# Boeing Alert Service Bulletin 777-78A0094: No revision named - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2011-0027; AD 2016-11-16 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 777-78A0094](https://openairdocs.org/service-documents/boeing/777-78a0094.md) - Title as filed: U.S. DOT/FAA - SB-777-78A0094-00 - Pages: 144 - PDF: https://openairdocs.org/files/sha256/e3/69/e369ffe8fbaa4cb2dd8b3cac0313450e1f5ca61474a3446a76ca7624f178c3a2 - Page: https://openairdocs.org/service-documents/boeing/777-78a0094/file/e369ffe8fbaa ## 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: 777-78A0094 Original Issue: July 29, 2014 ATA System: 7830 SUBJECT: EXHAUST (Trent 800 Engines) - Thrust Reverser System - Thrust Reverser Inner Wall Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. Original Issue: July 29, 2014 777-78A0094 1 of 144 3.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 2 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Summary ...................................................... 5 1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1 1. Airplanes ............................................ 1 1 2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 1 8 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 1 9 I. Electrical Load Data ......................................... 2 0 J. References .............................................. 2 0 1. Existing Data: ......................................... 2 0 2. Data Supplied with this Service Bulletin: ........................... 2 0 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 1 K. Publications Affected ........................................ 2 1 L. Interchangeability and Intermixability of Parts ........................... 2 2 M. Software Accomplishment Summary ................................ 2 2 2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 7 1. Kits/Parts ............................................ 2 7 2. Parts and Materials Supplied by the Operator ........................ 3 1 3. Parts Modified and Reidentified ................................ 3 2 4. Parts Removed and Not Replaced .............................. 3 2 D. Parts Necessary to Change Spares ................................. 3 2 E. Special Tooling - Price and Availability ............................... 3 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 2 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: LEFT TR HALF SPLICE PLATE FASTENER HOLE DETAILED INSPECTION ...... 6 5 FIGURE 2: RIGHT TR HALF SPLICE PLATE FASTENER HOLE DETAILED INSPECTION ...... 6 9 FIGURE 3: LEFT SIDE HINGE BEAM AND LATCH BEAM NUTPLATE INSTALLATION ....... 7 3 FIGURE 4: RIGHT SIDE HINGE BEAM AND LATCH BEAM NUTPLATE INSTALLATION ....... 7 9 FIGURE 5: LEFT TR HALF INNER WALL FORWARD EDGE INSPECTION AND TRIMMING .... 8 5 FIGURE 6: RIGHT TR HALF INNER WALL FORWARD EDGE INSPECTION AND TRIMMING .... 8 9 FIGURE 7: LEFT TR HALF SPLICE PLATE FASTENER INSTALLATION ............... 9 3 FIGURE 8: RIGHT TR HALF SPLICE PLATE FASTENER INSTALLATION ............... 9 7 FIGURE 9: LEFT SIDE INNER WALL CHANGED CLICK BOND LOCATIONS ............ 1 0 1 FIGURE 10: RIGHT SIDE INNER WALL CHANGED CLICK BOND LOCATIONS ........... 1 0 8 APPENDIX A: ALLOWABLE REPAIR LIMITS ................................ 1 1 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 3 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 4 APPENDIX B: TOOLING DIMENSIONS ................................... 1 2 1 APPENDIX C: NUTPLATE RETAINER FABRICATION ........................... 1 3 3 APPENDIX D: LEFT SIDE INNER WALL FLOWCHART .......................... 1 3 4 APPENDIX E: RIGHT SIDE INNER WALL FLOWCHART ......................... 1 3 7 APPENDIX F: HOLES AND DRILLING - CONDITIONS, PROCEDURES, DEFINITIONS AND TOOLS . 141 APPENDIX G: THRUST REVERSER INNER WALL SURFACE COLOR INSPECTION IP8.2 ZONE . . 143 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 4 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 5 Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-78A0094Original Issue: July 29, 2014 ATA System: 7830 SUBJECT: EXHAUST (Trent 800 Engines) - Thrust Reverser System - Thrust Reverser Inner Wall 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 will ensure that the Thrust Reversers (TRs) on Rolls-Royce Trent 800 engines have inner walls which contain no residual thermal damage. Later events have revealed that inner walls which have operated without thermal protection system (TPS) and IP8 related improvements may contain residual thermal damage. Some thermal damage is not detectable via current inspection methods or repairs conducted prior to Boeing Service Letter 777-SL-78-026 or SRM 54-32-01, Repair #6 may not have removed all of the existing thermal damage. Residual thermal degradation could cause structural pieces of the inner wall to separate from the TR in flight. A separated piece of the TR could cause damage to other airplane areas, or cause injury to persons on the ground. A separated TR piece at departure could cause a runway excursion because of thrust asymmetry from forward thrust on a Refused Take Off (RTO). Eighteen 777 Rolls-Royce TR events related to thermal damage of the TR inner wall have occurred since 2003. The events have included Air Turn Backs (ATB), In Flight Shut Downs (IFSD), TR inner wall panel collapses, engine fire loop messages, and TR inner wall panel sections and parts departing the airplane. No hull loss or personal injury has occurred from these events. This service bulletin provides instructions to perform maintenance records checks and detailed inspections of the TR inner wall to determine if the TR inner wall should be replaced. This service bulletin also provides instructions for replacement of the TR inner wall. This service bulletin also provides instructions to update the airplane scheduled maintenance program to incorporate 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02. Boeing Service Related Problem (SRP) 777-SRP-78-0076 is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 5 of 144 ### Page 6 ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedYesSpares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Air- plane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required Service History ReportYear of Event // Cy- cles // Hours Engine 2 Left Hand (LH) TR half. Shorted fire loop fault messages (intermittent) received during descent. Extensive delamination found during ground inspection. 2003 // 5,871 // 17,982 Engine 1 LH TR half. Extensive delamination found during ground inspection during planned engine change. 2004 // 4,600 // 13,100 Engine 2 LH TR half. Damage seen on arrival. Large portion of inner wall missing. Debris on runway. Nozzle outer sleeve not found. 2004 // 6,160 // 15,472 Engine 1 LH TR half. Panel collapsed during takeoff. Parts liberated. Air Turn Back (ATB) performed. Nozzle outer sleeve landed on vehicle. 2004 // 6,600 // 16,600 Engine 2 Right Hand (RH) TR half. Exhaust Gas Temperature (EGT) fluctuation during climb out and fire loop fault messages. Flight continued. Damage found during ground inspection. 2006 // 2,450 // 13,124 Engine 1 RH TR half. Panel collapsed during takeoff. Parts liberated. ATB per- formed. 2006 // 5,782 // 37,687 Engine 2 RH TR half. Engine fire warning after takeoff. In Flight Shut Down (IFSD) and ATB performed. Extensive delamination found during ground inspection. 2007 // 7,627 // 26,963 Engine 2 RH TR half. Intermittent status message "LOOP 1 ENG R" and "OVERHEAT CIRCUIT R", but no warning messages. Damage seen on arrival. Large portion of inner wall missing. Debris on takeoff runway. 2007 // 9,770 // 34,895 Engine 1 RH TR. During climb, status messages "ENG EEC R", "TRIM AIR PRSOV R+L", "OVERHEAT CIRCUIT L1", and "FIRE LOOP ENG L". ATB performed. Inner wall panel collapse and damage found during ground inspection. 2008 // 3,865 // 28,213 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 6 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 7 Service History ReportYear of Event // Cy- cles // Hours Engine 2 RH TR half. Fire detection advisory message at take off, flight continued. Damage found during ground inspection. 2009 // 5,616 // 37,245 Engine 2 LH TR half. Indication on take off. Thud heard 5 hrs into flights. PDA, nozzle inner and outer walls liberated. 2010 // 4,702 // 35,471 Crew notified that debris had been collected from the departing runway. Flight diverted. PDA (nozzle intact). 2010 // 7,719 // 38,952 Engine 2, LH TR half. Nozzle outer sleeve recovered from departing airport.2011 // 12,308 // 58,335 Engine 1, LH TR half. Flight diverted. Inner wall collapsed. Aft cowl intact. Nozzle outer sleeve severely damaged but not liberated. 2011 // 8,751 // 40,482 Engine 2, LH TR half. Inner wall collapse during climbout - flight returned to depar- ture airport. PDA - aft cowl & portions of inner wall. 2012 // 7,838 // 50,004 Engine 2, RH TR half. Inner wall collapse during takeoff roll - flight returned to departure airport. PDA - Debris including aft cowl recovered on runway. 2013 // 11,927 // 40,317 Engine 2, RH TR half. Flight continued to destination. PDA - portions of inner wall.2013 // 8,597 // 51,844 Engine 1, RH TR half. Flight returned to departure airport. PDA - aft portions of the TR inner wall. 2013 // 7,241 // 58,668 ACTION (PRR 62402-R) All Airplanes 1. Install a serviceable left and right Thrust Reverser (TR) half on left and right engines. NOTE: A serviceable TR half is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Packages 3 (left TR half) or 4 (right TR half) of this service bulletin. 2. Update airplane scheduled maintenance program to incorporate 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02 from the most current published 777 MPD Section 9. For each TR half 1. Group 1, Configuration 1-2: Do a maintenance records check for replacement of the Inner Wall (IW) concurrently with or after incorporation of Boeing Service Bulletin (SB) 777-78-0071 or 777-78-0082. 2. Group 1, Configuration 3: Install the Thermal Protection System (TPS). 3. Group 1, Configuration 4: Modify the aft cowl and install the TPS. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 7 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 8 4. Group 1, Configuration 1-2: Do a maintenance records check for incorporation of Boeing SB 777-75A0002 and Rolls-Royce SB RB.211-75-G765 on engines the TR half has operated on. 5. Group 1, Configuration 1-2: Do a maintenance records check for installation of IW part number 315W5100-63 or 315W5100-64. EFFECTIVITY 777-200 and 777-300 Airplanes with Rolls-Royce Model RB211 Trent 800 engines. Refer to Paragraph 1.A.1.,Airplanes, for the list of affected airplanes. Refer to Paragraph 1.A.2., Spares Affected for the list of affected components. 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 December 8, 2004. Please refer to Paragraph 2.B., Industry Support Information. MANPOWER Elapsed HoursTotal Task HoursEngines 14.00 (a)26.00 (a)Left Thrust Re- verser 14.00 (a)26.00 (a)Right Thrust Re- verser (a) Time given for the inner wall replacement must be added to total shown if inner wall is to be replaced. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 8 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 9 (OCR) BOEING SERVICE BULLETIN 777-78A0094 ALERT ALERT ALL AIRPLANES - UPDATE AIRPLANE SCHEDULED MAINTENANCE PROGRAM TO INCORPORATE 777 AIRWORTHINESS LIMITATION (AWL) 78-AWL-01 - INSTALL A SERVICEABLE LEFT AND RIGHT THRUST REVERSEF (TR) HALF ON LEFT AND RIGHT ENGINE NOTE: A SERVICEABLE TR HALF IS DEFINED AS ONE THAT HAS MET ALL THE REQUIREMENTS OF PARAGRAPH 3.B., WORK INSTRUCTIONS, WORK PACKAGES 3 (LEFT TR HALF) OR 4 (RIGHT TR HALF) OF THIS SERVICE BULLETIN. FOR EACH TR HALF GROUP 1, CONFIGURATION 1-2: -DO A MAINTENANCE RECORDS CHECK FOR REPLACEMENT OF THE INNER WALL (IW) CONCURRENTLY WITH OR AFTER INCORPORATIONOF BOEING SERVICE BULLETIN (SB) 777-78-0071 OR 777-78-0082 GROUP 1, CONFIGURATION 3: -INSTALL THE THERMAL PROTECTION SYSTEM (TPS). GROUP 1, CONFIGURATION 4: -MODIFY THE AFT COWL AND INSTALL THE TPS. GROUP 1, CONFIGURATION 1-2; -DO A MAINTENANCE RECORDS CHECK FOR INCORPORATION OF BOEING SB 777-75A0002 AND ROLLS-ROYCE SB RB.211-75-G765 ON ENGINES THE TR HALF HAS OPERATED ON. GROUP 1, CONFIGURATION 1-2: -DO A MAINTENANCE RECORDS CHECK FOR INSTALLATION OF IW PART NUMBER 315W5100-63 OR 315W5100-64. THRUST REVERSER INNER WALL THRUST REVERSER INNER WALL (LEFT SIDE SHOWN) (RIGHT SIDE SHOWN) 2260405 Original Issue: July 29, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 144 ### Page 10 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 10 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT BLANK PAGE ### Page 11 Commercial Airplanes 777 Service Bulletin ALERT Number: 777-78A0094 Original Issue: July 29, 2014 ATA System: 7830 SUBJECT: EXHAUST (Trent 800 Engines) - Thrust Reverser System - Thrust Reverser Inner Wall 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 Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is applicable to 777-200/300 Airplanes with Rolls-Royce Trent 800 engines, line numbers 1-796 in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below. Refer to PRR 62402-R for data about this change. NOTE: The airplanes shown in the effectivity below had the configuration of Thrust Reverser (TR) described in this service bulletin at delivery or by the incorporation of Boeing service bulletin 777-78-0071 or 777-78-0082. Installation of spare TRs since delivery or the incorporation of Boeing service bulletin 777-78-0071 or 777-78-0082, could put these configurations of TR on airplanes not shown in the effectivity below. Or, rotation of parts between airplanes could put these configurations of TR on airplanes with a different group relationship to that shown in the effectivity below. Check maintenance records to make sure the work in accordance with this service bulletin is accomplished on applicable TRs. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 11 of 144 ### Page 12 DESCRIPTIONCONFIGURATIONGROUP 777-200 and 777-300 airplanes with Rolls-Royce engines-1 Thrust reversers that installed TPS by incorporation of Boeing Service Bulletin 777-78-0071 1 Thrust reversers that installed TPS and modified the aft cowl by incorporation of Boeing Service Bulletin 777-78-0082 2 Thrust reversers with inner wall part number 315W5101-(all dash number after -1) for the left TR and part number 315W5102-(all dash numbers after -1) for the right TR that have not installed TPS by incorporation of Boeing Service Bulletin 777-78-0071. 3 Thrust reversers with inner wall part number 315W5101-1 for the left TR and part number 315W5102-1 for the right TR that have not installed TPS and have not modified the aft cowl by incorporation of Boeing Service Bulletin 777-78-0082. 4 Airplane Models: 777-200, 777-300 GroupVariable Number 1WA001 1WA086 - WA093 1WA101 - WA104 1WA196 - WA198 1WB031 - WB046 1WB101 - WB106 1WB161 - WB177 1WB181 - WB194 1WB201 - WB215 1WB231 - WB247 1WB416 - WB439 1WB446 - WB453 1WB501 - WB512 1WB601 - WB606 1WB611 - WB622 1WB631 - WB638 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 12 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 13 GroupVariable Number 1WB646 - WB649 1WC051 - WC073 1WC101 - WC104 1WC456 - WC459 1WC486 - WC493 1WC531 - WC536 1WC566 - WC567 1WC571 - WC574 2. Spares Affected Examine your spares supply for the parts or components identified below. If any parts or components are found, refer to Paragraph 3.B., Work Instructions for the recommended action. Part Number All RR Thrust Reversers with part numbers 315W5001-() B. Concurrent Requirements The service bulletins listed below must be done before or at the same time as this service bulletin: DescriptionService BulletinCompany Thermal Insulation Blankets and Thermal Protection System Change 777-78-0071, Revision 01 or Revision 02The Boeing Compa- ny Thrust Reverser Aft Cowl Modification and Thermal Protection System Change 777-78-0082, Original IssueThe Boeing Compa- ny C. Reason This service bulletin will ensure that the Thrust Reversers (TRs) on Rolls-Royce Trent 800 engines have inner walls which contain no residual thermal damage. Later events have revealed that inner walls which have operated without thermal protection system (TPS) and IP8 related improvements may contain residual thermal damage. Some thermal damage is not detectable via current inspection methods or repairs conducted prior to Boeing Service Letter 777-SL-78-026 or SRM 54-32-01, Repair #6 may not have removed all of the existing thermal damage. Residual thermal degradation could cause structural pieces of the inner wall to separate from the TR in flight. A separated piece of the TR could cause damage to other airplane areas, or cause injury to persons on the ground. A separated TR piece at departure could cause a runway excursion because of thrust asymmetry from forward thrust on a Refused Take Off (RTO). Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 13 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 14 Eighteen 777 Rolls-Royce TR events related to thermal damage of the TR inner wall have occurred since 2003. The events have included such things as Air Turn Backs (ATB), In Flight Shut Downs (IFSD), TR inner wall panel collapse, engine fire loop messages, and TR inner wall panel sections and parts have departed the airplane. No hull loss or personal injury has occurred from these events. This service bulletin provides instructions to perform maintenance records checks and detailed inspections of the TR inner wall to determine if the TR inner wall should be replaced. This service bulletin also provides instructions for replacement of the TR inner wall. Boeing Service Related Problem (SRP) 777-SRP-78-0076 is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information. Service History ReportYear of Event // Cy- cles // Hours Engine 2 Left Hand (LH) TR half. Shorted fire loop fault messages (intermittent) received during descent. Extensive delamination found during ground inspection. 2003 // 5,871 // 17,982 Engine 1 LH TR half. Extensive delamination found during ground inspection during planned engine change. 2004 // 4,600 // 13,100 Engine 2 LH TR half. Damage seen on arrival. Large portion of inner wall missing. Debris on runway. Nozzle outer sleeve not found. 2004 // 6,160 // 15,472 Engine 1 LH TR half. Panel collapsed during takeoff. Parts liberated. Air Turn Back (ATB) performed. Nozzle outer sleeve landed on vehicle. 2004 // 6,600 // 16,600 Engine 2 Right Hand (RH) TR half. Exhaust Gas Temperature (EGT) fluctuation during climb out and fire loop fault messages. Flight continued. Damage found during ground inspection. 2006 // 2,450 // 13,124 Engine 1 RH TR half. Panel collapsed during takeoff. Parts liberated. ATB per- formed. 2006 // 5,782 // 37,687 Engine 2 RH TR half. Engine fire warning after takeoff. In Flight Shut Down (IFSD) and ATB performed. Extensive delamination found during ground inspection. 2007 // 7,627 // 26,963 Engine 2 RH TR half. Intermittent status message "LOOP 1 ENG R" and "OVERHEAT CIRCUIT R", but no warning messages. Damage seen on arrival. Large portion of inner wall missing. Debris on takeoff runway. 2007 // 9,770 // 34,895 Engine 1 RH TR. During climb, status messages "ENG EEC R", "TRIM AIR PRSOV R+L", "OVERHEAT CIRCUIT L1", and "FIRE LOOP ENG L". ATB performed. Inner wall panel collapse and damage found during ground inspection. 2008 // 3,865 // 28,213 Engine 2 RH TR half. Fire detection advisory message at take off, flight continued. Damage found during ground inspection. 2009 // 5,616 // 37,245 Engine 2 LH TR half. Indication on take off. Thud heard 5 hrs into flights. PDA, nozzle inner and outer walls liberated. 2010 // 4,702 // 35,471 Crew notified that debris had been collected from the departing runway. Flight diverted. PDA (nozzle intact). 2010 // 7,719 // 38,952 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 14 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 15 Service History ReportYear of Event // Cy- cles // Hours Engine 2, LH TR half. Nozzle outer sleeve recovered from departing airport.2011 // 12,308 // 58,335 Engine 1, LH TR half. Flight diverted. Inner wall collapsed. Aft cowl intact. Nozzle outer sleeve severely damaged but not liberated. 2011 // 8,751 // 40,482 Engine 2, LH TR half. Inner wall collapse during climbout - flight returned to depar- ture airport. PDA - aft cowl & portions of inner wall. 2012 // 7,838 // 50,004 Engine 2, RH TR half. Inner wall collapse during takeoff roll - flight returned to departure airport. PDA - Debris including aft cowl recovered on runway. 2013 // 11,927 // 40,317 Engine 2, RH TR half. Flight continued to destination. PDA - portions of inner wall.2013 // 8,597 // 51,844 Engine 1, RH TR half. Flight returned to departure airport. PDA - aft portions of the TR inner wall. 2013 // 7,241 // 58,668 D. Description All Airplanes 1. Install a serviceable left and right Thrust Reverser (TR) half on left and right engines. NOTE: A serviceable TR half is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Packages 3 (left TR half) or 4 (right TR half) of this service bulletin. 2. Update airplane scheduled maintenance program to incorporate 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02 from the most current published 777 MPD Section 9. For each TR half 1. Group 1, Configuration 1-2: Do a maintenance records check for replacement of the Inner Wall (IW) concurrently with or after incorporation of Boeing Service Bulletin (SB) 777-78-0071 or 777-78-0082. 2. Group 1, Configuration 3: Install the Thermal Protection System (TPS). 3. Group 1, Configuration 4: Modify the aft cowl and install the TPS. 4. Group 1, Configuration 1-2: Do a maintenance records check for incorporation of Boeing SB 777-75A0002 and Rolls-Royce SB RB.211-75-G765 on engines the TR half has operated on. 5. Group 1, Configuration 1-2: Do a maintenance records check for installation of IW part number 315W5100-63 or 315W5100-64. The work in this service bulletin is done in the maintenance zone(s) given below. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 15 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 16 Affected Maintenance Zones ZoneModel 415, 416, 425, 426777-200, 777-300 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. Airplanes that have completed this SB will be restricted to installing TRs that are serviceable units, as defined by this SB, to maintain compliance with this SB. After completing this SB, airplanes that install TRs that are not serviceable units, as defined by this SB, are no longer in compliance with this SB. Thrust reversers modified by this service bulletin must be restricted for use on engines that have incorporated Rolls-Royce Service Bulletin RB.211-75-G765. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. Table 1: WORK PACKAGE 1 AND 2 - THRUST REVERSER REMOVAL AND INSTALLATION - AIRPLANE WORK Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 5 years after the Original Issue date of this Service Bulletin. Install serviceable TR left and right halves on the left and right engines in accordance with Para- graph 3.B., Work Instruc- tions, Work Packages 1 and 2, Steps 1 and 2 (a). All Airplanes (a) A serviceable left half TR is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Package 3 of this service bulletin. A serviceable right half TR is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Package 4 of this service bulletin. Table 2: WORK PACKAGE 3 - THRUST REVERSER LEFT HALF - COMPONENT WORK Repeat Interval (Not to Exceed) Compliance TimeActionCondition --Do Paragraph 3.B., Work Instructions, Work Pack- age 3 of this service bul- letin (a) (b) Each left TR half (a) For each TR half, accomplishment of Paragraph 3.B., Work Instructions, Work Package 3 of this service bulletin terminates the 2000 Flight Cycle repeat inspections of the TR inner wall from Service Bulletin 777-78-0071, Paragraph 3.B., Work Packages 2 and 3, and Service Bulletin 777-78-0082, Paragraph 3.B., Work Packages 4 and 5. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 16 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 17 Table 2: WORK PACKAGE 3 - THRUST REVERSER LEFT HALF - COMPONENT WORK Repeat Interval (Not to Exceed) Compliance TimeActionCondition (b) Thrust reversers that have completed Paragraph 3.B., Work Instructions, Work Package 3 of this service bulletin are subject to 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02 from the most current published 777 MPD Section 9. Table 3: WORK PACKAGE 4 - THRUST REVERSER RIGHT HALF - COMPONENT WORK Repeat Interval (Not to Exceed) Compliance TimeActionCondition --Do Paragraph 3.B., Work Instructions, Work Pack- age 4 of this service bul- letin (a) (b) Each right TR half (a) For each TR half, accomplishment of Paragraph 3.B., Work Instructions, Work Package 4 of this service bulletin terminates the 2000 Flight Cycle repeat inspections of the TR inner wall from Service Bulletin 777-78-0071, Paragraph 3.B., Work Packages 2 and 3, and Service Bulletin 777-78-0082, Paragraph 3.B., Work Packages 4 and 5. (b) Thrust reversers that have completed Paragraph 3.B., Work Instructions, Work Package 4 of this service bulletin are subject to 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02 from the most current published 777 MPD Section 9. Table 4: WORK PACKAGE 5 - THRUST REVERSER THERMAL PROTECTION SYSTEM AIRPLANE SCHEDULED MAINTENANCE PROGRAM CHANGE Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 180 days after the Original Issue date of this Service Bulletin. Update airplane sched- uled maintenance pro- gram to incorporate 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02 from the most current published 777 MPD Section 9, in accor- dance with Paragraph 3.B., Work Instructions, Work Package 5 (a) All Airplanes (a) Accomplishment of this Service Bulletin terminates the 12 month repeat inspections of the IP and HP bleed valves from Service Bulletin 777-78-0082, Paragraph 3.B., Work Package 3. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 17 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 18 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. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (g) and (h) of AD 2005-07-24. All provisions of AD 2005-07-24 that are not specifically referenced in the above statement remain fully applicable and must be complied with. 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 change for each TR half. 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. Left Thrust Reverser Elapsed HoursTask HoursNumber of PersonsTask 3.009.003Remove Thrust Re- verser Half 3.253.251Remove Insulation Blankets 0.50 (a)0.50 (a)1Figure 1 1.25 (a)1.25 (a)1Figure 3 3.50 (a)7.00 (a)2Figure 5 1.30 (a)1.30 (a)1Figure 7 1.501.501Figure 9 36.00(a)180.00(a)5Replace Inner Wall 3.253.251Install Insulation Blankets Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 18 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 19 Left Thrust Reverser Elapsed HoursTask HoursNumber of PersonsTask 3.009.003Install Thrust Revers- er Half 14.0026.00TOTAL FOR EACH THRUST REVERSER HALF (a) Time given for inner wall replacement must be added to total shown if inner wall is to be replaced. Right Thrust Reverser Elapsed HoursTask HoursNumber of PersonsTask 3.009.003Remove Thrust Re- verser Half 3.253.251Remove Insulation Blankets 0.50 (a)0.50 (a)1Figure 2 1.25 (a)1.25 (a)1Figure 4 3.50 (a)7.00 (a)2Figure 6 1.30 (a)1.30 (a)1Figure 8 1.501.501Figure 10 36.00(a)180.00(a)5Replace Inner Wall 3.253.251Install Insulation Blankets 3.009.003Install Thrust Revers- er Half 14.0026.00TOTAL FOR EACH THRUST REVERSER HALF (a) Time given for inner wall replacement must be added to total shown if inner wall is to be replaced. H. Weight and Balance Changes Group 1, Configuration 1-2: None. Group 1, Configuration 3: Change in Moment (Pound-Inches) Change in Weight (Pounds)Engine +48066.4+45.2Each engine Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 19 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 20 Group 1, Configuration 4: Change in Moment (Pound-Inches) Change in Weight (Pounds)Engine +45811.0+43.1Each engine I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 62402-R b. Boeing Service Bulletin 777-78-0071, 777-78-0082 c. Boeing Service Letter 777-SL-51-013 d. Boeing Service Related Problem (SRP) 777-SRP-78-0076 e. Service Bulletin Index D624W001 f. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-50-01, 20-50-07, 20-50-18, 20-50-19, 20-50-20 g. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19 h. 777 Aircraft Maintenance Manual (AMM) 78-31-00, 78-31-01, 78-31-06, 78-31-10 i. 777 Maintenance Planning Data (MPD) Section 9 j. 777 Non-Destructive Testing (NDT) Manual Part 4, 78-30-01, Part 4, 78-30-02, Part 4, 78-30-03 k. 777-200 Structural Repair Manual (SRM) 51-20-08, 51-40-05 l. 777-300 Structural Repair Manual (SRM) 51-40-05 m. Rolls-Royce Service Bulletin RB.211-75-G765 2. Data Supplied with this Service Bulletin: a. Drawings: ADCNDCN/REVSheetTitleDrawing No -G1FASTENER INSTL. ADJ. CLAMPING FORCE POSITIVE LOCK 315T3558 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 20 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 21 ADCNDCN/REVSheetTitleDrawing No --12TRACK BEAM INSTALLATION315W5105 -C13 -BPSDL --19AFT COWL INST.315W5150 --20 --21 --PSDL --3KIT - RETROFIT, AFT COWL315W5163 --4 --PSDL -A21RETAINER INSTALLATION, UPPER BI- FUR, FIRESEAL 315W5319 -A22 -CPSDL -A10RETAINER INSTL - FIRE SEAL, LOWER315W5469 -BPSDL 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number AERODYNAMIC SMOOTHNESS REQTS - NACELLE, STRUT300W5000 TRACK BEAM INSTALLATION315W5105 AFT COWL INST.315W5150 RETAINER INSTALLATION, UPPER BIFUR, FIRESEAL315W5319 RETAINER INSTL - FIRE SEAL, LOWER BIFURCATION315W5469 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Chapter-SectionPublication Section 09777 Maintenance Planning Data 2. Damage Tolerance Based Structural Inspections: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 21 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 22 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 does not affect FCS, therefore DTIs are not necessary. L. Interchangeability and Intermixability of Parts Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information. M. Software Accomplishment Summary Not affected. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 22 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 23 2. MATERIAL INFORMATION A. Material - Price and Availability The operator can supply the parts and materials shown in the kits in Paragraph 2.C., Parts Necessary for Each Airplane, and Paragraph 2.D., Parts Necessary to Change Spares. As an alternative, operators can purchase the kits from Boeing Spares. The Boeing price data shown below is given for planning purposes. Supply data can be given if requested. 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 original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) QTYDateNameKit/Part Number $33,053.00612105/19/2014TOP KIT - LEFT SIDE ROLLS-ROYCE TR IN- NER WALL REPLACE- MENT 005W3567-1 2007/16/2014 2007/30/2014 2008/13/2014 2008/27/2014 1909/11/2014 $33,053.00612105/19/2014TOP KIT - RIGHT SIDE ROLLS-ROYCE TR IN- NER WALL REPLACE- MENT 005W3567-2 2007/16/2014 2007/30/2014 2008/13/2014 2008/27/2014 1909/11/2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 23 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 24 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 original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) QTYDateNameKit/Part Number $367,598.00-804/22/2013INNER WALL - SPARES - 777 RR EN- GINES 315W5100-63 (a) 805/20/2013 806/18/2013 807/17/2013 808/14/2013 809/12/2013 810/10/2013 811/07/2013 812/09/2013 801/15/2014 802/12/2014 803/12/2014 804/09/2014 805/07/2014 806/05/2014 807/03/2014 808/01/2014 808/29/2014 809/29/2014 810/27/2014 811/24/2014 801/02/2015 801/30/2015 802/27/2015 803/27/2015 804/24/2015 805/22/2015 806/22/2015 807/21/2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 24 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 25 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 original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) QTYDateNameKit/Part Number 08/18/2015 8 809/16/2015 810/14/2015 811/11/2015 812/11/2015 801/19/2016 802/16/2016 803/15/2016 404/12/2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 25 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 26 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 original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) QTYDateNameKit/Part Number $367,598.00-804/22/2013INNER WALL - SPARES - 777 RR EN- GINES 315W5100-64 (b) 805/20/2013 806/18/2013 807/17/2013 808/14/2013 809/12/2013 810/10/2013 811/07/2013 812/09/2013 801/15/2014 802/12/2014 803/12/2014 804/09/2014 805/07/2014 806/05/2014 807/03/2014 808/01/2014 808/29/2014 809/29/2014 810/27/2014 811/24/2014 801/02/2015 801/30/2015 802/27/2015 803/27/2015 804/24/2015 805/22/2015 806/22/2015 807/21/2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 26 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 27 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 original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) QTYDateNameKit/Part Number 08/18/2015 8 809/16/2015 810/14/2015 811/11/2015 812/11/2015 801/19/2016 802/16/2016 803/15/2016 404/12/2016 (a) The 315W5100-63 inner wall contains the 315W5101-316 bond panel. (b) The 315W5100-64 inner wall contains the 315W5102-316 bond panel. B. Industry Support Information Boeing warranty remedies are available for 777 airplanes in warranty as of December 8, 2004. For task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Warranty & Product Assurance Contracts. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Material Management. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. The warranty remedies will expire eight years from the original issue date of this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each thrust reverser half. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 27 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 28 Kit 005W3567 NotesExisting Part Number NameQTYNew Part Number -2-1 TOP KIT - LEFT SIDE ROLLS- ROYCE TR INNER WALL REPLACE- MENT .-005W3567-1 TOP KIT - RIGHT SIDE ROLLS- ROYCE TR INNER WALL REPLACE- MENT -.005W3567-2 PIN112ASPFF-V06-09AC (2MAFFF-V06- 09AC optional) PIN222ASPFF-V06-11AC (2MAFFF-V06- 11AC optional) PIN112ASPFF-V06-12AC (2MAFFF-V06- 12AC optional) PIN222ASPFF-V06-13AC (2MAFFF-V06- 13AC optional) PIN112ASPFF-V06-15AC (2MAFFF-V06- 15AC optional) PIN222ASPFP-V06- 09AC SLEEVE882ASPP-S-V06 SLEEVE882MAFP-S-V06 LOCK COLLAR5151ASP-LC-MV06 LOCK COLLAR66ASP-LC-MV08 SLEEVE4343ASPF-S-V06AC SLEEVE66ASPF-S-V08N7AC PIN3030ASPFF-V06-06AC (MAFFF-V06-06AC optional) PIN66ASPFF-V06-08AC (MAFFF-V06-08AC optional) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 28 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 29 Kit 005W3567 NotesExisting Part Number NameQTYNew Part Number -2-1 PIN22ASPFF-V08- 22N7AC (MAFFF- V08-22N7AC op- tional) PIN44ASPFF-V08- 23N7AC (MAFFF- V08-23N7AC op- tional) PIN66ASPFP-V06-24AC BOLT, PAN HD, CROSS 1010BACB30LK3K3 BOLT55BACB30MY8K5 BOLT, HEX DRIVE22BACB30MY8K6 HEX DRIVE BOLT33BACB30NW6K11 BOLT11BACB30NW6K15 BOLT, 100 DEG HEX D 33BACB30NW6K19 BOLT33BACB30NW6K21 BOLT, 100 DEG HEX D 22BACB30NW6K22 BOLT8585BACB30NW6K23 BOLT3636BACB30NW6K24 BOLT, 100 DEG HEAD 22BACB30NW6K26 HI-LOK11BACB30NW6K6 BOLT1616BACB30NW6K7 BOLT, 100 DEG HEX D 2020BACB30NW8K22 BOLT TITANIUM11BACB30NW8K23 BOLT, 100 DEG SHR HD 3333BACB30NW8K24 BOLT, HEX DRIVE6262BACB30NW8K25 BOLT, HEX-DRIVE11BACB30NW8K28 BOLT3434BACB30NY6K6 HI-LOK44BACB30NY6K7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 29 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 30 Kit 005W3567 NotesExisting Part Number NameQTYNew Part Number -2-1 BOLT, 100 DEG HEX DR 22BACB30NY6K8 BOLT, 100 DEG HEX DR 22BACB30NY6K9 BOLT11BACB30VF3K2 BOLT, BLIND, 100 DEG RED HD 44BACB30VF4K5 BOLT44BACB30VF4K6 BOLT33BACB30VT6K6 BOLT8585BACB30VT8K5 FILLER22BACF3W05P9N9 NUTPLATE1313BACN10JP4DCD NUT5050BACN10YR3CM NUT, SELF-LOCK, HEX 4545BACN10YT3CSA NUT, SELF-LOCK, HEX 126126BACN10YT4CD NUT33BACN10ZV3 NUT SELF-LOCK- ING 8989BACN10ZV4 RIVET2626BACR15BA3D3C RIVET, 100 DEG11BACR15CE4M3 RIVET, 100 DEG11BACR15CE4M5 RIVET, 100 DEG11BACR15CE4M7 FAIRING SCREWS88BACS12FA08K3 SCREW, CAP88BACS12GU3K7 SCREW1010BACS12GU4K24 SHIM, LAMINAT- ED 1010BACS40R012C120F SHIM11BACS40R012W031 SHIM, LAMINAT- ED 2424BACS40R024L050 SHIM, LAMINAT- ED 1010BACS40V012C130 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 30 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 31 Kit 005W3567 NotesExisting Part Number NameQTYNew Part Number -2-1 SHIM, LAMINAT- ED 11BACS40V018F029 SHIM, LAMINAT- ED 11BACS40V024B265 SHIM55BACS40V024C264 RIVET22CSR902B-4-3 RIVET1010CSR922C-6EA-5 RIVET3030CSR922C-6EA-6 RIVET66CSR922C-6EA-8 RIVET22CSR922C-8EA-7 NUT ASSY9797KFN522DL3 WASHER1010NAS1149D0332J WASHER, PLAIN9999NAS1149V0316M WASHER, PLAIN5050NAS1149V0363M 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. NotesNameQTYPart Number / Specification INNER WALL - SPARES - 777 RR ENGINES 1315W5100-63 INNER WALL - SPARES - 777 RR ENGINES 1315W5100-64 As required, if existing part needs to be replaced. PLATE - SPLICE, UPR INNER WALL 1315W5103-1 As required, if existing part needs to be replaced. PLATE - SPLICE, UPR INNER WALL 1315W5103-2 (a)SEALANT1 QtBMS 5-63, Type 1 or 2, Class B Any 2000, 6000, or 7000 series aluminum sheet, any temper other than annealed 1 inch x 14 inch, thickness 0.040 - 0.063 inch thick. Aluminum Sheet1Aluminum Sheet Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 31 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 32 NotesNameQTYPart Number / Specification (a)SEALANT1BMS 5-45, Class B (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. QTYNamePart Number 1TOP KIT - LEFT SIDE ROLLS- ROYCE TR INNER WALL REPLACE- MENT 005W3567-1 1TOP KIT - RIGHT SIDE ROLLS- ROYCE TR INNER WALL REPLACE- MENT 005W3567-2 1INNER WALL - SPARES - 777 RR ENGINES 315W5100-63 1INNER WALL - SPARES - 777 RR ENGINES 315W5100-64 E. Special Tooling - Price and Availability The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Tool price and supply data are not given. F. Special Tooling Necessary to do this Service Bulletin Refer to Appendix B for specifications required for the design/build of tooling required for the installation of the TR inner wall. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 32 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 33 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. 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. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values: — Values for structural fasteners are given in 777 Structural Repair Manual, Chapter 51. — Values for airframe maintenance tasks are included in Chapter 20 of 777 Airplane Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). — Values for engine maintenance tasks are included in Chapter 70 of 777 Airplane Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step. 5. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 6. The approved fastener and process material substitutions in accordance with Appendix F supersede those in SRM Chapter 51. 7. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 33 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 34 8. The necessary conditions for selection of clamp type and size are included in SWPM 20-10-12. If any wire bundle support clamp specified in this service bulletin does not make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted procedure to select a clamp that fits correctly. 9. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 10. 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. 11. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 12. 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. 13. 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. More information can be found in Boeing Service Letters 777-SL-78-026 and 777-SL-78-027. 14. Refer to Appendix D and E for logic diagram(s). Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 15. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 34 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 35 16. 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. 17. 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. 18. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. 19. 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. 20. If shading is used, shaded areas in Figures are to separate the non-critical and non-authoritative information from the critical and authoritative information. 21. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 22. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 23. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC must be done to comply with the AD. Alternative procedures for steps not identified with RC can be used if the RC steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. 24. When drilling holes for fasteners that will be wet installed, use lubricants in accordance with SOPM 20-50-07 for metal and SOPM 20-50-18 for composite parts. After drilling and or countersinking operations are complete, clean residual lubricant from surfaces to be sealed, including countersinks but excluding fastener holes. 25. When removing the inner wall from the thrust reverser, remove all shims, fay surface seals, and fillet seals that may stay attached to the faying surfaces or edges of the mating parts. Remove fay surface seals and fillet seals in accordance with SOPM 20-50-19. 26. The inner wall replacement instructions and tooling appendix provide the NSTA, NBL, and NWL for tooling interfaces and feature requirements. When installing the TR and Inner Wall in the tooling fixture, it is critical that the relative three dimensional position of all components is maintained. 27. Install ASP/MAF fasteners in accordance with 315T3558. 28. Install shims in accordance with SOPM 20-50-20. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 35 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 36 29. Ensure the inner wall is properly supported at all times to avoid damaging parts or the locating tool. B. WORK INSTRUCTIONS WORK PACKAGE 1 - THRUST REVERSER LEFT HALF - REMOVAL AND INSTALLATION - AIRPLANE WORK 1. Remove the Thrust Reverser (TR) left half from the engine. Refer to 777 AMM 78-31-01 as an accepted procedure. NOTE: If a serviceable TR left half is installed on the engine, it is not necessary to remove it. Proceed to Step 3. NOTE: A serviceable TR left half is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Package 3 of this service bulletin. 2. RC - Install a serviceable Thrust Reverser (TR) left half on engine. Refer to 777 AMM 78-31-01 as an accepted procedure. NOTE: A serviceable TR left half is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Package 3 of this service bulletin. 3. Put the airplane back to a serviceable condition. WORK PACKAGE 2 - THRUST REVERSER RIGHT HALF - REMOVAL AND INSTALLATION - AIRPLANE WORK 1. Remove the Thrust Reverser (TR) right half from the engine. Refer to 777 AMM 78-31-01 as an accepted procedure. NOTE: If a serviceable TR right half is installed on the engine, it is not necessary to remove it. Proceed to Step 3. NOTE: A serviceable TR right half is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Package 4 of this service bulletin. 2. RC - Install a serviceable Thrust Reverser (T/R) right half on engine. Refer to 777 AMM 78-31-01 as an accepted procedure. NOTE: A serviceable TR right half is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Package 4 of this service bulletin. 3. Put the airplane back to a serviceable condition. RC - WORK PACKAGE 3 - THRUST REVERSER LEFT HALF - COMPONENT WORK 1. Group 1, Configuration 1-2: Do PART 1: MAINTENANCE RECORDS CHECK FOR REPLACEMENT OF LEFT TR HALF IW CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-00071 OR 777-78-0082 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 36 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 37 2. Group 1, Configuration 3: Install TPS in accordance with Boeing Service Bulletin 777-78-0071, Revision 02, Work Package 1 and Work Package 4 and Work Package 6, except install a new inner wall (315W5100-63) in accordance with Part 8 of this Service Bulletin in lieu of Steps 3-17 in Boeing Service Bulletin 777-78-0071, Revision 02, Work Package 1. 3. Group 1, Configuration 4: Modify the aft cowl and install TPS in accordance with Boeing Service Bulletin 777-78-0082, Original Issue, Work Package 1 and Work Package 6, except install a new inner wall (315W5100-63) in accordance with Part 8 of this Service Bulletin in lieu of Step 6 in SB 777-78-0082, Original Issue, Work Package 6. 4. Group 1, Configuration 1-2: Do PART 2: MAINTENANCE RECORDS CHECK OF LEFT TR HALF FOR INCORPORATION OF BOEING SERVICE BULLETIN 777-75A0002 ON ENGINES THE TR HALF HAS OPERATED ON. 5. Group 1, Configuration 1-2: Do PART 3: MAINTENANCE RECORDS CHECK OF LEFT TR HALF FOR INSTALLATION OF INNER WALL PART NUMBER 315W5100-63. 6. Mark the TR identification plate with the service bulletin number, service bulletin revision level and the work package number to show the change was done. Refer to SOPM 20-50-10 as an accepted procedure. RC - WORK PACKAGE 4 - THRUST REVERSER RIGHT HALF - COMPONENT WORK 1. Group 1, Configuration 1-2: Do PART 4: MAINTENANCE RECORDS CHECK FOR REPLACEMENT OF RIGHT TR HALF IW CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-00071 OR 777-78-0082 2. Group 1, Configuration 3: Install TPS in accordance with Boeing Service Bulletin 777-78-0071, Revision 02, Work Package 1 and Work Package 4 and Work Package 6, except install a new inner wall (315W5100-64) in accordance with Part 9 of this Service Bulletin in lieu of Steps 3-17 in Boeing Service Bulletin 777-78-0071, Revision 02, Work Package 1. 3. Group 1, Configuration 4: Modify the aft cowl and install TPS in accordance with 777-78-0082, Original Issue, Work Package 2 and Work Package 6, except install a new inner wall (315W5100-64) in accordance with Part 9 of this Service Bulletin in lieu of Step 6 in SB 777-78-0082, Original Issue, Work Package 6. 4. Group 1, Configuration 1-2: Do PART 5: MAINTENANCE RECORDS CHECK OF RIGHT TR HALF FOR INCORPORATION OF BOEING SERVICE BULLETIN 777-75A0002 AND ROLLS-ROYCE SERVICE BULLETIN RB.211-75-G765 ON ENGINES THE TR HALF HAS OPERATED ON. 5. Group 1, Configuration 1-2: Do PART 6: MAINTENANCE RECORDS CHECK OF RIGHT TR HALF FOR INSTALLATION OF INNER WALL PART NUMBER 315W5100-64. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 37 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 38 6. Mark the TR identification plate with the service bulletin number, service bulletin revision level and the work package number to show the change was done. Refer to SOPM 20-50-10 as an accepted procedure. RC - WORK PACKAGE 5 - THRUST REVERSER THERMAL PROTECTION SYSTEM AIRPLANE SCHEDULED MAINTENANCE PROGRAM CHANGE 1. Update airplane scheduled maintenance program to incorporate 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02 from the most current published 777 MPD Section 9. Group 1, Configuration 1-2: RC - PART 1: MAINTENANCE RECORDS CHECK FOR REPLACEMENT OF LEFT TR HALF IW CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-0071 OR 777-78-0082 1. Do a maintenance records check to determine if the IW was replaced concurrently or after incorporation of Boeing Service Bulletin 777-78-0071 or 777-78-0082 a. CONDITION 1: LEFT TR HALF INNER WALL WAS NOT REPLACED CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-0071 or BOEING SERVICE BULLETIN 777-78-0082. (1) ACTION 1: Do PART 8: LEFT TR HALF INNER WALL REPLACEMENT (2) ACTION 2: No further action. This TR half inner wall meets the requirements of Parts 1, 2, and 3. b. CONDITION 2: LEFT TR HALF INNER WALL WAS REPLACED CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-0071 or BOEING SERVICE BULLETIN 777-78-0082. (1) ACTION 1: No further action for Part 1. This TR half inner wall meets the requirements of Part 1. Group 1, Configuration 1-2: RC - PART 2: MAINTENANCE RECORDS CHECK OF LEFT TR HALF FOR INCORPORATION OF BOEING SERVICE BULLETIN 777-75A0002 ON ENGINES THE TR HALF HAS OPERATED ON. 1. Do a maintenance records check to determine if the left TR half inner wall has always flown on an engine that has incorporated Boeing Service Bulletin 777-75A0002. a. CONDITION 3: LEFT TR HALF INNER WALL HAS ALWAYS OPERATED ON AN ENGINE WITH BOEING SERVICE BULLETIN 777-75A0002 INCORPORATED. (1) ACTION 1: No further action for Part 2. This TR half inner wall meets the requirements of Part 2 b. CONDITION 4: LEFT TR HALF INNER WALL HAS NOT ALWAYS OPERATED ON AN ENGINE WITH BOEING SERVICE BULLETIN 777-75A0002 INCORPORATED. (1) ACTION 1: Go to Step 2 - Do a detailed inspection of the left TR half inner wall for previous composite repairs. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 38 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 39 2. Do a detailed inspection of the left TR half inner wall for previous composite repairs. a. CONDITION 5: NO PREVIOUS COMPOSITE REPAIRS FOUND (1) ACTION 1: Go to Step 4 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the entire TR inner wall. b. CONDITION 6: ANY PREVIOUS COMPOSITE REPAIR FOUND. PREVIOUS COMPOSITE REPAIR IS DETERMINED TO EXCEED THE ALLOWABLE REPAIR LIMITS IN APPENDIX A. (1) ACTION 1: Do PART 8: LEFT TR HALF INNER WALL REPLACEMENT (2) ACTION 2: No further action. This TR half inner wall meets the requirements of Parts 1, 2, and 3. c. CONDITION 7: ANY PREVIOUS COMPOSITE REPAIR FOUND. PREVIOUS COMPOSITE REPAIR IS DETERMINED TO BE WITHIN THE ALLOWABLE REPAIR LIMITS IN APPENDIX A. (1) ACTION 1: Go to Step 3 - Do a maintenance records check to determine if the previous composite repair was performed in accordance with the limitations and procedures in SRM 54-32-01, Repair 6 or Boeing approved resin injection repair after October 22, 2013. 3. Do a maintenance records check to determine if the previous composite repair was performed in accordance with the limitations and procedure in SRM 54-32-01, Repair 6 or Boeing approved resin injection repair after October 22, 2013. a. CONDITION 8: PREVIOUS COMPOSITE REPAIR WAS PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) ACTION 1: Go to Step 4 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the entire TR inner wall. b. CONDITION 9: PREVIOUS COMPOSITE REPAIR WAS NOT PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6, OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) (OPTION 1) ACTION 1: Re-do the repair in accordance with the limitations and procedures in SRM 54-32-01, Repair 6 or Boeing approved potted through bolt clickbond repairafter June 24, 2014. (2) (OPTION 1) ACTION 2: Go to Step 4 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION (3) (OPTION 2) ACTION 1: Do PART 8: LEFT TR HALF INNER WALL REPLACEMENT (4) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 1, 2, and 3. 4. Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the entire TR inner wall. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 39 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 40 a. CONDITION 10: THRUST REVERSER INNER WALL PASSES THE THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION (1) ACTION 1: No further action for Part 2. This TR half inner wall meets the requirements of Part 2. b. CONDITION 11: THRUST REVERSER INNER WALL DOES NOT PASS THE THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION. (1) (OPTION 1) ACTION 1: Do PART 7: NDT OF TR HALF INNER WALL of the failed areas. (2) (OPTION 1) ACTION 2: Contact Boeing for repair of inner wall and do the repair. (3) (OPTION 1) ACTION 3: No further action for Part 2. This TR half inner wall meets the requirements of Part 2 (4) (OPTION 2) ACTION 1: Do PART 8: LEFT TR HALF INNER WALL REPLACEMENT (5) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 1, 2, and 3. Group 1, Configuration 1-2: RC - PART 3: MAINTENANCE RECORDS CHECK FOR INSTALLATION OF LEFT TR HALF INNER WALL PART NUMBER 315W5100-63. 1. Do a maintenance records check to determine if the left TR half inner wall was replaced with part number 315W5100-63. a. CONDITION 12: LEFT TR HALF INNER WALL WAS REPLACED WITH PART NUMBER 315W5100-63. (1) ACTION 1: No further action for Part 3. This TR half inner wall meets the requirements of Part 3. b. CONDITION 13: LEFT TR HALF INNER WALL WAS NOT REPLACED WITH PART NUMBER 315W5100-63 (1) ACTION 1: Go to Step 2 - Do PART 7: NDT OF TR HALF INNER WALL at reworked clickbond areas. Refer to FIGURE 9 for re-worked click bond locations. 2. Do PART 7: NDT OF TR HALF INNER WALL at reworked clickbond areas. Refer to FIGURE 9 for re-worked click bond locations. a. CONDITION 14: ANY DISBOND OR DELAMINATION FOUND ON LEFT TR HALF INNER WALL (1) (OPTION 1) ACTION 1: Repair the inner wall in accordance with the limitations and procedures in SRM 54-32-01, Repair 6 or Boeing approved potted through bolt clickbond repair after June 24, 2014. (2) (OPTION 1) ACTION 2: Go to Step 3 - Do a detailed inspection of the clickbond areas for previous repairs. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 40 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 41 (3) (OPTION 2) ACTION 1: Do PART 8: LEFT TR HALF INNER WALL REPLACEMENT (4) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Parts 1, 2, and 3. b. CONDITION 15: NO DISBONDS OR DELAMINATIONS FOUND ON LEFT TR HALF INNER WALL (1) ACTION 1: Go to Step 3 - Do a detailed inspection of the clickbond areas for previous repairs. 3. Do a detailed inspection of the clickbond areas for previous repairs. Refer to FIGURE 9 for re-worked click bond locations. a. CONDITION 16: NO PREVIOUS REPAIRS FOUND (1) ACTION 1: No further action for part 3. This TR half inner wall meets the requirements of Part 3 b. CONDITION 17: ANY PREVIOUS REPAIR IS FOUND. (1) ACTION 1: Go to Step 4 - Do a maintenance records check to determine if the previous non-thermal repair was performed in accordance with the limitations and procedures in SRM 54-32-01, Repair 6 or Boeing approved resin injection repair after October 22, 2013. 4. Do a maintenance records check to determine if the previous non-thermal repair was performed in accordance with the limitations and procedures in SRM 54-32-01, Repair 6 or Boeing approved resin injection repair after October 22, 2013. a. CONDITION 18: PREVIOUS REPAIR WAS PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTIONS REPAIR AFTER OCTOBER 22, 2013. (1) ACTION 1: No further action for Part 3. This TR half inner wall meets the requirements of Part 3 b. CONDITION 19: PREVIOUS REPAIR WAS NOT PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTIONS REPAIR AFTER OCTOBER 22, 2013. (1) (OPTION 1) ACTION 1: Re-do the repair in accordance with the limitations and procedures in SRM 54-32-01, Repair 6 or Boeing approved potted through bolt clickbond repair after June 24, 2014. (2) (OPTION 1) ACTION 2: No further action for Part 3. This TR half inner wall meets the requirements of Part 3 (3) (OPTION 2) ACTION 1: Do PART 8: LEFT TR HALF INNER WALL REPLACEMENT (4) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Parts 1, 2, and 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 41 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 42 Group 1, Configuration 1-2: RC - PART 4: MAINTENANCE RECORDS CHECK FOR REPLACEMENT OF RIGHT TR HALF IW CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-0071 OR BOEING SERVICE BULLETIN 777-78-0082 1. Do a maintenance records check to determine if the right TR half IW was replaced concurrently of after incorporation of Boeing Service Bulletin 777-78-0071 or Boeing Service Bulletin 777-78-0082 a. CONDITION 20: RIGHT TR HALF INNER WALL WAS NOT REPLACED CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-0071 or BOEING SERVICE BULLETIN 777-78-0082. (1) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT. (2) ACTION 2: No further action. This TR half inner wall meets the requirements of Parts 4, 5, and 6. b. CONDITION 21: RIGHT TR HALF INNER WALL WAS REPLACED CONCURRENTLY OR AFTER INCORPORATION OF BOEING SERVICE BULLETIN 777-78-0071 or BOEING SERVICE BULLETIN 777-78-0082. (1) ACTION 1: No further action for Part 4. This TR half inner wall meets the requirements of Part 4. Group 1, Configuration 1-2: RC - PART 5: MAINTENANCE RECORDS CHECK OF RIGHT TR HALF FOR INCORPORATION OF BOEING SERVICE BULLETIN 777-75A0002 AND ROLLS-ROYCE SERVICE BULLETIN RB.211-75-G765 ON ENGINES THE TR HALF HAS OPERATED ON. 1. Do a maintenance records check to determine if the TR has always flown on an engine that has incorporated Boeing Service Bulletin 777-75A0002 and Rolls-Royce Service Bulletin RB.211-75-G765. a. CONDITION 22: RIGHT TR HALF INNER WALL HAS ALWAYS OPERATED ON AN ENGINE WITH BOEING SERVICE BULLETIN 777-75A0002 AND ROLLS-ROYCE SERVICE BULLETIN RB.211-75-G765 INCORPORATED. (1) ACTION 1: No further action for Part 5. This TR half inner wall meets the requirements of Part 5. b. CONDITION 23: RIGHT TR HALF INNER WALL HAS NOT ALWAYS OPERATED ON AN ENGINE WITH BOEING SERVICE BULLETIN 777-75A0002 AND ROLLS-ROYCE SERVICE BULLETIN RB.211-75-G765 INCORPORATED. (1) ACTION 1: Go to Step 2 - Do a detailed inspection of the right TR half inner wall for previous composite repairs. c. CONDITION 24: RIGHT TR HALF INNER WALL HAS ALWAYS OPERATED ON AN ENGINE WITH BOEING SERVICE BULLETIN 777-75A0002, BUT HAS NOT ALWAYS OPERATED ON AN ENGINE WITH ROLLS-ROYCE SERVICE BULLETIN RB.211-75-G765 INCORPORATED. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 42 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 43 (1) ACTION 1: Go to Step 5 - Do a detailed inspection of the IP8.2 zone on the right TR half inner wall for previous composite repairs. Refer to Appendix G for location of the IP8.2 zone. 2. Do a detailed inspection of the right TR half inner wall for previous composite repairs. a. CONDITION 25: NO PREVIOUS COMPOSITE REPAIRS FOUND (1) ACTION 1: Go to Step 4 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the entire TR inner wall. b. CONDITION 26: ANY PREVIOUS COMPOSITE REPAIR FOUND. PREVIOUS COMPOSITE REPAIR IS DETERMINED TO EXCEED THE ALLOWABLE REPAIR LIMITS IN APPENDIX A. (1) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT (2) ACTION 2: No further action. This TR half inner wall meets the requirements of Parts 4, 5, and 6. c. CONDITION 27: ANY PREVIOUS COMPOSITE REPAIR FOUND. PREVIOUS COMPOSITE REPAIR IS DETERMINED TO BE WITHIN THE ALLOWABLE REPAIR LIMITS IN APPENDIX A. (1) ACTION 1: Go to Step 3 - Do a maintenance records check to determine if the previous composite repairs were performed in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved resin injection repair after October 22, 2013. 3. Do a maintenance records check to determine if the previous composite repairs were performed in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved resin injection repair after October 22, 2013. a. CONDITION 28: PREVIOUS COMPOSITE REPAIR WAS PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) ACTION 1: Go to Step 4 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the entire TR inner wall. b. CONDITION 29: PREVIOUS REPAIR WAS NOT PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) (OPTION 1) ACTION 1: Re-do the repair in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved potted through bolt clickbond repair after June 24, 2014. (2) (OPTION 1) ACTION 2: Go to Step 4 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION (3) (OPTION 2) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 43 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 44 (4) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 4, 5, and 6 4. Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the entire TR inner wall. a. CONDITION 30: THRUST REVERSER INNER WALL PASSES THE THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION (1) ACTION 1: No further action for Part 5. This TR half inner wall meets the requirements of Part 5 b. CONDITION 31: THRUST REVERSER INNER WALL DOES NOT PASS THE THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION. (1) (OPTION 1) ACTION 1: Do PART 7: NDT OF TR HALF INNER WALL at failed areas. (2) (OPTION 1) ACTION 2: Contact Boeing for repair of inner wall and do the repair. (3) (OPTION 1) ACTION 3: No further action for Part 5. This TR half inner wall meets the requirements of Part 5. (4) (OPTION 2) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT (5) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 4, 5, and 6. 5. Do a detailed inspection of the IP8.2 zone of the right TR half inner wall for previous composite repairs. Refer to Appendix G for location of the IP8.2 zone. a. CONDITION 32: NO PREVIOUS COMPOSITE REPAIRS FOUND (1) ACTION 1: Go to Step 7 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on IP8.2 zone. Refer to Appendix G for the location of the IP8.2 zone. b. CONDITION 33: ANY PREVIOUS COMPOSITE REPAIR FOUND. PREVIOUS COMPOSITE REPAIR IS DETERMINED TO BE THERMALLY RELATED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN APPENDIX A. (1) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT (2) ACTION 2: No further action. This TR half inner wall meets the requirements of Parts 4, 5, and 6. c. CONDITION 34: ANY PREVIOUS COMPOSITE REPAIR FOUND. PREVIOUS COMPOSITE REPAIRS ARE DETERMINED TO BE NOT THERMALLY RELATED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN APPENDIX A. (1) ACTION 1: Go to Step 6 - Do a maintenance records check to determine if the previous composite non-thermal repairs were performed in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved resin injection repair after October 22, 2013. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 44 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 45 6. Do a maintenance records check to determine if the previous composite non-thermal repairs were performed in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved resin injection repair after October 22, 2013. a. CONDITION 35: PREVIOUS COMPOSITE REPAIR WAS PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) ACTION 1: Go to Step 7 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the IP8.2 zone. Refer to Appendix G for the location of the IP8.2 zone. b. CONDITION 36: PREVIOUS REPAIR WAS NOT PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) (OPTION 1) ACTION 1: Re-do the repair in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved potted through bolt clickbond repair after June 24, 2014. (2) (OPTION 1) ACTION 2: Go to Step 7 - Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION in the IP8.2 zone. Refer to Appendix G for location of the IP8.2 zone. (3) (OPTION 2) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT (4) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 4, 5, and 6 7. Do PART 10: THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION on the IP8.2 zone. Refer to Appendix G for the location of the IP8.2 zone. a. CONDITION 37: THRUST REVERSER INNER WALL PASSES THE THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION ON THE IP8.2 ZONE. (1) ACTION 1: No further action for Part 5. This TR half inner wall meets the requirements of Part 5 b. CONDITION 38: THRUST REVERSER INNER WALL DOES NOT PASS THE THRUST REVERSER INNER WALL SURFACE COLOR DETAILED INSPECTION ON THE IP8.2 ZONE. (1) (OPTION 1) ACTION 1: Do PART 7: NDT OF TR HALF INNER WALL at failed areas. (2) (OPTION 1) ACTION 2: Contact Boeing for repair of inner wall and do the repair. (3) (OPTION 1) ACTION 3: No further action for Part 5. This TR half inner wall meets the requirements of Part 5. (4) (OPTION 2) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT (5) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 4, 5, and 6. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 45 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 46 Group 1, Configuration 1-2: RC - PART 6: MAINTENANCE RECORDS CHECK FOR INSTALLATION OF RIGHT TR HALF INNER WALL PART NUMBER 315W5100-64. 