Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-57A0097

Original Issue: January 10, 2014

ATA System: 5720

SUBJECT: WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection

and Repair

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 © 2014 Boeing.

Unpublished Work. All Rights Reserved.

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

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

Boeing Company.

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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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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT

BLANK PAGE
Table of Contents

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 16

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 18

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION [Group 1, 3] . . . . . . 24

FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION [Group 2-3] . . . . . . 28

FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR [Group 1, 3] . . . . . . . . . 32

FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR [Group 2-3] . . . . . . . . . 35

FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION [Group 1, 3] . . . . 38

FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION [Group 2-3] . . . . 41

APPENDIX A: SEALANT REMOVAL TOOLS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . 44

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Summary Number: 777-57A0097

Original Issue: January 10, 2014

ATA System: 5720

SUBJECT: WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection

and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Accomplishment of this service bulletin will find if sealant was applied to the wing skin panel gaps above the

underwing fittings. Missing sealant in the wing skin panel gaps above the underwing fittings can allow undetected

corrosion to develop in the wing skin panels above the underwing fittings. Undetected corrosion in the wing skin

panels above the underwing fittings can result in undetected fatigue cracks in the wing skin panels. Undetected

fatigue cracks in the wing skin panels can result in the loss of limit load capability of the wing skins and structural

failure of the wings.

Boeing found that sealant may not have been applied in production to the wing skin panel gaps above the

underwing fittings on certain underwing fittings on certain 777 airplanes. Sealant is required to be applied to the

wing skin panel gaps above the underwing fittings prior to installation of the underwing fittings. A review of Boeing

installation records found that sealant may not have been applied above certain underwing fittings on certain

previously delivered and in-production 777 airplanes. The affected in-production 777 airplanes have been

inspected to make sure sealant is applied to the wing skin panel gaps above the underwing fittings. Production

installation procedures have also been addressed to make sure sealant is applied to the wing skin panel gaps

above the underwing fittings on future 777 production airplanes.

This service bulletin gives instructions to inspect and restore the sealant in the wing skin panel gaps above the

underwing fittings. If sealant is missing, this service bulletin also gives instructions to inspect for corrosion in the

wing skin panels gaps to prevent possible fatigue cracks in the wing skin panels, loss of limit load capability of

the wing skins and potential subsequent structural failure of the wings.

Boeing Fleet Team Digest (FTD) 777 FTD 57-13003 is related to this service bulletin.

Boeing Service Related Problem (SRP) 777-SRP-57-0265 is related to this service bulletin.

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

information.

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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 No Paragraph 1.K., Publications Affected

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

Operations Manual and/or FAA Approved Airplane Flight Manual)

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

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

by the Operator

Operator Supplied Parts/Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin and APPENDIX A for

additional optional tool information.

Special Tooling Required No

ACTION

Do a Detailed Inspection (DET) of the wing skin panel gaps above the underwing fittings for any missing sealant,

on the left wing (applicable to Groups 1,3) and on the right wing (applicable to Groups 2-3). If sealant is missing,

do a DET of the wing skin panel gaps above the underwing fittings for corrosion. If any corrosion is found, contact

Boeing for repair instructions, do the repair, and restore the missing sealant and the sealant that was previously

removed to gain inspection access. If no corrosion is found, restore the missing sealant and the sealant that

was previously removed to gain inspection access. If sealant is not missing, restore the sealant that was previously

removed to gain inspection access.

EFFECTIVITY

777-200/-200LR/-300ER, 777F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

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

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

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of August 7, 2013. Please refer to Paragraph

2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of

this service bulletin.

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
MANPOWER

Elapsed

Hours

Total

Task

Hours

Airplanes

Group 1 and Group 2 Airplanes 51.85 15.85

Group 3 Airplanes 103.70 19.70

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-57A0097

Original Issue: January 10, 2014

ATA System: 5720

SUBJECT: WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection

and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

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

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

Serial Number data.

GROUP CONFIGURATION DESCRIPTION

777-200/-200LR/-300ER and 777F airplanes that require inspection

for missing sealant on the left wing only.

1 -

777-300ER and 777F airplanes that require inspection for missing

sealant on the right wing only.

2 -

777-300ER and 777F airplanes that require inspection for missing

sealant on both the left and the right wings.

