# Boeing Alert Service Bulletin 777-55A0016: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2012-0803; AD 2013-08-02 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 777-55A0016](https://openairdocs.org/service-documents/boeing/777-55a0016.md) - Title as filed: U.S. DOT/FAA - Boeing Service Bulletin - Pages: 103 - PDF: https://openairdocs.org/files/sha256/b4/74/b4745d646e86a990bdf7e9a356c2e4c3f6ab19171c785353465471a9eff18102 - Page: https://openairdocs.org/service-documents/boeing/777-55a0016/file/b4745d646e86 ## 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: 777-55A0016 Original Issue: October 27, 2009 Revision 1: August 25, 2011 ATA System: 5527 SUBJECT: STABILIZERS - Elevator Attach Fittings - Elevator Actuator Fitting Assembly Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. 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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 1 of 103 6.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 2 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 9 1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3 1. Airplanes ............................................ 1 3 2. Spares Affected ........................................ 1 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 7 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F. Approval ............................................... 1 9 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2 1. Existing Data .......................................... 2 2 2. Data supplied with this Service Bulletin ............................ 2 2 3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 2 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 3 2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 6 1. Kits/Parts ............................................ 2 6 2. Parts and Materials Supplied by the Operator ........................ 3 2 3. Parts Modified and Reidentified ................................ 3 3 4. Parts Removed and Not Replaced .............................. 3 4 D. Parts Necessary to Change Spares ................................. 3 4 E. Special Tooling - Price and Availability ............................... 3 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 4 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 7 FIGURE 1: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 1] ................ 3 9 FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 1] .............. 4 4 FIGURE 3: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 1] ................ 5 1 FIGURE 4: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 1] .............. 5 6 FIGURE 5: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 2] ................ 6 3 FIGURE 6: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 2] .............. 6 8 FIGURE 7: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 2] ................ 7 5 FIGURE 8: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 2] .............. 8 0 FIGURE 9: MORE WORK NECESSARY ON AIRPLANES CHANGED IN ACCORDANCE WITH THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN - DETAILED INSPECTION ....... 8 7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 3 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 4 FIGURE 10: MORE WORK NECESSARY ON AIRPLANES CHANGED IN ACCORDANCE WITH THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN - FASTENER REPLACEMENT [Group 1] .................................................. 9 0 FIGURE 11: MORE WORK NECESSARY ON AIRPLANES CHANGED IN ACCORDANCE WITH THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN - FASTENER REPLACEMENT [Group 2] .................................................. 9 3 APPENDIX A: FASTENER HOLE LOCATIONS IN FITTING ASSEMBLIES [Group 1] ........... 9 6 APPENDIX B: FASTENER HOLE LOCATIONS IN FITTING ASSEMBLIES [Group 2] .......... 1 0 0 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 4 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 5 Commercial Airplanes 777 Service Bulletin ALERT Revision Transmittal SheetNumber: 777-55A0016Original Issue: October 27, 2009 Revision 1: August 25, 2011 ATA System: 5527 SUBJECT: STABILIZERS - Elevator Attach Fittings - Elevator Actuator Fitting Assembly Replacement This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue of this service bulletin, if the installation torque values listed in the original issue of this service bulletin for BACB30NR4K6 and BACB30NR4K7 bolts were used. If any of these bolts were installed with 200 - 250 inch-pounds of torque, do inspections and replace the affected bolts in accordance with Paragraph 1.E., Compliance, Table 1 and Paragraph 3.B., Work Instructions, PART 3. No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin if the BACB30NR4K6 and BACB30NR4K7 bolts were installed with 78 - 82 inch-pounds of torque as described in 777-55A0016 IN 03. No airplanes was added to the service bulletin effectivity. Federal Aviation Administration (FAA) Airworthiness Directive 2007-26-05 is related to this service bulletin. REASON FOR REVISION This revision is sent to include additional access data, new kit information, and clarification of instructions for accomplishment of the fitting replacement shown in this service bulletin. These changes have resulted from service bulletin validation. The validation results were previously described in 777-55A0016 IN 02. In addition, this revision is sent to change the installation torque values In Figures 2, 4, 6 and 8. In the Fastener Table for these figures, the installation torque for fastener codes D and E were changed from 200 - 250 inch-pounds to 78 - 82 inch-pounds. As a part of a service bulletin validation program, the change in this service bulletin was completed on airplane WB375 by Service Bulletin 777-55A0016 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane WB375 by Service Bulletin 777-55A0016 Original Issue is equivalent to Revision 1 of this service bulletin. Airplane WB375 has the configuration of a Group 2 airplane. References to Boeing Service Related Problem (SRP) 777-SRP-55-0052 were also added. These sections were changed: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 5 of 103 ### Page 6 1. In Paragraph 1.E., Compliance, Table 1 was added to show the actions necessary if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts. 2. The estimate in Paragraph 1.G., Manpower, has been updated based on the additional access required. New estimates were also added for the inspection and bolt replacement necessary if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts. 3. Weight and balance data was added to Paragraph 1.H., Weight and Balance Changes. This data was previously included in Information Notice 777-55A0016 IN 01. 4. The statement in Paragraph 1.K.2., Damage Tolerance Based Structural Inspections:, has been changed. New Damage Tolerance Inspections (DTI) are required after actuator fitting replacement in accordance with this service bulletin. 5. In Paragraph 2.A., Material - Price and Availability, price and availability data has been added for new Replacement Top Kits 005W3356-5 and 005W3356-6 and new Supplemental Kits 005W3356-3 and 005W3356-4. 6. In Paragraph 2.C., Parts Necessary for Each Airplane, parts lists have been added for new Replacement Top Kits 005W3356-5 and 005W3356-6 and new Supplemental Kits 005W3356-3 and 005W3356-4. 7. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, parts have been listed that will be necessary if bolts must be replaced if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts. 8. In Paragraph 3.A., General Information, general notes have been added. 9. In Paragraph 3.B., Work Instructions, the existing fitting replacement instructions have been labeled as PART 1 for Group 1 and PART 2 for Group 2. PART 3 has been added for the actions necessary if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts. 10. In Paragraph 3.B., Work Instructions, statements have been added to refer to Paragraph 1.E., Compliance for inspections required after fitting replacement. 