1. Do a maintenance records check to determine if the right TR half inner wall was replaced with part number 315W5100-64. a. CONDITION 39: RIGHT TR HALF INNER WALL WAS REPLACED WITH PART NUMBER 315W5100-64. (1) ACTION 1: No further action for Part 6. This TR half inner wall meets the requirements of Part 6. b. CONDITION 40: RIGHT TR HALF INNER WALL WAS NOT REPLACED WITH PART NUMBER 315W5100-64 (1) ACTION 1: Go to Step 2 - Do PART 7: NDT OF TR HALF INNER WALL at re-worked click bond areas. Refer to FIGURE 10 for location of re-worked click bonds 2. Do PART 7: NDT OF TR HALF INNER WALL at re-worked click bond areas. Refer to FIGURE 10 for location of re-worked click bonds a. CONDITION 41: ANY DISBOND OR DELAMINATION FOUND ON RIGHT TR HALF INNER WALL (1) (OPTION 1) ACTION 1: Repair the inner wall in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved potted through bolt clickbond repair after June 24, 2014. (2) (OPTION 1) ACTION 2: Go to Step 3 - Do a detailed inspection of the re-worked clickbond areas for previous repairs. (3) (OPTION 2) ACTION 1: Do PART 9: RIGHT HALF TR INNER WALL REPLACEMENT (4) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 4, 5, and 6 b. CONDITION 42: NO DISBONDS OR DELAMINATIONS FOUND ON RIGHT TR HALF INNER WALL (1) ACTION 1: Go to Step 3 - Do a detailed inspection of the clickbond areas for previous repairs. 3. Do a detailed inspection of the re-worked clickbond areas for previous repairs. Refer to FIGURE 10 for the location of the re-worked click bonds. a. CONDITION 43: NO PREVIOUS REPAIRS FOUND (1) ACTION 1: No further action for Part 6. This TR half inner wall meets the requirements of Part 6 b. CONDITION 44: ANY PREVIOUS REPAIR IS FOUND Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 46 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 47 (1) ACTION 1: Go to Step 4 - Do a maintenance records check to determine if the previous composite non-thermal repairs were performed in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved resin injection repair after October 22, 2013 4. Do a maintenance records check to determine if the previous composite non-thermal repairs were performed in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved resin injection repair after October 22, 2013. a. CONDITION 45: PREVIOUS REPAIR WAS PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) ACTION 1: No further action for Part 6. This TR half inner wall meets the requirements of Part 6 b. CONDITION 46: PREVIOUS REPAIR WAS NOT PERFORMED IN ACCORDANCE WITH THE LIMITATIONS AND PROCEDURES IN SRM 54-32-01, REPAIR 6 OR BOEING APPROVED RESIN INJECTION REPAIR AFTER OCTOBER 22, 2013. (1) (OPTION 1) ACTION 1: Re-do the repair in accordance with the limitations and procedures in SRM 54-32-01, REPAIR 6 or Boeing approved potted through bolt clickbond repair after June 24, 2014. (2) (OPTION 1) ACTION 2: No further action for Part 6. This TR half inner wall meets the requirements of Part 6 (3) (OPTION 2) ACTION 1: Do PART 9: RIGHT TR HALF INNER WALL REPLACEMENT (4) (OPTION 2) ACTION 2: No further action. This TR half inner wall meets the requirements of Part 4, 5, and 6. Group 1, Configuration 1-2: PART 7: NDT OF TR HALF INNER WALL 1. Open the TR half. Refer to 777 AMM 78-31-00 as an accepted procedure to open the TR half. Operators may remove the TR half if desired. Refer to 777 AMM 78-31-01 as an accepted procedure. 2. Remove and keep the insulation blankets from the TR half inner wall. Refer to 777 AMM 78-31-06 as an accepted procedure to remove the insulation blankets. NOTE: The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. 3. Solvent clean the inner wall panel. Refer to SOPM 20-30-03 as an accepted procedure to solvent clean the inner wall. NOTE: In addition to the acceptable solvents found in SOPM 20-30-03, Isopropyl Alcohol can also be used. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 47 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 48 a. Do not remove marks on the inner wall that have recorded information that should be kept for inspectors or other personnel. 4. RC - Do a Nondestructive Test (NDT) of the specified areas. Look for delaminations and disbonds of the inner wall panel. Use a one inch grid pattern to scan the specified areas. a. Do an NDT of field core areas (four ply areas) in accordance with 777 NDT Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), or Low Frequency Bond Test, 777 NDT Part 4, 78-30-03. Refer to 777 NDT Part 4, 78-30-03 for locations of ply build up areas. b. Do an NDT of ply build-up areas (greater than 4 plies) with 777 NDT Part 4, 78-30-01 (High Frequency Bond Test), 777 NDT Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), or 777 NDT Part 4, 78-30-03 (Low Frequency Bond Test). Refer to 777 NDT Part 4, 78-30-03 for locations of ply build up areas. RC - PART 8 - LEFT TR HALF INNER WALL REPLACEMENT 1. Group 1, Configuration 1-2: Remove the left TR half from the engine. Refer to 777 AMM 78-31-01 as an acceptable procedure. 2. Group 1, Configuration 1-2: Remove and keep the insulation blankets from the TR half inner wall. Refer to 777 AMM 78-31-06 as an accepted procedure. NOTE: The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. 3. Remove the translating sleeve from the left TR half. Refer to 777 AMM 78-31-10 as an acceptable procedure. 4. Remove and keep the upper bifurcation bulb seal and three forward inner wall bulb seals. Refer to 777 AMM 78-31-05 as an acceptable procedure. 5. Group 1, Configuration 1, 3: Remove and keep the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly, and 315W5322 retainers from the inner wall, 315W5300 hinge beam, and aft cowl. Refer to 315W5319 SH21 and 315W5150 SH20. NOTE: Do not remove the 315W5322 retainers from the 315W5328 flame shield assembly or 315W5329 retainer assembly. 6. Group 1, Configuration 2: Remove and keep the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly, and 315W5322 retainers from the inner wall, 315W5300 hinge beam, and aft cowl. Refer to 315W5319 SH21 and 315W5163 SH3. NOTE: Do not remove the 315W5322 retainers from the 315W5328 flame shield assembly or 315W5329 retainer assembly. 7. Remove and save the 315W5333 seal deflector from the inner wall. Refer to 315W5319 SH 21. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 48 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 49 8. Install the left TR half into the locating tool by fixing the TR outer v-blade, hinge beam, and latch beam to the tool fixture. Refer to APPENDIX B for tooling guidance. a. Fix the aft edge of the outer v-blade to the tooling fixture at NSTA 218.31 at a minimum of 3 locations separated by a minimum of 45 degrees. Ensure clamping is in its free state, and not up against a hard point on the tool to avoid preloading the inner wall during assembly. NOTE: Locate using unworn sections of the aft edge of the outer v-blade. Missing surface finish is acceptable, provided no corrosion. b. Fix the NWL and NBL of the hinge beam to the tooling fixture at minimum two of the three locations below. See Appendix B for tooling guidance. (1) Fix the center line of the No. 2 hinge at NWL 160.18 and NBL 16.10 (2) Fix the center line of the No. 3 hinge at NWL 160.18 and NBL 16.10 (3) Fix the center line of the No. 4 hinge at NWL 160.18 and NBL 16.10 c. Fix the NWL of the latch beam to the tooling fixture at a minimum two of the three locations below. See Appendix B for tooling guidance (1) Fix the center line of the No. 2 latch pin hole at NWL 37.60. (2) Fix the center line of the No. 3 latch pin hole at NWL 39.65. (3) Fix the center line of the No. 4 latch pin hole at NWL 39.65. d. Fix the NBL of the latch beam to the tooling fixture using a minimum of one of the two methods below. See Appendix B for tooling guidance (1) Fix the same latch pin holes used in c. at NBL 1.75. (2) Remove the tension latch wear plates and shims on the latch beam and fix a minimum three of the five machined compression pad fittings at NBL 0.14. Refer to 777 AMM 78-31-01 as an acceptable procedure to remove the compressions pads and shims. CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 9. Group 1, Configuration 1, 3: Remove and keep the aft cowl with 315W5009 stud assembly and two BACF3W05P9N9 fillers by removing all fasteners common to the aft cowl and the inner wall and all fasteners common to the aft cowl and 315W5106 aft closeout assembly. Refer to 315W5150 SH19-21. 10. Group 1, Configuration 2: Remove and keep the aft cowl with 315W5009 stud assembly and two BACF3W05P9N9 fillers by removing all fasteners common to the aft cowl and the inner wall and all fasteners common to the aft cowl and 315W5106 aft closeout assembly. Refer to 315W5163 SH03-04. 11. If installed, remove and save the 315W5473 wear pad fitting. Refer to 315W5469 SH10. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 49 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 50 12. Remove and keep the 315W5106 aft closeout assembly by removing all fasteners common to the aft closeout assembly and inner wall and all fasteners common to the aft closeout assembly and 315W5400 latch beam. Refer to 315W5105 SH13. CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 13. Remove and keep the 315W5103 upper splice and two 315W5009 brackets by removing the upper and lower row of splice plate fasteners. Refer to 315W5105 SH12. 14. Remove and keep the two 315W5104 lower splice plates and five 315W5009 brackets by removing the upper and lower rows of splice plate fasteners. Refer to 315W5105 SH13. 15. Remove the inner wall by removing all remaining fasteners common to the inner wall and 315W5300 hinge beam and all remaining fasteners common to the inner wall and 315W5400 latch beam. Refer to 315W5105 SH12-13. 16. Do a detailed inspection of the countersunk holes in the 315W5103 upper splice plate in accordance with FIGURE 1. Rework the upper splice plate and 315W5300 hinge beam fastener holes if required in accordance with FIGURE 1. 17. Do a detailed inspection of the countersunk holes in the 315W5104 lower splice plate in accordance with FIGURE 1. Rework the lower splice plate and 315W5400 latch beam fastener holes if required in accordance with FIGURE 1. 18. Install nutplates in the hinge beam and latch beam in accordance with FIGURE 3. CAUTION: DO NOT DRILL ANY HOLES INTO THE INNER WALL AT THIS TIME CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 19. Locate the fore-aft position of the new 315W5100-63 inner wall assembly by locating the inner wall v-blade to the locating tool. Refer to APPENDIX B for tooling guidance. NOTE: The nominal distance between the upper surface of the inner wall and hinge beam is 0.19. The nominal distance between the lower surface of the inner wall and latch beam is 0.23. These dimensions are provided as reference only to help with inner wall position. NOTE: The hinge beam forward fire seal retainer may not align properly with the inner wall upper bifurcation fire seal retainer. The forward fire seal retainers should not be used to locate the inner wall panel. NOTE: The leading edge of the Inner Wall panel may extend beyond the Hinge Beam, even with the inner wall panel properly aligned. The forward edge of the inner wall panel should not be used to locate the inner wall panel. 20. Clamp the inner v-blade to the tooling fixture at a minimum of 3 locations separated by a minimum of 45 degrees. Refer to APPENDIX B for tooling guidance. Ensure clamping is in its free state, and not up against a hard point on the tool to avoid preloading the inner wall during assembly. 21. Do a detailed inspection of the leading edge of the inner wall panel at the upper bifurcation in accordance with FIGURE 5. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 50 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 51 a. If the inner wall panel does not extend beyond the edge of the hinge beam, no action is required. b. If the inner wall panel extends beyond the edge of the hinge beam up to 0.125, trim the leading edge of the inner wall panel in accordance with FIGURE 5. c. If the inner wall panel extends beyond the edge of the hinge beam more than 0.125, contact Boeing for repair and do that repair. 22. Locate the 315W5103 upper splice plate to the new inner wall by temporarily installing the splice plate to the 315W5300 hinge beam using existing fastener holes common to the splice plate and hinge beam only. Refer to 315W5105 SH12. 23. Locate the 315W5104 lower splice plates to the new inner wall by temporarily installing the splice plates to the 315W5400 latch beam using existing fastener holes common to the splice plates and latch beam only. Refer to 315W5105 SH13. 