3 -

Airplane Models:

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

Variable Number Group

WC593 1

WD106 1

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Variable Number Group

WD889 2

WD890 - WD892 1

WD918 1

WD923 - WD925 1

WD927 1

WD928 2

WD941 - WD943 1

WD956 - WD957 1

WD993 1

WE094 1

WE141 1

WE159 - WE164 1

WE203 1

WE206 3

WE207 - WE208 1

WE240 1

WE242 - WE243 1

WE262 2

WE263 - WE265 1

WE272 1

WE273 3

WE274 1

WE276 1

WE301 1

WE303 - WE304 1

WE307 1

WE331 1

WE333 1

WE351 1

WE416 1

WF035 1

WF037 3

WF038 1

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
Variable Number Group

WF062 2

WF064 1

WF146 - WF147 1

WF152 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Accomplishment of this service bulletin will find if sealant was applied to the wing skin panel gaps above

the underwing fittings. Missing sealant in the wing skin panel gaps above the underwing fittings can

allow undetected corrosion to develop in the wing skin panels above the underwing fittings. Undetected

corrosion in the wing skin panels above the underwing fittings can result in undetected fatigue cracks

in the wing skin panels. Undetected fatigue cracks in the wing skin panels can result in the loss of limit

load capability of the wing skins and structural failure of the wings.

Boeing found that sealant may not have been applied in production to the wing skin panel gaps above

the underwing fittings on certain underwing fittings on certain 777 airplanes. Sealant is required to be

applied to the wing skin panel gaps above the underwing fittings prior to installation of the underwing

fittings. A review of Boeing installation records found that sealant may not have been applied above

certain underwing fittings on certain previously delivered and in-production 777 airplanes. The affected

in-production 777 airplanes have been inspected to make sure sealant is applied to the wing skin panel

gaps above the underwing fittings. Production installation procedures have also been addressed to

make sure sealant is applied to the wing skin panel gaps above the underwing fittings on future 777

production airplanes.

This service bulletin gives instructions to inspect and restore the sealant in the wing skin panel gaps

above the underwing fittings. If sealant is missing, this service bulletin also gives instructions to inspect

for corrosion in the wing skin panels gaps to prevent possible fatigue cracks in the wing skin panels,

loss of limit load capability of the wing skins and potential subsequent structural failure of the wings.

Boeing Fleet Team Digest (FTD) 777 FTD 57-13003 is related to this service bulletin.

Boeing Service Related Problem (SRP) 777-SRP-57-0265 is related to this service bulletin.

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
D. Description

Do a Detailed Inspection (DET) of the wing skin panel gaps above the underwing fittings for any missing

sealant, on the left wing (applicable to Groups 1,3) and on the right wing (applicable to Groups 2-3). If

sealant is missing, do a DET of the wing skin panel gaps above the underwing fittings for corrosion. If

any corrosion is found, contact Boeing for repair instructions, do the repair, and restore the missing

sealant and the sealant that was previously removed to gain inspection access. If no corrosion is found,

restore the missing sealant and the sealant that was previously removed to gain inspection access. If

sealant is not missing, restore the sealant that was previously removed to gain inspection access.

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

Group 1:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777- 533

300ER, 777F

Group 2:

Affected Maintenance Zones

Model Zone

777-300ER, 777F 633

Group 3:

Affected Maintenance Zones

Model Zone

777-300ER, 777F 533, 633

E. Compliance

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

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

service bulletin mandatory.

The Conditions, Actions and Compliance times shown apply to each wing panel gap location

independently.

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

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

more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION

numbers for that CONDITION number or OPTION number.

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
Table 1: Detailed Inspection Intervals for Missing Sealant

Repeat Interval (Not

to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Within 4000 flight cy- -

cles or 750 days,

whichever occurs

first, after the original

issue date of this

service bulletin

Within 6000 flight cycles or 1500 days,

whichever occurs

first, from the date of

issuance of the original certificate of airworthiness or the

original export certificate of airworthiness.

Do PART 1: WING

SKIN PANEL GAPS

- DETAILED

SEALANT INSPECTION for missing

sealant in the wing

skin panel gaps

above the underwing

fittings.

All Airplanes

Do PART 2: WING Before further flight. - -

SKIN PANEL GAPS

- SEALANT

RESTORATION

(Terminating Action)

CONDITION 1: NO

MISSING SEALANT

FOUND

Do PART 3: WING Before further flight. - -

SKIN PANEL GAPS

- DETAILED CORROSION INSPECTION

for corrosion in the

wing skin panel gaps

above the underwing

fittings.

