# Boeing Alert Service Bulletin 777-53A0081: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2016-9520; AD 2017-16-10 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-777-53A0081-00--BOEING - Pages: 315 - PDF: https://openairdocs.org/files/sha256/f3/54/f354eeb8730e533c1d983c8c52d8ef3b774990337ed5dc7be606affb3749c3f9 - Page: https://openairdocs.org/service-documents/boeing/777-53a0081/file/f354eeb8730e ## 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 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 Unpublished Work.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September 08, 2016 777-53A0081 1 of 315 3.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 2 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT BLANK PAGE ### Page 3 Table of Contents S u m m a r y ...................................................... 7 1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1 1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 9 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 2 0 E. Compliance .............................................. 2 0 F . A p p r o v a l ............................................... 4 2 G. Manpower .............................................. 4 2 H. Weight and Balance Changes .................................... 4 9 I. Electrical Load Data ......................................... 4 9 J . R e f e r e n c e s .............................................. 4 9 1. Existing Data: ......................................... 4 9 2. Data Supplied with this Service Bulletin: ........................... 4 9 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 0 K. Publications Affected ........................................ 5 0 L. Interchangeability and Intermixability of Parts ........................... 5 0 M. Software Accomplishment Summary ................................ 5 0 2. MATERIAL INFORMATION ........................................ 5 1 A. Material - Price and Availability ................................... 5 1 B. Industry Support Information .................................... 5 2 C. Parts Necessary for Each Airplane ................................. 5 2 1 . K i t s / P a r t s ............................................ 5 2 2. Parts and Materials Supplied by the Operator ........................ 5 7 3. Parts Modified and Reidentified ................................ 5 8 4. Parts Removed and Not Replaced .............................. 5 8 D. Parts Necessary to Change Spares ................................. 5 8 E. Special Tooling - Price and Availability ............................... 5 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 8 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 9 A. GENERAL INFORMATION ..................................... 5 9 B. WORK INSTRUCTIONS ....................................... 6 1 FIGURE 1: DETAILED INSPECTION OF THE LEFT SIDE BUILT-UP UNDERWING LONGERON [Group 1 - 2 , 9 ] .............................................. 7 1 FIGURE 2: DETAILED INSPECTION OF THE RIGHT SIDE BUILT-UP UNDERWING LONGERON [Group 1 - 2 , 9 ] .............................................. 7 4 FIGURE 3: DETAILED INSPECTION OF THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 3 - 8 , 1 0 - 1 2 ] ........................................... 7 7 FIGURE 4: DETAILED INSPECTION OF THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 3 - 8 , 1 0 - 1 2 ] ........................................... 7 9 FIGURE 5: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) 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 ] ................. 8 1 FIGURE 6: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT INSPECTION (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 ] ................ 8 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 3 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 4 FIGURE 7: DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE LEFT SIDE MACHINED LONGERON [Group 3-8, 10-12] ................................ 8 7 FIGURE 8: DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE MACHINED LONGERON [Group 3-8, 10-12] ................................ 8 9 FIGURE 9: REMOVAL OF THE LEFT SIDE UNDERWING LONGERON ................ 9 1 FIGURE 10: INSPECTION OF THE FUSELAGE SKIN AROUND THE LEFT SIDE UNDERWING LONGERON .................................................. 9 4 FIGURE 11: INSPECTION OF THE LOWER WING SKIN AROUND THE LEFT SIDE UNDERWING L O N G E R O N.......................................... 9 6 FIGURE 12: INSPECTION OF THE LOWER WING BODY CHORD, SPAR CHORD AND SPAR WEB AROUND THE LEFT SIDE LONGERON ........................... 9 8 FIGURE 13: INSTALL THE FASTENERS [Group 1, 3, 5] ......................... 1 0 1 FIGURE 14: INSTALL THE FASTENERS [Group 2, 4, 6-12] ....................... 1 0 4 FIGURE 15: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 1, 3] .... 1 0 7 FIGURE 16: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 2, 4, 7] . . . 118 FIGURE 17: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 5] ...... 