24. Do these steps at the same time:. a. Check faying surfaces between the new inner wall and the hinge beam for gaps and shim as required in accordance with 315W5105 SH12 FL2. Use shims BACS40V024C264. b. Check the faying surfaces between the 315W5103 upper splice plate and hinge beam and shim as required in accordance with 315W5105 SH12 FL2. Use shims BACS40V024C264. c. Check the faying surfaces between the 315W5103 upper splice plate and new inner wall for gaps and shim as required in accordance with 315W5105 SH12 FL2. Use shims BACS40V024C264. 25. Do these steps at the same time:. a. Check faying surfaces between the new inner wall and the latch beam for gaps and shim as required in accordance with 315W5105 SH13 FL2. Use shims BACS40V024C264. b. Check the faying surfaces between the 315W5104 lower splice plates and the inner wall for gaps and shim as required in accordance with 315W5105 SH13 FL4. Use shims BACS40V024C264. c. Check the faying surfaces between the 315W5104 lower splice plate and latch beam for gaps and shim as required in accordance with 315W5105 SH13 FL7. Use shims BACS40R***B***F. 26. Locate the 315W5106 aft closeout assembly to the new inner wall by temporarily installing the aft closeout assembly to the 315W5400 latch beam. 27. Do these steps at the same time:. a. Check the faying surfaces between the 315W5106 aft closeout assembly and latch beam for gaps and shim as required in accordance with 315W5105 SH13 FL7. Use shims BACS40R***B***F. b. Check the faying surfaces between the 315W5106 aft closeout assembly and the inner wall panel for gaps and shim as required in accordance with 315W5105 SH13 FL2. Use shims BACS40V024C264. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 51 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 52 28. Temporarily install the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly, and 315W5322 retainers to the inner wall and 315W5300 hinge beam. Refer to 315W5319 SH21.. CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 29. Group 1, Configuration 1, 3: Temporarily install the aft cowl to the 315W5106 aft closeout assembly using fastener holes common to the aft cowl and aft closeout assembly only. Refer to 315W5150 SH20. 30. Group 1, Configuration 1, 3: Temporarily install the aft cowl to the 315W5328 flame shield and 315W5322 retainer using fastener holes common to the aft cowl, flame shield, and retainer only. Refer to 315W5150 SH20. NOTE: There is a tooling hole in the new inner wall that may be used to help position the aft cowl assembly. Do not drill this hole to full diameter at this step. 31. Group 1, Configuration 1, 3: Do these steps at the same time: a. Check the faying surfaces between the aft cowl and the 315W5106 aft closeout assembly for gaps and shim as required in accordance with 315W5150 SH20 FL4. Use shims BACS40R012W031. b. Ensure that the aero smoothness requirements are met at the interface between the aft cowl and the inner wall. Refer to Appendix B, Sheet 12, View A-A. If the aero smoothness requirements cannot be met, contact Boeing for disposition and do Boeing disposition. Do not fill the gap between the aft cowl and inner wall panel at this step. 32. Group 1, Configuration 1, 3: Clamp the aft cowl to the inner wall and 315W5106 aft closeout assembly. 33. Group 1, Configuration 1, 3: Remove and keep the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly and the 315W5322 retainers from the inner wall, 315W5300 hinge beam, and aft cowl. Refer to 315W5319 SH21 and 315W5150 SH20. 34. Group 1, Configuration 2: Temporarily install the aft cowl to the 315W5106 aft closeout assembly using fastener holes common to the aft cowl and aft closeout assembly only. Refer to 315W5163 SH03. 35. Group 1, Configuration 2: Temporarily install the aft cowl to the 315W5328 flame shield and 315W5322 retainer using fastener holes common to the aft cowl, flame shield, and retainer only. Refer to 315W5163 SH03. NOTE: There is a tooling hole in the new inner wall that may be used to help position the aft cowl assembly. Do not drill this hole to full diameter at this step. 36. Group 1, Configuration 2: Do these steps at the same time: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 52 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 53 a. Check the faying surfaces between the aft cowl and the 315W5106 aft closeout assembly for gaps and shim as required in accordance with 315W5163 SH03 FL4. Use shims BACS40R012W031 b. Ensure that the aero smoothness requirements are met at the interface between the aft cowl and the inner wall. Refer to Appendix B, Sheet 12, View A-A. If the aero smoothness requirements cannot be met, contact Boeing for disposition and do Boeing disposition. Do not fill the gap between the aft cowl and inner wall panel at this step. 37. Group 1, Configuration 2: Clamp the aft cowl to the inner wall and 315W5106 aft closeout assembly. 38. Group 1, Configuration 2: Remove and keep the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly and the 315W5322 retainers from the inner wall, 315W5300 hinge beam, and aft cowl. Refer to 315W5319 SH21 and 315W5163 SH03. 39. If existing, temporarily install the 315W5473 wear pad fitting to the latch beam using the fastener hole common to the wear pad fitting and the latch beam only. 40. Do these steps at the same time: a. Check the gap between the 315W5473 wear pad fitting and the inner wall panel and shim as required in accordance with 315W5469 SH10 FL5. Use shim BACS40R***L***. b. Check the gap between the 315W5473 wear pad fitting and the latch beam and shim as required in accordance with 315W5469 SH10 FL8. Use shim BACS40R***C***. 41. Group 1, Configuration 1, 3: Back drill fastener holes in the new inner wall common to the aft cowl in accordance with the 315W5150 SH19-21 fastener hole requirements. 42. Group 1, Configuration 2: Back drill fastener holes in the new inner wall common to the aft cowl in accordance with the 315W5163 SH03-04 fastener hole requirements. 43. Back drill fastener holes in the new inner wall common to the hinge beam and the 315W5103 upper splice plate in accordance with the 315W5105 SH12 fastener hole requirements. 44. Back drill fastener holes in the new inner wall common to the 315W5400 latch beam and the 315W5104 lower splice plates in accordance with the 315W5105 SH13 fastener hole requirements. 45. Back drill fastener holes in the new inner wall common to the 315W5106 aft closeout assembly in accordance with the 315W5105 SH12 fastener hole requirements. 46. If installed, back drill fastener holes in the new inner wall common to the 315W5473 wear pad fitting in accordance with the 315W5469 SH10 fastener hole requirements. 47. Remove and keep the splice plates, aft closeout, aft cowl, wear pad fitting (if installed) and inner wall in order to deburr the holes drilled in the previous steps. Refer to 777-200 SRM 51-20-08 as an accepted procedure. 48. Re-install the inner wall into the tool in accordance with Steps 19-20. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 53 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 54 49. Apply a fay surface seal between the inner wall and hinge beam and inner wall and 315W5103 upper splice plate in accordance with 315W5105 SH12 FL1. 50. Install the nine countersunk fasteners common to the 315W5103 upper splice plate and the 315W5300 hinge beam in accordance with FIGURE 7. 51. Install the two 315W5009 brackets and all remaining fasteners common to the new inner wall and the 315W5300 hinge beam in accordance with the fastener callouts and torque requirements given in 315W5105 SH12. Install the 315W5009 brackets last because the brackets restrict access for other fasteners in this installation. Wet install all fasteners with BMS5-63 per SOPM 20-50-19 Method 3. 52. Apply a fay surface seal between the inner wall and latch beam and inner wall and 315W5104 lower splice plates in accordance with 315W5105 SH13 FL1. 53. Install the 4 countersunk fasteners common to the 315W5104 lower splice plate and the 315W5400 latch beam in accordance with FIGURE 7. 54. Install the five 315W5009 brackets and all remaining fasteners common to the new inner wall and the 315W5400 latch beam in accordance with the fastener callouts and torque requirements given in 315W5105 SH13. Wet install all fasteners with BMS5-63 per SOPM 20-50-19 Method 3. 55. Apply a fay surface seal between the aft closeout assembly and the inner wall and between the aft closeout assembly and the latch beam in accordance with 315W5105 SH13 FL1. 56. Install the 315W5106 aft closeout to the 315W5400 latch beam and inner wall in accordance with the fastener callouts, torque requirements, and flag note requirements given in 315W5105 SH13. Wet install all fasteners with BMS5-63 per SOPM 20-50-19 Method 3. 57. Fill the gap between the 315W5104 lower splice plates and 315W5400 latch beam in accordance with 315W5105 FL3. 58. Fill the gap between the 315W5106 aft closeout assembly and the inner wall in accordance with 315W5105 SH13 FL5. 59. Apply a fay surface seal to the faying surfaces of the 315W5323 filler, 315W5324 fire seal standoff, and 315W5328 flame shield in accordance with 315W5319 SH21 FL1. 60. Do these steps at the same time: a. Install the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly and the 315W5322 retainers to the inner wall and 315W5300 hinge beam in accordance with the fastener callouts, torque requirements and flag note requirements given in 315W5319 SH21. b. Seal the gap between the 315W5328 flame shield assembly and the inner wall in accordance with 315W5319 SH21 FL8. 61. Apply a continuous fillet seal along both edges of the 315W5323 filler and 315W5329 flame shield in accordance with 315W5319 SH21 FL2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 54 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 55 62. Group 1, Configuration 1, 3: Fill gap and apply fay seal between 315W5009 stud assembly and the inner wall in accordance with 315W5150 SH21 FL2. 63. Group 1, Configuration 1, 3: Install the aft cowl to the inner wall, 315W5106 aft closeout assembly in accordance with the fastener callouts, torque requirements, and flag note requirements given in 315W5150 SH19-21. Use BACF3W05P9N9 fillers to install the two fasteners through the ramp section of the inner wall panel in accordance with 315W5150 SH21. Wet install all fasteners in composites per BAC5063 with BMS5-63 per SOPM 20-50-19 Method 3. 64. Group 1, Configuration 1, 3: Fill the gap between the inner wall and the aft cowl in accordance with 315W5150 SH19 FL3. 65. Group 1, Configuration 1, 3: Install the aft cowl to 315W5328 flame shield and 315W5322 retainer in accordance with the fastener callout given in 315W5150 SH20. Wet install all fasteners in composites per BAC5063 with BMS5-63 per SOPM 20-50-19 Method 3. 66. Group 1, Configuration 2: Fill gap and apply fay seal between 315W5009 stud assembly and the inner wall in accordance with 315W5163 SH04 FL2. 67. Group 1, Configuration 2: Install the aft cowl to the inner wall, 315W5106 aft closeout assembly in accordance with the fastener callouts, torque requirements, and flag note requirements given in 315W5163 SH03-04. Use BACF3W05P9N9 fillers to install the two fasteners through the ramp section of the inner wall panel in accordance with 315W5163 SH04. Wet install all fasteners in composites per BAC5063 with BMS5-63 per SOPM 20-50-19 Method 3. 68. Group 1, Configuration 2: Fill the gap between the inner wall and the aft cowl in accordance with 315W5163 SH03 FL3. 69. Group 1, Configuration 2: Install the aft cowl to 315W5328 flame shield and 315W5322 retainer in accordance with the fastener callout given in 315W5163 SH03. Wet install all fasteners in composites per BAC5063 with BMS5-63 per SOPM 20-50-19 Method 3. 70. Apply a surface fay seal between the 315W5473 wear pad, 315W5400 latch beam, and inner wall in accordance with 315W5469 SH10 FL1 if the 315W5473 wear pad is present. 71. Install the 315W5473 wear pad to the 315W5400 latch beam and inner wall in accordance with the fastener callouts, torque requirements, and flag note requirements given in 315W5469 SH10. Wet install all fasteners in composites per BAC5063 with BMS5-63 per SOPM 20-50-19 Method 3. 72. Remove the left TR half from the tooling fixture. 73. Apply a fay surface seal between the 315W5333 deflector and the inner wall in accordance with 315W5319 SH21 FL1. 74. Install the 315W5333 seal deflector to the inner wall in accordance with the fastener callouts and torque requirements given in 315W5319 SH21. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 55 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 56 NOTE: The 315W5333 deflector can be installed after the insulation blankets are installed. 75. Install the upper bifurcation bulb seal and three forward inner wall bulb seals. Refer to 777 AMM 78-31-05 as an acceptable procedure. 