Boeing Special Attention Service Bulletin 757-54-0050: U.S. DOT/FAA

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION Number: 757-54-0050 Original Issue: July 16, 2007 Revision 1: October 07, 2009 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification

- Rolls Royce RB211-535E Engines Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 1 of 71

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Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 2 of 71 BOEING SERVICE BULLETIN 757-54-0050

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Table of Contents

Revision Transmittal Sheet5

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 4 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 1 8 J. References .............................................. 1 8

1. Existing Data: ......................................... 1 8

2. Data supplied with this Service Bulletin: ........................... 1 8

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8 K. Publications Affected ........................................ 1 8 L. Interchangeability and Intermixability of Parts ........................... 1 9

2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 2 C. Parts Necessary For Each Airplane ................................. 2 2

1. Kits/Parts: ........................................... 2 2

2. Parts and Materials Supplied by the Operator: ........................ 2 3

3. Parts Modified and Reidentified: ............................... 2 3

4. Parts Removed and Not Replaced: .............................. 2 3 D. Parts Necessary to Change Spares ................................. 2 4 E. Special Tooling - Price and Availability ............................... 2 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 4

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION [Group 1, Configuration 1] ................................... 3 1 FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION [Group 1, Configuration 1] ................................... 3 4 FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM [Group 1, Configuration 1] ......................................... 3 7 FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM [Group 1, Configuration 1] ......................................... 4 1 FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1 ] ................................................ 4 5

Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 3 of 71 BOEING SERVICE BULLETIN 757-54-0050

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FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1 ] ................................................ 4 7 FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION [Group 1, Configuration 1] .................. 4 9 FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION [Group 1, Configuration 1] .................. 5 2 FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1 ] ................................................ 5 5 FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration 1 ] ................................................ 5 7 FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION ................................. 5 9 FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION ................................. 6 2 FIGURE 13: ENGINE NUMBER 1 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL ANDINTERIMINSTALLATION [Group 1, Configuration 1] .................. 6 5 FIGURE 14: ENGINE NUMBER 2 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL ANDINTERIMINSTALLATION [Group 1, Configuration 1] .................. 6 8 APPENDIX A: AFT HINGE FITTING FASTENER STACKUP ........................ 7 1

Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 4 of 71 BOEING SERVICE BULLETIN 757-54-0050

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION Revision Transmittal SheetNumber: 757-54-0050Original Issue: July 16, 2007 Revision 1: October 07, 2009 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification

- Rolls Royce RB211-535E Engines This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed as shown in the original issue of this service bulletin. Washer stackup should be inspected for the correct installation sequence. If the installation is found to be incorrect, the nut(s) and bolt(s) must be removed and the washers reinstalled.

Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2008-13-20, is related to this service bulletin.

REASON FOR REVISION This revision is sent to change the Work Instructions for Part III - Preventive Modification, and the associated figures, to allow the option of doing the Part III - Preventive Modification on just the hinges that are damaged, and allow continued repeat inspections on the hinges that are undamaged. This revision also corrects the names of the different washers (special washer, countersunk washer, plain washer) used in Figure 11 and Figure 12.

This revision is also sent to add an inspection for airplanes, that did the original issue, to inspect the fastener stackup securing the aft hinge fittings to the strut.

Changes to this service bulletin include:

— Paragraph 1.E., Compliance - Footnote and Damage Tolerance note added.

— Paragraph 3.B., Work Instructions, Part III-Preventive Modification - Added steps 4, 5. Added Caution note to step 3.

— Figures 1-12 were modified to include a footnote adding flexibility in inspecting and modifying the hinges.

— Figures 13 and 14 were modified to include a note stating that quantities could be halved if only one hinge is removed/installed on either strut.

— The fastener tables in Figures 11 and 12 were modified to correct the names of washers and to add words that clarify the washer orientation.

— Added note to Figures 5, 6, 9 and 10, to clarify that you remove one bolt at a time, replace it with a new bolt, and then go to the next bolt.

— Added a second configuration for those airplanes that have completed the original issue of this service bulletin, to inspect for washer stackup in Figures 11 and 12. Added Appendix A to show correct fastener stackup.

— Added flexibility to install a new aft hinge fitting if heat damage is found after trimming.

— Added ammonium persulfate in addition to Nital to use for inspecting for heat damage.

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— Replaced BMS 3-24 grease with BMS 3-33 grease.

— Changed torque reference from SOPM 20-50-01 to BAC5009.

— Added the word "interim" to the title for Figures 13 and 14 and removed the torque specifications in the footnotes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY July 16, 2007Original Issue:

October 07, 2009Revision 1:

Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 6 of 71 BOEING SERVICE BULLETIN 757-54-0050

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 757-54-0050Original Issue: July 16, 2007 Revision 1: October 07, 2009 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification

- Rolls Royce RB211-535E Engines BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin gives instructions to do a detailed inspection and preventive modification on the thrust reverser aft hinge fittings, and hinge fitting attachment bolts. Attachment bolts have been reported to fail at the thrust reverser aft hinge fittings. The hinge has integral fail-safe features, but loss of the entire four bolt pattern constitutes complete loss of the load path. Loss of the load path could result in the departure of the thrust reverser from the airplane which could result in damage to the airplane and hazards to persons or property on the ground.

Boeing has received 13 reports of 14 separate incidents of bolt failure at the thrust reverser aft hinge fittings.

