# Boeing Alert Service Bulletin 777-55A0010: Revision 1

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- Document: [Boeing Alert Service Bulletin 777-55A0010](https://openairdocs.org/service-documents/boeing/777-55a0010.md)
- Title as filed: Boeing - Service Bulletin
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### Page 1

Commercial
Airplane
Group
777
Service Bulletin
Number: 777-55A0010 Revision Transmittal SheetDate: October 26, 2000
Revision 1: April 17, 2001
ATA System: 5500
SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper
Additions
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
No more work is necessary on airplanes changed as shown in the initial release of this service bulletin.
REASON FOR REVISION
This revision is sent to do the following:
1. Replace solid rivets with blind rivets in 8 locations on the horizontal stabilizer.
2. Delete instruction to remove the VOR antenna for access.
3. Modify instruction to position rudder and elevator prior to modification.
4. Add instruction to remove additional access panels on vertical and horizontal stabilizers.
5. Add access panel numbers in access / restoration figures.
6. Clarify illustrations with bold lines to show removed panels.
The initial release of this service bulletin was validated at an operator's maintenance facility on an operator's
airplane.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the
Effectivity paragraph for changes.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location
of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY
Original Release: October 26, 2000
Revision 1: April 17, 2001
777-55A0010
Revision Transmittal Page 1 of 1

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(No text on this page.)

### Page 3

Commercial
Airplane
Group
777
Service Bulletin
Number: 777-55A0010 SummaryDate: October 26, 2000
Revision 1: April 17, 2001
ATA System: 5500
SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper
Additions
CONCURRENT REQUIREMENTS
None
BACKGROUND
Accomplishment of this service bulletin will reduce
potential high resistance bond paths between the
rudder / vertical fin and also between the elevator /
horizontal stabilizer. This modification will reduce the
potential effects of a large lightning strike on the
hydraulic and flight control system in the
empennage. A lightning strike to the empennage
with high resistance bond paths could cause
excessive current on hydraulic lines resulting in
pitting at in-line fittings causing pin-hole leaks on
hydraulic lines. Leaks due to lightning strikes could
lead to loss of hydraulic systems in the empennage
which could adversely affect airplane controllability.
In addition, excessive current through the elevator /
rudder graphite composite structure can lead to
melting / vaporization of epoxy and internal
structural damage that will reduce the life of the
parts.
Additional bonding jumpers in the empennage will
provide a lower resistance path during lightning
strikes. Low resistances are important in providing
an alternate path for large currents to be "grounded"
to the airplane structure instead of damaging
hydraulics and / or flight controls.
One operator has told Boeing of two separate
reports of lightning strikes which caused hydraulic
line leaks in Section 48 of a 777-200. High
resistance bond paths between the rudder / vertical
fin and also between the elevator / horizontal
stabilizer were found during certification testing for
the 777-300, and were later found to exist on the
777-200. Airplanes after line number 155 were
delivered with additional bonding jumpers installed
in production. The initial release of this service
bulletin was validated at an operator's maintenance
facility on an operator's airplane.
Accomplishment of this service bulletin will make
sure that high resistance bond paths are reduced
between the rudder / vertical fin and also between
the elevator / horizontal stabilizer to reduce the
damaging effects of airplane lightning strikes.
Boeing Service Related Problem (SRP)
777-SRP-55-0018 is related to this service bulletin.
ACTION (PRR 61847)
Install five bonding jumpers, related ground clips
and fasteners to the rudder / vertical fin. Install
fourteen (seven per side) bonding jumpers, related
ground clips and fasteners to the elevators /
horizontal stabilizers. Revise two fasteners from
titanium to corrosion resistant steel in the vertical fin
tip. Conduct resistance checks of installed bonding
jumpers.
EFFECTIVITY
All 777-200 airplanes and 777-300 airplanes line
numbers 002 through 155.
COMPLIANCE
Boeing recommends that operators do this service
bulletin as manpower, materials, and facilities are
available, but not later than 12 months after the date
on this service bulletin.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are available for
airplanes in warranty as of March 22, 1999. Please
refer to Paragraph 2.B., Industry Support
Information.
777-55A0010
Summary Page 1 of 2

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BOEING SERVICE BULLETIN 777-55A0010
MANPOWER
Total Elapsed Time
Airplanes Man-Hours (Hours)
777-200 66 36
777-300 66 36
MATERIAL INFORMATION
Boeing Supplied Kits/Parts
Refer to Paragraph 2.A., Material - Price and
Availability.
INSTALL FOURTEEN (SEVEN PER SIDE) BONDING
CONDUCT RESISTANCE CHECKS.
ELEVATORS/HORIZONTAL STABILIZERS.
JUMPERS AND RELATED HARDWARE TO
FIN TIP. CONDUCT RESISTANCE CHECKS.
CORROSION RESISTANT STEEL IN THE VERTICAL
REVISE TWO FASTENERS FROM TITANIUM TO
HARDWARE TO THE RUDDER/VERTICAL FIN.
INSTALL FIVE BONDING JUMPERS AND RELATED
V32373
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 Summary Page 2 of 2

### Page 5

Commercial
Airplane
Group
777
Service Bulletin
Number: 777-55A0010
Date: October 26, 2000
Revision 1: April 17, 2001
ATA System: 5500
SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper
Additions
1. PLANNING INFORMATION
A. Effectivity
1. Airplanes
Refer to Service Bulletin Index Document D624W001, Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent
production airplanes. Refer to PRR61847 for data about this change.
Airplane Models:
777-200 777-300
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
AEROFLOT (ARO)
WB336
AIR FRANCE (AFA)
WB311-WB313
ALL NIPPON AIRWAYS (ANA)
WA131-WA137 WA221-WA223 WA231-WA232 WB531-WB533
BRITISH AIRWAYS (BAB)
WA076-WA080 WB001-WB013
CATHAY PACIFIC AIRWAYS (CAT)
WA101-WA104 WB501-WB504
CHINA SOUTHERN AIRLINES (GUN)
WA116-WA119 WB121-WB125
EGYPTAIR (EGP)
WB151-WB153
EMIRATES (EAD)
WA196-WA198 WB101-WB104
JAPAN AIR SYSTEM (JAS)
WA206-WA210
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 Page 1 of 52

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BOEING SERVICE BULLETIN 777-55A0010
JAPAN AIRLINES (JAL)
WA171-WA175 WB591
KOREAN AIR (KAL)
WB131-WB133 WB551
KUWAIT AIRWAYS (KUW)
WB306-WB307
LAUDA AIR (LAL)
WB271
MALAYSIA AIRLINES (MAS)
WB161-WB169
SAUDI ARABIAN AIRLINES (SVA)
WB276-WB286
SINGAPORE AIRLINES (SIA)
WB181-WB186 WB231-WB234
THAI (TII)
WA086-WA093
UNITED AIRLINES (UAL)
WA002-WA017 WB051-WB068
IDENTIFICATION BY VARIABLE NUMBER
WA002-WA017 WA076-WA080 WA086-WA093 WA101-WA104 WA116-WA119 WA131-WA137
WA171-WA175 WA196-WA198 WA206-WA210 WA221-WA223 WA231-WA232 WB001-WB013
WB051-WB068 WB101-WB104 WB121-WB125 WB131-WB133 WB151-WB153 WB161-WB169
WB181-WB186 WB231-WB234 WB271 WB276-WB286 WB306-WB307 WB311-WB313
WB336 WB501-WB504 WB531-WB533 WB551 WB591
2. Spares Affected
None
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 2

