Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-27-0062

Original Issue: July 18, 2006

Revision 2: January 27, 2014

ATA System: 2721 2731 1221

SUBJECT: FLIGHT CONTROLS - Elevator and Rudder Control System - Elevator, Rudder and

Rudder Tab - Freeplay Inspection and Lubrication

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 © 2006 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Unpublished Work.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

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2.0
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BLANK PAGE
Table of Contents

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

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 21

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 23

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIGURE 1: ELEVATOR FREEPLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 2: RUDDER FREEPLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FIGURE 3: RUDDER TAB FREEPLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Appendix A: ELEVATOR FREEPLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Appendix B: RUDDER FREEPLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Appendix C: RUDDER TAB FREEPLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 777-27-0062

Original Issue: July 18, 2006

Revision 2: January 27, 2014

ATA System: 2721 2731 1221

SUBJECT: FLIGHT CONTROLS - Elevator and Rudder Control System - Elevator, Rudder and

Rudder Tab - Freeplay Inspection and Lubrication

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive (AD) FAA AD 2007-13-05, is related to this service

bulletin. The effective date of FAA AD 2007-13-05 is July 25, 2007.

The FAA will possibly release an additional AD related to this service bulletin. The AD will make the compliance

tasks and times given in this service bulletin mandatory.

No more work is necessary on the airplanes inspected in accordance with Revision 1 of this service bulletin.

REASON FOR REVISION

This revision is sent to give an improved procedure to inspect for rudder freeplay. The procedure for the rudder

freeplay inspection as given in Revision 1 of this service bulletin does not properly detect excessive freeplay in

the rudder control load loop. One operator reported that the procedure in Revision 1 had passed a freeplay

inspection on an airplane that had missing self-lubricating liners in the reaction link end cap of each rudder

Power Control Unit (PCU). An investigation found that the force specified in the procedure was not sufficient to

overcome the normal friction of the rudder. The rudder freeplay test procedure as given in this service bulletin

was validated.

Boeing Fleet Team Digest (FTD) 777 FTD 27-12002 is related to this service bulletin.

Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph

3.A., General Information - Notes.

These sections were changed:

1. Summary - Background: Added summary evaluation table.

2. Summary- Background and Paragraph 1.C., Reason: Added new references and updated the background

information.

3. Summary- Paragraph 1.C., Reason: Added reason for revision paragraph and new information notice

incorporation.

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4. Summary- Compliance: Added the effective date of the Airworthiness Directive (AD).

5. Paragraph 1.A.1, Airplanes: Added note.

6. Paragraph 1.E., Compliance: Revised the compliance tables to change the time units from months to

days and added an AD paragraph. Time units were revised to be consistent with standard 777 operator

maintenance intervals.

7. Paragraph 1.J.1., Existing Data: Added references and updated Component Maintenance Manual

(CMM) supplier information.

8. Paragraph 1.F., Approval: Added reference, deleted text.

9. Paragraph 1.M., Software Accomplishment Summary, added text.

10. Paragraph 3.B., Work Instructions: Updated the general notes section, changed terminology for work

instruction steps.

11. Appendix A: Changed terminology, added tolerances, clarified the force scale range, and revised

supplier manual references.

12. Appendix B: Added notes, revised the procedure to inspect for rudder freeplay, clarified the force scale

range, added tolerances, revised illustration, and revised supplier manual references.

13. Appendix C: Added notes, added tolerances, and clarified the force scale range.

The data given in Information Notice 777-27-0062 IN 02 is included in this revision.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes,

to show the location of all content changes.

Pages with no vertical lines have no changes.

REVISION HISTORY

Original Issue: July 18, 2006

Revision 1: October 01, 2009

Revision 2: January 27, 2014

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BOEING SERVICE BULLETIN 777-27-0062
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Summary Number: 777-27-0062

Original Issue: July 18, 2006

Revision 2: January 27, 2014

ATA System: 2721 2731 1221

SUBJECT: FLIGHT CONTROLS - Elevator and Rudder Control System - Elevator, Rudder and

Rudder Tab - Freeplay Inspection and Lubrication

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None

BACKGROUND

This inspection and lubrication will help prevent freeplay-induced vibration of the control surfaces. Excessive

corrosion and wear of components and/or interfaces allows excessive freeplay of the control surfaces and can

cause unacceptable airframe vibration during flight. The potential for vibration of the control surface should be

avoided because the point of transition from vibration to divergent flutter is unknown. Flutter can cause damage

to the control surface structure during flight, which could result in the loss of control of the airplane.

This inspection and lubrication will help prevent conditions which could allow excessive freeplay of control

surfaces. There have been reports pertaining to flutter-critical unbalanced control surfaces on 727, 737, 757,

767 and 777 airplanes.

Boeing Service Related Problems (SRPs) 777-SRP-27-0166 and 777-SRP-27-0228 are related to this service

bulletin.

Boeing Fleet Team Digest (FTD) 777 FTD 27-12002 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

Publications Affected Yes Paragraph 1.K., Publications Affected

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Planning Data Affected Reference

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

PART 1

Do the procedure to inspect the elevator freeplay. Make the necessary repairs if the freeplay is more than the

specified limit.

PART 2

Do a lubrication of the elevator hinge bearings, reaction links, and Power Control Unit (PCU) rod ends.

PART 3

Do the procedure to inspect the rudder freeplay. Make the necessary repairs if the freeplay is more than the

specified limit.

PART 4

Do a lubrication of the rudder hinge bearings, reaction links, and PCU rod ends.

PART 5

Do the procedure to inspect the rudder tab freeplay. Make the necessary repairs if the freeplay is more than the

specified limit.

PART 6

Do a lubrication of the rudder tab hinge bearings.

NOTE: The terms Power Control Unit (PCU) and Power Control Actuator (PCA) are used interchangeably in

both Boeing and Vendor supplied manuals and drawings. For consistency throughout this service

bulletin, the term PCU is used.

EFFECTIVITY

All 777-200, 777-200LR, 777-300, and 777-300ER Airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity.

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BOEING SERVICE BULLETIN 777-27-0062
COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive (AD) FAA AD 2007-13-05, is related to this service

bulletin. The effective date of FAA AD 2007-13-05 is July 25, 2007.

The FAA will possibly release an additional AD related to this service bulletin. The AD will make the compliance

tasks and times given in this service bulletin mandatory.

Refer to Paragraph 1.E., for Compliance information.

INDUSTRY SUPPORT INFORMATION

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

bulletin.

MANPOWER

Total Task Hours Elapsed Hours

PART 1 4.0 2.0

PART 2 16.5 8.25

PART 3 4.0 2.0

PART 4 7.0 3.5

PART 5 3.0 1.5

PART 6 5.0 2.5

NOTE: The manpower for Part 5, "Rudder Tab Freeplay Inspection," can be decreased if it is done at the same

time as Part 3, "Rudder Freeplay Inspection".

MATERIAL INFORMATION

None.

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BOEING SERVICE BULLETIN 777-27-0062
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-27-0062

Original Issue: July 18, 2006

Revision 2: January 27, 2014

ATA System: 2721 2731 1221

SUBJECT: FLIGHT CONTROLS - Elevator and Rudder Control System - Elevator, Rudder and

Rudder Tab - Freeplay Inspection and Lubrication

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

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

Number, and Serial Number data.

