Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0268

Original Issue: April 01, 2015

ATA System: 5363

SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Web Inspection at Web

to Pressure Chord Joint

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 © 2015 Boeing.

Unpublished Work. All Rights Reserved.

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

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

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and

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connection with this document unless provided in writing by Boeing.

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ALERT ALERT

BLANK PAGE
Table of Contents

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

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

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

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

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

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

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

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

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

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

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 22

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: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE AFT PRESSURE

BULKHEAD WEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD [Group 2, Configuration 1] . . . . . 30

APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD [Group 3, Configuration 1] . . . . . 32

APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD [Group 1; Group 2-3, Configuration 2]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-53A0268

Original Issue: April 01, 2015

ATA System: 5363

SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Web Inspection at Web

to Pressure Chord Joint

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

Widespread Fatigue Damage (WFD) analysis of the 767, as required by 14 CFR 26.21(b), has resulted in the

conclusion that existing MPD Section 9, Airworthiness Limitation Item (ALI) inspection program is not sufficient

to preclude the occurrence of WFD in the aft pressure bulkhead to pressure chord joint as the airplane ages.

The aft pressure bulkhead web to pressure chord joint has multiple adjacent identical details which have the

potential for Multi-Site Damage (MSD) and the potential for WFD. 14 CFR 26.21 requires evaluation of such

designs for the potential for WFD and implementation of the appropriate service actions to ensure that WFD is

precluded before the Limit of Validity (LOV). Boeing has not received any reports of cracks in the bulkhead web

to pressure chord joint. Accomplishment of the inspection described in this service bulletin will enable detection

and repair of cracks if they should occur, at the STA 1582 Aft Pressure Bulkhead Web to Pressure Chord joint.

If Widespread Fatigue cracking is not found and repaired, the cracks can rapidly link up and can result in possible

rapid decompression and loss of structural integrity.

The aft pressure bulkhead web to pressure chord joint affected by this service bulletin has been determined to

be structure that is susceptible to WFD.

Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.

Boeing 767 MPD 622T001-9 Section 9, SSI 53-80-l01A is related to this service bulletin.

Boeing Service Bulletin 767-53A0087 is related to this service bulletin.

Boeing Service Bulletin 767-53A0139 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 No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Get access to the forward side of the aft pressure bulkhead at STA 1582. Remove the aft galley and the main

water tank(s) in the lower lobe. Do a Surface High Frequency Eddy Current (HFEC) inspection of all visible

locations of the aft pressure bulkhead web at the aft/inboard row of fasteners common to the aft pressure

bulkhead web and pressure chord around the entire circumference of the pressure chord for any crack. If any

crack is found, contact Boeing to get instructions for the repair for this service bulletin, and do the work instructed

by Boeing. If no crack is found, repeat the inspection.

EFFECTIVITY

All 767-200 and 767-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).

COMPLIANCE

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

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

mandatory.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-05-16 is related to this service bulletin.

The effective date of AD 2004-05-16 is April 13, 2004.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-09-08 is related to this service bulletin.

The effective date of AD 2012-09-08 is June 18, 2012.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2014-14-04 is related to this service bulletin.

The effective date of AD 2014-14-04 is September 5, 2014.

This service bulletin affects SSI 53-80-I01A of 767 MPD 622T001-9 Section 9, which is mandated by AD

2014-14-04. All other MPD inspections outside the of the affected area are not affected and must continue.

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BOEING SERVICE BULLETIN 767-53A0268

ALERT ALERT
Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection given in this service bulletin.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

Group 1, 2 and 3 Airplanes with one water tank 55.00 17.25

removal required

Group 1, 2 and 3 Airplanes with two water tank 57.00 17.75

removals required

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

None.

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ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0268

Original Issue: April 01, 2015

ATA System: 5363

SUBJECT: FUSELAGE - Section 48 - STA 1582 Aft Pressure Bulkhead Web Inspection at Web

to Pressure Chord Joint

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 applicable to all 767-200 and 767-300 Airplanes in 3 Group(s). The Variable

Numbers and Group Information for the applicable airplanes is given below.

Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1068.

Affected airplanes after Line Number 1068 will be added to the service bulletin's

MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet

Profile Page.

GROUP CONFIGURATION DESCRIPTION

Airplanes Line Numbers 1-175 with replaced aft pressure bulkhead

in accordance with SB 767-53A0139.

1 -

2 - Airplanes Line Numbers 176-423.

1 Airplanes with original production aft pressure bulkhead installed.

Airplanes with aft pressure bulkhead replaced in accordance with a

Boeing Organization Design Authorization (ODA) approval via FAA

Form 8100-9.

2

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GROUP CONFIGURATION DESCRIPTION

3 - Airplanes Line Numbers 424 and on (767-200/300 only).

1 Airplanes with original production aft pressure bulkhead installed.

Airplanes with aft pressure bulkhead replaced in accordance with a

Boeing Organization Designation Authorization (ODA) approval via

FAA Form 8100-9.

2

Airplane Models:

767-200, 767-300

Variable Number Group

VA001 - VA020 1

VA301 - VA315 1

VA501 - VA526 1

VA527 - VA530 2

VA701 - VA712 1

VA713 - VA719 2

VA801 - VA810 1

VB001 - VB002 1

VB051 - VB055 1

VB101 - VB125 1

VB201 - VB202 1

VB251 - VB253 1

VB281 - VB284 1

VB301 - VB302 1

VB321 - VB324 1

VB325 - VB332 2

VB371 - VB373 1

VB401 1

VB441 - VB444 3

VE001 - VE002 1

VE003 2

VE021 - VE023 1

VE041 - VE043 1

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Variable Number Group

VE061 - VE068 1

VE069 2

VE083 - VE084 1

VE085 - VE086 2

VE101 - VE103 1

VE104 2

VE116 - VE117 1

VE118 2

VE121 - VE123 1

VE124 - VE126 2

VE141 - VE142 1

VE143 - VE151 2

VE152 3

VE171 - VE172 2

VF001 - VF002 2

VF041 - VF042 2

VF051 2

VF061 - VF062 2

VF071 - VF072 2

VF091 - VF093 2

VF101 - VF102 2

VF161 2

VF162 3

VF171 - VF172 3

VF180 - VF184 3

VF251 3

VK001 - VK004 1

VK005 - VK011 2

VK012 - VK016 3

VK021 - VK022 2

VK031 - VK037 1

VK038 - VK053 2

VK054 - VK056 3

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Variable Number Group

VK081 - VK099 2

VK100 - VK113 3

VK131 - VK133 2

VK141 - VK142 2

VK143 - VK148 3

VK161 - VK164 3

VK171 3

VK181 3

VK186 3

VL001 1

VL002 - VL006 2

VL011 1

VL701 - VL703 3

VL751 - VL755 3

VL806 - VL807 3

VL871 - VL873 3

VL891 - VL900 3

VL911 - VL914 3

VL931 - VL932 3

VL941 3

VN001 - VN019 2

VN020 - VN041 3

VN051 - VN062 2

VN063 - VN064 3

VN081 - VN092 2

VN093 - VN099 3

VN111 - VN124 2

VN125 - VN127 3

VN130 - VN132 2

VN133 - VN137 3

VN151 - VN158 2

VN163 - VN168 2

VN171 - VN173 2

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Variable Number Group

VN174 3

VN191 - VN193 2

VN194 - VN198 3

VN211 - VN212 2

VN221 - VN224 2

VN225 3

VN231 - VN234 2

VN241 2

VN242 - VN243 3

VN251 - VN259 2

VN260 - VN276 3

VN291 2

VN292 - VN293 3

VN301 - VN306 2

VN307 - VN314 3

VN371 - VN372 2

VN376 2

VN381 2

VN382 - VN388 3

VN421 - VN427 3

VN436 3

VN471 - VN472 2

VN491 - VN496 2

VN497 - VN513 3

VN531 - VN532 2

VN536 - VN537 2

VN541 - VN542 2

VN546 - VN547 3

VN551 2

VN556 - VN557 3

VN561 - VN562 3

VN631 - VN633 2

VN634 - VN638 3

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ALERT ALERT
Variable Number Group

