blind Rivet
FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING
(SHEET 4 OF 5)
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NOTESQTYPART NUMBERNAMETASKSTEP
to SOPM 20-50-19 as an
accepted procedure.
with BMS5-26. Ref. 767 AMM
51-31-01.
-- -Bushing Plate EdgesFillet Seal
to new part number shown in
Paragraph 2.C.3., Parts Modified
and Reidentified and the SOPM
20-50-10, Paragraph 6, Rubber
Stamping.
1( )Aft Cascade Ring
Part Number
Change12
Note: The part mark may be placed at any convenient location on the aft cascade ring assembly and
may be hidden by other structures.
(a) If cracks are found, repair or replace as necessary. Refer to CMM 71-11-31 as an accepted procedure.
FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING
(SHEET 5 OF 5)
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### Page 40

FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE
(SHEET 1 OF 3)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
DEACTIVATION
PIN HOLE
(INBEDDED INSERT)
OUTER PANEL
REVERSER SLEEVE
(CARBON GRAPHITE
COMPOSITE)
- APPROX. 0.080
INNER PANEL
REVERSER SLEEVE
(CARBON GRAPHITE  OUTER PANEL
COMPOSITE)  REVERSER SLEEVE
(CARBON GRAPHITE
COMPOSITE)
APPROX. 0.840
A-A  V44005
FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE
(SHEET 2 OF 3)
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### Page 42

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts associated with one reverser sleeve.
NOTESQTYPART NUMBERNAMETASKSTEP
slowly, by your hand, to the
deploy position.
1- -Reverser SleeveMove1
in the deactivation pin hole.1MIT315T4500-3Saw Pilot BushingThread2
to installed pilot1MIT315T4500-2/-5Hole Saw with ArborLocate3
WARNING: CUTTING OUT THE INSERT WILL CAUSE A FINE DUST. BE SURE YOU WEAR A DUST
MASK OR RESPIRATOR. USE A VACUUM TO REMOVE DUST DURING THE SAWING OPERATION AND
FOR CLEANUP , AFTER THE INSERT IS REMOVED.
"drill" down between 0.70 - 0.80
inches. When you first start to cut
(the outer carbon panel), you will
get brown dust. When you go the
potting, you will get yellow/white
dust. Then as you start to get
brown dust (the inner carbon
panel) the insert will start to spin.
1- -Inbedded InsertCut Out4
when it spins within the hole.- -Inbedded InsertRemove
back into the hole, so that the hole
can act as a guide, for the saw to
cut thru the inner panel of the
sleeve.
1MIT315T4500-2/-5Hole Saw with ArborLocate5
to complete the hole. Be sure
cutting pressure is such as to
create the best possible edge
corner when cutter passes thru
the inner panel.
-- -Inner panel of the
sleeve
Cut thru6
FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE
(SHEET 3 OF 3)
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### Page 43 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
LEFT SIDE SHOWN
(RIGHT SIDE OPPOSITE)
SEE
ENGINE  ENGINE
CORE  CORE
INNER 2  2 OUTER
INSERT  INSERT  V44006
A-A
FIGURE 6: NEW INSERT FIT CHECK
(SHEET 1 OF 6)
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### Page 44 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
SPANNER
HOLDER (6  FWD I
FIGURE 6: NEW INSERT FIT CHECK
(SHEET 2 OF 6)
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### Page 45 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
FWD •
UP
INBD
FWD K
ENGINE
CORE
® 0.004  8 0.004
0.00  B-B  0.00  V44010
FIGURE 6: NEW INSERT FIT CHECK
(SHEET 3 OF 6)
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### Page 46

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts necessary for one reverser sleeve.
FIGURE 6: NEW INSERT FIT CHECK
(SHEET 4 OF 6)
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### Page 47