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

NOTE: Variable numbers for airplanes scheduled to be delivered more than a year after the

Revision 2 date of this service bulletin are not listed in the table below. MyBoeingFleet

(MBF) will show current listing of the affected airplanes.

NOTE: This service bulletin is for the airplanes shown in the effectivity list below. The effectivity

list includes all affected airplanes scheduled to be delivered before NOV 25, 2014. In

addition, at least one airplane scheduled to be delivered after NOV 25, 2014 is affected

by this service bulletin and is in Group(s) 1 as described in the Group Configuration table.

Affected airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) "get

effectivity" result when they are added to the MBF Fleet Profile Page.

GROUP CONFIGURATION DESCRIPTION

1 - All 777-200, 777-200LR, 777-300, and 777-300ER airplanes.

Airplane Models:

777-200, 777-200LR, 777-300, 777-300ER

Variable Number Group

WA001 - WA017 1

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Variable Number Group

WA076 - WA080 1

WA086 - WA093 1

WA101 - WA104 1

WA116 - WA119 1

WA131 - WA137 1

WA171 - WA175 1

WA196 - WA198 1

WA206 - WA212 1

WA221 - WA223 1

WA231 - WA232 1

WA241 - WA250 1

WA261 - WA266 1

WA281 - WA283 1

WA301 - WA304 1

WB001 - WB021 1

WB031 - WB046 1

WB051 - WB088 1

WB101 - WB106 1

WB121 - WB125 1

WB131 - WB148 1

WB151 - WB155 1

WB161 - WB177 1

WB181 - WB194 1

WB201 - WB215 1

WB231 - WB247 1

WB271 - WB273 1

WB276 - WB286 1

WB291 - WB302 1

WB306 - WB307 1

WB311 - WB337 1

WB341 - WB342 1

WB366 - WB368 1

WB371 - WB388 1

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BOEING SERVICE BULLETIN 777-27-0062
Variable Number Group

WB406 1

WB411 - WB413 1

WB416 - WB439 1

WB446 - WB453 1

WB476 1

WB481 - WB484 1

WB501 - WB512 1

WB531 - WB537 1

WB551 - WB554 1

WB591 - WB597 1

WB601 - WB606 1

WB611 - WB622 1

WB631 - WB638 1

WB646 - WB649 1

WC051 - WC073 1

WC101 - WC104 1

WC111 - WC120 1

WC221 - WC224 1

WC241 - WC243 1

WC281 - WC290 1

WC301 - WC308 1

WC361 - WC364 1

WC371 - WC374 1

WC381 - WC395 1

WC441 1

WC446 - WC449 1

WC456 - WC459 1

WC486 - WC493 1

WC506 - WC508 1

WC521 - WC522 1

WC531 - WC536 1

WC546 - WC548 1

WC556 1

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BOEING SERVICE BULLETIN 777-27-0062
Variable Number Group

WC566 - WC567 1

WC571 - WC574 1

WC581 1

WC586 - WC587 1

WC591 - WC595 1

WD001 - WD002 1

WD011 - WD018 1

WD031 - WD036 1

WD046 - WD055 1

WD066 - WD075 1

WD081 - WD089 1

WD091 1

WD096 1

WD101 - WD106 1

WD111 1

WD116 - WD117 1

WD121 - WD122 1

WD501 - WD513 1

WD521 - WD541 1

WD546 - WD554 1

WD561 - WD573 1

WD581 - WD599 1

WD606 - WD609 1

WD621 - WD632 1

WD651 - WD665 1

WD671 - WD677 1

WD691 - WD709 1

WD741 - WD752 1

WD761 - WD771 1

WD786 - WD788 1

WD796 - WD837 1

WD846 - WD867 1

WD871 - WD897 1

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BOEING SERVICE BULLETIN 777-27-0062
Variable Number Group

WD911 - WD918 1

WD921 - WD930 1

WD936 - WD957 1

WD966 - WD970 1

WD981 - WD982 1

WD986 - WD987 1

WD991 - WD994 1

WD996 1

WE001 - WE004 1

WE011 - WE012 1

WE021 - WE026 1

WE031 - WE034 1

WE051 - WE057 1

WE071 - WE078 1

WE081 - WE084 1

WE091 - WE095 1

WE126 - WE146 1

WE151 - WE169 1

WE176 - WE178 1

WE186 - WE219 1

WE226 - WE231 1

WE236 - WE248 1

WE251 - WE253 1

WE261 - WE267 1

WE271 - WE278 1

WE291 - WE293 1

WE301 - WE314 1

WE331 - WE340 1

WE351 - WE356 1

WE376 - WE377 1

WE381 1

WE386 - WE387 1

WE396 - WE399 1

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BOEING SERVICE BULLETIN 777-27-0062
Variable Number Group

WE416 - WE420 1

WE426 1

WE436 - WE437 1

WE441 - WE443 1

WE451 1

WE486 1

WE501 - WE503 1

WE556 - WE557 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This inspection and lubrication will help prevent freeplay-induced vibration of the control surfaces.

Excessive corrosion and wear of components and/or interfaces allows excessive freeplay of the control

surfaces and can cause unacceptable airframe vibration during flight. The potential for vibration of the

control surface should be avoided because the point of transition from vibration to divergent flutter is

unknown. Flutter can cause damage to the control surface structure during flight, which could result in

the loss of control of the airplane.

This inspection and lubrication will help prevent conditions which could allow excessive freeplay of

control surfaces. There have been reports pertaining to flutter-critical unbalanced control surfaces on

727, 737, 757, 767 and 777 airplanes.

Boeing Service Related Problems (SRPs) 777-SRP-27-0166 and 777-SRP-27-0228 are related to

this service bulletin.

Boeing Fleet Team Digest (FTD) 777 FTD 27-12002 is related to this service bulletin.

Revision 1 is sent to replace optional tool kit J27079-1 with optional tool kit J27079-31 in Appendix A,

and add tool kit J20003-34 as optional to J20003-1 in Appendices A, B and C. The indicator included

in J27079-1 does not have the range of travel necessary for the work in Appendix A. Thus Boeing

superseded tool kit J27079-1 with tool kit J27079-31. The indicator included in J27079-31 has the range

of travel necessary for the work in Appendix A. Also, Federal Aviation Administration (FAA) Airworthiness

Directive FAA AD 2007-13-05 is added, and in Paragraph 3.B., Work Instructions, Part 1 thru Part 6,

the notes which tell you to do the freeplay inspection before the lubrication if at the same maintenance

period are removed.

The data given in Information Notice 777-27-0062 IN 01 is included in this revision.

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BOEING SERVICE BULLETIN 777-27-0062
Revision 2 is sent to give an improved procedure to inspect for rudder freeplay. The procedure for the

rudder freeplay inspection as given in Revision 1 of this service bulletin does not properly detect

excessive freeplay in the rudder control load loop. One operator reported that the procedure in Revision

1 had passed a freeplay inspection on an airplane that had missing self-lubricating liners in the reaction

link end cap of each rudder Power Control Unit (PCU). An investigation found that the force specified

in the procedure was not sufficient to overcome the normal friction of the rudder. The rudder freeplay

test procedure as given in this service bulletin was validated.

The data given in Information Notice 777-27-0062 IN 02 is included in this revision.

