# Boeing Alert Service Bulletin 777-53A0081: Revision 2 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2019-0407; AD 2019-11-02 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 777-53A0081](https://openairdocs.org/service-documents/boeing/777-53a0081.md) - Title as filed: SB-777-53A0081-02 - Pages: 335 - PDF: https://openairdocs.org/files/sha256/13/ee/13ee2f705e017328ab02ec6b23ef1be2203db8a0f2bfecd80a60e7048480ba39 - Page: https://openairdocs.org/service-documents/boeing/777-53a0081/file/13ee2f705e01 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 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: BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2016 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 Unpublished Work.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: September 08, 2016 777-53A0081Revision 2: March 29, 2019 1 of 335 5.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 2 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 7 S u m m a r y ...................................................... 9 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. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 3 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 4 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. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 4 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 5 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. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 5 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 6 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT BLANK PAGE ### Page 7 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 7 of 335 ### Page 8 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: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 8 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 9 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. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 9 of 335 ### Page 10 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 Air- plane 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 10 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 11 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 11 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 12 (OCR) 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 ### Page 13 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 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. 1. PLANNING INFORMATION A. Effectivity 1. Airplanes This bulletin is applicable to 777-200, 777-200LR, 777-300, 777-300ER, 777F Airplane(s), line number(s) 1-1522, 1524 in 13 Group(s). The Variable Numbers and Group Information for the applicable airplanes is given below. Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. DESCRIPTIONCONFIGURATIONGROUP 777-200 airplanes, line numbers 1 through 400, with built-up longeron without center wing fuel tank. -1 777-200 airplanes, line numbers 1 through 400, with built-up longeron and center wing fuel tank. -2 777-200 airplanes, line numbers 401 through 629, with machined longeron and without center wing fuel tank. -3 777-200 airplanes, line numbers 401 through 629, with machined longeron and center wing fuel tank. -4 777-200 airplanes, line number 635, with extra tabs on machined longeron and without center wing fuel tank. -5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 13 of 335 ### Page 14 DESCRIPTIONCONFIGURATIONGROUP 777-200 airplanes, line numbers 630 through 1117, with extra tabs on machined longeron and center wing fuel tank. -6 777-200LR, line numbers 401 through 629, with machined longeron.-7 777-200LR and 777F airplanes, line numbers 640 through 1524, with extra tabs on machined longeron. -8 777-300 airplanes, line numbers 1 through 400, with built-up longeron.-9 777-300 airplanes, line numbers 401 through 629, with machined longeron. -10 777-300ER airplanes, line numbers 401 through 629, with machined longeron. -11 777-300ER airplanes, line numbers 848 through 1521, with extra tabs on machined longeron. -12 777-300ER airplanes, line numbers 631 through 847 with different machined longerons. -13 Airplane Models: 777-200, 777-200LR, 777-300, 777-300ER, 777F GroupVariable Number 1WA001 - WA017 1WA076 - WA080 1WA086 - WA093 1WA101 - WA104 1WA116 - WA119 1WA131 - WA137 1WA171 - WA175 1WA196 - WA198 1WA206 - WA212 1WA221 - WA223 1WA231 - WA232 1WA241 - WA250 1WA261 - WA266 3WA281 - WA282 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 14 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 15 GroupVariable Number 5WA283 3WA301 - WA304 2WB001 - WB021 2WB031 - WB046 2WB051 - WB088 2WB101 - WB106 2WB121 - WB125 2WB131 - WB136 4WB137 - WB142 6WB143 - WB148 2WB151 - WB155 2WB161 - WB174 4WB175 - WB177 2WB181 - WB189 4WB190 - WB194 2WB201 - WB207 4WB208 - WB215 2WB231 - WB241 4WB242 - WB247 2WB271 - WB273 2WB276 - WB286 2WB291 - WB302 2WB306 - WB307 2WB311 - WB334 4WB335 2WB336 - WB337 2WB341 - WB342 2WB366 - WB367 4WB368 2WB371 - WB388 2WB406 2WB411 - WB413 2WB416 - WB435 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 15 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 16 GroupVariable Number 4WB436 - WB439 2WB446 - WB453 2WB476 2WB481 - WB484 9WB501 - WB507 10WB508 - WB512 9WB531 - WB535 10WB536 - WB537 9WB551 - WB554 9WB591 - WB595 10WB596 - WB597 9WB601 - WB606 9WB611 - WB617 10WB618 - WB622 9WB631 - WB632 10WB633 - WB635 9WB636 - WB638 10WB646 - WB649 2WC051 - WC073 2WC101 - WC103 4WC104 2WC111 - WC113 4WC114 - WC117 6WC118 - WC120 4WC221 - WC222 6WC223 - WC224 4WC241 - WC243 4WC281 - WC290 4WC301 - WC308 4WC361 - WC364 4WC371 - WC374 4WC381 - WC394 6WC395 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 16 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 17 GroupVariable Number 4WC441 4WC446 - WC449 4WC456 - WC459 4WC486 - WC493 4WC506 - WC508 4WC521 - WC522 4WC531 - WC534 6WC535 - WC536 4WC546 - WC547 6WC548 4WC556 6WC566 - WC567 6WC571 - WC574 6WC581 6WC586 - WC587 6WC591 - WC595 7WD001 - WD002 7WD011 - WD013 8WD014 - WD018 8WD031 - WD036 8WD046 - WD055 8WD066 - WD075 8WD081 - WD089 8WD091 8WD096 8WD101 - WD106 8WD111 - WD112 8WD116 - WD117 8WD121 - WD122 11WD501 - WD506 13WD507 - WD513 11WD521 - WD534 13WD535 - WD541 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 17 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 18 GroupVariable Number 11WD546 - WD551 13WD552 - WD554 11WD561 - WD568 13WD569 - WD573 11WD581 - WD591 13WD592 - WD599 11WD606 - WD609 11WD621 - WD631 13WD632 11WD651 - WD655 13WD656 - WD664 12WD665 11WD671 - WD675 13WD676 12WD677 11WD691 - WD699 13WD700 - WD709 11WD741 - WD742 13WD743 - WD752 11WD761 13WD762 - WD771 11WD786 - WD787 13WD788 13WD796 - WD811 12WD812 - WD825 13WD826 - WD834 12WD835 - WD837 13WD846 - WD860 12WD861 - WD867 13WD871 - WD878 12WD879 - WD906 13WD911 - WD914 12WD915 - WD918 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 18 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 19 GroupVariable Number 13WD921 - WD922 12WD923 - WD935 13WD936 - WD939 12WD940 - WD945 13WD946 - WD948 12WD949 - WD957 13WD966 - WD969 12WD970 13WD981 - WD982 13WD986 - WD987 12WD991 - WD996 13WE001 12WE002 - WE007 12WE011 - WE012 12WE021 - WE026 12WE031 - WE040 12WE051 - WE057 12WE071 - WE078 12WE081 - WE084 12WE091 - WE095 12WE126 - WE178 12WE186 - WE219 12WE226 - WE231 12WE236 - WE253 12WE261 - WE267 12WE271 - WE278 12WE291 - WE298 12WE301 - WE320 12WE331 - WE346 12WE351 - WE356 12WE376 - WE377 12WE381 12WE386 - WE387 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 19 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 20 GroupVariable Number 12WE391 - WE392 12WE396 - WE405 12WE416 - WE420 12WE426 - WE431 12WE436 - WE446 12WE451 - WE478 12WE486 - WE493 12WE495 - WE499 12WE501 - WE504 12WE511 - WE516 12WE526 - WE528 12WE536 - WE549 12WE556 - WE571 12WE576 - WE583 12WE591 12WE601 - WE605 12WE626 - WE627 12WE631 12WE641 - WE642 12WE646 - WE647 12WE651 - WE661 12WE666 - WE677 12WE681 12WE701 - WE705 12WE711 - WE712 12WE731 - WE732 12WE736 - WE740 12WE746 - WE764 12WE776 - WE786 12WE791 - WE792 12WE796 12WE811 - WE812 12WE826 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 20 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 21 GroupVariable Number 8WF001 - WF004 8WF016 - WF027 8WF031 - WF043 8WF046 - WF069 8WF075 - WF077 8WF081 - WF088 8WF096 - WF101 8WF106 - WF109 8WF111 - WF124 8WF131 - WF144 8WF146 - WF147 8WF151 - WF152 8WF156 - WF160 8WF166 - WF173 8WF176 - WF179 8WF181 - WF184 8WF191 8WF206 - WF208 8WF216 - WF217 2. Spares Affected None. B. Concurrent Requirements None. C. Reason 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 21 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 22 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 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. Revision 1 was sent to correct typographical errors, provide additional access and inspection requirements, and to add special tooling for cold working. This revision adds reference to FAA Notice of Proposed Rule Making NPRM 2016-NM-163-AD. The data given in Information Notice 777-53A0081 IN 01 was added in Revision 1. Revision 2 includes data given in Information Notice 777-53A0081 IN 02. 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. D. Description 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. Effects of this Revision on airplanes on which Original Issue and Revision 1 was previously done: None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 22 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 23 Boeing recommends affected operators revise their existing aircraft maintenance schedule to accommodate the change to compliance information. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1-6: Affected Maintenance Zones ZoneModel 121, 122, 125, 126, 133, 134, 191, 192, 195, 196777-200 Group 7: Affected Maintenance Zones ZoneModel 121, 122, 125, 126, 133, 134, 191, 192, 195, 196777-200LR Group 8: Affected Maintenance Zones ZoneModel 121, 122, 125, 126, 133, 134, 191, 192, 195, 196777-200LR, 777F Group 9-10: Affected Maintenance Zones ZoneModel 121, 122, 125, 126, 133, 134, 191, 192, 195, 196777-300 Group 11-13: Affected Maintenance Zones ZoneModel 121, 122, 125, 126, 133, 134, 191, 192, 195, 196777-300ER E. 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. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 23 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 24 A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX A, APPENDIX B, APPENDIX C, APPENDIX D, APPENDIX E, APPENDIX F, APPENDIX G, APPENDIX H, APPENDIX I, APPENDIX J, APPENDIX K, APPENDIX L, APPENDIX M, APPENDIX N, and APPENDIX O. The accomplishment of the longeron modification in accordance with Service Bulletin 777-53-0084 terminates initial and repeat inspection requirements given in this service bulletin. The accomplishment of the longeron modification in accordance with Service Bulletin 777-53-0087 terminates initial and repeat inspection requirements given in this service bulletin. Group 1-2: Table 1: Inspect the built-up underwing longeron for any crack in 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the ef- fective date of AD 2017-16-10, whichever oc- curs first. Before 57,000 Total Flight Hours or 9,500 Total Flight Cy- cles, whichever occurs first. OPTION 1: Do PART 2: DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack and Do PART 3: DETAILED IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. All Airplanes OPTION 2: Do PART 4: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack and Do PART 5: DETAILED INSPEC- TION AND HIGH FRE- QUENCY EDDY CUR- RENT (HFEC) INSPEC- TION OF THE RIGHT SIDE UNDERWING LONGERON for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 24 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 25 Group 1-2: Table 1: Inspect the built-up underwing longeron for any crack in 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 1,800 Flight Hours or 230 Flight Cy- cles, whichever oc- curs first. --CONDITION 1 (OPTION 1): Repeat PART 2: DE- TAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 1: NO CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 20,000 Flight Hours or 2,500 Flight Cycles, whichever occurs first. --CONDITION 1 (OPTION 2): Repeat PART 4: DE- TAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) --Before Further Flight Do PART 8: LEFT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(b) CONDITION 2: ANY CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 1,800 Flight Hours or 230 Flight Cy- cles, whichever oc- curs first. --CONDITION 3 (OPTION 1): Repeat PART 3: DE- TAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 3: NO CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. 