NOTESQTYPART NUMBERNAMETASKSTEP
for sharp edges. Remove as
necessary. Hole sides should be
clean with no ragged edges and
sides are not broken through.
1- -HoleInspect1
diameter. It should be 1.1865 -
1.1885 inches. If diameter is less
than this, use a reamer to be
within the above diameter.
1- -HoleMeasure
to be sure their shoulders will fit
in the hole.
1315T4027-4Inner InsertCheck2
1315T4027-2Outer Insert
Note: If they do not fit, Ream hole to 1.1885 -1.1905 inches in diameter. Be sure to remove sharp
edges on both sides. Be sure not to remove any material from the face of the sleeve.
to holder tool.1315T4027-4Inner InsertAttach3
as shown. Do not remove holder
tool from inner insert.
1315T4027-4Inner InsertInstall4
CAUTION: BE SURE NOT TO TIGHTEN SO AS TO SQUISH THE REVERSER SLEEVE PANEL.TIGHTEN
ONL Y HAND SNUG SO AS TO BE REMOVABLE LATER. ADJUST TIGHTENING SO THAT THE
INJECTION HOLES, OF THE OUTER INSERT, ARE VERTICAL.
Use spanner to tighten.1315T4027-2Outer InsertInstall5
Note: To pull the inner insert into the hole, you may have to use the deactivation pin by screwing
it in the outer insert up to a 1/8 turn and then gently, with a slight wiggle, pull outward.
from inner insert.1- -Holder ToolRelease6
from access.1- -Holder ToolRemove
thru the gap between the sleeve
and cascades to be sure insert is
in the hole. Look to see that the
top edge of the insert has the
same relationship, to the inner
sleeve, as the bottom edge. Look
to see that the FWD edge has the
same relationship to the sleeve
as the AFT edge.
1315T4027-4Inner InsertLook At7
for a gap of 0.004 inches, or less,
at the FWD and AFT edges with
the sleeve. The top edge should
have the similar relationship, to
the sleeve, as the bottom edge.
1315T4027-2Outer InsertCheck8
Note: If you do not get the conditions given in STEP 7 & 8, than it may be necessary to remove
material from the side of the hole to make the insert fit evenly. Do NOT remove more than 0.030
inches, total, from the side of the hole. Do NOT remove material from the face of the sleeve.
FIGURE 6: NEW INSERT FIT CHECK
(SHEET 5 OF 6)
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### Page 48

NOTESQTYPART NUMBERNAMETASKSTEP
CAUTION: WHEN MOVING SLEEVE, USE A SLOW RATE OF MOVEMENT AND BE CAREFUL NOT
TO DAMAGE ACTUATORS WITH CLEVISES ON THE SLEEVE.
slowly, by your hand, towards
stow. Be sure the actuators fit into
their clevises on the sleeve.
1- -Reverser SleeveMove9
CAUTION: DO NOT SCREW IN DEACTIVATION PIN INTO THE OUTER INSERT.
into outer insert.1315T1604-6New Deactivation PinPlace10
goes into bushing without the pin
being screwed in.
-- -Pin EndVerify
1315T1604-6New Deactivation PinRemove
to the deploy position.1- -Reverser sleeveMove11
1315T4027-2Outer InsertRemove12
1315T4027-4Inner Insert
FIGURE 6: NEW INSERT FIT CHECK
(SHEET 6 OF 6)
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### Page 49

FIGURE 7: INSERT INSTALLATION
(SHEET 1 OF 5)
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### Page 50 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
SPANNER
10) 0.004  0.00
FWD I
HOLDER
V44013
FIGURE 7: INSERT INSTALLATION
(SHEET 2 OF 5)
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### Page 51

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts necessary for one reverser sleeve.
FIGURE 7: INSERT INSTALLATION
(SHEET 3 OF 5)
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### Page 52

NOTESQTYPART NUMBERNAMETASKSTEP
on outer surface of sleeve panel
as shown.Y ou may go beyond
the flange diameter of the outer
insert by 0.150 inches.
-- -PaintRemove1
Ref. 767 AMM 51-31-01.1- -HoleClean2
to inner and outer inserts as
shown. Apply enough to fill gaps
under flanges when inserts are
installed. Ref. 767 AMM
51-31-01.
-BMS5-141Adhesive (liquid
Shim)
Apply3
to thread of outer insert.-Loctite 242Thread AdhesiveApply4
to holder tool.1315T4027-4Inner InsertAttach5
as shown. Do not remove holder
tool from inner insert.
1315T4027-4Inner InsertInstall6
CAUTION: BE SURE NOT TO TIGHTEN SO AS TO SQUISH THE REVERSER SLEEVE PANEL. ADJUST
TIGHTENING SO THAT THE INJECTION HOLES, OF THE OUTER INSERT, ARE VERTICAL.
Use spanner to tighten.1315T4027-2Outer InsertInstall7
NOTE: To pull the inner insert into the hole, you may have to use the deactivation pin by screwing
it in the outer insert up to a 1/8 turn and then gently, with a slight wiggle, pull outward.Then, remove
deactivation pin and finish tightening insert.
from inner insert.1- -Holder ToolRelease8
from access.1- -Holder ToolRemove
from outer insert1Spanner Tool
thru the gap between the sleeve
and cascade to be sure insert is
in the hole. Also look to see that
the top edge of the insert has the
same relationship, to the inner
1315T4027-4Inner InsertLook At9
sleeve, as the bottom edge. Look
to see that the FWD edge has the
same relationship to the sleeve
as the AFT edge. Be sure
adhesive fills all gaps between
insert and sleeve panel.
for a gap of 0.004 inches or less
at the FWD and AFT edges with
the sleeve. The top edge should
have the same relationship, to the
sleeve, as the bottom edge. Be
sure adhesive fills all gaps
between insert and sleeve panel.
1315T4027-2Outer InsertCheck10
FIGURE 7: INSERT INSTALLATION
(SHEET 4 OF 5)
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### Page 53

