### 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. 9E991 ECCN: 

## 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 Unpublished Work.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 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: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 1 of 58 2.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 2 of 58 **BOEING SERVICE BULLETIN 777-27-0062**

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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 3 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 4 of 58 **BOEING SERVICE BULLETIN 777-27-0062**

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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 5 of 584. 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** July 18, 2006 Original Issue: October 01, 2009 Revision 1: January 27, 2014 Revision 2:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 6 of 58 **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.
**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 Paragraph 1.K., Publications Affected Yes Publications Affected

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 7 of 58**Reference Affected**  **Planning Data** 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** 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 8 of 58 **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 Elapsed Hours**  **Total Task Hours** 2.0 4.0 PART 1 8.25 16.5 PART 2 2.0 4.0 PART 3 3.5 7.0 PART 4 1.5 3.0 PART 5 2.5 5.0 PART 6
**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 9 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 10 of 58 **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.
**DESCRIPTION CONFIGURATION**  **GROUP** All 777-200, 777-200LR, 777-300, and 777-300ER airplanes.

- 1

Airplane Models: 777-200, 777-200LR, 777-300, 777-300ER **Group Variable Number**  1 WA001 - WA017

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 11 of 58**Group Variable Number**  1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 12 of 58 **BOEING SERVICE BULLETIN 777-27-0062 Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 13 of 58 **BOEING SERVICE BULLETIN 777-27-0062 Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 14 of 58 **BOEING SERVICE BULLETIN 777-27-0062 Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 15 of 58 **BOEING SERVICE BULLETIN 777-27-0062 Group**  **Variable Number** 1 WE416 - WE420 1 WE426 1 WE436 - WE437 1 WE441 - WE443 1 WE451 1 WE486 1 WE501 - WE503 1 WE556 - WE557 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 16 of 58 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 17 of 58 **BOEING SERVICE BULLETIN 777-27-0062 Affected Maintenance Zones** **Zone Model**  324, 325, 326, 335, 336, 345, 346 777-200, 777-200LR, 777-300, 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) Compliance Time (whichever occurs later)**  **Action Condition**  12,000 Flight Hours or 1,125 days whichever occurs first. Within 1,125 days after thedate of issuance of the original standard certificate ofairworthiness or original export certificate of airworthiness Within 1,125 daysafter 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 thedate of issuance of the original standard certificate ofairworthiness or original export certificate of airworthinessWithin 500 days after the original issue date on this service bulletin Lubricate the elevator hinge bearings, reaction links, andPCU 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) Compliance Time (whichever occurs later)**  **Action Condition**  12,000 Flight Hours or 1,125 days whichever occurs first. Within 1,125 days after thedate of issuance of the original standard certificate ofairworthiness or original export certificate of airworthiness Within 1,125 daysafter the original issue date on this service bulletin Inspect the Rudder Freeplayin accordance with Accomplishment Instruction 3.B., Part 3. (a) All

5,000 Flight Hours or 500 days whichever occurs first. Within 500 days after thedate of issuance of the original standard certificate ofairworthiness or original export certificate of airworthinessWithin 500 days after the original issue date on this service bulletin Lubricate the rudder hinge bearings, reaction links, andPCU rod ends in accordance with Accomplishment Instruction 3.B., Part 4.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 18 of 58 **BOEING SERVICE BULLETIN 777-27-0062 Table 2 - Freeplay Inspection and Lubrication of the Rudder**  **Repeat Interval (not to exceed)**  **Compliance Time (whichever occurs later) Action**  **Condition** (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) Compliance Time (whichever occurs later)**  **Action Condition**  12,000 Flight Hours or 1,125 days whichever occurs first. Within 1,125 days after thedate of issuance of the original standard certificate ofairworthiness or original export certificate of airworthiness Within 1,125 daysafter 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 thedate of issuance of the original standard certificate ofairworthiness or original export certificate of airworthinessWithin 500 days after the original issue date on this service bulletin Lubricate the rudder tabhinge 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 19 of 58 **BOEING SERVICE BULLETIN 777-27-0062**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. **Elapsed Hours Task-Hours**  **Number of Persons**  **Task**

2.0 4.0 2 PART 1 8.25 16.5 2 PART 2 10.25 20.5 TOTAL FOR EACH AIRPLANE **Elapsed Hours Task-Hours**  **Number of Persons**  **Task**

2.0 4.0 2 PART 3 3.5 7.0 2 PART 4 5.5 11.0 TOTAL FOR EACH AIRPLANE **Elapsed Hours Task-Hours**  **Number of Persons**  **Task**

