Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-78-0051

Original Issue: October 23, 2003

Revision 3: August 23, 2012

ATA System: 7811

SUBJECT: EXHAUST (TRENT 800 Series Engines) - Collector/Nozzle - Turbine Exhaust Plug

Assembly - Inspection and Retrofit

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2003 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, DreamlinerTM,

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 Boeing

liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection

with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management

Company.

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BLANK PAGE
Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 25

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 28

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 31

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY - NUTPLATE REMOVAL AND HOLE INSPECTION

PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

FIGURE 2: TURBINE EXHAUST PLUG ASSEMBLY HOLES - GENERAL VISUAL INSPECTION . . 41

FIGURE 3: IDENTIFICATION TAG - DEEP ETCH MARK . . . . . . . . . . . . . . . . . . . . . . . . 42

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER

BOLTS WITH 1/4 INCH DIAMETER BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . 43

FIGURE 5: TURBINE EXHAUST PLUG ASSEMBLY BOLTS - GENERAL VISUAL INSPECTION [Group

1, Configuration 2-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIGURE 6: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL REMAINING 3/16 INCH

DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS . . . . . . . . . . . . . . . . . . 51

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BOEING SERVICE BULLETIN 777-78-0051
FIGURE 7: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD PLUG, 1/4 INCH DIAMETER NUTPLATE

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

FIGURE 8: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD AND AFT PLUG IDENTIFICATION TAG

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

FIGURE 9: TURBINE EXHAUST PLUG ASSEMBLY - INSTALLATION . . . . . . . . . . . . . . . . 60

APPENDIX A: 'WEDGELOCK' FASTENER INSTALLATION PROCESS FOR THE REPLACEMENT OF ALL

33 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS . . . . . . . . . . 62

APPENDIX B: 'WEDGELOCK' AND TEMPORARY FASTENER INSTALLATION PROCESS FOR THE

REPLACEMENT OF ALL REMAINING 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH

DIAMETER BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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BOEING SERVICE BULLETIN 777-78-0051
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 777-78-0051

Original Issue: October 23, 2003

Revision 3: August 23, 2012

ATA System: 7811

SUBJECT: EXHAUST (TRENT 800 Series Engines) - Collector/Nozzle - Turbine Exhaust Plug

Assembly - Inspection and Retrofit

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on the airplane(s) changed in accordance with the Original Issue, Revision 1 or Revision

2 of this service bulletin.

Airplanes identified as Group 1 Configuration 3, that have done Revision 1 or Revision 2 of this service bulletin,

must do a general visual inspection of the fasteners that attach the forward and aft plugs of the turbine exhaust

plug assembly together of each engine, to identify if 3/16 inch diameter and/or 1/4 inch diameter bolts are used

and, if necessary, install a serviceable turbine exhaust plug assembly with 1/4 inch diameter bolts at all 33

locations of the forward and aft plug interface.

Airplanes identified as Group 1 Configuration 2, that have done the Original Issue, but not Revision 1 or Revision

2 of this service bulletin, must do a general visual inspection of the fasteners that attach the forward and aft

plugs of the turbine exhaust plug assembly together of each engine, to identify if 3/16 inch diameter and/or 1/4

inch diameter bolts are used and, if necessary, install a serviceable turbine exhaust plug assembly with 1/4 inch

diameter bolts at all 33 locations of the forward and aft plug interface. Additionally, if only 1/4 inch diameter bolts

are found installed at all 33 locations, it is recommended that the identification tag on each forward and aft plug

of each turbine exhaust plug assembly of each engine is replaced with one that has the correct post service

bulletin identity.

REASON FOR REVISION

This revision is sent because of misleading instructions in the Original Issue, Revision 1 and Revision 2 of this

service bulletin. As a result, some airplanes could have turbine exhaust plug assemblies with a mix of 1/4 inch

and 3/16 inch diameter bolts used to attach the forward and aft plugs together. After accomplishment of the

change in this service bulletin only 1/4 inch diameter bolts are to be installed at all 33 locations of the forward

and aft plug interface of each turbine exhaust plug assembly, which is the same as the latest production

configuration. Also this revision corrects a post service bulletin identification relationship error for the forward

and aft plug, where the instructions of the Original Issue, Revision 1 and Revision 2 of this service bulletin gave

them the identification intended for the next higher assembly part number.

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These sections are changed:

– Summary Background paragraph and Paragraph 1.C., Reason: Changed to add more in-service data and

correct the intent of this service bulletin to agree with the reason for this revision. Also Boeing Fleet Team

Digest (FTD) reference is added.

– Summary Action paragraph and Paragraph 1.D., Description: Changed to add applicability and the work

necessary related to the reason for this revision.

– Summary Effectivity paragraph: Changed to add spares affected reference.

– Summary Compliance paragraph: Changed to refer to Paragraph 1.E., Compliance and FAA possible AD

information added.

– Summary Manpower paragraph: Changed to refer to Paragraph 1.G., Manpower.

– Summary Material Information paragraph: Changed to refer to Paragraph 2.A., Material - Price and Availability.

– Summary Illustration: Changed to add applicability and the work necessary related to the reason for this

revision.

– Paragraph 1.A.1., Airplanes: Note added related to the installation of spare turbine exhaust plugs

– Paragraph 1.A.2., Spares Affected: Changed to add turbine exhaust plug assembly part numbers and Quick

Engine Change (QEC) kits affected by this service bulletin.

– Paragraph 1.E., Compliance: Changed to give the recommended compliance for the work necessary related

to the reason for this revision. FAA possible AD information added.

– Paragraph 1.G., Manpower: Changed to add estimates for Parts 1 thru 4 and for the forward plug nutplate

replacement of the changed Paragraph 3.B., Work Instructions.

– Paragraph 1.H., Weight and Balance: Data added.

– Paragraph 1.J.1., Existing Data: FTD, AMM, Service Bulletin Index and Service Letter references added.

SRM references corrected. Boeing Drawing reference deleted.

– Paragraph 1.J.3., Installation Drawings Used in the Preparation of this Service Bulletin: Data added.

– Paragraph 1.M., Software Accomplishment Summary: Section added.

– Paragraph 2.A., Material - Price and Availability: ROLT data changed.

– Paragraph 2.C., Kits/Parts: Existing part number data added. Invalid rivet part number MS20427-3M4

corrected to MS20427M3-4.

– Paragraph 2.C.2., Parts and Material Supplied by the Operator: Changed to show parts and materials

necessary for Component Work.

– Paragraph 2.C.3., Parts Modified and Reidentified: Changed to give the corrected turbine exhaust plug

assembly (or 'primary plug assembly') reidentification and to show other related part number data.

– Paragraph 2.D., Parts Necessary to Change Spares: Added part and kit data for Component Work.

– Paragraph 2.E., Special Tooling - Price and Availability: Added data for operator supplied special tools.

– Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin: Added data that was incorrectly

located in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, of the Original Issue, Revision

1 and Revision 2 of this service bulletin.

– Paragraph 3.A., General Information: Notes added and changed.

– Paragraph 3.B., Work Instructions: Changed to add Parts 1 thru 4.

– Figure 1 thru Figure 4: Changed related to Part 2 and 3.

– Figure 5 thru Figure 9: Added related to Part 1, 2 and 4.

– Appendix A and Appendix B: Added related to the installation of 'wedgelocks' and temporary fasteners in

the turbine exhaust plug assembly.

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

of important changes.

Pages with no vertical lines have no important changes.

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BOEING SERVICE BULLETIN 777-78-0051
REVISION HISTORY

Original Issue: October 23, 2003

Revision 1: December 15, 2005

Revision 2: February 18, 2010

Revision 3: August 23, 2012

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Summary Number: 777-78-0051

Original Issue: October 23, 2003

Revision 3: August 23, 2012

ATA System: 7811

SUBJECT: EXHAUST (TRENT 800 Series Engines) - Collector/Nozzle - Turbine Exhaust Plug

Assembly - Inspection and Retrofit

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Accomplishment of this service bulletin will make sure the integrity of the interface is kept between the forward

plug and the aft plug of the turbine exhaust plug assembly to prevent separation occurrences. The aft plug can

come off during a separation occurrence which could result in a potential hazard to persons on the ground or

damage to the airplane.

