# Boeing Alert Service Bulletin 777-55A0017: No revision named

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2010-1156; AD 2011-05-12 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 777-55A0017](https://openairdocs.org/service-documents/boeing/777-55a0017.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin
- Pages: 55
- PDF: https://openairdocs.org/files/sha256/bb/ff/bbffa6d970f1db564edc56ab789bbe656fadeb8c266ea9cf9106d13cef48d207
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## Text

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### Page 1

Commercial 
Airplanes
777
Service Bulletin
ALERT
Number: 777-55A0017
Original Issue: May 20, 2010
ATA System: 5518 2741
SUBJECT: STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon
Lined Bushing Inspection and 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 © 2010 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Unpublished Work - All Rights Reserved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.
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4.0

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### Page 3

Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
2. Spares Affected ........................................ 1 3
B. Concurrent Requirements ...................................... 1 3
C. Reason ................................................ 1 3
D. Description .............................................. 1 4
E. Compliance .............................................. 1 5
F. Approval ............................................... 1 6
G. Manpower .............................................. 1 6
H. Weight and Balance Changes .................................... 1 9
I. Electrical Load Data ......................................... 1 9
J. References .............................................. 1 9
1. Existing Data .......................................... 1 9
2. Data supplied with this Service Bulletin ............................ 2 0
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 0
K. Publications Affected ........................................ 2 0
L. Interchangeability and Intermixability of Parts ........................... 2 0
2. MATERIAL INFORMATION ........................................ 2 1
A. Material - Price and Availability ................................... 2 1
B. Industry Support Information .................................... 2 2
C. Parts Necessary For Each Airplane ................................. 2 2
1. Kits/Parts ............................................ 2 2
2. Parts and Materials Supplied by the Operator ........................ 2 2
3. Parts Modified and Reidentified ................................ 2 3
4. Parts Removed and Not Replaced .............................. 2 3
D. Parts Necessary to Change Spares ................................. 2 3
E. Special Tooling - Price and Availability ............................... 2 3
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 6
FIGURE 1: INSPECTION AND MEASUREMENT OF BULKHEAD SUPPORT JACKSCREW FITTING
KARON LINED BUSHINGS .................................. 3 1
FIGURE 2: INSPECTION AND MEASUREMENT OF HORIZONTAL STABILIZER JACKSCREW FITTING
KARON LINED BUSHINGS .................................. 3 3
FIGURE 3: INSPECTION AND MEASUREMENT OF UPPER GIMBAL - BRAKE HOUSING AND UPPER
GIMBAL - BULKHEAD SUPPORT KARON LINED BUSHINGS ............... 3 5
FIGURE 4: INSPECTION AND MEASUREMENT OF TRIM ACTUATOR PRIMARY BRAKE HOUSING
KARON LINED BUSHINGS .................................. 3 7
FIGURE 5: INSPECTION AND MEASUREMENT OF LOWER GIMBAL KARON LINED BUSHINGS . 39
FIGURE 6: INSPECTION AND MEASUREMENT OF PINS ....................... 4 1
FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL . . 43
FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT
.................................................. 4 6
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### Page 4

FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION
.................................................. 5 0
FIGURE 10: KARON LINED BUSHING SERVICE WEAR LIMITS ..................... 5 5
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### Page 5

Commercial 
Airplanes
777
Service Bulletin
ALERT
SummaryNumber: 777-55A0017Original Issue: May 20, 2010
ATA System: 5518 2741
SUBJECT: STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon
Lined Bushing Inspection and 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
None.
BACKGROUND
Accomplishment of work given in this service bulletin will find damage to Karon lined bushings and pins in the
HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) and HSTA attachment locations on the airplane structure.
There are twenty-four (24) Karon lined bushings and six (6) pins in the fuselage, horizontal stabilizer, HSTA
upper and lower gimbals, and HSTA primary brake housing. If the Karon liners in the bushings are damaged,
this may cause the Karon liners to completely disbond from the bushings. The completely disbonded Karon
liners may migrate out of the joint causing excessive joint clearance. A joint with excessive clearance would
result in fatigue cracking of the pins. The fatigue cracking of the pins in the HSTA and HSTA attachment locations
on the airplane structure can compromise the structural integrity of the joints resulting in loss of controllability
of the airplane.
The 24 Karon lined bushings are installed in the following joint locations: BULKHEAD SUPPORT JACKSCREW
FITTING, HORIZONTAL STABILIZER JACKSCREW FITTING, UPPER GIMBAL - BRAKE HOUSING, UPPER
GIMBAL - BULKHEAD SUPPORT, TRIM ACTUATOR PRIMARY BRAKE HOUSING, AND LOWER GIMBAL.
The bore of the bushings is lined with Karon, a material that is intended to reduce friction and resist wear.
Research tests have shown that Karon liners would not wear in service; therefore, lubrication and inspection of
these would not be necessary.
During a scheduled inspection of the HSTA components for 777-200, one operator found a Karon lined bushing
in the HORIZONTAL STABILIZER JACKSCREW FITTING with Karon liner broken into five pieces. The broken
Karon liner had worn and disbonded from the bushing. The broken Karon liner of the bushing was found on an
airplane that had accumulated 35,145 flight hours and 5,335 fight cycles.
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### Page 6

Boeing analysis shows that the broken Karon lined bushing was one of the 149 bushings that used an early
manufacturing process, which has since been improved. However, further investigation and analysis by Boeing
show that Karon lined bushings in the HSTA and HSTA attachment locations on the airplane structure using
both the early and the improved process could wear in service. The analysis also shows that the wear of the
Karon liner may cause excessive joint clearance, which could lead to fatigue cracking of the pins.
Accomplishment of the inspection in this service bulletin will find any disbond, tear, or wear in the 24 Karon lined
bushings; any gouge, crack, or wear in the 6 pins; and any gouge or crack in the fail-safe components in the
HSTA and HSTA attachment locations on the airplane structure. The inspection will make sure that Karon lined
bushings and pins are returned to the design standard.
Boeing Service Related Problem (SRP) 777-SRP-55-0042 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) article 777 FTD 55-07001
ACTION
Airplane Work
1. Remove hydraulic pressure, hydraulic power, and install safety tags to the HORIZONTAL STABILIZER
TRIM ACTUATOR (HSTA).
2. Gain access to HSTA area and remove the HSTA.
3. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. If
any disbond or tear is found, or the ID is greater than the allowable MAXIMUM DIAMETER on the Karon
lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the
bushings; then no bushing replacement is necessary.
4. Install the HSTA that is in a known serviceable condition or has been overhauled in accordance with this
service bulletin.
NOTE: If the replacement HSTA is not in a known serviceable condition, then do a Detailed Inspection
and measurement of the Karon lined bushings and pins; and a Detailed Inspection of the fail-safe
components of the replacement HSTA in accordance with this service bulletin before further flight.
Refer to Paragraph 3.A., General Information, for the applicable known serviceable conditions.
5. Do the Horizontal Stabilizer Trim Actuator Installation Test.
6. Close access and put the airplane back to a serviceable condition.
7. Repeat the Detailed Inspection and measurement of the Karon lined bushings at the time in accordance
with Paragraph 1.E., Compliance.
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### Page 7