1.5 3.0 2 PART 5 2.5 5.0 2 PART 6 4.0 8.0 TOTAL FOR EACH AIRPLANE

**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 20 of 58 **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:
**Title Drawing Number**  Rudder Installation 173W0012 Rudder Power Control Unit - Installation 251W3100 Elevator Power Control Unit - Installation 251W2100 Elevator Installation 183W0001 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 21 of 58 **BOEING SERVICE BULLETIN 777-27-0062 K. Publications Affected**  1. Publications: **Chapter-Section**

**Publication** 27-21, 27-31 777 Maintenance Manual SECTION 1 777 Maintenance Planning Document 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 22 of 58 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 23 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 24 of 58 **BOEING SERVICE BULLETIN 777-27-0062**

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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 25 of 58 **BOEING SERVICE BULLETIN 777-27-0062**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 26 of 58 **BOEING SERVICE BULLETIN 777-27-0062**2. Put the airplane back to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2: January 27, 2014 27 of 58 **BOEING SERVICE BULLETIN 777-27-0062**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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in accordance with APPENDIX A - Elevator Freeplay Inspection. - - Elevator Freeplay (Left Side) Inspect 1

in accordance with APPENDIX A - Elevator Freeplay Inspection. - - Elevator Freeplay (Right Side) Inspect 2

**FIGURE 1: ELEVATOR FREEPLAY INSPECTION (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 28 of 58 **BOEING SERVICE BULLETIN 777-27-0062**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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in accordance with APPENDIX B - Rudder Freeplay Inspection - - Rudder Freeplay Inspect 1

**FIGURE 2: RUDDER FREEPLAY INSPECTION (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 29 of 58 **BOEING SERVICE BULLETIN 777-27-0062**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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in accordance with APPENDIX C - Rudder Tab Freeplay Inspection. - - Rudder Tab Freeplay Inspect 1

**FIGURE 3: RUDDER TAB FREEPLAY INSPECTION (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 30 of 58 **BOEING SERVICE BULLETIN 777-27-0062**1. Elevator Freeplay Inspection a. References:
**Task Reference**  Supply Electrical Power 777 AMM 24-22-00 Main Hydraulic System Pressurization 777 AMM 29-11-00 Main Hydraulic System Power Removal 777 AMM 29-11-00 Elevator - Removal/Installation 777 AMM 27-31-10 Elevator Power Control Units - Removal/Installation 777 AMM 27-31-09 Elevator Assembly CMM 55-20-23 Elevator Assembly CMM 55-20-24 Elevator Power Control Unit Link Assemblies CMM 27-32-06 Elevator Power Control Unit Assembly Nabtesco CMM 27-31-01 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)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 31 of 58 **BOEING SERVICE BULLETIN 777-27-0062**(4) Rig pin E1 and E2. c. Location Zones
**Area Zone**  Left Horizontal Stabilizer - Rear Spar to Trailing Edge 335 Left Elevator 336 Right Horizontal Stabilizer - Rear Spar to Trailing Edge 345 Right Elevator 346
d. Access Panels
**Name/Location Number**  Forward Access Door 112AL 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)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 32 of 58 **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 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**
**HYDRAULIC SYSTEM PRESSURE STEP**  **POWER CONTROL UNIT (PCU)**  **RIGHT CENTER**  **LEFT** ON ON ON Setup Left Elevator, Outboard PCU ON OFF ON Inspection ON ON ON Setup Left Elevator, Inboard PCU ON ON OFF Inspection ON ON ON Setup Right Elevator, Inboard PCU ON ON OFF Inspection ON ON ON Setup Right Elevator, Outboard PCU OFF ON ON Inspection

**Appendix A: ELEVATOR FREEPLAY INSPECTION (SHEET 3 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 33 of 58 **BOEING SERVICE BULLETIN 777-27-0062**(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)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 34 of 58 **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 (SHEET 5 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 35 of 58 **BOEING SERVICE BULLETIN 777-27-0062**(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 (SHEET 6 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 36 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 1a - Elevator Rig Pin Installation

**Appendix A: ELEVATOR FREEPLAY INSPECTION (SHEET 7 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 37 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 1b - Elevator Rig Pin Installation

**Appendix A: ELEVATOR FREEPLAY INSPECTION (SHEET 8 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 38 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 2 - Dial Indicator Setup Example

**Appendix A: ELEVATOR FREEPLAY INSPECTION (SHEET 9 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 39 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 3a - Jack and Force Gauge Setup

**Appendix A: ELEVATOR FREEPLAY INSPECTION (SHEET 10 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 40 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 3b - Jack and Force Gauge Setup