Boeing has had three reports of in-flight separations of the aft plug from the forward plug, which are the two

parts of the turbine exhaust plug assembly. Subsequent to the first report where the separation occurred during

takeoff, an investigation showed that some of the interface bolts were found loose or missing. The turbine exhaust

plug assembly was sent back to Boeing for analysis and it was found that the remaining bolts had less than the

necessary minimum run-on torque value. It was also found that the operator of the analyzed turbine exhaust

plug assembly had disassembled it a minimum of three times during maintenance actions. Repeated assembly

and disassembly causes the locking property of the nut on the nutplates to wear out and subsequently let the

bolts become loose or removed in-service.

This service bulletin gives instructions to do a general visual inspection of the forward and aft plug interface

fasteners and holes of the turbine exhaust plug assembly of each engine and install 1/4 inch diameter bolts at

all 33 locations.

Boeing Service Related Problem (SRP) 777-SRP-78-0071 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 777 FTD 78-01002 is related to this service bulletin.

ACTION (PRR 62039)

Group 1, Configuration 1:

Part 1 - Turbine Exhaust Plug - Airplane Work

1. Install a serviceable turbine exhaust plug assembly on each engine with 1/4 inch diameter bolts at all

33 locations of the forward and aft plug interface.

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NOTE: A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 3, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

Group 1, Configuration 2-3:

Part 1 - Turbine Exhaust Plug - Airplane Work

1. Do a general visual inspection of the 33 bolt locations of the forward and aft plug interface of each

turbine exhaust plug assembly of each engine.

2. If only 3/16 inch diameter bolts are found used, or if a mix of 3/16 inch and 1/4 inch diameter bolts are

found used, install a serviceable turbine exhaust plug assembly on each engine with 1/4 inch diameter

bolts at all 33 locations of the forward and aft plug interface.

NOTE: A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 2 or 3, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

3. For Group 1 Configuration 2 airplanes only, if only 1/4 inch diameter bolts are found installed at all 33

locations, reidentify turbine exhaust plug assembly in accordance with Part 4.

Part 2 - Replacement Of All Remaining 3/16 Inch Diameter Bolts With 1/4 Inch Diameter Bolts -

Component Work: 314W5520-1; 314W5521-1

1. Remove the nutplates of 3/16 inch diameter bolts from the forward plug holes that interface with the

aft plug.

2. Do a general visual inspection of the 33 holes for damage.

3. Ream the damaged hole(s) to remove damage and/or increase the diameter of all 33 holes to 1/4 inch

or all remaining 3/16 inch diameter holes to 1/4 inch. Install new nutplates for 1/4 inch diameter bolts

at all 33 locations or at all remaining locations.

4. For each component identified with part number 314W5520-1, reidentify the turbine exhaust plug

assembly in accordance with Part 4.

5. For each component identified with part number 314W5521-1, no turbine exhaust plug assembly

reidentification is necessary.

Part 3 - Replacement Of All 33 3/16 Inch Diameter Bolts With 1/4 Inch Diameter Bolts - Component

Work: 314W5520-15, -19; 314W5520-1; 314W5521-1

1. Remove the nutplates of the 33 3/16 inch diameter bolts from the forward plug holes that interface with

the aft plug.

2. Do a general visual inspection of the 33 holes for damage.

3. Ream the damaged hole(s) to remove damage and increase diameter of all 33 holes to 1/4 inch. Install

new nutplates for 1/4 inch diameter bolts at all 33 locations.

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BOEING SERVICE BULLETIN 777-78-0051
4. For each component identified with part number 314W5520-15, 19, part mark and install identification

tags on the forward and aft plugs to reidentify the turbine exhaust plug assembly.

5. For each component identified with part number 314W5520-1, reidentify the turbine exhaust plug

assembly in accordance with Part 4.

6. For each component identified with part number 314W5521-1, no turbine exhaust plug assembly

reidentification is necessary.

Part 4 - Reidentification of the Turbine Exhaust Plug Assembly - Component Work: 314W5520-1

1. Remove the tags that have an incorrect part number identification.

2. Deep etch mark replacement identification tags and install one on the forward and aft plug.

EFFECTIVITY

777-200/300 airplanes powered by Rolls-Royce Trent 800 Series Engines. Refer to Paragraph 1.A.1., Airplanes,

for the list of affected airplanes.

Refer to Paragraph 1.A.2., Spares Affected for the list of affected components.

COMPLIANCE

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

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

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing and Operator Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN 777-78-0051
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-78-0051

Original Issue: October 23, 2003

Revision 3: August 23, 2012

ATA System: 7811

SUBJECT: EXHAUST (TRENT 800 Series Engines) - Collector/Nozzle - Turbine Exhaust Plug

Assembly - Inspection and Retrofit

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent

production airplanes. Refer to PRR 62039 for data about this change.

NOTE: The airplanes shown below had the configuration of turbine exhaust plug assemblies

described in this service bulletin on their engines at delivery. Installation of spare turbine

exhaust plug assemblies since delivery could put this configuration on engines of airplanes

not shown in the effectivity below. Check your records to make sure the change in

accordance with this service bulletin is accomplished on applicable turbine exhaust plug

assemblies.

GROUP CONFIGURATION DESCRIPTION

777-200/300 airplanes powered by Trent 800 engines before line

position 470.

1 -

That have not done the Original Issue, Revision 1 or Revision 2 of

this service bulletin

1

That have done the Original Issue, but not Revision 1 or Revision 2

of this service bulletin

2

3 That have done Revision 1 or Revision 2 of this service bulletin

Airplane Models:

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777-200, 777-300

Variable Number Group

WA001 1

WA086 - WA093 1

WA101 - WA104 1

WA196 - WA198 1

WB031 - WB046 1

WB101 - WB106 1

WB161 - WB175 1

WB181 - WB192 1

WB201 - WB214 1

WB231 - WB247 1

WB416 - WB437 1

WB446 - WB453 1

WB501 - WB509 1

WB601 - WB606 1

WB611 - WB618 1

WB631 - WB638 1

WB646 - WB649 1

WC051 - WC073 1

WC101 - WC104 1

2. Spares Affected

Examine your Quick Engine Change (QEC) kits for parts or components changed as shown in this

service bulletin. If any parts or components are found, refer to Paragraph 2.C., Parts Necessary

for Each Airplane, for the recommended use.

Serial Number or

Dash Number

Part Number

C0028, C0029, C0030,

C0031, C0032, C0041,

C0042, C0045, C5001,

C0049, C0050

654W0003-62

654W0003-3 C0001, C0002

654W0003-46 C0052

654W0003-68 C0034, C0035

654W0003-73 C0043

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BOEING SERVICE BULLETIN 777-78-0051
Serial Number or

Dash Number

Part Number

654W0003-18 C0003, C0004

654W0003-37 C0020

654W0003-81 C0051

654W0003-30 C0012

C0013, C0014, C0015,

C0016, C0017

654W0003-23

654W0003-24 C0033

654W0003-12 C0005, C0006, C0007

654W0003-55 C0027

654W0003-57 C0036, C0039

QECRR777 -3, -4

Examine your spares supply for the parts or components identified below. If any parts or components

are found, refer to Paragraph 3.B., Work Instructions for the recommended action.

Part Number

314W5520-15

314W5520-19

314W5520-1 (a)

(a) Existing part number 314W5520-1 could also exist

because of the instructions in the Original Issue

of this service bulletin. But part number 314W5520-

1 is incorrect as the post service bulletin identity.

B. Concurrent Requirements

None.

C. Reason

Accomplishment of this service bulletin will make sure the integrity of the interface is kept between the

forward plug and the aft plug of the turbine exhaust plug assembly to prevent separation occurrences.

The aft plug can come off during a separation occurrence which could result in a potential hazard to

persons on the ground or damage to the airplane.

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BOEING SERVICE BULLETIN 777-78-0051
Boeing has had three reports of in-flight separations of the aft plug from the forward plug, which are

the two parts of the turbine exhaust plug assembly. Subsequent to the first report where the separation

occurred during takeoff, an investigation showed that some of the interface bolts were found loose or

missing. The turbine exhaust plug assembly was sent back to Boeing for analysis and it was found that

the remaining bolts had less than the necessary minimum run-on torque value. It was also found that

the operator of the analyzed turbine exhaust plug assembly had disassembled it a minimum of three

times during maintenance actions. Repeated assembly and disassembly causes the locking property

of the nut on the nutplates to wear out and subsequently let the bolts become loose or removed

in-service.