20,000 Flight Hours or 2,500 Flight Cycles, whichever occurs first. --CONDITION 3 (OPTION 2): Repeat PART 5: DE- TAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE RIGHT SIDE UN- DERWING LONGERON for any crack.(a) --Before Further Flight. Do PART 9: RIGHT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(c) CONDITION 4: ANY CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. (b) Post replacement inspections are required in accordance with Table 7: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-200 Airplanes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 25 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 26 Group 1-2: Table 1: Inspect the built-up underwing longeron for any crack in 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (c) Post replacement inspections are required in accordance with Table 8: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-200 Airplanes. Group 3-6: Table 2: Inspect the machined underwing longeron for any crack in 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the ef- fective date of AD 2017-16-10, whichever oc- curs first. Before 57,000 Total Flight Hours or 9,500 Total Flight Cy- cles, whichever occurs first. OPTION 1: Do PART 2: DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack and Do PART 3: DETAILED IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. All Airplanes OPTION 2: Do PART 6: DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack and Do PART 7: DETAILED INSPEC- TION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 26 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 27 Group 3-6: Table 2: Inspect the machined underwing longeron for any crack in 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 1,800 Flight Hours or 230 Flight Cy- cles, whichever oc- curs first. --CONDITION 1 (OPTION 1): Repeat PART 2: DE- TAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 1: NO CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 20,000 Flight Hours or 2,500 Flight Cycles, whichever occurs first. --CONDITION 1 (OPTION 2): Repeat PART 6: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) --Before Further Flight Do PART 8: LEFT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(b) CONDITION 2: ANY CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 1,800 Flight Hours or 230 Flight Cy- cles, whichever oc- curs first. --CONDITION 3 (OPTION 1): Repeat PART 3: DE- TAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 3: NO CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. 20,000 Flight Hours or 2,500 Flight Cycles, whichever occurs first. --CONDITION 3 (OPTION 2): Repeat PART 7: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(a) --Before Further Flight. Do PART 9: RIGHT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(c) CONDITION 4: ANY CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. (b) Post replacement inspections are required in accordance with Table 7: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-200 Airplanes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 27 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 28 Group 3-6: Table 2: Inspect the machined underwing longeron for any crack in 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (c) Post replacement inspections are required in accordance with Table 8: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-200 Airplanes. Group 7-8: Table 3: Inspect the machined underwing longeron for 777-200LR and 777F Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the ef- fective date of AD 2017-16-10, whichever oc- curs first. Before 48,000 Total Flight Hours or 8,000 Total Flight Cy- cles, whichever occurs first. OPTION 1: Do PART 2: DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack and Do PART 3: DETAILED IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. All Airplanes OPTION 2: Do PART 6: DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack and Do PART 7: DETAILED INSPEC- TION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 28 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 29 Group 7-8: Table 3: Inspect the machined underwing longeron for 777-200LR and 777F Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. --CONDITION 1 (OPTION 1): Repeat PART 2: DE- TAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 1: NO CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. --CONDITION 1 (OPTION 2): Repeat PART 6: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) --Before Further Flight Do PART 8: LEFT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(b) CONDITION 2: ANY CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. --CONDITION 3 (OPTION 1): Repeat PART 3: DE- TAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 3: NO CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. --CONDITION 3 (OPTION 2): Repeat PART 7: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON For any crack.