VN651 - VN652 2

VN653 - VN658 3

VN671 - VN672 2

VN676 3

VN681 - VN683 2

VN684 - VN691 3

VN731 2

VN732 3

VN751 - VN753 2

VN791 - VN792 3

VN811 - VN813 3

VN921 - VN922 3

VN931 - VN936 3

VN951 - VN953 3

VN966 - VN972 3

VR051 - VR060 3

VR081 3

VR084 3

VR086 - VR089 3

VR106 - VR109 3

VR401 3

VR421 - VR423 3

VR426 3

VR441 3

VR461 3

VR471 - VR472 3

VS051 - VS056 3

VS061 3

VS066 - VS070 3

VS073 - VS078 3

VS091 - VS104 3

VS111 - VS113 3

VS131 - VS133 3

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ALERT ALERT
Variable Number Group

VS136 - VS137 3

VS176 - VS177 3

VS186 - VS187 3

VS196 - VS203 3

VS206 - VS208 3

VS211 3

VS216 - VS217 3

VS231 3

VS246 - VS248 3

VS261 - VS263 3

VS266 - VS274 3

VS291 - VS293 3

VS301 - VS303 3

VS306 - VS311 3

VS316 3

VS321 - VS324 3

VS331 - VS333 3

VS336 - VS337 3

VS366 - VS367 3

VS381 - VS382 3

VS391 - VS392 3

VS401 3

VS426 - VS428 3

VS466 - VS472 3

VS486 3

VS496 - VS497 3

VS506 - VS507 3

VS526 3

VS546 - VS549 3

VS701 - VS736 3

VS751 - VS759 3

VS821 - VS825 3

VS841 - VS844 3

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Variable Number Group

VS861 3

VS881 - VS883 3

VS891 3

VS896 3

VS901 - VS912 3

VS916 3

VS921 - VS928 3

VS931 - VS933 3

VS941 3

VS951 - VS954 3

VS961 - VS969 3

VS971 - VS977 3

VS981 - VS984 3

VT001 - VT013 3

VT021 3

VT031 - VT033 3

VV001 3

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Widespread Fatigue Damage (WFD) analysis of the 767, as required by 14 CFR 26.21(b), has resulted

in the conclusion that existing MPD Section 9, Airworthiness Limitation Item (ALI) inspection program

is not sufficient to preclude the occurrence of WFD in the aft pressure bulkhead to pressure chord joint

as the airplane ages. The aft pressure bulkhead web to pressure chord joint has multiple adjacent

identical details which have the potential for Multi-Site Damage (MSD) and the potential for WFD. 14

CFR 26.21 requires evaluation of such designs for the potential for WFD and implementation of the

appropriate Service Actions to ensure that WFD is precluded before the Limit of Validity (LOV). Boeing

has not received any reports of cracks in the bulkhead web to pressure chord joint. Accomplishment

of the inspection described in this service bulletin will enable detection and repair of cracks if they

should occur, at the STA 1582 Aft Pressure Bulkhead Web to Pressure Chord joint. If Widespread

Fatigue cracking is not found and repaired, the cracks can rapidly link up and can result in possible

rapid decompression and loss of structural integrity.

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BOEING SERVICE BULLETIN 767-53A0268

ALERT ALERT
The aft pressure bulkhead web to pressure chord joint affected by this service bulletin has been

determined to be structure that is susceptible to WFD.

Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.

Boeing 767 MPD 622T001-9 Section 9, SSI 53-80-l01A is related to this service bulletin.

Boeing Service Bulletin 767-53A0087 is related to this service bulletin.

Boeing Service Bulletin 767-53A0139 is related to this service bulletin.