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BOEING SERVICE BULLETIN 777-55A0010
B. Concurrent Requirements
None
C. Reason
Accomplishment of this service bulletin will reduce potential high resistance bond paths between the
rudder / vertical fin and also between the elevator / horizontal stabilizer. This modification will reduce
the potential effects of a large lightning strike on the hydraulic and flight control system in the
empennage. A lightning strike to the empennage with high resistance bond paths could cause
excessive current on hydraulic lines resulting in pitting at in-line fittings causing pin-hole leaks on
hydraulic lines. Leaks due to lightning strikes could lead to loss of hydraulic systems in the
empennage which could adversely affect airplane controllability. In addition, excessive current
through the elevator / rudder graphite composite structure can lead to melting / vaporization of epoxy
and internal structural damage that will reduce the life of the parts.
Additional bonding jumpers in the empennage will provide a lower resistance path during lightning
strikes. Low resistances are important in providing an alternate path for large currents to be
"grounded" to the airplane structure instead of damaging hydraulics and / or flight controls.
One operator has told Boeing of two separate reports of lightning strikes which caused hydraulic line
leaks in Section 48 of a 777-200. High resistance bond paths between the rudder / vertical fin and
also between the elevator / horizontal stabilizer were found during certification testing for the
777-300, and were later found to exist on the 777-200. Airplanes after line number 155 were
delivered with additional bonding jumpers installed in production. The initial release of this service
bulletin was validated at an operator's maintenance facility on an operator's airplane.
Accomplishment of this service bulletin will make sure that high resistance bond paths are reduced
between the rudder / vertical fin and also between the elevator / horizontal stabilizer to reduce the
damaging effects of airplane lightning strikes.
Revision 1 is sent to do the following:
1. Replace solid rivets with blind rivets in 8 locations on the horizontal stabilizer.
2. Delete instruction to remove the VOR antenna for access.
3. Modify instruction to position rudder and elevator prior to modification.
4. Add instruction to remove additional access panels on vertical and horizontal stabilizers.
5. Add access panel numbers in access / restoration figures.
6. Clarify illustrations with bold lines to show removed parts.
Boeing Service Related Problem (SRP) 777-SRP-55-0018 is related to this service bulletin.
D. Description
Install five bonding jumpers, related ground clips and fasteners to the rudder / vertical fin. Install
fourteen (seven per side) bonding jumpers, related ground clips and fasteners to the elevators /
horizontal stabilizers. Revise two fasteners from titanium to corrosion resistant steel in the vertical fin
tip. Conduct resistance checks of installed bonding jumpers.
Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this
service bulletin.
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 3

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BOEING SERVICE BULLETIN 777-55A0010
An evaluation form is attached to this service bulletin. Please use this form to tell us what you think
of the quality of this service bulletin.
E. Compliance
Boeing recommends that operators do this service bulletin as manpower, materials, and facilities are
available, but not later than 12 months after the date on this service bulletin.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes
specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and
are FAA approved. This service bulletin and the FAA approval were based on the airplane in its
original Boeing delivery configuration or as modified by other FAA 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.
NOTE: Joint Airworthiness Requirements (JAR) compliance status may be found in the Service
Bulletin Index, Part 1.
G. Manpower
The tables below show an estimate of the man-hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
man-hour data if necessary. The estimate does not include lost time. These are some examples of
lost time:
- Time to adjust to the workplace
- Time to schedule the work
- Time to examine the work
- Time to cure the materials
- Time to make the parts
- Time to find the tools.
BONDING JUMPER ADDITION TO RUDDER / VERTICAL FIN
Task Number of Persons Man-Hours Elapsed Time (Hours)
Open Access 1-2 6 3
Install Bonding
Jumpers and
related
hardware
1-2 5 3
Conduct
Resistance
Checks
1 1 1
Close Access 1-2 6 4
TOTAL FOR EACH AIRPLANE (a) 18 11
(a) Total is for bonding jumper addition to rudder / vertical fin.
October 26, 2000 777-55A0010
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BOEING SERVICE BULLETIN 777-55A0010
BONDING JUMPER ADDITION TO ELEVATORS / HORIZONTAL STABILIZERS
Task Number of Persons Man-Hours Elapsed Time (Hours)
Open Access 2 16 8
Install Bonding
Jumpers and
related
hardware
2 14 7
Conduct
Resistance
Checks
1 2 2
Close Access 2 16 8
TOTAL FOR EACH AIRPLANE (a) 48 25
(a) Total is for bonding jumper addition to elevators / horizontal stabilizers on both
sides of the airplane.
H. Weight and Balance Changes
Change in Weight Change in Moment
Airplane (Pounds) (Pound-Inches)
777-200 +6.2 +15128.0
777-300 +6.2 +16299.8
I. Electrical Load Data
Not changed
J. References
1. Existing Data:
a. Engineering Change Memo PRR 61847
b. 777 Maintenance Manual (AMM) Subjects 55-11-01, 55-15-01, 55-31-01, 55-31-02, 55-35-01,
55-36-01
c. Boeing Standard Overhaul Practices Manual (BSOPM) Subject 20-50-19
d. Boeing Standard Wiring Practices Manual (BSWPM) Subject 20-20-00
2. Data supplied with this service bulletin:
None
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 5

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BOEING SERVICE BULLETIN 777-55A0010
3. Installation Drawings Used in the Preparation of This Service Bulletin:
Drawing Number Title
183W0001 Elevator Installation
173W0012 Rudder Installation
These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
K. Publications Changed
Publication Chapter-Section
777 Maintenance Manual 05-55
L. Interchangeability and Intermixability of Parts
None
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 6

