### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Number: 777-55A0017**  Original Issue: May 20, 2010 ATA System: 5518 2741 **SUBJECT:** STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon Lined Bushing Inspection and Replacement 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 1 of 55 4.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 2 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1. Existing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2. Data supplied with this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 20 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1. Kits/Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 22 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 23 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 1: INSPECTION AND MEASUREMENT OF BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 2: INSPECTION AND MEASUREMENT OF HORIZONTAL STABILIZER JACKSCREW FITTING KARON LINED BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 FIGURE 3: INSPECTION AND MEASUREMENT OF UPPER GIMBAL - BRAKE HOUSING AND UPPER GIMBAL - BULKHEAD SUPPORT KARON LINED BUSHINGS. . . . . . . . . . . . . . . 35 FIGURE 4: INSPECTION AND MEASUREMENT OF TRIM ACTUATOR PRIMARY BRAKE HOUSING KARON LINED BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 5: INSPECTION AND MEASUREMENT OF LOWER GIMBAL KARON LINED BUSHINGS . 39 FIGURE 6: INSPECTION AND MEASUREMENT OF PINS. . . . . . . . . . . . . . . . . . . . . . . 41 FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL . . 43 FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 3 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 FIGURE 10: KARON LINED BUSHING SERVICE WEAR LIMITS. . . . . . . . . . . . . . . . . . . . . 55

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 4 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Summary**  **Number: 777-55A0017** Original Issue: May 20, 2010 ATA System: 5518 2741 **SUBJECT:** STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon Lined Bushing Inspection and Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None.

**BACKGROUND** Accomplishment of work given in this service bulletin will find damage to Karon lined bushings and pins in the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) and HSTA attachment locations on the airplane structure. There are twenty-four (24) Karon lined bushings and six (6) pins in the fuselage, horizontal stabilizer, HSTA upper and lower gimbals, and HSTA primary brake housing. If the Karon liners in the bushings are damaged, this may cause the Karon liners to completely disbond from the bushings. The completely disbonded Karon liners may migrate out of the joint causing excessive joint clearance. A joint with excessive clearance would result in fatigue cracking of the pins. The fatigue cracking of the pins in the HSTA and HSTA attachment locations on the airplane structure can compromise the structural integrity of the joints resulting in loss of controllability of the airplane. The 24 Karon lined bushings are installed in the following joint locations: BULKHEAD SUPPORT JACKSCREW FITTING, HORIZONTAL STABILIZER JACKSCREW FITTING, UPPER GIMBAL - BRAKE HOUSING, UPPER GIMBAL - BULKHEAD SUPPORT, TRIM ACTUATOR PRIMARY BRAKE HOUSING, AND LOWER GIMBAL. The bore of the bushings is lined with Karon, a material that is intended to reduce friction and resist wear. Research tests have shown that Karon liners would not wear in service; therefore, lubrication and inspection of these would not be necessary. During a scheduled inspection of the HSTA components for 777-200, one operator found a Karon lined bushing in the HORIZONTAL STABILIZER JACKSCREW FITTING with Karon liner broken into five pieces. The broken Karon liner had worn and disbonded from the bushing. The broken Karon liner of the bushing was found on an airplane that had accumulated 35,145 flight hours and 5,335 fight cycles.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 5 of 55Boeing analysis shows that the broken Karon lined bushing was one of the 149 bushings that used an early manufacturing process, which has since been improved. However, further investigation and analysis by Boeing show that Karon lined bushings in the HSTA and HSTA attachment locations on the airplane structure using both the early and the improved process could wear in service. The analysis also shows that the wear of the Karon liner may cause excessive joint clearance, which could lead to fatigue cracking of the pins. Accomplishment of the inspection in this service bulletin will find any disbond, tear, or wear in the 24 Karon lined bushings; any gouge, crack, or wear in the 6 pins; and any gouge or crack in the fail-safe components in the HSTA and HSTA attachment locations on the airplane structure. The inspection will make sure that Karon lined bushings and pins are returned to the design standard. Boeing Service Related Problem (SRP) 777-SRP-55-0042 is related to this service bulletin. Boeing Fleet Team Digest (FTD) article 777 FTD 55-07001 **ACTION Airplane Work**  1. Remove hydraulic pressure, hydraulic power, and install safety tags to the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA). 2. Gain access to HSTA area and remove the HSTA. 3. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. If any disbond or tear is found, or the ID is greater than the allowable MAXIMUM DIAMETER on the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the bushings; then no bushing replacement is necessary. 4. Install the HSTA that is in a known serviceable condition or has been overhauled in accordance with this service bulletin. **NOTE:** If the replacement HSTA is not in a known serviceable condition, then do a Detailed Inspection and measurement of the Karon lined bushings and pins; and a Detailed Inspection of the fail-safe components of the replacement HSTA in accordance with this service bulletin before further flight. Refer to Paragraph 3.A., General Information, for the applicable known serviceable conditions. 5. Do the Horizontal Stabilizer Trim Actuator Installation Test. 6. Close access and put the airplane back to a serviceable condition. 7. Repeat the Detailed Inspection and measurement of the Karon lined bushings at the time in accordance with Paragraph 1.E., Compliance.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 6 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Component (Horizontal Stabilizer Trim Actuator, HSTA) Work**  1. Disassemble the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) as necessary. 2. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. Do a Detailed Inspection and measurement of the pins for any gouge, crack, or wear. Do a Detailed Inspection of the fail-safe components for any gouge or crack. 3. If any disbond or tear is found, or the ID is greater than the MAXIMUM DESIGN DIMENSION on the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the bushings; then no bushing replacement is necessary. 4. If any gouge or crack is found, or the OD is less than the MINIMUM DESIGN DIMENSION on the pins; then a pin replacement or refurbishment is necessary. If any gouge or crack is found on the fail-safe components, then a replacement or refurbishment is necessary. For any cracked pins that are found during the Detailed Inspection, replace the pin and do a magnetic particle inspection of the fail-safe components as applicable. If any crack is found on the fail-safe components during a magnetic particle inspection, then replacement is necessary. If no gouge, crack, and wear are found on the pins; then a replacement or refurbishment is not necessary. If no gouge and crack are found on the fail-safe components, then a replacement or refurbishment is not necessary. 5. Assemble the HSTA. **EFFECTIVITY** 777-200, 777-200LR, 777-300, and 777-300ER airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of March 3, 2007. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER** Refer to Paragraph 1.G., Manpower. **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: May 20, 2010 777-55A0017 7 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 8 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Number: 777-55A0017**  Original Issue: May 20, 2010 ATA System: 5518 2741 **SUBJECT:** STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon Lined Bushing Inspection and Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplanes shown below. Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. **NOTE:** This service bulletin is for the airplanes identified below. The effectivity list shown below is complete for airplanes through line number 893. At least one airplane after line number 893 is also affected by this service bulletin, and these airplanes are in Group(s) 1. These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page.
**DESCRIPTION CONFIGURATION**  **GROUP** 777-200, 777-200LR, 777-300, and 777-300ER airplanes.