D. Description

PART 1

Do the procedure to inspect the elevator freeplay. Make the necessary repairs if the freeplay is more

than the specified limit.

PART 2

Do a lubrication of the elevator hinge bearings, reaction links, and Power Control Unit (PCU) rod ends.

PART 3

Do the procedure to inspect the rudder freeplay. Make the necessary repairs if the freeplay is more

than the specified limit.

PART 4

Do a lubrication of the rudder hinge bearings, reaction links, and PCU rod ends.

PART 5

Do the procedure to inspect the rudder tab freeplay. Make the necessary repairs if the freeplay is more

than the specified limit.

PART 6

Do a lubrication of the rudder tab hinge bearings.

NOTE: The terms Power Control Unit (PCU) and Power Control Actuator (PCA) are used

interchangeably in both Boeing and Vendor supplied manuals and drawings. For consistency

throughout this service bulletin, the term PCU is used.

Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of

this service bulletin. But, operators must continue to do the repeat inspections/lubrications in accordance

with Paragraph 1.E., Compliance.

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

service bulletin. But, operators must continue to do the repeat inspections/lubrications in accordance

with Paragraph 1.E., Compliance.

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

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Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777-300, 324, 325, 326, 335, 336, 345, 346

777-300ER

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive (AD) FAA AD 2007-13-05, is related to

this service bulletin. The effective date of FAA AD 2007-13-05 is July 25, 2007.

The FAA will possibly release an additional AD related to this service bulletin. The AD will make the

compliance tasks and times given in this service bulletin mandatory.

Table 1 - Freeplay Inspection and Lubrication of the Elevator

Repeat Interval

(not to exceed)

Condition Action Compliance Time (whichever occurs later)

12,000 Flight

Hours or 1,125

days whichever

occurs first.

Within 1,125 days after the

date of issuance of the original standard certificate of

airworthiness or original export certificate of airworthiness

Within 1,125 days

after the original issue date on this

service bulletin

Inspect the Elevator

Freeplay in accordance with

Accomplishment Instruction

3.B., Part 1. (a)

All

5,000 Flight Hours

or 500 days

whichever occurs

first.

Within 500 days after the

date of issuance of the original standard certificate of

airworthiness or original export certificate of airworthiness

Within 500 days after the original issue date on this

service bulletin

Lubricate the elevator hinge

bearings, reaction links, and

PCU rod ends in accordance with Accomplishment

Instruction 3.B., Part 2.

(a) If any discrepancies are found in the system, as specified in the listed accomplishment instruction, the

discrepancy must be corrected before further flight.

Table 2 - Freeplay Inspection and Lubrication of the Rudder

Repeat Interval

(not to exceed)

Condition Action Compliance Time (whichever occurs later)

12,000 Flight

Hours or 1,125

days whichever

occurs first.

Within 1,125 days after the

date of issuance of the original standard certificate of

airworthiness or original export certificate of airworthiness

Within 1,125 days

after the original issue date on this

service bulletin

Inspect the Rudder Freeplay

in accordance with Accomplishment Instruction 3.B.,

Part 3. (a)

All

5,000 Flight Hours

or 500 days

whichever occurs

first.

Within 500 days after the

date of issuance of the original standard certificate of

airworthiness or original export certificate of airworthiness

Within 500 days after the original issue date on this

service bulletin

Lubricate the rudder hinge

bearings, reaction links, and

PCU rod ends in accordance with Accomplishment

Instruction 3.B., Part 4.

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Table 2 - Freeplay Inspection and Lubrication of the Rudder

Repeat Interval

(not to exceed)

Condition Action Compliance Time (whichever occurs later)

(a) If any discrepancies are found in the system, as specified in the listed accomplishment instruction, the

discrepancy must be corrected before further flight.

Table 3 - Freeplay Inspection and Lubrication of the Rudder Tab

Repeat Interval

(not to exceed)

Condition Action Compliance Time (whichever occurs later)

12,000 Flight

Hours or 1,125

days whichever

occurs first.

Within 1,125 days after the

date of issuance of the original standard certificate of

airworthiness or original export certificate of airworthiness

Within 1,125 days

after the original issue date on this

service bulletin

Inspect the Rudder Tab

Freeplay in accordance with

Accomplishment Instruction

3.B., Part 5. (a)

All

5,000 Flight Hours

or 500 days

whichever occurs

first.

Within 500 days after the

date of issuance of the original standard certificate of

airworthiness or original export certificate of airworthiness

Within 500 days after the original issue date on this

service bulletin

Lubricate the rudder tab

hinge bearings in accordance with Accomplishment

Instruction 3.B., Part 6.

(a) If any discrepancies are found in the system, as specified in the listed accomplishment instruction, the

discrepancy must be corrected before further flight.

NOTE: The tasks given in this service bulletin are related to scheduled maintenance. To help keep

compliance with this service bulletin, you can adjust your maintenance plan to include the

procedures and intervals given in this service bulletin. These are the related item numbers in

the 777 Maintenance Planning Document (MPD), Section 1:

— 12-002-01, Elevator PCU and Hinge lubrication

— 12-004-00, Rudder and Rudder Tab lubrication

— 27-240-00, Elevator Freeplay

— 27-430-00, Rudder and Rudder Tab Freeplay

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.

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

Certification Office approves the freeplay inspection and lubrication methods of the elevator, rudder,

and rudder tab components as specified in this service bulletin as an AMOC to the freeplay inspection

and lubrication methods of the elevator, rudder and rudder tabs components defined in Service Bulletin

777-27-0062, dated July 18, 2006, required by paragraph (f) and (g) of AD 2007-13-05. All provisions

of AD 2007-13-05 that are not specifically referenced in the preceding sentence remain fully applicable

and must be complied with.

G. Manpower

The table below shows an estimate of the task-hours necessary to do the check and lubrication for the

rudder, elevator and rudder tab. 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.

Number of Task-Hours Elapsed Hours

Persons

Task

PART 1 2 4.0 2.0

PART 2 2 16.5 8.25

TOTAL FOR EACH AIRPLANE 20.5 10.25

Number of Task-Hours Elapsed Hours

Persons

Task

PART 3 2 4.0 2.0

PART 4 2 7.0 3.5

TOTAL FOR EACH AIRPLANE 11.0 5.5

Number of Task-Hours Elapsed Hours

Persons

Task

PART 5 2 3.0 1.5

PART 6 2 5.0 2.5

TOTAL FOR EACH AIRPLANE 8.0 4.0

NOTE: — The manpower for Part 5, "Rudder Tab Freeplay Inspection," can be decreased if it is

done at the same time as Part 3, "Rudder Freeplay Inspection".

— These estimates do not include the time to replace worn components found by the

inspections.