11. In Figures 1, 3, 5, and 7, instructions were added for removal of spar upper and lower chord fasteners and the hinge fitting at elevator station 182.29. These parts are removed to give access for replacement of the outboard actuator fitting. 12. In Figures 2, 4, 6, and 8, instructions were added for installation of spar upper and lower chord fasteners and the hinge fitting at elevator station 182.29. 13. In Figures 2, 4, 6, and 8, shim installation instructions have been revised. 14. In the Fastener Table for Figures 2, 4, 6, and 8, the hole diameter information for fastener code C has been changed. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 6 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 7 15. In the Fastener Table for Figures 2, 4, 6, and 8, the washer installation instruction in footnote (b) has been changed to allow installation of only one washer, rather than two, if necessary to ensure proper fastener thread protrusion. 16. New Figure 9 was added to show the inspections that is necessary on airplanes changed in accordance with the original issue of this service bulletin, if the installation torque values listed in the original issue of this service bulletin were used. 17. New Figures 10 and 11 were added to show the bolt replacement that is necessary on airplanes changed in accordance with the original issue of this service bulletin, if the installation torque values listed in the original issue of this service bulletin were used. The data given in Information Notice 777-55A0016 IN 01, 777-55A0016 IN 02 and 777-55A0016 IN 03 are included in this revision. IN 01 included weight and balance data. IN 02 advised operators of the results of the service bulletin validation. IN 03 advised operators that the installation torque for fastener codes D and E in the Fastener Table for Figures 2, 4, 6, and 8 should be 78 - 82 inch-pounds, not 200 - 250 inch-pounds. 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 October 27, 2009Original Issue: August 25, 2011Revision 1: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 7 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 8 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT BLANK PAGE ### Page 9 Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-55A0016Original Issue: October 27, 2009 Revision 1: August 25, 2011 ATA System: 5527 SUBJECT: STABILIZERS - Elevator Attach Fittings - Elevator Actuator Fitting Assembly Replacement THIS BULLETIN 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 SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements. BACKGROUND This service bulletin gives instructions to replace the elevator actuator fitting assemblies at left and right Elevator Stations 169.79 and 194.79. The new actuator fitting assemblies will give adequate residual strength to react flight loads. Undetected elevator actuator fitting assembly cracks can become large, and result in the fitting becoming detached from the elevator that can result in an unrestrained elevator. An unrestrained elevator is an unacceptable flutter condition which can result in loss of airplane control. One operator has told Boeing that a cracked left outboard actuator fitting was found on a 777 airplane with 17,346 flight-hours and 14,043 flight-cycles. The crack extended through the lower inboard flange of the fitting and into the vertical flange. Analysis by Boeing indicates that this crack resulted from fatigue due to higher than anticipated stress levels in the fitting flanges. Accomplishment of this service bulletin will provide an acceptable level of safety to terminate the repeat inspection requirements of Service Bulletin 777-55A0015. If replacement of the actuator support fitting assemblies is not accomplished, operators will be required to continue to do inspections in accordance with Service Bulletin 777-55A0015. Boeing Service Related Problem (SRP) 777-SRP-55-0040 and 777-SRP-55-0052 are related to this service bulletin. ACTION (PRR 62777-59S) This service bulletin provides instruction to replace the elevator actuator fitting assemblies at left and right elevator Stations 169.79 and 194.79. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 9 of 103 ### Page 10 EFFECTIVITY 777-200, 777-200LR, 777-300 and 777-300ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive 2007-26-05 is related to this service bulletin. Refer to Paragraph 1.E., Compliance. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of November 17, 2006. Please refer to Paragraph 2.B., Industry Support Information. MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 10 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 11 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 11 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 12 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 12 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT BLANK PAGE ### Page 13 Commercial Airplanes 777 Service Bulletin ALERT Number: 777-55A0016 Original Issue: October 27, 2009 Revision 1: August 25, 2011 ATA System: 5527 SUBJECT: STABILIZERS - Elevator Attach Fittings - Elevator Actuator Fitting Assembly Replacement THIS BULLETIN 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 SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. 1. PLANNING INFORMATION A. Effectivity 1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-59S or data about this change. Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. DESCRIPTIONCONFIGURATIONGROUP All 777-200 airplanes line number 1 through 40.-1 777-200, 777-200LR, 777-300, and 777-300ER airplanes line number 41 to 717. -2 Airplane Models: 777-200, 777-200LR, 777-300, 777-300ER GroupVariable Number 1WA001 - WA017 1WA076 - WA080 1WA086 - WA087 2WA088 - WA093 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 13 of 103 ### Page 14 GroupVariable Number 1WA101 - WA104 1WA116 - WA117 2WA118 - WA119 1WA131 - WA135 2WA136 - WA137 1WA171 - WA173 2WA174 - WA175 1WA196 - WA197 2WA198 2WA206 - WA212 2WA221 - WA223 2WA231 - WA232 2WA241 - WA250 2WA261 - WA266 2WA281 - WA283 2WA301 - WA304 2WB001 - WB021 2WB031 - WB046 2WB051 - WB088 2WB101 - WB106 2WB121 - WB125 2WB131 - WB147 2WB151 - WB155 2WB161 - WB177 2WB181 - WB194 2WB201 - WB215 2WB231 - WB247 2WB271 - WB273 2WB276 - WB286 2WB291 - WB302 2WB306 - WB307 2WB311 - WB337 2WB341 - WB342 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 14 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 15 GroupVariable Number 2WB366 - WB368 2WB371 - WB388 2WB406 2WB411 - WB413 2WB416 - WB439 2WB446 - WB453 2WB476 2WB481 - WB484 2WB501 - WB512 2WB531 - WB537 2WB551 - WB554 2WB591 - WB597 2WB601 - WB606 2WB611 - WB622 2WB631 - WB638 2WB646 - WB649 2WC051 - WC073 2WC101 - WC104 2WC111 - WC119 2WC221 - WC222 2WC241 - WC243 2WC281 - WC290 2WC301 - WC308 2WC361 - WC364 2WC371 - WC374 2WC381 - WC395 2WC441 2WC446 - WC449 2WC456 - WC459 2WC486 - WC493 2WC506 - WC508 2WC521 - WC522 2WC531 - WC536 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 15 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 16 GroupVariable Number 2WC546 - WC548 2WC556 2WC566 - WC567 2WD001 - WD002 2WD011 - WD015 2WD031 - WD036 2WD046 - WD049 2WD066 - WD067 2WD501 - WD507 2WD521 - WD538 2WD546 - WD552 2WD561 - WD572 2WD581 - WD594 2WD606 - WD609 2WD621 - WD632 2WD651 - WD659 2WD671 - WD675 2WD691 - WD706 2WD741 - WD748 2WD761 - WD770 2WD786 - WD788 2WD796 - WD802 2WD826 - WD829 2WD846 - WD849 2WD871 - WD872 2WD911 - WD912 2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use. B. Concurrent Requirements None. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 16 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 17 C. Reason This service bulletin gives instructions to replace the elevator actuator fitting assemblies at left and right Elevator Stations 169.79 and 194.79. The new actuator fitting assemblies will give adequate residual strength to react flight loads. Undetected elevator actuator fitting assembly cracks can become large, and result in the fitting becoming detached from the elevator that can result in an unrestrained elevator. An unrestrained elevator is an unacceptable flutter condition which can result in loss of airplane control. One operator has told Boeing that a cracked left outboard actuator fitting was found on a 777 airplane with 17,346 flight-hours and 14,043 flight-cycles. The crack extended through the lower inboard flange of the fitting and into the vertical flange. Analysis by Boeing indicates that this crack resulted from fatigue due to higher than anticipated stress levels in the fitting flanges. Accomplishment of this service bulletin will provide an acceptable level of safety to terminate the repeat inspection requirements of Service Bulletin 777-55A0015. If replacement of the actuator support fitting assemblies is not accomplished, operators will be required to continue to do inspections in accordance with Service Bulletin 777-55A0015. Revision 1 is sent to include additional access data, new kit information, and clarification of instructions for accomplishment of the fitting replacement shown in this service bulletin. These changes have resulted from service bulletin validation. The validation results were previously described in 777-55A0016 IN 02. In addition, instructions for the inspections that are required after fitting replacement have been added. In addition, this revision is sent to change the installation torque values In Figures 2, 4, 6 and 8. In the Fastener Table for these figures, the installation torque for fastener codes D and E were changed from 200 - 250 inch-pounds to 78 - 82 inch-pounds. References to Boeing Service Related Problem (SRP) 777-SRP-55-0052 were also added. Boeing Service Related Problem (SRP) 777-SRP-55-0040 and 777-SRP-55-0052 are related to this service bulletin. D. Description This service bulletin provides instruction to replace the elevator actuator fitting assemblies at left and right elevator Stations 169.79 and 194.79 Revision 1 - On airplanes changed in accordance with the original issue of this service bulletin, if the installation torque values listed in the original issue of this service bulletin for BACB30NR4K6 and BACB30NR4K7 bolts were used. If any of these bolts were installed with 200 - 250 inch-pounds of torque, do inspections and replace the affected bolts in accordance with Paragraph 1.E., Compliance, Table 1 and Paragraph 3.B., Work Instructions, PART 3. No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin if the BACB30NR4K6 and BACB30NR4K7 bolts were installed with 78 - 82 inch-pounds of torque as described in 777-55A0016 IN 03. The work in this service bulletin is done in the maintenance zone(s) given below. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 17 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 18 Group 1: Affected Maintenance Zones ZoneModel 336, 346777-200 Group 2: Affected Maintenance Zones ZoneModel 336, 346777-200, 777-200LR, 777-300, 777-300ER E. Compliance Federal Aviation Administration (FAA) Airworthiness Directive 2007-26-05 is related to this service bulletin. No compliance time is given for the elevator actuator fitting replacement in this service bulletin. For compliance time and additional work that may be necessary on any airplanes changed in accordance with the original issue of this service bulletin refer to Table 1. Table 1: More Work Necessary on Airplanes Changed in Accordance With the Original Issue of this Service Bulletin Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition --Within 180 days after the Revi- sion 1 date of this service bul- letin. Do a detailed inspection of the new elevator actua- tor fitting assemblies for indications of fastener head movement, or for indications of fitting movement along the spar web, in accordance with Paragraph 3.B., Work In- structions, PART 3. Any airplane modified in accordance with the origi- nal issue of this service bulletin, using the fastener torque values given in the original issue of this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 18 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 19 Table 1: More Work Necessary on Airplanes Changed in Accordance With the Original Issue of this Service Bulletin Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 90 days, or 360 flight-cycles, whichever occurs first, but do not ex- ceed 4,200 flight- cycles or 750 days after the Revision 1 date of this ser- vice bulletin, whichever occurs first. Before 360 flight-cycles af- ter the previous inspection. Within 90 days of the previous inspection. Repeat the detailed in- spection for indications of fastener head movement, or for indications of fitting movement along the spar web, in accordance with Paragraph 3.B., Work In- structions, PART 3. or If no indications of fastener or fitting movement are found. -At each affected fitting lo- cation, replace the twelve bolts common to the ele- vator actuator fitting and the spar web in accor- dance with Paragraph 3.B., Work Instructions, PART 3. --Before further flight. At each affected fitting lo- cation, replace the twelve bolts common to the ele- vator actuator fitting and the spar web in accor- dance with Paragraph 3.B., Work Instructions, PART 3. If any indications of fasten- er or fitting movement are found, ---No more work is neces- sary. On any airplane modified in accordance with the original issue of this service bulletin, using the fastener torque values given in 777- 55A0016 IN 03. 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 19 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 20 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. This service bulletin has been approved by the FAA. In addition, the Manager of the Seattle Aircraft Certification Office approves the replacement of the elevator fitting assemblies as specified in this service bulletin as an AMOC to the inspection and repair procedures defined in Service Bulletin 777-55A0015, Revision 1, dated April 19, 2007, required by paragraph (f) of AD 2007-26-05. All provisions of AD 2007-26-05 that are not specifically referenced in the preceding sentence remain fully applicable and must be complied with. G. Manpower The table below shows an estimate of the task hours necessary to do this 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: Table 1 - Elevator Actuator Fitting Replacement Elapsed HoursTask HoursNumber of Per- sons Task 9.2537.004Open Access 3.256.502Figure 1 5.0010.002Figure 2 3.256.502Figure 3 5.0010.002Figure 4 12.7551.004Close Access 5.5011.002Test 44.00132.00TOTAL FOR EACH AIRPLANE Group 2: Table 2 - Elevator Actuator Fitting Replacement Elapsed HoursTask HoursNumber of Per- sons Task 9.2537.004Open Access 3.256.502Figure 5 5.0010.002Figure 6 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 20 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 21 Group 2: Table 2 - Elevator Actuator Fitting Replacement Elapsed HoursTask HoursNumber of Per- sons Task 3.256.502Figure 7 5.0010.002Figure 8 12.7551.004Close Access 5.5011.002Test 44.00132.00TOTAL FOR EACH AIRPLANE Table 3 - More Work (Inspection) Necessary on Airplanes Changed In Accordance With the Original Issue of This Service Bulletin Elapsed HoursTask HoursNumber of Per- sons Task 1.503.002Open Access 4.008.002Inspect - Figure 9 1.503.002Close Access 7.0014.00TOTAL FOR EACH AIRPLANE Table 4 - More Work (Bolt Replacement) Necessary on Airplanes Changed In Accordance With the Original Issue of This Service Bulletin Elapsed HoursTask HoursNumber of Per- sons Task 9.2537.004Open Access (Re- move Elevators) 3.006.002Bolt Replacement Figure 10 12.7551.004Close Access 5.5011.002Test 30.50105.00TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +27596.9+11.3Group 