Original Issue: April 14, 1994

Revision 6: November 05, 2009 767-54A0062

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 66

ALERT ALERT

Commercial

Airplanes 767

ALERT ALERT

Service Bulletin

Number: 767-54A0062

Original Issue: April 14, 1994

Revision 6: November 05, 2009

ATA System: 5451

SUBJECT: NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and 

Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 1994 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Unpublished Work - All Rights Reserved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.
 BLANK PAGE

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ALERT ALERT

BLANK PAGE
 Table of Contents

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

Table of Contents

Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 35

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 35

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 36

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 38

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 40

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

FIGURE 1: DELETED - REFER TO PARAGRAPH 1.E. - COMPLIANCE . . . . . . . . . . . . . . . 48

FIGURE 2: MIDSPAR FUSE PIN ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . 51

FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . 55

FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 58

FIGURE 6: OFF WING MIDSPAR FUSE PIN MAGNETIC PARTICLE INSPECTION . . . . . . . . . 60

FIGURE 7: MIDSPAR FUSE PIN FINISH RESTORATION . . . . . . . . . . . . . . . . . . . . . . 61

APPENDIX A: APPROVED REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
 Table of Contents

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ALERT ALERT

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ALERT ALERT

Commercial

Airplanes 767

ALERT ALERT

Service Bulletin

Number: 767-54A0062 Revision Transmittal Sheet

Original Issue: April 14, 1994

Revision 6: November 05, 2009

ATA System: 5451

SUBJECT: NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and 

Replacement

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to 

this service bulletin. 

More work is necessary on airplanes that have not been changed in accordance with either service bulletin 767-

54-0069, or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082. Continued 

inspections of the midspar fuse pins are required at reduced thresholds and repeat intervals in accordance with 

Paragraph 1.E., Compliance.

No more work is necessary on airplanes that have been changed in accordance with either service bulletin 767-

54-0069, or the applicable 767 Strut Improvement Program (SIP) service bulletin 767-54-0080, 767-54-0081 or 

767-54-0082. Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 

767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin.

REASON FOR REVISION

This revision is sent to reduce the midspar fuse pin inspection threshold and repeat intervals based on an 

operator report of a cracked midspar fuse pin, after the Revision 5 date of this service bulletin. 

These sections were changed:

1. Summary: Added statement of consequences of not accomplishing the service bulletin; added/changed 

references; added service history; changed Action paragraph; changed effectivity statement; added FAA 

AD statement; changed illustration.

2. Paragraph 1.A., Effectivity: Added Group/Configuration table

3. Paragraph 1.C., Reason: Added statement of consequences of not accomplishing the service bulletin; 

added/changed references; added service history; added Revision 6 changes information.
 

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4. Paragraph 1.D., Description: Changed reference; added note; deleted Group descriptions; added Revision 

6 change information.

5. Paragraph 1.E., Compliance: Added/deleted references; added/changed compliance table; added ferry 

flight information.

6. Paragraph 1.F., Approval: Added references.

7. Paragraph 1.G., Manpower: Changed task names

8. Paragraph 1.J.1., Existing Data: Added/changed/deleted references

9. Paragraph 1.K., Publications Affected: Added paragraph

10. Paragraph 2.C., Material - Price and Availability: Updated price and availability data

11. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Changed part number; deleted materials; 

revised notes.

12. Paragraph 3.A., General Instructions: Added instructions; added inspection information; revised 

referenced procedures information; added serviceable pin criteria.

13. Paragraph 3.B., Work Instructions: Changed instructions to CONDITION/Option format; added/changed/

deleted instructions; deleted torque stripe requirement.

14. Figure 1: Deleted figure

15. Figure 2: Changed title; changed illustration; changed step numbers; added/changed references.

16. Figure 3: Changed/added illustration; added/changed steps; added/changed/deleted references; added 

corrosion information.

17. Figure 4: Added/changed illustration; added/changed steps; changed reference; added option for Magnetic 

Particle Inspection; added corrosion information.

18. Figure 5: Changed illustration; changed/deleted steps; changed reference.

19. Figure 6: Completely revised figure

20. Figure 7: New Figure

21. Appendix A: New Appendix

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity 

paragraph for changes.

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

of important changes.
 

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ALERT ALERT

REVISION HISTORY

Original Issue: April 14, 1994

Revision 1: May 11, 1994

Revision 2: December 21, 1994

Revision 3: June 15, 1995

Revision 4: May 7, 1998

Revision 5: November 11, 2002

Revision 6: November 5, 2009
 

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ALERT ALERT

BLANK PAGE
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ALERT ALERT

Commercial

Airplanes 767

ALERT ALERT

Service Bulletin

Number: 767-54A0062 Summary

Original Issue: April 14, 1994

Revision 6: November 05, 2009

ATA System: 5451

SUBJECT: NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and 

Replacement

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN 

PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This inspection/replacement program will permit early detection of cracks in the midspar fuse pin on the inboard 

and outboard sides of the number one and number two pylons. Midspar fuse pin cracks can result in the loss of 

structural integrity of the midspar fuse pins and cause an engine breakaway from the airplane.

There have been eight reports involving a total of fourteen midspar fuse pins suspected of having longitudinal 

cracks. Of these fuse pins, seven pins were confirmed cracked. The cracked pins were from one operator on 

airplanes with 15,628 to 23,056 flight cycles. Both airplanes are equipped with CF6-80A engines. 

The first pins suspected of being cracked were found during midspar bushing migration rework. The cracks were 

found by a detailed visual inspection. The cracking was confirmed by magnetic particle inspection with the pins 

removed. The second cracked pin was found using eddy current inspection on the inner bore of the fuse pin with 

the engine installed. Subsequent inspections of at least sixty-nine additional fuse pins from the same engine 

type have revealed no cracks. These additional pins were on airplanes with as many as 23,007 flight cycles. 

These cracks are believed to be caused by stresses due to ovalization of the fuse pin. Because this strut has 

redundant load paths, one pin can fail without affecting flight safety. Boeing testing of similar fuse pins showed 

no significant reduction in shear strength with longitudinal cracks up to 1 inch. 

An all base message M-7240-94-0006 was sent to inform operators of the development of this service bulletin 

and of Delta Airlines involvement as the “Lead the Fleet” airline. 
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

Subsequent to the release of Revision 4 of this service bulletin one operator has reported a fractured midspar 

fuse pin. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the 

number one pylon. Further inspection of the inboard side of the number one pylon, revealed the midspar fuse 

pin to have corrosion within the bore and on the pin surface. The 767-ER airplane was equipped with RB211 

engines and had accumulated 9,456 flight cycles. Service bulletin 767-54-0069 to replace the midspar fuse pins 

and service bulletin 767-54-0082 to modify the nacelle strut and wing structure had not been incorporated on 

this airplane.

Reduced thresholds for the inspections given in this service bulletin will provide early detection of cracks and 

ensure the structural integrity of the number one and two pylons.

An all base message M-7200-02-01708 was sent to inform operators of the development of revision 5 of this 

service bulletin.

After the Revision 5 date of this service bulletin, one operator of a 767-300 airplane with CF6-80C2 engines 

reported a fractured midspar fuse pin. The airplane had accumulated 16,054 flight cycles and neither service 

bulletin 767-54-0069 nor 767 Strut Improvement Program (SIP) service bulletin 767-54-0081 had been 

incorporated. The fractured midspar fuse pin was found during routine maintenance on the outboard side of the 

number one pylon, prior to the next scheduled midspar fuse pin inspection in accordance with Revision 5 of this 

service bulletin. Further inspection revealed a cracked midspar fuse pin on the inboard side of the number one 

pylon. Subsequent inspection of both midspar fuse pins revealed discrepant circumferential machining grooves 

on the fuse pin main bore surface, in addition to longitudinal cracks. Eddy Current Inspection (ECI) of the 

midspar fuse pins in accordance with the requirements of Revision 5 of this service bulletin will not reveal the 

presence of the discrepant machining grooves. The roughness of the discrepant machining grooves exceeded 

the maximum allowable roughness of the fuse pin main bore surface. Metallurgical analysis determined the fuse 

pin fracture or crack origins coincided with the discrepant machining groove locations, in all cases. Stresses due 

to pin ovalization contributed to the longitudinal cracking of the midspar fuse pins.

Multi-Operator Message (MOM) 1-1171248586 was sent to inform operators of the development of Revision 6 

of this service bulletin.

Reduced inspection thresholds and repeat intervals in accordance with Revision 6 of this service bulletin will 

provide early detection of cracks due to discrepant circumferential machining grooves and will ensure the 

structural integrity of the number one and two pylons.

Boeing Service Related Problems (SRP) 767-SRP-54-0093 and 767-SRP-54-0131 are related to this service 

bulletin.

ACTION

Do either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection or 

Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one and 

two pylons, for any crack and any corrosion. 

— If any crack is found on the midspar fuse pin, replace the fuse pin.

— If any corrosion is only found on a non-critical midspar fuse pin surface, remove the corrosion and continue 

the fuse pin inspection or replace the fuse pin.

— If any corrosion is found on any midspar fuse pin surface except a non-critical surface, either contact 

Boeing for repair instructions and do the repair or replace the fuse pin.
 

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ALERT ALERT

— If no crack is found and no corrosion is found on the midspar fuse pin, install the fuse pin (if removed) or 

replace the fuse pin.

Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin Inspection 

or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin on the number one 

and two pylons, in accordance with Paragraph 1.E., Compliance.

Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767-54-0080, 

767-54-0081 or 767-54-0082 is terminating action for this service bulletin.

EFFECTIVITY

767-200, 767-300 and 767-300F 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 Revision 

6 of this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this 

service bulletin mandatory.

FAA Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to this service bulletin.

See Service Bulletin Paragraph 1.E. for compliance information.

INDUSTRY SUPPORT INFORMATION

This service bulletin was first released before October of 1994. Thus industry support for affected airplanes 

depends upon whether you ever filed a warranty claim with Boeing on this service bulletin.

MANPOWER

See the table in the Manpower section.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

PIN

COTTER

DETAIL I

SEE

WING

FITTING

WASHER

MIDSPAR

FITTING

WASHER

SELF-LOCKING NUT

(2 LOCATIONS)

DETAIL I

TYPICAL MIDSPAR FITTING

DO A DETAILED AND EDDY CURRENT (MAGNETIC PARTICLE OPTIONAL, OFF WING)

INSPECTION OF THE MIDSPAR FUSE PIN FOR ANY CRACK AND ANY CORROSION.

REPLACE FUSE PIN IF ANY CRACK OR ANY CORROSION IS FOUND, EXCEPT ON

NON-CRITICAL SURFACES. REMOVE CORROSION ON NON-CRITICAL SURFACES OR

REPLACE FUSE PIN. DO REPEAT INSPECTIONS.