This service bulletin gives instructions to do a general visual inspection of the forward and aft plug

interface fasteners and holes of the turbine exhaust plug assembly of each engine and install 1/4 inch

diameter bolts at all 33 locations.

Boeing Service Related Problem (SRP) 777-SRP-78-0071 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 777 FTD 78-01002 is related to this service bulletin.

Revision 1 was sent to tell operators that the assembly number shown on the identification tag was

incorrect in Figure 3. This revision changes the assembly number shown on the identity tag from

314W5520-1 to 314W5521-1. This revision also corrects the spelling of the word "Separate," on the

identification tag, and in the table of Figure 3. Airplane WB510, line 470, was deleted from this service

bulletin effectivity. It was included in error.

Revision 2 was sent to change the classification of the service bulletin from Standard to Special Attention

and to add a compliance recommendation. Revision 2 also corrected a typographical error, adds

damage tolerance data and adds maintenance zone data.

Revision 3 is sent because of misleading instructions in the Original Issue, Revision 1 and Revision 2

of this service bulletin. As a result, some airplanes could have turbine exhaust plug assemblies with a

mix of 1/4 inch and 3/16 inch diameter bolts used to attach the forward and aft plugs together. After

accomplishment of the change in this service bulletin only 1/4 inch diameter bolts are to be installed

at all 33 locations of the forward and aft plug interface of each turbine exhaust plug assembly, which

is the same as the latest production configuration. Also this revision corrects a post service bulletin

identification relationship error for the forward and aft plug, where the instructions of the Original Issue,

Revision 1 and Revision 2 of this service bulletin gave them the identification intended for the next

higher assembly part number.

D. Description

Group 1, Configuration 1:

Part 1 - Turbine Exhaust Plug - Airplane Work

1. Install a serviceable turbine exhaust plug assembly on each engine with 1/4 inch diameter bolts

at all 33 locations of the forward and aft plug interface.

NOTE: A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 3, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

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Group 1, Configuration 2-3:

Part 1 - Turbine Exhaust Plug - Airplane Work

1. Do a general visual inspection of the 33 bolt locations of the forward and aft plug interface of each

turbine exhaust plug assembly of each engine.

2. If only 3/16 inch diameter bolts are found used, or if a mix of 3/16 inch and 1/4 inch diameter bolts

are found used, install a serviceable turbine exhaust plug assembly on each engine with 1/4 inch

diameter bolts at all 33 locations of the forward and aft plug interface.

NOTE: A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 2 or 3, or it can be a spare turbine

exhaust plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new

turbine exhaust plug assembly, with part number 314W5520-22.

3. For Group 1 Configuration 2 airplanes only, if only 1/4 inch diameter bolts are found installed at

all 33 locations, reidentify turbine exhaust plug assembly in accordance with Part 4.

Part 2 - Replacement Of All Remaining 3/16 Inch Diameter Bolts With 1/4 Inch Diameter Bolts -

Component Work: 314W5520-1; 314W5521-1

1. Remove the nutplates of 3/16 inch diameter bolts from the forward plug holes that interface with

the aft plug.

2. Do a general visual inspection of the 33 holes for damage.

3. Ream the damaged hole(s) to remove damage and/or increase the diameter of all 33 holes to 1/4

inch or all remaining 3/16 inch diameter holes to 1/4 inch. Install new nutplates for 1/4 inch diameter

bolts at all 33 locations or at all remaining locations.

4. For each component identified with part number 314W5520-1, reidentify the turbine exhaust plug

assembly in accordance with Part 4.

5. For each component identified with part number 314W5521-1, no turbine exhaust plug assembly

reidentification is necessary.

Part 3 - Replacement Of All 33 3/16 Inch Diameter Bolts With 1/4 Inch Diameter Bolts - Component

Work: 314W5520-15, -19; 314W5520-1; 314W5521-1

1. Remove the nutplates of the 33 3/16 inch diameter bolts from the forward plug holes that interface

with the aft plug.

2. Do a general visual inspection of the 33 holes for damage.

3. Ream the damaged hole(s) to remove damage and increase diameter of all 33 holes to 1/4 inch.

Install new nutplates for 1/4 inch diameter bolts at all 33 locations.

4. For each component identified with part number 314W5520-15, 19, part mark and install

identification tags on the forward and aft plugs to reidentify the turbine exhaust plug assembly.

5. For each component identified with part number 314W5520-1, reidentify the turbine exhaust plug

assembly in accordance with Part 4.

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6. For each component identified with part number 314W5521-1, no turbine exhaust plug assembly

reidentification is necessary.

Part 4 - Reidentification of the Turbine Exhaust Plug Assembly - Component Work: 314W5520-1

1. Remove the tags that have an incorrect part number identification.

2. Deep etch mark replacement identification tags and install one on the forward and aft plug.

Revision 1 - More work was necessary on airplanes changed as shown in the initial release of this

service bulletin. Identification tags with the incorrect assembly number should be corrected when

manpower and facilities are available.

Revision 2 - No more work was necessary on airplanes changed in accordance with Revision 1 of this

service bulletin.

Revision 3 - More work is necessary on the airplane(s) changed in accordance with the Original Issue,

Revision 1 or Revision 2 of this service bulletin.

– Airplanes identified as Group 1 Configuration 3, that have done Revision 1 or Revision 2 of this

service bulletin, must do a general visual inspection of the fasteners that attach the forward and

aft plugs of the turbine exhaust plug assembly together of each engine, to identify if 3/16 inch

diameter and/or 1/4 inch diameter bolts are used and, if necessary, install a serviceable turbine

exhaust plug assembly with 1/4 inch diameter bolts at all 33 locations of the forward and aft plug

interface.

– Airplanes identified as Group 1 Configuration 2, that have done the Original Issue, but not Revision

1 or Revision 2 of this service bulletin, must do a general visual inspection of the fasteners that

attach the forward and aft plugs of the turbine exhaust plug assembly together of each engine, to

identify if 3/16 inch diameter and/or 1/4 inch diameter bolts are used and, if necessary, install a

serviceable turbine exhaust plug assembly with 1/4 inch diameter bolts at all 33 locations of the

forward and aft plug interface. Additionally, if only 1/4 inch diameter bolts are found installed at all

33 locations, it is recommended that the identification tag on each forward and aft plug of each

turbine exhaust plug assembly of each engine is replaced with one that has the correct post service

bulletin identity.

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones

Model Zone

777-200, 777-300 419, 429

E. Compliance

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

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

service bulletin mandatory.

Accomplish the required action(s), based on the applicable condition(s), in Table(s) 1 thru 3, in

accordance with Paragraph 3. Accomplishment Instructions.

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BOEING SERVICE BULLETIN 777-78-0051
Group 1, Configuration 1:

Table 1: Turbine Exhaust Plug Assembly - Replacement Of All 33 3/16 Inch Diameter Bolts With

1/4 Inch Diameter Bolts

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 60 months -

after the Revision

3 date of this service bulletin.

Install a serviceable turbine exhaust plug assembly on each engine with

1/4 inch diameter bolts at

all 33 locations of the forward and aft plug interface in accordance with

Paragraph 3.B., Work Instructions, Part 1, Step

2.b. (a)

All airplanes

(a) A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 3, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

Group 1, Configuration 2:

Table 2: Turbine Exhaust Plug Assembly - General Visual Inspection of Bolts

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 60 months -

after the Revision

3 date of this service bulletin.

Do a general visual inspection of all 33 bolt locations of each turbine exhaust plug assembly in

accordance with Paragraph 3.B., Work Instructions, Part 1, Step 3., to

identify if 3/16 inch and/or

1/4 inch diameters are

used at the forward and

aft plug interface.

All Airplanes

Before further -

flight.

Install a serviceable turbine exhaust plug assembly on each engine with

1/4 inch diameter bolts at

all 33 locations of the forward and aft plug interface in accordance with

Paragraph 3.B., Work Instructions, Part 1, Step

3.a.(2). (a)

Only 3/16 inch diameter

bolts are found used at all

33 locations of the forward

and aft plug interface.