1 2 9 FIGURE 18: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 6, 8] .... 1 3 9 FIGURE 19: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 9-11] .... 1 4 9 FIGURE 20: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 12] ..... 1 6 1 FIGURE 21: REMOVAL OF THE RIGHT SIDE UNDERWING LONGERON .............. 1 7 1 FIGURE 22: INSPECTION OF THE FUSELAGE SKIN AROUND THE RIGHT SIDE UNDERWING L O N G E R O N .......................................... 1 7 4 FIGURE 23: INSPECTION OF THE LOWER WING SKIN AROUND THE RIGHT SIDE UNDERWING L O N G E R O N .......................................... 1 7 6 FIGURE 24: INSPECTION OF THE LOWER WING BODY CHORD, SPAR CHORD AND SPAR WEB AROUND THE RIGHT SIDE LONGERON ......................... 1 7 8 FIGURE 25: INSTALL THE FASTENERS [Group 1, 3, 5] ......................... 1 8 1 FIGURE 26: INSTALL THE FASTENERS [Group 2, 4, 6-12] ....................... 1 8 4 FIGURE 27: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 1, 3] .... 1 8 7 FIGURE 28: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 2, 4, 7] . . 198 FIGURE 29: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 5] ..... 2 0 9 FIGURE 30: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 6, 8] .... 2 1 9 FIGURE 31: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 9-11] . . . 229 FIGURE 32: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 12] .... 2 4 1 FIGURE 33: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE MACHINED UNDERWING L O N G E R O N .......................................... 2 5 1 FIGURE 34: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE MACHINED UNDERWING LONGERON ................................. 2 5 3 FIGURE 35: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE LEFT SIDE MACHINED UNDERWING LONGERON .................... 2 5 5 FIGURE 36: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE MACHINED UNDERWING LONGERON ................... 2 5 7 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] . . 259 APPENDIX B: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-200 AIRPLANES [Group 3-6] . . 263 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 4 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 5 APPENDIX C: L OGIC 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 6 7 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] . . . 271 APPENDIX E: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 5: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-300 AIRPLANES [Group 10] . . . 275 APPENDIX F: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 6: INSPECT THE MACHINED UNDERWING LONGERONS FOR ANY CRACK IN 777-300ER AIRPLANES [Group 11-12] ................................................. 2 7 9 APPENDIX G: 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] ................................... 2 8 3 APPENDIX H: 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] .............................. 2 8 7 APPENDIX I: 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] ...................... 2 9 1 APPENDIX J: 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] ...................... 2 9 5 APPENDIX K: 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] .................................. 2 9 9 APPENDIX L: 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 0 3 APPENDIX M: 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 11-12] ........................... 3 0 7 APPENDIX N: 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 11-12] ........................... 3 1 1 APPENDIX O: PART DEMAND INTENT .................................. 3 1 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 5 of 315 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 777-53A0081 6 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT BLANK PAGE ### Page 7 Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0081Original Issue: September 08, 2016 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, three more operators have reported cracks on the left 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 and three operators noted the front lower wing spar chord had cracked. 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 31,2403,784777-300ER 43,3445,247777-300ER 39,5935,359777-300ER 51,4527,299777-300ER 51,2127,413777-300ER Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 7 of 315 ### Page 8 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 ChangesYesWeight 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 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 All 777 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Refer to Paragraph 1.E., Compliance. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 8 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 9 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 O 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 777-53A0081 9 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 10 (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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 777-53A0081 Work - See page 1 for details. 