(a) --Before Further Flight. Do PART 9: RIGHT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(c) CONDITION 4: ANY CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. (b) Post replacement inspections are required in accordance with Table 9: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-200LR and 777F Airplanes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 29 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 30 Group 7-8: Table 3: Inspect the machined underwing longeron for 777-200LR and 777F Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (c) Post replacement inspections are required in accordance with Table 10: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-200LR and 777F Airplanes. Group 9: Table 4: Inspect the built-up underwing longeron in 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the ef- fective date of AD 2017-16-10, whichever oc- curs first. Before 27,000 Total Flight Hours or 4,500 Total Flight Cy- cles, whichever occurs first. OPTION 1: Do PART 2: DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack and Do PART 3: DETAILED IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. All Airplanes OPTION 2: Do PART 4: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack and Do PART 5: DETAILED INSPEC- TION AND HIGH FRE- QUENCY EDDY CUR- RENT (HFEC) INSPEC- TION OF THE RIGHT SIDE UNDERWING LONGERON for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 30 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 31 Group 9: Table 4: Inspect the built-up underwing longeron in 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. --CONDITION 1 (OPTION 1): Repeat PART 2: DE- TAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 1: NO CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. --CONDITION 1 (OPTION 2): Repeat PART 4: DE- TAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) --Before Further Flight Do PART 8: LEFT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(b) CONDITION 2: ANY CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. --CONDITION 3 (OPTION 1): Repeat PART 3: DE- TAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 3: NO CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. --CONDITION 3 (OPTION 2): Repeat PART 5: DE- TAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE RIGHT SIDE UN- DERWING LONGERON for any crack.(a) --Before Further Flight. Do PART 9: RIGHT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(c) CONDITION 4: ANY CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. (b) Post replacement inspections are required in accordance with Table 11: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-300 Airplanes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 31 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 32 Group 9: Table 4: Inspect the built-up underwing longeron in 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (c) Post replacement inspections are required in accordance with Table 12: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-300 Airplanes. Group 10: Table 5: Inspect the machined underwing longeron in 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Oc- curs First) ActionCondition -Whichever occurs later: Whichever occurs later: OPTION 1: Do PART 2: DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack and Do PART 3: DETAILED IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. All Airplanes a) Before 110,000 Total Flight Hours (TFH), or before 25,000 Total Flight Cycles (TFC), or before the result of 27,889 - (0.1444*TFH) - TFC is less than or equal to zero, whichever occurs first. (a) a) Before 27,000 Total Flight Hours or 4,500 Total Flight Cycles, whichever occurs first. . OR . b) Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the ef- fective date of AD 2017-16-10, whichever occurs first. OPTION 2: Do PART 6: DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack and Do PART 7: DETAILED INSPEC- TION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. . OR . b) Within 90 days after the Revision 2 date of this ser- vice bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 32 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 33 Group 10: Table 5: Inspect the machined underwing longeron in 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Oc- curs First) ActionCondition 1,300 Flight Hours or 180 Flight Cy- cles, whichever occurs first. --CONDITION 1 (OPTION 1): Repeat PART 2: DE- TAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(b) CONDITION 1: NO CRACK FOUND IN THE LEFT SIDE UNDER- WING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. --CONDITION 1 (OPTION 2): Repeat PART 6: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(b) --Before Further Flight Do PART 8: LEFT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(c) CONDITION 2: ANY CRACK FOUND IN THE LEFT SIDE UNDER- WING LONGERON. 1,300 Flight Hours or 180 Flight Cy- cles, whichever occurs first. --CONDITION 3 (OPTION 1): Repeat PART 3: DE- TAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(b) CONDITION 3: NO CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. --CONDITION 3 (OPTION 2): Repeat PART 7: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(b) --Before Further Flight. Do PART 9: RIGHT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(d) CONDITION 4: ANY CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. (a) As an aid, refer to APPENDIX P: Longeron Inspection Compliance Graph. (b) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. (c) Post replacement inspections are required in accordance with Table 11: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-300 Airplanes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 33 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 34 Group 10: Table 5: Inspect the machined underwing longeron in 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Oc- curs First) ActionCondition (d) Post replacement inspections are required in accordance with Table 12: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-300 Airplanes. Group 12: Table 6: Inspect the machined underwing longerons in 777-300ER Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the