CASTELLATED

NUT

WASHER

BOLT

WASHER

END CAP

FWD

UP

E09896
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ALERT ALERT

Commercial

Airplanes 767

ALERT ALERT

Service Bulletin

Number: 767-54A0062

Original Issue: April 14, 1994

Revision 6: November 05, 2009

ATA System: 5451

SUBJECT: NACELLES / PYLONS - Strut Attach Fuse Pins - Midspar Fuse Pin Inspection and 

Replacement

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN 

PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-24T001 Part 3 for Airplane Variable Number, Line 

Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - 767-200 airplane line numbers 6 thru 347 with 

CF6-80A Engines and 311T3102-1 (311T3102-3 

Optional) Midspar Fuse Pins

2 - 767-200 airplane line numbers 1 thru 254 with 

JT9D-7R4 Engines and 311T3102-1 (311T3102-

3 Optional) Midspar Fuse Pins

3 - 767-300 airplane line numbers 136 thru 427 

with CF6-80A Engines and 311T3102-2 

(311T3102-4 Optional) Midspar Fuse Pins

4 - 767-300 airplane line numbers 132 thru 329 

with JT9D-7R4 Engines and 311T3102-2 

(311T3102-4 Optional) Midspar Fuse Pins
 

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ALERT ALERT

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AA 767 LLC (SVX)

2 VE067

ABX AIR (ABX)

1 VA301 VA304–VA305 VA309–VA312 VA314–VA315

VA509 VB101–VB123 VB125

2 VA803 VA807–VA809 VB302

AEROFLOT (ARO)

5 VL896–VL897 VN471–VN472

AEROMEXICO (AMX)

6 VF071 VF093 VF162 VN166

VN531

AEROSVIT (UKA)

6 VN154–VN155 VN157

AEROTURBINE (AUB)

1 VB051 VB054–VB055 VB321

5 VB331–VB332

AIR ALGERIE (ALG)

5 VK131–VK133

AIR CANADA (ACN)

2 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202

5 VN051–VN054 VN056–VN062 VN546–VN547 VN751–VN752

VN811–VN812

6 VN541 VN931–VN936

AIR CHINA (BEJ)

6 VE085 VK161–VK164

5 - 767-200, 767-300 and 767-300F airplane line 

numbers 158 thru 636 with CF6-80C2 Engines 

and 311T2102-1 (311T2102-2 Optional) Midspar 

Fuse Pins

6 - 767-200 and 767-300 airplane line numbers 165 

thru 635 with PW4000 Engines and 311T2102-1 

(311T2102-2 Optional) Midspar Fuse Pins

7 - 767-300 airplane line numbers 265 thru 627 

with RB211-524H Engines and 311T2102-1 

(311T2102-2 Optional) Midspar Fuse Pins

GROUP CONFIGURATION DESCRIPTION
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

AIR ITALY (RIT)

5 VF001–VF002 VL913

AIR MADAGASCAR (MAD)

6 VN167 VN556

AIR NEW ZEALAND (ANZ)

5 VN653 VN655–VN656

AIR PACIFIC (APC)

5 VN676

AIR SEYCHELLES (ASY)

1 VE104

2 VB301

AIR TRANSPORT INTERNATIONAL (TIN)

1 VA313 VA511–VA512

AIR ZIMBABWE (ZMB)

6 VF061–VF062

ALITALIA COMPAGNIA AEREA ITALIANA SPA (ILQ)

5 VL701–VL702 VN426 VN732 VN813

ALL NIPPON AIRWAYS (ANA)

5 VK081–VK112 VN191–VN196

AMERICAN AIRLINES (AAL)

1 VA501–VA505 VA514–VA523 VA525 VA527–VA530

5 VN001–VN041

AMERIJET INTERNATIONAL (AMJ)

1 VA303 VA306

ARKEFLY (HXL)

6 VN156 VN164–VN165

ASIANA AIRLINES (AAR)

5 VK143–VK144 VW851

AUSTRIAN AIRLINES AG (AUL)

6 VN242–VN243 VN671

AVIANCA (AVI)

6 VE171 VF072 VF161 VN152

VN500 VN532

AWAS (AWW)

1 VB325

5 VN651

6 VE172 VF092
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

BELLVIEW AIRLINES (BEB)

5 VE125–VE126

BLUE CITY HOLDING (BCY)

2 VE069

BLUE PANORAMA AIRLINES (BPA)

6 VN174 VN225 VN681

BOEING (TBC)

2 VA001

BOEING CAPITAL CORPORATION (ZMF)

1 VE117

BRISTOL AIR LIMITED (BMD)

2 VA804

BRITISH AIRWAYS (BAB)

7 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137

BTM CAPITAL CORPORATION (BTO)

2 VE022–VE023

CARGOJET AIRWAYS LTD. (WNT)

1 VA510 VA513

CHILEAN AIR FORCE (CHF)

6 VN561

CHINA EASTERN AIRLINES (CEA)

7 VL871–VL873

COLOMBIAN AIR FORCE (CLB)

6 VE086

COMPANIA MEXICANA DE AVIACION S.A. DE C.V. (CMA)

5 VF041–VF042 VL001–VL002

CONDOR (CDF)

6 VN683–VN691

CSDS AVIATION (CSO)

1 VA506–VA507

DELTA AIR LINES (DAL)

1 VA302

3 VK036 VK039–VK054

5 VL753 VN301–VN306

6 VK055–VK056 VN251–VN268

DNIPROAVIA (DNE)

6 VN495
 

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ALERT ALERT

EL AL ISRAEL AIRLINES (ELA)

2 VB283–VB284

6 VF101–VF102 VN537 VN682 VN972

ERITREAN AIR LINES (ERJ)

2 VE066

ETHIOPIAN AIRLINES (ETH)

5 VL898

6 VN388

EUROATLANTIC AIRWAYS (MAE)

5 VN055

6 VN151 VN551 VN562

EVERGREEN MAINTENANCE CENTER (EAC)

2 VE061

FIRST AIR (BRS)

1 VA508

FLYGLOBESPAN.COM (FGS)

5 VL891 VN654

GA TELESIS (GTG)

4 VK002–VK003

GABON AIRLINES (GBO)

2 VA017–VA018

GECAS (GEF)

5 VN731

GENERIC CUSTOMER/SUPPLIER (XXX)

2 VA005 VE002 VE041 VE063

5 VN310 VN314

6 VN221–VN222

GOL AIRLINES (GOT)

5 VF171 VN637 VN753

6 VN163 VN557

GUGGENHEIM AVIATION PARTNERS (GPR)

6 VN153

HAWAIIAN AIRLINES (HWI)

3 VK031–VK034

6 VN171–VN173 VN381

HEWA BORA AIRWAYS (EXD)

2 VE021
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

HIS MAJESTY THE SULTAN'S FLIGHT (BWN)

5 VF180

ICELANDAIR (ICE)

6 VN158 VN211

ILFC (ILF)

5 VF051

INTEGRATED DEFENSE SYSTEMS (BAC)

2 VA806

ITOCHU CORPORATION (CIT)

5 VF181–VF183

JAL INTERNATIONAL (JAL)

2 VB371–VB373

4 VK001 VK004–VK011 VK021–VK022

5 VK012–VK015

JETAIRFLY (TLB)

5 VN234

JORDAN AVIATION (JOR)

1 VB327 VB329–VB330

KALAIR (BERMUDA) (KLB)

5 VN311

KAM AIR (KMC)

2 VA019

KENYA AIRWAYS (KEN)

5 VK141 VL003 VN421

LAN AIRLINES (LAN)

5 VL703 VN063–VN064

6 VN168 VN966–VN967 VN971

LOT POLISH AIRLINES (LOT)

5 VL893 VN233 VN291–VN292 VN652

MALEV HUNGARIAN AIRLINES LTD. (HGA)

5 VF172

MARTINAIR HOLLAND (MTH)

6 VN223–VN224 VN385 VN672

MID EAST JET (SKL)

5 VF251

NEOS (NEO)

5 VL892 VL894
 

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ALERT ALERT

NORTH AMERICAN AIRLINES (NNA)

5 VL755 VL895 VL911 VN634

VN922

OMNI AIR INTERNATIONAL (OAE)

5 VN424 VN427 VN635

PACE AIRLINES (PIE)

1 VB053

PHOENIX AIRCRAFT LEASING, INC. (PLB)

2 VA810

PTC AEROSPACE (PTE)

2 VB282

QANTAS (QAN)

5 VN081–VN097

7 VN115–VN117 VN123 VN130–VN132

ROYAL AIR MAROC (RAM)

5 VN636

ROYAL BRUNEI AIRLINES (RBA)

6 VN372 VN382–VN384 VN386–VN387

RYAN INTERNATIONAL AIRLINES (RYN)

3 VK035 VK038

6 VL011 VN376

S7 AIRLINES (SBR)

5 VN638

SAFI AIRWAYS (FFI)

2 VE084

SALAMIS AVIATION (LMV)

2 VE068

SHANGHAI AIRLINES (SHA)

6 VK171

SKY HOLDING COMPANY (PSH)

6 VL931

SKY KING (SKN)

2 VE064

SKYSTAR (SYW)

2 VA008 VA011–VA012 VA020

SMARTLYNX AIRLINES (LCH)

6 VN536 VN542
 

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ALERT ALERT

SOJITZ CORPORATION (SOJ)

5 VN231–VN232

STAR AIR (SBJ)

1 VA307–VA308 VB323 VB328 VE101–VE103

5 VB441–VB444

TAA (TNL)

2 VA002–VA004 VA007 VA014–VA015

TAM (TPR)

5 VN422–VN423 VN425

TAMPA CARGO (TMP)

5 VE121–VE124

TEEBAH AIRLINES (EBH)

2 VA710

THOMAS COOK AIRLINES UK (JMA)

5 VN951–VN952

THOMSON AIRWAYS (BRI)

5 VL751–VL752 VL754 VN791–VN792 VN921

TRANSAERO AIRLINES (TRX)

1 VE116 VE118

5 VE143 VN307–VN309 VN313

6 VN371 VN631–VN633

TRANSATLANTIC INTL AIRLINES (TIB)

2 VA016

TUIFLY NORDIC (TNS)

5 VL912

UNITED AIR LINES (UAL)

6 VN491–VN494 VN496–VN499 VN501–VN513

UPS (UPS)

5 VW701–VW713

US AIRWAYS (USA)

5 VE141–VE142 VE144–VE149 VE151–VE152

UT FINANCE CORPORATION (ZZJ)

2 VE001

UZBEKISTAN AIRWAYS (UZB)

6 VL806

VISION AIR (VEG)

2 VA006 VA009–VA010
 

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ALERT ALERT

VIVA MACAU (VMC)

5 VK142

6 VF091

WELLS FARGO (FSB)