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BOEING SERVICE BULLETIN 777-78-0051
Group 1, Configuration 2:

Table 2: Turbine Exhaust Plug Assembly - General Visual Inspection of Bolts

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Install a serviceable turbine exhaust plug assembly on each engine with

1/4 inch diameter bolts at

all 33 locations of the forward and aft plug interface in accordance with

Paragraph 3.B., Work Instructions, Part 1, Step

3.b.(2). (b)

A mix of 3/16 and 1/4 inch

diameter bolts are found

used at the 33 locations of

the forward and aft plug interface.

Reidentify the forward None. -

and aft plug in accordance with Paragraph

3.B., Work Instructions,

Part 4, Step 1 and 2.

Only 1/4 inch diameter

bolts are found installed at

all 33 locations forward and

aft plug interface.

(a) A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 3, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

(b) A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 2, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

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BOEING SERVICE BULLETIN 777-78-0051
Group 1, Configuration 3:

Table 3: Turbine Exhaust Plug Assembly - General Visual Inspection of Bolts

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 60 months -

after the Revision

3 date of this service bulletin.

Do a general visual inspection all 33 bolt locations of each turbine exhaust plug assembly in

accordance with Paragraph 3.B., Work Instructions, Part 1, Step 3., to

identify if 3/16 inch and/or

1/4 inch diameters are

used at the forward and

aft plug interface.

All Airplanes

Before further -

flight.

Install a serviceable turbine exhaust plug assembly on each engine with

1/4 inch diameter bolts at

all 33 locations of the forward and aft plug interface in accordance with

Paragraph 3.B., Work Instructions, Part 1, Step

3.a.(2). (a)

Only 3/16 inch diameter

bolts are found used at all

33 locations of the forward

and aft plug interface.

Before further -

flight.

Install a serviceable turbine exhaust plug assembly on each engine with

1/4 inch diameter bolts at

all 33 locations of the forward and aft plug interface in accordance with

Paragraph 3.B., Work Instructions, Part 1, Step

3.b.(2). (b)

A mix of 3/16 and 1/4 inch

diameter bolts are found

used at the 33 locations of

the forward and aft plug interface.

Only 1/4 inch diameter None. - -

bolts are found installed at

all 33 locations forward and

aft plug interface.

(a) A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 3, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

(b) A serviceable turbine exhaust plug assembly can be one that is removed from the airplane

and subsequently changed in accordance with Part 2, or it can be a spare turbine exhaust

plug assembly that is changed in accordance with Part 2 or 3. Or it can be a new turbine

exhaust plug assembly, with part number 314W5520-22.

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BOEING SERVICE BULLETIN 777-78-0051
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.

G. Manpower

The tables below show an estimate of the task-hours necessary to do this service bulletin for each

engine. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with

operator task-hour data if necessary. The estimate does not include lost time. These are some examples

of lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Group 1, Configuration 1:

Part 1 - Airplane Work

Task Number of Persons Task Hours Elapsed Hours

Deactivate Thrust 1 1.00 1.00

Reverser

Remove Turbine Ex- 2 1.25 0.63

haust Plug Assembly

FIGURE 9 (a) 2 1.25 0.63

Activate Thrust Re- 1 1.00 1.00

verser

TOTAL FOR EACH ENGINE 4.50 3.25

(a) This estimate does not include the time to replace nutplates in accordance

with FIGURE 7, if necessary.

Group 1, Configuration 2-3:

Part 1 - Airplane Work

Task Number of Persons Task Hours Elapsed Hours

Deactivate Thrust 1 1.00 1.00

Reverser

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Group 1, Configuration 2-3:

Part 1 - Airplane Work

Task Number of Persons Task Hours Elapsed Hours

FIGURE 5 1 1.80 1.80

Remove Turbine Ex- 2 1.25 0.63

haust Plug Assembly

FIGURE 9 (a) 2 1.25 0.63

Activate Thrust Re- 1 1.00 1.00

verser

TOTAL FOR EACH ENGINE 5.30 4.05

(a) This estimate does not include the time to replace nutplates in accordance

with FIGURE 7, if necessary.

Part 2 - Component Work: 314W5520-1

Task Number of Persons Task Hours Elapsed Hours

FIGURE 1 2 8.00 4.00

FIGURE 2 1 1.80 1.80

FIGURE 6 (a) 2 4.70 2.35

FIGURE 3 1 0.25 0.25

FIGURE 8 1 0.60 0.60

TOTAL FOR EACH ENGINE 15.35 9.00

(a) This estimate is the maximum time necessary, which assumes there is a

minimum of 1 1/4 inch diameter bolt installed and the remaining 32 3/16 inch

diameter bolts are to be replaced with 1/4 inch diameter bolts.

Part 2 - Component Work: 314W5521-1

Task Number of Persons Task Hours Elapsed Hours

FIGURE 1 2 8.00 4.00

FIGURE 2 1 1.80 1.80

FIGURE 6 (a) 2 4.70 2.35

TOTAL FOR EACH ENGINE 14.50 8.15

(a) This estimate is the maximum time necessary, which assumes there is a

minimum of 1 1/4 inch diameter bolt installed and the remaining 32 3/16 inch

diameter bolts are to be replaced with 1/4 inch diameter bolts.

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Part 3 - Component Work: 314W5520-15, -19

Task Number of Persons Task Hours Elapsed Hours

FIGURE 1 2 8.00 4.00

FIGURE 2 1 1.80 1.80

FIGURE 3 1 0.25 0.25

FIGURE 4 2 6.00 3.00

TOTAL FOR EACH ENGINE 16.05 9.05

Part 3 - Component Work: 314W5520-1; 314W5521-1

Task Number of Persons Task Hours Elapsed Hours

FIGURE 1 2 8.00 4.00

FIGURE 2 1 1.80 1.80

FIGURE 4 (a) 2 6.00 3.00

TOTAL FOR EACH ENGINE 15.80 8.80

(a) The time to do this task will be less than the estimate values, as they include

identification tag installation work which is not necessary in this task for turbine

exhaust plug assemblies identified with part number 314W5520-1 and

314W5521-1.

Part 4 - Component Work: 314W5520-1

Task Number of Persons Task Hours Elapsed Hours

FIGURE 3 1 0.25 0.25

FIGURE 8 1 0.60 0.60

TOTAL FOR EACH ENGINE 0.85 0.85

Turbine Exhaust Plug Assembly, Forward Plug Nutplate Replacement

Task Number of Persons Task Hours Elapsed Hours

FIGURE 7 1 0.20 0.20

TOTAL FOR EACH NUTPLATE 0.20 0.20

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BOEING SERVICE BULLETIN 777-78-0051
H. Weight and Balance Changes

Left and Right Engine Turbine Exhaust Plug Assemblies Changed to have All 1/4

Inch Diameter Bolts at their Forward and Aft Plug Interface

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

All + 0.2 + 189.5

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 62039.

b. Boeing Service Letter 777-SL-51-013.

c. Boeing Service Related Problem (SRP) 777-SRP-78-0071.

d. Service Bulletin Index D624W001.

e. Boeing Standard Overhaul Practices Manual (SOPM) 20-10-07, 20-50-10.

f. 777 Aircraft Maintenance Manual (AMM) 78-11-02, 78-31-00.

g. 777 Fleet Team Digest (FTD) 777 FTD 78-01002.

h. 777-200 Structural Repair Manual (SRM) 51-30-01, 51-40-02, 54-42-30.

i. 777-300 Structural Repair Manual (SRM) 51-30-01, 51-40-02, 54-42-30.

2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

RR AFT EXHAUST PLUG ATTACHMENT INTERFACE, REPAIR

AND RETROFIT

314W5521

The table above lists applicable drawings used to prepare this service bulletin. The drawings are

not necessary to make the specified changes, and are not supplied with this service bulletin. The

drawings may not be applicable to all airplane configurations or operators.

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BOEING SERVICE BULLETIN 777-78-0051
K. Publications Affected

1. Publications:

Publication Chapter-Section

777 Illustrated Parts Catalog 78-11

Component Maintenance Manual 78-11

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 does not affect FCS, therefore DTIs are not necessary.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary

Not affected.