10 of 315 ### Page 11 Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0081 Original Issue: September 08, 2016 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 service bulletin is applicable to 777-200, 777-200LR, 777-300, 777-300ER, and 777F line number 1 - 9999 in 12 Groups. 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. NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1503. Affected airplanes after Line Number 1503 will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page. 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 11 of 315 ### Page 12 DESCRIPTIONCONFIGURATIONGROUP 777-200 airplanes, line numbers 630 and on, with extra tabs on machined longeron and without center wing fuel tank. -5 777-200 airplanes, line numbers 630 and on, 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 630 and on, 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 630 and on, with extra tabs on machined longeron. -12 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 777-53A0081 12 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 13 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 777-53A0081 13 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 14 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 777-53A0081 14 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 15 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 12WD507 - WD513 11WD521 - WD534 12WD535 - WD541 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 15 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 16 GroupVariable Number 11WD546 - WD551 12WD552 - WD554 11WD561 - WD568 12WD569 - WD573 11WD581 - WD591 12WD592 - WD599 11WD606 - WD609 11WD621 - WD631 12WD632 11WD651 - WD655 12WD656 - WD665 11WD671 - WD675 12WD676 - WD677 11WD691 - WD699 12WD700 - WD709 11WD741 - WD742 12WD743 - WD752 11WD761 12WD762 - WD771 11WD786 - WD787 12WD788 12WD796 - WD837 12WD846 - WD867 12WD871 - WD904 12WD911 - WD918 12WD921 - WD957 12WD966 - WD970 12WD981 - WD982 12WD986 - WD987 12WD991 - WD996 12WE001 - WE007 12WE011 - WE012 12WE021 - WE026 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 16 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 17 GroupVariable Number 12WE031 - WE040 12WE051 - WE057 12WE071 - WE078 12WE081 - WE084 12WE091 - WE095 12WE126 - WE173 12WE176 - WE178 12WE186 - WE219 12WE226 - WE231 12WE236 - WE253 12WE261 - WE267 12WE271 - WE278 12WE291 - WE298 12WE301 - WE320 12WE331 - WE345 12WE351 - WE356 12WE376 - WE377 12WE381 12WE386 - WE387 12WE391 - WE392 12WE396 - WE405 12WE416 - WE420 12WE426 - WE431 12WE436 - WE446 12WE451 - WE468 12WE471 - WE478 12WE486 - WE493 12WE495 - WE499 12WE501 - WE504 12WE511 - WE516 12WE526 - WE528 12WE536 - WE549 12WE556 - WE570 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 17 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 18 GroupVariable Number 12WE576 - WE583 12WE591 12WE601 - WE605 12WE626 - WE627 12WE631 12WE641 - WE642 12WE646 - WE647 12WE651 - WE661 12WE666 - WE673 12WE701 - WE705 12WE711 - WE712 12WE731 - WE732 12WE736 - WE740 12WE746 - WE748 12WE751 - WE761 12WE776 - WE783 12WE786 12WE791 - WE792 12WE796 8WF001 - WF004 8WF016 - WF027 8WF031 - WF043 8WF046 - WF068 8WF075 - WF077 8WF081 - WF088 8WF096 - WF101 8WF106 - WF109 8WF111 - WF124 8WF131 - WF144 8WF146 - WF147 8WF151 - WF152 8WF156 - WF160 8WF166 - WF173 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 18 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 19 GroupVariable Number 8WF176 - WF179 8WF181 - WF184 8WF191 8WF206 - WF207 8WF216 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. Subsequently, three more operators have reported cracks on the left 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 and three operators noted the lower front spar chord had cracked. 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 31,2403,784777-300ER 43,3445,247777-300ER 39,5935,359777-300ER 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 19 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 20 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. 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 11-12: Affected Maintenance Zones ZoneModel 121, 122, 125, 126, 133, 134, 191, 192, 195, 196777-300ER E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 20 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 21 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. 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, and APPENDIX N. 