Component (Horizontal Stabilizer Trim Actuator, HSTA) Work
1. Disassemble the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) as necessary.
2. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. Do
a Detailed Inspection and measurement of the pins for any gouge, crack, or wear. Do a Detailed Inspection
of the fail-safe components for any gouge or crack.
3. If any disbond or tear is found, or the ID is greater than the MAXIMUM DESIGN DIMENSION on the Karon
lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the
bushings; then no bushing replacement is necessary.
4. If any gouge or crack is found, or the OD is less than the MINIMUM DESIGN DIMENSION on the pins; then
a pin replacement or refurbishment is necessary. If any gouge or crack is found on the fail-safe components,
then a replacement or refurbishment is necessary.
For any cracked pins that are found during the Detailed Inspection, replace the pin and do a magnetic
particle inspection of the fail-safe components as applicable. If any crack is found on the fail-safe components
during a magnetic particle inspection, then replacement is necessary.
If no gouge, crack, and wear are found on the pins; then a replacement or refurbishment is not necessary.
If no gouge and crack are found on the fail-safe components, then a replacement or refurbishment is not
necessary.
5. Assemble the HSTA.
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
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service
bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin
mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are available for airplanes in warranty as of March 3, 2007. Please refer to Paragraph
2.B., Industry Support Information.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability
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### Page 8 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
STA
2245.70
00000000
BULKHEAD SUPPORT
JACKSCREW FITTING
UPPER GIMBAL
TRIM ACTUATOR
PRIMARY
BRAKE HOUSING
HORIZONTAL
STABILIZER
TRIM ACTUATOR
(HSTA)
REMOVE THE HORIZONTAL
STABILIZER TRIM ACTUATOR
(HSTA). DO A DETAILED
INSPECTION AND MEASUREMENT OF
KARON LINED BUSHINGS IN THE
BULKHEAD SUPPORT JACKSCREW
FITTING AND HORIZONTAL
STABILIZER JACKSCREW FITTING.
REPLACE KARON LINED BUSHINGS IF
ANY DISCREPANCIES ARE FOUND.
INSTALL HSTA THAT IS IN A KNOWN
SERVICEABLE CONDITION OR
OVERHAULED IN ACCORDANCE WITH
THIS SERVICE BULLETIN. REPEAT
THE DETAILED INSPECTION AND
MEASUREMENT IN ACCORDANCE WITH
THIS SERVICE BULLETIN.
LOWER GIMBAL
FWD  HORIZONTAL STABILIZER
JACKSCREW FITTING
Original Issue: May 20, 2010
777-55A0017
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### Page 9

Commercial 
Airplanes
777
Service Bulletin
ALERT
Number: 777-55A0017
Original Issue: May 20, 2010
ATA System: 5518 2741
SUBJECT: STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon
Lined Bushing Inspection and 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.
Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below
is complete for airplanes through line number 893. At least one airplane after line number
893 is also affected by this service bulletin, and these airplanes are in Group(s) 1. These
airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity"
result when they are added to the MBF Fleet Profile Page.
DESCRIPTIONCONFIGURATIONGROUP
777-200, 777-200LR, 777-300, and 777-300ER airplanes.-1
Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER
GroupVariable Number
1WA001 - WA017
1WA076 - WA080
1WA086 - WA093
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GroupVariable Number
1WA101 - WA104
1WA116 - WA119
1WA131 - WA137
1WA171 - WA175
1WA196 - WA198
1WA206 - WA212
1WA221 - WA223
1WA231 - WA232
1WA241 - WA250
1WA261 - WA266
1WA281 - WA283
1WA301 - WA304
1WB001 - WB021
1WB031 - WB046
1WB051 - WB088
1WB101 - WB106
1WB121 - WB125
1WB131 - WB148
1WB151 - WB155
1WB161 - WB177
1WB181 - WB194
1WB201 - WB215
1WB231 - WB247
1WB271 - WB273
1WB276 - WB286
1WB291 - WB302
1WB306 - WB307
1WB311 - WB337
1WB341 - WB342
1WB366 - WB368
1WB371 - WB388
1WB406
1WB411 - WB413
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GroupVariable Number
1WB416 - WB439
1WB446 - WB453
1WB476
1WB481 - WB484
1WB501 - WB512
1WB531 - WB537
1WB551 - WB554
1WB591 - WB597
1WB601 - WB606
1WB611 - WB622
1WB631 - WB638
1WB646 - WB649
1WC051 - WC073
1WC101 - WC104
1WC111 - WC120
1WC221 - WC224
1WC241 - WC243
1WC281 - WC290
1WC301 - WC308
1WC361 - WC364
1WC371 - WC374
1WC381 - WC395
1WC441
1WC446 - WC449
1WC456 - WC459
1WC486 - WC493
1WC506 - WC508
1WC521 - WC522
1WC531 - WC536
1WC546 - WC548
1WC556
1WC566 - WC567
1WC571 - WC574
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GroupVariable Number
1WC581
1WD001 - WD002
1WD011 - WD018
1WD031 - WD036
1WD046 - WD055
1WD066 - WD075
1WD081 - WD088
1WD091
1WD501 - WD513
1WD521 - WD541
1WD546 - WD554
1WD561 - WD573
1WD581 - WD599
1WD606 - WD609
1WD621 - WD632
1WD651 - WD665
1WD671 - WD676
1WD691 - WD709
1WD741 - WD752
1WD761 - WD771
1WD786 - WD788
1WD796 - WD813
1WD826 - WD837
1WD846 - WD861
1WD871 - WD882
1WD911 - WD914
1WD921 - WD922
1WD936 - WD939
1WD946 - WD951
1WD966 - WD969
1WD981 - WD982
1WD986 - WD987
1WE001 - WE004
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### Page 13

