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Commercial Airplane Group 767 Service Bulletin Number: 767-25-0477 Date: August 27, 2009 ATA System: 2522 SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Passenger Compartment Ceiling Lining - Entryway Door Ceiling Panel Hinge Pin Inspection/Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

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

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

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

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August 27, 2009 767-25-0477 2 of 367 BOEING SERVICE BULLETIN 767-25-0477

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Table of Contents

Summary7

1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3

1. Airplanes ............................................ 1 3

2. Spares Affected ........................................ 2 0 B. Concurrent Requirements ...................................... 2 1 C. Reason ................................................ 2 1 D. Description .............................................. 2 1 E. Compliance .............................................. 2 3 F. Approval ............................................... 2 3 G. Manpower .............................................. 2 3 H. Weight and Balance Changes .................................... 2 7 I. Electrical Load Data ......................................... 2 7 J. References .............................................. 2 8

1. Existing Data .......................................... 2 8

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

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 8 K. Publications Affected ........................................ 2 9 L. Interchangeability and Intermixability of Parts ........................... 2 9

2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary For Each Airplane ................................. 3 2

1. Kits/Parts ............................................ 3 2

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

3. Parts Modified and Reidentified ................................ 3 3

4. Parts Removed and Not Replaced .............................. 4 4 D. Parts Necessary to Change Spares ................................. 4 4 E. Special Tooling - Price and Availability ............................... 4 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 6

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 7 A. GENERAL INFORMATION ..................................... 4 7 B. WORK INSTRUCTIONS ....................................... 4 8 FIGURE 1: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY, HINGE PIN - INSPECTION [Group 1] ............................................ 6 5 FIGURE 2: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY, HINGE PIN - INSPECTION [Group 2-6, 9-10, 12, 15] .................................... 7 0 FIGURE 3: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY, HINGE PIN - INSPECTION [Group 7-8, 11, 13-14, 16] ................................... 7 5 FIGURE 4: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY, HINGE PIN - INSPECTION [Group 20] ............................................ 8 0 FIGURE 5: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY, HINGE PIN - INSPECTION [Group 17-19] .......................................... 8 5 FIGURE 6: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 1] .................................................. 8 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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FIGURE 7: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 2, 10] ................................................ 9 1 FIGURE 8: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 3, 9 ] ................................................ 9 6 FIGURE 9: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 4] ................................................. 1 0 1 FIGURE 10: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 5] ................................................. 1 0 6 FIGURE 11: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 6] ................................................. 1 1 1 FIGURE 12: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 7] ................................................. 1 1 6 FIGURE 13: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 8] ................................................. 1 2 4 FIGURE 14: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 11, 13] ............................................... 1 3 2 FIGURE 15: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 12] ................................................. 1 4 0 FIGURE 16: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 14] ................................................. 1 4 5 FIGURE 17: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 15] ................................................. 1 5 3 FIGURE 18: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 16] ................................................. 1 5 8 FIGURE 19: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 17] ................................................. 1 6 6 FIGURE 20: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 18] ................................................. 1 6 8 FIGURE 21: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 19] ................................................. 1 7 0 FIGURE 22: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - IDENTIFICATION [Group 20] ................................................. 1 7 2 FIGURE 23: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 1] ................................................. 1 8 0 FIGURE 24: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 2, 10] ................................................. 1 8 6 FIGURE 25: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 3, 9] ................................................. 1 9 7 FIGURE 26: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 4] ................................................. 2 0 8 FIGURE 27: MOVABLE CEILING ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 5] . . 219 FIGURE 28: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 6] ................................................. 2 3 0 FIGURE 29: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 7] ................................................. 2 4 1 FIGURE 30: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 8] ................................................. 2 5 6 FIGURE 31: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 11, 13] ............................................... 2 7 1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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FIGURE 32: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 12] ................................................. 2 8 6 FIGURE 33: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 14] ................................................. 2 9 7 FIGURE 34: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 15] ................................................. 3 1 2 FIGURE 35: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 16] ................................................. 3 2 3 FIGURE 36: MOVABLE CEILING PANEL ASSEMBLY (LOWERED), HINGE ASSEMBLY - REPLACEMENT [Group 17] ........................................... 3 3 8 FIGURE 37: MOVABLE CEILING PANEL ASSEMBLY (LOWERED), HINGE ASSEMBLY - REPLACEMENT [Group 18] ........................................... 3 4 2 FIGURE 38: MOVABLE CEILING PANEL ASSEMBLY (LOWERED), HINGE ASSEMBLY - REPLACEMENT [Group 19] ........................................... 3 4 6 FIGURE 39: MOVABLE CEILING PANEL ASSEMBLY, HINGE ASSEMBLY - REPLACEMENT [Group 20] ................................................. 3 5 0 APPENDIX A: CRIMP INSPECTION ..................................... 3 6 5 APPENDIX B: PROCESS SPECIFICATION BAC 5018 INSTALLATION OF SAFETYING DEVICES . . 367 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Commercial Airplane Group 767 Service Bulletin SummaryNumber: 767-25-0477Date: August 27, 2009 ATA System: 2522 SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Passenger Compartment Ceiling Lining - Entryway Door Ceiling Panel Hinge Pin Inspection/Repair

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin is prepared to inspect/repair the movable ceiling panel above Type "A" entryway doors.