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BOEING SERVICE BULLETIN 777-55A0010
2. MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown
below. If there is a limit in the quantity (QTY) of kits, a supply sequence is given by Spares.
Unit Price thru
Kit Number Name Date QTY Mar 31/01
005W3106-1 Top Kit (a) (a) $2,668.00
(a) Contact Boeing Spares for kit availability data.
The kits are subject to the terms and conditions of the Boeing standard purchase order
acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States
dollars. Terms: Net 30 days.
Send purchase orders and letters about the supply data to the Director of Spares and refer to this
service bulletin number.
B. Industry Support Information
Boeing warranty remedies are available for 777 airplanes in warranty as of March 22, 1999. For
man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing
Product Assurance Contracts. The kits for airplanes in warranty as of that date will be supplied at no
charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin
number and reference the airplane variable number in your purchase order.
C. Parts Necessary For Each Airplane
1. Kits:
To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the
Operator, are necessary for each airplane.
005W3106 TOP KIT - LIGHTNING PROTECTION OF EMPENNAGE FLIGHT
CONTROL SURFACES
-3 -2 -1
Quantity Part Number Name
. . - 005W3106-1 Top Kit
. - 2 005W3106-2 Horizontal Subkit
- . 1 005W3106-3 Vertical Subkit
. 5 . 189W4000-14 Ground Clip
5 4 . 189W4000-32 Ground Clip
2 . . BACB30LH3-5 Bolt
8 12 . BACB30LJ4-4 Bolt
1 1 . BACB30LJ4U7 Bolt
. 5 . BACB30NX6K4X Bolt
2 . . BACB30VT6K3 Bolt
. 5 . BACC30BH6 Collar
October 26, 2000 777-55A0010
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BOEING SERVICE BULLETIN 777-55A0010
(Continued)
005W3106 TOP KIT - LIGHTNING PROTECTION OF EMPENNAGE FLIGHT
CONTROL SURFACES
-3 -2 -1
Quantity Part Number Name
2 . . BACC30BP6 Collar
. 2 . BACJ40E20-20 Jumper
. 1 . BACJ40E20-24 Jumper
. 1 . BACJ40E20-26 Jumper
1 1 . BACJ40E20-30 Jumper
2 . . BACJ40E20-36 Jumper
1 . . BACJ40E20-38 Jumper
1 . . BACJ40E20-40 Jumper
. 1 . BACJ40E20-44 Jumper
. 1 . BACJ40E20-48 Jumper
8 12 . BACN10JC4CD Nut
1 1 . BACN10JC4CM Nut
2 . . BACR15BB6D8C Rivet
1 5 . BACR15BB7AD4C Rivet
3 3 . BACR15BB7AD5C Rivet
. 3 . BACR15BB7AD8C Rivet
. 4 . BACR15FR6E2R Rivet
4 7 . BACR15FT6KE6C Rivet
1 1 . BACW10BP4APU Washer
8 12 . BACW10BP4DP Washer
1 1 . 189W4000U31 Ground Clip
NOTE: The kit has more parts than are necessary for installation. Discard parts that are not used
or keep the parts for spares.
2. Parts and Materials Supplied by the Operator:
QTY Part Number Name
24 oz BMS 5-95 Sealant (a)
(a) See the Qualified Products List at the end of the Boeing Material
Specification (BMS) for supplier data.
D. Parts Necessary to Change Spares
None
E. Existing Parts Accountability
None
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 8

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BOEING SERVICE BULLETIN 777-55A0010
F. Special Tooling - Price and Availability
None
G. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But,
maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be
necessary. Examine operator tool supply to make sure all necessary tools are available.
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 9

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BOEING SERVICE BULLETIN 777-55A0010
BLANK PAGE
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 10

### Page 15

BOEING SERVICE BULLETIN 777-55A0010
3. ACCOMPLISHMENT INSTRUCTIONS
GENERAL NOTES
1. The paragraphs identified with a letter give the general work instructions and the necessary tests.
The instructions identified with numbers on the figures give the recommended sequence of steps.
2. Unless shown differently, these dimensions and tolerances are used:
- Linear dimensions are in inches
- Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03
inch
- Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
- Angular tolerance is plus or minus 2 degrees
- Hole dimensions for standard solid rivets are given in 777 Structural Repair Manual, Chapter 51
- Torque limits to tighten nuts and bolts are given in 777 Structural Repair Manual, Chapter 51.
3. Alternative fasteners are given in 777 Structural Repair Manual, Chapter 51.
4. As an alternative to the Boeing specified Airplane Maintenance Manuals (AMM's), operator's
equivalent procedures can be used.
5. Obey all of the warnings and cautions given in the specified manual sections.
WORK INSTRUCTIONS
A. Set rudder and elevator in appropriate position for maintenance being performed. No specific
position is needed for access.
B. Remove Hydraulic power to rudder and elevators.
C. Obtain access for bonding jumper installation per Figure 1 (rudder / vertical fin), Figure 2 and
Figure 3 (elevator / horizontal stabilizer).
D. Install bonding jumpers and conduct resistance checks per Figure 4 (rudder / vertical fin), Figure 5
and Figure 6 (elevator / horizontal stabilizer).
E. Seal bonding jumpers per Figure 7 (rudder / vertical fin), Figure 8 and Figure 9 (elevator /
horizontal stabilizer).
F. Restore access per Figure 1 (rudder / vertical fin), Figure 2 and Figure 3 (elevator / horizontal
stabilizer).
G. Put the airplane back to a serviceable condition.
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 11

### Page 16

BOEING SERVICE BULLETIN 777-55A0010
FIGURE TABLE OF CONTENTS
Title Page
FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN . . . ........... 1 3
FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL
STABILIZER - OUTBOARD END.................................. 1 6
FIGURE 3. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL
STABILIZER - INBOARD END. ................................... 1 9
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE
CHECKS ON THE RUDDER / VERTICAL FIN ....................... 2 1
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE
CHECKS ON THE ELEVATOR / HORIZONTAL STABILIZER -
OUTBOARD END ............................................. 2 9
FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE
CHECKS ON THE ELEVATOR / HORIZONTAL STABILIZER -
INBOARD END ............................................... 3 9
FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER /
VERTICAL FIN . ............................................... 4 3
FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END ..................... 4 7
FIGURE 9. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR /
HORIZONTAL STABILIZER - INBOARD END ....................... 5 1
October 26, 2000 777-55A0010
Revision 1: April 17, 2001 12

### Page 17

BOEING SERVICE BULLETIN 777-55A0010
94
121
10
2 11
3
A
SEE A
BSEE
FWD
DIVERTER
LIGHTNING
V32390
FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN
October 26, 2000 SHEET 1 OF 3 777-55A0010
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### Page 18