GroupVariable Number
1WE011 - WE012
1WE021 - WE022
1WE071
1WE081
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Accomplishment of work given in this service bulletin will find damage to Karon lined bushings and
pins in the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) and HSTA attachment locations on
the airplane structure. There are twenty-four (24) Karon lined bushings and six (6) pins in the fuselage,
horizontal stabilizer, HSTA upper and lower gimbals, and HSTA primary brake housing. If the Karon
liners in the bushings are damaged, this may cause the Karon liners to completely disbond from the
bushings. The completely disbonded Karon liners may migrate out of the joint causing excessive joint
clearance. A joint with excessive clearance would result in fatigue cracking of the pins. The fatigue
cracking of the pins in the HSTA and HSTA attachment locations on the airplane structure can
compromise the structural integrity of the joints resulting in loss of controllability of the airplane.
The 24 Karon lined bushings are installed in the following joint locations: BULKHEAD SUPPORT
JACKSCREW FITTING, HORIZONTAL STABILIZER JACKSCREW FITTING, UPPER GIMBAL -
BRAKE HOUSING, UPPER GIMBAL - BULKHEAD SUPPORT, TRIM ACTUATOR PRIMARY BRAKE
HOUSING, AND LOWER GIMBAL. The bore of the bushings is lined with Karon, a material that is
intended to reduce friction and resist wear. Research tests have shown that Karon liners would not
wear in service; therefore, lubrication and inspection of these would not be necessary.
During a scheduled inspection of the HSTA components for 777-200, one operator found a Karon lined
bushing in the HORIZONTAL STABILIZER JACKSCREW FITTING with Karon liner broken into five
pieces. The broken Karon liner had worn and disbonded from the bushing. The broken Karon liner of
the bushing was found on an airplane that had accumulated 35,145 flight hours and 5,335 fight cycles.
Boeing analysis shows that the broken Karon lined bushing was one of the 149 bushings that used an
early manufacturing process, which has since been improved. However, further investigation and
analysis by Boeing show that Karon lined bushings in the HSTA and HSTA attachment locations on
the airplane structure using both the early and the improved process could wear in service. The analysis
also shows that the wear of the Karon liner may cause excessive joint clearance, which could lead to
fatigue cracking of the pins.
Accomplishment of the inspection in this service bulletin will find any disbond, tear, or wear in the 24
Karon lined bushings; any gouge, crack, or wear in the 6 pins; and any gouge or crack in the fail-safe
components in the HSTA and HSTA attachment locations on the airplane structure. The inspection will
make sure that Karon lined bushings and pins are returned to the design standard.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 20, 2010
777-55A0017
13 of 55
BOEING SERVICE BULLETIN 777-55A0017
ALERTALERT

### Page 14

Boeing Service Related Problem (SRP) 777-SRP-55-0042 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) article 777 FTD 55-07001 is related to this service bulletin.
D. Description
Airplane Work
1. Remove hydraulic pressure, hydraulic power, and install safety tags to the HORIZONTAL
STABILIZER TRIM ACTUATOR (HSTA).
2. Gain access to HSTA area and remove the HSTA.
3. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or
wear. If any disbond or tear is found, or the ID is greater than the allowable MAXIMUM DIAMETER
on the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and
wear are found on the bushings; then no bushing replacement is necessary.
4. Install the HSTA that is in a known serviceable condition or has been overhauled in accordance
with this service bulletin.
NOTE: If the replacement HSTA is not in a known serviceable condition, then do a Detailed
Inspection and measurement of the Karon lined bushings and pins; and a Detailed
Inspection of the fail-safe components of the replacement HSTA in accordance with this
service bulletin before further flight. Refer to Paragraph 3.A., General Information, for the
applicable known serviceable conditions.
5. Do the Horizontal Stabilizer Trim Actuator Installation Test.
6. Close access and put the airplane back to a serviceable condition.
7. Repeat the Detailed Inspection and measurement of the Karon lined bushings at the time in
accordance with Paragraph 1.E., Compliance.
Component (Horizontal Stabilizer Trim Actuator, HSTA) Work
1. Disassemble the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) as necessary.
2. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or
wear. Do a Detailed Inspection and measurement of the pins for any gouge, crack, or wear. Do a
Detailed Inspection of the fail-safe components for any gouge or crack.
3. If any disbond or tear is found, or the ID is greater than the MAXIMUM DESIGN DIMENSION on
the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear
are found on the bushings; then no bushing replacement is necessary.
4. If any gouge or crack is found, or the OD is less than the MINIMUM DESIGN DIMENSION on the
pins; then a pin replacement or refurbishment is necessary. If any gouge or crack is found on the
fail-safe components, then a replacement or refurbishment is necessary.
For any cracked pins that are found during the Detailed Inspection, replace the pin and do a
magnetic particle inspection of the fail-safe components as applicable. If any crack is found on the
fail-safe components during a magnetic particle inspection, then replacement is necessary.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 20, 2010
777-55A0017
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### Page 15

If no gouge, crack, and wear are found on the pins; then a replacement or refurbishment is not
necessary. If no gouge and crack are found on the fail-safe components, then a replacement or
refurbishment is not necessary.
5. Assemble the HSTA.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
311, 312777-200, 777-200LR, 777-300,
777-300ER
E. Compliance
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to
this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this
service bulletin mandatory.
Table 1: Inspection of Karon Lined Bushings and Pins
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later )
ActionCondition
-Within 24
months after the
original issue
date of this ser-
vice bulletin.
Before 32,000
total flight cy-
cles.
Do a Detailed Inspection
of the Karon lined bush-
ings for a disbond or tear
and measure the ID of
the Karon lined bushings
for wear in accordance
with PART 1 of Para-
graph 3.B., Work Instruc-
tions,
All airplanes.
-Before further flight.Do a Karon lined bushing
replacement in accor-
dance with PART 1 of
Paragraph 3.B., Work In-
structions, as applicable
Any disbond or tear found,
or the ID is greater than the
allowable MAXIMUM DIAM-
ETER on the Karon lined
bushings.
AND
Install HSTA that is in a
known serviceable condi-
tion or has been over-
hauled in accordance
with PART 2 of Para-
graph 3.B., Work Instruc-
tions.(a)
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### Page 16

