Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0260

Original Issue: August 26, 2014

ATA System: 5315

SUBJECT: FUSELAGE - Section 41 - S-2R Skin Lap Splice, STA 368 TO STA 434 - Inspection

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

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

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ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2014 Boeing.

Unpublished Work. All Rights Reserved.

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Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

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

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 20

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 21

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND

SURFACE HFEC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

APPENDIX A: LOGIC DIAGRAM [Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

APPENDIX B: LOGIC DIAGRAM [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-53A0260

Original Issue: August 26, 2014

ATA System: 5315

SUBJECT: FUSELAGE - Section 41 - S-2R Skin Lap Splice, STA 368 TO STA 434 - Inspection

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

The section 41, stringer S-2R skin lap splice from Body Station (STA) 368 to STA 434 has been determined to

be structure that is susceptible to Widespread Fatigue Damage (WFD). As a result of WFD analysis the S-2R

skin lap splice from STA 368 to STA 434 requires additional supplemental inspection beyond the inspections

given in 767 MPD. If fatigue cracking of the skin lap splice is not detected the cracking could grow which could

result in possible rapid decompression and loss of structural integrity.

This service bulletin gives inspection and repair instructions for cracking in the skin at S-2R skin lap splice from

Body Station (STA) 368 to STA 434.

The 767 MPD will be revised to give inspection requirements for 767-300 passenger airplanes after line number

1068.

Boeing Service Related Problem (SRP) 767-SRP-53-0449 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 53-13002 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

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Planning Data Affected Reference

Publications Affected Yes Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required No Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Do an external detailed and surface High Frequency Eddy Current (HFEC) inspection of the outer skin for

cracking around fastener heads common to the inboard fastener row of the stringer S-2R skin lap splice from

Body Station (STA) 368 to STA 434. If any crack is found do an SRM repair.

EFFECTIVITY

767-200/-300/-400ER Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).

COMPLIANCE

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

bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-18-10 is related to this service bulletin.

The effective date of AD 2003-18-10 is October 16, 2003.

This service bulletin affects SSI 53-10-I07A of MPD 622T001-9 Section 9, which is mandated by AD 2003-18-10.

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

Airplanes Total Task Hours Elapsed Hours

All airplanes 2.50 2.50

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

None.

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BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0260

Original Issue: August 26, 2014

ATA System: 5315

SUBJECT: FUSELAGE - Section 41 - S-2R Skin Lap Splice, STA 368 TO STA 434 - Inspection

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

This service bulletin is for the airplane(s) shown below.

GROUP CONFIGURATION DESCRIPTION

1 - 767-200/-300 airplanes line number 1 - 1068

2 - 767-400ER airplanes line number 758 - 965

Airplane Models:

767-200, 767-300, 767-400ER

Variable Number Group

VA001 - VA020 1

VA301 - VA315 1

VA501 - VA530 1

VA701 - VA719 1

VA801 - VA810 1

VB001 - VB002 1

VB051 - VB055 1

VB101 - VB125 1

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Variable Number Group

VB201 - VB202 1

VB251 - VB253 1

VB281 - VB284 1

VB301 - VB302 1

VB321 - VB332 1

VB371 - VB373 1

VB401 1

VB441 - VB444 1

VE001 - VE003 1

VE021 - VE023 1

VE041 - VE043 1

VE061 - VE069 1

VE083 - VE086 1

VE101 - VE104 1

VE116 - VE118 1

VE121 - VE126 1

VE141 - VE152 1

VE171 - VE172 1

VF001 - VF002 1

VF041 - VF042 1

VF051 1

VF061 - VF062 1

VF071 - VF072 1

VF091 - VF093 1

VF101 - VF102 1

VF161 - VF162 1

VF171 - VF172 1

VF180 - VF184 1

VF251 1

VK001 - VK016 1

VK021 - VK022 1

VK031 - VK056 1

VK081 - VK113 1

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Variable Number Group

VK131 - VK133 1

VK141 - VK148 1

VK161 - VK164 1

VK171 1

VK181 1

VK186 1

VL001 - VL006 1

VL011 1

VL701 - VL703 1

VL751 - VL755 1

VL806 - VL807 1

VL871 - VL873 1

VL891 - VL900 1

VL911 - VL914 1

VL931 - VL932 1

VL941 1

VN001 - VN041 1

VN051 - VN064 1

VN081 - VN099 1

VN111 - VN127 1

VN130 - VN137 1

VN151 - VN158 1

VN163 - VN168 1

VN171 - VN174 1

VN191 - VN198 1

VN211 - VN212 1

VN221 - VN225 1

VN231 - VN234 1

VN241 - VN243 1

VN251 - VN276 1

VN291 - VN293 1

VN301 - VN314 1

VN371 - VN372 1

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Variable Number Group

VN376 1

VN381 - VN388 1

VN421 - VN427 1

VN436 1

VN471 - VN472 1

VN491 - VN513 1

VN531 - VN532 1

VN536 - VN537 1

VN541 - VN542 1

VN546 - VN547 1

VN551 1

VN556 - VN557 1

VN561 - VN562 1

VN631 - VN638 1

VN651 - VN658 1

VN671 - VN672 1

VN676 1

VN681 - VN691 1

VN731 - VN732 1

VN751 - VN753 1

VN791 - VN792 1

VN811 - VN813 1

VN921 - VN922 1

VN931 - VN936 1

VN951 - VN953 1

VN966 - VN972 1

VQ001 - VQ021 2

VQ071 - VQ086 2

VQ111 2

VR051 - VR060 1

VR081 1

VR084 1

VR086 - VR089 1

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Variable Number Group

VR106 - VR109 1

VR401 1

VR421 - VR423 1

VR426 1

VR441 1

VR461 1

VR471 - VR472 1

VS051 - VS056 1

VS061 1

VS066 - VS070 1

VS073 - VS078 1

VS091 - VS104 1

VS111 - VS113 1

VS131 - VS133 1

VS136 - VS137 1

VS176 - VS177 1

VS186 - VS187 1

VS196 - VS203 1

VS206 - VS208 1

VS211 1

VS216 - VS217 1

VS231 1

VS246 - VS248 1

VS261 - VS263 1

VS266 - VS274 1

VS291 - VS293 1

VS301 - VS303 1

VS306 - VS311 1

VS316 1

VS321 - VS324 1

VS331 - VS333 1

VS336 - VS337 1

VS366 - VS367 1

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Variable Number Group

VS381 - VS382 1

VS391 - VS392 1

VS401 1

VS426 - VS428 1

VS466 - VS472 1

VS486 1

VS496 - VS497 1

VS506 - VS507 1

VS526 1

VS546 - VS549 1

VS701 - VS736 1

VS751 - VS759 1

VS821 - VS825 1

VS841 - VS844 1

VS861 1

VS881 - VS883 1

VS891 1

VS896 1

VS901 - VS912 1

VS916 1

VS921 - VS928 1

VS931 - VS933 1

VS941 1

VS951 - VS954 1

VS961 - VS969 1

VS971 - VS977 1

VS981 - VS984 1

VT001 - VT013 1

VT021 1

VT031 - VT033 1

VV001 1

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BOEING SERVICE BULLETIN 767-53A0260

ALERT ALERT
2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

The section 41, stringer S-2R skin lap splice from Body Station (STA) 368 to STA 434 has been

determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). As a result of

WFD analysis the S-2R skin lap splice from STA 368 to STA 434 requires additional supplemental

inspection beyond the inspections given in 767 MPD. If fatigue cracking of the skin lap splice is not

detected the cracking could grow which could result in possible rapid decompression and loss of

structural integrity.

This service bulletin gives inspection and repair instructions for cracking in the skin at S-2R skin lap

splice from Body Station (STA) 368 to STA 434.

The 767 MPD will be revised to give inspection requirements for airplanes after line number 1068.

Boeing Service Related Problem (SRP) 767-SRP-53-0449 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 53-13002 is related to this service bulletin.

D. Description

Do an external detailed and surface High Frequency Eddy Current (HFEC) inspection of the outer skin

for cracking around fastener heads common to the inboard fastener row of the stringer S-2R skin lap

splice from Body Station (STA) 368 to STA 434. If any crack is found do an SRM repair.

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

Group 1:

Affected Maintenance Zones

Model Zone

767-200, 767-300 224

Group 2:

Affected Maintenance Zones

Model Zone

767-400ER 224

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ALERT ALERT
E. Compliance

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

this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-18-10 is related to this service

bulletin. The effective date of AD 2003-18-10 is October 16, 2003.

This service bulletin affects SSI 53-10-I07A of MPD 622T001-9 Section 9, which is mandated by AD

2003-18-10. All other MPD inspections outside of the affected area, including SSI 53-10-I07B, are not

affected and must continue.

Boeing recommends that the inspection and repair given in this service bulletin be done in accordance

with Paragraph 1.E., Compliance, Table 1.

Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

Group 1:

Table 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

Within 3,000 -

flight cycles after the original

issue date of

this service bulletin

Before 43,000

total flight cycles

Do PART 1: SECTION 41

- S-2R SKIN LAP

SPLICE, STA 368 TO

STA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION (a)

All airplanes

Repeat PART 1: SEC- - 9,000 flight cycles

TION 41 - S-2R SKIN

LAP SPLICE, STA 368

TO STA 434 - DETAILED

INSPECTION AND SURFACE HFEC INSPECTION (a)

CONDITION 1: NO

CRACK IS FOUND

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Group 1:

Table 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

CONDITION 2 (ACTION Before further flight -

1):

CONDITION 2: ANY

CRACK IS FOUND

Do PART 2: SECTION 41

- S-2R SKIN LAP

SPLICE, STA 368 TO

STA 434 - REPAIR

CONDITION 2 (ACTION - 9,000 flight cycles

2):

Repeat PART 1: SECTION 41 - S-2R SKIN

LAP SPLICE, STA 368

TO STA 434 - DETAILED

INSPECTION AND SURFACE HFEC INSPECTION (a)

(a) If any existing external repair is found in the inspection area, then Part 1 inspection is not required in the

area hidden by the repair, provided that the repair was previously approved by the FAA or by a Boeing

Authorized Representative or installed in accordance with 767 SRM 53-00-01 (as specified in PART 2).

Part 1 inspections remain applicable in areas not hidden by the repair.

Group 2:

Table 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight cycles after the original

issue date of

this service bulletin

Before 40,000

total flight cycles

Do PART 1: SECTION 41

- S-2R SKIN LAP

SPLICE, STA 368 TO

STA 434 - DETAILED INSPECTION (a)

All airplanes

Repeat PART 1: SEC- - 9,000 flight cycles

TION 41 - S-2R SKIN

LAP SPLICE, STA 368

TO STA 434 - DETAILED

INSPECTION AND SURFACE HFEC INSPECTION (a)

CONDITIONS 1: NO

CRACK IS FOUND

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Group 2:

Table 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - INSPECTION AND REPAIR

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

CONDITION 2 (ACTION Before further flight -

1):

CONDITIONS 2: ANY

CRACK IS FOUND

Do PART 2: SECTION 41

- S-2R SKIN LAP

SPLICE, STA 368 TO

STA 434 - REPAIR

CONDITION 2 (ACTION - 9,000 flight cycles

2):

Repeat PART 1: SECTION 41 - S-2R SKIN

LAP SPLICE, STA 368

TO STA 434 - DETAILED

INSPECTION AND SURFACE HFEC INSPECTION (a)

(a) If any existing external repair is found in the inspection area, then Part 1 inspection is not required in the

area hidden by the repair, provided that the repair was previously approved by the FAA or by a Boeing

Authorized Representative or installed in accordance with 767 SRM 53-00-01 (as specified in PART 2).

Part 1 inspections remain applicable in areas not hidden by the repair.

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.

In addition, the Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the

accomplishment of the inspections per this service bulletin (SB) along with the corresponding compliance

times specified in paragraph 1.E., "Compliance," of SB 767-53A0260, Original issue as an alternative

method of compliance (AMOC) to the inspections, defined in D622T001-DTR Structural Significant

Item 53-10-I07A and Section 9 of the Maintenance Planning Document D622T001-9, required by

paragraphs (c) and (d) of Airworthiness Directive (AD) 2003-18-10. This AMOC only applies to the

areas inspected in accordance with this service bulletin. When this SB specifies contacting Boeing for

repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph

(e) of the AD. All provisions of AD 2003-18-10 that are not specifically referenced in this paragraph

remain fully applicable and must be complied with accordingly.

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G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

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 inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Task Number of Persons Task Hours Elapsed Hours

FIGURE 1 1 2.50 2.50

Repair (a) (a) (a)

TOTAL FOR EACH AIRPLANE (a) 2.50 2.50

(a) Manpower estimates for the repair are not included.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Boeing Service Letter 767-SL-51-036

b. Boeing Service Related Problem (SRP) 767-SRP-53-0449

c. 767 Fleet Team Digest (FTD) 53-13002

d. 767 Maintenance Planning Data (MPD)

e. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01

f. 767-200 Structural Repair Manual (SRM) 53-00-01

g. 767-200SF Structural Repair Manual (SRM) 53-00-01

h. 767-300 Structural Repair Manual (SRM) 53-00-01

i. 767-300BCF Structural Repair Manual (SRM) 53-00-01

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j. 767-400 Structural Repair Manual (SRM) 53-00-01

k. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-18-10

2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

140T0110 MONOCOQUE INTEGRATION - SECTION 41/43

SKIN SPLICE INTEGRATION INSTL - STRINGERS 2R, 26L AND

26R

141T0016

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.

K. Publications Affected

1. Publications:

Publication Chapter-Section

767 Maintenance Planning Data Section 9 (D622T001-9)

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. DTI requirements for the structure affected

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

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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2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

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

None.