CONDITION 2:

MISSING SEALANT

FOUND

ACTION 1: Contact Before further flight. - -

Boeing for repair instructions and do the

repair.

CONDITION 3: ANY

CORROSION

FOUND

ACTION 2: Do PART

2: WING SKIN PANEL GAPS -

SEALANT

RESTORATION

(Terminating Action)

Do PART 2: WING Before further flight. - -

SKIN PANEL GAPS

- SEALANT

RESTORATION

(Terminating Action)

CONDITION 4: NO

CORROSION

FOUND

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

G. Manpower

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

panel gap location in the area of the underwing fittings. This estimate is for direct labor only, done by

an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does

not include lost time. These are some examples of lost time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Group 1:

Table 1: Manpower Information for Group 1 Airplanes

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 24.00 6.00

FIGURE 1 1 1.75 1.75

FIGURE 3 1 1.00 1.00

FIGURE 5 1 1.10 1.10

Close Access 4 24.00 6.00

TOTAL FOR EACH AIRPLANE 51.85 15.85

Group 2:

Table 2: Manpower Information for Group 2 Airplanes

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 24.00 6.00

FIGURE 2 1 1.75 1.75

FIGURE 4 1 1.00 1.00

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ALERT ALERT
Group 2:

Table 2: Manpower Information for Group 2 Airplanes

Task Number of Persons Task Hours Elapsed Hours

FIGURE 6 1 1.10 1.10

Close Access 4 24.00 6.00

TOTAL FOR EACH AIRPLANE 51.85 15.85

Group 3:

Table 3: Manpower Information for Group 3 Airplanes

Task Number of Persons Task Hours Elapsed Hours

Open Access 8 48.00 6.00

FIGURE 1 1 1.75 1.75

FIGURE 2 1 1.75 1.75

FIGURE 3 1 1.00 1.00

FIGURE 4 1 1.00 1.00

FIGURE 5 1 1.10 1.10

FIGURE 6 1 1.10 1.10

Close Access 8 48.00 6.00

TOTAL FOR EACH AIRPLANE 103.70 19.70

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

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

b. Boeing Service Related Problem (SRP) 777-SRP-57-0265

c. Service Bulletin Index D624W001

d. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-43-03, 20-50-01, 20-50-19

e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19

f. 777 Aircraft Maintenance Manual (AMM) 51-31-01, 54-52-04, 78-11-02

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
g. 777 Fleet Team Digest (FTD) 57-13003

2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

112W7000 Nacelle Support Installation - Lower Panel

The table above lists applicable drawing used to prepare this service bulletin. The drawing is not

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

may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS but no new DTIs are 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 777-57A0097

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are available for 777 airplanes in warranty as of August 7, 2013. For inspection

labor task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Warranty & Product Assurance Contracts. If the condition described in this service bulletin is found

during the inspection for airplanes in warranty as of that date and additional task hours are required,

send a warranty claim to Boeing Warranty & Product Assurance Contracts. Please refer to this service

bulletin number and reference the airplane variable numbers in your purchase order. The warranty

remedies will expire eight years from the original issue date of this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

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

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

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

Part Number / QTY Name Notes

Specification

BMS 5-95 1 Qt Sealant (a)

BMS 10-79, Type 8 Oz Primer (a)

III

SOPM 20-43-03 8 Oz Corrosion Inhibiting Compound (a)

BMS 10-60, Type 8 Oz Enamel (a)

II

(a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)

for supplier data.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

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

operator tool supply to make sure all necessary tools are available. Refer to APPENDIX A for optional

tools that Boeing used to do this rework.

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

SRM Chapter 51.

5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

6. The necessary conditions for selection of clamp type and size are included in SWPM

20-10-12. If any wire bundle support clamp specified in this service bulletin does not

make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted

procedure to select a clamp that fits correctly.

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

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

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

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

grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate

full threaded fasteners (screws) needed for installation in this service bulletin.

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ALERT ALERT
8. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

9. 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.

10. Boeing Service Letter 777-SL-51-013, Damage Reporting and Repair Plan/Design

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

additional structural repair instructions. The Service Letter describes what information

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

11. Refer to APPENDIX A for information on tools and procedures used by Boeing for

the production rework equivalent to this Service Bulletin.

12. 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.

13. 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.

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

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

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

non-authoritative information from the critical and authoritative information.

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

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

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

OPTION number.

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

are in Paragraph 1.E., Compliance.