Table 1: Inspection of Karon Lined Bushings and Pins
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later )
ActionCondition
-Before further flight.Install HSTA that is in a
known serviceable condi-
tion or has been over-
hauled in accordance
with PART 2 of Para-
graph 3.B., Work Instruc-
tions.(a)
No disbond and tear found,
and the ID is less than or
equal to the allowable
MAXIMUM DIAMETER on
the Karon lined bushings.
16,000 flight cy-
cles.
Within 16,000 flight cycles from
the initial inspection.
Do a Detailed Inspection
of the Karon lined bush-
ings for a disbond or tear
and measure the ID of
the Karon lined bushings
for wear in accordance
with PART 1 of Para-
graph 3.B., Work Instruc-
tions.
Accomplished PART 1 of
Paragraph 3.B., Work In-
structions, and installed
HSTA that is in a known
serviceable condition or
has been overhauled in
accordance with PART 2
of Paragraph 3.B., Work
Instructions.
(a) If the replacement HSTA is not in a known serviceable condition, then do a Detailed Inspection and
measurement of the Karon lined bushings and pins; and a Detailed Inspection of the fail-safe components
of the HSTA in accordance with PART 2 of Paragraph 3.B., Work Instructions, before further flight. Refer
to Paragraph 3.A., General Information, for the descriptions of HSTA's that are in a known serviceable
conditions.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
G. Manpower
The table below shows an estimate of the task hours necessary to do this inspection 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
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 Time to cure the materials
 Time to make the parts
 Time to find the tools.
Table 1: Airplane Work - Inspection and Measurement of Karon Lined Bushings
Elapsed HoursTask HoursNumber of Per-
sons
Task
1.803.602PART 1: Prepara-
tion, Open Access,
and Actuator Re-
moval
0.750.751PART 1: BULK-
HEAD SUPPORT
JACKSCREW FIT-
TING Karon lined
bushings (FIGURE
1)
0.750.751PART 1: HORIZON-
TAL STABILIZER
JACKSCREW FIT-
TING Karon lined
bushings (FIGURE
2)
2.85.62PART 6: HSTA In-
stallation, HSTA In-
stallation Test, and
Close Access.
6.1010.70TOTAL FOR EACH AIRPLANE
Note: More time is needed if bushing replacement is necessary. Refer to Table 3
for additional hours for bushing replacement.
Table 2: Component (Horizontal Stabilizer Trim Actuator, HSTA) Work - Inspection and
Measurement of Karon Lined Bushings and Pins
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.500.501PART 2: UPPER
GIMBAL - BRAKE
HOUSING Karon
lined bushings
(FIGURE 3)
0.500.501PART 2: UPPER
GIMBAL - BULK-
HEAD SUPPORT
Karon lined bush-
ings (FIGURE 3)
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Table 2: Component (Horizontal Stabilizer Trim Actuator, HSTA) Work - Inspection and
Measurement of Karon Lined Bushings and Pins
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.500.501PART 2: TRIM AC-
TUATOR PRIMARY
BRAKE HOUSING
Karon lined bush-
ings (FIGURE 4)
0.750.751PART 2: LOWER
GIMBAL Karon
lined bushings
(FIGURE 5)
0.500.501PART 2: Pins (FIG-
URE 6)
2.752.75TOTAL FOR EACH COMPONENT
Note: More time is needed if bushing and/or pin replacement/refurbishment are
necessary. Refer to Table 3 for additional hours for bushing replacement.
Table 3: Karon Lined Bushing Replacement
Elapsed HoursTask HoursNumber of Per-
sons
Task
2.002.001PART 1: BULK-
HEAD SUPPORT
JACKSCREW FIT-
TING, Bushing Re-
moval (FIGURE
7)(a)
2.152.151PART 1: BULK-
HEAD SUPPORT
JACKSCREW FIT-
TING, Intermediate
Sleeve Replace-
ment (FIGURE 8)(a)
(b) (c)
1.001.001PART 1: BULK-
HEAD SUPPORT
JACKSCREW FIT-
TING, Bushing In-
stallation (FIGURE
9)(a) (c)
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Table 3: Karon Lined Bushing Replacement
Elapsed HoursTask HoursNumber of Per-
sons
Task
3.003.001PART 1: HORIZON-
TAL STABILIZER
JACKSCREW FIT-
TING, Bushing Re-
placement(a) (c)
1.751.751PART 2: UPPER
GIMBAL - UPPER
BRAKE, Bushing
Replacement(a) (c)
1.751.751PART 2: UPPER
GIMBAL - BULK-
HEAD SUPPORT,
Bushing Replace-
ment(a) (c)
1.751.751PART 2: TRIM AC-
TUATOR PRIMARY
BRAKE HOUSING,
Bushing Replace-
ment(a) (c)
3.003.001PART 2: LOWER
GIMBAL, Bushing
Replacement(a) (c)
(a) Hours given are for a typical in-line set replacement.
(b) Replacement of the intermediate sleeve is necessary if a damage is found on
the sleeve.
(c) More time will be necessary to perform machining steps.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data
a. Boeing Service Related Problem (SRP) 777-SRP-55-0042
b. Component Maintenance Manual (CMM) 27-41-03
c. Standard Overhaul Practices Manual (SOPM) 20-10-02, 20-20-02, 20-30-03, 20-50-03
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d. 777 Aircraft Maintenance Manual (AMM) 27-41-13
e. 777 Fleet Team Digest (FTD) 55-07001
f. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-04
g. 777-200 Structural Repair Manual (SRM) 51-20-01, 55-10-90, REPAIR 1
h. 777-300 Structural Repair Manual (SRM) 51-20-01, 55-10-90, REPAIR 1
i. 777 Maintenance Planning Document (MPD) 27-290-00, 55-507-00
2. Data supplied with this Service Bulletin
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin
TitleDrawing Number
SUPPORT ASSEMBLY - HORIZONTAL STABILIZER
JACKSCREW, STA 2245.70
148W9100
SPLICE ASSEMBLY - FRONT SPAR, HORIZONTAL STABILIZER182W7400
UPPER GIMBAL ASSEMBLY - STABILIZER TRIM251W4170
HOUSING ASSEMBLY - PRIMARY BRAKE, STABILIZER TRIM251W4140
GIMBAL ASSEMBLY - LOWER, ACTUATOR, STABILIZER TRIM251W4180
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 Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the parts shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown
below. Parts availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date
Boeing gets the purchase order.
Unit Price thru
12/31/2010
ROLT
(Weeks)
NamePart Number
$541.0031BUSHING - JACKSCREW,
SUPPORT
148W9106-2
$1,135.0023BUSHING - JACKSCREW,
HORIZONTAL STABILIZER
182W7404-1
$985.0033BUSHING - GIMBAL, UPPER
BRAKE HOUSING
251W4172-3
$1,072.0023BUSHING - GIMBAL, LOWER
HORIZONTAL STABILIZER
251W4172-4
$1,029.0023BUSHING - GIMBAL, UPPER
SUPPORT
251W4172-5
$1,001.0023BUSHING - GIMBAL, BRAKE
HOUSING
251W4172-6
$1,187.0086PIN - UPPER GIMBAL, STABI-
LIZER TRIM, BRAKE HOUSING
251W4173-3
$3,191.0076PIN - UPPER GIMBAL, STABI-
LIZER TRIM, SUPPORT
251W4175-3
$7,791.0045PIN ASSEMBLY - NUT GIM-
BAL, STABILIZER TRIM
251W4187-7 (ALTER-
NATIVE SUBSTITUTE,
-9)
$839.0058SHAFT-SAFETY, UPPER GIM-
BAL, STABILIZER TRIM
(SAFETY SHAFT)
251W4188-1
$725.0052INTERMEDIATE SLEEVE148W9107-1
The parts are subject to the terms and conditions of the Boeing standard purchase order
acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United
States dollars. Terms: Net 30 days.
REFERENCE THIS SERVICE BULLETIN AND SUBMIT YOUR PURCHASE ORDER BY ONE OF
THE METHODS THAT FOLLOW:
1. Order on-line via ATA Spec 2000 or Boeing Part Page
2. Fax to (206) 662-7145
3. Spares Customer Support - MC 36-65
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Boeing Spares Department
P.O. Box 3707
Seattle, Washington 98124-2207 USA
B. Industry Support Information
Boeing warranty remedies are available for 777 airplanes in warranty as of March 7, 2007. For inspection
task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing
Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is found
during the inspection for airplanes in warranty as of that date and additional task hours are required,
send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to this service
bulletin number and reference the airplane variable numbers in your purchase order.
C. Parts Necessary For Each Airplane
1. Kits/Parts
NotesNameQTYPart Number /
Specification
-BUSHING - JACKSCREW, SUP-
PORT
4148W9106-2
-BUSHING - JACKSCREW, HORI-
ZONTAL STABILIZER
4182W7404-1
-BUSHING - GIMBAL, UPPER
BRAKE HOUSING
4251W4172-3
-BUSHING - GIMBAL, LOWER
HORIZONTAL STABILIZER
4251W4172-4
-BUSHING - GIMBAL, UPPER SUP-
PORT
4251W4172-5
-BUSHING - GIMBAL, BRAKE
HOUSING
4251W4172-6
-PIN - UPPER GIMBAL, STABILIZER
TRIM, BRAKE HOUSING
2251W4173-3
-PIN - UPPER GIMBAL, STABILIZER
TRIM, SUPPORT
2251W4175-3
-PIN ASSEMBLY - NUT GIMBAL,
STABILIZER TRIM
2251W4187-7 (AL-
TERNATIVE SUB-
STITUTE, -9)
-SHAFT-SAFETY, UPPER GIMBAL,
STABILIZER TRIM (SAFETY
SHAFT)
1251W4188-1
-INTERMEDIATE SLEEVE2148W9107-1
2. Parts and Materials Supplied by the Operator
None.
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3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
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.
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### Page 25