The hinge pin on the hinge assembly installed on the movable ceiling panel is not always retained in the hinge assembly stock. If this service bulletin is not done the hinge pin can migrate away from the hinge assembly and damage wires, tie-rods, and movable ceiling panel surfaces.

Boeing received a report that an operator experienced several fault messages during a maintenance check. An investigation of the fault messages revealed that the forward, left side, entryway door's movable ceiling panel hinge pin had come into contact with some wires, causing damage/breakage. There were also reported instances of migrating hinge pins causing minor cosmetic damage and one reported instance of a hinge pin causing tie-rod chafing.

Boeing conducted a Quality Assurance Investigation (QAI) with the vendor. It was determined that the cause of the migrating hinge pin is a result of the vendor not properly crimping the hinge assembly stock per specifications.

The vendor was told to review their crimping process and incorporate quality checks as necessary to provide an acceptable crimp.

This change gives instructions to inspect, identify, and/or replace the hinge assembly on the movable ceiling panel above Type "A" entryway doors. Inspection of the hinge assembly will make sure that the hinge stock has been crimped correctly. It will also determine if whether or not the hinge assembly needs to be replaced.

Replacement of the hinge assembly will make sure the hinge pin does not migrate.

Boeing Service Related Problem (SRP) 767-SRP-25-0262 is related to this service bulletin.

ACTION (PRR B12901-86S)

1. Do a detailed inspection of the hinge assembly for correct crimp and hinge pin migration.

a. Determine if hinge assembly crimp does/does not meet specification.

b. Determine if hinge assembly needs to be replaced.

2. Crimp the hinge assembly stock per specification if the crimp size is not acceptable.

3. Replace the hinge assembly if one or more of the following conditions are met:

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a. The crimp size is too small

b. The hinge assembly stock has cracks or missing material

c. The hinge pin is deformed (i.e. bent, cracked, broken, missing material)

4. Identify the movable ceiling panel and hinge assemblies after inspection/replacement with a new part number.

EFFECTIVITY 767-200, -300, -300F, -400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Boeing recommends that the inspection/repair given in this service bulletin be done within 6 years after the date on this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of October 18, 2005. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

3.056.10Group 1

6.1012.20Group 2

6.1012.20Group 3

6.1012.20Group 4

6.1012.20Group 5

6.1012.20Group 6

9.1518.30Group 7

9.1518.30Group 8

6.1012.20Group 9

6.1012.20Group 10

9.1518.30Group 11

6.1012.20Group 12

9.1518.30Group 13

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Elapsed HoursTotal Task HoursAirplanes

6.1012.20Group 15

9.1518.30Group 16

3.303.30Group 17

3.303.30Group 18

3.303.30Group 19

9.1518.30Group 20

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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BOEING SERVICE BULLETIN 767-25-0477

INSPECT, IDENTIFY, AND/OF

REPLACE THE HINGE ASSEMBLY

ON THE MOVABLE CEILING PANEL ABOVE THE FORWARD TYPE "A"

ENTRYWAY DOORS GROUP 1

INSPECT, INDENTIFY, AND/OR REPLACE

THE HINGE ASSEMBLY ON THE MOVABLE

CEILING PANEL ABOVE THE FORWARD AND AFT TYPE "A" ENTRYWAY DOORS GROUPS 2, 3 - 6, 9, 10, 12, 15

INSPECT, IDENTIFY, AND/OR REPLACE

THE HINGE ASSEMBLY ON THE

MOVABLE CEILING PANEL ABOVE THE

FORWARD, MID CABIN, AND AFT TYPE "A" ENTRYWAY DOORS GROUPS 7-8, 11, 13-14, 16, 20 1550952 August 27, 2009 767-25-0477 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 367

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BOEING SERVICE BULLETIN 767-25-0477

INSPECT, IDENTIFY, AND/OR REPLACE

THE HINGE ASSEMBLY ON THE

MOVABLE CEILING PANEL ABOVE THE

FORWARD, MID CABIN, AND AFT TYPE "A" ENTRYWAY DOORS GROUP 20

INSPECT, IDENTIFY, AND/OR REPLACE

THE HINGE ASSEMBLY ON THE MOVABLE

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