5 VL004–VL006

WEST DOVER LLC (WDR)

3 VK037

YONA (IOP)

5 VN312

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

VA001–VA020 2

VA301–VA315 1

VA501–VA530 1

VA701–VA719 2

VA801–VA810 2

VB001–VB002 2

VB051–VB055 1

VB101–VB125 1

VB201–VB202 2

VB251–VB253 1

VB281–VB284 2

VB301–VB302 2

VB321–VB330 1

VB331–VB332 5

VB371–VB373 2

VB401 1

VB441–VB444 5

VE001–VE003 2

VE021–VE023 2

VE041–VE043 2

VE061–VE069 2

VE083–VE084 2

VE085–VE086 6

VE101–VE104 1

VE116–VE118 1

VE121–VE126 5

VE141–VE152 5
 

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ALERT ALERT

VE171–VE172 6

VF001–VF002 5

VF041–VF042 5

VF051 5

VF061–VF062 6

VF071–VF072 6

VF091–VF093 6

VF101–VF102 6

VF161–VF162 6

VF171–VF172 5

VF180–VF183 5

VF251 5

VK001–VK011 4

VK012–VK015 5

VK021–VK022 4

VK031–VK054 3

VK055–VK056 6

VK081–VK112 5

VK131–VK133 5

VK141–VK144 5

VK161–VK164 6

VK171 6

VL001–VL006 5

VL011 6

VL701–VL703 5

VL751–VL755 5

VL806 6

VL871–VL873 7

VL891–VL898 5

VL911–VL913 5

VL931 6

VN001–VN041 5

VN051–VN064 5

VN081–VN097 5

VN111–VN127 7

VN130–VN137 7

VN151–VN158 6

VN163–VN168 6

VN171–VN174 6

Variable Group
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

VN191–VN196 5

VN211–VN212 6

VN221–VN225 6

VN231–VN234 5

VN241–VN243 6

VN251–VN268 6

VN291–VN292 5

VN301–VN314 5

VN371–VN372 6

VN376 6

VN381–VN388 6

VN421–VN427 5

VN471–VN472 5

VN491–VN513 6

VN531–VN532 6

VN536–VN537 6

VN541–VN542 6

VN546–VN547 5

VN551 6

VN556–VN557 6

VN561–VN562 6

VN631–VN633 6

VN634–VN638 5

VN651–VN656 5

VN671–VN672 6

VN676 5

VN681–VN691 6

VN731–VN732 5

VN751–VN753 5

VN791–VN792 5

VN811–VN813 5

VN921–VN922 5

VN931–VN936 6

VN951–VN952 5

VN966–VN967 6

VN971–VN972 6

VW701–VW713 5

VW851 5

Variable Group
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

2. Spares Affected

None

B. Concurrent Requirements

None.

C. Reason

This inspection/replacement program will permit early detection of cracks in the midspar fuse pin on 

the inboard and outboard sides of the number one and number two pylons. Midspar fuse pin cracks 

can result in the loss of structural integrity of the midspar fuse pins and cause an engine breakaway 

from the airplane.

There have been eight reports involving a total of fourteen midspar fuse pins suspected of having 

longitudinal cracks. Of these fuse pins, seven pins were confirmed cracked. The cracked pins were 

from one operator on airplanes with 15,628 to 23,056 flight cycles. Both airplanes are equipped with 

CF6-80A engines. 

The first pins suspected of being cracked were found during a midspar bushing migration rework. The 

cracks were found by a detailed visual inspection. The cracking was confirmed by magnetic particle 

inspection with the pins removed. The second cracked pin was found using eddy current inspection 

on the inner bore of the fuse pin with the engine installed. Subsequent inspections of at least sixtynine additional fuse pins from the same engine type have revealed no cracks. These additional pins 

were on airplanes with as many as 23,007 flight cycles. 

These cracks are believed to be caused by stresses due to ovalization of the fuse pin. Because this 

strut has redundant load paths, one pin can fail without affecting flight safety. Boeing testing of similar 

fuse pins showed no significant reduction in shear strength with longitudinal cracks up to 1 inch. 

An all base message M-7240-94-0006 was sent to inform operators of the development of this service 

bulletin and of Delta Airlines involvement as the “Lead the Fleet” airline. 

Subsequent to the release of Revision 4 of this service bulletin one operator has reported a fractured 

midspar fuse pin. The fractured midspar fuse pin was found during routine maintenance on the 

outboard side of the number one pylon. Further inspection of the inboard side of the number one 

pylon, revealed the midspar fuse pin to have corrosion within the bore and on the pin surface. The 

767-ER airplane was equipped with RB211 engines and had accumulated 9,456 flight cycles. Service 

bulletin 767-54-0069 to replace the midspar fuse pins and service bulletin 767-54-0082 to modify the 

nacelle strut and wing structure had not been incorporated on this airplane.

Reduced thresholds for the inspections given in this service bulletin will provide early detection of 

cracks and ensure the structural integrity of the number one and two pylons.

An all base message M-7200-02-01708 was sent to inform operators of the development of Revision 

5 of this service bulletin.
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

After the Revision 5 date of this service bulletin, one operator of a 767-300 airplane with CF6-80C2 

engines reported a fractured midspar fuse pin. The airplane had accumulated 16,054 flight cycles and 

neither service bulletin 767-54-0069 nor 767 Strut Improvement Program (SIP) service bulletin 767-

54-0081 had been incorporated. The fractured midspar fuse pin was found during routine 

maintenance on the outboard side of the number one pylon, prior to the next scheduled midspar fuse 

pin inspection in accordance with Revision 5 of this service bulletin. Further inspection revealed a 

cracked midspar fuse pin on the inboard side of the number one pylon. Subsequent inspection of both 

midspar fuse pins revealed discrepant circumferential machining grooves on the fuse pin main bore 

surface, in addition to longitudinal cracks. Eddy Current Inspection of the midspar fuse pins in 

accordance with the requirements of Revision 5 of this service bulletin will not reveal the presence of 

the discrepant machining grooves. The roughness of the discrepant machining grooves exceeded the 

maximum allowable roughness of the fuse pin main bore surface. Metallurgical analysis determined 

the fuse pin fracture or crack origins coincided with the discrepant machining groove locations, in all 

cases. Stresses due to pin ovalization contributed to the longitudinal cracking of the midspar fuse pins.

Multi-Operator Message (MOM) 1-1171248586 was sent to inform operators of the development of 

Revision 6 of this service bulletin.

Reduced inspection thresholds and repeat intervals in accordance with Revision 6 of this service 

bulletin will provide early detection of cracks due to discrepant circumferential machining grooves and 

will ensure the structural integrity of the number one and two pylons.

Boeing Service Related Problems (SRP) 767-SRP-54-0093 and 767-SRP-54-0131 are related to this 

service bulletin.

Revision 1 is sent to do the following:

Revise the compliance and repeat inspection thresholds in Figure 1. 

Add BMS 10-11 primer to the operator supplied parts list. 

Change the VN546-VN547 airplanes from Group 6 to Group 5.

Modify the action and description to direct operators to contact Boeing for a possible ferry flight to 

repair facility if cracks are found. 

Change 767 Maintenance Manual 54-51-02 Temporary Revision dates to reflect a change in tooling 

requirements. 

Clarify the removal of cadmium plating in Figure 4. 

Revision 2 is sent to do the following:

— Clarify the fuse pin plating removal. 

— Call out BMS 5-95 as a superseding sealant to BMS 5-79. 

— Add VE118 to Group 1 airplanes.

— Clarify aft fairing door access panel numbers.

— Add corrosion inspection text to Figure 3 and 4.

— Add “Remove and Retain” text to Figure 3.

— Remove torque values and add 767 AMM reference to Figure 3. 

— Add statements to Figure 1 addressing corrosion inspection. 

Revision 3 is sent to do the following:
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

Change the text in Figure 1 to read: “On Group 5, 6 and 7 airplanes with 311T2102-1 fuse pins, when 

the fuse pins reach or exceed 15,000 flight-cycles within 90 days of the release date of revision 1 of 

this service bulletin.” The word “within” was omitted.

Change the text in Figure 1 to read: “Replace or reinspect fuse pin within 15,000 flight-cycles.” The 

text “15,000” was inadvertently replaced with 10,000 during the last revision.

Revision 4 is sent to do the following:

Limit the effectivity to 767 airplanes line position 1 through 636. Airplanes line position 637 and on 

have received a new fuse pin configuration in production that do not require inspections as specified 

in this service bulletin.

Add new replacement fuse pin part numbers.

Add Alternate Method of Compliance for installation of the new fuse pin part numbers.

Add reference to service bulletin 767-54-0069 as terminating action for the repeat inspections.

Add requirement to install a torque stripe on midspar fuse pin primary nut.

Revision 5 is sent to do the following:

Reduce the compliance recommendation statements given in “Figure 1 - Inspection Threshold and 

Repeat Inspection Interval Logic Diagram”.

Add reference to service bulletins 767-54-0080, 767-54-0081 and 767-54-0082 as terminating action 

to the repeat inspections. 

Add clarification to the finish and corrosion preventive compound requirements during the installation 

of the midspar fuse pins within Figures 3, 5 and 6.

Revision 6 is sent to reduce inspection thresholds and repeat intervals to provide early detection of 

cracks due to discrepant circumferential machining grooves and to ensure the structural integrity of 

the number one and two pylons. Refer to the Reason For Revision paragraph of the Revision 

Transmittal Sheet for a detailed list of changes in this revision.

Boeing Service Related Problems (SRP) 767-SRP-54-0093 and 767-SRP-54-0131 are related to this 

service bulletin.

D. Description

Do either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin 

Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin 

on the number one and two pylons, for any crack and any corrosion. 

— If any crack is found on the midspar fuse pin, replace the fuse pin.

— If any corrosion is only found on a non-critical midspar fuse pin surface, remove the corrosion 

and continue the fuse pin inspection or replace the fuse pin.

— If any corrosion is found on any midspar fuse pin surface except a non-critical surface, either 

contact Boeing for repair instructions and do the repair or replace the fuse pin.

— If no crack is found and no corrosion is found on the midspar fuse pin, install the fuse pin (if 

removed) or replace the fuse pin.
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin 

Inspection or Part 3 - Midspar Fuse Pin Replacement of each inboard and outboard midspar fuse pin 

on the number one and two pylons, in accordance with Paragraph 1.E., Compliance.

Accomplishment of either service bulletin 767-54-0069 or the applicable 767 SIP service bulletin 767-

54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service bulletin.

Revision 1: No more work is necessary on airplanes changed by the original issue of this service 

bulletin.

Revision 2: No more work is necessary on airplanes changed by the original issue or Revision 1 of 

this service bulletin.

Revision 3: No more work is necessary on airplanes changed by the original issue, Revision 1 or 

Revision 2 of this service bulletin.