18. The CONDITIONS, ACTIONS and OPTIONS shown apply to each wing panel gap

location independently.

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

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

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

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

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

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

as RC.

B. WORK INSTRUCTIONS

1. Do PART 1: WING SKIN PANEL GAPS - DETAILED SEALANT INSPECTION for missing sealant

in the wing skin panel gaps above the underwing fittings.

CONDITION 1: NO MISSING SEALANT FOUND

a. Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action).

CONDITION 2: MISSING SEALANT FOUND

a. Do PART 3: WING SKIN PANEL GAPS - DETAILED CORROSION INSPECTION for corrosion

in the wing skin panel gaps above the underwing fittings.

CONDITION 3: ANY CORROSION FOUND

(1) ACTION 1: Contact Boeing for repair instructions and do the repair.

(2) ACTION 2: Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION

(Terminating Action).

CONDITION 4: NO CORROSION FOUND

(1) Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action).

PART 1: WING SKIN PANEL GAPS - DETAILED SEALANT INSPECTION

1. Remove the aft fairing. Refer to 777 AMM 54-52-04 as an accepted procedure.

NOTE: It is recommended to remove the aft turbine exhaust plug before the removal of the aft

fairing, to prevent any damage to the aft turbine exhaust plug. Refer to 777 AMM 78-11-02

as an accepted procedure.

2. RC - Do a Detailed Inspection (DET) for missing sealant in the wing skin panel gaps above the

underwing fittings in accordance with the figures below:

Group 1:

Left Wing Right Wing

FIGURE 1 -

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
Group 2:

Left Wing Right Wing

- FIGURE 2

Group 3:

Left Wing Right Wing

FIGURE 1 FIGURE 2

PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION

1. RC - Restore the sealant in accordance with the figures below:

Group 1:

Left Wing Right Wing

FIGURE 3 -

Group 2:

Left Wing Right Wing

- FIGURE 4

Group 3:

Left Wing Right Wing

FIGURE 3 FIGURE 4

2. Install the aft fairing. Refer to 777 AMM 54-52-04 as an accepted procedure.

NOTE: If the aft turbine exhaust plug was removed for access, install the aft turbine exhaust

plug. Refer to 777 AMM 78-11-02 as an accepted procedure.

3. Put the airplane back to a serviceable condition.

PART 3: WING SKIN PANEL GAPS - DETAILED CORROSION INSPECTION

1. RC - Do a detailed inspection for corrosion in accordance with the figures below.

Group 1:

Left Wing Right Wing

FIGURE 5 -

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
Group 2:

Left Wing Right Wing

- FIGURE 6

Group 3:

Left Wing Right Wing

FIGURE 5 FIGURE 6

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ALERT ALERT
This Figure applies only to: Group 1, 3.

FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
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 this figure.

CAUTION: USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE

DAMAGE TO THE WING SKIN.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Remove sealant from the wing skin

panel gaps not covered by the underwing fittings in the area shown. Refer to

777 AMM 51-31-01 as an accepted procedure.

1 Remove Sealant - -

(a)

Remove sealant from the wing skin

panel gaps covered by the underwing

fittings in the area shown. Refer to 777

AMM 51-31-01 as an accepted procedure.

2 Remove Sealant - -

(a)

Do a Detailed Inspection (DET) for any

void that may indicate missing sealant

in the area beyond the sealant portion

that was removed.

3 Inspect Sealant - -

(a) (b)

(a) Refer to APPENDIX A for additional optional tool information.

FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 3 OF 4)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(b) Any solvent used for sealant removal should be allowed to dry for a minimum of 15 minutes before inspecting

the remaining sealant.

It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps,

which are 0.06 inch to 0.2 inch wide.

One method to inspect for the presence or absence of sealant is to lightly tap the remaining sealant in the

wing skin panel gaps above the underwing fittings using a rubber mallet and a non-metallic tool. Another

method for this inspection is to probe the sealant using a non-metallic tool by applying firm hand pressure

to the existing sealant.

The presence of properly applied sealant in the wing skin panel gaps above the underwing fittings is indicated by resistance against the non-metallic tool when the non-metallic tool is tapped with a rubber mallet,

or when firm hand pressure is applied to it. The non-metallic tool should not advance into the existing

sealant when tapped or when firm hand pressure it applied to it.