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BOEING SERVICE BULLETIN 777-27-0062
H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. 777 Aircraft Maintenance Manual (AMM) 12-21-04, 12-21-06, 24-22-00, 27-21-11, 27-21-12,

27-31-09, 27-31-10, 29-11-00

b. Component Maintenance Manual (CMM) 27-21-77, 27-32-06, 55-20-23, 55-20-24, 55-40-14,

55-40-15, 55-40-16, 55-40-17, 55-40-18

c. Nabtesco Component Maintenance Manual (CMM) 27-21-01, 27-21-11, 27-31-01

d. Parker Aerospace Component Maintenance Manual (CMM) 27-21-02

e. Service Letter 777-SL-20-006-C

f. Boeing Service Related Problem (SRP) 777-SRP-27-0166, 777-SRP-27-0228

g. 777 MPD Section 1

h. Federal Aviation Administration (FAA) Airworthiness Directive 2007-13-05

i. Information Notice 777-27-0062 IN 01, 777-27-0062 IN 02

j. 777 Fleet Team Digest (FTD) 27-12002

2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

173W0012 Rudder Installation

251W3100 Rudder Power Control Unit - Installation

251W2100 Elevator Power Control Unit - Installation

183W0001 Elevator Installation

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

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

not be applicable to all airplane configurations or operators.

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BOEING SERVICE BULLETIN 777-27-0062
K. Publications Affected

1. Publications:

Publication Chapter-Section

777 Maintenance Manual 27-21, 27-31

777 Maintenance Planning Document SECTION 1

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 777-27-0062
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 appendices and 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 777 Structural Repair Manual,

Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 777

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 777

Airplane Maintenance Manual (AMM).

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

applicable installation step.

4. 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.

5. 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.

6. 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.

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

are in Paragraph 1.E., Compliance.

B. WORK INSTRUCTIONS

PART 1: ELEVATOR FREEPLAY INSPECTION

1. At the times given in Paragraph 1.E., Compliance, do a freeplay inspection of the Left Side and

Right Side Elevator in accordance with FIGURE 1.

2. Put the airplane back to a serviceable condition.

PART 2: LUBRICATION OF ELEVATOR COMPONENTS

1. Refer to Paragraph 1.E., Compliance, for the interval at which the elevator hinge bearings, reaction

links, and PCU rod ends need lubrication.

a. Lubricate the elevator hinge bearings, reaction links, and PCU rod ends. Refer to 777 AMM

12-21-04 as an accepted procedure.

2. Put the airplane back to a serviceable condition.

PART 3: RUDDER FREEPLAY INSPECTION

1. At the times given in Paragraph 1.E., Compliance, do a freeplay inspection of the Rudder in

accordance with FIGURE 2.

2. Put the airplane back to a serviceable condition.

PART 4: LUBRICATION OF RUDDER COMPONENTS

1. Refer to Paragraph 1.E., Compliance, for the interval at which the rudder hinge bearings, reaction

links, and PCU rod ends need lubrication.

a. Lubricate the rudder hinge bearings, reaction links, and PCU rod ends. Refer to 777 AMM

12-21-06 as an accepted procedure.

2. Put the airplane back to a serviceable condition.

PART 5: RUDDER TAB FREEPLAY INSPECTION

1. At the times given in Paragraph 1.E., Compliance, do a freeplay inspection of the Rudder Tab in

accordance with FIGURE 3.

2. Put the airplane back to a serviceable condition.

PART 6: LUBRICATION OF RUDDER TAB COMPONENTS

1. Refer to Paragraph 1.E., Compliance, for the interval at which the rudder tab hinge bearings need

lubrication.

a. Lubricate the rudder tab hinge bearings. Refer to 777 AMM 12-21-06 as an accepted procedure.

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2. Put the airplane back to a serviceable condition.

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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 airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in accordance with APPENDIX A - Elevator Freeplay Inspection.Elevator Freeplay - -

(Left Side)

1 Inspect

in accordance with APPENDIX A - Elevator Freeplay Inspection.Elevator Freeplay - -

(Right Side)

2 Inspect

FIGURE 1: ELEVATOR FREEPLAY INSPECTION

(SHEET 1 OF 1)

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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 airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in accordance with APPENDIX B -

Rudder Freeplay Inspection

1 Inspect Rudder Freeplay - -

FIGURE 2: RUDDER FREEPLAY INSPECTION

(SHEET 1 OF 1)

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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 airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

in accordance with APPENDIX C -

Rudder Tab Freeplay Inspection.

Rudder Tab - -

Freeplay

1 Inspect

FIGURE 3: RUDDER TAB FREEPLAY INSPECTION

(SHEET 1 OF 1)

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1. Elevator Freeplay Inspection

a. References:

Reference Task

777 AMM 24-22-00 Supply Electrical Power

777 AMM 29-11-00 Main Hydraulic System Pressurization

777 AMM 29-11-00 Main Hydraulic System Power Removal

777 AMM 27-31-10 Elevator - Removal/Installation

777 AMM 27-31-09 Elevator Power Control Units - Removal/Installation

CMM 55-20-23 Elevator Assembly

CMM 55-20-24 Elevator Assembly

CMM 27-32-06 Elevator Power Control Unit Link Assemblies

Nabtesco CMM 27-31-01 Elevator Power Control Unit Assembly

b. Tools/Equipment

The tools and equipment described below are necessary to do this inspection.

NOTE: You can get the mounting device, dial indicator, and force gage from the optional

tool kit J27079-31, Inspection Equipment - Elevator Freeplay.

—

— You can get the rig pins from tool kit J20003-1 (J20003-34 optional), Pin Set - Rigging

(1) Dial Indicator - 0.001 inch (0.03 mm) accuracy or better, 0.50 inch (15 mm) minimum range.

NOTE: Analog type dial indicator is recommended.

(2) Mounting device to hold the dial indicator tightly against the fuselage.

NOTE: A magnetic indicator base, tape, and a thin piece of steel approximately 3 inches

(80 mm) wide and 3 inches (80 mm) long can be used as an alternative to the

J27079-4 Suction Cup Assembly.

(3) Force scale or transducer capable of the application and measurement of the specified forces.

The accepted measurement device specifications are as follows:

(a) Specifications for the device to apply and measure the 170 +/- 10 pound (756 +/- 45

newton) upward force:

1) Range: 0 to 200 pound (0 to 890 newtons) or more.

2) Accuracy: +/- 2.5 pounds (11 newtons) or better.

3) Resolution: 5 pounds (22 newtons) or better.

Appendix A: ELEVATOR FREEPLAY INSPECTION

(SHEET 1 OF 11)

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(4) Rig pin E1 and E2.

c. Location Zones

Zone Area

335 Left Horizontal Stabilizer - Rear Spar to Trailing Edge

336 Left Elevator

345 Right Horizontal Stabilizer - Rear Spar to Trailing Edge

346 Right Elevator

d. Access Panels

Number Name/Location

112AL Forward Access Door

e. Prepare for the Freeplay Inspection

(1) Supply electrical power. Refer to 777 AMM 24-22-00 as an accepted procedure.

WARNING: DO NOT MOVE THE CONTROL COLUMNS DURING THIS PROCEDURE. IF A

CONTROL COLUMN IS MOVED, THEN THE ELEVATOR WILL MOVE.

(2) Attach DO-NOT-OPERATE tags to the captain's and first officer's control columns.

(3) Open access panel 112AL - Forward Access Door.

(4) From the rigging pin set, install rig pins E1 and E2 in the torque tubes for the control columns.

Refer to Appendix A - Illustration 1a and 1b.

NOTE: Install the rig pins to prevent accidental movement of the control columns.

f. Freeplay Inspection

NOTE: Each elevator surface has two PCUs. You will do this elevator freeplay inspection once

for each PCU. Each time, only one PCU will have hydraulic power (on the elevator surface

that you inspect).