Revision 4: No more work is necessary on airplanes changed by the original issue, Revision 1, 

Revision 2, or Revision 3 of this service bulletin.

Revision 5:

More work is necessary on airplanes that have not completed the midspar fuse pin inspections or 

replacement requirements given in this service bulletin within the last 5 years or 5000 flight cycles. 

Accomplish the midspar fuse pin inspection and replacement requirements given in this service 

bulletin within 30 days from the release date of revision 5 of this service bulletin.

Airplanes that have accomplished the midspar fuse pin inspections or replacement requirements 

given in this service bulletin within the last 5 years or 5000 flight cycles, repeat the inspection and 

replacement requirements as given in Figure 1 - Inspection Threshold and Repeat Inspection Interval 

Logic Diagram”, until terminating action is completed.

Revision 6:

More work is necessary on airplanes that have not been changed in accordance with either service 

bulletin 767-54-0069, or the applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-

0082. Continued inspections of the midspar fuse pins are required at reduced thresholds and repeat 

intervals in accordance with Paragraph 1.E., Compliance.

No more work is necessary on airplanes that have been changed in accordance with either service 

bulletin 767-54-0069, or the applicable 767 Strut Improvement Program (SIP) service bulletin 767-54-

0080, 767-54-0081 or 767-54-0082. Accomplishment of either service bulletin 767-54-0069 or the 

applicable 767 SIP service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action 

for this service bulletin.

These service bulletins have similar access requirements as this service bulletin but are not required 

by this service bulletin:

— 767-54-0059 "Nacelle Pylon - Wing to Strut Attach Fittings - Mid Spar Bushing - Inspection and 

Replacement"

— 767-54-0061 "Nacelle Pylon - Wing to Strut Attach Fittings - Lower Spar Bushing - Inspection and 

Replacement"

— 767-54-0095 "Nacelle Pylon - Wing to Strut Attach Fittings - Upper Spar Bushing - Inspection and 

Replacement" (Replaced 767-54-0060)

The changes in this service bulletin will not change the Engine Indication and Crew Alerting System 

(EICAS).
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to 

Revision 6 of this service bulletin. The Airworthiness Directive will make the compliance tasks and 

times given in this service bulletin mandatory.

Accomplish the actions in Table 1 below in accordance with Paragraph 3., Accomplishment 

Instructions.

Evaluate and accomplish the actions in Table 1 below independently for each midspar fuse pin.

Table 1: Midspar Fuse Pin Inspection 

Condition Action (a)

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)

ALL 

AIRPLANES

Do Part 1 - On Wing 

Midspar Fuse Pin Inspection 

for any crack and any 

corrosion

-ORDo Part 2 - Off Wing 

Midspar Fuse Pin Inspection 

for any crack and any 

corrosion

-ORDo Part 3 - Midspar Fuse 

Pin Replacement

1) Before 5,000 Total 

Flight Cycles on the 

midspar fuse pin or 5 

Years since the 

midspar fuse pin was 

installed as new, 

whichever occurs first

-OR2) Within 2,000 Flight 

Cycles or 2 Years after 

the midspar fuse pin 

was last inspected in 

accordance with this 

service bulletin, 

whichever occurs first.

Within 30 

days after 

the 

Revision 6 

date of this 

service 

bulletin

Within 2,000 Flight 

Cycles or 2 Years, 

whichever occurs first

CONDITION 1: 

Any Crack Is 

Found by 

Detailed 

Inspection

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 1

BEFORE FURTHER 

FLIGHT (b)

- -

CONDITION 2: 

No Crack Is 

Found AND 

Any Corrosion 

Is Only Found 

On A NonCritical Surface 

(c)

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2, Option 1

-ORDo the Midspar Fuse Pin 

Rework in accordance with 

CONDITION 2, Option 2

BEFORE FURTHER 

FLIGHT (b)

- -
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

CONDITION 

2.1: Any 

Corrosion 

Found Is 

Removed

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2.1, Option 1

-ORDo an Eddy Current 

Inspection (ECI) of the 

Midspar Fuse Pin for any 

crack in accordance with 

CONDITION 2.1, Option 2

-ORDo Part 4 - Magnetic 

Particle Inspection of the 

Midspar Fuse Pin for any 

crack in accordance with 

CONDITION 2.1, Option 3

BEFORE FURTHER 

FLIGHT (b)

- -

CONDITION 

2.1.1: Any 

Crack Is Found 

By ECI

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2.1.1, Option 1

-ORDo Part 4 - Magnetic 

Particle Inspection of the 

Midspar Fuse Pin for any 

crack in accordance with 

CONDITION 2.1.1, Option 2

BEFORE FURTHER 

FLIGHT (b)

- -

Table 1: Midspar Fuse Pin Inspection 

Condition Action (a)

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

CONDITION 

2.1.2: No 

Crack Is Found 

By ECI

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2.1.2, Option 1

-ORDo Part 5 - Fuse Pin 

Secondary Retention 

Hardware Installation in 

accordance with Part 1, 

CONDITION 2.1.2, Option 2

-ORInstall the Midspar Fuse Pin 

(if removed) in accordance 

with Part 2, CONDITION 

2.1.2, Option 2

BEFORE FURTHER 

FLIGHT

- -

CONDITION 

2.1.3: Any 

Crack Is Found 

By MPI

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2.1.3

BEFORE FURTHER 

FLIGHT (b)

- -

CONDITION 

2.1.4: No 

Crack Is Found 

By MPI

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2.1.4, Option 1

-ORInstall the Midspar Fuse Pin 

in accordance with 

CONDITION 2.1.4, Option 2

BEFORE FURTHER 

FLIGHT

- -

CONDITION 

2.1.5: No 

Crack Is Found 

By MPI

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2.1.3

-ORDo a Midspar Fuse Pin 

Repair in accordance with 

CONDITION 2.1.5, Option 2

BEFORE FURTHER 

FLIGHT (b)

- -

CONDITION 

2.2: Any 

Corrosion 

Found Is Not 

Removed

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 2.2

BEFORE FURTHER 

FLIGHT (b)

- -

Table 1: Midspar Fuse Pin Inspection 

Condition Action (a)

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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ALERT ALERT

CONDITION 3: 

No Crack Is 

Found AND 

Any Corrosion 

Is Found On 

Any Surface 

Other Than A 

Non-Critical 

Surface (c)

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 3, Option 1

-ORDo a Midspar Fuse Pin 

Repair in accordance with 

CONDITION 3, Option 2

BEFORE FURTHER 

FLIGHT (b)

- -

CONDITION 

3.1: Any Crack 

Is Found By 

ECI

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 3.1, Option 1

-ORDo a Magnetic Particle 

Inspection (MPI) of the 

Midspar Fuse Pin for any 

crack in accordance with 

CONDITION 3.1 Option 2

BEFORE FURTHER 

FLIGHT (b)

- -

CONDITION 

3.2: No Crack 

Is Found By 

ECI

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 3.2, Option 1

-ORDo a Midspar Fuse Pin 

Repair in accordance with 

CONDITION 3.2, Option 2

BEFORE FURTHER 

FLIGHT (b)

- -

CONDITION 4: 

No Crack Is 

Found AND No 

Corrosion Is 

Found By 

Detailed 

Inspection

Do Part 3 - Midspar Fuse 

Pin Replacement in 

accordance with 

CONDITION 4, Option 1

-ORDo an Eddy Current 

Inspection (ECI) of the 

Midspar Fuse Pin for any 

crack in accordance with 

CONDITION 4, Option 2

BEFORE FURTHER 

FLIGHT

- -

Table 1: Midspar Fuse Pin Inspection 

Condition Action (a)

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

Federal Aviation Administration (FAA) Airworthiness Directives (AD) 94-11-02 and 2003-03-02 are related to 

this service bulletin.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes 

specified in this service bulletin comply with the applicable regulations and are FAA approved, as well 

as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/

JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval 

were based on the airplane in its original Boeing delivery configuration or as modified by other 

approved Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected 

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency 

approval before incorporating this service bulletin.

The FAA has examined the inspection, and/or replacement procedures specified in Revision 3 to 

Service Bulletin 767-54A0062 “Nacelles/Pylon - Strut Attach fuse Pins - Midspar Fuse Pin Inspection 

and Replacement”. The FAA has approved the inspection, and/or replacement as an alternative to 

those specified in Airworthiness Directives (AD) 94-11-02, Amendment 39-8918.

The FAA has examined the configuration changes, inspection, and/or repair procedures specified in 

Revision 4 to this service bulletin. The FAA has approved the configuration changes, inspection, and/

or repair procedures as an alternative to those specified in Airworthiness Directives (AD) 94-11-02, 

Amendment 39-8918.

The FAA has examined the configuration changes, inspection, and/or repair procedures specified in 

Revision 5 to this service bulletin. The FAA has approved the configuration changes, inspection, and/

or repair procedures as an alternative to those specified in Airworthiness Directives (AD) 94-11-02, 

Amendment 39-8918.

(a) Accomplishment of service bulletin 767-54-0069, or the applicable 767 Strut Improvement Program 

(SIP) service bulletin 767-54-0080, 767-54-0081 or 767-54-0082 is terminating action for this service 

bulletin.

(b) A non-revenue ferry flight to a repair facility may be allowed. Non-revenue ferry flights for airplanes with 

one or less midspar fuse pin with either CONDITION 1, 2, 2.1, 2.1.1, 2.1.3, 2.2, 3, 3.1 or 3.2 per wing, will 

be considered on a case-by-case basis. An airplane with more than one midspar fuse pin with either 

CONDITION 1, 2, 2.1, 2.1.1, 2.1.3, 2.2, 3, 3.1 or 3.2 found on one wing, will not be considered for ferry 

flights. Ferry flight approval will be contingent on Eddy Current Inspection of both midspar fuse pins on each 

wing, and verification that only one midspar fuse pin per wing has either CONDITION 1, 2, 2.1, 2.1.1, 2.1.3, 

2.2, 3, 3.1 or 3.2. A Detailed Inspection of the other strut-to-wing load paths, including the Upper Link, 

Upper Link Fuse Pin, Diagonal Brace and Lower Diagonal Brace Fuse Pin is required. Contact Boeing with 

inspection results and for further instructions.

(c) Refer to Paragraph 3.A.,General Information, for more information on non-critical midspar fuse pin 

surfaces. 

Table 1: Midspar Fuse Pin Inspection 

Condition Action (a)

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

This service bulletin has been approved by the FAA. In addition, the Manager of the Seattle Aircraft 

Certification Office approves the accomplishment of the inspections, replacements, and repairs 

specified in Section 1.E, Compliance, of SB 767-54A0062, Revision 6 as an AMOC to the applicable 

inspections, replacements, and repairs required by paragraphs (h), (i), and (j) of AD 2003-03-02. All 

provisions of AD 2003-03-02 that are not specifically referenced in the preceding sentence remain 

fully applicable and must be complied with.