ef- fective date of AD 2017-16-10, whichever oc- curs first. Before 24,000 Total Flight Hours or 4,000 Total Flight Cy- cles, whichever occurs first. OPTION 1: Do PART 2: DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack and Do PART 3: DETAILED IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. All Airplanes OPTION 2: Do PART 6: DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack and Do PART 7: DETAILED INSPEC- TION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 34 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 35 Group 12: Table 6: Inspect the machined underwing longerons in 777-300ER Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 1,000 Flight Hours or 120 Flight Cy- cles, whichever oc- curs first. --CONDITION 1 (OPTION 1): Repeat PART 2: DE- TAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 1: NO CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 12,000 Flight Hours or 1,400 Flight Cycles, whichever occurs first. --CONDITION 1 (OPTION 2): Repeat PART 6: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) --Before Further Flight Do PART 8: LEFT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(b) CONDITION 2: ANY CRACK FOUND IN THE LEFT SIDE UNDERWING LONGERON. 1,000 Flight Hours or 120 Flight Cy- cles, whichever oc- curs first. --CONDITION 3 (OPTION 1): Repeat PART 3: DE- TAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 3: NO CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. 12,000 Flight Hours or 1,400 Flight Cycles, whichever occurs first. --CONDITION 3 (OPTION 2): Repeat PART 7: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(a) --Before Further Flight. Do PART 9: RIGHT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(c) CONDITION 4: ANY CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. (b) Post replacement inspections are required in accordance with Table 13: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-300ER Airplanes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 35 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 36 Group 12: Table 6: Inspect the machined underwing longerons in 777-300ER Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (c) Post replacement inspections are required in accordance with Table 14: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-300ER Airplanes. Group 1-6: Table 7: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 57,000 Flight Hours or 9,500 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack. Airplanes with the Left Side Underwing Longeron Re- placed in accordance with this service bulletin. OPTION 2: Do PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack. 1,800 Flight Hours or 230 Flight Cy- cles, whichever oc- curs first. -CONDITION 5 (OPTION 1): Repeat PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 5: NO CRACK FOUND ON THE LEFT SIDE UNDERWING LONGERON. 20,000 Flight Hours or 2,500 Flight Cycles, whichever occurs first. -CONDITION 5 (OPTION 2): Repeat PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF LEFT SIDE UNDERWING LONGERON for any crack.(a) -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 6: ANY CRACK FOUND ON THE LEFT SIDE UNDERWING WING LONGERON. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 36 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 37 Group 1-6: Table 7: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Group 1-6: Table 8: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 57,000 Flight Hours or 9,500 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack. Airplanes with the Right Side Underwing Longeron Replaced in accordance with this service bulletin. OPTION 2: Do PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. 1,800 Flight Hours or 230 Flight Cy- cles, whichever oc- curs first. -CONDITION 7 (OPTION 1): Repeat PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 7: NO CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. 20,000 Flight Hours or 2,500 Flight Cycles, whichever occurs first. -CONDITION 7 (OPTION 2): Repeat PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(a) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 37 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 38 Group 1-6: Table 8: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-200 Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 8: ANY CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Group 7-8: Table 9: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-200LR and 777F Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 48,000 Flight Hours or 8,000 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack. Airplanes with the Left Side Underwing Longeron Re- placed in accordance with this service bulletin. OPTION 2: Do PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 38 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 39 Group 7-8: Table 9: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-200LR and 777F Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. -CONDITION 5 (OPTION 1): Repeat PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 5: NO CRACK FOUND ON THE LEFT SIDE UNDERWING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. -CONDITION 5 (OPTION 2): Repeat PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 6: ANY CRACK FOUND ON THE LEFT SIDE UNDERWING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 39 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 40 Group 7-8: Table 10: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-200LR and 777F Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 48,000 Flight Hours or 8,000 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack. Airplanes with the Right Side Underwing Longeron Replaced in accordance with this service bulletin. OPTION 2: Do PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. -CONDITION 7 (OPTION 1): Repeat PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 7: NO CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. -CONDITION 7 (OPTION 2): Repeat PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(a) -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 8: ANY CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 40 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 41 Group 9-10: Table 11: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 27,000 Flight Hours or 4,500 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack. Airplanes with the Left Side Underwing Longeron Re- placed in accordance with this service bulletin. OPTION 2: Do PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack. 