D. Description

Get access to the forward side of the aft pressure bulkhead at STA 1582. Remove the aft galley and

the main water tank(s) in the lower lobe. Do a Surface High Frequency Eddy Current (HFEC) inspection

of all visible locations of the aft pressure bulkhead web at the aft/inboard row of fasteners common to

the aft pressure bulkhead web and pressure chord around the entire circumference of the pressure

chord for any crack. If any crack is found, contact Boeing to get instructions for the repair for this service

bulletin, and do the work instructed by Boeing. If no crack is found, repeat the inspection.

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

Affected Maintenance Zones

Model Zone

767-200, 767-300 165, 166, 251, 252, 253, 254

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.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-05-16 is related to this service

bulletin. The effective date of AD 2004-05-16 is April 13, 2004.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-09-08 is related to this service

bulletin. The effective date of AD 2012-09-08 is June 18, 2012.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2014-14-04 is related to this service

bulletin. The effective date of AD 2014-14-04 is September 5, 2014.

This service bulletin affects SSI 53-80-I01A of 767 MPD 622T001-9 Section 9, which is mandated by

AD 2014-14-04. All other MPD inspections outside the of the affected area are not affected and must

continue.

Logic diagrams showing compliance tasks and compliance times are included as an aid in APPENDIX

A, APPENDIX B and APPENDIX C.

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

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ALERT ALERT
Group 2, Configuration 1:

Table 1: Surface High Frequency Eddy Current Inspection for Any Crack at STA 1582 Aft Pressure

Bulkhead

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight cycles after the original

issue date of

this service bulletin.

Before 50,000

total flight cycles.

Do PART 2: SURFACE

HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT

PRESSURE BULKHEAD

WEB, for any crack. (a)

(b)

All Airplanes.

Contact Boeing to get in- Before further flight. -

structions for the repair

for this service bulletin,

and do the work instructed by Boeing.

CONDITION 1: ANY

CRACK FOUND

Repeat PART 2: HIGH - 3,000 flight cycles.

FREQUENCY EDDY

CURRENT INSPECTION

OF THE AFT PRESSURE BULKHEAD WEB,

for any crack. (a) (b)

CONDITION 2: NO

CRACK FOUND

(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs

approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance

Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the

repaired area must continue in accordance with this service bulletin.

(b) Inspection of the web in accordance with this service bulletin does not require removal of permanently

attached structure such as stiffeners, splice plates, or clips.

Group 3, Configuration 1:

Table 2: Surface High Frequency Eddy Current Inspection for Any Crack at STA 1582 Aft Pressure

Bulkhead

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight cycles after the original

issue date of

this service bulletin.

Before 62,000

total flight cycles.

Do PART 2: SURFACE

HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT

PRESSURE BULKHEAD

WEB, for any crack. (a)

(b)

All Airplanes.

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ALERT ALERT
Group 3, Configuration 1:

Table 2: Surface High Frequency Eddy Current Inspection for Any Crack at STA 1582 Aft Pressure

Bulkhead

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Contact Boeing to get in- Before further flight. -

structions for the repair

for this service bulletin,

and do the work instructed by Boeing.

CONDITION 1: ANY

CRACK FOUND

Repeat PART 2: SUR- - 4,400 flight cycles.

FACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT

PRESSURE BULKHEAD

WEB, for any crack. (a)

(b)

CONDITION 2: NO

CRACK FOUND

(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs

approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance

Inspection instructions specified in approval for existing repairs must continue. Inspections outside of the

repaired area must continue in accordance with this service bulletin.

(b) Inspection of the web in accordance with this service bulletin does not require removal of permanently

attached structure such as stiffeners, splice plates, or clips.

Group 1; Group 2-3, Configuration 2:

Table 3: Surface High Frequency Current Inspection for Any Crack at STA 1582 Aft Pressure Bulkhead

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight cycles after the original

issue date of

this service bulletin.

Within 37,500

flight cycles after aft pressure

bulkhead replacement.

Do PART 2: SURFACE

HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT

PRESSURE BULKHEAD

WEB, for any crack. (a)

(b)

All Airplanes.

Contact Boeing to get in- Before further flight. -

structions for the repair

for this service bulletin,

and do the work instructed by Boeing.

