### 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 1 of 54 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 2 of 54 **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 3 of 54 **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 4 of 54 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 5 of 546. 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** September 15, 2009 Original Issue: July 19, 2011 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 6 of 54 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 7 of 54**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 Elapsed Hours**  **Total Task Hours Airplanes**  13.90 19.40 All
**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 8 of 54 **BOEING SERVICE BULLETIN 757-57-0068**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 9 of 54 **BOEING SERVICE BULLETIN 757-57-0068**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 10 of 54 **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.
**DESCRIPTION CONFIGURATION**  **GROUP** All 757 Airplanes

- 1

Airplane Models: 757-200, 757-200CB, 757-200PF, 757-300 **Group Variable Number**  1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 11 of 54**Group Variable Number**  1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 12 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Group**  **Variable Number** 1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 13 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Group**  **Variable Number** 1 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 2. Spares Affected None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 14 of 54 **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 Zone**  **Model** 512, 522, 523, 524, 525, 612, 622, 623, 624, 625 757-200, 757-200CB, 757- 200PF, 757-300

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 15 of 54 **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**  **Compliance Time Action**  **Condition** Within 24 months after the date on this service bulletin Do a detailed inspection of the inboard and outboardmain track downstop assemblies of slat numbers 2, 3, 4 and the inboardmain track downstop assembly of slat number 1 inaccordance with Accomplishment Instructions 3.B.1.d. All airplanes

Before further flight Remove and correctly rein- stall main track downstop assembly in accordancewith Accomplishment Instructions 3.B.1.d.(1) Main track downstopassembly order is incorrect

Before further flight Replace main track down-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 ofslat number 1 in accordance with Accomplishment Instructions 3.B.1.e. All airplanes

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 16 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Table 2: Left Wing - Slat Number 5 - Detailed Inspection of Main Track Downstop Assemblies**  **Compliance Time Action**  **Condition** Within 24 months after the date on this service bulletin Do a detailed inspection of the inboard and outboardmain track downstop assemblies of slat number 5in accordance with Accomplishment Instructions 3.B.1.f. All airplanes

Before further flight Remove and correctly rein- stall main track downstop assembly in accordancewith Accomplishment Instructions 3.B.1.f.(1) Main track downstopassembly order is incorrect

Before further flight Replace main track down-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 ofslat 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**  **Compliance Time Action**  **Condition** Within 24 months after the date on this service bulletin Do a detailed inspection of the inboard and outboardmain track downstop assemblies of slat numbers 7, 8, 9 and the inboardmain track downstop assembly of slat number 10in accordance with Accomplishment Instructions 3.B.1.i. All airplanes

Before further flight Remove and correctly rein- stall main track downstop assembly in accordancewith Accomplishment Instructions 3.B.1.i.(1) Main track downstopassembly order is incorrect

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 17 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Table 3: Right Wing - Slat Numbers 7, 8, 9 and 10 - Detailed Inspection of Main Track Downstop**  **Assemblies Compliance Time**  **Action Condition**  Before further flight Replace main track down-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 ofslat 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 Compliance Time**  **Action Condition**  Within 24 months after the date on this service bulletin Do a detailed inspection of the inboard and outboardmain track downstop assemblies of slat number 6in accordance with Accomplishment Instructions 3.B.1.k. All airplanes

Before further flight Remove and correctly rein- stall main track downstop assembly in accordancewith Accomplishment Instructions 3.B.1.k.(1) Main track downstopassembly order is incorrect

Before further flight Replace main track down-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 assemblynut of slat number 6 in accordance with Accomplishment Instructions 3.B.1.l. All airplanes

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 18 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Table 5: Left Wing - Slat Numbers 1, 2, 3, 4 and 5 - Detailed Inspection of Slat Track Housing**  **Compliance Time Action**  **Condition** 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 and5 in accordance with Accomplishment Instructions 3.B.1.h. All airplanes

Before further flight Remove foreign object de- bris in accordance withAccomplishment Instructions 3.B.1.h.(1) Foreign object debris found in the slat track housing Before further flight Repair the slat track hous-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 withAccomplishment Instructions 3.B.1.h.(2) Before further flight Replace slat track housing or contact Boeing for repair instructions in accordancewith 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 Compliance Time**  **Action Condition**  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 and10 in accordance with Accomplishment Instructions 3.B.1.m. All airplanes

Before further flight Remove foreign object de- bris in accordance withAccomplishment Instructions 3.B.1.m.(1) Foreign object debris found in the slat track housing

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 19 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Table 6: Right Wing - Slat Number 6, 7, 8, 9 and 10 - Detailed Inspection of Slat Track Housing**  **Compliance Time Action**  **Condition** Before further flight Repair the slat track hous-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 withAccomplishment Instructions 3.B.1.m.(2) Before further flight Replace slat track housing or contact Boeing for repair instructions in accordancewith 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 20 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 
2.75 5.50 2 Deactivate Slats and Open Access 1.75 1.75 1 FIGURE 1 0.75 0.75 1 FIGURE 2 1.75 1.75 1 FIGURE 3 0.75 0.75 1 FIGURE 4 1.10 1.10 1 FIGURE 5 1.10 1.10 1 FIGURE 6 0.50 0.50 1 FIGURE 7 0.10 0.10 1 FIGURE 8 0.50 0.50 1 FIGURE 9 0.10 0.10 1 FIGURE 10 1.50 (a) 1.50 (a) 1 FIGURE 11 2.75 5.50 2 Close Access and Activate Slats 13.90 19.40 TOTAL FOR EACH AIRPLANE (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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 21 of 54 **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
**Title Drawing Number**  Slat No. 5 and No. 6 Installation - Inboard Leading Edge 114N3001 Slat No. 5 and No. 6 Installation - Inboard Leading Edge (Rework) 114N3047 Leading Edge Slat Installation - Outboard Wing 114N4001 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 Chapter-Section** 

