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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0075 Original Issue: January 14, 2015 Revision 2: February 22, 2021 ATA System: 5380 SUBJECT: FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair 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:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2015 Boeing.
Unpublished Work. All Rights Reserved.
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: January 14, 2015 777-53A0075Revision 2: February 22, 2021 1 of 156
5.0
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Original Issue: January 14, 2015 777-53A0075Revision 2: February 22, 2021 2 of 156 BOEING SERVICE BULLETIN 777-53A0075
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet7
Summary11
1. PLANNING INFORMATION17
A. Effectivity17
1. Airplanes17
2. Spares Affected19
B. Concurrent Requirements19
C. Reason19
D. Description22
E. Compliance23
F. Approval35
G. Manpower35
H. Weight and Balance Changes39
I. Electrical Load Data39
J. References39
1. Existing Data:39
2. Data Supplied with this Service Bulletin:39
3. Installation Drawings Used in the Preparation of this Service Bulletin:39
K. Publications Affected40
L. Interchangeability and Intermixability of Parts40
M. Software Accomplishment Summary40
2. MATERIAL INFORMATION41
A. Material - Price and Availability41
B. Industry Support Information42
C. Parts Necessary for Each Airplane42
1. Kits/Parts42
2. Parts and Materials Supplied by the Operator44
3. Parts Modified and Reidentified44
4. Parts Removed and Not Replaced45
D. Parts Necessary to Change Spares45
E. Special Tooling - Price and Availability45
F. Special Tooling Necessary to do this Service Bulletin45
3. ACCOMPLISHMENT INSTRUCTIONS47
A. GENERAL INFORMATION47
B. WORK INSTRUCTIONS49
FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL [Group 1, Configuration 1-2, 4; Group 2,
Configuration 1-2, 4]61
FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL [Group 1, Configuration 1-2, 4; Group 2,
Configuration 1-2, 4]65
FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND LONGERON FITTING - DET AND HFEC INSPECTION [Group 1, Configuration 1-2, 4; Group 2, Configuration
1-2, 4]69
FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND LONGERON FITTING - DET AND HFEC INSPECTION [Group 1, Configuration 1-2, 4; Group 2, Configuration
1-2, 4]74
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FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION [Group 1, Configuration 1-2, 4; Group 2,
Configuration 1-2, 4]79
FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION [Group 1, Configuration 1-2, 4; Group
2, Configuration 1-2, 4]84
FIGURE 7: THIS FIGURE IS DELETED89
FIGURE 8: THIS FIGURE IS DELETED90
FIGURE 9: THIS FIGURE IS DELETED91
FIGURE 10: THIS FIGURE IS DELETED92
FIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD ASSEMBLY STRUCTURE - HFEC INSPECTION
[Group 1, Configuration 1-2, 4; Group 2, Configuration 1-2, 4]93
FIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD ASSEMBLY STRUCTURE - HFEC INSPECTION
[Group 1, Configuration 1-2, 4; Group 2, Configuration 1-2, 4]95
FIGURE 13: THIS FIGURE IS DELETED97
FIGURE 14: THIS FIGURE IS DELETED98
FIGURE 15: THIS FIGURE IS DELETED99
FIGURE 16: THIS FIGURE IS DELETED100
FIGURE 17: THIS FIGURE IS DELETED101
FIGURE 18: THIS FIGURE IS DELETED102
FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND LONGERON FITTING - POST-REPAIR DET AND HFEC INSPECTION [Group 1-2, Configuration 3] . 103 FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND LONGERON FITTING - POST-REPAIR DET AND HFEC INSPECTION [Group 1-2, Configuration 3] . 107 FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST-REPAIR
INSPECTION - SKIN PANEL INSTALLATION [Group 1-2, Configuration 3]111
FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST-REPAIR
INSPECTION - SKIN PANEL INSTALLATION [Group 1-2, Configuration 3]116
FIGURE 23: THIS FIGURE IS DELETED121
FIGURE 24: THIS FIGURE IS DELETED122
FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL [Group 1-2, Configuration 3]123
FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL [Group 1-2, Configuration 3]127
FIGURE 27: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST REPAIR -
FASTENER REMOVAL [Group 1, Configuration 3-4; Group 2, Configuration 3-4]131
FIGURE 28: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST REPAIR -
FASTENER REMOVAL [Group 1, Configuration 3-4; Group 2, Configuration 3-4]133
FIGURE 29: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST REPAIR -
FASTENER INSTALLATION [Group 1, Configuration 3-4]135
FIGURE 30: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST REPAIR -
FASTENER INSTALLATION [Group 1, Configuration 3-4]137
FIGURE 31: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST REPAIR -
FASTENER INSTALLATION [Group 2, Configuration 3-4]139
FIGURE 32: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD POST REPAIR -
FASTENER INSTALLATION [Group 2, Configuration 3-4]141