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. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s)
give the recommended sequence of steps. The sequence of steps to do this service
bulletin can be changed.
2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
3. Obey all of the warnings and cautions given in the specified manual sections.
4. The work instructions are divided into work packages. Task Hours and Elapsed Hours
for each package are given in Paragraph 1.G., Manpower. You can do each work
package independently.
5. 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
– Torque limits to tighten nuts and bolts are in 777 SRM, Chapter 51.
6. Use the approved fastener and process material substitutions in accordance with
777 SRM, Chapter 51. Alternate fasteners are listed in 777 SRM, Chapter 51 and
Boeing Drawing 012W6100.
7. 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.
8. 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.
9. The Detailed inspection and measurement of Karon lined bushings and pins in the
HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) and HSTA attachment
locations on the airplane structure are necessary at the following joint locations:
– BULKHEAD SUPPORT JACKSCREW FITTING
– HORIZONTAL STABILIZER JACKSCREW FITTING
– UPPER GIMBAL - BRAKE HOUSING
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– UPPER GIMBAL - BULKHEAD SUPPORT
– TRIM ACTUATOR PRIMARY BRAKE HOUSING
– LOWER GIMBAL
10. The fail-safe components in the six joint locations of the HSTA are SHAFT-SAFETY,
UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT) and the inner pin of PIN
ASSEMBLY - NUT GIMBAL, STABILIZER TRIM.
11. Each joint location has four (4) Karon lined bushings in the in-line set; 2 bushings
per side. If Karon lined bushing replacement is necessary for a joint, it is
recommended to replace the bushings in a set of 4. However, as a minimum replace
Karon lined bushings as a pair on either side of the joint.
12. The instructions identified in Paragraph 3.B., Work Instructions, and Figure(s) are
for a typical in-line set.
13. A replacement Horizontal Stabilizer Trim Actuator (HSTA) is in a known serviceable
condition if your records agree with one these conditions:
– The HSTA is new.
– The HSTA is overhauled as specified in the applicable CMM 27-41-03.
– The condition of the HSTA is found satisfactory with the tests and checks as
specified in CMM 27-41-03.
B. WORK INSTRUCTIONS
PART 1 - AIRPLANE WORK
1. Preparation, Open Access, and HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) Removal
a. Remove hydraulic pressure, hydraulic power, and install safety tags to the HSTA. Refer to
777 AMM 27-41-13 as an accepted procedure.
b. Gain access to the HSTA through service access door 311BL.
c. Remove the HSTA. Refer to 777 AMM 27-41-13 as an accepted procedure.
2. Inspection and Measurement of Karon Lined Bushings
a. Do a Detailed Inspection and measure the internal diameter (ID) of the BUSHING -
JACKSCREW, SUPPORT in the BULKHEAD SUPPORT JACKSCREW FITTING in accordance
with FIGURE 1.
(1) Condition 1: If any disbond or tear is found, or the ID is greater than the allowable
MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined bushings; then
do bushing replacement as follows:
(a) Remove the Karon lined bushings in accordance with FIGURE 7.
1) Condition 1: If any damage is found or the ID is greater than the allowable hole
diameter in accordance with FIGURE 7 on the intermediate sleeve, then replace
the intermediate sleeve in accordance with FIGURE 8. Do the following when
replacing the intermediate sleeve:
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a) Condition 1: If any damage is found or the ID is greater than the allowable
hole diameter in accordance with FIGURE 8 on the fitting, then contact
Boeing for alternative repair instructions.
b) Condition 2: If no damage is found and the ID is within the allowable hole
diameter in accordance with FIGURE 8 on the fitting, then continue with
the repair in accordance with FIGURE 8.
2) Condition 2: If no damage is found and the ID is within the allowable hole
diameter in accordance with FIGURE 7 on the intermediate sleeve, then
replacement of the intermediate sleeve is not necessary.
(b) Install the new Karon lined bushings in accordance with FIGURE 9.
(2) Condition 2: If no disbond and tear are found, and the ID is less than or equal to the
allowable MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined
bushings; then bushing replacement is not necessary.
b. Do a Detailed Inspection and measure the ID of the BUSHING - JACKSCREW, HORIZONTAL
STABILIZER in the HORIZONTAL STABILIZER JACKSCREW FITTING in accordance with
FIGURE 2.
(1) Condition 1: If any disbond or tear is found, or the ID is greater than the allowable
MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined bushings; then
do bushing replacement and finish the repair area of the fitting as necessary in accordance
with Structural Repair Manual 777-200 SRM 55-10-90, REPAIR 1 or 777-300 SRM
55-10-90, REPAIR 1.
(2) Condition 2: If no disbond and tear are found, and the ID is less than or equal to the
allowable MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined
bushings; then bushing replacement is not necessary.
3. Installation of the HSTA
a. Option 1: If the replacement HSTA is in a known serviceable condition, then install the HSTA.
Refer to 777 AMM 27-41-13 as an accepted procedure.
NOTE: If the replacement HSTA is not in a known serviceable condition, then do the Detailed
Inspection and measurement of the Karon lined bushings, pins, and fail-safe
components of the replacement HSTA as applicable in accordance with PART 2 of
Paragraph 3.B., Work Instructions. Refer to Paragraph 3.A., General Information,
for the descriptions of HSTA's that are in a known serviceable conditions.
b. Option 2: If the replacement or the existing HSTA is not in a known serviceable condition,
then do PART 2.
4. Do the Horizontal Stabilizer Trim Actuator Test. Refer to 777 AMM 27-41-13 as an accepted
procedure.
5. Close access and put the airplane back to a serviceable condition.
6. Repeat the Detailed Inspection and measurement of the Karon lined bushings at the time in
accordance with Paragraph 1.E., Compliance.
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PART 2 - COMPONENT (HORIZONTAL STABILIZER TRIM ACTUATOR, HSTA) WORK
1. Disassemble the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) as necessary. Refer to
CMM 27-41-03 as an accepted procedure.
2. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, UPPER BRAKE
HOUSING in the UPPER GIMBAL - BRAKE HOUSING in accordance with FIGURE 3.
a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN
DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined
bushings; then do bushing replacement and refinish the repair area of the gimbal as necessary.
Refer to Components Maintenance Manual CMM 27-41-03, REPAIR 8-1 and CMM 27-41-03,
REPAIR 8-2; respectively as an accepted procedure.
b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM
DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the
Karon lined bushings; then bushing replacement is not necessary.
3. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, UPPER SUPPORT in
the UPPER GIMBAL - BULKHEAD SUPPORT in accordance with FIGURE 3.
a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN
DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined
bushings; then do bushing replacement and refinish the repair area of the gimbal as necessary.
Refer to CMM 27-41-03, REPAIR 8-1 and CMM 27-41-03, REPAIR 8-2; respectively as an
accepted procedure.
b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM
DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the
Karon lined bushings; then bushing replacement is not necessary.
4. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, BRAKE HOUSING in
the TRIM ACTUATOR PRIMARY BRAKE HOUSING in accordance with FIGURE 4.
a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN
DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined
bushings; then do bushing replacement and refinish the repair area of the housing as
necessary. Refer to CMM 27-41-03, REPAIR 3-1 and CMM 27-41-03, REPAIR 3-2; respectively
as an accepted procedure.
b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM
DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the
Karon lined bushings; then bushing replacement is not necessary.
5. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, LOWER HORIZONTAL
STABILIZER in the LOWER GIMBAL in accordance with FIGURE 5.
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a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN
DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined
bushings; then do bushing replacement and refinish the repair area of the gimbal as necessary.
Refer to CMM 27-41-03, REPAIR 16-1 as an accepted procedure.
b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM
DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the
Karon lined bushings; then bushing replacement is not necessary.
6. Do a Detailed Inspection of the pins and the safety shaft; and measure the outer diameter (OD)
of the pins in accordance with FIGURE 6.
a. Condition 1: If any crack is found, do the following as applicable:
(1) For the PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING in the UPPER
GIMBAL, replace the pin.
(2) For the PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT in the UPPER GIMBAL,
replace the pin. Also do a magnetic particle inspection of the SHAFT-SAFETY, UPPER
GIMBAL, STABILIZER TRIM (SAFETY SHAFT) for a crack. Refer to SOPM 20-20-01 as
an accepted procedure for magnetic particle inspection.
(a) Condition 1: If any crack is found, replace the safety shaft.
(b) Condition 2: If no crack is found, then refurbish the safety shaft as necessary. Refer
to CMM 27-41-03, REPAIR 10-1, as an accepted procedure for refurbishment of the
safety shaft.
(3) For the PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM in the LOWER GIMBAL,
replace the outer pin or the entire assembly. If the outer pin is replaced, do a magnetic
particle inspection of the inner pin. Refer to SOPM 20-20-01 as an accepted procedure
for magnetic particle inspection.
(a) Condition 1: If any crack is found, replace the inner pin.
(b) Condition 2: If no crack is found, then refurbish the pin assembly as necessary. Refer
to CMM 27-41-03, REPAIR 1-1, as an accepted procedure for refurbishment of the
pins.
(4) For the SHAFT-SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT), replace
the safety shaft.
b. Condition 2: If any gouge is found, do the following as applicable:
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### Page 30