2. Parts and Materials Supplied by the Operator

None.

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

None.

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, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

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

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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. 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 Values:

— Values for structural fasteners are given in 767 Structural Repair Manual,

Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 767

Airplane Maintenance Manual (AMM).

— Values for electrical maintenance tasks are included in Chapter 20 of

Standard Wiring Practices Manual (SWPM).

— Values for engine maintenance tasks are included in Chapter 70 of 767

Airplane Maintenance Manual (AMM).

— Non-standard torque values for maintenance tasks are included in the

applicable installation step.

4. 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.

5. 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.

6. Boeing Service Letter 767-SL-51-036, 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.

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7. Refer to Appendix A and Appendix B for logic diagram(s). Logic diagrams are provided

as an aid only. Information contained in Paragraph 1.E., Compliance is the primary

source for compliance times. Information in Paragraph 3.B., Work Instructions is the

primary source for tasks required for compliance.

8. 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.

9. If shading is used, shaded areas in Figures are to separate the non-critical and

non-authoritative information from the critical and authoritative information.

10. Use of colors in Figures is based on guidance from the ATA e-Business Program

(ATA) iSpec 2200.

11. When more than one OPTION is given for a CONDITION, do only one of the OPTION

numbers. When more than one ACTION is given for a CONDITION number or an

OPTION number, do all of the ACTION numbers for that CONDITION number or

OPTION number.

12. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

13. Some steps in the Work Instructions are identified as Required for Compliance (RC).

If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps

identified as RC must be done to comply with the AD. Alternative procedures for

steps not identified with RC can be used if the RC steps can still be done as specified,

and the airplane can be put back in a serviceable condition. An Alternative Method

of Compliance (AMOC) is not necessary for deviations to steps that are not identified

as RC.

B. WORK INSTRUCTIONS

1. Do PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED

INSPECTION AND SURFACE HFEC INSPECTION

CONDITION 1: NO CRACK IS FOUND

a. Repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED

INSPECTION AND SURFACE HFEC INSPECTION at the time given in Paragraph 1.E.,

Compliance.

NOTE: It is not necessary to repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA

368 TO STA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION

in areas that are covered by a repair that was previously approved by the FAA or by

a Boeing Authorized Representative or installed in accordance with 767 SRM 53-00-01

(as specified in PART 2).

CONDITION 2: ANY CRACK IS FOUND

a. CONDITION 2 (ACTION 1): Do PART 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368

TO STA 434 - REPAIR

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b. CONDITION 2 (ACTION 2): Repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA

368 TO STA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION at the time

given in Paragraph 1.E., Compliance.

NOTE: It is not necessary to repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA

368 TO STA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION

in areas that are covered by a repair that was previously approved by the FAA or by

a Boeing Authorized Representative or installed in accordance with 767 SRM 53-00-01

(as specified in PART 2).

PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION

AND SURFACE HFEC INSPECTION

1. RC - Do an external detailed and surface High Frequency Eddy Current (HFEC) inspection of the

outer skin for cracking around fastener heads common to the inboard fastener row of the stringer

S-2R skin lap splice from Body Station (STA) 368 to STA 434 in accordance with FIGURE 1.

2. Put airplane back to a serviceable condition.

PART 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - REPAIR

1. Repair cracking in accordance with 767-200 SRM 53-00-01, 767-200SF SRM 53-00-01, 767-300

SRM 53-00-01, 767-300BCF SRM 53-00-01, 767-400 SRM 53-00-01.

2. Put airplane back to a serviceable condition.

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FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND

SURFACE HFEC INSPECTION

(SHEET 1 OF 3)

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FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND

SURFACE HFEC INSPECTION

(SHEET 2 OF 3)

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

Step Task Name Identification Qty More Data

1 Inspect OUTER SKIN - - (a)

2 Inspect OUTER SKIN - - (b)

(a) Do an external detailed inspection for cracks.

(b) Do an external surface HFEC inspection of the outer skin for cracking around fastener heads common

to the inboard fastener row of the S-2R skin lap splice from STA 368 to STA 434 in accordance with 767

NDT Manual Part 6, 51-00-01 or 767 NDT Manual Part 6, 51-00-19.

FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND

SURFACE HFEC INSPECTION

(SHEET 3 OF 3)

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This Appendix applies only to: Group 1.

APPENDIX A: LOGIC DIAGRAM

(SHEET 1 OF 1)

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This Appendix applies only to: Group 2.

APPENDIX B: LOGIC DIAGRAM

(SHEET 1 OF 1)

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