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: LEFT AND RIGHT SIDE, DET AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD OUTER
CHORD [Group 1-2, Configuration 1]143
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: LEFT AND RIGHT SIDE, DET AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD OUTER
CHORD [Group 1-2, Configuration 2]146
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APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 3: LEFT AND RIGHT SIDE, POST-REPAIR DET AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD OUTER CHORD FOR SMALL CRACK REPAIR [Group 1-2, Configuration 3] . 149 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 4: LEFT AND RIGHT SIDE, POST-MODIFICATION DET AND HFEC INSPECTION OF THE STA 2370 PIVOT BULKHEAD
FORWARD OUTER CHORD [Group 1-2, Configuration 4]153
APPENDIX E: BOEING PART DEMAND INTENT156
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Commercial Airplanes 777 Service Bulletin ALERT Revision Transmittal SheetNumber: 777-53A0075Original Issue: January 14, 2015 Revision 2: February 22, 2021 ATA System: 5380 SUBJECT: FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2016-09-01 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Effects of this Revision on airplanes on which Original Issue or Revision 1 was previously done:
ActionConditionGroup Do PART 1: STATION 2370 PIVOT
BULKHEAD FORWARD OUTER
CHORD AND LONGERON FITTING
- DET AND HFEC INSPECTION, for any crack at the times specified in Compliance.
Airplanes that have done Boeing Service Bulletin 777-53A0075 Original Issue or Revision 1 and have no crack found and no small crack repair done in accordance with Boeing Service Bulletin 777-53A0075 or modification installed in accordance with Boeing Service Bulletin 777-53- 0076 on the left or right side.
Group 1 and 2, Configuration 2 Do the post-repair DET and HFEC inspection in accordance with PART 3, for any crack at the times specified in Compliance. As an option, do the modification in accordance with Boeing Service Bulletin 777-53-0076 Revision 2.
Airplanes that have done Boeing Service Bulletin 777-53A0075 Original Issue or Revision 1 PART 2 station 2370 pivot bulkhead forward chord - small crack repair on the left or right side, and have not done the modification in accordance with Boeing Service Bulletin 777-53-0076 on the left or right side.
Group 1 and 2, Configuration 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075Revision 2: February 22, 2021 7 of 156
ActionConditionGroup Do PART 4: POST-MODIFICATION
DET AND HFEC INSPECTION OF THE STA 2370 PIVOT BULKHEAD
FORWARD OUTER CHORD,
LONGERON FITTING AND BULK-
HEAD ASSEMBLY STRUCTURE, for any crack at the times specified in Compliance.
Airplanes that have done Boeing Service Bulletin 777-53A0075 and have done the modification in accordance with Boeing Service Bulletin 777-53-0076.
Group 1 and 2, Configuration 4
REASON FOR REVISION This revision is sent to add a reference to Federal Aviation Administration (FAA) Airworthiness Directive AD 2016-09-01, add new post repair or modification inspection requirement, add new inspection locations on the longeron fitting and to remove the option to do a small crack repair because operators have experienced early crack findings prior to the inspection threshold.
These sections were changed:
1. In Summary, Background, updated statement, added additional service history table, added Boeing Fleet Team Digest (FTD) and added Boeing Service Related Problem (SRP) reference.
2. In Summary, Action, updated statement.
3. In Summary, Compliance, added a reference to FAA Airworthiness Directive AD 2016-09-01, information for a possible release of an additional FAA AD, and updated conditions.
4. In Summary, Manpower, removed table.
5. In Summary, Material Information, updated appendix reference.
6. In Summary, updated the summary Illustration.
7. Paragraph 1.A.1., Airplanes, updated statement and added new configurations.
8. Paragraph 1.C., Reason, updated statement, added additional service history table, added Boeing FTD, added Boeing SRP reference and added the reason for revision statement.
9. Paragraph 1.D., Description, added new inspection requirements and update the effects of this revision on airplanes on which Original Issue or Revision 1 was previously done statement.
10. Paragraph 1.E., Compliance, added a reference to FAA Airworthiness Directive AD 2016-09-01, information for a possible release of an additional FAA AD, add appendix reference, updated existing compliance tables, added new compliance tables for new inspection requirements, and updated conditions.
11. Paragraph 1.F., Approval, updated statement and added Alternative Method of Compliance (AMOC) statement.
12. Paragraph 1.G., Manpower, updated existing, and added new manpower tables and notes.
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13. Paragraph 1.H. Weight and Balance Changes: added new statement.
14. In Paragraph 1.J.1., Existing Data, added reference to PRR, new Boeing SRP, new Boeing FTD and added FAA Airworthiness Directive AD 2016-09-01.