1 +25888.4+10.6Group 2 (777-200) +27891.8+10.6Group 2 (777-300) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 21 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 22 I. Electrical Load Data Not changed. J. References 1. Existing Data a. Engineering Change Memo PRR 62777-59S. b. Service Related Problem (SRP) 777-SRP-55-0040 and 777-SRP-55-0052 c. 777 Aircraft Maintenance Manual (AMM) 27-31-10 d. Component Maintenance Manual (CMM) 55-20-23 and 55-20-24. e. Standard Overhaul Practices Manual (SOPM) 20-10-08, 20-44-04, 20-50-19, and 20-50-20 f. Boeing Service Bulletin 777-55A0015. g. FAA Airworthiness Directive 2007-26-05. h. Boeing Parts Standards Document D-590 2. Data supplied with this Service Bulletin None. 3. Installation Drawings Used in the Preparation of this Service Bulletin TitleDrawing Number Elevator Installation183W0001 Spar Instl - Elevator183W1001 This drawing is used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Chapter-SectionPublication 55-27777 Illustrated Parts Catalog 55-20Component Maintenance Manual 2. Damage Tolerance Based Structural Inspections: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 22 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 23 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 Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 23 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 24 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 24 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT BLANK PAGE ### Page 25 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 1 date of this Service Bulletin (US Dollars) ROLT as of the Revi- sion 1 date of this Service Bulletin (Cal- endar Days DateNameKit Number $19,725.00217AvailableTop Kit - Group 1 (a)005W3356-1 $21,643.00881AvailableTop Kit - Group 2 (b)005W3356-2 $2,007.00(c)(c)Supplemental Kit - Group 1 (a) 005W3356-3 $1,811.00(c)(c)Supplemental Kit - Group 2 (b) 005W3356-4 $22,168.00(c)(c)Replacement Top Kit - Group 1 (a) 005W3356-5 $24,009.00(c)(c)Replacement Top Kit - Group 2 (b) 005W3356-6 (a) Original Top Kit 005W3356-1 plus Supplemental Kit 005W3356-3 is equivalent to Replacement Top Kit 005W3356-5. (b) Original Top Kit 005W3356-2 plus Supplemental Kit 005W3356-4 is equivalent to Replacement Top Kit 005W3356-6. (c) Not available at the time of release of Revision 1. Refer to the Boeing Part Page on myboeingfleet.com or contact firstresponder at fr@boeing.com for information. B. Industry Support Information Boeing warranty remedies are available for 777 airplanes in warranty as of November 17, 2006. For task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the parts to Boeing Spares. Please refer to this service bulletin number and reference the airplane Puget sound Model number in your purchase order. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 25 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 26 C. Parts Necessary For Each Airplane 1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One Top Kit and one Supplemental Kit, or one Replacement Top Kit, and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. The Top Kit is divided into Figure kits for each installation figure shown in the table below. Figure Kit 8642Top Kit --11005W3356-5 11--005W3356-6 Group 1: KIT 005W3356-5 NOTES Existing Part NumberName Figure New Part Number 42 QTY BOLT44125438-6K11 183W1300-2, 183W1300-6 ACTUATOR FIT- TING ASSEMBLY 1183W1310-10 183W1300-1, 183W1300-5 ACTUATOR FIT- TING ASSEMBLY 1183W1310-9 183W1300-4, 183W1300-8 ACTUATOR FIT- TING ASSEMBLY 1183W1320-10 183W1300-3, 183W1300-7 ACTUATOR FIT- TING ASSEMBLY 1183W1320-9 RADIUS FILLER44183W1701-11 RADIUS FILLER44183W1701-9 BOLT1212BACB30NR4K5 BOLT, HEX HEAD2424BACB30NR4K6 BOLT, 100 DEG HEX DR 2424BACB30NZ6K7 BOLT, 100 DEG HEX DR 44BACB30NZ8K9 BOLT, 100 DEG HEX DR 2424BACB30YM10K14 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 26 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 27 Group 1: KIT 005W3356-5 NOTES Existing Part NumberName Figure New Part Number 42 QTY BOLT88BACB30YM10K15 BOLT, 100 DEG HEX DR 22BACB30YP8K9 COLLAR, PRELOAD 2424BACC30AB6S COLLAR44BACC30AB8C COLLAR22BACC30BQ8 COLLAR, PRELOAD 3232BACC30CQ10CR SELF-LOCKING NUT 22BACN10MT4 SELF-LOCKING NUT 44BACN10YR6CD NUT22BACN11Z4CD NUT11BACN11Z5CD SHIM, LAMINAT- ED 11BACS40V019F046 SHIM , LAMINAT- ED 11BACS40V019F048 SHIM, LAMINAT- ED 11BACS40V024B072 SHIM, LAMINAT- ED 22BACS40V026B084 SHIM, LAMINAT- ED 22BACS40V026B085 SHIM, LAMINAT- ED 11BACS40V027B048 SHIM, LAMINAT- ED 11BACS40V084B095 SHIM, LAMINAT- ED 11BACS40V084B100 WASHER, SELF- ALIGN 22BACW10AU4 WASHER66BACW10BP4DP BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 27 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 28 Group 1: KIT 005W3356-5 NOTES Existing Part NumberName Figure New Part Number 42 QTY WASHER44BACW10BP4NDP WASHER-PLAIN22BACW10BP5DP WASHER88BACW10BP6DP WASHER, PLAIN1212BACW10P208S WASHER, FLAT2424BACW10P447CG BOLT11HLT423AP10-9 (BACB30YM10K9 optional) BOLT44HLT423AP8-9 (BACB30YM8K9 optional) Group 2: KIT 005W3356-6 NOTES Existing Part NumberName Figure New Part Number 86 QTY BOLT44125438-6K12 FITTING ASSEM- BLY 1183W1312-10 FITTING ASSEM- BLY 1183W1312-9 FITTING ASSEM- BLY 1183W1322-10 FITTING ASSEM- BLY 1183W1322-9 RADIUS FILLER44183W1701-11 RADIUS FILLER44183W1701-9 BOLT1212BACB30NR4K5 BOLT, HEX HEAD88BACB30NR4K6 BOLT1616BACB30NR4K7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 28 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 29 Group 2: KIT 005W3356-6 NOTES Existing Part NumberName Figure New Part Number 86 QTY BOLT, 100 DEG HEX DR 2424BACB30NZ6K7 BOLT, 100 DEG HEX DR 66BACB30NZ8K10 BOLT, 100 DEG HEX DR 11BACB30YM10K10 BOLT, 100 DEG HEX DR 2424BACB30YM10K14 BOLT88BACB30YM10K15 BOLT, 100 DEG HEX DR 22BACB30YM8K10 BOLT, 100 DEG HEX DR 22BACB30YM8K9 COLLAR, PRELOAD 2424BACC30AB6S COLLAR44BACC30AB8C COLLAR, PRELOAD 3232BACC30CQ10CR SELF-LOCKING NUT 44BACN10MT4 SELF-LOCKING NUT 11BACN10MT5 SELF-LOCKING NUT 44BACN10YR6CD SHIM , LAMINAT- ED 11BACS40V019F045 SHIM , LAMINAT- ED 11BACS40V019F048 SHIM , LAMINAT- ED 11BACS40V023B071 SHIM,LAMINATED11BACS40V026B048 SHIM, LAMINAT- ED 22BACS40V026B084 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 29 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 30 Group 2: KIT 005W3356-6 NOTES Existing Part NumberName Figure New Part Number 86 QTY SHIM, LAMINAT- ED 22BACS40V026B085 SHIM, LAMINAT- ED 11BACS40V084B095 SHIM, LAMINAT- ED 11BACS40V084B100 WASHER, SELF- ALIGN 44BACW10AU4 WASHER, SELF- ALIGN 11BACW10AU5 WASHER44BACW10BP4DP WASHER44BACW10BP4NDP WASHER-PLAIN11BACW10BP5DP WASHER88BACW10BP6DP WASHER, PLAIN1212BACW10P208S WASHER, FLAT2424BACW10P447CG COLLAR22HL175DU8AWU Group 1: KIT 005W3356-3 NotesNameQTYNew Part Number BOLT24BACB30NR4K5 BOLT, 100 DEG HEX DR 48BACB30NZ6K7 BOLT, 100 DEG HEX DR 8BACB30NZ8K9 BOLT, 100 DEG HEX DR 4BACB30YP8K9 COLLAR, PRELOAD 48BACC30AB6S COLLAR8BACC30AB8C COLLAR4BACC30BQ8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 30 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 31 Group 1: KIT 005W3356-3 NotesNameQTYNew Part Number SELF-LOCKING NUT 4BACN10MT4 NUT4BACN11Z4CD NUT2BACN11Z5CD SHIM, LAMINAT- ED 2BACS40V019F046 SHIM , LAMINAT- ED 2BACS40V019F048 SHIM, LAMINAT- ED 2BACS40V024B072 SHIM, LAMINAT- ED 2BACS40V027B048 WASHER, SELF- ALIGN 4BACW10AU4 WASHER12BACW10BP4DP WASHER8BACW10BP4NDP WASHER-PLAIN4BACW10BP5DP WASHER, PLAIN24BACW10P208S BOLT2HLT423AP10-9 BOLT8HLT423AP8-9 Group 2: KIT 005W3356-4 NotesNameQTYNew Part Number SHIM , LAMINAT- ED 2BACS40V019F045 SHIM , LAMINAT- ED 2BACS40V019F048 SHIM , LAMINAT- ED 2BACS40V023B071 SHIM,LAMINATED2BACS40V026B048 COLLAR4HL175DU8AWU WASHER8BACW10BP4DP WASHER-PLAIN2BACW10BP5DP BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 31 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 32 Group 2: KIT 005W3356-4 NotesNameQTYNew Part Number BOLT24BACB30NR4K5 COLLAR, PRELOAD 48BACC30AB6S COLLAR8BACC30AB8C WASHER8BACW10BP4NDP BOLT, 100 DEG HEX DR 48BACB30NZ6K7 BOLT, 100 DEG HEX DR 12BACB30NZ8K10 BOLT, 100 DEG HEX DR 2BACB30YM10K10 BOLT, 100 DEG HEX DR 4BACB30YM8K10 BOLT, 100 DEG HEX DR 4BACB30YM8K9 SELF-LOCKING NUT 8BACN10MT4 SELF-LOCKING NUT 2BACN10MT5 WASHER, SELF- ALIGN 8BACW10AU4 WASHER, SELF- ALIGN 2BACW10AU5 WASHER, PLAIN24BACW10P208S 2. Parts and Materials Supplied by the Operator NotesNameQTYPart Number / Specification (a)SEALANT1 PintBMS 5-95 (a)PRIMER1 PintBMS 10-79, Type III (a)PRIMER1 PintBMS 10-11, Type I (a)GLOSS ENAMEL1 PintBMS 10-60, Type 1 Group 1. Refer to Figure 10.Bolt48BACB30NR4K6 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 32 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 33 NotesNameQTYPart Number / Specification Group 2. Refer to Figure 11.Bolt16BACB30NR4K6 Group 2. Refer to Figure 11.Bolt32BACB30NR4K7 All affected airplanes. Refer to Figure 10 and 11. Washer48BACW10P447CG (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. 