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BOEING SERVICE BULLETIN 777-78-0051
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane and Paragraph

2.D., Parts Necessary to Change Spares . Operators are encouraged to share schedule requirements

with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of

the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net

30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

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

2. Fax to (206) 662-7145

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the Revision 02

date of this Service Bulletin (US

Dollars)

ROLT as of the

Revision 03 date

of this Service

Bulletin (Calendar

Days)

Kit Number Name

005W3246-1 Top Kit - 777 Airplanes, Trent -800 Powered 567 $7,198

005W3246-2 Subkit, Engine 553 $3,599

B. Industry Support Information

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this

service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts:

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

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by

the Operator , as applicable, are necessary for each airplane.

Part 3 - Component Work: 314W5520-15, -19

Kit 005W3246

Existing Part Notes

Number

New Part Number QTY Name

-2 -1

005W3246-1 . - Top Kit, Airplane

005W3246-2 - 2 Subkit, Engine

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BOEING SERVICE BULLETIN 777-78-0051
Part 3 - Component Work: 314W5520-15, -19

Kit 005W3246

Existing Part Notes

Number

New Part Number QTY Name

-2 -1

314W5520-23 2 . Identification Tag

BACB30UU4-1 33 . Bolt (a)

BACN11G4DE1F 33 . Nutplate, Self-Locking BACN11G3AE1F

MS20427M3-4 66 . Rivet (a)

MS20615-4M3 6 . Rivet (a)

(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one

grip length longer than indicated. Also, if any fasteners part numbers listed are not

available or have been superseded, substitute fasteners may be supplied in kits.

2. Parts and Materials Supplied by the Operator:

The following parts or materials are necessary to do the change in this service bulletin. Parts and

materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine

operator part and material supply to make sure all necessary parts and materials are available.

Part 2 - Component Work: 314W5520-1; 314W5521-1

Part Number / QTY Name Notes

Specification

Maximum quantity. Adjust

as necessary.

BACN11G4DE1F 64 Nutplate, Self-Locking

Maximum quantity for two

for each nutplate. Adjust as

necessary. (a)

MS20427M3-4 128 Rivet

Maximum quantity. Adjust

as necessary.

BACB30UU4-1 64 Bolt

(a) Refer to 777 Structural Repair Manual Chapter 51 for alternate fasteners.

Part 3 - Component Work: 314W5520-1

Part Number / QTY Name Notes

Specification

005W3246-2 1 Subkit, Engine

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Part 3 - Component Work: 314W5521-1

Part Number / QTY Name Notes

Specification

BACN11G4DE1F 66 Nutplate, Self-Locking

MS20427M3-4 132 Rivet (a)

BACB30UU4-1 66 Bolt

(a) Refer to 777 Structural Repair Manual Chapter 51 for alternate fasteners.

Part 4 - Component Work: 314W5520-1

Part Number / QTY Name Notes

Specification

314W5520-23 4 Identification Tag

MS20615-4M3 12 Rivet (a)

(a) Refer to 777 Structural Repair Manual Chapter 51 for alternate fasteners.

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the

number of parts changed on each airplane. Components or subassembly parts are indented. The

quantity of the indented part is the number of parts used on the next higher assembly.

Existing Part QTY Name New Part Number Notes

Number

Referred to as 'Turbine Exhaust Plug

Assembly'. (a) (b) (c)

(e) (f)

314W5520-15 or 2 Primary Plug Assy 314W5521-1

314W5520-19

314W5520-1

.314W5520-3 or 1 Aft Plug Assy - (a) (d)

314W5520-20

.314W5520-16 or 1 Forward Plug Assy - (a) (d)

314W5520-21

(a) Make the change in accordance with this service bulletin.

(b) This is the part number after the change is done in accordance with this service bulletin.

(c) This part is not used in production.

(d) There is no equivalent Boeing part number for the changed part.

(e) The equivalent production part number is 314W5520-22.

(f) Existing part number 314W5520-1 could also exist because of the instructions in the Original

Issue of this service bulletin. But part number 314W5520-1 is incorrect as the post service

bulletin identity.

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BOEING SERVICE BULLETIN 777-78-0051
4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

It is recommended that primary plug assemblies (or 'turbine exhaust plug' assemblies) held as spares

are inspected in accordance with FIGURE 5 and if necessary change them in accordance with Paragraph

3.B., Work Instructions, Part 2, 3 or 4, as applicable.

To get the kits shown below, for each turbine exhaust plug assembly, refer to Paragraph 2.A., Material

- Price and Availability.

Part 2 - Component Work: 314W5520-1

Part Number Name QTY

314W5520-23 Identification Tag 2

Nutplate, Self-Lock- 32 (maximum)

ing

BACN11G4DE1F

MS20427M3-4 Rivet 64 (maximum)

MS20615-4M3 Rivet 6

BACB30UU4-1 Bolt 32 (maximum)

Part 2 - Component Work: 314W5521-1

Part Number Name QTY

Nutplate, Self-Lock- 32 (maximum)

ing

BACN11G4DE1F

MS20427M3-4 Rivet 64 (maximum)

BACB30UU4-1 Bolt 32 (maximum)

Part 3 - Component Work: 314W5520-15, -19; 314W5520-1

Kit Number Name QTY

005W3246-2 Subkit, Engine 1

Part 3 - Component Work: 314W5521-1

Part Number Name QTY

Nutplate, Self-Lock- 33

ing

BACN11G4DE1F

MS20427M3-4 Rivet 66

BACB30UU4-1 Bolt 33

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BOEING SERVICE BULLETIN 777-78-0051
Part 4 - Component Work: 314W5520-1

Part Number Name QTY

314W5520-23 Identification Tag 2

MS20615-4M3 Rivet 6

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

To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability.

Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be

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

Part Number Name

ST1864R-2820-2550- Step Reamer

4-221-4-64-2-4, or

equivalent (a)

3/16 inch diameter temporary

fastener

ST30-7216A-200-

216-1.0, or equivalent

(b)

1/4 inch diameter temporary

fastener

ST30-7216A-200-

279-1.0, or equivalent

(b)

(a) Can be purchased from: Boeing, Spares Customer

Support - MC 36-65, Boeing Spares Department,

P.O.Box 3707, Seattle, WA 98124-2207, USA.

(b) A quantity of 32 are necessary.

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BOEING SERVICE BULLETIN 777-78-0051

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

3. The work instructions are divided into Parts. Task Hours and Elapsed Hours for each

Part are given in Paragraph 1.G., Manpower. You can do Part 1, 2, 3 and 4

independently.

4. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque limits to tighten nuts and bolts are in SRM Chapter 51

5. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

6. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

7. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

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

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

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

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

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BOEING SERVICE BULLETIN 777-78-0051
9. Boeing Service Letter 777-SL-51-013, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

10. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

11. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

12. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

B. WORK INSTRUCTIONS

Part 1 - Turbine Exhaust Plug - Airplane Work

1. Deactivate the Thrust Reversers (T/R's) for ground maintenance. Refer to 777 AMM 78-31-00 as

an accepted procedure.

2. Group 1, Configuration 1:

a. Remove the turbine exhaust plug assembly from each engine. Refer to 777 AMM 78-11-02

as an accepted procedure.

b. Install a serviceable turbine exhaust plug assembly, with 1/4 inch diameter bolts at all 33

locations of the forward and aft plug interface, back on each engine in accordance with FIGURE

9.

NOTE: A serviceable turbine exhaust plug assembly can be one that is removed from the

airplane and subsequently changed in accordance with Part 3, or it can be a spare

turbine exhaust plug assembly that is changed in accordance with Part 2 or 3. Or it

can be a new turbine exhaust plug assembly, with part number 314W5520-22.

(1) If one or more of the 1/4 inch diameter bolts has a run-on torque value of less than 5.0

inch-pounds, replace the nutplate on the forward plug for each of the related bolt(s) in

accordance with FIGURE 7.

3. Group 1, Configuration 2-3:

At each engine, do a general visual inspection of the all of the 33 bolt locations at the forward and

aft plug interface in accordance with FIGURE 5.

a. Only 3/16 inch diameter bolts are found used at all 33 locations:

(1) Remove the turbine exhaust plug assembly from each engine. Refer to 777 AMM 78-11-02

as an accepted procedure.