Missing sealant is indicated by reduced resistance of the sealant being tapped or manually pressed with

the non-metallic tool. Obvious movement of the non-metallic tool into the existing sealant also indicates

the absence of sealant. Missing sealant may also be indicated by any obvious sealant discontinuities

found during the minimum of 0.5 inch sealant removal from the wing skin panel gaps, for access. The

non-metallic tools used for sealant removal for access may advance suddenly, indicating incorrectly applied

sealant at that location during production.

FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
This Figure applies only to: Group 2-3.

FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
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 this figure.

CAUTION: USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE

DAMAGE TO THE WING SKIN.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Remove sealant from the wing skin

panel gaps not covered by the underwing fittings in the area shown. Refer to

777 AMM 51-31-01 as an accepted procedure.

1 Remove Sealant - -

(a)

Remove sealant from the wing skin

panel gaps covered by the underwing

fittings in the area shown. Refer to 777

AMM 51-31-01 as an accepted procedure.

2 Remove Sealant - -

(a)

Do a Detailed Inspection (DET) for any

void that may indicate missing sealant

in the area beyond the sealant portion

that was removed.

3 Inspect Sealant - -

(a) (b)

(a) Refer to APPENDIX A for additional optional tool information.

FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(b) Any solvent used for sealant removal should be allowed to dry for a minimum of 15 minutes before inspecting

the remaining sealant.

It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps,

which are 0.06 inch to 0.2 inch wide.

One method to inspect for the presence or absence of sealant is to lightly tap the remaining sealant in the

wing skin panel gaps above the underwing fittings using a rubber mallet and a non-metallic tool. Another

method for this inspection is to probe the sealant using a non-metallic tool by applying firm hand pressure

to the existing sealant.

The presence of properly applied sealant in the wing skin panel gaps above the underwing fittings is indicated by resistance against the non-metallic tool when the non-metallic tool is tapped with a rubber mallet,

or when firm hand pressure is applied to it. The non-metallic tool should not advance into the existing

sealant when tapped or when firm hand pressure it applied to it.

Missing sealant is indicated by reduced resistance of the sealant being tapped or manually pressed with

the non-metallic tool. Obvious movement of the non-metallic tool into the existing sealant also indicates

the absence of sealant. Missing sealant may also be indicated by any obvious sealant discontinuities

found during the minimum of 0.5 inch sealant removal from the wing skin panel gaps, for access. The

non-metallic tools used for sealant removal for access may advance suddenly, indicating incorrectly applied

sealant at that location during production.

FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION

(SHEET 4 OF 4)

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ALERT ALERT
This Figure applies only to: Group 1, 3.

FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
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 this figure.

CAUTION: USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE

DAMAGE TO THE WING SKIN.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Refer to SOPM 20-30-03 as an accepted

procedure.

1 Clean Wing Skin Panel Gap - -

(a)

Chemical Conversion - - to any bare aluminum surface.

Coating

2 Apply

Refer to SOPM 20-43-03 as an accepted

procedure.

to any surface where primer was removed.BMS 10-79, Type

III

3 Apply Primer

Refer to SOPM 20-50-19 as an accepted

procedure.

4 Apply Sealant BMS 5-95 -

(a)

5 Apply Primer BMS10-79, Type III

6 Apply Enamel BMS10-60, Type II

(a) If the sealant was removed from the entire gap area above the underwing fitting, then clean the entire

area where sealant was removed before new sealant is applied.

FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR

(SHEET 3 OF 3)

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ALERT ALERT
This Figure applies only to: Group 2-3.

FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
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 this figure.

CAUTION: USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE

DAMAGE TO THE WING SKIN.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Refer to SOPM 20-30-03 as an accepted

procedure.

1 Clean Wing Skin Panel Gap - -

(a)

Chemical Conversion - - to any bare aluminum surface.

Coating

2 Apply

Refer to SOPM 20-43-03 as an accepted

procedure.

to any surface where primer was removed.BMS 10-79, Type

III

3 Apply Primer

Refer to SOPM 20-50-19 as an accepted

procedure.

4 Apply Sealant BMS 5-95 -

(a)

5 Apply Primer BMS10-79, Type III

6 Apply Enamel BMS10-60, Type II

(a) If the sealant was removed from the entire gap area above the underwing fitting, then clean the entire

area where sealant was removed before new sealant is applied.

FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
This Figure applies only to: Group 1, 3.

FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
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 location where missing sealant was found.

CAUTION: USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE

DAMAGE TO THE WING SKIN.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

from the area directly above the underwing fitting, where sealant was not previously removed. Refer to 777 AMM 51-

31-01 as an accepted procedure.