Appendix A: ELEVATOR FREEPLAY INSPECTION

(SHEET 2 OF 11)

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WARNING: KEEP PERSONS AND EQUIPMENT CLEAR OF THE FLIGHT CONTROL

SURFACES, THE THRUST REVERSERS, AND THE LANDING GEAR. THESE

COMPONENTS CAN MOVE SUDDENLY WHEN YOU SUPPLY HYDRAULIC

POWER. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO

EQUIPMENT.

WARNING: DO NOT CLOSE THE FLIGHT CONTROL SHUTOFF VALVES DURING THIS

INSPECTION. IF A VALVE IS CLOSED BEFORE ITS RELATED HYDRAULIC

SYSTEM IS DEPRESSURIZED, AN ELEVATOR MAY MOVE. THIS CAN CAUSE

INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT.

WARNING: REMOVING HYDRAULIC PRESSURE TO ALL THE PCU'S FOR A SINGLE

ELEVATOR SURFACE MAY RESULT IN THAT SURFACE SLOWLY LOWERING.

KEEP PERSONS AND EQUIPMENT CLEAR OF THE ELEVATOR SURFACE WHEN

REMOVING ALL HYDRAULIC SYSTEM PRESSURE TO THE PCU'S OF THAT

SURFACE. FAILURE TO OBEY THESE INSTRUCTIONS CAN CAUSE INJURIES

TO PERSONS AND DAMAGE TO EQUIPMENT.

(1) Supply pressure to one of the two PCUs for the elevator surface. Table 1 shows the correct

hydraulic systems to pressurize for each inspection.

(a) Supply hydraulic power to the left, center, and right hydraulic systems. Refer to 777 AMM

29-11-00 as an accepted procedure. This is the setup step for the inspection.

NOTE: You can do the inspections in any order. For each PCU, you must do this setup

step before the inspection step in accordance with Table 1.

(b) Remove hydraulic power from one hydraulic system in accordance with Table 1 for the

inspection step. Refer to 777 AMM 29-11-00 as an accepted procedure.

TABLE 1

POWER CONTROL UNIT STEP HYDRAULIC SYSTEM PRESSURE

(PCU) LEFT CENTER RIGHT

Left Elevator, Outboard PCU Setup ON ON ON

Inspection ON OFF ON

Left Elevator, Inboard PCU Setup ON ON ON

Inspection OFF ON ON

Right Elevator, Inboard PCU Setup ON ON ON

Inspection OFF ON ON

Right Elevator, Outboard PCU Setup ON ON ON

Inspection ON ON OFF

Appendix A: ELEVATOR FREEPLAY INSPECTION

(SHEET 3 OF 11)

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(2) Install a dial indicator on the side of the empennage. Put the plunger of the dial indicator on

the elevator so that it will measure the vertical movement at the elevator trailing edge. Make

sure that the plunger is less than 0.50 inches (12.7 mm) forward of the trailing edge. Refer to

Appendix A - Illustration 2.

NOTE: Illustration 2 shows the equipment from optional tool kit J27079-31. Shims may be

required to make sure that the base is stable.

CAUTION: USE SUFFICIENT PADDING WHEN YOU APPLY THE FORCE TO PREVENT

DAMAGE TO THE ELEVATOR SURFACE. USE A PAD THAT DISTRIBUTES THE

FORCE OVER AN AREA OF 20 SQUARE INCHES (130 SQUARE CENTIMETERS)

OR MORE.

(3) Push down on the elevator with a force of 100 +/- 10 pounds (445 +/- 45 newtons) and then

release the elevator. The center of the force must be on the elevator rib that is aligned with

the PCU that has hydraulic power. Also, the center of the force must be 6 +/- 1 inches (152

+/- 25 mm) forward of the trailing edge of the elevator.

(4) Set the dial indicator to zero.

NOTE: The elevator PCU makes small position adjustments continuously. This can cause

the dial indicator needle to move continuously through a constant range. Set the

zero on the dial indicator to the middle of the needle's movement range.

WARNING: MAKE SURE THAT YOU USE A STRONG AND STABLE PLATFORM TO HOLD

YOU, YOUR EQUIPMENT, AND THE ADDITIONAL 170 POUNDS (77 KILOGRAMS)

FORCE OF THE JACK. THE PLATFORM CAN FALL IF IT DOES NOT HAVE A

SUFFICIENT WEIGHT CAPACITY.

CAUTION: USE SUFFICIENT PADDING ON THE FORCE GAGE TO PREVENT DAMAGE TO

THE ELEVATOR SURFACE. USE A PAD THAT DISTRIBUTES THE FORCE OVER

AN AREA OF 20 SQUARE INCHES (130 SQUARE CENTIMETERS) OR MORE.

(5) Put a pad, a force gage, and a jack in position under the elevator. Refer to Appendix A -

Illustration 3. The center of the pad must be on the elevator rib that is aligned with the PCU

that has hydraulic power. Also, the center of the pad must be 6 +/- 1 inches (152 +/- 25 mm)

forward of the trailing edge of the elevator.

NOTE: Illustration 3b shows the equipment from optional tool kit J27079-31.

(6) Use the jack to push the elevator up with 170 +/- 10 pounds (756 +/- 45 newtons) of force.

(7) Read the dial indicator.

NOTE: The elevator PCU makes small position adjustments continuously. This can cause

the dial indicator needle to move continuously through a constant range. To read

the value, find the middle of the needle's movement range.

Appendix A: ELEVATOR FREEPLAY INSPECTION

(SHEET 4 OF 11)

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BOEING SERVICE BULLETIN 777-27-0062
(a) If the dial indicator shows more than 0.30 inch (7.6 millimeters), then you must make

repairs as necessary to decrease the freeplay to less than 0.30 inch (7.6 mm). Do the

freeplay inspection again after you have made the necessary repairs. You can use these

accepted procedures and documents to help find, repair, or replace the worn parts:

1) Refer to 777 AMM 27-31-10 as an accepted procedure for the removal and installation

of the elevators.

2) Refer to CMM 55-20-23 or CMM 55-20-24 as an accepted procedure for the inspection

and repair of the elevator hinges, actuator fittings, and related bushings.

3) Refer to 777 AMM 27-31-09 as an accepted procedure for the inspection, removal,

or replacement of the PCU and PCU reaction links. Refer to CMM 27-32-06 as an

accepted procedure for the repair of the reaction link and kick link bearings.

NOTE: Kick link bearings can affect freeplay. The kick link is an integral part of the

elevator PCU installation. A partial removal of the kick link from the PCU is

included in the AMM procedure for the reaction link removal.

4) Refer to Nabtesco CMM 27-31-01 as an accepted procedure for the inspection and

repair of the PCU rod end bearing.

NOTE:

— The PCU rod end bearing will make a small amount of dark-colored

powder which can be seen at the edge of the bearing liner. This powder

is permitted and comes from the wear of the self-lubricating bearing

liner.

— It is possible that the dust seal has come off the PCU rod end bearing.

It is not necessary to replace the bearing or the dust seal if the bearing

is within the permitted wear limits.

(8) Remove the force.

(9) Remove the dial indicator, the force gauge, the jack, and the pad.