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 is- sue date of this service bulletin, 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 777-53A0081 21 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 22 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 777-53A0081 22 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 23 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 is- sue date of this service bulletin, 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 777-53A0081 23 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 24 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 777-53A0081 24 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 25 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 is- sue date of this service bulletin, 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 777-53A0081 25 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 26 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 777-53A0081 26 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 27 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 is- sue date of this service bulletin, 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 777-53A0081 27 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 28 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 777-53A0081 28 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 29 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 Occurs Later) ActionCondition -Within 12,000 Flight Hours or 4,000 Flight Cy- cles after the is- sue date of this service bulletin, 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 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 777-53A0081 29 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 30 Group 10: Table 5: Inspect the machined 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 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 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 777-53A0081 30 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 31 Group 10: Table 5: Inspect the machined 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 11-12: 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 is- sue date of this service bulletin, 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 777-53A0081 31 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 32 Group 11-12: 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 777-53A0081 32 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 33 Group 11-12: 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 777-53A0081 33 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 34 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 777-53A0081 34 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 35 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 777-53A0081 35 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 36 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 777-53A0081 36 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 37 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 777-53A0081 37 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 38 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 777-53A0081 38 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 39 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 777-53A0081 39 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 40 Group 11-12: 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 777-53A0081 40 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 41 Group 11-12: 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 777-53A0081 41 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 42 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. 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 1.001.001Open Access 1.001.001Figure 1 1.001.001Figure 2 1.001.001Close Access 4.004.00TOTAL FOR EACH AIRPLANE Group 3-8, 10-12: Table 2: Detailed Inspection of the underwing longeron Elapsed HoursTask HoursNumber of PersonsTask 1.001.001Open Access 0.800.801Figure 3 0.800.801Figure 4 1.001.001Close Access 3.603.60TOTAL FOR EACH AIRPLANE Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 42 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 43 Group 1-2, 9: Table 3: Detailed Inspection and High Frequency Eddy Current (HFEC) Inspection of the Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.001.001Open Access 2.505.002Figure 5 2.505.002Figure 6 1.001.001Close Access 7.0012.00TOTAL FOR EACH AIRPLANE Group 3-8, 10-12: Table 4: Detailed Inspection and Ultrasonic Inspection of the Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 1.001.001Open Access 2.004.002Figure 7 2.004.002Figure 8 0.501.002Close Access 5.5010.00TOTAL FOR EACH AIRPLANE Group 1, 3: Table 5: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 9 5.7511.502Figure 10 3.256.52Figure 11 2.505.002Figure 12 0.500.501Figure 13 4.008.002Figure 15 4.1020.505Close Access 31.60102.00TOTAL FOR EACH AIRPLANE Group 1, 3: Table 6: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 43 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 44 Group 1, 3: Table 6: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 2.505.002Figure 21 5.7511.502Figure 22 3.256.502Figure 23 2.505.002Figure 24 0.500.501Figure 25 4.008.002Figure 27 4.1020.505Close Access 31.60102.00TOTAL FOR EACH AIRPLANE Group 2, 4, 7: Table 7: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 9 5.7511.502Figure 10 3.256.52Figure 11 2.505.002Figure 12 0.500.501Figure 