Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Number: 757-57-0068

Original Issue: September 15, 2009

Revision 1: July 19, 2011

ATA System: 5740

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Detailed Inspection of Inboard

and Outboard Slats Main Track Downstop Assembly and Slat Track Housing

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). 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 © 2009 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more

information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the

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3.0
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BOEING SERVICE BULLETIN 757-57-0068

BLANK PAGE
Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

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

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

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

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

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

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . 24

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

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

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

FIGURE 1: LEFT WING - SLAT NUMBERS 1, 2, 3 AND 4 - DETAILED INSPECTION OF MAIN TRACK

DOWNSTOP ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 2: LEFT WING - SLAT NUMBER 5 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP

ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 3: RIGHT WING - SLAT NUMBERS 7, 8, 9 AND 10 - DETAILED INSPECTION OF MAIN TRACK

DOWNSTOP ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 4: RIGHT WING - SLAT NUMBER 6 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP

ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

FIGURE 5: LEFT WING - SLAT NUMBER 1, 2, 3, 4 AND 5 - DETAILED INSPECTION OF SLAT TRACK

HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FIGURE 6: RIGHT WING - SLAT NUMBER 6, 7, 8, 9 AND 10 - DETAILED INSPECTION OF SLAT TRACK

HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 7: LEFT WING - SLAT NUMBER 1, 2, 3 AND 4 - MAIN TRACK DOWNSTOP ASSEMBLY NUT -

TORQUE APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FIGURE 8: LEFT WING - SLAT NUMBER 5 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE

APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

FIGURE 9: RIGHT WING - SLAT NUMBERS 7, 8, 9 AND 10 - MAIN TRACK DOWNSTOP ASSEMBLY

NUT - TORQUE APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

FIGURE 10: RIGHT WING - SLAT NUMBER 6 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE

APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIGURE 11: WINGS - SLAT NUMBERS 1 - 10 SLAT TRACK HOUSING - REPAIR . . . . . . . . . . . 51

APPENDIX A: INSPECTION RESULTS REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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BOEING SERVICE BULLETIN 757-57-0068
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 757-57-0068

Original Issue: September 15, 2009

Revision 1: July 19, 2011

ATA System: 5740

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Detailed Inspection of Inboard

and Outboard Slats Main Track Downstop Assembly and Slat Track Housing

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on the airplane(s) changed in accordance with the original issue of this service

bulletin.

REASON FOR REVISION

This revision is sent to clarify downstop assembly components, damage condition limits for the slat track housing,

and torquing requirements for downstop fasteners. In addition, the part numbers were deleted from the inspection

tables, and the option to replace a slat can instead of repairing it was added.

These sections were changed:

1. Paragraph 1.E., Compliance, Tables 5 and 6, changed damage condition limits for the slat track housing

in the last row of the tables to less than 0.040 inches. Added option to replace the slat track housing if

damage was found and the remaining thickness was 0.040 inches or greater. Added requirement to replace

the slat track housing if a crack was found.

2. Paragraph 3.A., General Information, updated the general notes.

3. Paragraph 3.B.1.a., added option to reactivate the slats to reposition them. Paragraph 3.B.1.c., added option

to position the slat track to gain access to the downstop assembly. Paragraph 3.B.1.h.(2) and 3.B.1.m.(2),

added option to replace the slat track housing. Paragraph 3.B.1.h.(3) and 3.B.1.m.(3), added requirement

to replace the slat track housing if a crack is found during the detailed inspection. Paragraph 3.B.1.n and

3.B.2.e., added option to lubricate the slats before reinstalling the access panels. Paragraph 3.B.1.p., moved

Appendix completion conditions to Part 3.

4. Figures 1 and 3, removed part numbers and footnotes d through e.

5. Figures 2 and 4, updated parts shown in exploded view in illustration. Removed part numbers and footnotes

d through f.

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6. Figures 8 and 10, updated parts shown in exploded view in illustration. Added inspection step for the size

of the nut. Removed part number and specified diameter for each torque step. Reworded footnote b to

distinguish from size 4 and size 6 hardware. Removed footnote d. Also added Warning Note regarding

torquing the fasteners.

7. Figures 7 and 9, removed part number for torque step and footnote b.

8. Figure 11, removed "x" from illustration view B. Removed minimum distance between damage occurrences

from view B. Removed detail view A-A.

9. Appendix A, changed remaining thickness in last column to be less than 0.040 inches.

The data given in Information Notices 757-57-0068 IN02 and IN04 is included in this revision.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: September 15, 2009

Revision 1: July 19, 2011

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BOEING SERVICE BULLETIN 757-57-0068
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Summary Number: 757-57-0068

Original Issue: September 15, 2009

Revision 1: July 19, 2011

ATA System: 5740

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Detailed Inspection of Inboard

and Outboard Slats Main Track Downstop Assembly and Slat Track Housing

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This Service Bulletin gives instruction to do a detailed inspection of the inboard and outboard main track downstop

assemblies of slat numbers 2 thru 9 and the inboard main track downstop assembly of slat numbers 1 and 10.

Instruction is also given to do a detailed inspection of all slat track housings for foreign object debris or visible

damage. An incorrectly installed main track downstop assembly can allow the main track downstop hardware

to fall off the slat track and into the slat track housing which could cause a puncture in the slat track housing

when the slat is retracted. A punctured slat track housing could result in a fuel leak and an increased risk of a

fire.