NOTESQTYPART NUMBERNAMETASKSTEP
11 deactivation pin hole, to prevent
potting compound from getting in.
1315T4027-2Outer InsertTape
in lower hole, slowly, until it
comes out the upper hole in a
long stream, without air.
-BMS5-28, Type 6Potting CompoundInject12
shut and let compound cure.2- -Injections HolesTape
to new part number shown in
Paragraph 2.C.3., Parts Modified
and Reidentified and the SOPM
20-50-10, Paragraph 6, Rubber
Stamping.
1( )Reverser Sleeve Part
Number
Change13
Note: The part mark may be placed at any convenient location on the thrust reverser sleeve except
the decorative finish side of the outer sleeve and may be hidden by other structures.
FIGURE 7: INSERT INSTALLATION
(SHEET 5 OF 5)
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### Page 54 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
LEFT SIDE SHOWN
(RIGHT SIDE OPPOSITE)
THRUST  HYDRAULIC
REVERSER  ACTUATOR
SLEEVE  ACCESS PANEL
1 BOLT  (3 LOCATIONS)
HYDRAULIC
ACTUATOR  1 WASHER  SEE
(2) BUSHING
2) WASHER
3 HYDRAULIC ACTUATOR
ACCESS PANEL
> NUT AND
COTTER PIN  V44014
FIGURE 8: RECONNECTION OF LINEAR ACTUATOR
(SHEET 1 OF 2)
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### Page 55

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts associated with one reverser sleeve.
NOTESQTYPART NUMBERNAMETASKSTEP
by hand, all the way to stow. Be
careful to position the actuators
into the clevis of the sleeve.
1- -Reverser SleeveTranslate1
3MS24665-153Cotter PinInstall2
3BACN10JD105NutInstall /
Kept 6AN960-516Washer
3NAS6705D18Bolt
3NAS74A5E006PBushing
The actuator access cover panel is install later, after the reverser is checked manually as shown
in the AMM. Refer to General Accomplishment Instructions.
3
FIGURE 8: RECONNECTION OF LINEAR ACTUATOR
(SHEET 2 OF 2)
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### Page 56 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
LEFT SIDE SHOWN
(RIGHT SIDE OPPOSITE)
UP
FWD
THRUST
SEE  REVERSER
SLEEVE
SEE ®
......
1) LEFT THRUST
RIGHT THRUST  REVERSER
REVERSER  DEACTIVATION
DEACTIVATION  PIN
PIN  FWD  V44016
FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN
REPLACEMENT
(SHEET 1 OF 4)
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### Page 57 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
HOLD  HOLD
OPEN  OPEN
ROD  ROD
JUP
+  2 A 6F (8 LOCATIONS)
(RIGHT SIDE SHOWN, LEFTT SIDE OPPOSITE)  A—A  N83433
FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN
REPLACEMENT
(SHEET 2 OF 4)
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### Page 58

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the numbers of parts associated with one engine reverser.
NOTESQTYPART NUMBERNAMETASKSTEP
from the stowage area on
reverser.
2315T1604-1,
315T1604-2,
315T1604-3,
315T1604-4, or
315T1604--5
Deactivation PinRemove /
Discard
1
8-Fastener, ExistingRemove /
Discard
2
Install on right thrust reverser
only. Match drill the holes in the
bracket assembly to the holes left
open by the fastener removal
accomplished in step 2.
1015T0196-4Bracket AssyInstall3
Install on left thrust reverser only.
Match drill the holes in the
bracket assembly to the holes left
open by the fastener removal
accomplished in step 2.
1015T0196-5
8BACB30NX6K3XHi-Lok
8BACC30M6Collar
in the stowage area on the
reverser.
2315T1604-6Deactivation PinInstall4
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.
A number in the lower right corner gives the grip length of the fastener.
FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN
REPLACEMENT
(SHEET 3 OF 4)
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### Page 59

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than
indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute
fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to
determine the part numbers used as substitutes.
NOTESHOLE
DIA
PART NUMBERNAMECODE
Install with fastener head
on the far side.
0.218 -
0.229
BACB30NX6K3XHi-LokA
-BACC30M6Collar
FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN
REPLACEMENT
(SHEET 4 OF 4)
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### Page 60 (OCR)

BOEING SERVICE BULLETIN 767-78A0089
ALERT  ALERT
AIRCRAFT MOD.
MFR CODE
PART NO.
CONT. NO.
SERIAL NO.
CONT.  CUST.
INSP.
MODIFICAION INCORPORATED
SEE A
CLEFT SIDE SHOWN,
RIGHT SIDE EQUIVALENT)
W56755
FIGURE 10: MARK THRUST REVERSER ID PLATE WITH SERVICE BULLETIN NUMBER
(SHEET 1 OF 2)
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