BOEING SERVICE BULLETIN 777-55A0010
76
85
B
FWD
V32391
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for the airplane.
ACCESS
STEP TASK NAME REFERENCES QTY NOTES
WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE RUDDER WHEN YOU
WORK ON OR NEAR IT. THE RUDDER MOVES QUICKLY AND WITH FORCE. IF THE
RUDDER MOVES WHEN PERSONS ARE NEAR IT, YOU CAN CAUSE INJURY TO
THEM.
WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE VERTICAL FIN.
FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP PERSONS AWAY
FROM THE AREA BELOW THE VERTICAL FIN. PARTS COULD ACCIDENTALLY FALL
AND CAUSE INJURY TO PERSONS.
1 Remove /
Discard
Bolt - 2 Removed titanium fasteners will
be replaced with corrosion
resistant steel fasteners.
2 Remove /
Keep
Vertical Stabilizer Tip
Fairing
777 AMM 55-31-01 1 -
3 Remove /
Keep
Aft Panel - 2 Remove / keep 179W3310-1 Aft
Panel (left side) and
179W3310-2 Aft Panel (right
side - not shown).
FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN
October 26, 2000 SHEET 2 OF 3 777-55A0010
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BOEING SERVICE BULLETIN 777-55A0010
(Continued)
ACCESS
4 Remove /
Keep
Trailing Edge Seal 777 AMM 55-36-01 2 Remove / keep left side trailing
edge seal (panel number
324WL) and right side trailing
edge seal (panel number
324WR - not shown).
5 Remove /
Keep
Leading Edge Panel 777 AMM 55-35-01 1 Remove / keep leading edge
panel number 321F.
6 Remove /
Keep
Auxiliary Spar to
Front Spar Panel
- 1 Remove / keep 177W300-45F
Auxiliary Spar to Front Spar
Panel (left side). Panel number
322HL.
RESTORATION
STEP TASK NAME REFERENCES QTY NOTES
WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE RUDDER WHEN YOU
WORK ON OR NEAR IT. THE RUDDER MOVES QUICKLY AND WITH FORCE. IF THE
RUDDER MOVES WHEN PERSONS ARE NEAR IT, YOU CAN CAUSE INJURY TO
THEM.
WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE VERTICAL FIN.
FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP PERSONS AWAY
FROM THE AREA BELOW THE VERTICAL FIN. PARTS COULD ACCIDENTALLY FALL
AND CAUSE INJURY TO PERSONS.
7 Install /
Kept
Auxiliary Spar to
Front Spar Panel
- 1 Install / kept 177W300-45F
Auxiliary Spar to Front Spar
Panel (left side). Panel number
322HL.
8 Install /
Kept
Leading Edge Panel 777 AMM 55-35-01 1 Install / kept leading edge panel
number 321F.
9 Install /
Kept
Trailing Edge Seal 777 AMM 55-36-01 2 Install / kept left side trailing
edge seal (panel number
324WL) and right side trailing
edge seal (panel number
324WR - not shown).
10 Install /
Kept
Aft Panel - 2 Install / kept 179W3310-1 Aft
Panel (left side) and
179W3310-2 Aft Panel (right
side).
11 Install /
Kept
Vertical Stabilizer Tip
Fairing
777 AMM 55-31-01 1 -
12 Install Bolt 777 AMM 55-31-02 2 Install two BACB30LH3-5 Bolts
per 777 AMM 55-31-02 Section
3.G.(2)(b).
FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN
October 26, 2000 SHEET 3 OF 3 777-55A0010
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BOEING SERVICE BULLETIN 777-55A0010
LEFT SIDE SHOWN
RIGHT SIDE OPPOSITE
FWD 74
83
10
SEE A
A
65
1
92
V32428
FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 1 OF 3 777-55A0010
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BOEING SERVICE BULLETIN 777-55A0010
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.
ACCESS
STEP TASK NAME REFERENCES QTY NOTES
WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER
WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY
AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU
CAN CAUSE INJURY TO THEM.
WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL
STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP
PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS
COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.
1 Remove /
Keep
Lower Panel - 1 Remove / keep 189W4000-21
Lower Panel (panel number
355LB - left side), 189W4000-22
Lower Panel (panel number
345LB - right side).
2 Remove /
Keep
Forward Box Lower
Panel
- 1 Remove / keep forward box
lower panel number 333FB (left
side) and 343FB (right side).
3 Remove /
Keep
Leading Edge
Outboard Panel
777 AMM 55-15-01 1 Panel number 332EL (left side).
Panel number 342ER (right
side).
4 Remove /
Keep
Trailing Edge Seal - 2 Remove / keep 185W1102-41
(top left), -42 (top right) Trailing
Edge Seal and 185W1202-57
(bottom left), -58 (bottom right)
Trailing Edge Seal.
5 Remove /
Keep
Horizontal Stabilizer
Tip Fairing
777 AMM 55-11-01 1 -
RESTORATION
STEP TASK NAME REFERENCES QTY NOTES
WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER
WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY
AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU
CAN CAUSE INJURY TO THEM.
WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL
STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP
PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS
COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.
6 Install /
Kept
Horizontal Stabilizer
Tip Fairing
777 AMM 55-11-01 1 (a)
7 Install /
Kept
Trailing Edge Seal - 2 Install / kept 185W1102-41 (top
left), -42 (top right) Trailing Edge
Seal and 185W1202-57 (bottom
left), -58 (bottom right) Trailing
Edge Seal.
FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 2 OF 3 777-55A0010
Revision 1: April 17, 2001 17

### Page 22

BOEING SERVICE BULLETIN 777-55A0010
(Continued)
RESTORATION
8 Install /
Kept
Leading Edge
Outboard Panel
777 AMM 55-15-01 1 Panel number 332EL (left side).
Panel number 342ER (right
side).
9 Install /
Kept
Forward Box Lower
Panel
- 1 Install / kept forward box lower
panel number 333FB (left side)
and 343FB (right side).
10 Install /
Kept
Lower Panel - 1 Install / kept 189W4000-21
Lower Panel (panel number
335LB - left side), 189W4000-22
Lower Panel (panel number
345LB - right side).
(a) One bonding jumper attaches to the fixed structure of the horizontal stabilizer and to the structure of
the removed tip fairing. With the tip fairing rotated on to the upper surface of the horizontal stabilizer,
connect this bonding jumper, measure resistance, and add required sealing. Rotate the tip fairing into
the installed position and complete installation per 777 AMM 55-11-01. Two bonding jumpers connect to
the bracket on the elevator front spar. Connect these bonding jumpers, measure resistance, and add
required sealing.
FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 3 OF 3 777-55A0010
Revision 1: April 17, 2001 18

### Page 23

BOEING SERVICE BULLETIN 777-55A0010
5243 61
V32877
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.
ACCESS
STEP TASK NAME REFERENCES QTY NOTES
WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER
WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY
AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU
CAN CAUSE INJURY TO THEM.
WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL
STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP
PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS
COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.
1 Remove /
Keep
Straklet Panel 777 AMM 55-15-01 1 Panel number 332BL (left side).
Panel number 342BR (right
side).
2 Remove /
Keep
Forward Box Lower
Panel
- 1 Panel number 333BB (left side).
Panel number 343BB (right
side).
3 Remove /
Keep
Inboard Lower Panel 777 AMM 55-10-01 1 Panel number 333AB (left side).
Panel number 343AB (right
side).
FIGURE 3. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - INBOARD END
October 26, 2000 SHEET 1 OF 2 777-55A0010
Revision 1: April 17, 2001 19