(10) Repeat step 1.F., Freeplay Inspection, for each remaining elevator PCU.

g. Put the Airplane Back to a Serviceable Condition

WARNING: REMOVING HYDRAULIC SYSTEM PRESSURE TO ALL THE PCU'S FOR A SINGLE

ELEVATOR SURFACE MAY RESULT IN THAT SURFACE SLOWLY LOWERING.

KEEP PERSONS AND EQUIPMENT CLEAR OF THE ELEVATOR SURFACE WHEN

REMOVING ALL HYDRAULIC SYSTEM PRESSURE TO THE PCU'S OF THAT

SURFACE. FAILURE TO OBEY THESE INSTRUCTIONS CAN CAUSE INJURIES

TO PERSONS AND DAMAGE TO EQUIPMENT.

(1) Remove power from the left, center and right hydraulic systems. Refer to 777 AMM 29-11-00

as an accepted procedure.

Appendix A: ELEVATOR FREEPLAY INSPECTION

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(2) Remove rig pins E1 and E2 from the torque tubes for the control columns. Refer to Appendix

A - Illustration 1a and 1b.

(3) Close access panel 112AL - Forward Access Door.

(4) Remove the DO-NOT-OPERATE tags from the captain's and first officer's control columns.

Appendix A: ELEVATOR FREEPLAY INSPECTION

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Illustration 1a - Elevator Rig Pin Installation

Appendix A: ELEVATOR FREEPLAY INSPECTION

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Illustration 1b - Elevator Rig Pin Installation

Appendix A: ELEVATOR FREEPLAY INSPECTION

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Illustration 2 - Dial Indicator Setup Example

Appendix A: ELEVATOR FREEPLAY INSPECTION

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Illustration 3a - Jack and Force Gauge Setup

Appendix A: ELEVATOR FREEPLAY INSPECTION

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Illustration 3b - Jack and Force Gauge Setup

Appendix A: ELEVATOR FREEPLAY INSPECTION

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BOEING SERVICE BULLETIN 777-27-0062
1. Rudder Freeplay Inspection

a. General Notes

(1) It is recommended to do this inspection in an enclosed area. Wind speeds more than 4 knots

can decrease the accuracy of the forces applied during this inspection.

(2) It is recommended that you schedule this inspection at a time when other work on the airplane

is at a minimum.

(3) It is permitted to do this inspection when the airplane is lifted on airplane jacks.

(4) It is optional to install the airplane jack at the tail jack point. If you install the airplane jack, it

is necessary only to tighten the jack sufficiently to make the tail stable. It is not necessary to

lift the tail of the airplane. Refer to 777 AMM 07-11-01 as an accepted procedure.

NOTE: The precision of the indications can be better if the tail of the airplane is stable during

this inspection.

b. References

Reference Title

777 AMM 27-21-12 Rudder

777 AMM 27-21-11 Rudder Power Control Units (PCU)

777 AMM 24-22-00 Supply Electrical Power

777 AMM 29-11-00 Main Hydraulic System Pressurization

777 AMM 29-11-00 Main Hydraulic System Power Removal

CMM 55-40-14 Rudder Assembly

CMM 55-40-17 Rudder Assembly

CMM 55-40-18 Rudder Assembly

CMM 27-21-77 Rudder Power Control Unit Link Assemblies

Nabtesco CMM 27-21-01 Rudder Power Control Unit Assembly

Parker CMM 27-21-02 B Market Rudder Power Control Unit Assembly

Nabtesco CMM 27-21-11 777-300ER Rudder Power Control Unit Assembly

c. Tools/Equipment

The tools and equipment described below are necessary to do this inspection.

(1) Dial Indicator - 0.001 inch (0.03 mm) accuracy or better, 0.50 inch (15 mm) minimum range.

NOTE: Analog type dial indicator is recommended.

Appendix B: RUDDER FREEPLAY INSPECTION

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BOEING SERVICE BULLETIN 777-27-0062
(2) Mounting device to hold the dial indicator tightly against the fuselage.

NOTE: A magnetic indicator base, tape, and a thin piece of steel approximately 3 inches

(80 mm) wide and 3 inches (80 mm) long can be used.

(3) Force scale or transducer capable of the application and measurement of the specified forces.

The accepted measurement device specifications are as follows:

(a) Specifications for the device to apply and measure the specified force:

NOTE: Tool kit A27124-1 can be used during the rudder and rudder tab freeplay

inspections to apply the specified force.

1) Range: 0 to 100 pounds ( 0 to 400 newtons) or more.

2) Resolution: 5 pound (22 newtons) or better.

3) Accuracy: +/- 2.5 pound (11 newtons) or better.

(4) Rig pin R1, R2 and R3.

NOTE: You can get the rig pins from tool kit J20003-1 (J20003-34 optional), Pin Set - Rigging.

d. Location Zones

Zone Area

115 Area Outboard and Above Nose Landing Gear Wheel Well, Left

116 Area Outboard and Above Nose Landing Gear Wheel Well, Right

211 Flight Compartment, Left

212 Flight Compartment, Right

320 Subzone 320 - Vertical Stabilizer and Rudder

e. Prepare for the Freeplay Inspection

(1) Supply electrical power. Refer to 777 AMM 24-22-00 as an accepted procedure.

WARNING: DO NOT MOVE THE RUDDER PEDALS DURING THIS PROCEDURE. IF THE

RUDDER PEDALS ARE MOVED, THEN THE RUDDER WILL MOVE.

(2) Attach DO-NOT-OPERATE tags to the captain's and first officer's rudder pedals.

(3) Install rig pins R1, R2 and R3. Refer to Appendix B - Illustration 1a and 1b.

NOTE: Install the rig pins to prevent accidental movement of the rudder pedals.

f. Freeplay Inspection

Appendix B: RUDDER FREEPLAY INSPECTION

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BOEING SERVICE BULLETIN 777-27-0062
WARNING: KEEP PERSONS AND EQUIPMENT CLEAR OF THE FLIGHT CONTROL

SURFACES, THE THRUST REVERSERS, AND THE LANDING GEAR. THESE

COMPONENTS CAN MOVE SUDDENLY WHEN YOU SUPPLY HYDRAULIC

POWER. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO

EQUIPMENT.

WARNING: DO NOT CLOSE THE HYDRAULIC TAIL VALVES DURING THIS INSPECTION.

IF YOU CLOSE A VALVE BEFORE THE RELATED HYDRAULIC PRESSURE IS

REMOVED, THE RUDDER CAN MOVE. THIS CAN CAUSE INJURIES TO PERSONS

AND DAMAGE TO EQUIPMENT.

(1) Supply hydraulic power to one of the three rudder PCUs. Appendix B - Table 1 shows the

hydraulic system that supplies pressure to each PCU. Refer to 777 AMM 29-11-00 as an

accepted procedure.

NOTE: You will do this rudder freeplay inspection once for each PCU. Each time, only one

PCU will have hydraulic power.

APPENDIX B - TABLE 1

POWER CONTROL UNIT (PCU) HYDRAULIC SYSTEM

Upper Rudder PCU Center Hydraulic System

Lower Rudder PCU Right Hydraulic System

Middle Rudder PCU Left Hydraulic System

(2) Do these steps to install the measurement equipment. Refer to Appendix B - Illustration 2a.

(a) Attach a mounting device for the dial indicator to the aft body on the left side of the rudder.

(b) Attach the dial indicator to the mounting device.