There have been two reports of a fuel leak from the front spar of the wing through the slat track housing. In at

least one case, the source of the fuel leak was from a puncture of the slat track housing that was caused by a

roller that had fallen into the slat track housing. It was determined that the roller was not a component of the slat

installation or the slat track support rib. The roller was subsequently driven into the slat track housing by the

retracting slat track. In both cases, there were no reports of a fire as a result of the fuel leak.

Boeing Service Related Problem (SRP) 757-SRP-57-0210 is related to this service bulletin.

ACTION

Do a detailed inspection of the inboard and outboard main track downstop assemblies of slat numbers 2 thru 9

and the inboard main track downstop assembly of slat numbers 1 and 10 to make sure that each main track

downstop assembly is correctly installed and has no damaged or missing parts. Apply torque to the main track

downstop assembly nut to make sure it has been correctly installed. Do a detailed inspection of all slat track

housings for foreign object debris and damage to the wall of the slat track housing.

If a main track downstop assembly is incorrectly installed, remove and correctly reinstall the main track downstop

assembly. If a main track downstop assembly has a damaged or missing part, then replace the main track

downstop assembly part. If foreign object debris is found in the housing assembly of the slat track, remove all

foreign object debris from the area. If visible damage in the slat track housing is found, repair the damage or

replace the slat track housing.

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EFFECTIVITY

All 757 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 not available for the inspection, repair, reinstallation and torque measurement

given in this service bulletin.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

All 19.40 13.90

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 757-57-0068

BLANK PAGE
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Number: 757-57-0068

Original Issue: September 15, 2009

Revision 1: July 19, 2011

ATA System: 5740

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Detailed Inspection of Inboard

and Outboard Slats Main Track Downstop Assembly and Slat Track Housing

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - All 757 Airplanes

Airplane Models:

757-200, 757-200CB, 757-200PF, 757-300

Variable Number Group

NA001 - NA028 1

NA191 - NA199 1

NA201 - NA239 1

NA301 - NA305 1

NA341 - NA352 1

NA391 - NA399 1

NA401 - NA408 1

NA441 - NA447 1

NA501 - NA586 1

NB001 - NB004 1

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Variable Number Group

NB021 - NB023 1

NB036 - NB041 1

NB051 - NB053 1

NB061 - NB073 1

NB079 1

NB131 - NB148 1

NB161 - NB162 1

NB166 - NB168 1

NB201 - NB204 1

NB221 - NB228 1

NB230 1

NB236 1

NB239 1

NB261 - NB267 1

NB291 - NB299 1

NB301 - NB302 1

NB311 - NB312 1

NB321 - NB331 1

NB421 - NB438 1

NB446 1

NB451 - NB454 1

NB501 - NB523 1

NB561 1

NB571 1

NB581 - NB583 1

NC001 - NC033 1

NC041 - NC042 1

NC051 - NC052 1

NC056 - NC062 1

NC066 - NC084 1

NC091 - NC094 1

NC151 1

NC161 1

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BOEING SERVICE BULLETIN 757-57-0068
Variable Number Group

NC901 - NC951 1

NC971 - NC974 1

ND001 - ND007 1

ND011 - ND059 1

ND111 - ND113 1

ND161 - ND199 1

ND201 - ND203 1

ND221 - ND225 1

ND241 - ND248 1

ND301 - ND322 1

ND401 1

ND891 1

ND895 1

NE001 - NE008 1

NE011 - NE088 1

NE091 - NE094 1

NE141 - NE150 1

NE161 - NE177 1

NE201 - NE204 1

NE301 - NE302 1

NE311 - NE325 1

NJ001 - NJ004 1

NJ031 - NJ032 1

NJ551 - NJ555 1

NL001 - NL002 1

NL006 - NL017 1

NL101 - NL109 1

NL141 1

NL601 - NL616 1

NN001 - NN002 1

NN051 - NN052 1

NP901 - NP904 1

NS601 - NS616 1

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BOEING SERVICE BULLETIN 757-57-0068
Variable Number Group

NT001 - NT009 1

NT201 - NT202 1

NT231 - NT234 1

NT237 - NT240 1

NT242 1

NT245 - NT248 1

NT281 - NT289 1

NT341 - NT347 1

NT351 - NT360 1

NT371 - NT373 1

NT375 - NT379 1

NT381 - NT386 1

NT401 - NT409 1

NT411 - NT412 1

NT426 - NT427 1

NT431 - NT432 1

NT436 - NT438 1

NT441 - NT442 1

NT446 1

NT701 - NT769 1

NT791 - NT796 1

NT861 - NT862 1

NT881 - NT885 1

NT901 - NT916 1

NT971 - NT985 1

NU031 - NU038 1

NU701 - NU705 1

NU721 - NU728 1

NU731 - NU732 1

2. Spares Affected

None.

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BOEING SERVICE BULLETIN 757-57-0068
B. Concurrent Requirements

None.

C. Reason

This Service Bulletin gives instruction to do a detailed inspection of the inboard and outboard main

track downstop assemblies of slat numbers 2 thru 9 and the inboard main track downstop assembly

of slat numbers 1 and 10. Instruction is also given to do a detailed inspection of all slat track housings

for foreign object debris or visible damage. An incorrectly installed main track downstop assembly can

allow the main track downstop hardware to fall off the slat track and into the slat track housing which

could cause a puncture in the slat track housing when the slat is retracted. A punctured slat track

housing could result in a fuel leak and an increased risk of a fire.