CONDITION 1: ANY

CRACK FOUND

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ALERT ALERT
Group 1; Group 2-3, Configuration 2:

Table 3: Surface High Frequency Current Inspection for Any Crack at STA 1582 Aft Pressure Bulkhead

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Repeat PART 2: SUR- - 4,400 flight cycles.

FACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT

PRESSURE BULKHEAD

WEB, for any crack. (a)

(b)

CONDITION 2: NO

CRACK FOUND

(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs

approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance

Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the

repaired region must continue as instructed per this service bulletin

(b) Inspection of the web in accordance with this service bulletin does not require removal of permanently

attached structure such as stiffeners, splice plates, or clips.

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.

The Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the accomplishment of

the inspections defined in this Service Bulletin (SB) along with the corresponding compliance times

specified in Paragraph 1.E., Compliance of this SB, Original Issue, as an Alternative Method Of

Compliance (AMOC) to the inspections defined in D622T001-DTR Structural Significant Item (SSI)

53-80-I01A and Section 9 of the Maintenance Planning Document (MPD) D622T001-9, required by

paragraphs (i) and (k) of Airworthiness Directive (AD) 2014-14-04. This AMOC only applies to the areas

inspected in accordance with this SB. All other inspections outside of this SB inspection region are not

affected and must continue. All provisions of AD 2014-14-04 that are not specifically referenced in this

paragraph remain fully applicable and must be complied with.

The Manager of the FAA SACO approves the accomplishment of the inspections defined in this SB

along with the corresponding compliance times specified in Paragraph 1.E., Compliance of this SB,

Original Issue, as an AMOC to the inspections defined in SB 767-53A0087 required by paragraphs (a)

and (b) of AD 2004-05-16. This AMOC only applies to the areas inspected in accordance with this SB.

All other inspections outside of this SB inspection region are not affected and must continue.

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ALERT ALERT
In Addition, the Manager of the FAA SACO approves the accomplishment of the inspections defined

in this SB along with the corresponding compliance times specified in Paragraph 1.E., Compliance of

this SB, Original Issue, as an AMOC to the inspections defined in SB 767-53A0139 required by paragraph

(h) of AD 2012-09-08. This AMOC only applies to the areas inspected in accordance with this SB. All

other inspections outside of this SB inspection region are not affected and must continue.

G. Manpower

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

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

GROUP 1, 2 AND 3 AIRPLANES (WITH ONE WATER TANK REMOVAL REQUIRED):

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 19.00 4.75

FIGURE 1 2 14.00 7.00

Close Access 4 22.00 5.50

TOTAL FOR EACH AIRPLANE (a) 55.00 17.25

(a) The manpower estimate does not include repairs, if necessary.

GROUP 1, 2 AND 3 AIRPLANES (WITH TWO WATER TANK REMOVALS REQUIRED):

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 20.00 5.00

FIGURE 1 2 14.00 7.00

Close Access 4 23.00 5.75

TOTAL FOR EACH AIRPLANE (a) 57.00 17.75

(a) The manpower estimate does not include repairs, if necessary.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

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ALERT ALERT
J. References

1. Existing Data:

a. Boeing Service Bulletin 767-53A0087, 767-53A0139

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

c. Boeing Service Related Problem (SRP) 767-SRP-53-0469

d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-05-16, 2004-05-16

, 2012-09-08, 2014-14-04

e. Service Bulletin Index D624T001

f. 767 Aircraft Maintenance Manual (AMM) 25-31-04, 25-52-01, 25-52-03, 38-11-01, 38-11-64,

38-32-11

g. 767 Maintenance Planning Data (MPD) 622T001-9Section 9

h. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-19, Part 6, 53-80-05

2. Data Supplied with this Service Bulletin:

None.

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

None.

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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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

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

service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

None.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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ALERT ALERT

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque Values:

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

Chapter 51.

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

Aircraft Maintenance Manual (AMM).

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

Standard Wiring Practices Manual (SWPM).