15. In Paragraph 1.K.1., Publications, changed table.
16. In Paragraph 2, Material Information, updated tables.
17. In Paragraph 2.B., Industry Support Information, updated statement.
18. In Paragraph 2.C.1., Kits/Parts, added new Replacement Kits and new Supplemental Kits.
19. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added footnote.
20. In Paragraph 3.A., General Information, updated detailed inspection note and added appendix reference.
21. In Paragraph 3.B., Work Instructions, revised RC steps, updated existing work instructions and added new work instructions for new inspection requirements.
22. FIGURE 1, 2, 3, 4, 5, 6, 11, 12, 21, 22, 25 and 26, added group applicability.
23. FIGURE 3 and 4, updated title, added new inspection location and updated step tables.
24. FIGURE 7, 8, 9, 10, 13, 14, 15, 16, 17, 18, 23 and 24, information has been deleted within the figure.
25. FIGURE 11 and 12, updated figures and step tables.
26. FIGURE 19 and 20, updated title, added group applicability and new inspection location.
27. Added new Figure 27 thru Figure 32.
28. APPENDIX A, B, C and D, updated existing and added new logic diagrams.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY January 14, 2015Original Issue:
December 14, 2015Revision 1:
February 22, 2021Revision 2:
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Original Issue: January 14, 2015 777-53A0075Revision 2: February 22, 2021 10 of 156 BOEING SERVICE BULLETIN 777-53A0075
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0075Original Issue: January 14, 2015 Revision 2: February 22, 2021 ATA System: 5380 SUBJECT: FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair
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 for inspections of the left and right side forward outer chords of the Body Station (STA) 2370 pivot bulkhead and longeron fitting for cracks. Cracks in the STA 2370 pivot bulkhead forward outer chords that are not found and repaired can become large and result in a severed forward outer chord. Since the horizontal stabilizer is attached to the STA 2370 bulkhead at two pivot locations, this damage could cause the loss of horizontal stabilizer control, resulting in loss of controllability of the airplane.
Two operators have reported finding cracks in the outer flanges of the left and right side forward outer chords of the STA 2370 pivot bulkhead on a total of eleven airplanes which prompted a safety investigation and the release of Boeing Service Bulletin (SB) 777-53A0075. Upon inspection in accordance with SB 777-53A0075 Revision 1, an operator reported large crack findings on eleven of fourteen airplanes below the 16,000 total flight cycle threshold. This led Boeing to reopen the safety investigation and MOM-MOM-19-0583 was sent to operators to gather additional information on the early crack finding. Based upon the data gathered, a total of 32 airplanes had crack findings below the Boeing SB 777-53A0075 Revision 1 inspection threshold. The cracks were fatigue cracks caused by a combination of a stress concentration and high stress due to complex loading in the structure at the transition radius of the forward outer chord flange.
Accomplishment of the inspections in this service bulletin will help ensure that STA 2370 pivot bulkhead forward outer chord cracks are found and repaired before they can become large and result in damage that could result in the loss of horizontal stabilizer control.
Boeing SB 777-53-0076 gives instructions to do a modification of the STA 2370 pivot bulkhead forward outer chord.
The table below shows the crack findings and related service data that have been reported to Boeing prior to Boeing SB 777-53A0075 Revision 1.
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Original Issue: January 14, 2015 777-53A0075Revision 2: February 22, 2021 11 of 156
Service History Crack Length (Inches)Crack LocationFlight HoursFlight CyclesModel
1.4 and 3.3Left Side39,14231,384777-200
2.93Right Side
2.3Left Side39,79731,504777-200
2.2Right Side
2.5Left Side38,75832,181777-200
2.3Right Side
2.5Left Side37,18229,383777-200
2.5Right Side
2.2Left Side34,29124,653777-300
2.2Right Side
2.25Left Side40,07435,011777-200
2.2Right Side
2.5Left Side33,56824,251777-300
2.03Right Side
2.35Left Side38,45530,462777-200
2.2Right Side
2.2Left Side39,16630,826777-200
2.4Right Side
2.5Left Side40,58833,809777-200
2.4Right Side
1.2Left Side63,94017,530777-300
1.65Right Side The table below shows the early crack findings prior to the inspection threshold of 16,000 total flight cycles accomplished in accordance with Boeing SB 777-53A0075 Original Issue or Revision 1, and related service data that have been reported to Boeing.
Service History Crack Length (Inches)Crack LocationFlight HoursFlight CyclesModel
1.5Left Side93,27313,717777-200 -Right Side 2Left Side90,31713,671777-200 -Right Side Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075Revision 2: February 22, 2021 12 of 156 BOEING SERVICE BULLETIN 777-53A0075