14 4.008.002Figure 16 4.1020.505Close Access 31.60102.00TOTAL FOR EACH AIRPLANE Group 2, 4, 7: Table 8: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 21 5.7511.502Figure 22 3.256.502Figure 23 2.505.002Figure 24 0.500.501Figure 26 4.008.002Figure 28 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 44 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 45 Group 2, 4, 7: Table 8: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 4.1020.505Close Access 31.60102.00TOTAL FOR EACH AIRPLANE Group 5: Table 9: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 9 5.7511.502Figure 10 3.256.502Figure 11 2.505.002Figure 12 0.500.501Figure 13 3.507.002Figure 17 4.1020.505Close Access 31.10101.00TOTAL FOR EACH AIRPLANE Group 5: Table 10: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 21 5.7511.502Figure 22 3.256.502Figure 23 2.505.002Figure 24 0.500.501Figure 25 3.5072Figure 29 4.1020.505Close Access 31.10101.00TOTAL FOR EACH AIRPLANE Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 45 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 46 Group 6, 8: Table 11: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 9 5.7511.502Figure 10 3.256.502Figure 11 2.505.002Figure 12 0.500.501Figure 14 3.507.002Figure 18 4.1020.505Close Access 31.10101.00TOTAL FOR EACH AIRPLANE Group 6, 8: Table 12: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 21 5.7511.502Figure 22 3.256.502Figure 23 2.505.002Figure 24 0.500.501Figure 26 3.5072Figure 30 4.1020.505Close Access 31.10101.00TOTAL FOR EACH AIRPLANE Group 9-11: Table 13: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 9 5.7511.502Figure 10 3.256.502Figure 11 2.505.002Figure 12 0.500.501Figure 14 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 46 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 47 Group 9-11: Table 13: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 4.008.002Figure 19 4.1020.505Close Access 31.60102.00TOTAL FOR EACH AIRPLANE Group 9-11: Table 14: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 21 5.7511.502Figure 22 3.256.502Figure 23 2.505.002Figure 24 0.500.501Figure 26 4.008.002Figure 31 4.1020.505Close Access 31.60102.00TOTAL FOR EACH AIRPLANE Group 12: Table 15: Removal and Replacement of the Left Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 9 5.7511.502Figure 10 3.256.502Figure 11 2.505.002Figure 12 0.500.501Figure 14 3.507.002Figure 20 4.1020.505Close Access 31.10101.00TOTAL FOR EACH AIRPLANE Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 47 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 48 Group 12: Table 16: Removal and Replacement of the Right Side Underwing Longeron Elapsed HoursTask HoursNumber of PersonsTask 9.0045.005Open Access 2.505.002Figure 21 5.7511.502Figure 22 3.256.502Figure 23 2.505.002Figure 24 0.500.501Figure 26 3.507.002Figure 32 4.1020.505Close Access 31.10101.00TOTAL FOR EACH AIRPLANE 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 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 48 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 49 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 Weight and Balance changes affected by incorporation of this service bulletin are dependent on the type and number of inspection and repairs done on each particular airplane. Weight and Balance are to be calculated by the operator by weighing parts installed or removed. Operators should make necessary revisions to the appropriate weight and balance report. I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Boeing Service Letter 777-SL-00-007, 777-SL-51-013 b. Boeing Service Related Problem (SRP) 777-SRP-53-0485 c. Service Bulletin Index D624W001 d. Standard Overhaul Practices Manual (SOPM) 20-10-03, 20-41-02, 20-43-03, 20-50-01, 20-50-01, 20-50-19 e. 777 Aircraft Maintenance Manual (AMM) 06-41-00, 07-11-01, 12-15-01, 12-15-02, 28-11-00, 28-11-02, 28-26-00, 51-24-09, 53-36-01 f. 777 Fleet Team Digest (FTD) 53-15002 g. 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 h. 777-200 Structural Repair Manual (SRM) 51-10-02, 51-40-02, 51-40-05, 51-40-09 i. 777-300 Structural Repair Manual (SRM) 51-10-02, 51-40-02, 51-40-05, 51-40-09 j. 777F Structural Repair Manual (SRM) 51-10-02, 51-40-02, 51-40-05, 51-40-09 2. Data Supplied with this Service Bulletin: None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 49 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 50 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: Chapter-SectionPublication 51-40777 Structural Repair Manual 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 777-53A0081 50 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 51 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 NameKit Number TOP KIT, RETROFIT - LONGERON INSPECT, R&R -300 LH SIDE LONGERON AND FILLER (d) 005W3620-1 (a) TOP KIT, RETROFIT - LONGERON INSPECT, R&R -300 RH SIDE LONGERON AND FILLER (d) 005W3620-2 (a) TOP KIT, RETROFIT - LONGERON INSPECT, R&R -300 FASTENER KIT (d) 005W3620-3 (a) (b) TOP KIT, RETROFIT - LONGERON