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BOEING SERVICE BULLETIN 777-78-0051
(2) Install a serviceable turbine exhaust plug assembly, with 1/4 inch diameter bolts at all 33

locations of the forward and aft plug interface, back on each engine in accordance with

FIGURE 9.

NOTE: A serviceable turbine exhaust plug assembly can be one that is removed from

the airplane and subsequently changed in accordance with Part 3, or it can be

a spare turbine exhaust plug assembly that is changed in accordance with Part

2 or 3. Or it can be a new turbine exhaust plug assembly, with part number

314W5520-22.

(a) If one or more of the 1/4 inch diameter bolts has a run-on torque value of less than

5.0 inch-pounds, replace the nutplate on the forward plug for each of the related

bolt(s) in accordance with FIGURE 7.

b. A mix of 3/16 inch diameter and 1/4 inch diameter bolts are found used at the 33 locations.

(1) Remove the turbine exhaust plug assembly from each engine. Refer to 777 AMM 78-11-02

as an accepted procedure.

(2) Install a serviceable turbine exhaust plug assembly, with 1/4 inch diameter bolts at all 33

locations of the forward and aft plug interface, back on each engine in accordance with

FIGURE 9.

NOTE: A serviceable turbine exhaust plug assembly can be one that is removed from

the airplane and subsequently changed in accordance with Part 2, or it can be

a spare turbine exhaust plug assembly that is changed in accordance with Part

2 or 3. Or it can be a new turbine exhaust plug assembly, with part number

314W5520-22.

(a) If one or more of the 1/4 inch diameter bolts has a run-on torque value of less than

5.0 inch-pounds, replace the nutplate on the forward plug for each of the related

bolt(s) in accordance with FIGURE 7.

c. Only 1/4 inch diameter bolts are found installed at all 33 locations.

(1) Group 1, Configuration 2:

Reidentify the turbine exhaust plug assembly:

(a) Remove the turbine exhaust plug assembly from each engine. Refer to 777 AMM

78-11-02 as an accepted procedure.

(b) Do Part 4.

(c) Install the turbine exhaust plug assembly with the reidentified forward and aft plugs

back on each engine in accordance with FIGURE 9.

1) If one or more of the 1/4 inch diameter bolts has a run-on torque value of less

than 5.0 inch-pounds, replace the nutplate on the forward plug for each of the

related bolt(s) in accordance with FIGURE 7.

(2) Group 1, Configuration 3:

No more work is necessary.

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BOEING SERVICE BULLETIN 777-78-0051
4. If not done, activate the T/R's after ground maintenance. Refer to 777 AMM 78-31-00 as an

accepted procedure.

5. Put the airplane back to a serviceable condition.

Part 2 - Replacement Of All Remaining 3/16 Inch Diameter Bolts With 1/4 Inch Diameter Bolts -

Component Work: 314W5520-1; 314W5521-1

1. As applicable:

– Get each spare turbine exhaust plug assembly on which the description of Part 2 is necessary

to be accomplished.

– Get each removed turbine exhaust plug assembly for which the description of Part 2 is

necessary to be accomplished.

2. Put and hold the forward plug vertically and remove all of the remaining 3/16 inch diameter nutplates

from the holes that interface with the aft plug in accordance with FIGURE 1.

3. Do a general visual inspection of the holes, related to the removed 3/16 inch diameter nutplates,

at the forward and aft plug interface in accordance with FIGURE 2.

a. If a hole has damage that is more than the 0.2910 inch limit, contact Boeing for repair

instructions. Refer to Boeing Service Letter 777-SL-51-013.

4. Install 1/4 inch diameter nutplates at all remaining hole locations where 3/16 inch diameter nutplates

were removed in accordance with FIGURE 6.

5. For each component identified with part number 314W5520-1:

a. Reidentify the turbine exhaust plug assembly in accordance with Part 4

6. For each component identified with part number 314W5521-1:

a. No turbine exhaust plug assembly reidentification is necessary.

Part 3 - Replacement Of All 33 3/16 Inch Diameter Bolts With 1/4 Inch Diameter Bolts - Component

Work: 314W5520-15, -19; 314W5520-1; 314W5521-1

1. As applicable:

– Get each spare turbine exhaust plug assembly on which the description of Part 3 is necessary

to be accomplished.

– Get each removed turbine exhaust plug assembly for which the description of Part 3 is

necessary to be accomplished.

2. Put and hold the forward plug vertically and remove all of the 33 3/16 inch diameter nutplates from

the holes that interface with the aft plug in accordance with FIGURE 1.

3. Do a general visual inspection of the holes, related to the removed 3/16 inch diameter nutplates,

at the forward and aft plug interface in accordance with FIGURE 2.

a. If a hole has damage that is more than the 0.2910 inch limit, contact Boeing for repair

instructions. Refer to Boeing Service Letter 777-SL-51-013.

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BOEING SERVICE BULLETIN 777-78-0051
4. For each component identified with part number 314W5520-15, -19:

a. Deep etch mark the new identification tags for the forward and aft plugs in accordance with

FIGURE 3.

b. Install 1/4 inch diameter nutplates at all 33 hole locations and reidentify the turbine exhaust

plug assembly in accordance with FIGURE 4.

5. For each component identified with part number 314W5520-1:

a. Install 1/4 inch diameter nutplates at all 33 hole locations in accordance with FIGURE 4.

b. Reidentify the turbine exhaust plug assembly in accordance with Part 4.

6. For each component identified with part number 314W5521-1:

a. Install 1/4 inch diameter nutplates at all 33 hole locations in accordance with FIGURE 4.

b. No turbine exhaust plug assembly reidentification is necessary.

Part 4 - Reidentification of the Turbine Exhaust Plug Assembly - Component Work: 314W5520-1

1. Deep etch mark the replacement identification tags for the forward and aft plugs in accordance

with FIGURE 3.

2. Remove the incorrectly identified identification tags and install the replacement identification tags

for the forward and aft plugs in accordance with FIGURE 8.

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BOEING SERVICE BULLETIN 777-78-0051
FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY - NUTPLATE REMOVAL AND HOLE INSPECTION

PREPARATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each turbine exhaust plug assembly.

Step Task Name Identification Qty More Data

1 Remove RIVET - - (a) (c)

Remove NUTPLATE BACN11G3AE1F - (b)

FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY - NUTPLATE REMOVAL AND HOLE INSPECTION

PREPARATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

314W5520-16 OR 1 on the aft plug.

314W5520-21

2 Put / Hold FORWARD PLUG

314W5520-3 OR 1 on the forward plug.

314W5520-20

Put / Hold AFT PLUG

3 Align HOLE - 33 of each plug.

(a) Quantity 66, if each turbine exhaust plug assembly is to have all 33 3/16 inch diameter bolts replaced

with 1/4 inch diameter bolts. Or, quantity as necessary, for each turbine exhaust plug assembly that is to

have all remaining locations that have 3/16 inch diameter bolts replaced with 1/4 inch diameter bolts.

Refer to 777-200 SRM 51-40-02 or 777-300 SRM 51-40-02 an accepted procedure.

(b) Quantity 33, if each turbine exhaust plug assembly is to have all 33 3/16 inch diameter bolts replaced

with 1/4 inch diameter bolts. Or, quantity as necessary, for each turbine exhaust plug assembly that is to

have all remaining locations that have 3/16 inch diameter bolts replaced with 1/4 inch diameter bolts.

(c) Be careful during the removal of rivets to minimize damage to the holes.

FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY - NUTPLATE REMOVAL AND HOLE INSPECTION

PREPARATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each turbine exhaust plug assembly.

Step Task Name Identification Qty More Data

1 Inspect HOLE - - (a)

(a) by general visual inspection, at the 33 locations of the forward plug and aft plug interface, for wear damage

and/or hole elongation, for each turbine exhaust plug assembly that is to have all 33 3/16 inch diameter

bolts replaced. Or, by general visual inspection, at each 3/16 inch diameter bolt location, at the forward

plug and aft plug interface, for wear damage and/or hole elongation, for each turbine exhaust plug assembly

that is to have all remaining locations that have 3/16 inch diameter bolts replaced with 1/4 inch diameter

bolts.