### Page 24

BOEING SERVICE BULLETIN 777-55A0010
RESTORATION
STEP TASK NAME REFERENCES QTY NOTES
WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER
WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY
AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU
CAN CAUSE INJURY TO THEM.
WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL
STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP
PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS
COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.
4 Install /
Kept
Inboard Lower Panel 777 AMM 55-10-01 1 Panel number 333AB (left side).
Panel number 343AB (right
side).
5 Install /
Kept
Forward Box Lower
Panel
- 1 Panel number 333BB (left side).
Panel number 343BB (right
side).
6 Install /
Kept
Straklet Panel 777 AMM 55-15-01 1 Panel number 332BL (left side).
Panel number 342BR (right
side).
FIGURE 3. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - INBOARD END
October 26, 2000 SHEET 2 OF 2 777-55A0010
Revision 1: April 17, 2001 20

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BOEING SERVICE BULLETIN 777-55A0010
FWD
SEE A
A
DSEE
BSEE
CSEE
C
C
A
A
B
B
OMITTED FOR CLARITY.
SPAR
AUXILIARY
NOTE: RIGHT SIDE CHORDS OF THE AUXILIARY
SPAR AND CLOSURE RIB ASSEMBLY ARE
CLOSURE RIB
ASSEMBLY
V32439
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 1 OF 8 777-55A0010
Revision 1: April 17, 2001 21

### Page 26

BOEING SERVICE BULLETIN 777-55A0010
1 1
FWD
A−A
V32910
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 2 OF 8 777-55A0010
Revision 1: April 17, 2001 22

### Page 27

BOEING SERVICE BULLETIN 777-55A0010
1
1
C−C
B−B
UP
UP
V32931
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 3 OF 8 777-55A0010
Revision 1: April 17, 2001 23

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BOEING SERVICE BULLETIN 777-55A0010
42
42
4
3C
2
B
C
42
4
87
4
5 6
UP
FWD
2
3B
3
2
A3
A
FWD
UPD−D
D
D
V33111
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 4 OF 8 777-55A0010
Revision 1: April 17, 2001 24

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BOEING SERVICE BULLETIN 777-55A0010
10 10
1514D12
1311
9
2120 1918
1716
D FWD
UP
BRACKET
0.43
0.43
CLIP
INSTALL NEW
E−E
REMOVE EXISTING
CLIP
RUDDER
FRONT
NEW GROUND
CLIP
SPAR
E
E
V33175
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 5 OF 8 777-55A0010
Revision 1: April 17, 2001 25

### Page 30

BOEING SERVICE BULLETIN 777-55A0010
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for the airplane.
The parts necessary to do the steps in this figure are available in Boeing kit 005W3106-1.
NOTE: IF A BONDING JUMPER HAS ALREADY BEEN INSTALLED, REMOVAL AND
RE-INSTALLATION OF A NEW BONDING JUMPER IS NOT REQUIRED EXCEPT FOR THE
ONE BONDING JUMPER WHICH IS SPECIFIED FOR REMOVAL IN THIS FIGURE.
STEP TASK NAME PART NUMBER QTY NOTES
CAUTION: MAKE SURE THAT SURFACE PREPARATION IS ACCOMPLISHED ON AIRPLANE
STRUCTURE, BRACKET, GROUND CLIPS, AND JUMPERS PER THESE
ACCOMPLISHMENT INSTRUCTIONS IN ORDER TO PREPARE AN ACCEPTABLE
ELECTRICAL BOND.
1 Remove /
Discard
Fasteners - 8 Remove / discard existing
fasteners in locations shown.
2 Install Ground Clip 189W4000-32 5 (a)
3 Install Fasteners - 8 Install per Fastener
Identification Table.
4 Measure Resistance - - (b)
5 Install Jumper BACJ40E20-38 1 (c)(d)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 (e)
6 Measure Resistance - - (f)
7 Install Jumper BACJ40E20-30 1 (c)(d)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 (e)
8 Measure Resistance - - (f)
9 Remove /
Discard
Ground Clip - 1 Remove / discard existing
ground clip and attaching
jumper. Remove / discard all
bolts, washers, and nuts which
attach to this jumper on both
ends.
Jumper - 1
Bolt - 2
Washer - 2
Nut - 2
10 Install Rivet BACR15BB7AD4C 1 (g)
11 Install Ground Clip 189W4000U31 1 (a)
12 Install Fasteners - 3 Install per Fastener
Identification Table.
13 Measure Resistance - - (b)
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 6 OF 8 777-55A0010
Revision 1: April 17, 2001 26

### Page 31

BOEING SERVICE BULLETIN 777-55A0010
(Continued)
STEP TASK NAME PART NUMBER QTY NOTES
14 Install Jumper BACJ40E20-36 1 (c)(h)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 (e)
15 Measure Resistance - - (f)
16 Install Jumper BACJ40E20-40 1 (c)(i)
Bolt BACB30LJ4-4 1 -
Washer BACW10BP4DP 1 Install between nut and ground
clip.
Nut BACN10JC4CD 1 (e)
17 Measure Resistance - - (f)
18 Install Jumper BACJ40E20-36 1 (c)(j)
Bolt BACB30LJ4-4 1 -
Washer BACW10BP4DP 1 Install between nut and ground
clip.
Nut BACN10JC4CD 1 (e)
19 Measure Resistance - - (f)
20 Install Bolt BACB30LJ4U7 1 Remove protective finish and
clean to bare metal surface of
173W3200-11 per Note (a). Bolt
is used to attach
BACJ40E20-40 Jumper and
BACJ40E20-36 Jumper to
173W3200-11 Bracket.
Washer BACW10BP4APU 1 Install between nut and existing
173W3200-11 Bracket.
Nut BACN10JC4CM 1 (e)
21 Measure Resistance - - (k)
(a) The protective finish on the airplane structure must be removed in the area where the clip is attached.
The protective finish on the ground clip must be removed from the flange that is in contact with the
airplane structure. The protective finish on the ground clip must be removed from the surface of the clip
where the jumper is attached. Remove the protective finish and clean to bare metal surfaces per
BSWPM 20-20-00, Section 2, Cleaning Procedure 1, 2, or 3.
(b) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 0.5 milliohms (0.0005
ohms) maximum between each ground clip installed and the airplane structure.
(c) The surface of the jumper that is in contact with the ground clip must be clean before installation.
Clean the jumper per BSWPM 20-20-00, Section 2, Cleaning Procedure 5.
(d) Install jumper between 189W4000-32 Ground Clips with fasteners specified.
(e) Torque to 65 - 70 inch-pounds.
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 7 OF 8 777-55A0010
Revision 1: April 17, 2001 27