There have been two reports of a fuel leak from the front spar of the wing through the slat track housing.

In at least one case, the source of the fuel leak was from a puncture of the slat track housing that was

caused by a roller that had fallen into the slat track housing. It was determined that the roller was not

a component of the slat installation or the slat track support rib. The roller was subsequently driven

into the slat track housing by the retracting slat track. In both cases, there were no reports of a fire as

a result of the fuel leak.

Revision 1: This revision is sent to clarify downstop assembly components, damage condition limits

for the slat track housing, and torquing requirements for downstop fasteners. In addition, the part

numbers were deleted from the inspection tables, and the option to replace a slat can instead of repairing

it was added.

The data given in Information Notices 757-57-0068 IN02 and IN04 is included in this revision.

Boeing Service Related Problem (SRP) 757-SRP-57-0210 is related to this service bulletin.

D. Description

Do a detailed inspection of the inboard and outboard main track downstop assemblies of slat numbers

2 thru 9 and the inboard main track downstop assembly of slat numbers 1 and 10 to make sure that

each main track downstop assembly is correctly installed and has no damaged or missing parts. Apply

torque to the main track downstop assembly nut to make sure it has been correctly installed. Do a

detailed inspection of all slat track housings for foreign object debris and damage to the wall of the slat

track housing.

If main track downstop assembly is incorrectly installed, remove and correctly reinstall the main track

downstop assembly. If the main track downstop assembly has a damaged or missing part, then replace

the main track downstop assembly part. If foreign object debris is found in the housing assembly of

the slat track, remove all foreign object debris from the area. If visible damage in the slat track housing

is found, repair the damage or replace the slat track housing.

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

Affected Maintenance Zones

Model Zone

757-200, 757-200CB, 757- 512, 522, 523, 524, 525, 612, 622, 623, 624, 625

200PF, 757-300

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BOEING SERVICE BULLETIN 757-57-0068
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.

Table 1: Left wing - Slat Numbers 1, 2, 3 and 4 - Detailed Inspection of Main Track Downstop

Assemblies

Condition Action Compliance Time

Within 24 months after the date on this

service bulletin

Do a detailed inspection of

the inboard and outboard

main track downstop assemblies of slat numbers

2, 3, 4 and the inboard

main track downstop assembly of slat number 1 in

accordance with Accomplishment Instructions

3.B.1.d.

All airplanes

Remove and correctly rein- Before further flight

stall main track downstop

assembly in accordance

with Accomplishment Instructions 3.B.1.d.(1)

Main track downstop

assembly order is incorrect

Replace main track down- Before further flight

stop assembly part in accordance with Accomplishment Instructions

3.B.1.d.(2)

Main track downstop

assembly part is

missing or damaged

Within 24 months after the date on this

service bulletin

Apply torque to the inboard

and outboard main track

downstop assembly nut of

slat numbers 2, 3, 4 and

the inboard main track

downstop assembly nut of

slat number 1 in accordance with Accomplishment Instructions 3.B.1.e.

All airplanes

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BOEING SERVICE BULLETIN 757-57-0068
Table 2: Left Wing - Slat Number 5 - Detailed Inspection of Main Track Downstop Assemblies

Condition Action Compliance Time

Within 24 months after the date on this

service bulletin

Do a detailed inspection of

the inboard and outboard

main track downstop assemblies of slat number 5

in accordance with Accomplishment Instructions

3.B.1.f.

All airplanes

Remove and correctly rein- Before further flight

stall main track downstop

assembly in accordance

with Accomplishment Instructions 3.B.1.f.(1)

Main track downstop

assembly order is incorrect

Replace main track down- Before further flight

stop assembly part in accordance with Accomplishment Instructions

3.B.1.f.(2)

Main track downstop

assembly part is

missing or damaged

Within 24 months after the date on this

service bulletin

Apply torque to the inboard

and outboard main track

downstop assembly nut of

slat number 5 in accordance with Accomplishment Instructions 3.B.1.g.

All airplanes

Table 3: Right Wing - Slat Numbers 7, 8, 9 and 10 - Detailed Inspection of Main Track Downstop

Assemblies

Condition Action Compliance Time

Within 24 months after the date on this

service bulletin

Do a detailed inspection of

the inboard and outboard

main track downstop assemblies of slat numbers

7, 8, 9 and the inboard

main track downstop assembly of slat number 10

in accordance with Accomplishment Instructions

3.B.1.i.

All airplanes

Remove and correctly rein- Before further flight

stall main track downstop

assembly in accordance

with Accomplishment Instructions 3.B.1.i.(1)

Main track downstop

assembly order is incorrect

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BOEING SERVICE BULLETIN 757-57-0068
Table 3: Right Wing - Slat Numbers 7, 8, 9 and 10 - Detailed Inspection of Main Track Downstop

Assemblies

Condition Action Compliance Time

Replace main track down- Before further flight

stop assembly part in accordance with Accomplishment Instructions

3.B.1.i.(2)

Main track downstop

assembly part is

missing or damaged

Within 24 months after the date on this

service bulletin

Apply torque to the in

board and outboard main

track downstop assembly

nut of slat numbers 7, 8, 9

and the inboard main track

downstop assembly nut of

slat number 10 in accordance with Accomplishment Instructions 3.B.1.j.