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. -CONDITION 5 (OPTION 1): Repeat PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 5: NO CRACK FOUND ON THE LEFT SIDE UNDERWING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. -CONDITION 5 (OPTION 2): Repeat PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 6: ANY CRACK FOUND ON THE LEFT SIDE UNDERWING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 41 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 42 Group 9-10: Table 12: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-300 Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 27,000 Flight Hours or 4,500 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack. Airplanes with the Right Side Underwing Longeron Replaced in accordance with this service bulletin. OPTION 2: Do PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. 1,300 Flight Hours or 180 Flight Cy- cles, whichever oc- curs first. -CONDITION 7 (OPTION 1): Repeat PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 7: NO CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. 15,000 Flight Hours or 2,000 Flight Cycles, whichever occurs first. -CONDITION 7 (OPTION 2): Repeat PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(a) -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 8: ANY CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 42 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 43 Group 11-13: Table 13: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-300ER Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 24,000 Flight Hours or 4,000 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack. Airplanes with the Left Side Underwing Longeron Re- placed in accordance with this service bulletin. OPTION 2: Do PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack. 1,000 Flight Hours or 120 Flight Cy- cles, whichever oc- curs first. -CONDITION 5 (OPTION 1): Repeat PART 12: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(a) CONDITION 5: NO CRACK FOUND ON THE LEFT SIDE UNDERWING LONGERON. 12,000 Flight Hours or 1,400 Flight Cycles, whichever occurs first. -CONDITION 5 (OPTION 2): Repeat PART 14: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(a) -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 6: ANY CRACK FOUND ON THE LEFT SIDE UNDERWING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 43 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 44 Group 11-13: Table 14: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-300ER Airplanes Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 24,000 Flight Hours or 4,000 Flight Cycles after underwing longeron replace- ment, whichever occurs first. OPTION 1: Do PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack. Airplanes with the Right Side Underwing Longeron Replaced in accordance with this service bulletin. OPTION 2: Do PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. 1,000 Flight Hours or 120 Flight Cy- cles, whichever oc- curs first. -CONDITION 7 (OPTION 1): Repeat PART 13: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(a) CONDITION 7: NO CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. 12,000 Flight Hours or 1,400 Flight Cycles, whichever occurs first. -CONDITION 7 (OPTION 2): Repeat PART 15: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(a) -Before further flight. Contact The Boeing Company for repair in- structions and do the re- pair. CONDITION 8: ANY CRACK FOUND ON THE RIGHT SIDE UNDER- WING LONGERON. (a) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 44 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 45 Group 11, 13: Table 15: Inspect the machined underwing longerons in 777-300ER Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Oc- curs First) ActionCondition -Whichever occurs later: Whichever occurs later: OPTION 1: Do PART 2: DETAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack and Do PART 3: DETAILED IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. All Airplanes a) Before 100,000 Total Flight Hours (TFH), or before 14,000 Total Flight Cycles (TFC), or before the result of 18,290 - (0.1129*TFH) - TFC is less than or equal to zero, whichever occurs first.(a) a) Before 24,000 Total Flight Hours or 4,000 Total Flight Cycles, whichever occurs first. . OR . b) Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the ef- fective date of AD 2017-16-10, whichever occurs first. OPTION 2: Do PART 6: DETAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack and Do PART 7: DETAILED INSPEC- TION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack. . OR . b) Within 90 days after the Revision 2 date of this ser- vice bulletin. 1,000 Flight Hours or 120 Flight Cy- cles, whichever occurs first. --CONDITION 1 (OPTION 1): Repeat PART 2: DE- TAILED INSPECTION OF THE LEFT SIDE UN- DERWING LONGERON for any crack.(b) CONDITION 1: NO CRACK FOUND IN THE LEFT SIDE UNDER- WING LONGERON. 12,000 Flight Hours or 1,400 Flight Cycles, whichever occurs first. --CONDITION 1 (OPTION 2): Repeat PART 6: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE LEFT SIDE UNDER- WING LONGERON for any crack.(b) --Before Further Flight Do PART 8: LEFT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(c) CONDITION 2: ANY CRACK FOUND IN THE LEFT SIDE UNDER- WING LONGERON. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 45 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 46 Group 11, 13: Table 15: Inspect the machined underwing longerons in 777-300ER Airplanes Repeat Interval (Not to Exceed) Compliance Time (Whichever Oc- curs First) ActionCondition 1,000 Flight Hours or 120 Flight Cy- cles, whichever occurs first. --CONDITION 3 (OPTION 1): Repeat PART 3: DE- TAILED INSPECTION OF THE RIGHT SIDE UNDERWING LONGERON for any crack.(b) CONDITION 3: NO CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. 12,000 Flight Hours or 1,400 Flight Cycles, whichever occurs first. --CONDITION 3 (OPTION 2): Repeat PART 7: DE- TAILED INSPECTION AND ULTRASONIC IN- SPECTION OF THE RIGHT SIDE UNDER- WING LONGERON for any crack.(b) --Before Further Flight. Do PART 9: RIGHT SIDE UNDERWING LONGERON REMOVAL AND REPLACEMENT.(d) CONDITION 4: ANY CRACK FOUND IN THE RIGHT SIDE UNDER- WING LONGERON. (a) As an aid, refer to APPENDIX Q: Longeron Inspection Compliance Graph. (b) An operator can change inspection method at their discretion to meet operational needs. The previous inspection method determines the interval to the next inspection. (c) Post replacement inspections are required in accordance with Table 13: Post Replacement Inspections on the Left Side Underwing Longeron for Any Crack on 777-300ER Airplanes. (d) Post replacement inspections are required in accordance with Table 14: Post Replacement Inspections on the Right Side Underwing Longeron for Any Crack on 777-300ER Airplanes. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 46 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 47 In addition, the Manager of the FAA Seattle ACO Branch approves accomplishing the inspections and related corrective actions in accordance with this service bulletin as an alternative method of compliance to the requirements of paragraphs (g) and (h) of AD 2017-16-10. All provisions of AD 2017-16-10 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. G. Manpower The table below shows an estimate of the task hours necessary to do this Inspection and Repair for each Airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task 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 inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools Group 1-2, 9: Table 1: Detailed Inspection of the underwing longeron Elapsed HoursTask HoursNumber of PersonsTask 1.501.501Open Access 1.001.001Figure 1 1.001.001Figure 2 1.501.501Close Access 5.005.00TOTAL FOR EACH AIRPLANE Group 3-8, 10-13: Table 2: Detailed Inspection of the underwing longeron Elapsed HoursTask HoursNumber of PersonsTask 1.501.501Open Access 0.800.801Figure 3 0.800.801Figure 4 1.501.501Close Access 4.604.60TOTAL FOR EACH AIRPLANE Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 47 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 48 Group 1-2, 9: Table 3: Detailed Inspection and High Frequency Eddy Current (HFEC) Inspection of the Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.501.501Open Access 2.505.002Figure 5 2.505.002Figure 6 1.501.501Close Access 8.0013.0TOTAL FOR EACH AIRPLANE Group 3-8, 10-13: Table 4: Detailed Inspection and Ultrasonic Inspection of the Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.501.501Open Access 2.004.002Figure 7 2.004.002Figure 8 1.501.502Close Access 7.0011.0TOTAL FOR EACH AIRPLANE Group 1, 3: Table 5: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 9 8.7518.002Figure 10 6.2514.002Figure 11 4.508.502Figure 12 1.501.501Figure 13 47.0094.002Figure 15 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 48 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 49 Group 1, 3: Table 6: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 21 8.7518.002Figure 22 6.2514.002Figure 23 4.508.502Figure 24 1.501.501Figure 25 47.0094.002Figure 27 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 2, 4, 7: Table 7: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 9 8.7518.002Figure 10 6.2514.002Figure 11 4.508.502Figure 12 1.501.501Figure 14 47.0094.002Figure 16 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 2, 4, 7: Table 8: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 21 8.7518.002Figure 22 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 49 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 50 Group 2, 4, 7: Table 8: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 6.2514.002Figure 23 4.508.502Figure 24 1.501.501Figure 26 47.0094.002Figure 28 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 5: Table 9: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 9 8.7518.002Figure 10 6.2514.002Figure 11 4.508.502Figure 12 1.501.501Figure 13 47.0094.002Figure 17 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 5: Table 10: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 21 8.7518.002Figure 22 6.2514.002Figure 23 4.508.502Figure 24 1.501.501Figure 25 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 50 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 51 Group 5: Table 10: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 47.0094.002Figure 29 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 6, 8: Table 11: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 9 8.7518.002Figure 10 6.2514.002Figure 11 4.508.502Figure 12 1.501.501Figure 14 47.0094.002Figure 18 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 6, 8: Table 12: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 21 8.7518.002Figure 22 6.2514.002Figure 23 4.508.502Figure 24 1.501.501Figure 26 47.0094.002Figure 30 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 51 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 52 Group 6, 8: Table 12: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 9, 11: Table 13: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 9 8.7518.002Figure 10 6.2514.002Figure 11 4.508.502Figure 12 1.501.501Figure 14 47.0094.002Figure 19 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 9, 11: Table 14: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 