### Page 32

BOEING SERVICE BULLETIN 777-55A0010
(Continued)
STEP TASK NAME PART NUMBER QTY NOTES
(f) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001
ohms) maximum between each ground clip installed and each jumper installed.
(g) Rivet is used to fill one existing hole. Optional rivet is BACR15BB7D4C.
(h) Install jumper between 189W4000-32 Ground Clip and 189W4000U31 Ground Clip (center flange)
with fasteners specified.
(i) Install jumper on 189W4000U31 Ground Clip (upper flange) with fasteners specified.
(j) Install jumper on 189W4000U31 Ground Clip (lower flange) with fasteners specified.
(k) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001
ohms) maximum between 173W3200-11 Bracket and each jumper attached to 173W3200-11 Bracket.
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the
figure. A number in the lower right corner gives the grip length of the fastener. If grip length shown is not
available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.
EXAMPLE OF FASTENER SYMBOL
FASTENER
LENGTH/GRIP
FASTENER
D6 F
7
LETTER CODE
DIAMETER
(OPTIONAL)
HEAD LOCATION
N = NEAR SIDE
F = FAR SIDE
(OPTIONAL)
(OPTIONAL)
A51639
CODE NAME PART NUMBER HOLE DIA NOTES
A Rivet BACR15FT6KE6C - -
B Bolt BACB30VT6K3 - -
Collar BACC30BP6 - -
C Rivet BACR15BB6D8C - -
D Rivet BACR15BB7AD5C - Optional rivet is
BACR15BB7D5C.
FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /
VERTICAL FIN
October 26, 2000 SHEET 8 OF 8 777-55A0010
Revision 1: April 17, 2001 28

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BOEING SERVICE BULLETIN 777-55A0010
RIGHT SIDE OPPOSITE
LEFT SIDE SHOWN
CSEE
ESEE
A
DSEE
BSEE
SEE A
INSTALLED FOR CLARITY
TIP FAIRING IS SHOWN
NOTE: HORIZONTAL STABILIZERFWD
TIP
FAIRING
B
B C
C
A
A
V32544
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 1 OF 10 777-55A0010
Revision 1: April 17, 2001 29

### Page 34

BOEING SERVICE BULLETIN 777-55A0010
11
1
FWD B−B
INBD
A−A
V33215
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 2 OF 10 777-55A0010
Revision 1: April 17, 2001 30

### Page 35

BOEING SERVICE BULLETIN 777-55A0010
1
C−CINBD
V32759
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 3 OF 10 777-55A0010
Revision 1: April 17, 2001 31

### Page 36

BOEING SERVICE BULLETIN 777-55A0010
3
B
5
B 4 2
7
5
A4
6
C
8 9
53
4 C
25
4D
FWD
FWD
D
D
E
E
V33238
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 4 OF 10 777-55A0010
Revision 1: April 17, 2001 32

### Page 37

BOEING SERVICE BULLETIN 777-55A0010
5
5
3
3
2221
4 B
D
0.43 (TYPICAL)
0.34
FWD E−E
3.0
D−D
FWD
V37054
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 5 OF 10 777-55A0010
Revision 1: April 17, 2001 33

### Page 38

BOEING SERVICE BULLETIN 777-55A0010
FWD
12 14
13
1110
2423
1817
19 20
16
F
E
15
2
E 4
3.84
0.43
(TYPICAL)
0.43 (TYPICAL)
0.34
F−F G−G
SPAR
FRONT
ELEVATOR
BRACKET
REMOVE EXISTING CLIP
INSTALL NEW CLIP
NEW GROUND CLIP
(VIEW LOOKING UP)
FWD
F
F
G
G
V33266
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 6 OF 10 777-55A0010
Revision 1: April 17, 2001 34

### Page 39

BOEING SERVICE BULLETIN 777-55A0010
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.
The parts necessary to do the steps in this figure are available in Boeing kit 005W3106-1.
NOTE: IF A BONDING JUMPER HAS ALREADY BEEN INSTALLED, REMOVAL AND
RE-INSTALLATION OF A NEW BONDING JUMPER IS NOT REQUIRED EXCEPT FOR THE
ONE BONDING JUMPER WHICH IS SPECIFIED FOR REMOVAL IN THIS FIGURE.
STEP TASK NAME PART NUMBER QTY NOTES
CAUTION: MAKE SURE THAT SURFACE PREPARATION IS ACCOMPLISHED ON AIRPLANE
STRUCTURE, BRACKET, GROUND CLIPS, AND JUMPERS PER THESE
ACCOMPLISHMENT INSTRUCTIONS IN ORDER TO PREPARE AN ACCEPTABLE
ELECTRICAL BOND.
1 Remove /
Discard
Fasteners - 10 Remove / discard existing
fasteners in locations shown.
2 Install Ground Clip 189W4000-32 3 (a)
3 Install Ground Clip 189W4000-14 4 (a)
4 Install Fasteners - 14 Install per Fastener
Identification table.
5 Measure Resistance - - (b)
6 Install Jumper BACJ40E20-24 1 (c)(d)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 (e)
7 Measure Resistance - - (f)
8 Install Jumper BACJ40E20-20 1 (c)(d)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 (e)
9 Measure Resistance - - (f)
10 Remove /
Discard
Ground Clip - 1 Remove / discard existing
ground clip and attaching
jumper. Remove / discard all
bolts, washers, and nuts which
attach to this jumper on both
ends.
Jumper - 1
Bolt - 2
Washer - 2
Nut - 2
11 Install Rivet BACR15BB7AD4C 1 (g)
12 Install Ground Clip 189W4000U31 1 (a)
13 Install Fasteners - 3 Install per Fastener
Identification table.
14 Measure Resistance - - (b)
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 7 OF 10 777-55A0010
Revision 1: April 17, 2001 35

### Page 40

BOEING SERVICE BULLETIN 777-55A0010
(Continued)
STEP TASK NAME PART NUMBER QTY NOTES
15 Install Jumper BACJ40E20-20 1 (c)(h)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 (e)
16 Measure Resistance - - (f)
17 Install Jumper BACJ40E20-30 1 (c)(i)
Bolt BACB30LJ4-4 1 -
Washer BACW10BP4DP 1 Install between nut and ground
clip.
Nut BACN10JC4CD 1 (e)
18 Measure Resistance - - (f)
19 Install Jumper BACJ40E20-26 1 (c)(j)
Bolt BACB30LJ4-4 1 -
Washer BACW10BP4DP 1 Install between nut and ground
clip.
Nut BACN10JC4CD 1 (e)
20 Measure Resistance - - (f)
CAUTION: BE CAREFUL WHEN YOU MOVE THE HORIZONTAL STABILIZER TIP FAIRING NEAR
THE HORIZONTAL STABILIZER. INSTALL PROTECTIVE COVERS OVER THE END OF
THE HORIZONTAL STABILIZER.
21 Install Jumper BACJ40E20-48 1 (c)(d)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 (e)
NOTE: JUST PRIOR TO INSTALLATION OF THE JUMPER AND FASTENERS IN STEP 21
AND FASTENERS IN STEP 23 THE HORIZONTAL STABILIZER TIP FAIRING CAN BE
TEMPORARILY PLACED OVER THE TOP OF THE HORIZONTAL STABILIZER AND
ROTATED AROUND FOR INSTALLATION DURING RESTORATION OF ACCESS.
22 Measure Resistance - - (f)
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 8 OF 10 777-55A0010
Revision 1: April 17, 2001 36