- 1

Airplane Models: 777-200, 777-200LR, 777-300, 777-300ER **Group Variable Number**  1 WA001 - WA017 1 WA076 - WA080 1 WA086 - WA093

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 9 of 55**Group Variable Number**  1 WA101 - WA104 1 WA116 - WA119 1 WA131 - WA137 1 WA171 - WA175 1 WA196 - WA198 1 WA206 - WA212 1 WA221 - WA223 1 WA231 - WA232 1 WA241 - WA250 1 WA261 - WA266 1 WA281 - WA283 1 WA301 - WA304 1 WB001 - WB021 1 WB031 - WB046 1 WB051 - WB088 1 WB101 - WB106 1 WB121 - WB125 1 WB131 - WB148 1 WB151 - WB155 1 WB161 - WB177 1 WB181 - WB194 1 WB201 - WB215 1 WB231 - WB247 1 WB271 - WB273 1 WB276 - WB286 1 WB291 - WB302 1 WB306 - WB307 1 WB311 - WB337 1 WB341 - WB342 1 WB366 - WB368 1 WB371 - WB388 1 WB406 1 WB411 - WB413

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 10 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Group**  **Variable Number** 1 WB416 - WB439 1 WB446 - WB453 1 WB476 1 WB481 - WB484 1 WB501 - WB512 1 WB531 - WB537 1 WB551 - WB554 1 WB591 - WB597 1 WB601 - WB606 1 WB611 - WB622 1 WB631 - WB638 1 WB646 - WB649 1 WC051 - WC073 1 WC101 - WC104 1 WC111 - WC120 1 WC221 - WC224 1 WC241 - WC243 1 WC281 - WC290 1 WC301 - WC308 1 WC361 - WC364 1 WC371 - WC374 1 WC381 - WC395 1 WC441 1 WC446 - WC449 1 WC456 - WC459 1 WC486 - WC493 1 WC506 - WC508 1 WC521 - WC522 1 WC531 - WC536 1 WC546 - WC548 1 WC556 1 WC566 - WC567 1 WC571 - WC574

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 11 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Group**  **Variable Number** 1 WC581 1 WD001 - WD002 1 WD011 - WD018 1 WD031 - WD036 1 WD046 - WD055 1 WD066 - WD075 1 WD081 - WD088 1 WD091 1 WD501 - WD513 1 WD521 - WD541 1 WD546 - WD554 1 WD561 - WD573 1 WD581 - WD599 1 WD606 - WD609 1 WD621 - WD632 1 WD651 - WD665 1 WD671 - WD676 1 WD691 - WD709 1 WD741 - WD752 1 WD761 - WD771 1 WD786 - WD788 1 WD796 - WD813 1 WD826 - WD837 1 WD846 - WD861 1 WD871 - WD882 1 WD911 - WD914 1 WD921 - WD922 1 WD936 - WD939 1 WD946 - WD951 1 WD966 - WD969 1 WD981 - WD982 1 WD986 - WD987 1 WE001 - WE004