All airplanes

Table 4: Right Wing - Slat Number 6 - Detailed Inspection Of Main Track Downstop Assemblies

Condition Action Compliance Time

Within 24 months after the date on this

service bulletin

Do a detailed inspection of

the inboard and outboard

main track downstop assemblies of slat number 6

in accordance with Accomplishment Instructions

3.B.1.k.

All airplanes

Remove and correctly rein- Before further flight

stall main track downstop

assembly in accordance

with Accomplishment Instructions 3.B.1.k.(1)

Main track downstop

assembly order is incorrect

Replace main track down- Before further flight

stop assembly part in accordance with Accomplishment Instructions

3.B.1.k.(2)

Main track downstop

assembly part is

missing or damaged

Within 24 months after the date on this

service bulletin

Apply torque to the main

track downstop assembly

nut of slat number 6 in accordance with Accomplishment Instructions 3.B.1.l.

All airplanes

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BOEING SERVICE BULLETIN 757-57-0068
Table 5: Left Wing - Slat Numbers 1, 2, 3, 4 and 5 - Detailed Inspection of Slat Track Housing

Condition Action Compliance Time

Within 24 months after the date on this

service bulletin

Do a detailed inspection of

the slat track housings of

slat numbers 1, 2, 3, 4 and

5 in accordance with Accomplishment Instructions

3.B.1.h.

All airplanes

Remove foreign object de- Before further flight

bris in accordance with

Accomplishment Instructions 3.B.1.h.(1)

Foreign object debris

found in the slat track

housing

Repair the slat track hous- Before further flight

ing in accordance with Accomplishment Instructions

3.B.1.h.(2)

Damage found in the

slat track housing that

results in a remaining

thickness of 0.040

inches or greater OR

Replace the slat track

housing in accordance with

Accomplishment Instructions 3.B.1.h.(2)

Replace slat track housing Before further flight

or contact Boeing for repair

instructions in accordance

with Accomplishment Instructions 3.B.1.h.(3)

Damage found in the

slat track housing that

results in a remaining

thickness less than

0.040 inches or if a

crack was found

Table 6: Right Wing - Slat Number 6, 7, 8, 9 and 10 - Detailed Inspection of Slat Track Housing

Condition Action Compliance Time

Within 24 months after the date on this

service bulletin

Do a detailed inspection of

the slat track housings of

slat numbers 6, 7, 8, 9 and

10 in accordance with Accomplishment Instructions

3.B.1.m.

All airplanes

Remove foreign object de- Before further flight

bris in accordance with

Accomplishment Instructions 3.B.1.m.(1)

Foreign object debris

found in the slat track

housing

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BOEING SERVICE BULLETIN 757-57-0068
Table 6: Right Wing - Slat Number 6, 7, 8, 9 and 10 - Detailed Inspection of Slat Track Housing

Condition Action Compliance Time

Repair the slat track hous- Before further flight

ing in accordance with Accomplishment Instructions

3.B.1.m.(2)

Damage found in the

slat track housing that

results in a remaining

thickness of 0.040

inches or greater OR

Replace the slat track

housing in accordance with

Accomplishment Instructions 3.B.1.m.(2)

Replace slat track housing Before further flight

or contact Boeing for repair

instructions in accordance

with Accomplishment Instructions 3.B.1.m.(3)

Damage found in the

slat track housing that

results in a remaining

thickness less than

0.040 inches or if a

crack was found

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 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.

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BOEING SERVICE BULLETIN 757-57-0068
Number of Per- Task Hours Elapsed Hours

sons

Task

Deactivate Slats 2 5.50 2.75

and Open Access

FIGURE 1 1 1.75 1.75

FIGURE 2 1 0.75 0.75

FIGURE 3 1 1.75 1.75

FIGURE 4 1 0.75 0.75

FIGURE 5 1 1.10 1.10

FIGURE 6 1 1.10 1.10

FIGURE 7 1 0.50 0.50

FIGURE 8 1 0.10 0.10

FIGURE 9 1 0.50 0.50

FIGURE 10 1 0.10 0.10

FIGURE 11 1 1.50 (a) 1.50 (a)

Close Access and 2 5.50 2.75

Activate Slats

TOTAL FOR EACH AIRPLANE 19.40 13.90

(a) Time estimates is for each slat track housing that requires repair and is not

included in the totals given.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Service Related Problem (SRP) 757-SRP-57-0210

b. Boeing Service Letter 757-SL-51-022

c. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-43-03

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

e. 757 Aircraft Maintenance Manual (AMM) 06-44-00, 12-21-08, 27-81-00, 27-81-10, 27-81-12,

27-81-18, 57-41-01

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BOEING SERVICE BULLETIN 757-57-0068
2. Data supplied with this Service Bulletin

None.

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

Drawing Number Title

114N3001 Slat No. 5 and No. 6 Installation - Inboard Leading Edge

114N3047 Slat No. 5 and No. 6 Installation - Inboard Leading Edge (Rework)

114N4001 Leading Edge Slat Installation - Outboard Wing

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

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

not be applicable to all airplane configurations or operators.

K. Publications Affected

Publication Chapter-Section

757 Maintenance Manual 27-81, 30-11, 57-41

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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BOEING SERVICE BULLETIN 757-57-0068
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection, repair, reinstallation and torque

measurement given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

Part Number / Specifica- QTY Name Notes

tion

Chemical Conversion (a) (b)

Coating

Alodine 600 -

BMS 10-20 TYPE II - Primer (a) (c)

(a) Only required if damage to the slat track housing is removed in accordance with this service

bulletin.

