Boeing ASB 777-53A0081: Revision 2, text

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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0081 Original Issue: September 08, 2016 Revision 2: March 29, 2019 ATA System: 5330 5710 SUBJECT: FUSELAGE - Section 43 - Inspection of the Underwing Longeron 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.

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Table of Contents

Revision Transmittal Sheet7

S u m m a r y9

1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3

1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 2 1 B. Concurrent Requirements ...................................... 2 1 C. Reason ................................................ 2 1 D. Description .............................................. 2 2 E. Compliance .............................................. 2 3 F . A p p r o v a l ............................................... 4 6 G. Manpower .............................................. 4 7 H. Weight and Balance Changes .................................... 5 4 I. Electrical Load Data ......................................... 5 4 J . R e f e r e n c e s .............................................. 5 5

1. Existing Data: ......................................... 5 5

2. Data Supplied with this Service Bulletin: ........................... 5 5

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 5 K. Publications Affected ........................................ 5 5 L. Interchangeability and Intermixability of Parts ........................... 5 6 M. Software Accomplishment Summary ................................ 5 6

2. MATERIAL INFORMATION ........................................ 5 7 A. Material - Price and Availability ................................... 5 7 B. Industry Support Information .................................... 6 3 C. Parts Necessary for Each Airplane ................................. 6 3 1 . K i t s / P a r t s ............................................ 6 3

2. Parts and Materials Supplied by the Operator ........................ 6 8

3. Parts Modified and Reidentified ................................ 6 9

4. Parts Removed and Not Replaced .............................. 6 9 D. Parts Necessary to Change Spares ................................. 6 9 E. Special Tooling - Price and Availability ............................... 6 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 7 0