G. Manpower

The data below shows an estimate of the man-hours necessary to do this inspection/replacement for 

each airplane and/or strut whichever is applicable. This estimate is for direct labor only, done by an 

experienced crew. Adjust the estimate with operator man-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 examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

FUSE PIN INSPECTION - ENGINE NOT REMOVED

Task Number of Persons Man-Hours Elapsed Time (Hours)

Open Access 2 2 1

Inspection 1 2 2

Close Access 2 2 1

TOTAL FOR EACH STRUT 6 4

FUSE PIN INSPECTION - ON BENCH

Task Number of Persons Man-Hours Elapsed Time (Hours)

Inspection 1 2 2

TOTAL PER AIRPLANE 2 2

FUSE PIN REPLACEMENT - ENGINE NOT REMOVED

Task Number of Persons Man-Hours Elapsed Time (Hours)

Open Access 5 15 3

Removal of components

from aft fairing hydraulic

bay

1 88

-EDP supply shut off

valve.

-Hydraulic reservoir

-Alternating current

pump.

Replace fuse pins 1 1 1
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

H. Weight and Balance Changes

None

I. Electrical Load Data

Not changed

J. References

1. Existing Data:

a. Service Related Problem (SRP) 767-SRP-54-0093, 767-SRP-54-0131.

b. 767 Airplane Maintenance Manual (AMM) 6-43-00, 27-81-00, 29-11-00, 29-11-06, 

29-11-20, 54-51-04, 54-52-00, 54-52-01, 54-53-00, and 78-31-00.

c. Boeing Multi-Operator Message (MOM) 1-1171248586

d. 767 Nondestructive Test (NDT) Manual D634T301, Part 6, Subject 54-51-01

e. Boeing Service Bulletin 767-54-0059, “Nacelles/Pylons - Wing to Strut Attach Fittings - 

Midspar Bushing Inspection and Replacement”.

f. Boeing Service Bulletin 767-54-0095, “Nacelles/Pylons - Wing to Strut Attach Fittings - 

Forward Upper Spar Bushing Inspection and Replacement”.

Install components from

aft fairing hydraulic bay

1 10 10

Close Access 5 15 3

TOTAL PER STRUT 49 25

FUSE PIN REPLACEMENT - ENGINE REMOVED 

Task Number of Persons Man-Hours Elapsed Time (Hours)

Remove engine 5 20 4

Removal of components

from aft fairing hydraulic

bay

1 88

-EDP supply shut off valve.

-Hydraulic reservoir

-Alternating current pump. 

Replace fuse pin 1 1 1

Install components from aft

fairing hydraulic bay

1 10 10

Install engine 5 30 6

TOTAL PER STRUT 69 29
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

NOTE: Service bulletin 767-54-0060 was replaced by 767-54-0095.

g. Boeing Service Bulletin 767-54-0061, “Nacelles/Pylons - Wing to Strut Attach Fittings - 

Lower Spar Bushing Inspection and Replacement”.

h. Boeing Service Bulletin 767-54-0069, “Nacelles/Pylons - Midspar Fitting - Underwing Side 

Load Fitting - Fuse Pin Replacement and Wing Rework”.

i. Boeing Service Bulletin 767-54-0080, “NACELLES/PYLONS - Pratt and Whitney Powered 

Airplanes - Nacelle Strut and Wing Structure Modification”.

j. Boeing Service Bulletin 767-54-0081, “NACELLES/PYLONS - General Electric Powered 

Airplanes - Nacelle Strut and Wing Structure Modification”.

k. Boeing Service Bulletin 767-54-0082, “NACELLES/PYLONS - Rolls Royce Powered 

Airplanes - Nacelle Strut and Wing Structure Modification”.

l. Boeing Standard Overhaul Practices Manual (BSOPM) 20-10-01, 20-10-03, 20-20-01, 20-

30-02, 20-30-03 and 20-50-10.

m. Boeing All Base Message M-7240-94-0006, M-7200-02-01708

n. FAA Airworthiness Directive (AD) 94-11-02, 2003-03-02

o. Boeing Parts Standards Document D-590

p. Boeing Drawing 012W6100

q. 767 Component Maintenance Manual (CMM) 54-50-21.

2. Data supplied with this Service Bulletin:

None

3. Installation Drawings Used in the Preparation of this Service Bulletin:

These drawings were used to prepare this service bulletin. These drawings are not necessary to 

make the specified changes, and are not supplied with this service bulletin. These drawings may 

not be applicable to all airplane configurations or operators.

Drawing Number Title

311T5700 STRUT TO WING INSTL

310T3030 ENGINE TO STRUT MOUNT INSTL

310T1030 ENGINE STRUT MOUNT INSTL - CF6-80 ENGINE

310T2030 STRUT TO WING INSTL - CF6-80C ENGINE

310T4040 STRUT TO WING INSTL
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

K. Publications Affected

1. Publications

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue 

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the 

Maintenance Program. This service bulletin affects FCS and new DTI requirements for the 

structure affected are contained in Paragraph 1.E., Compliance, of this service bulletin.

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability 

information.

Publication Chapter-Section

767 Airplane Maintenance Manual 54-51
 

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ALERT ALERT

2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the parts shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown 

below. If there is a limit to the quantity (QTY) of available parts, a supply sequence is given by Spares. 

More parts become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from 

the date Boeing gets the purchase order.

The parts are subject to the terms and conditions of the Boeing standard purchase order 

acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in 

United States dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of the methods that follow: 

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

B. Industry Support Information

This service bulletin was first released before October of 1994. Thus industry support for affected 

airplanes depends upon whether you ever filled a warranty claim with Boeing on this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.

Part Number Name ROLT

(weeks)

Unit Price Thru

Dec 31/09

311T3102-1 Fuse Pin (a) No Longer Available

311T3102-2 Fuse Pin (b) No Longer Available

311T2102-1 Fuse Pin (c) No Longer Available

311T3102-3 Fuse Pin (a) 35 $4,596.00

311T3102-4 Fuse Pin (b) 35 $4,596.00

311T2102-2 Fuse Pin (c) 46 $1,635.00

(a) The 311T3102-1 fuse pin is no longer available. The 311T3102-3 fuse pin replaces the

311T3102-1 fuse pin.

(b) The 311T3102-2 fuse pin is no longer available. The 311T3102-4 fuse pin replaces the

311T3102-2 fuse pin.

(c) The 311T2102-1 fuse pin is no longer available. The 311T2102-2 fuse pin replaces the

311T2102-1 fuse pin.
 

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ALERT ALERT

2. Parts and Materials Supplied by the Operator:

To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
 

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ALERT ALERT

NOTE: Quantities shown are necessary for each airplane. 

NOTE: Parts in the table below are listed for replacement if not serviceable. Quantities shown

are necessary for each airplane. Not all operator supplied parts are used on all airplane

groups. Parts can be salvaged from existing installation if in serviceable condition.

Airplane Group

7654321

Quantity New Part Number Notes Existing Part Number Name

. . . . . 4 4 311T3102-1 (a) 311T3102-1 Fuse Pin

. . . 4 4 . . 311T3102-2 (b) 311T3102-2 Fuse Pin

4 4 4 . . . . 311T2102-1 (c) 311T2102-1 Fuse Pin

. . . . . 4 4 311T3102-3 (a)(d) 311T3102-1 Fuse Pin

. . . 4 4 . . 311T3102-4 (b)(d) 311T3102-2 Fuse Pin

4 4 4 . . . . 311T2102-2 (c)(d) 311T2102-1 Fuse Pin

(a) The 311T3102-1 fuse pin is no longer available. The 311T3102-3 fuse pin replaces the 

311T3102-1 fuse pin.

(b) The 311T3102-2 fuse pin is no longer available. The 311T3102-4 fuse pin replaces the 

311T3102-2 fuse pin.

(c) The 311T2102-1 fuse pin is no longer available. The 311T2102-2 fuse pin replaces the 

311T2102-1 fuse pin.

(d) Discard the existing part if cracked. Keep if not cracked and confirmed by magnetic particle 

inspection. If kept part is installed reinspections of the part is required in this bulletin as

specified in Paragraph 1.E., Compliance.

(e) This is the part number for the new equivalent or replacement part.

Airplane Group 

7654321

Quantity Part Number Name

. . . 4 4 4 4 BACB30LT6D83 (j) Bolt

. . 4 . . . . BACB30LT6D86 (j) Bolt

. 4 . . . . . BACB30LT6D87 (j) Bolt

4 . . . . . . BACB30LT6D88 (j) Bolt

4 4 4 4 4 4 4 MS24665-304 (h)(j) Cotter Pin

4 4 4 4 4 4 4 BACN10JD6AU (j) Nut

4 4 4 4 4 4 4 NAS1805-16 (j) Nut

4 4 . . . 4 4 311N5066-2 (b) (j) Washer 

. . . 4 4 4 4 311T3097-3 (b) (j) Washer 

4 4 4 4 4 4 4 311T3097-4 (b) (j) Washer 

. . . 4 4 4 4 311T3097-5 (b) (j) Washer 

4 4 4 4 4 4 4 AN960C616L (j) Washer 

4 4 4 4 4 4 4 AN970-6 (j) Washer 

4 4 . . . . . BACW10BN6SP (j) Washer 
 

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ALERT ALERT

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None

E. Special Tooling - Price and Availability

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

No special tools or equipment are necessary to do the change in this service bulletin. But, new 

maintenance tools listed below and in the manuals given in Paragraph 1.J., References, will be 

necessary. Examine operator tool supply to make sure all necessary tools are available.

. . . . . 4 4 311T3103-2 (d) End Retaining cap 

. . . 4 4 . . 311T3103-3 (e) End Retaining cap 

4 4 4 . . . . 311T2103-1 (f) End Retaining cap 

(c) (c) (c) (c) (c) (c) (c) BMS 10-11, Type I Primer

(a) This note is not used.

(b) Not all washer part numbers are used.

(c) One pint required.

(d) End cap 311T3103-2 is used with 311T3102-1 (311T3102-3 optional) fuse pin.

(e) End cap 311T3103-3 is used with 311T3102-2 (311T3102-4 optional) fuse pin.

(f) End cap 311T2103-1 is used with 311T2102-1 (311T2102-2 optional) fuse pin.

(g) This note is not used.

(h) Refer to the applicable Qualified Products List (QPL) of the military specification listed for 

the approved material part number vendor.

(j) Refer to 767 Structural Repair Manual Chapter 51, Boeing document D-590 and Boeing 

drawing 012W6100 for alternative fasteners.

Tool Kit Number Name

A54011 (a) Mid Spar Fuse Pin Removal / Installation Tool Kit

(a) Tool kit is used to perform inspection and removal/installation of fuse pin.
 