(b) Refer to SOPM 20-43-03 for material sources.

(c) See 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.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

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BOEING SERVICE BULLETIN 757-57-0068
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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BOEING SERVICE BULLETIN 757-57-0068
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 limits to tighten nuts and bolts are in SRM Chapter 51

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.

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.

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BOEING SERVICE BULLETIN 757-57-0068
9. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

10. 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.

11. Boeing Service Letter 757-SL-51-022, 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.

12. Refer to Appendix A for Inspection Results Report.

13. 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.

14. 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.

15. 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.

The removed part can be discarded if a new or serviceable part is installed.

16. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

17. Some Boeing parts are supplied in a temporary configuration. Those parts are

identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is

permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'

(dash) part number. Boeing Drawing 005W0900 contains more data.

B. WORK INSTRUCTIONS

1. Part 1 - Main Track Downstop Assembly and Slat Track Housing - Inspection.

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a. Deactivate the leading edge slats. Refer to 757 AMM 27-81-00 as an accepted procedure.

You may have to reactivate the leading edge slats later to reposition them.

b. Remove access panels on the lower surface of the wing leading edge to get access to the

inboard and outboard main tracks of slat numbers 2, 3, 4, 5, 6, 7, 8, 9 and the inboard track

of slat number 1 and 10. Refer to 757 AMM 06-44-00 and 757 AMM 57-41-01 as accepted

procedures.

c. Position the slat track, if necessary, to gain access to the main track downstop assembly.

d. Do a detailed inspection for correct assembly order and missing or damaged parts of the

inboard and outboard main track downstop assemblies of slat numbers 2, 3, 4 and inboard

main track downstop assembly of slat number 1 in accordance with FIGURE 1.

(1) If the main track downstop assembly order is incorrect, then remove the main track

downstop assembly and reinstall the parts in the correct order. Refer to 757 AMM 27-81-12

as an accepted procedure.

NOTE: Figure 1 shows the downstop assembly bolt head pointing inboard in the

assembly sequence. However a reverse sequence with the downstop assembly

bolt head pointing outboard is acceptable.

(2) If main track downstop assembly part is missing or damaged, replace the part. Refer to

757 AMM 27-81-12 as an accepted procedure.

NOTE: A relative motion check can be used to confirm the presence of the bushing in

the slat track. If the downstop cannot be moved more than 0.010 inch relative

to the slat track in a vertical direction, then a visual inspection to confirm the

presence of the bushing is not required. If the downstop can be moved 0.010

inch relative to the slat track in a vertical direction, then the downstop assembly

must be visually inspected to confirm the presence of the bushing.

e. Apply torque to the inboard and outboard main track downstop assembly nut of slat numbers

2, 3, 4 and the inboard main track downstop assembly nut of slat number 1 in accordance

with FIGURE 7.

f. Do a detailed inspection for correct assembly order and missing or damaged parts of the

inboard and outboard main track downstop assemblies of slat number 5 in accordance with

FIGURE 2.

(1) If main track downstop assembly order is incorrect, then remove the main track downstop

assembly and reinstall the parts in the correct order. Refer to 757 AMM 27-81-10 as an

accepted procedure.

NOTE: Figure 2 shows the downstop assembly bolt head pointing inboard in the

assembly sequence. However a reverse sequence with the downstop assembly

bolt head pointing outboard is acceptable.

(2) If main track downstop assembly part is missing or damaged, replace the part. Refer to

757 AMM 27-81-10 as an accepted procedure.

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NOTE: A relative motion check can be used to confirm the presence of the bushing or

washer in the slat track. If the downstop assembly bolt cannot be moved more

than 0.010 inch relative to the slat track, then a visual inspection to confirm the

presence of the bushing is not required. If the downstop can be moved 0.010

inch relative to the slat track, then the downstop assembly must be visually

inspected to confirm the presence of the bushing or washer.

g. Apply torque to the inboard and outboard main track downstop assembly nut of slat number

5 in accordance with FIGURE 8.

h. Do a detailed inspection of the interior (dry side) of the slat track housing of slat numbers 1,

2, 3, 4 and 5 in accordance with FIGURE 5.

(1) If foreign object debris is found, remove it.

(2) If a slat track housing is damaged and the damage results in a remaining thickness of

0.040 inches or greater, do Part 2 - Slat Track Housing Repair, or replace the slat track

housing.

(3) If a slat track housing is damaged and the damage results in a remaining thickness less

than 0.040 inches or if a crack was found, replace the slat track housing or contact Boeing

for repair instructions and do the repair.

i. Do a detailed inspection for correct assembly order and missing or damaged parts of the

inboard and outboard main track downstop assemblies of slat numbers 7, 8, 9 and the inboard

main track downstop assembly of slat number 10 in accordance with FIGURE 3.

(1) If main track downstop assembly order is incorrect, then remove the main track downstop

assembly and reinstall the parts in the correct order. Refer to 757 AMM 27-81-12 as an

accepted procedure.

NOTE: Figure 3 shows the downstop assembly bolt head pointing inboard in the

assembly sequence. However a reverse sequence with the downstop assembly

bolt head pointing outboard is acceptable.