**Publication** 27-81, 30-11, 57-41 757 Maintenance Manual **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 22 of 54 **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
**Notes Name**  **QTY Part Number / Specifica-**  **tion** (a) (b) Chemical Conversion Coating - Alodine 600 (a) (c) Primer

- BMS 10-20 TYPE II (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 23 of 54 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 24 of 54 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 25 of 54 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 26 of 54 **BOEING SERVICE BULLETIN 757-57-0068**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 27 of 54 **BOEING SERVICE BULLETIN 757-57-0068 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 28 of 54 **BOEING SERVICE BULLETIN 757-57-0068**(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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 29 of 54 **BOEING SERVICE BULLETIN 757-57-0068**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1: July 19, 2011 30 of 54 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 31 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) (b) (c) 7
- Bolt Inspect 1 (a) (b) (c) 7
- Stop Inspect (a) (b) (c) 7
- Bushing Inspect (a) (b) (c) 7
- Stop Inspect (a) (b) (c) 7
- Nut Inspect (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 32 of 54 **BOEING SERVICE BULLETIN 757-57-0068 FIGURE 2: LEFT WING - SLAT NUMBER 5 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP**  **ASSEMBLIES (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 33 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) (b) (c) 2
- Bolt Inspect 1 (a) (b) (c) 2
- Washer Inspect (a) (b) (c) 2
- Bushing Inspect (a) (b) (c) 2
- Rocker Downstop Inspect (a) (b) (c) 2
- Bushing Inspect (a) (b) (c) 2
- Washer Inspect (a) (b) (c) 2
- Nut Inspect (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 34 of 54 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 35 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) (b) (c) 7
- Bolt Inspect 1 (a) (b) (c) 7
- Stop Inspect (a) (b) (c) 7
- Bushing Inspect (a) (b) (c) 7
- Stop Inspect (a) (b) (c) 7
- Nut Inspect (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 36 of 54 **BOEING SERVICE BULLETIN 757-57-0068 FIGURE 4: RIGHT WING - SLAT NUMBER 6 - DETAILED INSPECTION OF MAIN TRACK DOWNSTOP**  **ASSEMBLIES (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 37 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) (b) (c) 2
- Bolt Inspect 1 (a) (b) (c) 2
- Washer Inspect (a) (b) (c) 2
- Bushing Inspect (a) (b) (c) 2
- Rocker Downstop Inspect (a) (b) (c) 2
- Bushing Inspect (a) (b) (c) 2
- Washer Inspect (a) (b) (c) 2
- Nut Inspect (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 38 of 54 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 39 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) (b) 11
- Slat Track Housing Inspect 1 (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 40 of 54 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 41 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) (b) 11
- Slat Track Housing Inspect 1 (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 42 of 54 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 43 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) 7
- Nut Torque 1 (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 44 of 54 **BOEING SERVICE BULLETIN 757-57-0068 FIGURE 8: LEFT WING - SLAT NUMBER 5 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE**  **APPLICATION (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 45 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) 2 SIZE Nut Inspect 1 **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. (a) 2 1/4 INCH DIAMETER Nut Torque 2 (c) 2 3/8 INCH DIAMETER Nut Torque (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 46 of 54 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 47 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) 7
- Nut Torque 1 (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 48 of 54 **BOEING SERVICE BULLETIN 757-57-0068 FIGURE 10: RIGHT WING - SLAT NUMBER 6 - MAIN TRACK DOWNSTOP ASSEMBLY NUT - TORQUE**  **APPLICATION (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 49 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) 2 SIZE Nut Inspect 1 **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. (a) 2 1/4 INCH DIAMETER Nut Torque 2 (c) 2 3/8 INCH DIAMETER Nut Torque(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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 50 of 54 **BOEING SERVICE BULLETIN 757-57-0068 FIGURE 11: WINGS - SLAT NUMBERS 1 - 10 SLAT TRACK HOUSING - REPAIR**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 51 of 54 **BOEING SERVICE BULLETIN 757-57-0068 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a)

- - Damage Remove 1 (b)

- - Slat Track Housing Clean 2 (c)

- ALODINE 600 Chemical Conversion Coating Apply 3 (d)

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 52 of 54 **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:**  **Condition Slat**  **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 ob ject debris**  **found in the slat track**  **housing Main track** **downstop as sembly part**  **is missing or damaged**  **Main track downstop as**  **sembly order is incorrect**  **End Number** 

Inbd 1 N/A N/A Outbd Inbd 2 Outbd Inbd 3 Outbd Inbd 4 Outbd Inbd 5 Outbd Inbd 6 Outbd Inbd 7 Outbd

**APPENDIX A: INSPECTION RESULTS REPORT (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 53 of 54 **BOEING SERVICE BULLETIN 757-57-0068 Service Bulletin 757-57-0068 inspection results report**  **Airplane Registry, Variable or Line Number: Condition**  **Slat 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 ob**  **ject debris found in the**  **slat track housing**  **Main track downstop as**  **sembly part is missing or**  **damaged Main track** **downstop as sembly order**  **is incorrect End**  **Number**

Inbd 8 Outbd Inbd 9 Outbd Inbd 10 N/A N/A Outbd
Comments:

**APPENDIX A: INSPECTION RESULTS REPORT (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2009 757-57-0068 Revision 1 July 19, 2011 54 of 54 **BOEING SERVICE BULLETIN 757-57-0068**