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED

MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES

CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE

SPARKS OR OTHER ELECTRICAL DAMAGE.

NOTE:

1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figures give the 

recommended sequence of steps. The sequence of steps to do this service bulletin can 

be changed.

2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for 

definition of the acronyms.

3. Obey all of the warnings and cautions given in the specified manual sections.

4. 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 are given in 767 Structural Repair 

Manual, Chapter 51.

— Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual, 

Chapter 51.

5. For approved fastener and process material substitutions, refer to 767 Structural Repair 

Manual, Chapter 51, Alternate fasteners are given in 767 Structural Repair Manual 

Chapter 51 and Boeing Drawing 012W6100.

6. If the length of fasteners specified in this service bulletin do not meet the installation 

standards, fasteners of the same specification, or an approved substitute, one grip 

length longer or shorter may be used.

7. A Detailed Inspection is defined as: An intensive examination of a specific item, 

installation, or assembly to detect damage, failure, or irregularity. Available lighting is 

normally supplemented with a direct source of good lighting at an intensity deemed 

appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. 

Surface cleaning and elaborate procedures may be required.

8. These work instructions refer to procedures included on other Boeing documents. When 

the words "refer to" are used and the operator has an accepted alternative procedure, 

the accepted alternative procedure can be used. When the words "in accordance with" 

are included in the instruction, the procedure in the Boeing document must be used.

9. A serviceable midspar fuse pin meets the following criteria:

— Has prior service history
 

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ALERT ALERT

AND

— No crack or corrosion can be found by Detailed Inspection in accordance with 

paragraph 3.B., Work Instructions,

AND EITHER

— No crack can be found by Eddy Current Inspection (ECI) in accordance with 

Paragraph 3.B., Work Instructions,

OR

— Any crack found by ECI cannot also be found by Magnetic Particle Inspection (MPI) 

in accordance with Paragraph 3.B., Work Instructions,

OR

— No crack can be found by MPI in accordance with Paragraph 3.B., Work 

Instructions.

10. The midspar fuse pins have multiple non-critical surfaces. The non-critical fuse pin 

surfaces are shown in Figure 3, Figure 4 and Appendix A.

B. WORK INSTRUCTIONS

1. Do either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse Pin 

Inspection or Part 3 - Midspar Fuse Pin Replacement of the inboard and outboard midspar fuse 

pins, on the number one and two pylons.

Part 1 - On Wing Midspar Fuse Pin Inspection

1. Retract the leading edge slats if they are extended and install the leading edge slat drive unit 

locks. Refer to 767 AMM 27-81-00 and 767 AMM 78-31-00 as accepted procedures.

2. Remove aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2.

3. Do a Detailed Inspection of the midspar fuse pin for any crack and any corrosion in accordance 

with Figure 3.

a. CONDITION 1: Any Crack Is Found By Detailed Inspection, Do Part 3 - Midspar Fuse Pin 

Replacement

b. CONDITION 2: No Crack Is Found AND Any Corrosion Is Only Found On A Non-Critical 

Surface

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

(2) Option 2: Midspar Fuse Pin Rework

(a) Remove any light corrosion in accordance with Figure 3; remove any heavy 

corrosion in accordance with Appendix A.

(b) CONDITION 2.1: Any Corrosion Found Is Removed

1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 

2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for 

any crack in accordance with Figure 3. 

{a} CONDITION 2.1.1: Any Crack Is Found By ECI 
 

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ALERT ALERT

1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2} Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar 

Fuse Pin for Any Crack

{b} CONDITION 2.1.2: No Crack Is Found By ECI

1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2} Option 2: Do Part 5 - Fuse Pin Secondary Retention Hardware 

Installation

3) Option 3: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin 

for Any Crack 

(c) CONDITION 2.2: Any Corrosion Found Is Not Removed, Do Part 3 - Midspar 

Fuse Pin Replacement

c. CONDITION 3: No Crack Is Found AND Any Corrosion Is Found On Any Surface Other 

Than A Non-Critical Surface

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

(2) Option 2: Midspar Fuse Pin Repair

(a) Remove the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted 

procedure.

(b) Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in 

accordance with Figure 4. 

1) CONDITION 3.1: Any Crack Is Found By ECI 

{a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

{b} Option 2: Do Part 6 - Magnetic Particle Inspection of the Midspar Fuse 

Pin for Any Crack Prior to Repair

2) CONDITION 3.2: No Crack Is Found By ECI

{a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

{b} Option 2: Midspar Fuse Pin Repair

1} Contact Boeing for Repair Instructions and Do the Repair.

2} Install the repaired midspar fuse pin. Refer to 767 AMM 54-51-04 

as an accepted procedure.

d. CONDITION 4: No Crack Is Found AND No Corrosion Is Found By Detailed Inspection

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement
 

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ALERT ALERT

(2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack 

in accordance with Figure 3.

(a) CONDITION 2.1.1: Any Crack Is Found By ECI 

1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2) Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin 

for Any Crack

(b) CONDITION 2.1.2: No Crack Is Found By ECI

1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2) Option 2: Do Part 5 - Fuse Pin Secondary Retention Hardware Installation

4. Install aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2.

5. Remove the leading edge slat drive unit locks, if installed. Refer to 767 AMM 27-81-00 as an 

accepted procedure.

6. Return airplane to a serviceable condition.

7. Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse 

Pin Inspection or Part 3 - Midspar Fuse Pin Replacement in accordance with Paragraph 1.E., 

Compliance.

Part 2 - Off Wing Midspar Fuse Pin Inspection

1. Retract the leading edge slats if they are extended and install the leading edge slat drive unit 

locks. Refer to 767 AMM 27-81-00 and 767 AMM 78-31-00 as accepted procedures.

2. Remove aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2.

3. Remove the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted procedure.

4. Do a Detailed Inspection of the midspar fuse pin for any crack and any corrosion in accordance 

with Figure 4.

a. CONDITION 1: Any Crack Is Found By Detailed Inspection, Do Part 3 - Midspar Fuse Pin 

Replacement

b. CONDITION 2: No Crack Is Found AND Any Corrosion Is Only Found On A Non-Critical 

Surface

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

(2) Option 2: Midspar Fuse Pin Rework

(a) Remove any light corrosion in accordance with Figure 3; remove any heavy 

corrosion in accordance with Appendix A.

(b) CONDITION 2.1: Any Corrosion Found Is Removed
 

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ALERT ALERT

1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement 

2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for 

any crack in accordance with Figure 4. 

{a} CONDITION 2.1.1: Any Crack Is Found By ECI

1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2} Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar 

Fuse Pin for Any Crack

{b} CONDITION 2.1.2: No Crack Is Found By ECI

1} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2} Option 2: Install the midspar fuse pin. Refer to 767 AMM 54-51-04 

as an accepted procedure.

3) Option 3: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin 

for Any Crack 

(c) CONDITION 2.2: Any Corrosion Found Is Not Removed, Do Part 3 - Midspar 

Fuse Pin Replacement

c. CONDITION 3: No Crack Is Found AND Any Corrosion Is Found On Any Surface Other 

Than A Non-Critical Surface

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

(2) Option 2: Midspar Fuse Pin Repair

(a) Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack in 

accordance with Figure 4. 

1) CONDITION 3.1: Any Crack Is Found By ECI 

{a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

{b} Option 2: Do Part 6 - Magnetic Particle Inspection of the Midspar Fuse 

Pin for Any Crack Prior to Repair

2) CONDITION 3.2: No Crack Is Found By ECI

{a} Option 1: Do Part 3 - Midspar Fuse Pin Replacement

{b} Option 2: Midspar Fuse Pin Repair

1} Contact Boeing for Repair Instructions and Do the Repair.

2} Install the repaired midspar fuse pin. Refer to 767 AMM 54-51-04 

as an accepted procedure.
 

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ALERT ALERT

d. CONDITION 4: No Crack Is Found AND No Corrosion Is Found By Detailed Inspection

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

(2) Option 2: Do an Eddy Current Inspection (ECI) of the midspar fuse pin for any crack 

in accordance with Figure 3.

(a) CONDITION 2.1.1: Any Crack Is Found By ECI 

1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2) Option 2: Do Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin 

for Any Crack

(b) CONDITION 2.1.2: No Crack Is Found By ECI

1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

2) Option 2: Install the midspar fuse pin. Refer to 767 AMM 54-51-04 as an 

accepted procedure.

5. Install aft fairing access doors and midspar fuse pin access doors in accordance with Figure 2.

6. Remove the leading edge slat drive unit locks, if installed. Refer to 767 AMM 27-81-00 as an 

accepted procedure.

7. Return airplane to a serviceable condition.

8. Repeat either Part 1 - On Wing Midspar Fuse Pin Inspection or Part 2 - Off Wing Midspar Fuse 

Pin Inspection or Part 3 - Midspar Fuse Pin Replacement in accordance with Paragraph 1.E., 

Compliance.

Part 3 - Midspar Fuse Pin Replacement

1. Replace the midspar fuse pin in accordance with Figure 5.

Part 4 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack

1. Remove the midspar fuse pin, if required. Refer to 767 AMM 54-51-04 as an accepted procedure.

2. Do a Magnetic Particle Inspection (MPI) of the midspar fuse pin for any crack in accordance with 

Figure 6.

a. CONDITION 2.1.3: Any Crack is Found by MPI, Do Part 3 - Midspar Fuse Pin Replacement

b. CONDITION 2.1.4: No Crack is Found by MPI

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

(2) Option 2: Midspar Fuse Pin Installation

(a) If the midspar fuse pin finish was previously removed, restore the fuse pin finish 

in accordance with Figure 7. 
 

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ALERT ALERT

(b) Install the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted 

procedure. 

Part 5 - Fuse Pin Secondary Retention Hardware Installation

1. If the midspar fuse pin finish was previously removed, restore the fuse pin finish in accordance 

with Figure 7. 

2. Install the fuse pin secondary retention hardware in accordance with Figure 3.

Part 6 - Magnetic Particle Inspection of the Midspar Fuse Pin for Any Crack Prior to Repair

1. Remove the midspar fuse pin, if required. Refer to 767 AMM 54-51-04 as an accepted procedure.

2. Do a Magnetic Particle Inspection (MPI) of the midspar fuse pin for any crack in accordance with 

Figure 6.

a. CONDITION 2.1.3: Any Crack is Found by MPI, Do Part 3 - Midspar Fuse Pin Replacement

b. CONDITION 2.1.5: No Crack is Found by MPI

(1) Option 1: Do Part 3 - Midspar Fuse Pin Replacement

(2) Option 2: Midspar Fuse Pin Repair

(a) Contact Boeing for Repair Instructions and Do the Repair.