(2) If main track downstop assembly part is missing or damaged, replace the part. Refer to

757 AMM 27-81-12 as an acceptable procedure.

NOTE: A relative motion check can be used to confirm the presence of the bushing in

the slat track. If the downstop cannot be moved more than 0.010 inch relative

to the slat track in a vertical direction, then a visual inspection to confirm the

presence of the bushing is not required. If the downstop can be moved 0.010

inch relative to the slat track in a vertical direction, then the downstop assembly

must be visually inspected to confirm the presence of the bushing.

j. Apply torque to the inboard and outboard main track downstop assembly nut of slat numbers

7, 8, 9 and the inboard main track downstop assembly nut of slat number 10 in accordance

with FIGURE 9

k. Do a detailed inspection for correct assembly order and missing or damaged parts of the

inboard and outboard main track downstop assemblies of slat number 6 in accordance with

FIGURE 4.

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(1) If main track downstop assembly order is not correct, then remove the main track downstop

assembly and reinstall the parts in the correct order. Refer to 757 AMM 27-81-10 as an

accepted procedure.

NOTE: Figure 4 shows the downstop assembly bolt head pointing inboard in the

assembly sequence. However a reverse sequence with the downstop assembly

bolt head pointing outboard is acceptable.

(2) If main track downstop assembly part is missing or damaged, replace the part. Refer to

757 AMM 27-81-10 as an accepted procedure.

NOTE: A relative motion check can be used to confirm the presence of the bushing or

washer in the slat track. If the downstop cannot be moved more than 0.010 inch

relative to the slat track in any direction, then a visual inspection to confirm the

presence of the bushing is not required. If the downstop can be moved 0.010

inch relative to the slat track in any direction, then the downstop assembly must

be visually inspected to confirm the presence of the bushing or washer.

l. Apply torque to the inboard and outboard downstop assembly nut of slat number 6 in

accordance with FIGURE 10.

m. Do a detailed inspection of the interior (dry side) of the slat track housing of slat numbers 6,

7, 8, 9 and 10 in accordance with FIGURE 6.

(1) If foreign object debris is found, remove it.

(2) If a slat track housing is damaged and the damage results in a remaining thickness of

0.040 inches or greater, do Part 2 - Slat Track Housing Repair, or replace the slat track

housing.

(3) If a slat track housing is damaged and the damage results in a remaining thickness less

than 0.040 inches or if a crack was found, replace the slat track housing or contact Boeing

for repair information and do the repair.

n. It is optional to lubricate the slats, if necessary. Refer to 757 AMM 12-21-08 as an accepted

procedure.

o. Install access panels that were removed. Refer to 757 AMM 57-41-01 as an accepted

procedure.

p. Put the Slats back into its usual condition. Refer to 757 AMM 27-81-00 as an accepted

procedure.

q. Put the airplane back to a serviceable condition.

2. Part 2 - Slat Track Housing Repair

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a. Remove the slat track. For the inboard slats, refer to 757 AMM 27-81-10 as an accepted

procedure and for the outboard slats, refer to 757 AMM 27-81-12 as an accepted procedure.

b. Blend out damage in accordance with FIGURE 11.

c. Remove any foreign object debris from the slat track housing.

d. Install the slat track. For the inboard slats, refer to 757 AMM 27-81-10 as an accepted

procedure and for the outboard slats, refer to 757 AMM 27-81-12 as an accepted procedure.

e. It is optional to lubricate the slats, if necessary. Refer to 757 AMM 12-21-08 as an accepted

procedure.

3. Part 3 - Appendix A: Inspection Results Report

a. If any of the following conditions are found during the Part 1 inspections, complete Appendix

A and send the results to Boeing:

– Main track downstop assembly order is incorrect

– Main track downstop assembly part is missing or damaged

– Foreign object debris found in the slat track housing

– Damage found in the slat track housing that results in a remaining thickness of 0.040

inches or greater

– Damage found in the slat track housing that results in a remaining thickness of less than

0.040 inches or a crack is found.

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 1: LEFT WING - SLAT NUMBERS 1, 2, 3 AND 4 - DETAILED INSPECTION OF MAIN TRACK

DOWNSTOP ASSEMBLIES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Bolt - 7 (a) (b) (c)

Inspect Stop - 7 (a) (b) (c)

Inspect Bushing - 7 (a) (b) (c)

Inspect Stop - 7 (a) (b) (c)

Inspect Nut - 7 (a) (b) (c)

(a) Do a detailed inspection for the correct assembly order as shown and for missing or damaged parts.

(b) The main track downstop assembly can be inspected by using a one inch extendable mirror or similar

mirror, placed between the two ribs. The main track downstop assembly can also be viewed through the

access hole in the ribs on each side of the slat track. Disassembly of the main track downstop is not required

to accomplish this inspection.

(c) If necessary to line up the main track downstop with the access hole in the ribs, disconnect the slat actuator from the leading edge slats. Refer to 757 AMM 27-81-18 as an accepted procedure. Manually extend

the track until the main track downstop hole in the track lines up with the access hole in the main track

ribs.