(c) Put the plunger of the dial indicator on the rudder so that it will measure the horizontal

movement at the aft edge of the rudder.

1) Make sure that the plunger is not more than 0.1 inch (2.5 mm) forward of the tab

seal at the bottom of the rudder. Refer to Appendix B - Illustration 2a

2) Make sure that the plunger of the dial indicator has a minimum of 0.2 inches of travel

remaining in each direction.

(3) Put the pad and force gage in position on the left side of the rudder tab. The center of the pad

must be within 1.0 inch (25 millimeters) of the centerline of the rib rivets in the rudder tab.

Also, make sure the aft edge of the pad is between 1.0 and 3.0 inches (25 and 76 millimeters)

forward from the trailing edge of the rudder tab. Refer to Appendix B - Illustration 2b.

Appendix B: RUDDER FREEPLAY INSPECTION

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BOEING SERVICE BULLETIN 777-27-0062
WARNING: MAKE SURE THAT YOU USE A STRONG AND STABLE PLATFORM TO HOLD

YOU, YOUR EQUIPMENT, AND THE ADDITIONAL FORCE. THE PLATFORM CAN

FALL IF IT DOES NOT HAVE A SUFFICIENT CAPACITY.

CAUTION: USE SUFFICIENT PADDING WHEN YOU APPLY THE FORCE TO PREVENT

DAMAGE TO THE RUDDER TAB SURFACE. USE A PAD THAT DISTRIBUTES

THE FORCE OVER AN AREA OF 25 SQUARE INCHES (64 SQUARE

CENTIMETERS) OR MORE. THE FORCE SCALE CAN CAUSE DAMAGE TO THE

RUDDER TAB SURFACE.

(4) Apply a force of 70 +/- 5 pounds (311 +/- 22 newtons) to the rudder tab.

(5) Decrease the force to 20 +/- 5 pounds (89 +/- 22 newtons).

(6) While you hold the force at 20 +/- 5 pounds (89 +/- 22 newtons), set the dial indicator to zero.

NOTE: The rudder PCU makes small position adjustments continuously. This can cause the

dial indicator needle to move continuously through a constant range. Find the middle

of the needle's movement range to set the dial indicator to zero.

(7) Remove the force.

(8) Put the pad and force gage in position on the right side of the rudder tab. The center of the

pad must be within 1.0 inches (13 millimeters) of the centerline of the rib rivets in the rudder

tab. Also, make sure the aft edge of the pad is between 1.0 and 3.0 inches (25 and 76

millimeters) forward from the trailing edge of the rudder tab . Refer to Appendix B - Illustration

2b.

(9) Apply a force of 70 +/- 5 pounds (311 +/- 22 newtons) to the rudder tab.

(10) Record the value shown on the dial indicator as the rudder freeplay.

NOTE: The rudder PCU makes small position adjustments continuously. This can cause the

dial indicator needle to move continuously through a constant range. To read the

value, find the middle of the needle's movement range.

(11) Remove the force.

(12) If the rudder freeplay is more than 0.15 inch (3.8 mm), then you must make repairs as

necessary to decrease the freeplay to less than 0.15 inch (3.8 mm). Do the freeplay inspection

again after you have made the necessary repairs. You can use these accepted procedures

and documents to help find, repair, or replace the worn parts:

(a) Refer to 777 AMM 27-21-12 as an accepted procedure for the removal and installation

of the rudder.

(b) Refer to CMM 55-40-14, CMM 55-40-17, or CMM 55-40-18 as accepted procedures for

the inspection, fits, clearances, repairs or replacement of the hinge bolts.

Appendix B: RUDDER FREEPLAY INSPECTION

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(c) Refer to 777 AMM 27-21-11 as an accepted procedure for the inspection and wear limits

of the reaction link and kick link, and for the removal and installation of the rudder PCU

and reaction link.

(d) Refer to CMM 27-21-77 as accepted data for the repair or replacement of the reaction

link and kick link bearings or bushings.

(e) Refer to Nabtesco CMM 27-21-01, CMM 27-21-11 or Parker CMM 27-21-02, as accepted

data for the PCU rod end assembly repair or replacement.

(13) Remove the dial indicator, the mounting device, the force gauge, and the pad.

(14) Repeat step 1.E., Freeplay Inspection, for each remaining rudder PCU.

g. Put the Airplane Back to a Serviceable Condition

(1) Remove power from the main hydraulic system. Refer to 777 AMM 29-11-00 as an accepted

procedure.

(2) Remove rig pins R1, R2, and R3 from the rudder pedals and linkages. Refer to Appendix B -

Illustration 1a and 1b.

(3) Remove the DO-NOT-OPERATE tags from the captain's and first officer's rudder pedals.

Appendix B: RUDDER FREEPLAY INSPECTION

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Illustration 1a - Rudder Rig Pin Installation

Appendix B: RUDDER FREEPLAY INSPECTION

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Illustration 1b - Rudder Rig Pin Installation

Appendix B: RUDDER FREEPLAY INSPECTION

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Illustration 2a - Dial Indicator Setup Example

Appendix B: RUDDER FREEPLAY INSPECTION

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Illustration 2b - Force Gauge Setup Example

Appendix B: RUDDER FREEPLAY INSPECTION

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BOEING SERVICE BULLETIN 777-27-0062
1. Rudder Tab Freeplay Inspection

a. References

Reference Title

777 AMM 24-22-00 Supply Electrical Power

777 AMM 24-22-00 Remove Electrical Power

777 AMM 27-21-12 Rudder

777 AMM 27-21-11 Rudder Power Control Units (PCU)

777 AMM 29-11-00 Main Hydraulic System Pressurization

777 AMM 29-11-00 Main Hydraulic System Power Removal

CMM 55-40-14 Rudder Assembly

CMM 55-40-15 Tab Assembly

CMM 55-40-16 Tab Assemblies

CMM 55-40-17 Rudder Assembly

CMM 55-40-18 Rudder Assembly

b. Tools/Equipment

The tools and equipment described below are necessary to do this inspection.

(1) Dial Indicator - 0.001 inch (0.03 mm) accuracy or better, 0.50 inch (15 mm) minimum range.

NOTE: Analog type dial indicator is recommended.

(2) Mounting device to hold the dial indicator tightly against the rudder.

NOTE: A magnetic indicator base, tape, and a thin piece of steel approximately 3 inches

(80 mm) wide and 3 inches (80 mm) long can be used.

(3) Force scale or transducer capable of the application and measurement of the specified forces.

The accepted measurement device specifications are as follows:

(a) Specifications for the device to apply and measure the 30 +/- 3 pound (133 +/- 14 newton)

force:

NOTE: Tool kit A27124-1 can be used during the rudder and rudder tab freeplay

inspections to apply the specified force.

1) Range: 0 to 35 pound (0 to 150 newtons) or more.

2) Resolution: 1 pound (5 newtons) or better.

Appendix C: RUDDER TAB FREEPLAY INSPECTION

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3) Accuracy: +/-1 pound (5 newtons) or better.

(4) Rig pin R1, R2 and R3.