### Page 41

BOEING SERVICE BULLETIN 777-55A0010
(Continued)
STEP TASK NAME PART NUMBER QTY NOTES
23 Install Bolt BACB30LJ4U7 1 Remove the protective finish
and clean to bare metal surface
of 183W8101-3 Bracket per
Note (a) in the area where the
bolt, washer, and nut is
attached. Bolt is used to attach
BACJ40E20-30 Jumper and
BACJ40E20-26 Jumper to
183W8101-3 Bracket.
Washer BACW10BP4APU 1 Install between nut and existing
183W8101-3 Bracket.
Nut BACN10JC4CM 1 (e)
24 Measure Resistance - - (k)
(a) The protective finish on the airplane structure must be removed in the area where the clip is attached.
The protective finish on the ground clip must be removed from the flange that is in contact with the
airplane structure. The protective finish on the ground clip must be removed from the surface of the clip
where the jumper is attached. Remove the protective finish and clean to bare metal surfaces per
BSWPM 20-20-00, Section 2, Cleaning Procedure 1, 2, or 3.
(b) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 0.5 milliohms (0.0005
ohms) maximum between each ground clip installed and the airplane structure.
(c) The surface of the jumper that is in contact with the ground clip must be clean before installation.
Clean the jumper per BSWPM 20-20-00, Section 2, Cleaning Procedure 5.
(d) Install jumper between ground clips with fasteners specified.
(e) Torque to 65 - 70 inch-pounds.
(f) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001
ohms) maximum between each ground clip installed and each jumper installed.
(g) Rivet is used to fill one existing hole. Optional rivet is BACR15BB7D4C.
(h) Install jumper between 189W4000-32 Ground Clip and 189W4000U31 Ground Clip (center flange)
with fasteners specified.
(i) Install between 189W4000U31 Ground Clip (outboard flange) with fasteners specified.
(j) Install between 189W4000U31 Ground Clip (inboard flange) with fasteners specified.
(k) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001
ohms) maximum between 183W8103-3 Bracket and each jumper attached to 183W8103-3 Bracket.
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 9 OF 10 777-55A0010
Revision 1: April 17, 2001 37

### Page 42

BOEING SERVICE BULLETIN 777-55A0010
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the
figure. A number in the lower right corner gives the grip length of the fastener. If grip length shown is not
available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.
EXAMPLE OF FASTENER SYMBOL
FASTENER
LENGTH/GRIP
FASTENER
D6 F
7
LETTER CODE
DIAMETER
(OPTIONAL)
HEAD LOCATION
N = NEAR SIDE
F = FAR SIDE
(OPTIONAL)
(OPTIONAL)
A51639
CODE NAME PART NUMBER HOLE DIA NOTES
A Rivet BACR15FT6KE6C - -
B Bolt BACB30NX6K4X - -
Collar BACC30BH6 - -
C Rivet BACR15BB7AD8C - Optional rivet is
BACR15BB7D8C.
D Rivet BACR15FR6E2R - -
E Rivet BACR15FR6E2R - -
F Rivet BACR15BB7AD5C - Optional rivet is
BACR15BB7D5C.
FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - OUTBOARD END
October 26, 2000 SHEET 10 OF 10 777-55A0010
Revision 1: April 17, 2001 38

### Page 43

BOEING SERVICE BULLETIN 777-55A0010
SEE A
BSEE
CSEE
A
FWD
A
A
V36958
FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - INBOARD END
October 26, 2000 SHEET 1 OF 4 777-55A0010
Revision 1: April 17, 2001 39

### Page 44

BOEING SERVICE BULLETIN 777-55A0010
FWD
1
B
1
A−AFWD
SPAR RIB NO. 3
V36974
FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - INBOARD END
October 26, 2000 SHEET 2 OF 4 777-55A0010
Revision 1: April 17, 2001 40

### Page 45

BOEING SERVICE BULLETIN 777-55A0010
FWD
76
A4
52
A4
3 5
C
V36986
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.
The parts necessary to do the steps in this figure are available in Boeing kit 005W3106-1.
STEP TASK NAME PART NUMBER QTY NOTES
CAUTION: MAKE SURE THAT SURFACE PREPARATION IS ACCOMPLISHED ON AIRPLANE
STRUCTURE, BRACKET, GROUND CLIPS, AND JUMPERS PER THESE
ACCOMPLISHMENT INSTRUCTIONS IN ORDER TO PREPARE AN ACCEPTABLE
ELECTRICAL BOND.
1 Remove /
Discard
Fasteners - 5 Remove / discard existing
fasteners in locations shown.
2 Install Ground Clip 189W4000-14 1 (a)
3 Install Ground Clip 189W4000-32 1 (a)
4 Install Fasteners - 5 Install per Fastener
Identification Table.
FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - INBOARD END
October 26, 2000 SHEET 3 OF 4 777-55A0010
Revision 1: April 17, 2001 41

### Page 46

BOEING SERVICE BULLETIN 777-55A0010
(Continued)
STEP TASK NAME PART NUMBER QTY NOTES
5 Measure Resistance - - (b)
6 Install Jumper BACJ40E20-44 1 (c)(d)
Bolt BACB30LJ4-4 2 -
Washer BACW10BP4DP 2 Install between nut and ground
clip.
Nut BACN10JC4CD 2 Torque to 65 - 70 inch-pounds.
7 Measure Resistance - - (e)
(a) The protective finish on the airplane structure must be removed in the area where the clip is attached.
The protective finish on the ground clip must be removed from the flange that is in contact with the
airplane structure. The protective finish on the ground clip must be removed from the surface of the clip
where the jumper is attached. Remove the protective finish and clean to bare metal surfaces per
BSWPM 20-20-00, Section 2, Cleaning Procedure 1, 2, or 3.
(b) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 0.5 milliohms (0.0005
ohms) maximum between each ground clip installed and the airplane structure.
(c) The surface of the jumper that is in contact with the ground clip must be clean before installation.
Clean the jumper per BSWPM 20-20-00, Section 2, Cleaning Procedure 5.
(d) Install jumper between ground clips with fasteners specified.
(e) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001
ohms) maximum between each ground clip installed and each jumper installed.
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the
figure. A number in the lower right corner gives the grip length of the fastener. If grip length shown is not
available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.
EXAMPLE OF FASTENER SYMBOL
FASTENER
LENGTH/GRIP
FASTENER
D6 F
7
LETTER CODE
DIAMETER
(OPTIONAL)
HEAD LOCATION
N = NEAR SIDE
F = FAR SIDE
(OPTIONAL)
(OPTIONAL)
A51639
CODE NAME PART NUMBER HOLE DIA NOTES
A Rivet BACR15FT6KE6C - -
FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /
HORIZONTAL STABILIZER - INBOARD END
October 26, 2000 SHEET 4 OF 4 777-55A0010
Revision 1: April 17, 2001 42