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

Aircraft 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. Boeing Service Letter 767-SL-51-036, Damage Reporting and Repair Plan/Design

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

additional structural repair instructions. The Service Letter describes what information

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

6. Refer to APPENDIX A, APPENDIX B and APPENDIX C for logic diagram(s). Logic

diagrams are provided as an aid only. Information contained in Paragraph 1.E.,

Compliance is the primary source for compliance times. Information in Paragraph

3.B., Work Instructions is the primary source for tasks required for compliance.

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ALERT ALERT
7. 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.

8. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

9. 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.

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

(ATA) iSpec 2200.

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

are in Paragraph 1.E., Compliance.

12. 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 and steps indented under an RC step must be done to comply with

the AD. Alternative procedures for steps not identified with RC can be used if the

RC steps and indented 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: OPEN ACCESS.

2. RC - Do PART 2: SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT

PRESSURE BULKHEAD WEB, for any crack.

a. CONDITION 1: ANY CRACK FOUND

(1) RC - Contact Boeing to get instructions for the repair for this service bulletin and do the

work instructed by Boeing.

b. CONDITION 2: NO CRACK FOUND

(1) RC - Repeat PART 2: SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION

OF THE AFT PRESSURE BULKHEAD WEB, for any crack.

3. Do PART 3: CLOSE ACCESS.

4. Put the airplane back to a serviceable condition.

PART 1: OPEN ACCESS

1. Remove and keep the aft galley. Refer to 767 AMM 25-31-04 as an accepted procedure.

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ALERT ALERT
2. Remove and keep insulation from around splice plates that splice pressure chords on the aft

pressure bulkhead in the main deck compartment. Refer to 767 AMM 25-52-03 as an accepted

procedure.

3. Remove and keep the end wall in the bulk cargo compartment. Refer to 767 AMM 25-52-01 as an

accepted procedure.

4. Remove and keep the right side potable water tank. If installed, remove and keep the left side

potable water tank. Refer to 767 AMM 38-11-01 as an accepted procedure.

5. If necessary for access, remove and keep the waste tank. On some affected airplanes, the waste

tanks are installed forward of the affected area. On these airplanes, waste tank removal is not

necessary for access to the aft pressure bulkhead. Refer to 767 AMM 38-32-11 as an accepted

procedure.

6. Remove and keep insulation from around splice plates that splice pressure chords on the aft

pressure bulkhead in the bulk cargo compartment. Refer to 767 AMM 25-52-03 as an accepted

procedure.

PART 2: SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF THE AFT PRESSURE

BULKHEAD WEB

1. Do a surface HFEC Inspection of the aft pressure bulkhead web for any crack at the aft most

fastener row at all visible locations common to the pressure chord in accordance with FIGURE 1.

PART 3: CLOSE ACCESS

1. Install insulation to splice plates that splice pressure chords on the aft pressure bulkhead in the

bulk cargo compartment. Refer to 767 AMM 25-52-03 as an accepted procedure.

2. If removed, install the waste tank. Refer to 767 AMM 38-32-11 as an accepted procedure.

3. Install the right side potable water tank. If removed, install the left side potable water tank. Refer

to 767 AMM 38-11-64 as an accepted procedure.

4. Install the end wall in the bulk cargo compartment. Refer to 767 AMM 25-52-01 as an accepted

procedure.

5. Install insulation to splice plates that splice pressure chords on the aft pressure bulkhead in the

main deck compartment. Refer to 767 AMM 25-52-03 as an accepted procedure.

6. Install the aft galley. Refer to 767 AMM 25-31-04 as an accepted procedure.

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ALERT ALERT
FIGURE 1: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE AFT PRESSURE BULKHEAD

WEB

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 767-53A0268

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.

Step Task Name Identification Qty More Data

1 Inspect Bulkhead Web - - (a) (b) (c) (d) (e)

(a) Do a Surface HFEC Inspection for any crack in accordance with 767 NDT Manual Part 6, 51-00-01, 767

NDT Manual Part 6, 51-00-19 or 767 NDT Manual Part 6, 53-80-05.