INSPECT, R&R -200/-F LH SIDE LONGERON AND FILLER (d) 005W3620-4 (c) TOP KIT, RETROFIT - LONGERON INSPECT, R&R -200/-F RH SIDE LONGERON AND FILLER (d) 005W3620-5 (c) TOP KIT, RETROFIT - LONGERON INSPECT, R&R -200/-F FASTENER KIT (d) 005W3620-6 (c) (b) (a) Applicable to Group 9 - 12 airplanes. (b) One fastener kit provides sufficient quantity to replace one longeron, left side or right side. (c) Applicable to Group 1 - 8 airplanes. (d) Date and Qty of availability, ROLT and unit price are not available at the time of publication. Operators are encouraged to complete the survey provided in APPENDIX O 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 777-53A0081 51 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 52 B. Industry Support Information Boeing warranty remedies are available for 777 airplanes in warranty as of September 23, 2015. For inspection labor task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Fleet Support Contracts - Warranty. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours, kits and special tools are required, send a warranty claim to Boeing Fleet Support Contracts - Warranty. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. The warranty remedies will expire eight years from the original issue date of this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts ALL Kit 005W3620 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 TOP KIT, RETROFIT - LONGERON IN- SPECT, R&R -300 LH SIDE LONGERON AND FILLER .....-005W3620-1 TOP KIT, RETROFIT - LONGERON IN- SPECT, R&R -300 RH SIDE LONGERON AND FILLER ....-.005W3620-2 TOP KIT, RETROFIT - LONGERON IN- SPECT, R&R -300 FASTENER KIT ...-..005W3620-3 TOP KIT, RETROFIT - LONGERON IN- SPECT, R&R - 200/-F LH SIDE LONGERON AND FILLER ..-...005W3620-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 52 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 53 ALL Kit 005W3620 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 TOP KIT, RETROFIT - LONGERON IN- SPECT, R&R - 200/-F RH SIDE LONGERON AND FILLER .-....005W3620-5 TOP KIT, RETROFIT - LONGERON IN- SPECT, R&R - 200/-F FASTENER KIT -.....005W3620-6 FILLER - UNDER- WING LONGERON ....11140W9254-301 FILLER - UNDER- WING LONGERON .11...140W9254-401 (a)UNDERWING LONGERON, MA- CHINED .....1140W9255U303 (a)UNDERWING LONGERON, MA- CHINED ....1.140W9255U304 (a)UNDERWING LONGERON, MA- CHINED ..1...140W9255U403 (a)UNDERWING LONGERON, MA- CHINED .1....140W9255U404 (b) (c)BOLT, PROTRUD- ING HD 16..16..BACB30NX10K10X (b) (c)BOLT, PROTRUD- ING HD 17..17..BACB30NX10K11X (b) (c)BOLT, PROTRUD- ING HD 10..10..BACB30NX10K12X (b) (c)BOLT, PROTRUD- ING HD ...9..BACB30NX10K13X (b) (c)BOLT, PROTRUD- ING HD ...3..BACB30NX10K14X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 53 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 54 ALL Kit 005W3620 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 (b) (c)BOLT, PROTRUD- ING HD 5..5..BACB30NX10K15X (b) (c)BOLT, PROTRUD- ING HD 5..5..BACB30NX10K16X (b) (c)BOLT, PROTRUD- ING HD ...1..BACB30NX10K19X (b) (c)BOLT, PROTRUD- ING HD ...1..BACB30NX10K20X (b) (c)BOLT, PROTRUD- ING HD 1..1..BACB30NX10K9X (b) (c)BOLT, PROTRUD- ING HD 6.....BACB30NX12K11X (b) (c)BOLT, PROTRUD- ING HD 6.....BACB30NX12K12X (b) (c)BOLT, PROTRUD- ING HD 2..2..BACB30NX12K13 (b) (c)BOLT, PROTRUD- ING HD 8..8..BACB30NX12K13X (b) (c)BOLT, PROTRUD- ING HD 10..10..BACB30NX12K14X (b) (c)BOLT TIANIUM O/S ...2..BACB30NX12K15X (b) (c)BOLT, PROTRUD- ING HD ...2..BACB30NX12K16X (b) (c)BOLT, PROTRUD- ING HD 2..2..BACB30NX12K18 (b) (c)BOLT, PROTRUD- ING HD 2..2..BACB30NX12K18X (b) (c)BOLT, HEX DRIVE6.....BACB30NX14K13X (b) (c)BOLT, PROTRUD- ING HD 4.....BACB30NX14K14X (b) (c)BOLT TITANIUM O/S 6..6..BACB30NX14K15X (b) (c)BOLT, PROTRUD- ING HD 10..10..BACB30NX14K16X (b) (c)BOLT, HEX DRIVE7.....BACB30NX14K17X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 54 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 55 ALL Kit 005W3620 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 (b) (c)BOLT, PROTRUD- ING HD 1..1..BACB30NX14K18X (b) (c)BOLT, PROTRUD- ING HD 1..1..BACB30NX14K19X (b) (c)BOLT, PROTRUD- ING HD 1..1..BACB30NX14K20X (b) (c)BOLT, HEX-DRIVE...1..BACB30NX14K21X (b) (c)BOLT, PROTRUD- ING HD ...2..BACB30NX16K16X (b) (c)BOLT, HEX DRIVE...4..BACB30NX16K17X (b) (c)BOLT, PROTRUD- ING HD ...2..BACB30NX16K18X (b) (c)BOLT O/S...2..BACB30NX16K20X (b) (c)BOLT, PROTRUD- ING HD ...2..BACB30NX16K21X (b) (c)BOLT, PROTRUD- ING HD ...13..BACB30NX8K10X (b) (c)BOLT, PROTRUD- ING HD 14.....BACB30NX8K7X (b) (c)BOLT, PROTRUD- ING HD 14..14..BACB30NX8K8X (b) (c)BOLT, PROTRUD- ING HD 27..27..BACB30NX8K9X (b) (c)BOLT, 12 PT HEAD 2..2..BACB30US8K20X (b) (c)BOLT O/S2.....BACB30US8K21X (b) (c)BOLT, 12 PT HEAD 2.....BACB30US8K22X (b) (c)BOLT, 12 PT HEAD 2.....BACB30US8K23X (b) (c)BOLT, 12 PT HEAD 2.....BACB30US8K24X (b) (c)BOLT, 12 PT HEAD 2.....BACB30US8K25X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 55 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 56 ALL Kit 005W3620 