**Appendix A: ELEVATOR FREEPLAY INSPECTION (SHEET 11 OF 11)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 41 of 58 **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
**Title Reference**  Rudder 777 AMM 27-21-12 Rudder Power Control Units (PCU) 777 AMM 27-21-11 Supply Electrical Power 777 AMM 24-22-00 Main Hydraulic System Pressurization 777 AMM 29-11-00 Main Hydraulic System Power Removal 777 AMM 29-11-00 Rudder Assembly CMM 55-40-14 Rudder Assembly CMM 55-40-17 Rudder Assembly CMM 55-40-18 Rudder Power Control Unit Link Assemblies CMM 27-21-77 Rudder Power Control Unit Assembly Nabtesco CMM 27-21-01 B Market Rudder Power Control Unit Assembly Parker CMM 27-21-02 777-300ER Rudder Power Control Unit Assembly Nabtesco CMM 27-21-11 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 (SHEET 1 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 42 of 58 **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
**Area Zone**  Area Outboard and Above Nose Landing Gear Wheel Well, Left 115 Area Outboard and Above Nose Landing Gear Wheel Well, Right 116 Flight Compartment, Left 211 Flight Compartment, Right 212 Subzone 320 - Vertical Stabilizer and Rudder 320 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 (SHEET 2 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 43 of 58 **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**
**HYDRAULIC SYSTEM POWER CONTROL UNIT (PCU)**  Center Hydraulic System Upper Rudder PCU Right Hydraulic System Lower Rudder PCU Left Hydraulic System Middle Rudder PCU (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 (SHEET 3 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 44 of 58 **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 (SHEET 4 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 45 of 58 **BOEING SERVICE BULLETIN 777-27-0062**(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 (SHEET 5 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 46 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 1a - Rudder Rig Pin Installation

**Appendix B: RUDDER FREEPLAY INSPECTION (SHEET 6 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 47 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 1b - Rudder Rig Pin Installation

**Appendix B: RUDDER FREEPLAY INSPECTION (SHEET 7 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 48 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 2a - Dial Indicator Setup Example

**Appendix B: RUDDER FREEPLAY INSPECTION (SHEET 8 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 49 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 2b - Force Gauge Setup Example

**Appendix B: RUDDER FREEPLAY INSPECTION (SHEET 9 OF 9)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 50 of 58 **BOEING SERVICE BULLETIN 777-27-0062**1. Rudder Tab Freeplay Inspection a. References
**Title Reference**  Supply Electrical Power 777 AMM 24-22-00 Remove Electrical Power 777 AMM 24-22-00 Rudder 777 AMM 27-21-12 Rudder Power Control Units (PCU) 777 AMM 27-21-11 Main Hydraulic System Pressurization 777 AMM 29-11-00 Main Hydraulic System Power Removal 777 AMM 29-11-00 Rudder Assembly CMM 55-40-14 Tab Assembly CMM 55-40-15 Tab Assemblies CMM 55-40-16 Rudder Assembly CMM 55-40-17 Rudder Assembly CMM 55-40-18 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 (SHEET 1 OF 8)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 51 of 58 **BOEING SERVICE BULLETIN 777-27-0062**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
**Area Zone**  Area Outboard and Above Nose Landing Gear Wheel Well, Left 115 Area Outboard and Above Nose Landing Gear Wheel Well, Right 116 Flight Compartment, Left 211 Flight Compartment, Right 212 Subzone 320 - Vertical Stabilizer and Rudder 320 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 (SHEET 2 OF 8)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 52 of 58 **BOEING SERVICE BULLETIN 777-27-0062**(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 (SHEET 3 OF 8)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 53 of 58 **BOEING SERVICE BULLETIN 777-27-0062**(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 (SHEET 4 OF 8)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 54 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 1a - Rudder Rig Pin Installation

**Appendix C: RUDDER TAB FREEPLAY INSPECTION (SHEET 5 OF 8)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 55 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 1b - Rudder Rig Pin Installation

**Appendix C: RUDDER TAB FREEPLAY INSPECTION (SHEET 6 OF 8)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 56 of 58 **BOEING SERVICE BULLETIN 777-27-0062**Illustration 2a - Dial Indicator Setup Example

**Appendix C: RUDDER TAB FREEPLAY INSPECTION (SHEET 7 OF 8)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 18, 2006 777-27-0062 Revision 2 January 27, 2014 57 of 58 **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 777-27-0062 Revision 2 January 27, 2014 58 of 58 **BOEING SERVICE BULLETIN 777-27-0062**