3. Parts Modified and Reidentified The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane. Components or subassembly parts are indented. The quantity of the indented part is the number of parts used on the next higher assembly. Group 1: NotesNew Part NumberNameQTYExisting Part Number (a) (b)-Left Elevator Assembly1183W0060-1 (a)183W1310-9Actuator Fitting Assem- bly 1183W1300-1 or 183W1300-5 (a)183W1320-9Actuator Fitting Assem- bly 1183W1300-3 or 183W1300-7 (a) (b)-Right Elevator Assem- bly 1183W0060-2 (a)183W1310-10Actuator Fitting Assem- bly 1183W1300-2 or 183W1300-6 (a)183W1320-10Actuator Fitting Assem- bly 1183W1300-4 or 183W1300-8 (a) Make the change given in this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change given in this service bulletin was made. Group 2: NotesNew Part NumberNameQTYExisting Part Number (a) (b)-Left Elevator Assembly1183W0061-1, -3, - 5, -7, -9, -11, -13, - 15B, -15C, or -15D (a)183W1312-9Actuator Fitting Assem- bly 1183W1312-1 or 183W1312-5 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 33 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 34 Group 2: NotesNew Part NumberNameQTYExisting Part Number (a)183W1322-9Actuator Fitting Assem- bly 1183W1322-1 or 183W1322-5 (a) (b)-Right Elevator Assem- bly 1183W0061-2, -4, - 6, -8, -10, -12, -14, -16B, -16C, or - 16D (a)183W1312-10Actuator Fitting Assem- bly 1183W1312-2 or 183W1312-6 (a)183W1322-10Actuator Fitting Assem- bly 1183W1322-2 or 183W1322-6 (a) Make the change given in this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change given in this service bulletin was made. 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability. QTY (a)NameKit Part NumberReplacement Figures Right Elevator Assembly Part Number Left Elevator Assembly Part Number 1Top Kit005W3356-51, 2, 3, 4183W0060-2183W0060-1 1Top Kit005W3356-65, 6, 7, 8183W0061-2, -4 , -6, -8, -10, -12, -14, -16B, -16C, -16D 183W0061-1, -3, -5, -7, -9, -11, - 13, -15B, -15C, - 15D (a) One Top Kit can modify one left hand elevator and one right hand elevator. E. Special Tooling - Price and Availability None. F. 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 34 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 35 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. – Hole dimensions for standard solid rivets are in 777 SRM, 777 Chapter 51. – Torque limits to tighten nuts and bolts are in 777 SRM, Chapter 51. 4. Use the approved fastener and process material substitutions in accordance with 777 SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in 777 SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in 777 SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with 777 SRM Chapter 51. 6. 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. 7. It is important to locate the new actuator fittings so that the elevator attachment points remain in the same relative position. This service bulletin shows a method to locate the new fittings by installing them with shims that are the same dimensions as those that were installed between the original elevator actuator fitting and the elevator spar web and between the spar upper chord and the original elevator actuator fitting. Other fitting locating methods that ensure that the elevator attachment points remain in the same relative position can also be acceptable. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 35 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 36 8. As an alternative to measuring the shim installed between the spar upper chord and the original elevator actuator fitting, remove and clean the upper flange of the original actuator fitting and the mating surface of the elevator spar upper chord. Temporarily reinstall the original elevator actuator fitting and the original shims that were between the fitting and the spar web. Measure the gap between the fitting and the elevator spar upper chord, including any tapers that may exist, and use these dimensions to fabricate the new shim that will be installed between the new fitting upper flange and the elevator spar upper chord. 9. If oversize fastener holes are found during disassembly, or if hole damage makes it necessary for fastener holes to be made oversize, ask Boeing for repair instructions. 10. Appendix A and Appendix B show dimensional information for the locations of the fastener holes common to the elevator spar web in the existing elevator actuator fittings. Boeing recommends that this data be used as a reference and the existing fittings themselves be used to transfer the spar web hole locations to the new, blank elevator actuator fittings. After the new fittings have been located with the fastener locations common to the spar web, temporarily install the fittings with shims of the proper thickness between the spar web and the fitting. Backdrill the upper and lower flanges of the new fittings through the open fastener holes in the spar upper and lower chords. 11. 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. 12. 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. 13. 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. 14. 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. The removed part can be discarded if a new or serviceable part is installed. 15. 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. 16. 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 36 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 37 B. WORK INSTRUCTIONS Group 1: PART 1 - Modification 1. Remove the left and right elevator. Refer to 777 AMM 27-31-10 as an accepted procedure. 2. Replace the left elevator actuator fitting assemblies in accordance with Figures 1 and 2. 3. Replace the right elevator actuator fitting assemblies in accordance with Figures 3 and 4. 4. Identify on the elevators that the change given in this service bulletin was made. 5. Install the left and right elevators. Refer to 777 AMM 27-31-10 as an accepted procedure. 6. Put the airplane back to a serviceable condition. Group 2: PART 2 - Modification 1. Remove the left and right elevator. Refer to 777 AMM 27-31-10 as an accepted procedure. 2. Replace the left elevator actuator fitting assemblies in accordance with Figures 5 and 6. 3. Replace the right elevator actuator fitting assemblies in accordance with Figures 7 and 8. 4. Identify on the elevators that the change given in this service bulletin was made. 5. Install the left and right elevators. Refer to 777 AMM 27-31-10 as an accepted procedure. 6. Put the airplane back to a serviceable condition. PART 3 - More work necessary on airplanes changed in accordance with the original issue of this service bulletin 1. On any airplane modified in accordance with the original issue of this service bulletin, using the fastener torque values given in 777-55A0016 IN 03, no more work is necessary. 