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 7 1 A. GENERAL INFORMATION ..................................... 7 1 B. WORK INSTRUCTIONS ....................................... 7 3 FIGURE 1: DETAILED INSPECTION OF THE LEFT SIDE BUILT-UP UNDERWIN G LONGERON [Group 1 - 2 , 9 ] .............................................. 8 5 FIGURE 2: DETAILED INSPECTION OF THE RIGHT SIDE BUILT-UP UNDERWI NG LONGERON [Group 1 - 2 , 9 ] .............................................. 8 8 FIGURE 3: DETAILED INSPECTION OF THE LEFT SIDE MACHINED UNDERWIN G LONGERON [Group 3 - 8 , 1 0 - 1 3 ] ........................................... 9 1 FIGURE 4: DETAILED INSPECTION OF THE RIGHT SIDE MACHINED UNDERWI NG LONGERON [Group 3 - 8 , 1 0 - 1 3 ] ........................................... 9 3 FIGURE 5: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (H FEC) INSPECTION O F T H E L E F T S I D E B U I L T - U P L O N G E R O N [ G r o u p 1 - 2 , 9 ] ................. 9 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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FIGURE 6: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT IN SPECTION (HFEC) O F T H E R I G H T S I D E B U I L T - U P L O N G E R O N [ G r o u p 1 - 2 , 9 ] ................ 9 8 FIGURE 7: DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE L EFT SIDE MACHINED LONGERON [Group 3-8, 10-13] ............................... 1 0 1 FIGURE 8: DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE R IGHT SIDE MACHINED LONGERON [Group 3-8, 10-13] ............................... 1 0 3 FIGURE 9: REMOVAL OF THE LEFT SIDE UNDERWING LONGERON ............... 1 0 5 FIGURE 10: INSPECTION OF THE FUSELAGE SKIN AROUND THE LEFT SIDE UNDERWING LONGERON ................................................. 1 0 8 FIGURE 11: INSPECTION OF THE LOWER WING SKIN AROUND THE LEFT SID E UNDERWING L O N G E R O N .......................................... 1 1 0 FIGURE 12: INSPECTION OF THE LOWER WING BODY CHORD, SPAR CHORD A ND SPAR WEB AROUND THE LEFT SIDE LONGERON .......................... 1 1 2 FIGURE 13: INSTALL THE FASTENERS [Group 1, 3, 5] ......................... 1 1 5 FIGURE 14: INSTALL THE FASTENERS [Group 2, 4, 6-13] ....................... 1 1 8 FIGURE 15: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Gr oup 1, 3] .... 1 2 1 FIGURE 16: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Gr oup 2, 4, 7] . . . 132 FIGURE 17: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Gr oup 5] ...... 1 4 3 FIGURE 18: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Gr oup 6, 8] .... 1 5 3 FIGURE 19: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Gr o u p 9 - 1 1 ] .... 1 6 3 FIGURE 20: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Gr oup 12-13] . . . 175 FIGURE 21: REMOVAL OF THE RIGHT SIDE UNDERWING LONGERON .............. 1 8 5 FIGURE 22: INSPECTION OF THE FUSELAGE SKIN AROUND THE RIGHT SIDE UNDERWING L O N G E R O N .......................................... 1 8 8 FIGURE 23: INSPECTION OF THE LOWER WING SKIN AROUND THE RIGHT SI DE UNDERWING L O N G E R O N .......................................... 1 9 0 FIGURE 24: INSPECTION OF THE LOWER WING BODY CHORD, SPAR CHORD A ND SPAR WEB AROUND THE RIGHT SIDE LONGERON ......................... 1 9 2 FIGURE 25: INSTALL THE FASTENERS [Group 1, 3, 5] ......................... 1 9 5 FIGURE 26: INSTALL THE FASTENERS [Group 2, 4, 6-13] ....................... 1 9 8 FIGURE 27: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [G r o u p 1 , 3 ] .... 2 0 1 FIGURE 28: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [G roup 2, 4, 7] . . 212 FIGURE 29: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [G r o u p 5 ] ..... 2 2 3 FIGURE 30: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [G r o u p 6 , 8 ] .... 2 3 3 FIGURE 31: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [G roup 9-11] . . . 243 FIGURE 32: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [G roup 12-13] . . . 255 FIGURE 33: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE MACHINED UNDERWING L O N G E R O N .......................................... 2 6 5 FIGURE 34: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SID E MACHINED UNDERWING LONGERON ................................. 2 6 7 FIGURE 35: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC I NSPECTION OF THE LEFT SIDE MACHINED UNDERWING LONGERON .................... 2 6 9 FIGURE 36: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC I NSPECTION OF THE RIGHT SIDE MACHINED UNDERWING LONGERON ................... 2 7 1 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: INSPECT THE BUILT-UP UNDERWING LONGERON FOR ANY CRACK IN 777-200 AIRPLANES [Group 1- 2] . . 273 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-200 AIRPLANES [Group 3- 6] . . 277 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 3: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-200LR AND 777F AIRPLANES [Group 7 - 8 ] ............................................... 2 8 1 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 4: INSPECT THE BUILT-UP UNDERWING LONGERON FOR ANY CRACK IN 777-300 AIRPLANES [Group 9] ... 2 8 5 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 5: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-300 AIRPLANES [Group 10] ... 2 8 9 APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 6: INSPECT THE MACHINED UNDERWING LONGERONS FOR ANY CRACK IN 777-300ER AIRPLANES [Group 12] . 293 APPENDIX G: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 15: INSPECT THE MACHINED UNDERWING LONGERONS FOR ANY CRACK IN 777-300ER AIRPLANES [Group 1 1 , 1 3 ] ............................................. 2 9 7 APPENDIX H: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 7: POST REPLACEMENT INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200 AIRPLANES [Group 1-6] ................................... 3 0 1 APPENDIX I: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 8: POST REPLACEMENT

INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200 AIRPLANES [Group 1-6] .............................. 3 0 5 APPENDIX J: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 9: POST REPLACEMENT

INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200LR AND 777F AIRPLANES [Group 7-8] ...................... 3 0 9 APPENDIX K: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 10: POST REPLACEMENT

INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200LR AND 777F AIRPLANES [Group 7-8] ...................... 3 1 3 APPENDIX L: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 11: POST REPLACEMENT INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300 AIRPLANES [Group 9-10] .................................. 3 1 7 APPENDIX M: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 12: POST REPLACEMENT

INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300 AIRPLANES [Group 9-10] ............................. 3 2 1 APPENDIX N: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 13: POST REPLACEMENT

INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300ER AIRPLANES [Group 11-13] ........................... 3 2 5 APPENDIX O: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 14: POST REPLACEMENT

INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300ER AIRPLANES [Group 11-13] ........................... 3 2 9 APPENDIX P: LONGERON INSPECTION COMPLIANCE GRAPH FOR PARAGRAPH 1.E. COMPLIANCE:

TABLE 5 [Group 10] ..................................... 3 3 3 APPENDIX Q: LONGERON INSPECTION COMPLIANCE GRAPH FOR PARAGRAPH 1.E. COMPLIANCE:

TABLE 15 [Group 11, 13] ................................... 3 3 4 APPENDIX R: PART DEMAND INTENT .................................. 3 3 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Commercial Airplanes 777 Service Bulletin ALERT Revision Transmittal SheetNumber: 777-53A0081Original Issue: September 08, 2016 Revision 2: March 29, 2019 ATA System: 5330 5710 SUBJECT: FUSELAGE - Section 43 - Inspection of the Underwing Longeron This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2017-16-10 is related to this service bulletin.

Effects of this Revision on airplanes on which Original Issue and Revision 1 was previously done:

None.

Boeing recommends affected operators revise their existing aircraft maintenance schedule to accommodate the change to compliance information.

777F line numbers 1526 and on were removed from Group 8 of this service bulletin effectivity.

777-300ER line numbers 1522 and on were removed from Group 12 of this service bulletin effectivity.

777-300ER line numbers 632, 634, 636-639, 641-645, 647, 649-650, 652-653, 656, 658, 660-661, 664, 666-671, 673-676, 678, 680-681, 683, 685-686, 690-694, 696, 700-703, 705-710, 712-717, 719-724, 726-729, 731, 733-737, 740, 742-746, 748-751, 754-756, 758-759, 761, 763-765, 768-769, 777-779, 783, 785-787, 790, 792, 794-795, 797-798, 801-804, 806-810, 812, 814-819, 821-824, 826, 828, 830, 832-833, 835, 839-841, 843, 845, and 847 were moved from Group 12 to new Group 13.

REASON FOR REVISION This revision is sent to limit the service bulletin effectivity. Installation of an improved longeron has been incorporated on 777F line numbers 1526 and on, and 777-300ER line numbers 1522 and on. This revision also revises the compliance time for all 777-300 airplanes with machined underwing longerons and certain 777-300ER Airplanes.

These sections were changed:

1. In Summary, Compliance: Added reference to AD 2017-16-10.

2. In Paragraph 1.A., Effectivity: Updated effectivity line numb ers and Group configuration table.

3. In Paragraph 1.C., Reason: Added reasons for revision paragra ph.

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4. In Paragraph 1.D., Description: Updated no more work paragrap h and applicability for new Group 13.

5. In Paragraph 1.E., Compliance: Added reference to AD 2017-16-10 and updated compliance tables 1 through 6.

6. In Paragraph 1.E., Compliance: Changed Table 5 compliance req uirements.

7. In Paragraph 1.E., Compliance: Added statements for Service Bulletins 777-53-0084 and 777-53-0087.

8. In Paragraph 1.E., Compliance: Added new Table 15 compliance for Group 11 and new Group 13.

9. In Paragraph 1.F., Approval: Added Alternate Method of Compli ance paragraph.

10. In Paragraph 1.G., Manpower: Updated applicability for new G roup 13.

11. In Paragraph 1.K., Publications Affected: Added impacted man uals.

12. In Paragraph 2.B., Industry Support Information: Updated war ranty paragraph.

13. In Paragraph 2.C., Parts and Materials Supplied by the Opera tor: Added footnotes.

14. In Paragraph 3.B., Work Instructions: Updated applicability for new Group 13.

15. In Paragraph 3.B., Work Instructions: Updated Part 1, Part 8 , and Part 9.

16. In Paragraph 3.B., Work Instructions: Updated fastener refer ence identification in Figure 19, Figure 20, Figure 31 and Figure 32.