21 8.7518.002Figure 22 6.2514.002Figure 23 4.508.502Figure 24 1.501.501Figure 26 47.0094.002Figure 31 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 52 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 53 Group 12-13: Table 15: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 9 8.7518.002Figure 10 6.2514.002Figure 11 4.508.502Figure 12 1.501.501Figure 14 47.0094.002Figure 20 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Group 12-13: Table 16: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.3046.505Open Access (a) 40.0080.002Figure 21 8.7518.002Figure 22 6.2514.002Figure 23 4.508.502Figure 24 1.501.501Figure 26 47.0094.002Figure 32 4.4022.005Close Access (a) 121.7284.50TOTAL FOR EACH AIRPLANE (a) Hours shown do not include any additional access removals that may be necessary due to airplane configuration. Table 17: Post Replacement Detailed Inspection On the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.001.001Open Access 0.800.801Figure 33 1.001.001Close Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 53 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 54 Table 17: Post Replacement Detailed Inspection On the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 2.802.80TOTAL FOR EACH AIRPLANE Table 18: Post Replacement Detailed Inspection On the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.001.001Open Access 0.800.801Figure 34 1.001.001Close Access 2.802.80TOTAL FOR EACH AIRPLANE Table 19: Post Replacement Detailed Inspection and Ultrasonic Inspection On the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.001.001Open Access 2.004.002Figure 35 1.001.001Close Access 4.006.00TOTAL FOR EACH AIRPLANE Table 20: Post Replacement Detailed Inspection and Ultrasonic Inspection On the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.001.001Open Access 2.004.002Figure 36 1.001.001Close Access 4.006.00TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes None. I. Electrical Load Data Not changed. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 54 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 55 J. References 1. Existing Data: a. Engineering Change Memo PRR 62777-110S b. Boeing Service Letter 777-SL-00-007, 777-SL-51-013 c. Boeing Service Related Problem (SRP) 777-SRP-53-0485 d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2017-16-10 e. Service Bulletin Index D624W001 f. Standard Overhaul Practices Manual (SOPM) 20-10-03, 20-41-02, 20-43-03, 20-50-01, 20-50-01, 20-50-19 g. 777 Aircraft Maintenance Manual (AMM) 06-41-00, 07-11-01, 07-11-03, 12-15-01, 12-15-02, 28-11-00, 28-11-02, 28-26-00, 51-24-09, 53-36-01 h. 777 Fleet Team Digest (FTD) 53-15002 i. 777 Non-Destructive Testing (NDT) Manual Part 4, 53-40-05, Part 4, 57-10-06, Part 6, 51-00-01, Part 6, 51-00-02, Part 6, 51-00-04 j. 777-200 Structural Repair Manual (SRM) 51-10-02, 51-40-02, 51-40-05, 51-40-09, 53-00-01, 57-10-10 k. 777-300 Structural Repair Manual (SRM) 51-10-02, 51-40-02, 51-40-05, 51-40-09, 53-00-01, 57-10-10 l. 777F Structural Repair Manual (SRM) 51-10-02, 51-40-02, 51-40 -05, 51-40-09, 53-00-01, 57-10-10 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number UNDERWING LONGERON INSTL140W9250 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 55 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 56 Chapter-SectionPublication 51-40777 Structural Repair Manual 53-30777 Maintenance Planning Data 57-10777 Maintenance Planning Data 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. M. Software Accomplishment Summary Not affected. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 56 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 57 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) QTYDateNameKit Number $17,300.00-1September 08, 2016 TOP KIT, RETROFIT - LONGERON INSPECT, R&R -300 LH SIDE LONGERON AND FILLER 005W3620-1 (a) -1September 15, 2016 -1September 22, 2016 -1September 29, 2016 -26October 06, 2016 -25November 03, 2016 -25December 05, 2016 -25January 16, 2017 -25February 13, 2017 -25March 13, 2017 -32April 04, 2017 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 57 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 58 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) QTYDateNameKit Number $17,300.00-1September 08, 2016 TOP KIT, RETROFIT - LONGERON INSPECT, R&R -300 RH SIDE LONGERON AND FILLER 005W3620-2 (a) -1September 15, 2016 -1September 22, 2016 -2September 29, 2016 -25October 06, 2016 -25November 03, 2016 -25December 05, 2016 30January 16, 2017 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 58 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 59 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) QTYDateNameKit Number $12,862.00-1September 08, 2016 TOP KIT, RETROFIT - LONGERON INSPECT, R&R -300 FASTENER KIT 005W3620-3 (a) (b) -1September 15, 2016 -1September 22, 2016 -1September 29, 2016 1October 06, 2016 -25April 12, 2017 -25April 26, 2017 -25May 10, 2017 -25May 24, 2017 -25June 08, 2017 -25June 22, 2017 -25July 07, 2017 25July 21, 2017 -25August 04, 2017 -25August 18, 2017 -25September 01, 2017 -27September 15, 2017 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 59 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 60 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 01 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 01 date of this Service Bulletin (Calendar Days) QTYDateNameKit Number $17,300.00-1September 08, 2016 TOP KIT, RETROFIT - LONGERON INSPECT, R&R -200/-F LH SIDE LONGERON AND FILLER 005W3620-4 (c) -1September 15, 2016 -2September 22, 2016 -1September 29, 2016 -25October 20, 2016 -25November 03, 2016 -25November 17, 2016 -25December 05, 2016 -25December 19, 2016 -25January 11, 2017 -11January 25, 2017 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081Revision 2: March 29, 2019 60 of 335 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/777-53a0081/file/13ee2f705e01.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.