(b) Install the midspar fuse pin. Refer to 767 AMM 54-51-04 as an accepted 

procedure. 
 FIGURE 1: DELETED - REFER TO PARAGRAPH 1.E. - COMPLIANCE

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ALERT ALERT

FIGURE 1: DELETED - REFER TO PARAGRAPH 1.E. - COMPLIANCE

This Figure has been deleted. See Paragraph 1.E., Compliance, for inspection and maintenance alternatives.

THIS FIGURE DOES NOT HAVE AN ILLUSTRATION

V75032

(SHEET 1 OF 1)
 FIGURE 2: MIDSPAR FUSE PIN ACCESS

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ALERT ALERT

FIGURE 2: MIDSPAR FUSE PIN ACCESS

JT9D-7R4 ENGINES

PW4000 ENGINES

RB511-524 ENGINES

CF6-80A ENGINES

CF6-80C2 ENGINES

FWD

UP

1

1

4

2

3

1

E09773

(SHEET 1 OF 2)
 FIGURE 2: MIDSPAR FUSE PIN ACCESS

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ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME IDENTIFICATION QTY NOTES

1 Remove/

Install

Group 1 thru Group 6 airplanes only

Strut No. 1 -

Aft fairing and fuse 

pin access doors

437BL 1 Refer to 767 AMM 06-43-00, 767

AMM 54-52-00, 767 AMM 54-52-

01, and 767 AMM 54-53-00 as accepted procedures.

437ELX 1

436AL 1

437BR 1

437ERX 1

436AR 1

Strut No. 2 -

Aft fairing and fuse 

pin access doors

447BL 1

447ELX 1

446AL 1

447BR 1

447ERX 1

446AR 1

Group 7 airplanes only

Strut No. 1 -

Aft fairing and fuse 

pin access doors

433DL 1 Refer to 767 AMM 06-43-00, 767

AMM 54-52-00, 767 AMM 54-52-

01, and 767 AMM 54-53-00 as accepted procedures.

434AL 1

433LR 1

434AR 1

Strut No. 2 -

Aft fairing and fuse 

pin access doors

443FL 1

444AL 1

443LR 1

444AR 1

Optional Additional Access

2 Remove/

Install

Hydraulic line

clamps 

- 2 Additional access can be gained to

the left side fuse pins by removing

the clamp blocks that support the

hydraulic tubes on the left side of

the struts. The hydraulic lines may

need to be pushed upward after the

clamp blocks are removed, to gain

better access to the fuse pin secondary retention device nut and the

cotter pin.

3 Remove/

Install

EDP Supply Shut

Off Valve 

- 1 Refer to 767 AMM 29-11-00 and

767 AMM 29-11-06 as accepted

procedures. 

4 Remove/

Install

Hydraulic Reservoir - 1 Refer to 767 AMM 29-11-00 and

767 AMM 29-11-20 as accepted

procedures. 

(SHEET 2 OF 2)
 FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION

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ALERT ALERT

FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION

A

A

PIN

NUT

DETAIL I

SEE

BOLT

WING

FITTING

WASHER

FUSE PIN

MIDSPAR

FITTING

WASHER

SELF-LOCKING NUT

CASTELLATED

COTTER

END CAP

WASHER

WASHER

TYPICAL MIDSPAR FITTING

DETAIL I

(2 LOCATIONS)

FWD

UP

3

1 6

1 6

1 6

1 6

1 6

1 6

2 4 5

E09779

(SHEET 1 OF 4)
 FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION

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ALERT ALERT

NOTE:

1. This figure shows an expanded view of the midspar fuse pin installation. However, the fuse pin cleaning 

and inspections in this figure only require removal of the secondary retention hardware (cotter pin, 

castellated nut, washer, end cap, washer and bolt).

EDDY CURRENT INSPECTION AREA - FUSE

PIN MAIN BORE SURFACE

A-A

MIDSPAR

FITTING

LONGITUDINAL CRACK

(EXAMPLE)

WING ATTACH

FITTING

FUSE PIN

CROSS SECTION

ON WING MIDSPAR FUSE PIN INSPECTION AREAS

NON-CRITICAL FUSE PIN

HEAD BEARING SURFACE

FUSE PIN

MINOR BORE

NON-CRITICAL FUSE

PIN SHANK ENDFACE

SURFACE

DETAILED INSPECTION AREA COVERS VISIBLE

SURFACES EXCEPT THE MINOR BORE.

NON-CRITICAL FUSE

PIN END SURFACE

NON-CRITICAL

CHAMFER SURFACE

NON-CRITICAL FUSE PIN

HEAD EXTERIOR SURFACES

NON-CRITICAL FUSE PIN

HEAD EXTERIOR SURFACES

1852624

(SHEET 2 OF 4)
 FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

2. The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PART NUMBER QTY NOTES

Secondary Retention Hardware Removal 

1 Remove Cotter pin - 2 If cotter pin cannot be removed

normally, place wrench from the

A54011 tool kit on nut and torque

the secondary retention through

bolt until the cotter pin shears off.

Clean remaining pieces of cotter

pin from bolt and nut.

Remove/

Keep

Castellated Nut - 2 Refer to 767 AMM 54-51-04 as an

Washer - 2 accepted procedure.

End cap - 2

Washer - 2

Bolt - 2

2 Clean Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Remove any grease or corrosion

inhibitors from fuse pin bore. Do

this carefully so that the paint (primer) and cadmium plate are not

damaged. Refer to BSOPM 20-30-

03 as an accepted procedure.

Use caution when cleaning the 

fuse pin. Nicks or scratches can 

cause false crack indications 

during Eddy Current Inspection.

Detailed Inspection

3 Inspect Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Do a Detailed Inspection of the 

fuse pin inner and outer surfaces 

for any crack and any corrosion.

Light corrosion is characterized by 

discoloration or pitting that can be 

removed by hand sanding with a 

fine abrasive material.

Heavy corrosion is corrosion that 

cannot be removed by hand 

sanding with a fine abrasive 

material.

(SHEET 3 OF 4)
 FIGURE 3: ON WING MIDSPAR FUSE PIN INSPECTION

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ALERT ALERT

4 Clean (a) Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Hand sand with a fine abrasive 

material to remove any light 

corrosion from the non-critical 

surfaces, if required. Refer to Table 

2 below for a list of recommended 

light corrosion removal abrasives.

Use caution when cleaning the 

fuse pin. Nicks or scratches can 

cause false crack indications 

during Eddy Current Inspection.

Remove any heavy corrosion from 

the non-critical surfaces, in 

accordance with Appendix A, if 

required.

Eddy Current Inspection [ECI] (a)

5 Inspect Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Do an ECI of the fuse pin bore for 

any crack in accordance with 767 

NDT D634T301, Part 6, Subject 

54-51-01.

Secondary Retention Hardware Installation (a)(b)

6 Install

(Kept)

End cap - 2 Refer to 767 AMM 54-51-04 as an

accepted procedure. Bolt - 2

Washer - 2

Washer - 2

Castellated Nut - 2

Install

(New)

Cotter pin - 2

(a) Not required if any crack is found by Detailed Inspection.

(b) Not required if any crack is found by ECI.

Table 2: RECOMMENDED LIGHT CORROSION REMOVAL ABRASIVES

Backing Material Abrasive Material Recommended Grit Size

Abrasive Paper or Cloth Aluminum Oxide 150 or finer

Silicon Carbide 180 or finer

Fabric or Pad - Fine to Ultrafine

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 4 OF 4)
 FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION

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ALERT ALERT

FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION

A

A

EDDY CURRENT/MAGNETIC PARTICLE INSPECTION 

AREA - FUSE PIN MAIN BORE SURFACE

A-A

LONGITUDINAL CRACK

(EXAMPLE)

FUSE PIN

CROSS SECTION

OFF WING MIDSPAR FUSE PIN INSPECTION AREAS

NON-CRITICAL FUSE PIN

SHANK ENDFACE SURFACE

NON-CRITICAL FUSE PIN

HEAD BEARING SURFACE

FUSE PIN MINOR BORE

DETAILED INSPECTION AREA COVERS ALL INSIDE AND OUTSIDE FUSE PIN SURFACES

EXCEPT THE MINOR BORE.

NON-CRITICAL FUSE

PIN END SURFACE

NON-CRITICAL

CHAMFER SURFACE

NON-CRITICAL FUSE PIN

HEAD EXTERIOR SURFACES

NON-CRITICAL FUSE PIN

HEAD EXTERIOR SURFACES

1 2 3 4

E10317

(SHEET 1 OF 3)
 FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PART NUMBER QTY NOTES

1 Clean Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Remove any grease or corrosion

inhibitors from fuse pin bore. Do

this carefully so that the paint (primer) and cadmium plate are not

damaged. Refer to BSOPM 20-30-

03 as an accepted procedure.

Use caution when cleaning the 

fuse pin. Nicks or scratches can 

cause false crack indications 

during Eddy Current Inspection.

Detailed Inspection

2 Inspect Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Do a Detailed Inspection of the 

fuse pin inner and outer surfaces 

for any crack and any corrosion.

Light corrosion is characterized by 

discoloration or pitting that can be 

removed by hand sanding with a 

fine abrasive material.

Heavy corrosion is corrosion that 

cannot be removed by hand 

sanding with a fine abrasive 

material.

3 Clean Fuse Pin (a) 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Hand sand with a fine abrasive 

material to remove any light 

corrosion from the non-critical 

surfaces, if required. Refer to Table 

3 below for a list of recommended 

light corrosion removal abrasives.

Use caution when cleaning the 

fuse pin. Nicks or scratches can 

cause false crack indications 

during Eddy Current Inspection.

Remove any heavy corrosion from 

the non-critical surfaces, in 

accordance with Appendix A, if 

required.

Eddy Current Inspection (ECI) (a)(b)

(SHEET 2 OF 3)
 FIGURE 4: OFF WING MIDSPAR FUSE PIN INSPECTION

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ALERT ALERT

4 Inspect Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Do an ECI of the fuse pin for any 

crack in accordance with 767 NDT 

D634T301, Part 6, Subject 54-51-

01.

Optional to do a Magnetic Particle 

Inspection [MPI] of the fuse pin for 

any crack, in accordance with 

Figure 6.

(a) Not required if any crack is found by detailed inspection.

(b) MPI in accordance with Figure 6 is optional to the ECI, for fuse pin that is Off Wing.

