### 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 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 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 Unpublished Work.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, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, 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.

Original Issue: August 26, 2014 767-53A0260 1 of 30 4.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 2 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**

BLANK PAGE**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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 3 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 4 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**

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### 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.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 5 of 30**Reference Affected**  **Planning Data** Paragraph 1.K., Publications Affected Yes Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator No Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**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 Elapsed Hours**  **Total Task Hours Airplanes**  2.50 2.50 All airplanes Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 6 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 7 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 8 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**

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.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-200/-300 airplanes line number 1 - 1068

- 1 767-400ER airplanes line number 758 - 965

- 2

Airplane Models: 767-200, 767-300, 767-400ER **Group Variable Number**  1 VA001 - VA020 1 VA301 - VA315 1 VA501 - VA530 1 VA701 - VA719 1 VA801 - VA810 1 VB001 - VB002 1 VB051 - VB055 1 VB101 - VB125

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 9 of 30**Group Variable Number**  1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 10 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 11 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT Group**  **Variable Number** 1 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 2 VQ001 - VQ021 2 VQ071 - VQ086 2 VQ111 1 VR051 - VR060 1 VR081 1 VR084 1 VR086 - VR089

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 12 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 13 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 14 of 30 **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 Zone**  **Model** 224 767-200, 767-300 **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 224 767-400ER

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 15 of 30 **BOEING SERVICE BULLETIN 767-53A0260 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)**  **Action Condition** 

- Within 3,000flight cycles after the original issue date ofthis service bulletin Before 43,000 total flight cycles Do PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TOSTA 434 - DETAILED INSPECTION AND SURFACE HFEC INSPECTION (a) All airplanes

9,000 flight cycles

- Repeat PART 1: SEC- TION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILEDINSPECTION AND SURFACE HFEC INSPECTION (a) CONDITION 1: NO CRACK IS FOUND

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 16 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT 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) Action**  **Condition**

- Before further flight CONDITION 2 (ACTION 1): CONDITION 2: ANY CRACK IS FOUND Do PART 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - REPAIR 9,000 flight cycles

- CONDITION 2 (ACTION 2):Repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILEDINSPECTION 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)**  **Action Condition** 

- Within 3,000flight cycles after the original issue date ofthis service bulletin Before 40,000 total flight cycles Do PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TOSTA 434 - DETAILED INSPECTION (a) All airplanes

9,000 flight cycles

- Repeat PART 1: SEC- TION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILEDINSPECTION AND SURFACE HFEC INSPECTION (a) CONDITIONS 1: NO CRACK IS FOUND

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 17 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT 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) Action**  **Condition**

- Before further flight CONDITION 2 (ACTION 1): CONDITIONS 2: ANY CRACK IS FOUND Do PART 2: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - REPAIR 9,000 flight cycles

- CONDITION 2 (ACTION 2):Repeat PART 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILEDINSPECTION 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 18 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT 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. **Elapsed Hours Task Hours**  **Number of Persons Task**  2.50 2.50 1 FIGURE 1 (a) (a) (a) Repair 2.50 2.50 TOTAL FOR EACH AIRPLANE (a) (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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 19 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**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:
**Title Drawing Number**  MONOCOQUE INTEGRATION - SECTION 41/43 140T0110 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: **Chapter-Section Publication**  Section 9 (D622T001-9) 767 Maintenance Planning Data 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 20 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 21 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 22 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**

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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 23 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 24 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 25 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND**  **SURFACE HFEC INSPECTION (SHEET 1 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 26 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT FIGURE 1: SECTION 41 - S-2R SKIN LAP SPLICE, STA 368 TO STA 434 - DETAILED INSPECTION AND**  **SURFACE HFEC INSPECTION (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 27 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - OUTER SKIN Inspect 1 (b)

- - OUTER SKIN Inspect 2 (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)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 28 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT This Appendix applies only to: Group 1.** 

**APPENDIX A: LOGIC DIAGRAM (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 29 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT This Appendix applies only to: Group 2.** 

**APPENDIX B: LOGIC DIAGRAM (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 26, 2014 767-53A0260 30 of 30 **BOEING SERVICE BULLETIN 767-53A0260 ALERT**  **ALERT**