1 Remove Sealant - -

(a)

Refer to SOPM 20-30-03 as an accepted

procedure.

Clean Wing Skin Panel Gap - -

Do a DET for corrosion. A borescope or

Remote Visual Inspection (RVI) is recommended. Refer to APPENDIX A for additional optional borescope information.

2 Inspect Wing Skin Panel Gap - -

(a) Use non-metallic tools to abrade most of the sealant in the wing skin panel gaps without damaging the

adjacent wing and underwing fitting structure and finishes. Refer to APPENDIX A for additional tool information.

FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
This Figure applies only to: Group 2-3.

FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
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 this figure.

CAUTION: USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE

DAMAGE TO THE WING SKIN.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

from the area directly above the underwing fitting, where sealant was not previously removed. Refer to 777 AMM 51-

31-01 as an accepted procedure.

1 Remove Sealant - -

(a)

Refer to SOPM 20-30-03 as an accepted

procedure.

Clean Wing Skin Panel Gap - -

Do a DET for corrosion. A borescope or

Remote Visual Inspection (RVI) is recommended. Refer to APPENDIX A for additional optional borescope information.

2 Inspect Wing Skin Panel Gap - -

(a) Use non-metallic tools to abrade most of the sealant in the wing skin panel gaps without damaging the

adjacent wing and underwing fitting structure and finishes. Refer to APPENDIX A for additional tool information.

FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
This Appendix includes information about the non-metallic tools and materials that were used by Boeing for the

removal of sealant and the inspection for corrosion in production. Other procedures and other non-metallic tools

and materials may be used at the operators' discretion. This information is for reference only.

CAUTION: USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE

DAMAGE TO THE WING SKIN.

SEALANT REMOVAL TOOLS USED BY BOEING FOR THE WORK EQUIVALENT TO PART 1 DETAILED

(DET) INSPECTION

The following non-metallic tools were used by Boeing in production for the work equivalent to PART 1 sealant

removal in this service bulletin:

– Existing non-metallic sealant scrapers modified to match the width of the wing panel gaps, which are 0.06

inch to 0.2 inch wide.

– Small manual saws fabricated from Torlon polyamide-imide stock.

– Non-metallic drill bits fabricated from polyether imide (PEI) stock to make the sealant removal more time

effective.

Refer to Fleet Team Digest (FTD) article 777 FTD 57-13003 for additional tool photographs and information.

SEALANT REMOVAL TOOLS AND PROCEDURES USED IN PREPARATION FOR THE CORROSION

INSPECTION

Where missing sealant was found during the DET in Part 1, any sealant in the wing panel gap above the entire

width of the affected underwing fitting was required to be removed. This was done in production in preparation

for the corrosion inspection work that is equivalent to Part 3 DET in this service bulletin.

The sealant removal from the remaining area above the affected underwing fitting required non-metallic tools

capable to abrade most of the sealant in the wing skin panel gaps without damaging the adjacent wing and

underwing fitting structure and finishes. Some tool variations that were used to remove the sealant in the wing

skin panel gap above the entire width of the affected underwing fitting include, but are not limited to:

– Teflon or nylon rope that was knotted to create a rough surface that can abrade the sealant in the gap above

the underwing fittings

– Wire ties connected together to create a rough surface similar to the knotted Teflon or nylon rope mentioned

above

– OREGON brand Flexiblade nylon stock with 0.118 inch, 0.105 inch, and 0.099 inch cross sections (part

numbers 21-602, 21-601, and 21-600, respectively). Refer to http://www.oregonproducts.com for additional

information on this product.

BORESCOPE INFORMATION

APPENDIX A: SEALANT REMOVAL TOOLS AND PROCEDURES

(SHEET 1 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: January 10, 2014

777-57A0097

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BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT
Boeing performed a Remote Visual Inspection (RVI) of the wing panel gap for corrosion using an Olympus

IPLEX TX 2.4 mm (0.094 inch) videoscope. This videoscope was sufficiently small to fit in the wing panel gap,

which is 0.06 inch to 0.2 inch wide. Refer to http://www.olympus-ims.com for additional information on this

videoscope.

APPENDIX A: SEALANT REMOVAL TOOLS AND PROCEDURES

(SHEET 2 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: January 10, 2014

777-57A0097

45 of 45

BOEING SERVICE BULLETIN 777-57A0097

ALERT ALERT