(1) For the PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING in the UPPER
GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an
accepted procedure for refurbishment of the pins.
(2) For the PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT in the UPPER GIMBAL,
replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an accepted
procedure for refurbishment of the pins.
(3) For the PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM in the LOWER GIMBAL,
replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 1-1, as an accepted
procedure for refurbishment of the pins.
(4) For the SHAFT, SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT),
replace or refurbish the safety shaft. Refer to CMM 27-41-03, REPAIR 10-1, as an
accepted procedure for the refurbishment of the safety shaft.
c. Condition 3: If OD is less than MINIMUM DESIGN DIMENSION as specified in FITS AND
CLEARANCES of CMM 27-41-03 on the pins; then do the following as applicable:
(1) For the PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING in the UPPER
GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an
accepted procedure for refurbishment of the pins.
(2) For the PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT in the UPPER GIMBAL,
replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an accepted
procedure for refurbishment of the pins.
(3) For the PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM in the LOWER GIMBAL,
replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 1-1, as an accepted
procedure for refurbishment of the pins.
d. Condition 4: If no gouge, crack and wear are found on any of the pins and safety shaft as
applicable; and the OD is greater than or equal to MINIMUM DESIGN DIMENSION as specified
in FITS AND CLEARANCES of CMM 27-41-03 on the pins as applicable; then a replacement
or refurbishment is not necessary.
7. Assemble the HSTA. Refer to CMM 27-41-03 as an accepted procedure.
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
STA
2245.70
00000000
BULKHEAD SUPPORT
JACKSCREW FITTINGS
FWD C
1X2)  1522952
FIGURE 1: INSPECTION AND MEASUREMENT OF BULKHEAD SUPPORT JACKSCREW FITTING KARON
LINED BUSHINGS
(SHEET 1 OF 2)
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### Page 32

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a Detailed Inspec-
tion of the Karon lin-
er for any disbond or
tear.
4148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
Inspect1
Measure the ID of
the Karon lined
bushing for any
wear.
4148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
Measure2
FIGURE 1: INSPECTION AND MEASUREMENT OF BULKHEAD SUPPORT JACKSCREW FITTING KARON
LINED BUSHINGS
(SHEET 2 OF 2)
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ALERTALERT

### Page 33 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
STA
SEE A  2245.70
FWD K
1522974
FIGURE 2: INSPECTION AND MEASUREMENT OF HORIZONTAL STABILIZER JACKSCREW FITTING
_ KARON LINED BUSHINGS
(SHEET 1 OF 2)
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### Page 34

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a Detailed Inspec-
tion of the Karon lin-
er for any disbond or
tear.
4182W7404-1BUSHING -
JACKSCREW, HORI-
ZONTAL STABILIZER
Inspect1
Measure the ID of
the Karon lined
bushing for any
wear.
4182W7404-1BUSHING -
JACKSCREW, HORI-
ZONTAL STABILIZER
Measure2
FIGURE 2: INSPECTION AND MEASUREMENT OF HORIZONTAL STABILIZER JACKSCREW FITTING
KARON LINED BUSHINGS
(SHEET 2 OF 2)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
SEE 1
1523025
FIGURE 3: INSPECTION AND MEASUREMENT OF UPPER GIMBAL - BRAKE HOUSING AND UPPER
GIMBAL - BULKHEAD SUPPORT KARON LINED BUSHINGS
(SHEET 1 OF 2)
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### Page 36

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a Detailed Inspec-
tion of the Karon lin-
er for any disbond or
tear.
4251W4172-3BUSHING - GIMBAL,
UPPER BRAKE
HOUSING
Inspect1
Do a Detailed Inspec-
tion of the Karon lin-
er for any disbond or
tear.
4251W4172-5BUSHING - GIMBAL,
UPPER SUPPORT
Inspect2
Measure the ID of
the Karon lined
bushing for any
wear.
4251W4172-3BUSHING - GIMBAL,
UPPER BRAKE
HOUSING
Measure3
Measure the ID of
the Karon lined
bushing for any
wear.
4251W4172-5BUSHING - GIMBAL,
UPPER SUPPORT
Measure4
FIGURE 3: INSPECTION AND MEASUREMENT OF UPPER GIMBAL - BRAKE HOUSING AND UPPER
GIMBAL - BULKHEAD SUPPORT KARON LINED BUSHINGS
(SHEET 2 OF 2)
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### Page 37 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
SEE 1
1523053
FIGURE 4: INSPECTION AND MEASUREMENT OF TRIM ACTUATOR PRIMARY BRAKE HOUSING KARON
LINED BUSHINGS
(SHEET 1 OF 2)
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### Page 38