All of the reported incidents occurred on airplanes with Rolls Royce RB211-535E engines. Of the 14 incidents there were 9 hinges with 1 out of 4 bolts failed, 2 hinges with 2 out of 4 bolts failed, and 3 hinges with 3 out of 4 bolts failed.

The possible causes of the bolt failure can be attributed to high operational loads, contact loads caused by possible interference between the thrust reverser hinge and the hinge beam, and the 4 attachment bolts are installed with washers that can ride the radius of the hinge fitting spotface.

As a part of a service bulletin validation program, this change was completed on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 before the initial release of this service bulletin. The change completed on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 is equivalent to the initial release of this service bulletin.

Boeing Service Related Problem (SRP) 757-SRP-54-0098 is related to this service bulletin.

Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 7 of 71

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ACTION (PRR 54530-267RS) Inspections:

Get Access to the thrust reverser aft hinge fittings. Do a detailed inspection of the aft hinge fittings and the eight attachment bolts for signs of damage. If any damage to the aft hinge fittings and/or attachment bolts is found, the damage must be corrected before further flight and the preventive modification must be scheduled. For Group 1, Configuration 2 airplanes, do a detailed inspection of washer stackup. If the stackup is incorrect, the washers must be removed and reinstalled.

Preventive Modification:

Operators may do the preventive modification. After the preventive modification is accomplished it is no longer necessary to do the repeat inspections shown in this service bulletin. Get Access to the thrust reverser aft hinge fittings. Remove the thrust reverser C-ducts. Trim the aft hinge fitting lugs to clear possible contact with the hinge beam. Remove the four attachment bolts on each aft hinge fitting, high frequency eddy current (HFEC) inspect the fastener holes and replace with new and improved bolts, washers and nuts. Refit thrust reversers and return airplane to a serviceable condition.

The related 757-200 bulletin is Service Bulletin 757-54-0049.

EFFECTIVITY 757-300 airplanes with Rolls Royce RB211-535E engines. Refer to Paragraph 1.A.1.

COMPLIANCE Refer to Service Bulletin Paragraph 1.E for compliance.

Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2008-13-20 is related to this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of October 17, 2003. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Refer to Service Bulletin Paragraph 1.G Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 8 of 71 BOEING SERVICE BULLETIN 757-54-0050

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BOEING SERVICE BULLETIN 757-54-0050 -DO A DETAILED INSPECTION ON THE THRUST

REVERSER AFT HINGE FITTINGS AND ATTACH

BOLTS, AND HFEC THE ATTACH BOLT FASTENER HOLES FOR DAMAGE.

-REPAIR OR MODIFY AFT HINGE FITTING IF LEFT ENGINE SHOWN DAMAGE IS FOUND.

RIGHT ENGINE SIMILAR U70418 Original Issue: July 16, 2007 Revision 1: October 07, 2009 757-54-0050

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Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 10 of 71 BOEING SERVICE BULLETIN 757-54-0050

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Commercial Airplanes 757 Service Bulletin

- Rolls Royce RB211-535E Engines BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below. Refer to PRR 54530-267RS for data about this change.

DESCRIPTIONCONFIGURATIONGROUP 757-300 Airplanes, with Rolls Royce RB211-535E engines.-1 Airplanes that have not been modified in accordance with the original issue of this service bulletin.

1 Airplanes that have been modified in accordance with the original issue of this service bulletin.

2 Airplane Models:

757-300 GroupVariable Number 1NL001 - NL002 1NL006 - NL017 1NL101 - NL109

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GroupVariable Number 1NL141 1NU701 - NU705 1NU721 - NU728 1NU731 - NU732

2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use.

B. Concurrent Requirements None.

C. Reason This service bulletin gives instructions to do a detailed inspection and preventive modification on the thrust reverser aft hinge fittings, and hinge fitting attachment bolts. Attachment bolts have been reported to fail at the thrust reverser aft hinge fittings. The hinge has integral fail-safe features, but loss of the entire four bolt pattern constitutes complete loss of the load path. Loss of the load path could result in the departure of the thrust reverser from the airplane which could result in damage to the airplane and hazards to persons or property on the ground.

Boeing has received 13 reports of 14 separate incidents of bolt failure at the thrust reverser aft hinge fittings. All of the reported incidents occurred on airplanes with Rolls Royce RB211-535E engines. Of the 14 incidents there were 9 hinges with 1 out of 4 bolts failed, 2 hinges with 2 out of 4 bolts failed, and 3 hinges with 3 out of 4 bolts failed.

Revision 1: This revision is sent to change the Work Instructions for Part III - Preventive Modification, and the associated figures, to allow the option of doing the Part III - Preventive Modification on just the hinges that are damaged, and allow continued repeat inspections on the hinges that are undamaged.

This revision also corrects the names of the different washers (special washer, countersunk washer, plain washer) used in Figure 11 and Figure 12.

Changes to this service bulletin include:

Original Issue: July 16, 2007 757-54-0050Revision 1: October 07, 2009 12 of 71 BOEING SERVICE BULLETIN 757-54-0050

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Boeing Special Attention Service Bulletin 757-54-0050: U.S. DOT/FAA - SB-757-54-0050-01

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BOEING SERVICE BULLETIN 757-54-0050 -DO A DETAILED INSPECTION ON THE THRUST

REVERSER AFT HINGE FITTINGS AND ATTACH

BOLTS, AND HFEC THE ATTACH BOLT FASTENER HOLES FOR DAMAGE.

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