(b) Inspect all visible locations of web around the entire bulkhead circumference.

(c) Temporarily pull back insulation in area of inspection.

(d) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs

approved by the Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage Tolerance

Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the

repaired region must continue as instructed per this service bulletin.

(e) Inspection of the web in accordance with this service bulletin does not require removal of permanently

attached structure such as stiffeners, splice plates, or clips.

FIGURE 1: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE AFT PRESSURE BULKHEAD

WEB

(SHEET 2 OF 2)

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ALERT ALERT
This Appendix applies only to: Group 2, Configuration 1.

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

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

for tasks required for compliance.

1. The table below gives the description for the parts and conditions called out in the logic diagrams.

Description Table

Title Description

SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF AFT

PRESSURE BULKHEAD WEB.

PART 2

CONDITION 1 ANY CRACK FOUND.

CONDITION 2 NO CRACK FOUND.

2. The table below gives the description for the flag notes called out in the logic diagram.

Flag Notes

Flag Note Letter Description

It is not necessary to do inspections in accordance with this service bulletin

in areas where existing repairs approved by the Boeing ODA via FAA 8100-

9 form cover the affected inspection areas. Damage Tolerance Inspection

instructions specified in approval for existing repairs must continue. Inspection

outside of the repaired area must continue in accordance with this service

bulletin.

(a)

Inspection of the web in accordance with this service bulletin does not require

removal of permanently attached structure such as stiffeners, splice plates,

or clips.

(b)

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD

(SHEET 1 OF 2)

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ALERT ALERT
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD

(SHEET 2 OF 2)

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ALERT ALERT
This Appendix applies only to: Group 3, Configuration 1.

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

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

for tasks required for compliance.

1. The table below gives the description for the parts and conditions called out in the logic diagrams.

Description Table

Title Description

SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF AFT

PRESSURE BULKHEAD WEB.

PART 2

CONDITION 1 ANY CRACK FOUND.

CONDITION 2 NO CRACK FOUND.

2. The table below gives the description for the flag notes called out in the logic diagram.

Flag Notes

Flag Note Letter Description

It is not necessary to do inspections in accordance with this service bulletin

in areas where existing repairs approved by the Boeing ODA via FAA 8100-

9 form cover the affected inspection areas. Damage Tolerance Inspection

instructions specified in approval for existing repairs must continue. Inspection

outside of the repaired area must continue in accordance with this service

bulletin.

(a)

Inspection of the web in accordance with this service bulletin does not require

removal of permanently attached structure such as stiffeners, splice plates,

or clips.

(b)

APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD

(SHEET 1 OF 2)

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ALERT ALERT
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD

(SHEET 2 OF 2)

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ALERT ALERT
This Appendix applies only to: Group 1; Group 2-3, Configuration 2.

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

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

for tasks required for compliance.

1. The table below gives the description for the parts and conditions called out in the logic diagrams.

Description Table

Title Description

SURFACE HIGH FREQUENCY EDDY CURRENT INSPECTION OF AFT

PRESSURE BULKHEAD WEB.

PART 2

CONDITION 1 ANY CRACK FOUND.

CONDITION 2 NO CRACK FOUND.

2. The table below gives the description for the flag notes called out in the logic diagram.

Flag Notes

Flag Note Letter Description

It is not necessary to do inspections in accordance with this service bulletin

in areas where existing repairs approved by the Boeing ODA via FAA 8100-

9 form cover the affected inspection areas. Damage Tolerance Inspection

instructions specified in approval for existing repairs must continue. Inspection

outside of the repaired area must continue in accordance with this service

bulletin.

(a)

Inspection of the web in accordance with this service bulletin does not require

removal of permanently attached structure such as stiffeners, splice plates,

or clips.

(b)

APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD

(SHEET 1 OF 2)

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ALERT ALERT
APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: INSPECTION FOR ANY

CRACK AT STA 1582 AFT PRESSURE BULKHEAD

(SHEET 2 OF 2)

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ALERT ALERT