76. Install the 315W5114-27, 315W5114-29 and 315W5114-31 insulation blanket seals. Refer to 315W5006 SH34-36 as an acceptable procedure. 77. If the tension latch wear pads were removed from the latch beam in Step 7, install the tension latch wear plates and shims on the latch beam. Refer to 777 AMM 78-31-01 as an acceptable procedure. 78. Install the translating sleeve on the left TR half. Refer to 777 AMM 78-31-10 as an acceptable procedure. 79. Group 1, Configuration 1-2: Install the insulation blankets on the left TR half . Refer to 777 AMM 78-31-06 as an accepted procedure. NOTE: The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. RC - PART 9 - RIGHT TR HALF INNER WALL REPLACEMENT 1. Group 1, Configuration 1-2: Remove the right TR half from the engine. Refer to 777 AMM 78-31-01 as an acceptable procedure. 2. Group 1, Configuration 1-2: Remove and keep the insulation blankets from the TR half inner wall. Refer to 777 AMM 78-31-06 as an accepted procedure. NOTE: The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. 3. Remove the translating sleeve from the right TR half. Refer to 777 AMM 78-31-10 as an acceptable procedure. 4. Remove and keep the upper bifurcation bulb seal and three forward inner wall bulb seals. Refer to 777 AMM 78-31-05 as an acceptable procedure. 5. Group 1, Configuration 1, 3: Remove and keep the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly, and 315W5322 retainers from the inner wall, 315W5300 hinge beam, and aft cowl. Refer to 315W5319 SH21 and 315W5150 SH20. NOTE: Do not remove the 315W5322 retainers from the 315W5328 flame shield assembly or 315W5329 retainer assembly. 6. Group 1, Configuration 2: Remove and keep the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly, and 315W5322 retainers from the inner wall, 315W5300 hinge beam, and aft cowl. Refer to 315W5319 SH21 and 315W5163 SH3. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 56 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 57 NOTE: Do not remove the 315W5322 retainers from the 315W5328 flame shield assembly or 315W5329 retainer assembly. 7. Remove and save the 315W5333 seal deflector from the inner wall. Refer to 315W5319 SH 21. 8. Install the right TR half into the locating tool by fixing the TR outer v-blade, hinge beam, and latch beam to the tool fixture. Refer to APPENDIX B for tooling guidance. a. Fix the aft edge of the outer v-blade to the tooling fixture at NSTA 218.31 at a minimum of 3 locations separated by a minimum of 45 degrees. Ensure clamping is in its free state, and not up against a hard point on the tool to avoid preloading the inner wall during assembly. NOTE: Locate using unworn sections of the aft edge of the outer v-blade. Missing surface finish is acceptable, provided no corrosion. b. Fix the NWL and NBL of the hinge beam to the tooling fixture at minimum two of the three locations below. See Appendix B for tooling guidance. (1) Fix the center line of the No. 2 hinge at NWL 160.18 and NBL 16.10 (2) Fix the center line of the No. 3 hinge at NWL 160.18 and NBL 16.10 (3) Fix the center line of the No. 4 hinge at NWL 160.18 and NBL 16.10 c. Fix the NWL of the latch beam to the tooling fixture at a minimum two of the three locations below. See Appendix B for tooling guidance (1) Fix the center line of the No. 2 latch pin hole at NWL 37.60. (2) Fix the center line of the No. 3 latch pin hole at NWL 39.65. (3) Fix the center line of the No. 4 latch pin hole at NWL 39.65. d. Fix the NBL of the latch beam to the tooling fixture using a minimum of one of the two methods below. See Appendix B for tooling guidance (1) Fix the same latch pin holes used in c. at NBL 1.75. (2) Remove the tension latch wear plates and shims on the latch beam and fix a minimum three of the five machined compression pad fittings at NBL 0.14. Refer to 777 AMM 78-31-01 as an acceptable procedure to remove the compressions pads and shims. CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 9. Group 1, Configuration 1, 3: Remove and keep the aft cowl with 315W5009 stud assembly and two BACF3W05P9N9 fillers by removing all fasteners common to the aft cowl and the inner wall and all fasteners common to the aft cowl and 315W5106 aft closeout assembly. Refer to 315W5150 SH19-21. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 57 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 58 10. Group 1, Configuration 2: Remove and keep the aft cowl with 315W5009 stud assembly and two BACF3W05P9N9 fillers by removing all fasteners common to the aft cowl and the inner wall and all fasteners common to the aft cowl and 315W5106 aft closeout assembly. Refer to 315W5163 SH03-04. 11. If installed, remove and save the 315W5473 wear pad fitting. Refer to 315W5469 SH10. 12. Remove and keep the 315W5106 aft closeout assembly by removing all fasteners common to the aft closeout assembly and inner wall and all fasteners common to the aft closeout assembly and 315W5400 latch beam. Refer to 315W5105 SH13. CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 13. Remove and keep the 315W5103 upper splice and two 315W5009 brackets by removing the upper and lower row of splice plate fasteners. Refer to 315W5105 SH12. 14. Remove and keep the two 315W5104 lower splice plates and five 315W5009 brackets by removing the upper and lower rows of splice plate fasteners. Refer to 315W5105 SH13. 15. Remove the inner wall by removing all remaining fasteners common to the inner wall and 315W5300 hinge beam and all remaining fasteners common to the inner wall and 315W5400 latch beam. Refer to 315W5105 SH12-13. 16. Do a detailed inspection of the countersunk holes in the 315W5103 upper splice plate in accordance with FIGURE 2. Rework the upper splice plate and 315W5300 hinge beam fastener holes if required in accordance with FIGURE 2. 17. Do a detailed inspection of the countersunk holes in the 315W5104 lower splice plate in accordance with FIGURE 2. Rework the lower splice plate and 315W5400 latch beam fastener holes if required in accordance with FIGURE 2. 18. Install nutplates in the hinge beam and latch beam in accordance with FIGURE 4. CAUTION: DO NOT DRILL ANY HOLES INTO THE INNER WALL AT THIS TIME CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 19. Locate the fore-aft position of the new 315W5100-63 inner wall assembly by locating the inner wall v-blade to the locating tool. Refer to APPENDIX B for tooling guidance. NOTE: The nominal distance between the upper surface of the inner wall and hinge beam is 0.19. The nominal distance between the lower surface of the inner wall and latch beam is 0.23. These dimensions are provided as reference only to help with inner wall position. NOTE: The hinge beam forward fire seal retainer may not align properly with the inner wall upper bifurcation fire seal retainer. The forward fire seal retainers should not be used to locate the inner wall panel. NOTE: The leading edge of the Inner Wall panel may extend beyond the Hinge Beam, even with the inner wall panel properly aligned. The forward edge of the inner wall panel should not be used to locate the inner wall panel. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 58 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 59 20. Clamp the inner v-blade to the tooling fixture at a minimum of 3 locations separated by a minimum of 45 degrees. Refer to APPENDIX B for tooling guidance. Ensure clamping is in its free state, and not up against a hard point on the tool to avoid preloading the inner wall during assembly. 21. Do a detailed inspection of the leading edge of the inner wall panel at the upper bifurcation in accordance with FIGURE 6. a. If the inner wall panel does not extend beyond the edge of the hinge beam, no action is required. b. If the inner wall panel extends beyond the edge of the hinge beam up to 0.125, trim the leading edge of the inner wall panel in accordance with FIGURE 6. c. If the inner wall panel extends beyond the edge of the hinge beam more than 0.125, contact Boeing for repair and do that repair. 22. Locate the 315W5103 upper splice plate to the new inner wall by temporarily installing the splice plate to the 315W5300 hinge beam using existing fastener holes common to the splice plate and hinge beam only. Refer to 315W5105 SH12. 23. Locate the 315W5104 lower splice plates to the new inner wall by temporarily installing the splice plates to the 315W5400 latch beam using existing fastener holes common to the splice plates and latch beam only. Refer to 315W5105 SH13. 24. Do these steps at the same time:. a. Check faying surfaces between the new inner wall and the hinge beam for gaps and shim as required in accordance with 315W5105 SH12 FL2. Use shims BACS40V024C264. b. Check the faying surfaces between the 315W5103 upper splice plate and hinge beam and shim as required in accordance with 315W5105 SH12 FL2. Use shims BACS40V024C264. c. Check the faying surfaces between the 315W5103 upper splice plate and new inner wall for gaps and shim as required in accordance with 315W5105 SH12 FL2. Use shims BACS40V024C264. 25. Do these steps at the same time:. a. Check faying surfaces between the new inner wall and the latch beam for gaps and shim as required in accordance with 315W5105 SH13 FL2. Use shims BACS40V024C264. b. Check the faying surfaces between the 315W5104 lower splice plates and the inner wall for gaps and shim as required in accordance with 315W5105 SH13 FL4. Use shims BACS40V024C264. c. Check the faying surfaces between the 315W5104 lower splice plate and latch beam for gaps and shim as required in accordance with 315W5105 SH13 FL7. Use shims BACS40R***B***F. 26. Locate the 315W5106 aft closeout assembly to the new inner wall by temporarily installing the aft closeout assembly to the 315W5400 latch beam. 27. Do these steps at the same time:. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 59 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT ### Page 60 a. Check the faying surfaces between the 315W5106 aft closeout assembly and latch beam for gaps and shim as required in accordance with 315W5105 SH13 FL7. Use shims BACS40R***B***F. b. Check the faying surfaces between the 315W5106 aft closeout assembly and the inner wall panel for gaps and shim as required in accordance with 315W5105 SH13 FL2. Use shims BACS40V024C264. 28. Temporarily install the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly, and 315W5322 retainers to the inner wall and 315W5300 hinge beam. Refer to 315W5319 SH21. CAUTION: ENSURE THE INNER WALL IS PROPERLY SUPPORTED AT ALL TIMES TO AVOID DAMAGING THE PARTS OR LOCATING TOOL 29. Group 1, Configuration 1, 3: Temporarily install the aft cowl to the 315W5106 aft closeout assembly using fastener holes common to the aft cowl and aft closeout assembly only. Refer to 315W5150 SH20. 30. Group 1, Configuration 1, 3: Temporarily install the aft cowl to the 315W5328 flame shield and 315W5322 retainer using fastener holes common to the aft cowl, flame shield, and retainer only. Refer to 315W5150 SH20. NOTE: There is a tooling hole in the new inner wall that may be used to help position the aft cowl assembly. Do not drill this hole to full diameter at this step. 31. Group 1, Configuration 1, 3: Do these steps at the same time: a. Check the faying surfaces between the aft cowl and the 315W5106 aft closeout assembly for gaps and shim as required in accordance with 315W5150 SH20 FL4. Use shims BACS40R012W031. b. Ensure that the aero smoothness requirements are met at the interface between the aft cowl and the inner wall. Refer to Appendix B, Sheet 12, View A-A. If the aero smoothness requirements cannot be met, contact Boeing for disposition and do Boeing disposition. Do not fill the gap between the aft cowl and inner wall panel at this step. 32. Group 1, Configuration 1, 3: Clamp the aft cowl to the inner wall and 315W5106 aft closeout assembly. 33. Group 1, Configuration 1, 3: Remove and keep the 315W5329 retainer assembly, 315W5323 filler, 315W5328 flame shield assembly and the 315W5322 retainers from the inner wall, 315W5300 hinge beam, and aft cowl. Refer to 315W5319 SH21 and 315W5150 SH20. 34. Group 1, Configuration 2: Temporarily install the aft cowl to the 315W5106 aft closeout assembly using fastener holes common to the aft cowl and aft closeout assembly only. Refer to 315W5163 SH03. 35. Group 1, Configuration 2: Temporarily install the aft cowl to the 315W5328 flame shield and 315W5322 retainer using fastener holes common to the aft cowl, flame shield, and retainer only. Refer to 315W5163 SH03. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 29, 2014 777-78A0094 60 of 144 BOEING SERVICE BULLETIN 777-78A0094 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/777-78a0094/file/e369ffe8fbaa.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.