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a Detailed Inspec-
tion of the Karon lin-
er for any disbond or
tear.
4251W4172-6BUSHING - GIMBAL,
BRAKE HOUSING
Inspect1
Measure the ID of
the Karon lined
bushing for any
wear.
4251W4172-6BUSHING - GIMBAL,
BRAKE HOUSING
Measure2
FIGURE 4: INSPECTION AND MEASUREMENT OF TRIM ACTUATOR PRIMARY BRAKE HOUSING KARON
LINED BUSHINGS
(SHEET 2 OF 2)
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### Page 39 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
SEE A
1523092
FIGURE 5: INSPECTION AND MEASUREMENT OF LOWER GIMBAL KARON LINED BUSHINGS
(SHEET 1 OF 2)
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### Page 40

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a Detailed Inspec-
tion of the Karon lin-
er for any disbond or
tear.
4251W4172-4BUSHING - GIMBAL,
LOWER HORIZONTAL
STABILIZER
Inspect1
Measure the ID of
the Karon lined
bushing for any
wear.
4251W4172-4BUSHING - GIMBAL,
LOWER HORIZONTAL
STABILIZER
Measure2
FIGURE 5: INSPECTION AND MEASUREMENT OF LOWER GIMBAL KARON LINED BUSHINGS
(SHEET 2 OF 2)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
1551746
FIGURE 6: INSPECTION AND MEASUREMENT OF PINS
(SHEET 1 OF 2)
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### Page 42

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a Detailed Inspec-
tion of the pins on
the outer surface for
any gouge or crack.
2251W4173-3PIN - UPPER GIMBAL,
STABILIZER TRIM,
BRAKE HOUSING
Inspect1
Do a Detailed Inspec-
tion of the pins on
the outer surface for
any gouge or
crack.(a)
2251W4175-3PIN - UPPER GIMBAL,
STABILIZER TRIM,
SUPPORT
Inspect2
Do a Detailed Inspec-
tion of the outer pins
on the outer surface
for any gouge or
crack.(b)
2251W4187-7 (ALTER-
NATIVE SUBSTITUTE,
-9)
PIN ASSEMBLY - NUT
GIMBAL, STABILIZER
TRIM
Inspect3
Do a Detailed Inspec-
tion of the safety
shaft on the outer
surface for any
gouge or crack.(a)
1251W4188-1SHAFT-SAFETY, UP-
PER GIMBAL, STABI-
LIZER TRIM (SAFETY
SHAFT)
Inspect4
Measure the OD of
the pins for any
wear.
2251W4173-3PIN - UPPER GIMBAL,
STABILIZER TRIM,
BRAKE HOUSING
Measure5
Measure the OD of
the pins for any
wear.
2251W4175-3PIN - UPPER GIMBAL,
STABILIZER TRIM,
SUPPORT
Measure6
Measure the OD of
the pins for any
wear.
2251W4187-7 (ALTER-
NATIVE SUBSTITUTE,
-9)
PIN ASSEMBLY - NUT
GIMBAL, STABILIZER
TRIM
Measure7
(a) If any crack is found on PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT, additional inspection
may be necessary on SHAFT-SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT) in ac-
cordance with Paragraph 3.B., Work Instructions, PART 2, Section 6.
(b) The PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM has outer and inner pins. If any crack is found
on the outer pin, additional inspection may be necessary on the inner pin in accordance with Paragraph
3.B., Work Instructions, PART 2, Section 6.
FIGURE 6: INSPECTION AND MEASUREMENT OF PINS
(SHEET 2 OF 2)
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### Page 43 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
STA
OLS7ZZ
00000000
FWD DE
BULKHEAD SUPPORT
JACKSCREW
FITTTING
SEE
1523126
FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL
(SHEET 1 OF 3)
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### Page 44 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
FWD <
2.2510
2.2500
A-A  1523137
FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL
(SHEET 2 OF 3)
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### Page 45

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
CAUTION: USE CARE WHEN YOU REMOVE THE BUSHINGS. THE BUSHINGS WERE INSTALLED
WITH AN INTERFERENCE FIT. IF YOU DO NOT OBEY, DAMAGE TO THE BULKHEAD
SUPPORT JACKSCREW FITTING CAN OCCUR.
Refer to SOPM 20-
50-03 as an accept-
ed procedure.
4148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
Remove1
WARNING: KEEP THE SOLVENTS AWAY FROM SOURCES OF HEAT, FIRE OR SPARKS. IF YOU DO
NOT, AN EXPLOSION CAN OCCUR. DO NOT PERMIT THE SOLVENTS TO TOUCH YOUR
SKIN, EYES OR CLOTHING. DO NOT BREATHE THE VAPORS. WEAR PROTECTIVE
CLOTHING AND EYE PROTECTION. MAKE SURE THERE IS A GOOD FLOW OF CLEAN
AIR. IN A CONFINED SPACE, USE MECHANICAL VENTILATION FOR RESPIRATORY
PROTECTION. INJURY TO PERSONS CAN OCCUR.
CAUTION: USE CARE WHEN YOU WORK WITH THE INSIDE SURFACE OF THE BULKHEAD SUPPORT
JACKSCREW FITTING. MECHANICAL TOOLS AND ABRASION CAN CAUSE DAMAGE TO
THE FITTING HOLE. THE RESULT CAN BE A HOLE THAT IS LARGER THAN THE ALLOW-
ABLE MAXIMUM HOLE DIMENSIONS.
Remove all the dust
and sealant from the
inner surface of the
hole. Refer to SOPM
20-30-03 as an ac-
cepted procedure.
2148W9107-1INTERMEDIATE
SLEEVE
Clean2
Do a surface HFEC
inspection for a
crack on the inner
surface of the hole
in accordance with
777 NDT Part 6, 51-
00-04.(a)
2148W9107-1INTERMEDIATE
SLEEVE
Inspect3
Measure the ID of
the sleeve.
2148W9107-1INTERMEDIATE
SLEEVE
Measure4
(a) Penetrant inspection is optional to the surface HFEC inspection. Refer to SOPM 20-20-02 as an accepted
procedure.
FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL
(SHEET 3 OF 3)
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ALERTALERT

### Page 46 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
0L°5+ZZ
00000000
FWD L
BULKHEAD SUPPORT
JACKSCREW
FITTTING
SEE
1524251
FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT
(SHEET 1 OF 4)
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### Page 47 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
STA
2245.70
* B  -B-
FWD <
15.740
2.800
STA
2248.50
A-A  1524239
FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT
(SHEET 2 OF 4)
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### Page 48