Table 3: RECOMMENDED LIGHT CORROSION REMOVAL ABRASIVES

Backing Material Abrasive Material Recommended Grit Size

Abrasive Paper or Cloth Aluminum Oxide 150 or finer

Silicon Carbide 180 or finer

Fabric or Pad - Fine to Ultrafine

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 3 OF 3)
 FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT

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ALERT ALERT

FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT

PIN

1 2

1 2

1 2

1 2

1 2

1 4

1 2

1 2

1 2

1 2

DETAIL I

SEE

(2 LOCATIONS)

DETAIL I

TYPICAL MIDSPAR FITTING

WASHER END CAP

COTTER

NUT

CASTELLATED

FITTING

MIDSPAR

FUSE PIN

FITTING

WING

DETAIL I

SEE

BOLT

WASHER

SELF-LOCKING NUT

WASHER

WASHER

FWD

UP

E10319

(SHEET 1 OF 2)
 FIGURE 5: MIDSPAR FUSE PIN REPLACEMENT

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME IDENTIFICATIONQTY NOTES

1 Remove Fuse Pin - 1 and secondary retention hardware, if required. Refer

to 767 AMM 54-51-04 as an accepted procedure.

2 Install

New, Repaired, or

Serviceable

Fuse Pin Group 1 and 2

Airplanes:

311T3102-1 

(311T3102-3 

optional)

1 and secondary retention hardware. Refer to 767

AMM 54-51-04 as an accepted procedure.

Group 3 and 4

Airplanes:

311T3102-2 

(311T3102-4 

optional)

Group 5, 6 and 7

Airplanes:

311T2102-1 

(311T2102-2 

optional)

(SHEET 2 OF 2)
 FIGURE 6: OFF WING MIDSPAR FUSE PIN MAGNETIC PARTICLE INSPECTION

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

FIGURE 6: OFF WING MIDSPAR FUSE PIN MAGNETIC PARTICLE INSPECTION

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PART NUMBER QTY NOTES

1 Clean Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Remove primer and cadmium plate

from fuse pin, if necessary. Refer to

BSOPM 20-30-02 as an accepted

procedure.

2 Inspect Fuse Pin 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

OR

311T2102-1

(311T2102-2 optional)

2 Do a Magnetic Particle Inspection 

of the fuse pin for any crack. Refer 

to BSOPM 20-20-01 as an 

accepted procedure.

1 2

E10564

(SHEET 1 OF 1)
 FIGURE 7: MIDSPAR FUSE PIN FINISH RESTORATION

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BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

FIGURE 7: MIDSPAR FUSE PIN FINISH RESTORATION

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PART NUMBER QTY NOTES

1 Apply Cadmium Plate 311T3102-1

(311T3102-3 optional)

OR

311T3102-2

(311T3102-4 optional)

- to any area of the fuse pin where 

the existing cadmium plate was 

removed. Refer to 767 CMM 54-

50-21 Repair 7-1 as an accepted 

procedure. (a)

311T2102-1

(311T2102-2 optional)

to any area of the fuse pin where 

the existing cadmium plate was 

removed. Refer to 767 CMM 54-

50-21 Repair 22-1 as an accepted 

procedure. (a)

2 Apply Primer BMS 10-11, Type 1 - Apply two coats to any area of the 

fuse pin where the existing primer 

was removed. (b) 

(a) This step is not required if the cadmium plate was not removed from the fuse pin.

(b) This step is not required if the primer was not removed from the fuse pin.

1 2

1844041

(SHEET 1 OF 1)
 APPENDIX A: APPROVED REPAIRS

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ALERT ALERT

APPENDIX A: APPROVED REPAIRS

Heavy corrosion is corrosion that cannot be removed by hand sanding with one of the abrasives listed in Table 

4 below. The following repairs are approved for removal of heavy corrosion from the non-critical midspar fuse 

pin surfaces.

1. MIDSPAR FUSE PIN 311T2102-1, -2 HEAVY CORROSION REPAIR

Table 4: RECOMMENDED LIGHT CORROSION REMOVAL ABRASIVES

Backing Material Abrasive Material Recommended Grit Size

Abrasive Paper or Cloth Aluminum Oxide 150 or finer

Silicon Carbide 180 or finer

Fabric or Pad - Fine to Ultrafine
 APPENDIX A: APPROVED REPAIRS

Original Issue: April 14, 1994

Revision 6: November 05, 2009 767-54A0062

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 66

BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

This repair is for Midspar Fuse Pin 311T2102-1 or -2 with heavy corrosion on a non-critical fuse pin surface.

A 0.005

-B-

-AA

A

A-A

32

32

32

32

31°

29°

0.260

0.240

0.881

0.871 DIA.

0.080

0.020 R

(BOTH ENDS)

0.120

0.060 X 15° CHAMFER

0.08

0.02 R

0.250

0.230

3.655

3.640

0.135

0.115

32

5.070

5.050

CHAMFER 45° TO 

DEPTH OF THREAD

(NON-CRITICAL 

SURFACE)

NON-CRITICAL

FUSE PIN HEAD

EXTERIOR

SURFACES

NON-CRITICAL

FUSE PIN HEAD

EXTERIOR

SURFACES

46°

44°

1.210

1.190 DIA.

NON-CRITICAL FUSE

PIN HEAD BEARING

SURFACE

NON-CRITICAL FUSE

PIN SHANK ENDFACE

SURFACE

NON-CRITICAL 

FUSE PIN END

SURFACE

2.59

2.53 DIA.

2.19

2.13 DIA.

ADD HEAT TREAT, BATCH NUMBER AND RC

MARKINGS IN THIS AREA (IF REQUIRED)

1/8 HIGH LETTERS

PART MARK 1/8 HIGH

LETTERS IN THIS

AREA (IF REQUIRED)

0.040

0.020

CHAMFER

X 45°

SEE A

A

1852641
 APPENDIX A: APPROVED REPAIRS

Original Issue: April 14, 1994

Revision 6: November 05, 2009 767-54A0062

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 66

BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

NOTE: The fuse pin Part Number, Heat Treat, Batch Number and Rc markings are located on a noncritical surface of the fuse pin head, as indicated above. Heavy corrosion repair on this surface

may cause these markings to become unreadable. Make sure not to lose these markings during

fuse pin repair. 

— Machine the fuse pin as required to ensure complete removal of corrosion. The maximum allowable 

material removal depth for this repair is either 0.025 inch or the minimum applicable dimension shown 

in the figure above, whichever is less. Refer to Boeing Standard Overhaul Practices Manual (BSOPM) 

20-10-02 as an accepted procedure. The fuse pin material is either 4330M or 4340 steel, 33 Rc max.

NOTE: If removal of the maximum allowable material does not completely remove corrosion, the fuse 

pin is not serviceable.

— Do a Detailed Inspection of the reworked surfaces, to make sure corrosion is completely removed.

— Do a Magnetic Particle Inspection of the reworked surfaces for any crack. Refer to BSOPM 20-20-01 

as an accepted procedure. If any crack is found, the fuse pin is not serviceable. 

— Shotpeen the reworked surfaces: Shot Size 230-400, Intensity 0.016A, Coverage 1.0. Refer to 

BSOPM 20-10-03 as an accepted procedure.

— Vibroscribe or steel stamp the fuse pin Part Number in the indicated area, if required. 

— Part Mark the fuse pin Heat Treat, Batch Number and Rc info in the area shown, if required. Refer to 

BSOPM 20-50-10 as an accepted procedure.

— Refinish the reworked surfaces. Refer to 767 Component Maintenance Manual (CMM) 54-50-21, 

Repair 22-1 as an accepted procedure.

2. MIDSPAR FUSE PIN 311T3102-1, -2, -3, -4 HEAVY CORROSION REPAIR
 APPENDIX A: APPROVED REPAIRS

Original Issue: April 14, 1994

Revision 6: November 05, 2009 767-54A0062

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 66

BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

This repair is for Midspar Fuse Pin 311T3102-1, -2, -3 or -4 with heavy corrosion on a non-critical fuse pin 

surface.

A 0.005

-B-

-AA

A

A-A

-CC .005

32

32

32

32

31°

29°

0.260

0.240

0.881

0.871 DIA.

0.080

0.020 R

(BOTH ENDS)

0.120

0.060 X 15° CHAMFER

0.04

0.02 R

0.322

0.302

3.438

3.423

0.135

0.115

32

4.770

4.750

CHAMFER 45° TO 

DEPTH OF THREAD

(NON-CRITICAL 

SURFACE)

NON-CRITICAL

FUSE PIN HEAD

EXTERIOR

SURFACES

NON-CRITICAL

FUSE PIN HEAD

EXTERIOR

SURFACES

1.210

1.234 DIA.

NON-CRITICAL FUSE

PIN HEAD BEARING

SURFACE

NON-CRITICAL FUSE

PIN SHANK ENDFACE

SURFACE

NON-CRITICAL 

FUSE PIN END

SURFACE

2.59

2.53 DIA.

2.19

2.13 DIA.

ADD HEAT TREAT, BATCH NUMBER AND RC

MARKINGS IN THIS AREA (IF REQUIRED)

1/8 HIGH LETTERS

PART MARK 1/8 HIGH

LETTERS IN THIS

AREA (IF REQUIRED)

0.020

0.000

CHAMFER

X 45°

0.040

0.020

CHAMFER

X 45°

0.3756

0.3750 DIA.

0.040

0.020

CHAMFER

X 45°

0.08

0.02 R

SEE A

A

1852648
 APPENDIX A: APPROVED REPAIRS

Original Issue: April 14, 1994

Revision 6: November 05, 2009 767-54A0062

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 66

BOEING SERVICE BULLETIN 767-54A0062

ALERT ALERT

NOTE: The fuse pin Part Number, Heat Treat, Batch Number and Rc markings are located on a noncritical surface of the fuse pin head, as indicated above. Heavy corrosion repair on this surface

may cause these markings to become unreadable. Make sure not to lose these markings during

fuse pin repair. 

— Machine the fuse pin as required to ensure complete removal of corrosion. The maximum allowable 

material removal depth for this repair is either 0.025 inch or the minimum applicable dimension shown 

in the figure above, whichever is less. Refer to BSOPM 20-10-02 as an accepted procedure. The fuse 

pin material is either 4330M or 4340 steel, 33 Rc max.

NOTE: If removal of the maximum allowable material does not completely remove corrosion, the fuse 

pin is not serviceable.

— Do a Detailed Inspection of the reworked surfaces, to make sure corrosion is completely removed.

— Do a Magnetic Particle Inspection of the reworked surfaces for any crack. Refer to BSOPM 20-20-01 

as an accepted procedure. If any crack is found, the fuse pin is not serviceable. 

— Shotpeen the reworked surfaces: Shot Size 230-400, Intensity 0.016A, Coverage 1.0. Refer to 

BSOPM 20-10-03 as an accepted procedure.

— Vibroscribe or steel stamp the fuse pin Part Number in the indicated area, if required. 

— Part Mark the fuse pin Heat Treat, Batch Number and Rc info in the area shown, if required. Refer to 

BSOPM 20-50-10 as an accepted procedure.

— Refinish the reworked surfaces. Refer to CMM 54-50-21, Repair 7-1 as an accepted procedure.