### Page 47

BOEING SERVICE BULLETIN 777-55A0010
FWD
CSEE
ASEE
BSEE
OMITTED FOR CLARITY.
AUXILIARY
SPAR
NOTE: RIGHT SIDE CHORDS OF THE AUXILIARY
SPAR AND CLOSURE RIB ASSEMBLY ARE
CLOSURE RIB
ASSEMBLY
V32831
FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN
October 26, 2000 SHEET 1 OF 4 777-55A0010
Revision 1: April 17, 2001 43

### Page 48

BOEING SERVICE BULLETIN 777-55A0010
1 2
21 UP
FWD
1 2
1 2
B
A
FWD
UP
V32838
FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN
October 26, 2000 SHEET 2 OF 4 777-55A0010
Revision 1: April 17, 2001 44

### Page 49

BOEING SERVICE BULLETIN 777-55A0010
C FWD
UP
21
21
RUDDER
FRONT
SPAR
BRACKET
V33275
FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN
October 26, 2000 SHEET 3 OF 4 777-55A0010
Revision 1: April 17, 2001 45

### Page 50

BOEING SERVICE BULLETIN 777-55A0010
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for the airplane.
STEP TASK NAME REFERENCES QTY NOTES
1 Apply Sealant BSOPM 20-50-19 - (a)
2 Apply Sealant BSOPM 20-50-19 - (b)
(a) Apply protective coating to bare surfaces of the airplane structure and the ground clips to match the
surrounding surface. Filet seal around the periphery of the ground clips with BMS 5-95 Sealant per
BSOPM 20-50-19. Encapsulate both ends of all fasteners which attach the ground clips to the airplane
structure with BMS 5-95 Sealant.
(b) Fillet seal around edge of jumper and around edge of ground clip where the jumper is attached.
Encapsulate both ends of the bolt which attach the jumper. Make sure to fully cover the bolt head, nut,
washer, and threaded end of the bolt with BMS 5-95 Sealant per BSOPM 20-50-19.
FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN
October 26, 2000 SHEET 4 OF 4 777-55A0010
Revision 1: April 17, 2001 46

### Page 51

BOEING SERVICE BULLETIN 777-55A0010
LEFT SIDE SHOWN
RIGHT SIDE OPPOSITE
ASEE
CSEE
BSEE
DSEE
FWD
NOTE: HORIZONTAL STABILIZER
TIP FAIRING IS SHOWN
INSTALLED FOR CLARITY
FAIRING
TIP
V32845
FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -
OUTBOARD END
October 26, 2000 SHEET 1 OF 4 777-55A0010
Revision 1: April 17, 2001 47

### Page 52

BOEING SERVICE BULLETIN 777-55A0010
B
A
21
21 21
21
FWD
FWD
V33276
FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -
OUTBOARD END
October 26, 2000 SHEET 2 OF 4 777-55A0010
Revision 1: April 17, 2001 48

### Page 53

BOEING SERVICE BULLETIN 777-55A0010
FWD
C
21
21
21
21
21
21
D
FWD
BRACKET
(VIEW LOOKING UP)
V33277
FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -
OUTBOARD END
October 26, 2000 SHEET 3 OF 4 777-55A0010
Revision 1: April 17, 2001 49

### Page 54

BOEING SERVICE BULLETIN 777-55A0010
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for the airplane.
STEP TASK NAME REFERENCES QTY NOTES
1 Apply Sealant BSOPM 20-50-19 - (a)
2 Apply Sealant BSOPM 20-50-19 - (b)
(a) Apply protective coating to bare surfaces of the airplane structure and the ground clips to match the
surrounding surface. Filet seal around the periphery of the ground clips with BMS 5-95 Sealant per
BSOPM 20-50-19. Encapsulate both ends of all fasteners which attach the ground clips to the airplane
structure with BMS 5-95 Sealant.
(b) Fillet seal around edge of jumper and around edge of ground clip where the jumper is attached.
Encapsulate both ends of the bolt which attach the jumper. Make sure to fully cover the bolt head, nut,
washer, and threaded end of the bolt with BMS 5-95 Sealant per BSOPM 20-50-19.
FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -
OUTBOARD END
October 26, 2000 SHEET 4 OF 4 777-55A0010
Revision 1: April 17, 2001 50

### Page 55

BOEING SERVICE BULLETIN 777-55A0010
FWD
1 2
1 2
A
ASEE
FWD
V37064
FIGURE 9. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -
INBOARD END
October 26, 2000 SHEET 1 OF 2 777-55A0010
Revision 1: April 17, 2001 51

### Page 56

BOEING SERVICE BULLETIN 777-55A0010
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
The QTY numbers shown below are the numbers of parts necessary for the airplane.
STEP TASK NAME REFERENCES QTY NOTES
1 Apply Sealant BSOPM 20-50-19 - (a)
2 Apply Sealant BSOPM 20-50-19 - (b)
(a) Apply protective coating to bare surfaces of the airplane structure and the ground clips to match the
surrounding surface. Filet seal around the periphery of the ground clips with BMS 5-95 Sealant per
BSOPM 20-50-19. Encapsulate both ends of all fasteners which attach the ground clips to the airplane
structure with BMS 5-95 Sealant.
(b) Fillet seal around edge of jumper and around edge of ground clip where the jumper is attached.
Encapsulate both ends of the bolt which attach the jumper. Make sure to fully cover the bolt head, nut,
washer, and threaded end of the bolt with BMS 5-95 Sealant per BSOPM 20-50-19.
FIGURE 9. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -
INBOARD END
October 26, 2000 SHEET 2 OF 2 777-55A0010
Revision 1: April 17, 2001 52

### Page 57

Commercial
Airplane
Group
777
Service Bulletin
Number: 777-55A0010 Evaluation FormDate: October 26, 2000
Revision 1: April 17, 2001
ATA System: 5500
Prepared By: Frank DiMiceli
SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper
Additions
Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data
that you give us to improve the quality of our service bulletins.
NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these
changes, please use a Publication Change Request (PCR) form.
Please give us this data:
(If necessary, please use the other side. Thank you for the time you used to give us your comments.)
OPERATOR: TODAY'S DATE:
PREPARED BY: TITLE:
ORGANIZATION: TELEX CODE:
TELEPHONE NUMBER: BASE:
Please rate the quality of this service bulletin: (good) 4321 (poor)
Please rate the quality of the illustrations: (good) 4321 (poor)
Will you do the change given by this service bulletin? Yes No If not, please explain:
Is this service bulletin easy to understand? Yes No If not, please explain:
Is this service bulletin easy to use? Yes No If not, please explain:
Are the Planning Information, Material Information, and
Accomplishment Instructions accurate? Yes No If not, please explain:
Is the Manpower estimate accurate? Yes No If not, please explain:
Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form
directly to this address:
Manager
Service Bulletin Engineering
Boeing Commercial Airplane Group
P.O. Box 3707, Mail Stop 2H-37
Seattle, WA 98124-2207

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