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. It is necessary
to replace the intermediate sleeve with a damage or ID greater than the allowable hole diameter.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
CAUTION: USE CARE WHEN YOU REMOVE THE BUSHINGS. THE BUSHINGS WERE INSTALLED
WITH AN INTERFERENCE FIT. IF YOU DO NOT OBEY, DAMAGE TO THE BULKHEAD
SUPPORT JACKSCREW FITTING CAN OCCUR.
Refer to SOPM 20-
50-03 as an accept-
ed procedure.
2148W9107-1INTERMEDIATE
SLEEVE
Remove1
FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT
(SHEET 3 OF 4)
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ALERTALERT

### Page 49

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
WARNING: KEEP THE SOLVENTS AWAY FROM SOURCES OF HEAT, FIRE OR SPARKS. IF YOU DO
NOT, AN EXPLOSION CAN OCCUR. DO NOT PERMIT THE SOLVENTS TO TOUCH YOUR
SKIN, EYES OR CLOTHING. DO NOT BREATHE THE VAPORS. WEAR PROTECTIVE
CLOTHING AND EYE PROTECTION. MAKE SURE THERE IS A GOOD FLOW OF CLEAN
AIR. IN A CONFINED SPACE, USE MECHANICAL VENTILATION FOR RESPIRATORY
PROTECTION. INJURY TO PERSONS CAN OCCUR.
CAUTION: USE CARE WHEN YOU WORK WITH THE INSIDE SURFACE OF THE BULKHEAD SUPPORT
JACKSCREW FITTING. MECHANICAL TOOLS AND ABRASION CAN CAUSE DAMAGE TO
THE FITTING HOLE. THE RESULT CAN BE A HOLE THAT IS LARGER THAN THE ALLOW-
ABLE MAXIMUM HOLE DIMENSIONS.
Remove all the dust
and sealant from the
inner surface of the
hole. Refer to SOPM
20-30-03 as an ac-
cepted procedure.
2-BULKHEAD SUPPORT
JACKSCREW FITTING
Clean2
Do a surface HFEC
inspection of the in-
ner surface of the
hole for a crack in
accordance with 777
NDT Part 6, 51-00-
01.(a)
2-BULKHEAD SUPPORT
JACKSCREW FITTING
Inspect3
Measure the ID of
the hole.
2-BULKHEAD SUPPORT
JACKSCREW FITTING
Measure4
CAUTION: DO NOT CONTINUE WITH THE REPAIR IF A DAMAGE IS FOUND OR THE ID IS GREATER
THAN THE ALLOWABLE HOLE DIAMETER ON THE FITTING TO PREVENT MORE DAMAGE.
Refer to SOPM 20-
50-03 as an accept-
ed procedure.
2148W9107-1INTERMEDIATE
SLEEVE
Install (New)5
Machine the ID to
the diameters
shown. Refer to
SOPM 20-10-02 as
an accepted proce-
dure.
2148W9107-1INTERMEDIATE
SLEEVE
Ream6
(a) Penetrant inspection is optional to the surface HFEC inspection. Refer to SOPM 20-20-02 as an accepted
procedure.
FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT
(SHEET 4 OF 4)
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ALERTALERT

### Page 50 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
STA
2245.70
00000000
FWD L
BULKHEAD SUPPORT
JACKSCREW
FITTTING
SEE
1530358
FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION
(SHEET 1 OF 5)
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### Page 51 (OCR)

BOEING SERVICE BULLETIN 777-55A0017
ALERT  ALERT
020  2)5  2245.70  STA
15.740
2.800
STA
A-A  2248.50  1530357
FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION
(SHEET 2 OF 5)
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### Page 52

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Apply one layer of
BMS 10-11, Type I
primer to the mating
surfaces of the lug
face under the bush-
ing flange. Refer to
777-200 SRM 51-
20-01 or 777-300
SRM 51-20-01 as an
accepted proce-
dure.(a)
-BMS 10-11TYPE I PRIMERApply1
FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION
(SHEET 3 OF 5)
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### Page 53

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Apply the sealant
along the contact
surface between the
lug and bushing
flange. Refer to
SOPM 20-50-03 as
an accepted proce-
dure.
-BMS 5-95SEALANTApply2
WARNING: USE PROTECTION WHEN YOU DO WORK WITH LIQUID NITROGEN. MAKE SURE THAT
THE AREA HAS A GOOD FLOW OF CLEAN AIR. THE TEMPERATURE FOR LIQUID NITRO-
GEN IS APPROXIMATELY MINUS 320 F (MINUS 196 C). IF YOU DO NOT OBEY, INJURY
TO PERSONS CAN BE THE RESULT.
Hold the assembly
in position until the
assembly is at room
temperature. Refer
to SOPM 20-50-03
as an accepted pro-
cedure.
4148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
Install (New)3
(b) (c)4148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
Ream4
Line hone the bush-
ing hole to the final
ID dimension. Make
the surface finish 32
microinches (0.8 mi-
crometers ) Ra or
better.(b) (d)
4148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
Hone
Clean the inner sur-
face of the bushing
to make sure that all
the honing debris
and machining oil
are removed. Refer
to SOPM 20-30-03
as an accepted pro-
cedure.
-148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
Clean5
FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION
(SHEET 4 OF 5)
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### Page 54

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Apply a fillet seal on
the bushing flanges
and fill the gap be-
tween the bushings.
Refer to SOPM 20-
50-03 as an accept-
ed procedure.
-BMS 5-95SEALANTApply6
(a) If necessary, apply a chemical conversion coating to the mating surfaces of the lug face under the bushing
flange. Refer to 777-200 SRM 51-20-01 or 777-300 SRM 51-20-01 as an accepted procedure.
(b) Use a long piloted reamer as a tool to keep all bushing holes coaxial. The pilot part of the reamer must
be non-cutting to prevent damage to the bushing. Use a guide bush to slip into the adjacent bushing bore
to support the reamer and protect the initial bushings.
(c) Line ream the bushing hole to the inside diameter of 1.955 to 1.960 inches (49.66 to 49.78 mm). Machine
the Karon liner at 1000 surface feet per minute (SFPM) minimum with a feed rate between 0.001 and
0.003 inch (0.025 and 0.076 mm) per revolution. Machining can be done dry or with a water soluble
coolant. Use a diamond or carbide cutter with a 0.030 inch minimum radius.
(d) If necessary hone all the replacement bushings at the same time to keep them coaxial. Use the following
requirements for honing: Sunnen stone K6-A63 or equivalent (280 grit medium hard aluminum oxide),
speed of 300 to 1000 RPM (revolutions per minute), and Sunnen MB30 oil base coolant or equivalent.
FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION
(SHEET 5 OF 5)
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Original Issue: May 20, 2010
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### Page 55

Service Wear LimitsPart NumberPart NameJoint Location
MINIMUM DIAME-
TER
MAXIMUM DIAME-
TER
-ID: 2.0060148W9106-2BUSHING -
JACKSCREW, SUP-
PORT
BULKHEAD SUP-
PORT JACKSCREW
FITTING
-ID: 2.0098182W7404-1BUSHING -
JACKSCREW, HOR-
IZONTAL STABILIZ-
ER
HORIZONTAL STA-
BILIZER
JACKSCREW FIT-
TING
FIGURE 10: KARON LINED BUSHING SERVICE WEAR LIMITS
(SHEET 1 OF 1)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 20, 2010
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