FIGURE 1: LEFT WING - SLAT NUMBERS 1, 2, 3 AND 4 - DETAILED INSPECTION OF MAIN TRACK

DOWNSTOP ASSEMBLIES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 2: LEFT WING - SLAT NUMBER 5 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP

ASSEMBLIES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Bolt - 2 (a) (b) (c)

Inspect Washer - 2 (a) (b) (c)

Inspect Bushing - 2 (a) (b) (c)

Inspect Rocker Downstop - 2 (a) (b) (c)

Inspect Bushing - 2 (a) (b) (c)

Inspect Washer - 2 (a) (b) (c)

Inspect Nut - 2 (a) (b) (c)

(a) Do a detailed inspection for the correct assembly order as shown and for missing or damaged parts.

(b) The main track downstop assembly can be inspected by using a one inch extendable mirror or similar

mirror, placed between the two ribs. The main track downstop assembly can also be viewed through the

access hole in the ribs on each side of the slat track. Disassembly of the main track downstop is not required

to accomplish this inspection.

(c) If necessary to line up the main track downstop with the access hole in the ribs, disconnect the slat actuator from the leading edge slats. Refer to 757 AMM 27-81-18 as an accepted procedure. Manually extend

the track until the main track downstop hole in the track lines up with the access hole in the main track

ribs.

FIGURE 2: LEFT WING - SLAT NUMBER 5 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP

ASSEMBLIES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 3: RIGHT WING - SLAT NUMBERS 7, 8, 9 AND 10 - DETAILED INSPECTION OF MAIN TRACK

DOWNSTOP ASSEMBLIES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Bolt - 7 (a) (b) (c)

Inspect Stop - 7 (a) (b) (c)

Inspect Bushing - 7 (a) (b) (c)

Inspect Stop - 7 (a) (b) (c)

Inspect Nut - 7 (a) (b) (c)

(a) Do a detailed inspection for the correct assembly order as shown and for missing or damaged parts.

(b) The main track downstop assembly can be inspected by using a one inch extendable mirror or similar

mirror, placed between the two ribs. The main track downstop assembly can also be viewed through the

access hole in the ribs on each side of the slat track. Disassembly of the main track downstop is not required

to accomplish this inspection.

(c) If necessary to line up the main track downstop with the access hole in the ribs, disconnect the slat actuator from the leading edge slats. Refer to 757 AMM 27-81-18 as an accepted procedure. Manually extend

the track until the main track downstop hole in the track lines up with the access hole in the main track

ribs.

FIGURE 3: RIGHT WING - SLAT NUMBERS 7, 8, 9 AND 10 - DETAILED INSPECTION OF MAIN TRACK

DOWNSTOP ASSEMBLIES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 4: RIGHT WING - SLAT NUMBER 6 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP

ASSEMBLIES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Bolt - 2 (a) (b) (c)

Inspect Washer - 2 (a) (b) (c)

Inspect Bushing - 2 (a) (b) (c)

Inspect Rocker Downstop - 2 (a) (b) (c)

Inspect Bushing - 2 (a) (b) (c)

Inspect Washer - 2 (a) (b) (c)

Inspect Nut - 2 (a) (b) (c)

(a) Do a detailed inspection for the correct assembly order as shown and for missing or damaged parts.

(b) The main track downstop assembly can be inspected by using a one inch extendable mirror or similar

mirror, placed between the two ribs. The main track downstop assembly can also be viewed through the

access hole in the ribs on each side of the slat track. Disassembly of the main track downstop is not required

to accomplish this inspection.

(c) If necessary to line up the main track downstop with the access hole in the ribs, disconnect the slat actuator from the leading edge slats. Refer to 757 AMM 27-81-18 as an accepted procedure. Manually extend

the track until the main track downstop hole in the track lines up with the access hole in the main track

ribs.

FIGURE 4: RIGHT WING - SLAT NUMBER 6 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP

ASSEMBLIES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 5: LEFT WING - SLAT NUMBER 1, 2, 3, 4 AND 5 - DETAILED INSPECTION OF SLAT TRACK

HOUSING

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Slat Track Housing - 11 (a) (b)

(a) Do a detailed inspection of the slat track housing for any foreign object debris and damage to the wall of

the slat track housing.

(b) A borescope is recommended to do this inspection. The borescope can be inserted into the slat track

housing through the forward opening of the slat track housing.

FIGURE 5: LEFT WING - SLAT NUMBER 1, 2, 3, 4 AND 5 - DETAILED INSPECTION OF SLAT TRACK

HOUSING

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 6: RIGHT WING - SLAT NUMBER 6, 7, 8, 9 AND 10 - DETAILED INSPECTION OF SLAT TRACK

HOUSING

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Slat Track Housing - 11 (a) (b)

(a) Do a detailed Inspection of the slat track housing for any foreign object debris and damage to the wall of

the slat track housing.

(b) A borescope is recommended to do this inspection. The borescope can be inserted into the slat track

housing through the forward opening of the slat track housing.

FIGURE 6: RIGHT WING - SLAT NUMBER 6, 7, 8, 9 AND 10 - DETAILED INSPECTION OF SLAT TRACK

HOUSING

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 7: LEFT WING - SLAT NUMBER 1, 2, 3 AND 4 - MAIN TRACK DOWNSTOP ASSEMBLY NUT -

TORQUE APPLICATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Torque Nut - 7 (a)

(a) Hold the main track downstop assembly bolt head and tighten the nut within the torque range of 30 - 40

in-lbs.