NOTE: You can get the rig pins from tool kit J20003-1 (J20003-34 optional), Pin Set - Rigging.

c. Location Zones

Zone Area

115 Area Outboard and Above Nose Landing Gear Wheel Well, Left

116 Area Outboard and Above Nose Landing Gear Wheel Well, Right

211 Flight Compartment, Left

212 Flight Compartment, Right

320 Subzone 320 - Vertical Stabilizer and Rudder

d. Prepare for the Freeplay Inspection

(1) Supply electrical power. Refer to 777 AMM 24-22-00 as an accepted procedure.

WARNING: KEEP PERSONS AND EQUIPMENT CLEAR OF THE FLIGHT CONTROL

SURFACES, THE THRUST REVERSERS, AND THE LANDING GEAR. THESE

COMPONENTS CAN MOVE QUICKLY WHEN YOU SUPPLY HYDRAULIC POWER.

THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT.

(2) Supply hydraulic power to the main hydraulic system. Refer to 777 AMM 29-11-00 as an

accepted procedure.

(3) Operate the rudder trim switch on the aft electronic control panel, P8, until the rudder trim

indicator shows zero units of trim.

(a) Make sure the rudder pedals are in their neutral positions.

(4) Attach DO-NOT-OPERATE tags to the captain's and first officer's rudder pedals.

(5) Install rig pins R1, R2 and R3. Refer to Appendix C - Illustration 1a and 1b.

NOTE: Install the rig pins to prevent unintended movement of the rudder pedals.

e. Rudder Tab Surface Freeplay - Inspection

WARNING: DO NOT CLOSE THE HYDRAULIC TAIL VALVES DURING THIS INSPECTION.

IF YOU CLOSE A VALVE BEFORE THE RELATED HYDRAULIC PRESSURE IS

REMOVED, THE RUDDER CAN MOVE. THIS CAN CAUSE INJURIES TO PERSONS

AND DAMAGE TO EQUIPMENT.

(1) Do these steps to install the measurement equipment. Refer to Appendix C - Illustration 2a.

Appendix C: RUDDER TAB FREEPLAY INSPECTION

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(a) Attach to the rudder a mounting device for the dial indicator.

(b) Attach the dial indicator to the mounting device.

(c) Put the plunger of the dial indicator on the rudder tab so that it will measure the horizontal

movement at the aft edge of the rudder tab. Make sure that the plunger is not more than

0.5 inches (12.7 mm) forward of the trailing edge and 0.5 inches (12.7 mm) below the

top edge of the rudder tab.

(d) Set the dial indicator to zero.

NOTE: The rudder PCU makes small position adjustments continuously. The can cause

the dial indicator needle to move continuously through a constant range. Set

the zero on the dial indicator to the middle of the needle's movement range.

CAUTION: PUT SUFFICIENT PADDING BETWEEN THE FORCE SCALE, AND THE RUDDER

TAB TO PREVENT DAMAGE TO THE RUDDER TAB SURFACE. THE FORCE

SCALE CAN CAUSE DAMAGE TO THE RUDDER TAB SURFACE.

(2) Put the force gage and pad on the left side of the rudder tab within one inch of the centerline

line of the middle rudder PCU rib and at 12 +/- 1 inches (305 +/- 72 millimeters) forward of

the rudder tab trailing edge. Refer to Appendix C - Illustration 2b.

NOTE: Use the rows of fasteners on the rudder skin to identify the rib locations.

(3) Using the force gage, apply a 30 +/- pound (133 +/- 14 newton) force to the left side of the

rudder tab.

(4) Record the value shown on the dial indicator as Value A.

NOTE: The rudder PCU makes small position adjustments continuously. This can cause the

dial indicator needle to move continuously through a constant range. To read the

value, find the middle of the needle's movement range.

(5) Slowly remove the force from the left side of the rudder tab.

NOTE: Do not adjust the dial indicator to zero even if it does not return to the original zero.

CAUTION: PUT SUFFICIENT PADDING BETWEEN THE FORCE SCALE, AND THE RUDDER

TAB TO PREVENT DAMAGE TO THE RUDDER TAB SURFACE. THE FORCE

SCALE CAN CAUSE DAMAGE TO THE RUDDER TAB SURFACE.

(6) Put the force gage and pad on the right side of the rudder tab within one inch of the centerline

line of the middle rudder PCU rib and at 12 +/- 1 inches (305 +/- 72 millimeters) forward of

the rudder tab trailing edge. Refer to Appendix C - Illustration 2b.

NOTE: Use the rows of fasteners on the rudder skin to identify the rib locations.

(7) Using the force gage, apply a 30 +/- 3 pound (133 +/- 14 newton) force to the right side of the

rudder tab.

Appendix C: RUDDER TAB FREEPLAY INSPECTION

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(8) Record the value shown on the dial indicator as Value B.

NOTE: The rudder PCU makes small position adjustments continuously. This can cause the

dial indicator needle to move continuously through a constant range. To read the

value, find the middle of the needle's movement range.

(9) Slowly remove the force from the right side of the rudder tab.

(10) Add together Value A and Value B. This is the total freeplay of the rudder tab.

(11) If the rudder tab freeplay is more than 0.28 inches (7.11 mm) then you must make repairs as

necessary to decrease the freeplay to less than 0.28 inches (7.11 mm). Do the freeplay

inspection again after you have made the necessary repairs. You can use these accepted

procedures and documents to help find, repair, or replace the worn parts:

(a) Refer to 777 AMM 27-21-12 as an accepted procedure for the removal and installation

of the rudder tab.

(b) Refer to CMM 55-40-15 or CMM 55-40-16 as accepted data for the inspection, fits and

clearances, repair, or replacement of the tab hinge bolts and bushings.

(c) Refer to CMM 55-40-14, CMM 55-40-17, or CMM 55-40-18 as accepted data for the fits

and clearances, repairs, or replacements of the mating hinge bearings and PCU pushrod

attachment fittings.

(d) Refer to 777 AMM 27-21-11 as accepted data for the wear limits of the hinge

bolt-to-bearing connection (5 locations) and the PCU pushrod and bolt-to-bearing

connection (3 locations).

f. Put the Airplane Back to a Serviceable Condition

(1) Remove the force gage and pad.

(2) Remove the dial indicator and mounting device.

(3) Remove power from the main hydraulic system. Refer to 777 AMM 29-11-00 as an accepted

procedure.

(4) Remove rig pins R1, R2 and R3. Refer to Appendix C - Illustration 1a and 1b.

(5) Remove the DO-NOT-OPERATE tags from the captain's and first officer's rudder pedals.

(6) Remove electrical power from the airplane if it is not necessary. Refer to 777 AMM 24-22-00

as an accepted procedure.

Appendix C: RUDDER TAB FREEPLAY INSPECTION

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Illustration 1a - Rudder Rig Pin Installation

Appendix C: RUDDER TAB FREEPLAY INSPECTION

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Illustration 1b - Rudder Rig Pin Installation

Appendix C: RUDDER TAB FREEPLAY INSPECTION

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Illustration 2a - Dial Indicator Setup Example

Appendix C: RUDDER TAB FREEPLAY INSPECTION

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Revision 2 January 27, 2014 777-27-0062

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BOEING SERVICE BULLETIN 777-27-0062
Illustration 2b - Force Gauge Setup Example

Appendix C: RUDDER TAB FREEPLAY INSPECTION

(SHEET 8 OF 8)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: July 18, 2006

Revision 2 January 27, 2014 777-27-0062

58 of 58

BOEING SERVICE BULLETIN 777-27-0062