Boeing Special Attention Service Bulletin 767-57-0121: U.S. DOT/FAA - Service Information

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Commercial Airplanes 767 Service Bulletin

SPECIAL ATTENTION Number: 767-57-0121 Original Issue: October 07, 2010 Revision 1: July 27, 2011 ATA System: 5700 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Leading Edge Fluid Drainage Path Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

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

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

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

Original Issue: October 07, 2010 767-57-0121Revision 1: July 27, 2011 1 of 74

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Original Issue: October 07, 2010 767-57-0121Revision 1: July 27, 2011 2 of 74 BOEING SERVICE BULLETIN 767-57-0121

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Table of Contents

Revision Transmittal Sheet5

Summary9

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

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

2. Spares Affected ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F. Approval ............................................... 1 8 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 1 9 I. Electrical Load Data ......................................... 1 9 J. References .............................................. 1 9

1. Existing Data .......................................... 1 9

2. Data supplied with this Service Bulletin ............................ 2 0

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 0 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 0

2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 1 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 4

4. Parts Removed and Not Replaced .............................. 2 4 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: LEFT WING SKIN PANEL 521AB CHANGE ......................... 2 9 FIGURE 2: RIGHT WING SKIN PANEL 621AB CHANGE ........................ 3 1 FIGURE 3: LEFT WING SKIN PANEL 521EB CHANGE ......................... 3 3 FIGURE 4: RIGHT WING SKIN PANEL 621EB CHANGE ........................ 3 7 FIGURE 5: LEFT WING SEAL DOOR CHANGE AT OSS 424.097 ................... 4 1 FIGURE 6: RIGHT WING SEAL DOOR CHANGE AT OSS 424.097 ................... 4 4 FIGURE 7: LEFT WING RIB CHANGE AT OSS 464.475 ......................... 4 7 FIGURE 8: RIGHT WING RIB CHANGE AT OSS 464.475 ........................ 5 1 FIGURE 9: LEFT WING LEADING EDGE SEALING ........................... 5 5 FIGURE 10: RIGHT WING LEADING EDGE SEALING .......................... 5 9 FIGURE 11: LEFT WING RIB SEALING AT OSS 464.475 ......................... 6 3

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FIGURE 12: RIGHT WING RIB SEALING AT OSS 464.475 ........................ 6 9

Original Issue: October 07, 2010 767-57-0121Revision 1: July 27, 2011 4 of 74 BOEING SERVICE BULLETIN 767-57-0121

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Commercial Airplanes 767 Service Bulletin

SPECIAL ATTENTION Revision Transmittal SheetNumber: 767-57-0121Original Issue: October 07, 2010 Revision 1: July 27, 2011 ATA System: 5700 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Leading Edge Fluid Drainage Path Change This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.

REASON FOR REVISION This revision is sent to revise the quantity of one part in the kit, add optional materials and clarify Figures 5, 6, 11 and 12.

These sections were changed:

1. In Summary, Background, added validation information.

2. In Paragraph 1.C., Reason, added validation information.

3. In Paragraph 2.C.1., Kits/Parts, revised the quantity of part number BACS45B4 from 1 to 2 for Figures 7 and 8.

4. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added optional materials for BMS5-16 and BMS5-142.

5. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added wing skin panels to the bottom of the table.

6. In Paragraph 2.C.3., Parts Modified and Reidentified, removed the part number notation in the New Part Number column and replaced it with an existing footnote.

7. In Paragraph 2.C.3., Parts Modified and Reidentified, moved footnote (b) from the Notes column to the New Part Number column.

8. In Paragraph 2.C.3., Parts Modified and Reidentified, added a footnote (e) about purchasing panels from Boeing and applied it to both panels in the table.

9. In Paragraph 3.A., General Information, added new General Notes.

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10. In Paragraph 3.B., Work Instructions, added a note and applicable part numbers and panels in a table in Part 1.

11. In Paragraph 3.B., Work Instructions, revised the Task, Name, Identification and More Data columns of Step 8 of Figures 3 and 4.

12. In Paragraph 3.B., Work Instructions, added footnote (b) about fiberglass repair and applied it to Step 1 of Figures 3 and 4.

13. In Paragraph 3.B., Work Instructions, revised views A-A and B-B of Figures 5 and 6 to show the drain hole location correctly.

14. In Paragraph 3.B., Work Instructions, revised the quantity of seals installed from 1 to 2 of Step 8 of Figures 7 and 8.

15. In Paragraph 3.B., Work Instructions, added a substep to Step 8 of Figures 7 and 8 with instructions about applying sealant to the wires and wire bundle.

16. In Paragraph 3.B., Work Instructions, added optional materials to BMS5-16 to Step 1 of Figures 9 and 10.

17. In Paragraph 3.B., Work Instructions, added footnote (a) about leveling compound application and applied it to Step 2 of Figures 9 and 10.