FIGURE 7: LEFT WING - SLAT NUMBER 1, 2, 3 AND 4 - MAIN TRACK DOWNSTOP ASSEMBLY NUT -

TORQUE APPLICATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 8: LEFT WING - SLAT NUMBER 5 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE

APPLICATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Nut SIZE 2 (b)

WARNING: MAKE SURE TO APPLY THE TORQUE APPLICABLE TO THE SIZE NUT INSTALLED ON

YOUR MAIN SLAT TRACK. IF THE WRONG TORQUE IS APPLIED TO THE NUT, FOREIGN

OBJECT DEBRIS MAY BE INTRODUCED INTO THE SLAT CAN.

2 Torque Nut 1/4 INCH DIAMETER 2 (a)

Torque Nut 3/8 INCH DIAMETER 2 (c)

(a) Hold the main track downstop assembly bolt head and tighten the nut within the torque range of 60 - 70

in-lbs.

(b) The slat track downstops will have either 1/4 inch diameter hardware (size 4) or 3/8 inch diameter hardware

(size 6).

(c) Hold the main track downstop assembly bolt head and tighten the nut within the torque range of 194 -

206 in-lbs.

FIGURE 8: LEFT WING - SLAT NUMBER 5 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE

APPLICATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 9: RIGHT WING - SLAT NUMBERS 7, 8, 9 AND 10 - MAIN TRACK DOWNSTOP ASSEMBLY NUT

- TORQUE APPLICATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Torque Nut - 7 (a)

(a) Hold the main track downstop assembly bolt head and tighten the nut within the torque range of 30 - 40

in-lbs.

FIGURE 9: RIGHT WING - SLAT NUMBERS 7, 8, 9 AND 10 - MAIN TRACK DOWNSTOP ASSEMBLY NUT

- TORQUE APPLICATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 10: RIGHT WING - SLAT NUMBER 6 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE

APPLICATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Nut SIZE 2 (b)

WARNING: MAKE SURE TO APPLY THE TORQUE APPLICABLE TO THE SIZE NUT INSTALLED ON

YOUR MAIN SLAT TRACK. IF THE WRONG TORQUE IS APPLIED TO THE NUT, FOREIGN

OBJECT DEBRIS MAY BE INTRODUCED INTO THE SLAT CAN.

2 Torque Nut 1/4 INCH DIAMETER 2 (a)

Torque Nut 3/8 INCH DIAMETER 2 (c)

(a) Hold main track downstop assembly bolt head and tighten the nut within the torque range of 60 - 70 inlbs.

(b) The slat track downstops will have either 1/4 inch diameter hardware (size 4) or 3/8 inch diameter hardware

(size 6).

(c) Hold the main track downstop assembly bolt head and tighten the nut within the torque range of 194 -

206 in-lbs.

FIGURE 10: RIGHT WING - SLAT NUMBER 6 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE

APPLICATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
FIGURE 11: WINGS - SLAT NUMBERS 1 - 10 SLAT TRACK HOUSING - REPAIR

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Damage - - (a)

2 Clean Slat Track Housing - - (b)

Chemical Conversion ALODINE 600 - (c)

Coating

3 Apply

4 Apply Primer BMS 10-20 TYPE II - (d)

(a) Remove all nicks, gouges or scratches from the inside surface of the slat track housing to a 1.00 inch

radius minimum and blend out the damaged area.

(b) Clean the damaged area with a soft cloth moist with cleaning solvent. Refer to SOPM 20-30-03 as an

accepted procedure

(c) Apply to the repair area. Refer to SOPM 20-43-03 as an accepted procedure.

(d) Apply one coat to the repair area. Refer to SOPM 20-41-02 as an accepted procedure.

FIGURE 11: WINGS - SLAT NUMBERS 1 - 10 SLAT TRACK HOUSING - REPAIR

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
Reporting Instructions:

1. Record the airplane registry, variable or line number.

2. If a reportable condition is found, mark an 'X' in the applicable condition column for the applicable slat number

and end where the condition was found, and provide a detailed explanation of what was found in the comments

section.

3. Send the inspection results report to Boeing through the Boeing Communications System (BCS).

Service Bulletin 757-57-0068 inspection results report

Airplane Registry, Variable or Line Number:

Slat Condition

Damage

found in the

slat track

housing that

results in a

remaining

thickness

less than

0.040 inches

or a crack is

found

Damage

found in the

slat track

housing that

results in a

remaining

thickness of

0.040 inches

or greater

Foreign object debris

found in the

slat track

housing

Main track

downstop assembly part

is missing or

damaged

Main track

downstop assembly order

is incorrect

Number End

1 Inbd

Outbd N/A N/A

2 Inbd

Outbd

3 Inbd

Outbd

4 Inbd

Outbd

5 Inbd

Outbd

6 Inbd

Outbd

7 Inbd

Outbd

APPENDIX A: INSPECTION RESULTS REPORT

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068
Service Bulletin 757-57-0068 inspection results report

Airplane Registry, Variable or Line Number:

Slat Condition

Damage

found in the

slat track

housing that

results in a

remaining

thickness

less than

0.040 inches

or a crack is

found

Damage

found in the

slat track

housing that

results in a

remaining

thickness of

0.040 inches

or greater

Foreign object debris

found in the

slat track

housing

Main track

downstop assembly part

is missing or

damaged

Main track

downstop assembly order

is incorrect

Number End

8 Inbd

Outbd

9 Inbd

Outbd

10 Inbd

Outbd N/A N/A

Comments:

APPENDIX A: INSPECTION RESULTS REPORT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0068