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 (b) (c)BOLT, 12 PT HEAD 2.....BACB30US8K26X (b) (c)BOLT, 12 PT HEAD 2..2..BACB30US9K20X (b) (c)BOLT, 12 PT HEAD ...2..BACB30US9K21X (b) (c)BOLT, 12 PT HEAD 2..2..BACB30US9K22X (b) (c)BOLT4..4..BACB30US9K23X (b) (c)BOLT, 12 PT HEAD ...2..BACB30US9K24X (b) (c)BOLT...2..BACB30US9K25X (b) (c)BOLT, 12 PT HEAD ...2..BACB30US9K26X (b)COLLAR33..33..BACC30BH10 (b)COLLAR20..20..BACC30BH12 (b)COLLAR, PRELOAD 14..14..BACC30BH14 (b)COLLAR16..16..BACC30BH8 (b)COLLAR...8..BACC30X16 NUT2..2..BACN10HR8CD NUT6..6..BACN10HR9CD (b)WASHER, PLAIN40..40..BACW10BP41DP (b)WASHER, PLAIN66..66..BACW10BP51DP (b)WASHER, PLAIN28..28..BACW10BP61DP (b)WASHER, PLAIN32..32..BACW10BP71DP (b)WASHER, PLAIN8..8..BACW10BP81CD (b)WASHER, PLAIN24..24..BACW10BP81DP (b)WASHER, PLAIN10..10..BACW10BP91CD (b)WASHER, PLAIN12..12..BACW10BP91DP Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 56 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 57 ALL Kit 005W3620 NotesExisting Part Number NameQtyNew Part Number -6-5-4-3-2-1 (a) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the 'dash' configuration when installed as given in the Accomplishment Instructions of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Boeing Service Letter 777-SL-00-007 for more information. (b) There are more parts than are necessary. (c) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. NotesNameQtyPart Number/ Specifica- tion (a) (b)Chemical Conversion Coating 1 PintAlodine or equivalent Type 2, CLASS A (a) (c)Chemical Conversion Coating 1 PintAlodine 600 (a) (d)Primer1 QuartBMS 10-11 Type I (a) (d)Sealant1 PintBMS 5-45 (a) (d)Sealant1 PintBMS 5-95 (a) (d) (e)Sealant1 PintBMS 5-142 (a) (d)Sealant1 PintBMS 5-81 (a) (d)Corrosion Inhibiting Com- pound 1 PintBMS 3-23 (a) Quantities listed are only recommendations, more or less may be required. (b) Refer to SOPM 20-43-03 for a list of suppliers and equivalents (c) Refer to SOPM 20-43-03 for a list of suppliers. (d) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.0 (e) BMS 5-95 is an acceptable alternate. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 57 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 58 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability The 777-200 SRM 51-40-09, 777-300 SRM 51-40-09 and 777F SRM 51-40-09 give data about cold working tools and sleeves necessary to do the work given in this service bulletin. These tools are available from industry sources. Engineering, service, and a kit of cold working tools made for this change are available from West Coast Industries, Inc. • Refer To: WCI Kit Number: WCI-777-53A-0081 West Coast Industries, Inc. 14900 Whitman Avenue North Seattle, WA 98133-6532 USA Phone Number (206) 365-7513 Fax (206) 365-7483 F. Special Tooling Necessary to do this Service Bulletin Cold working tools are necessary to do the change given in this service bulletin. To get the cold working tools, refer to Paragraph 2.E., Special Tooling - Price and Availability. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 58 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 59 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values: — Values for structural fasteners are given in 777 Structural Repair Manual, Chapter 51. — Values for airframe maintenance tasks are included in Chapter 20 of 777 Aircraft Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). — Values for engine maintenance tasks are included in Chapter 70 of 777 Aircraft Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step. 4. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 6. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 59 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT ### Page 60 7. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 8. Boeing Service Letter 777-SL-51-013, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 9. Refer to Appendices A, B, C, D, E, F, G, H, I, J, K, L, M, and N for logic diagrams. Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 10. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 11. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 12. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 13. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data. 14. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 15. 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. 16. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 17. Some steps in the Work Instructions are labeled as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps labeled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. If a step or sub-step is labeled "RC Exempt," then the RC requirement is removed from that step or sub-step. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 08, 2016 777-53A0081 60 of 315 BOEING SERVICE BULLETIN 777-53A0081 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/777-53a0081/file/f354eeb8730e.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. 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