18. In Paragraph 3.B., Work Instructions, added optional materials to BMS5-45 to Step 3 of Figures 9 and 10.

19. In Paragraph 3.B., Work Instructions, added information about sealant application to the More Data column of Step 4 of Figures 9 and 10.

20. In Paragraph 3.B., Work Instructions, added a view H and revised view A of Figures 11 and 12 to show application of sealant on the outboard side of the rib.

21. In Paragraph 3.B., Work Instructions, added optional materials to BMS5-16 to Steps 1 and 2 of Figures 11 and 12.

22. In Paragraph 3.B., Work Instructions, revised the More Data column of Step 7 of Figures 11 and 12 to apply sealant to the outboard side of the rib.

23. In Paragraph 3.B., Work Instructions, added optional materials to BMS5-142 to step 8 of Figure 11 and 12.

24. In Paragraph 3.B., Work Instructions, revised the More Data column of Step 8 of Figures 11 and 12 to apply sealant to the outboard side of the rib.

25. In Paragraph 3.B., Work Instructions, revised the More Data column of Step 11 of Figures 11 and 12 to allow for the optional installation of purchased panels.

The data given in Information Notice 767-57-0121 IN 01 is included in this revision.

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.

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As a part of a service bulletin validation program, this change was completed on airplane VN092 by Service Bulletin 767-57-0121 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane VN092 by Service Bulletin 767-57-0121 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane VN092 has the configuration of a Group 1 airplane.

REVISION HISTORY October 07, 2010Original Issue:

July 27, 2011Revision 1:

Original Issue: October 07, 2010 767-57-0121Revision 1: July 27, 2011 7 of 74 BOEING SERVICE BULLETIN 767-57-0121

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Commercial Airplanes 767 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 767-57-0121Original Issue: October 07, 2010 Revision 1: July 27, 2011 ATA System: 5700 SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Leading Edge Fluid Drainage Path Change BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin gives instructions to modify the fluid drain path in the wing leading edge area, forward of the wing front spar. If this service bulletin is not incorporated, flammable fluids accumulating in the wing leading edge may drain inboard and onto the engine exhaust nozzle, which could result in a fire.

Boeing has received a report of leaking fuel from the wing leading edge area at the inboard end of the number 5 leading edge slat of a 737 airplane. The leak was discovered during a post flight inspection with a fuel quantity of over 2500 lbs. Subsequent investigation found that the leak occurred in an area of the front spar that does not have a proper drain path. This led to the fuel draining onto the engine exhaust nozzle. The leak appears to have been caused by a loose retaining nut of the slat track down stop and is the subject of Boeing Service Letter 737-SL-57-084.

Accomplishment of this service bulletin will make sure that there is a drain path to safely direct all fluid leakages from the wing leading edge away from the engine exhaust area.

Boeing Service Related Problem (SRP) 767-SRP-57-0213 is related to this service bulletin.

ACTION (PRR B12901-92S) Get access to the leading edge of the wing by removing access panels. Repair two access panels on each wing.

Install parts in rib and slat door. Apply sealant to create a fuel vapor barrier and a drain path. Close access.

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

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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 change given in this service bulletin be done within 60 months after the original issue date of this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of November 15, 2007. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

19.7522.00All Airplanes Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Original Issue: October 07, 2010 767-57-0121Revision 1: July 27, 2011 10 of 74 BOEING SERVICE BULLETIN 767-57-0121

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Commercial Airplanes 767 Service Bulletin

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplane(s) shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-92S for data about this change.

DESCRIPTIONCONFIGURATIONGROUP 767 Airplanes with line number 1-992.-1 Airplane Models:

767-200, 767-300, 767-300F, 767-400ER GroupVariable Number 1VA001 - VA020 1VA301 - VA315 1VA501 - VA530 1VA701 - VA719 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055

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GroupVariable Number 1VB101 - VB125 1VB201 - VB202 1VB251 - VB253 1VB281 - VB284 1VB301 - VB302 1VB321 - VB332 1VB371 - VB373 1VB401 1VB441 - VB444 1VE001 - VE003 1VE021 - VE023 1VE041 - VE043 1VE061 - VE069 1VE083 - VE086 1VE101 - VE104 1VE116 - VE118 1VE121 - VE126 1VE141 - VE152 1VE171 - VE172 1VF001 - VF002 1VF041 - VF042 1VF051 1VF061 - VF062 1VF071 - VF072 1VF091 - VF093 1VF101 - VF102 1VF161 - VF162 1VF171 - VF172 1VF180 - VF184 1VF251 1VK001 - VK016 1VK021 - VK022 1VK031 - VK056

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Boeing Special Attention Service Bulletin 767-57-0121: U.S. DOT/FAA - Service Information - 2

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