2. On any airplane modified in accordance with the original issue of this service bulletin, using the fastener torque values given in the original issue of this service bulletin, do the following: a. Get access to the actuator fittings on the left and right elevators. Refer to Boeing Service Bulletin 777-55A0015, Paragraph 3.B., Work Instructions, PART 3 as an accepted procedure. b. Do a detailed inspection of the elevator actuator fitting assemblies for indications of fastener head movement, or for indications of fitting movement along the spar web, in accordance with FIGURE 9. c. If no indications of fastener or fitting movement are found, put the airplane back to a serviceable condition. Do the inspection again at the time given in Paragraph 1.E., Compliance, Table 1. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 37 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 38 d. Group 1: If any indications of fastener or fitting movement are found, remove the affected elevator. Refer to 777 AMM 27-31-10 as an accepted procedure. At each affected fitting location, replace the twelve bolts common to the elevator actuator fitting and the spar web in accordance with FIGURE 10. After the affected fasteners have been replaced at all affected actuator fitting locations, no more work is necessary. NOTE: As an alternative to elevator removal and reinstallation, do the steps that follow. Refer to 777 AMM 27-31-10. (1) Bring the elevator to the full trailing edge down position and secure the elevator in position. Disconnect the elevator PCU from the elevator fittings. (2) Rotate the elevator to the trailing edge up position, using caution to prevent too much rotation and damage to the upper skin at the hinges. Secure the elevator in position. Remove and replace the lower bolts in the elevator fittings in accordance with FIGURE 10. (3) Disconnect the reaction links from the elevator fittings, and allow the actuator and reaction link to swing down to access the upper bolts in the elevator fittings. Remove and replace the upper bolts in the elevator fittings in accordance with FIGURE 10. (4) Reattach the reaction link and actuator. e. Group 2: If any indications of fastener or fitting movement are found, remove the affected elevator. Refer to 777 AMM 27-31-10 as an accepted procedure. At each affected fitting location, replace the twelve bolts common to the elevator actuator fitting and the spar web in accordance with FIGURE 11. After the affected fasteners have been replaced at all affected actuator fitting locations, no more work is necessary. NOTE: As an alternative to elevator removal and reinstallation, do the steps that follow. Refer to 777 AMM 27-31-10. (1) Bring the elevator to the full trailing edge down position and secure the elevator in position. Disconnect the elevator PCU from the elevator fittings. (2) Rotate the elevator to the trailing edge up position, using caution to prevent too much rotation and damage to the upper skin at the hinges. Secure the elevator in position. Remove and replace the lower bolts in the elevator fittings in accordance with FIGURE 11. (3) Disconnect the reaction links from the elevator fittings, and allow the actuator and reaction link to swing down to access the upper bolts in the elevator fittings. Remove and replace the upper bolts in the elevator fittings in accordance with FIGURE 11. (4) Reattach the reaction link and actuator. f. Install the elevators. Refer to 777 AMM 27-31-10 as an accepted procedure. g. Put the airplane back to a serviceable condition. Do inspections of the elevator actuator fittings in accordance with Paragraph 1.E., Compliance . BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 38 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 39 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT This Figure applies only to: Group 1. ELEV STA 194.79 ELEV STA 169.79 B LEFT ELEVATOR ASSEMBLY 1679197 FIGURE 1: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 1 OF 5) Original Issue: October 27, 2009 Revision 1 August 25, 2011 BOEING PROPRIETARY - 777-55A0016 Copyright © Unpublished Work - See page 1 for details. 39 of 103 ### Page 40 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT 8 LOCATIONS 16 LOCATIONS ( 2 LOCATIONS (1 4 LOCATIONS 4 ELEV STA 194.79 8) 12 LOCATIONS • 5 LOCATIONS 2 LOCATIONS 20 17) 12 LOCATIONS 23) 4 LOCATIONS (21 ELEV STA 182.29 .. 0 12 LOCATIONS 17) 1679198 FIGURE 1: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 2 OF 5) Original Issue: October 27, 2009 Revision 1 August 25, 2011 777-55A0016 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 103 ### Page 41 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT ELEV STA 169.79 (10 16 LOCATIONS 2 LOCATIONS (9 (11) 8 LOCATIONS 4 LOCATIONS (12 1693674 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. FIGURE 1: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 3 OF 5) Original Issue: October 27, 2009 Revision 1 August 25, 2011 BOEING PROPRIETARY - 777-55A0016 Copyright © Unpublished Work - See page 1 for details. 41 of 103 ### Page 42 NOTE: The hinge fitting at Elevator Station 182.29 is removed to provide access for installation of the new outboard actuator fitting at Elevator Station 194.79. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP -2-BoltRemove1 -4-WasherRemove -2-NutRemove -16-BoltRemove2 -32-WasherRemove -16-NutRemove -8-BoltRemove3 -8-WasherRemove -4-BoltRemove4 -4-WasherRemove 183W1300-5 option- al 1183W1300-1ACTUATOR FITTING ASSEMBLY Remove5 CAUTION: THE FAYING SURFACE OF THE FITTING IS SEALED TO A COMPOSITE SPAR. REFER TO SOPM 20-10-08 AS AN ACCEPTABLE PROCEDURE FOR REMOVAL. (b)3-SHIMRecord6 -1-SHIMRemove7 (a)1-SHIMRecord8 -2-BoltRemove9 -4-WasherRemove -2-NutRemove -16-BoltRemove10 -32-WasherRemove -16-NutRemove -8-BoltRemove11 -8-WasherRemove -4-BoltRemove12 -4-WasherRemove 183W1300-7 option- al 1183W1300-3ACTUATOR FITTING ASSEMBLY Remove13 FIGURE 1: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 4 OF 5) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 42 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 43 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP CAUTION: THE FAYING SURFACE OF THE FITTING IS SEALED TO A COMPOSITE SPAR. REFER TO SOPM 20-10-308 AS AN ACCEPTABLE PROCEDURE FOR REMOVAL. (b)3-SHIMRecord14 -1-SHIMRemove15 (a)1-SHIMRecord16 -24-FastenerRemove17 -12-BoltRemove18 -12-WasherRemove -5-BoltRemove19 -10-WasherRemove -5-NutRemove -2-BoltRemove20 -2-CollarRemove -4-BoltRemove21 -4-WasherRemove -4-CollarRemove (e)1-FittingRemove / Keep22 (d)1-SHIMRemove23 (d)1-SHIMRemove24 (c)2-SHIMRemove25 (a) Measure shim thickness and record. This data will be used when the new fittings are installed. (b) There are three separate shims installed between the elevator actuator fitting and the elevator spar. Measure and record the individual thickness of each shim. This data will be used when the new elevator actuator fittings are installed. (c) There are two separate shims installed between the hinge fitting and the elevator spar. Measure and record the individual thickness of each shim. This data will be used when the hinge fitting is reinstalled. (d) Measure shim thickness and record. This data will be used when the hinge fitting is reinstalled. (e) This hinge fitting is removed to ease removal and installation of the outboard actuator fitting. FIGURE 1: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 5 OF 5) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 43 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 44 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT This Figure applies only to: Group 1. ELEV STA 194.79 ELEV STA 169.79 LEFT ELEVATOR ASSEMBLY 1679200 FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 1 OF 7) Original Issue: October 27, 2009 Revision 1 August 25, 2011 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 103 ### Page 45 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT - 4 LOCATIONS 8 LOCATIONS ELEV STA 194.79 4 LOCATIONS A 4 LOCATIONS+ 4 LOCATIONS A K—12 LOCATIONS 18) 12 LOCATIONS ELEV STA 182.29 _ 12 LOCATIONS + 1689384 FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 2 OF 7) Original Issue: October 27, 2009 Revision 1 August 25, 2011 777-55A0016 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 103 ### Page 46 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT ELEV STA 169.79 - (4 LOCATIONS) (4 LOCATIONS) (8 LOCATIONS) (4 LOCATIONS) × (4 LOCATIONS) A C 1694462 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 3 OF 7) Original Issue: October 27, 2009 Revision 1 August 25, 2011 777-55A0016 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 103 ### Page 47 NOTE: The elevator spar tapers in height from inboard to the outboard direction, and can make it difficult to install the new outboard actuator fitting. To locate the new outboard actuator fitting, place it against the elevator spar near Elevator Station 182, then slide it outboard along the spar to its proper location at Elevator Station 194.79. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (b) (c) (e) (g)1BACS40V084B095SHIM, LAMINATEDInstall (New)1 (b) (e)1183W1310-9ACTUATOR FITTING ASSEMBLY Install (New)2 (a) (b) (c) (e) (i)1BACS40V026B085SHIM, LAMINATEDInstall (New)3 (a) (b) (c) (e) (f)1BACS40V026B085SHIM, LAMINATEDInstall (New)4 (b) (d) (e)2183W1701-11RADIUS FILLERInstall (New)5 (b) (d) (e)2183W1701-9RADIUS FILLERInstall (New)6 (b) (c) (e) (g)1BACS40V084B100SHIM, LAMINATEDInstall (New)7 (b) (e)1183W1320-9ACTUATOR FITTING ASSEMBLY Install (New)8 (b) (c) (e) (i)1BACS40V026B084SHIM, LAMINATEDInstall (New)9 (b) (c) (e) (f)1BACS40V026B084SHIM, LAMINATEDInstall (New)10 (b) (d) (e)2183W1701-11RADIUS FILLERInstall (New)11 (b) (d) (e)2183W1701-9RADIUS FILLERInstall (New)12 (b) (c) (e) (h)1BACS40V027B048SHIM, LAMINATEDInstall (New)13 (b) (c) (e) (h)1BACS40V024B072SHIM, LAMINATEDInstall (New)14 (b) (e)1-FittingInstall (Kept)15 (b) (c) (i)1BACS40V019F048SHIM , LAMINATEDInstall (New)16 (b) (c) (f)1BACS40V019F046SHIM, LAMINATEDInstall (New)17 -24BACB30NZ6K7BOLT, 100 DEG HEX DR Install (New)18 -24BACC30AB6SCOLLAR, PRELOADInstall (New) (a) The new outboard actuator fitting assembly has a "lip" that creates a blind area where the gap between the fitting and the spar upper and lower chords is difficult to measure. For these areas, if the actual required shim thickness cannot be measured, Boeing recommends that the new shims be delaminated as necessary to obtain a thickness within plus or minus 0.005 inch of the thickness of the previously removed shims in order to produce a similar straight taper. (b) Apply faying surface sealant, BMS 5-95. Apply prepack seal, BMS 5-95 to all cavities between fitting, shims, fillers and spar. Refer to SOPM 20-50-19 as an accepted procedure. (c) Apply faying surface sealant, BMS 5-95 both sides of shim. Refer to SOPM 20-50-19 and SOPM 20-50- 20 as an accepted procedure. FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 4 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 47 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 48 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (d) Apply one coat of BMS 10-79, Type III and BMS 10-60 Type 1. Refer to SOPM 20-44-04 and SOPM 20- 50-19 as an accepted procedure. (e) Touch up the edges of fastener holes with BMS 10-11, Type 1. Refer to SOPM 20-50-19 as an accepted procedure. (f) Delaminate as necessary. Maximum shim thickness is 0.030 inch. Maximum gap after shimming, before tightening fasteners, is 0.0080 inch when a 10 lb/foot maximum clamp up load is applied along the fastener centerline. (g) Delaminate shim as necessary to obtain a shim thickness equal to the shims previously removed from this location, plus or minus 0.0050 inch. Remove 0.0050 and/or 0.0030 laminations as required to obtain the required shim thickness. The shim against the spar must be fitted before the shims at the upper and lower chords at this fitting location. It is acceptable to average the thickness of the three shims measured previously to determine the proper shim thickness. (h) Delaminate shim as necessary to obtain a shim thickness equal to the shim previously removed from this location, plus or minus 0.0050 inch. Remove 0.0050 and/or 0.0030 laminations as required to obtain the required shim thickness. The shims against the spar must be fitted before the shims at the upper and lower chords at this fitting location. (i) Delaminate as necessary to obtain a shim thickness equal to the shim previously removed from this location, plus or minus 0.0050 inch. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. The QTY numbers shown below are the number of fasteners necessary for this figure. FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 5 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 48 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 49 MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE (a)0.312 - 0.31524BACB30YM10K14BOLT, 100 DEG HEX DR A -24BACC30CQ10CRCOLLAR, PRELOAD (a)0.312 - 0.3158BACB30YM10K15BOLTB -8BACC30CQ10CRCOLLAR, PRELOAD (a)0.375 - 0.3784125438-6K11BOLTC (b)-8BACW10BP6DPWASHER Torque 150 to 200 inch- pounds. -4BACN10YR6CDSELF-LOCKING NUT Torque 78 to 82 inch- pounds. (a) 0.250 - 0.25316BACB30NR4K6BOLT, HEX HEADD -16BACW10P447CGWASHER, FLAT Torque 78 to 82 inch- pounds. (a) 0.250 - 0.2538BACB30NR4K6BOLT, HEX HEADE --8BACW10P447CGWASHER, FLAT (a)-2HLT423AP8-9BOLTF (b)-2BACW10BP4DPWASHER (b)-2BACW10AU4WASHER, SELF- ALIGN Torque 80 to 95 inch- pounds. -2BACN10MT4SELF-LOCKING NUT (a) BACB30YM8K9 option- al -2HLT423AP8-9BOLTG (b)-4BACW10BP4DPWASHER Torque 80 to 95 inch- pounds. -2BACN11Z4CDNUT (a) BACB30YM10K9 op- tional -1HLT423AP10-9BOLTH (b)-2BACW10BP5DPWASHER-PLAIN Torque 150 to 200 inch- pounds. -1BACN11Z5CDNUT (a)-2BACB30YP8K9BOLT, 100 DEG HEX DR I --2BACC30BQ8COLLAR (a)-4BACB30NZ8K9J FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 6 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 49 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 50 MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE BOLT, 100 DEG HEX DR --4BACW10BP4NDPWASHER --4BACC30AB8CCOLLAR Torque 78 to 82 inch- pounds. (a) -12BACB30NR4K5BOLTK --12BACW10P208SWASHER, PLAIN (a) Apply BMS 5-95 sealant fastener wet. Refer to SOPM 20-50-19 Method 2 as accepted procedure. (b) Install one or two washers, as necessary, under the nut to ensure proper thread protrusion. FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 7 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 50 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 51 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT This Figure applies only to: Group 1. ELEV STA 194.79 ELEV STA 169.79 RIGHT ELEVATOR ASSEMBLY 1685560 FIGURE 3: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 1 OF 5) Original Issue: October 27, 2009 Revision 1 August 25, 2011 777-55A0016 Copyright © Unpublished Work - See page 1 for details. BOEING PROPRIETARY - 51 of 103 ### Page 52 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT ELEV STA 182.29 ) 12 LOCATIONS 21) 4 LOCATIONS 12 LOCATIONS ooo 5 LOCATIONS (19 20) 2 LOCATIONS ELEV STA 194.79 12 LOCATIONS 18 2 LOCATIONS 4 4 LOCATIONS 16 LOCATIONS 8 LOCATIONS FIGURE 3: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 2 OF 5) Original issue: October 27, 2009 Revision 1 August 25, 2011 777-55A0016 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 103 ### Page 53 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT ELEV STA 169.79 (10) 16 LOCATIONS 9) 2 LOCATIONS 13 8 LOCATIONS (12) 4 LOCATIONS 1693694 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. FIGURE 3: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 3 OF 5) Original Issue: October 27, 2009 Revision 1 August 25, 2011 777-55A0016 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 103 ### Page 54 NOTE: The hinge fitting at Elevator Station 182.29 is removed to provide access for installation of the new outboard actuator fitting at Elevator Station 194.79. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP -2-BoltRemove1 -4-WasherRemove -2-NutRemove -16-BoltRemove2 -32-WasherRemove -16-NutRemove -8-BoltRemove3 -8-WasherRemove -4-BoltRemove4 -4-WasherRemove 183W1300-6 option- al 1183W1300-2ACTUATOR FITTING ASSEMBLY Remove5 CAUTION: THE FAYING SURFACE OF THE FITTING IS SEALED TO A COMPOSITE SPAR. REFER TO SOPM 20-10-08 AS AN ACCEPTABLE PROCEDURE FOR REMOVAL. (b)3-SHIMRecord6 (a)1-SHIMRemove7 (a)1-SHIMRecord8 125438-6K12 option- al 2-BoltRemove9 -4-WasherRemove -2-NutRemove -16-BoltRemove10 -32-WasherRemove -16-NutRemove -8-BoltRemove11 -8-WasherRemove -4-BoltRemove12 -4-WasherRemove 183W1300-8 option- al 1183W1300-4ACTUATOR FITTING ASSEMBLY Remove13 FIGURE 3: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 4 OF 5) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 54 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 55 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP CAUTION: THE FAYING SURFACE OF THE FITTING IS SEALED TO A COMPOSITE SPAR. REFER TO SOPM 20-10-08 AS AN ACCEPTABLE PROCEDURE FOR REMOVAL. (b)3-SHIMRecord14 -1-SHIMRemove15 -1-SHIMRecord16 -24-FastenerRemove17 -12-BoltRemove18 -12-WasherRemove -5-BoltRemove19 -10-WasherRemove -5-NutRemove -2-BoltRemove20 -2-CollarRemove -4-BoltRemove21 -4-WasherRemove -4-CollarRemove -1-FittingRemove / Keep22 (d)1-SHIMRemove23 (d)1-SHIMRemove24 (c)2-SHIMRemove25 (a) Measure shim thickness and record. This data will be used when the new elevator actuator fittings are installed. (b) There are three separate shims installed between the elevator actuator fitting and the elevator spar. Measure and record the individual thickness of each shim. This data will be used when the new elevator actuator fittings are installed. (c) There are two separate shims installed between the hinge fitting and the elevator spar. Measure and record the individual thickness of each shim. This data will be used when the hinge fitting is reinstalled. (d) Measure shim thickness and record. This data will be used when the hinge fitting is reinstalled. FIGURE 3: ACTUATOR FITTING ASSEMBLIES - REMOVAL (SHEET 5 OF 5) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 55 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 56 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT This Figure applies only to: Group 1. ELEV STA 194.79 ELEV STA 169.79 RIGHT ELEVATOR ASSEMBLY 1679202 FIGURE 4: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 1 OF 7) Original Issue: October 27, 2009 Revision 1 August 25, 2011 BOEING PROPRIETARY - 777-55A0016 Copyright © Unpublished Work - See page 1 for details. 56 of 103 ### Page 57 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT ELEV STA 182.29 12 LOCATIONS+ 12 LOCATIONS ® 19 5 LOCATIONS ELEV STA 194.79 - 4 LOCATIONS + 4 LOCATIONS A 4 LOCATIONS 12 LOCATIONS K 4 LOCATIONS A 8 LOCATIONS 2021394 FIGURE 4: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 2 OF 7) Original issue: October 27, 2009 Revision 1 August 25, 2011 BOEING PROPRIETARY - 777-55A0016 Copyright © Unpublished Work - See page 1 for details. 57 of 103 ### Page 58 (OCR) BOEING SERVICE BULLETIN 777-55A0016 ALERT ALERT (4 LOCATIONS) A _ ELEV STA 169.79 4 (4 LOCATIONS) (8 LOCATIONS) (4 LOCATIONS) B_ EL A (4 LOCATIONS) 1700019 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. FIGURE 4: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 3 OF 7) Original Issue: October 27, 2009 Revision 1 August 25, 2011 777-55A0016 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 103 ### Page 59 NOTE: The elevator spar tapers in height from inboard to the outboard direction, and can make it difficult to install the new outboard actuator fitting. To locate the new outboard actuator fitting, place it against the elevator spar near Elevator Station 182, then slide it outboard along the spar to its proper location at Elevator Station 194.79. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (b) (c) (e) (g)1BACS40V084B095SHIM, LAMINATEDInstall (New)1 (b) (e)1183W1310-10ACTUATOR FITTING ASSEMBLY Install (New)2 (a) (b) (c) (e) (i)1BACS40V026B085SHIM, LAMINATEDInstall (New)3 (a) (b) (c) (e) (f)1BACS40V026B085SHIM, LAMINATEDInstall (New)4 (b) (d) (e)2183W1701-11RADIUS FILLERInstall (New)5 (b) (d) (e)2183W1701-9RADIUS FILLERInstall (New)6 (b) (c) (e) (g)1BACS40V084B100SHIM, LAMINATEDInstall (New)7 (b) (e)1183W1320-10ACTUATOR FITTING ASSEMBLY Install (New)8 (b) (c) (e) (i)1BACS40V026B084SHIM, LAMINATEDInstall (New)9 (b) (c) (e) (f)1BACS40V026B084SHIM, LAMINATEDInstall (New)10 (b) (d) (e)2183W1701-11RADIUS FILLERInstall (New)11 (b) (d) (e)2183W1701-9RADIUS FILLERInstall (New)12 (b) (c) (e) (h)1BACS40V027B048SHIM, LAMINATEDInstall (New)13 (b) (c) (e) (h)1BACS40V024B072SHIM, LAMINATEDInstall (New)14 (b) (e)1-FittingInstall (Kept)15 (b) (c) (i)1BACS40V019F048SHIM , LAMINATEDInstall (New)16 (b) (c) (f)1BACS40V019F046SHIM, LAMINATEDInstall (New)17 -24BACB30NZ6K7BOLT, 100 DEG HEX DR Install (New)18 -24BACC30AB6SCOLLAR, PRELOADInstall (New) (a) The new outboard actuator fitting assembly has a "lip" that creates a blind area where the gap between the fitting and the spar upper and lower chords is difficult to measure. For these areas, if the actual required shim thickness cannot be measured, Boeing recommends that the new shims be delaminated as necessary to obtain a thickness within plus or minus 0.005 inch of the thickness of the previously removed shims in order to produce a similar straight taper. (b) Apply faying surface sealant, BMS 5-95. Apply prepack seal, BMS 5-95 to all cavities between fitting, shims, fillers and spar. Refer to SOPM 20-50-19 as an accepted procedure. (c) Apply faying surface sealant, BMS 5-95 both sides of shim. Refer to SOPM 20-50-19 and SOPM 20-50- 20 as an accepted procedure. FIGURE 4: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 4 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 59 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT ### Page 60 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (d) Apply one coat of BMS 10-79, Type III and BMS 10-60 Type 1. Refer to SOPM 20-44-04 and SOPM 20- 50-19 as an accepted procedure. (e) Touch up the edges of fastener holes with BMS 10-11, Type 1. Refer to SOPM 20-50-19 as accepted procedure. (f) Delaminate as necessary. Maximum shim thickness is 0.030 inch. Maximum gap after shimming, before tightening fasteners, is 0.0080 inch when a 10 lb/foot maximum clamp up load is applied along the fastener centerline. (g) Delaminate shim as necessary to obtain a shim thickness equal to the shims previously removed from this location, plus or minus 0.0050 inch. Remove 0.0050 and/or 0.0030 laminations as required to obtain the required shim thickness. The shim against the spar must be fitted before the shims at the upper and lower chords at this fitting location. .It is acceptable to average the thickness of the three shims measured previously to determine the proper shim thickness. (h) Delaminate shim as necessary to obtain a shim thickness equal to the shim previously removed from this location, plus or minus 0.0050 inch. Remove 0.0050 and/or 0.0030 laminations as required to obtain the required shim thickness. The shims against the spar must be fitted before the shims at the upper and lower chords at this fitting location. (i) Delaminate as necessary to obtain a shim thickness equal to the shim previously removed from this location, plus or minus 0.0050 inch. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. The QTY numbers shown below are the number of fasteners necessary for this figure. FIGURE 4: ACTUATOR FITTING ASSEMBLIES - INSTALLATION (SHEET 5 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 27, 2009 777-55A0016Revision 1 August 25, 2011 60 of 103 BOEING SERVICE BULLETIN 777-55A0016 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/777-55a0016/file/b4745d646e86.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.