FIGURE 2: TURBINE EXHAUST PLUG ASSEMBLY HOLES - GENERAL VISUAL INSPECTION

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each turbine exhaust plug assembly.

Step Task Name Identification Qty More Data

with the text as follows, for the forward

and aft plug: Assy

314W5521-1;

MATCHED SET. DO

NOT SEPARATE;

S/N: XXX-XXXX.

Refer to SOPM 20-

50-10 as an accepted procedure. (a)

(b)

1 Identify IDENTIFICATION TAG 314W5520-23 2

(a) The serial number code is to be operator defined. A unique serial number is necessary for each matched

set of forward and aft plugs (turbine exhaust plug assembly) to help the operator keep the hardware as

a matched set. EXAMPLE: S/N TBC-0001.

(b) The serial number is recommended to be on one half of the identification tag and one-quarter inch (24

point) in height. The remaining text is recommended to be on the other half of the identification tag and

12 point in height. The text is recommended to be centered to keep a minimum 2D distance from each

of the rivets after installation.

FIGURE 3: IDENTIFICATION TAG - DEEP ETCH MARK

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 777-78-0051
FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER

BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 1 OF 6)

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FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER

BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each turbine exhaust plug assembly.

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER

BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 3 OF 6)

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BOEING SERVICE BULLETIN 777-78-0051
NOTE: If this Figure is used for a turbine exhaust plug assembly identified with part number 314W5520-1 or

314W5521-1, Steps 8 thru 11 are not necessary.

Step Task Name Identification Qty More Data

in the interface holes

of the aft plug and

the forward plug. (a)

ST30-7216A-200-216- 5

1.0 ('WEDGELOCK')

OR EQUIVALENT

3/16 INCH DIA FASTENER1 Install (Temporary)

WARNING: USE CARE WHEN DRILLING IN TITANIUM. SMALL PARTICLES AND FINE SHAVINGS OF

TITANIUM ARE HIGHLY FLAMMABLE. WATER WITH HOT TITANIUM CAN CAUSE A STEAM

EXPLOSION. EXTINGUISH ALL FIRES OF TITANIUM WITH FULLY DRY TALC, CALCIUM

CARBONATE, SAND, OR GRAPHITE. APPLY THE POWDER TO A DEPTH OF ONE-HALF

INCH OR MORE OVER THE BURNING METAL. DO NOT USE FOAM, WATER, CARBON

TETRACHLORIDE, OR CARBON DIOXIDE. IF YOU DO NOT OBEY, YOU CAN CAUSE INJURY

TO PERSONS.

to 1/4 inch diameter,

Class III hole. Use

Step Reamer part

number ST1864R2820-2550-4-221-4-

64-2-4, or equivalent, between the

first and fifth 'wedgelocks' to remove

damage up to the

repair limit, or to increase its diameter

to 1/4 inch. (c)

2 Ream HOLE - 1

that was reamed, by

general visual inspection, to make

sure there is no

damage.

3 Inspect HOLE - 1

into the repaired or

increased diameter

hole. (a)

ST30-7216A-200-279- 1

1.0 ('WEDGELOCK')

OR EQUIVALENT

1/4 INCH DIA FASTENER4 Install (Temporary)

that were temporarily installed. (a)ST30-7216A-200-216- 5

1.0 ('WEDGELOCK')

OR EQUIVALENT

3/16 INCH DIA FASTENER5 Remove / Keep

that were temporarily installed.ST30-7216A-200-279- 32

1.0 ('WEDGELOCK')

OR EQUIVALENT

1/4 INCH DIA FASTENER6 Remove

314W5520-3 OR 1

314W5520-20

Remove / Keep AFT PLUG

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER

BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 4 OF 6)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

on the inner circumference of the forward plug using the

existing rivet holes.

7 Install (New) NUTPLATE BACN11G4DE1F 33

Install (New) RIVET MS20427M3-4 66 (d)

CAUTION: ADJUST THE IDENTIFICATION TAG POSITIONS TO AVOID DRILLING HOLES WITHIN 0.31

INCHES OF A WELD CENTERLINE

identified for the forward plug. (b)8 Put / Hold IDENTIFICATION TAG 314W5520-23 1

0.124 - 0.128 inch

diameter. (c)

Drill / Ream HOLE - 3

identified for the forward plug.9 Install (New) IDENTIFICATION TAG 314W5520-23 1

Install (New) RIVET MS20615-4M3 3 (d)

identified for the aft

plug. (b)

10 Put / Hold IDENTIFICATION TAG 314W5520-23 1

0.124 - 0.128 inch

diameter. (c)

Drill / Ream HOLE - 3

identified for the aft

plug.

11 Install (New) IDENTIFICATION TAG 314W5520-23 1

Install (New) RIVET MS20615-4M3 3 (d)

(a) Do not install the 'wedgelocks' (or equivalent 3/16 inch diameter temporary fasteners) in a continuous

sequence. Install the first 'wedgelock' in the hole located sequentially next to the hole that is found to have

the largest damage. Install the second 'wedgelock' in the hole nearest to the circumferential opposite of

the first 'wedgelock' installed. Install the third 'wedgelock' in the hole nearest to the circumferential midpoint

between the first and second 'wedgelocks'. Install the fourth 'wedgelock' in the hole nearest to the circumferential opposite as the third installed 'wedgelock'. Install the fifth 'wedgelock' in the hole located sequentially next to the hole that to has the largest damage. After the hole is reamed and no damage is found,

install a 1/4 inch 'wedgelock' in the repaired or increased diameter hole. Move the first thru fifth 'wedgelocks'

clockwise or counter-clockwise to repair the hole with the next largest damage, until 5 3/16 inch diameter

'wedgelocks' cannot be installed because 1/4 inch diameter 'wedgelocks' are installed. Do steps 1 thru 5

again to repeat this process until 32 holes are filled with 1/4 inch 'wedgelocks' and all of the 33 holes are

repaired and/or increased to 1/4 inch diameter. Refer to APPENDIX A for a graphical example of the

'wedgelock' installation process.

(b) The identification tag is to be positioned on the side of the stringer where the distance between the stringer

and the skin chem-milled area is maximum, but with the minimum conditions that there is a 2D edge

margin between the rivets and the edges of the identification tag and that there is a 2D edge margin between the rivets and the chemically milled area. Refer to 777-200 SRM 54-42-30 or 777-300 SRM 54-42-

30 for turbine exhaust plug assembly details.

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER

BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 5 OF 6)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

(c) Refer to SOPM 20-10-07 and 777-200 SRM 51-30-01 or 777-300 SRM 51-30-01 Section 5, as an accepted

procedure, to drill or ream titanium.

(d) Refer to 777-200 SRM 51-40-02 or 777-300 SRM 51-40-02 as an accepted procedure.

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER

BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 6 OF 6)

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BOEING SERVICE BULLETIN 777-78-0051
This Figure applies only to: Group 1, Configuration 2-3.

FIGURE 5: TURBINE EXHAUST PLUG ASSEMBLY BOLTS - GENERAL VISUAL INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each engine.

Step Task Name Identification Qty More Data

by general visual inspection, at the forward and aft plug interface, to find if

3/16 inch diameter

bolts and/or 1/4 inch

diameter bolts are

used at the forward

and aft plug interface.

123423-3-1 OR 33

BACB30UU4-1

1 Inspect BOLT

FIGURE 5: TURBINE EXHAUST PLUG ASSEMBLY BOLTS - GENERAL VISUAL INSPECTION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each turbine exhaust plug assembly.

FIGURE 6: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL REMAINING 3/16 INCH

DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

Use 3/16 inch diameter fastener, ST30-

7216A-200-216-1.0

('Wedgelock') or

equivalent, in the interface holes of the

aft plug and the forward plug, that do

not have a nutplate.