17. In Paragraph 3.B., Work Instructions: Added footnote referen ce in Figure 22

18. Changed Appendicies A, B, C, D, and F to match compliance ta ble information.

19. Changed Appendix E to match new compliance requirements for Group 10.

20. Added new Appendix G and updated applicability in Appendices for Group 11 and new Group 13.

21. Added new Appendix P and Q to provide a visual aid for compl iance tables 5 and 15, respectively.

The data given in Information Notice 777-53A0081 IN 02 was added in Revision 2.

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 September 08, 2016Original Issue:

May 01, 2017Revision 1:

March 29, 2019Revision 2:

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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0081Original Issue: September 08, 2016 Revision 2: March 29, 2019 ATA System: 5330 5710 SUBJECT: FUSELAGE - Section 43 - Inspection of the Underwing Longeron

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 provide instructions for inspection and replacement of the underwing longeron at Station (STA) 1035. Cracks have been found which led to the underwing longeron becoming severed. The growth of cracks could lead to a crack in the wing lower spar chord. If left uncorrected, cracks could result in fuel leakage into the forward cargo area and consequent increased risk of a fire, or, in a more severe case, could adversely affect the structural integrity of the airplane.

The first underwing longeron crack was discovered in service. An operator had reports of fuel smell in the forward cargo area. The subsequent investigation found a crack in the center wing tank that was attributed to the longeron crack found. All models except some 777-200 models without a center wing tank, are affected by the potential for a fuel leak into the forward cargo area.

Subsequently, four more operators have reported cracks on the underwing longeron. The cracks have been reported in 777-300ER and 777-200 airplanes. The cracks have been reported as early as 3,784 Flight Cycles and 31,240 Flight Hours. As the cracks grow in the longeron further cracking has been reported in the front spar lower chord, front spar web, and front spar ring chord. The table below gives the flight cycles and flight hours at which operators reported finding airplanes with a crack.

Flight HoursFlight CyclesAirplane 85,44212,835777-200 90,59814,645777-200 31,2403,784777-300ER 41,4664,997777-300ER 43,3445,247777-300ER Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Flight HoursFlight CyclesAirplane 39,5935,359777-300ER 58,0006,264777-300ER 58,8866,403777-300ER 58,2096,360777-300ER 51,4527,299777-300ER 51,2127,413777-300ER Boeing Service Related Problem (SRP) 777-SRP-53-0485 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 777 FTD 53-15002 is related to this service bulletin.

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/PartsYesKits/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 YesSpecial Tooling Required ACTION (PRR 62777-113RS, PRR 62777-110S) Do a detailed inspection of the underwing longeron. If any crack is found in the underwing longeron, remove and replace the underwing longeron and inspect the front lower wing spar chord and body ring chord. If no crack is found, repeat the detailed inspection.

EFFECTIVITY 777-200, 777-200LR, 777-300, 777-300ER and 777F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

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COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2017-16-10 is related to this service bulletin.

The effective date of AD 2017-16-10 is September 25, 2017.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of September 23, 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 Boeing Supplied Kits/Parts.

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

Operators are encouraged to complete the survey provided in APPENDIX R of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

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BOEING SERVICE BULLETIN 777-53A0081

ALERT ALERT STA 1035

DO A DETAILED INSPECTION OF THE UNDERWING LONGERON. IF ANY CRACK IS FOUND IN THE UNDERWING

LONGERON, REMOVE AND REPLACE THE UNDERWING

LONGERON AND INSPECT THE FRONT LOWER WING SPAR CHORD AND BODY RING CHORD. IF NO CRACK IS FOUND,

REPEAT THE DETAILED INSPECTION 2503072 Original Issue: September 08, 2016 Revision 2: March 29, 2019 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING Work - See page 1 for details. 777-53A0081 12 of 335

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