Or, use 1/4 inch diameter fasteners in

the interface holes

of the aft plug and

the forward plug that

have a nutplate. (a)

1 Install (Temporary) FASTENER - 5

WARNING: USE CARE WHEN DRILLING IN TITANIUM. SMALL PARTICLES AND FINE SHAVINGS OF

TITANIUM ARE HIGHLY FLAMMABLE. WATER WITH HOT TITANIUM CAN CAUSE A STEAM

EXPLOSION. EXTINGUISH ALL FIRES OF TITANIUM WITH FULLY DRY TALC, CALCIUM

CARBONATE, SAND, OR GRAPHITE. APPLY THE POWDER TO A DEPTH OF ONE-HALF

INCH OR MORE OVER THE BURNING METAL. DO NOT USE FOAM, WATER, CARBON

TETRACHLORIDE, OR CARBON DIOXIDE. IF YOU DO NOT OBEY, YOU CAN CAUSE INJURY

TO PERSONS.

to 1/4 inch diameter,

Class III hole. Use

Step Reamer part

number ST1864R2820-2550-4-221-4-

64-2-4, or equivalent, between the

first and fifth 'wedgelocks', or first and

fifth 1/4 inch diameter temporary fasteners, to remove damage up to the repair

limit, or to increase

its diameter to 1/4

inch. (b)

2 Ream HOLE - 1

by general visual inspection, to make

sure there is no

damage.

3 Inspect HOLE - 1

into the repaired or

increased diameter

hole. (a)

ST30-7216A-200-279- 1

1.0 ('WEDGELOCK')

OR EQUIVALENT

1/4 INCH DIA FASTENER4 Install (Temporary)

FIGURE 6: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL REMAINING 3/16 INCH

DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

3/16 inch diameter

fasteners, ST30-

7216A-200-216-1.0

('Wedgelock') or

equivalent, that were

temporarily installed.

Or, 1/4 inch diameter fasteners that

were temporarily installed. (a)

5 Remove / Keep FASTENER - 5

1/4 inch diameter

fasteners, ST30-

7216A-200-279-1.0

('Wedgelock') or

equivalent, that were

temporarily installed.

Or, 1/4 inch diameter fasteners that

were temporarily installed.

6 Remove FASTENER - 32

314W5520-3 OR 1

314W5520-20

Remove / Keep AFT PLUG

as necessary, at all

remaining locations

that do not have nutplates for 1/4 inch

diameter bolts, on

the inner circumference of the forward

plug, using the existing rivet holes.

7 Install (New) NUTPLATE BACN11G4DE1F -

as necessary, two

for each nutplate. (c)

Install (New) RIVET MS20427M3-4 -

FIGURE 6: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL REMAINING 3/16 INCH

DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

(a) Do not install the 'wedgelocks' (or equivalent 3/16 inch diameter temporary fasteners) or temporary 1/4

inch diameter fasteners in a continuous sequence. Install the first 'wedgelock', in the hole located sequentially next to the hole that is found to have the largest damage or that is remaining at 3/16 inch diameter,

or install the first temporary fastener in the equivalently located 1/4 inch diameter hole. Install the second

'wedgelock' in the hole nearest to the circumferential opposite of the first 'wedgelock' installed, or install

the second temporary fastener in the equivalently located 1/4 inch diameter hole. Install the third

'wedgelock' in the hole nearest to the circumferential midpoint between the first and second 'wedgelocks',

or install the third temporary fastener in the equivalently located 1/4 inch diameter hole. Install the fourth

'wedgelock' in the hole nearest to the circumferential opposite as the third installed 'wedgelock', or install

the fourth temporary fastener in the equivalently located 1/4 inch diameter hole. Install the fifth 'wedgelock'

in the hole located sequentially next to the hole that to has the largest damage, or install the fifth temporary

fastener in the equivalently located 1/4 inch diameter hole. After the hole is reamed and no damage is

found, install a 1/4 inch 'wedgelock' in the repaired or increased diameter hole. Move the first thru fifth

'wedgelocks', or the first thru fifth 1/4 inch diameter temporary fasteners clockwise or counter-clockwise

to repair the hole with the next largest damage and/or increase its diameter to 1/4 inch, until 5 'wedgelocks'

cannot be installed because 1/4 inch diameter wedgelocks or 1/4 inch diameter temporary fasteners are

installed. Do steps 1 thru 5 again to repeat this process until 32 fastener holes are filled with 1/4 inch diameter 'wedgelocks' or 1/4 inch diameter temporary fasteners and all of the 33 fastener holes are repaired

and/or increased to 1/4 inch diameter. Refer to APPENDIX B for a graphical example of the 'wedgelock'

and/or temporary fastener installation process.

(b) Refer to SOPM 20-10-07 and 777-200 SRM 51-30-01 or 777-300 SRM 51-30-01 Section 5, as an accepted

procedure, to drill or ream titanium.

(c) Refer to 777-200 SRM 51-40-02 or 777-300 SRM 51-40-02 as an accepted procedure.

FIGURE 6: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL REMAINING 3/16 INCH

DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 777-78-0051
FIGURE 7: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD PLUG, 1/4 INCH DIAMETER NUTPLATE

REPLACEMENT

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each nut plate location of a turbine exhaust plug

assembly.

Step Task Name Identification Qty More Data

Refer to 777-200

SRM 51-40-02 or

777-300 SRM 51-

40-02 as an accepted procedure.

1 Remove RIVET MS20427M3-4 2

Remove NUTPLATE BACN11G4DE1F 1

2 Install (New) NUTPLATE BACN11G4DE1F 1

Refer to 777-200

SRM 51-40-02 or

777-300 SRM 51-

40-02 as an accepted procedure.

Install (New) RIVET MS20427M3-4 2

FIGURE 7: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD PLUG, 1/4 INCH DIAMETER NUTPLATE

REPLACEMENT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 777-78-0051
FIGURE 8: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD AND AFT PLUG IDENTIFICATION TAG

REPLACEMENT

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each turbine exhaust plug assembly.

FIGURE 8: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD AND AFT PLUG IDENTIFICATION TAG

REPLACEMENT

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

Refer to 777-200

SRM 51-40-02 or

777-300 SRM 51-

40-02 an accepted

procedure.

1 Remove RIVET MS20615-4M3 6

that were incorrectly

identified with 'Assy

314W5520-1'.

Remove IDENTIFICATION TAG 314W5520-23 2

one on the forward

plug and one on the

aft plug. (a)

2 Install (New) IDENTIFICATION TAG 314W5520-23 2

three for each identification tag. Refer to

777-200 SRM 51-

40-02 or 777-300

SRM 51-40-02 an

accepted procedure.

(a)

Install (New) RIVET MS20615-4M3 6

(a) Make sure the identification tag is located on the side of the stringer where the distance between the

stringer and the skin chem-milled area is maximum, but with the minimum conditions that there is a 2D

edge margin between the rivets and the edges of the identification tag and that there is a 2D edge margin

between the rivets and the chemically milled area.

FIGURE 8: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD AND AFT PLUG IDENTIFICATION TAG

REPLACEMENT

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-78-0051
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each engine.

FIGURE 9: TURBINE EXHAUST PLUG ASSEMBLY - INSTALLATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 777-78-0051
Step Task Name Identification Qty More Data

1 Install (Changed) FORWARD PLUG - 1 (b)

Install (Changed) AFT PLUG - 1 (a) (b)

TURBINE EXHAUST 314W5520-22 1 If applicable. (a)

PLUG ASSEMBLY

Install (New)

Install (New) BOLT BACB30UU4-1 33 If applicable. (a)

Install (Kept) BOLT BACB30UU4-1 33 If applicable. (a)

Torque BOLT BACB30UU4-1 33 73 - 83 inch-pounds.

(a) Refer to 777 AMM 78-11-02 as an accepted procedure. During the installation, make sure there is 5.0

inch-pounds or more of run-on torque for each of the bolts related to nutplates of the forward plug, at the

forward and aft plug interface.

(b) Together the installation of these changed parts relates to the installation of the changed turbine exhaust

plug assembly part number 314W5521-1. Refer to Paragraph 2.C.3., Parts Modified and Reidentified.

FIGURE 9: TURBINE EXHAUST PLUG ASSEMBLY - INSTALLATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 777-78-0051
APPENDIX A: 'WEDGELOCK' FASTENER INSTALLATION PROCESS FOR THE REPLACEMENT OF ALL

33 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 777-78-0051
APPENDIX B: 'WEDGELOCK' AND TEMPORARY FASTENER INSTALLATION PROCESS FOR THE

REPLACEMENT OF ALL REMAINING 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 777-78-0051