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 12 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Group**  **Variable Number** 1 WE011 - WE012 1 WE021 - WE022 1 WE071 1 WE081 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** Accomplishment of work given in this service bulletin will find damage to Karon lined bushings and pins in the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) and HSTA attachment locations on the airplane structure. There are twenty-four (24) Karon lined bushings and six (6) pins in the fuselage, horizontal stabilizer, HSTA upper and lower gimbals, and HSTA primary brake housing. If the Karon liners in the bushings are damaged, this may cause the Karon liners to completely disbond from the bushings. The completely disbonded Karon liners may migrate out of the joint causing excessive joint clearance. A joint with excessive clearance would result in fatigue cracking of the pins. The fatigue cracking of the pins in the HSTA and HSTA attachment locations on the airplane structure can compromise the structural integrity of the joints resulting in loss of controllability of the airplane. The 24 Karon lined bushings are installed in the following joint locations: BULKHEAD SUPPORT JACKSCREW FITTING, HORIZONTAL STABILIZER JACKSCREW FITTING, UPPER GIMBAL - BRAKE HOUSING, UPPER GIMBAL - BULKHEAD SUPPORT, TRIM ACTUATOR PRIMARY BRAKE HOUSING, AND LOWER GIMBAL. The bore of the bushings is lined with Karon, a material that is intended to reduce friction and resist wear. Research tests have shown that Karon liners would not wear in service; therefore, lubrication and inspection of these would not be necessary. During a scheduled inspection of the HSTA components for 777-200, one operator found a Karon lined bushing in the HORIZONTAL STABILIZER JACKSCREW FITTING with Karon liner broken into five pieces. The broken Karon liner had worn and disbonded from the bushing. The broken Karon liner of the bushing was found on an airplane that had accumulated 35,145 flight hours and 5,335 fight cycles. Boeing analysis shows that the broken Karon lined bushing was one of the 149 bushings that used an early manufacturing process, which has since been improved. However, further investigation and analysis by Boeing show that Karon lined bushings in the HSTA and HSTA attachment locations on the airplane structure using both the early and the improved process could wear in service. The analysis also shows that the wear of the Karon liner may cause excessive joint clearance, which could lead to fatigue cracking of the pins. Accomplishment of the inspection in this service bulletin will find any disbond, tear, or wear in the 24 Karon lined bushings; any gouge, crack, or wear in the 6 pins; and any gouge or crack in the fail-safe components in the HSTA and HSTA attachment locations on the airplane structure. The inspection will make sure that Karon lined bushings and pins are returned to the design standard.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 13 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**Boeing Service Related Problem (SRP) 777-SRP-55-0042 is related to this service bulletin. Boeing Fleet Team Digest (FTD) article 777 FTD 55-07001 is related to this service bulletin. **D. Description Airplane Work**  1. Remove hydraulic pressure, hydraulic power, and install safety tags to the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA). 2. Gain access to HSTA area and remove the HSTA. 3. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. If any disbond or tear is found, or the ID is greater than the allowable MAXIMUM DIAMETER on the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the bushings; then no bushing replacement is necessary. 4. Install the HSTA that is in a known serviceable condition or has been overhauled in accordance with this service bulletin. **NOTE:** If the replacement HSTA is not in a known serviceable condition, then do a Detailed Inspection and measurement of the Karon lined bushings and pins; and a Detailed Inspection of the fail-safe components of the replacement HSTA in accordance with this service bulletin before further flight. Refer to Paragraph 3.A., General Information, for the applicable known serviceable conditions. 5. Do the Horizontal Stabilizer Trim Actuator Installation Test. 6. Close access and put the airplane back to a serviceable condition. 7. Repeat the Detailed Inspection and measurement of the Karon lined bushings at the time in accordance with Paragraph 1.E., Compliance. **Component (Horizontal Stabilizer Trim Actuator, HSTA) Work** 1. Disassemble the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) as necessary. 2. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. Do a Detailed Inspection and measurement of the pins for any gouge, crack, or wear. Do a Detailed Inspection of the fail-safe components for any gouge or crack. 3. If any disbond or tear is found, or the ID is greater than the MAXIMUM DESIGN DIMENSION on the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the bushings; then no bushing replacement is necessary. 4. If any gouge or crack is found, or the OD is less than the MINIMUM DESIGN DIMENSION on the pins; then a pin replacement or refurbishment is necessary. If any gouge or crack is found on the fail-safe components, then a replacement or refurbishment is necessary. For any cracked pins that are found during the Detailed Inspection, replace the pin and do a magnetic particle inspection of the fail-safe components as applicable. If any crack is found on the fail-safe components during a magnetic particle inspection, then replacement is necessary.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 14 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**If no gouge, crack, and wear are found on the pins; then a replacement or refurbishment is not necessary. If no gouge and crack are found on the fail-safe components, then a replacement or refurbishment is not necessary. 5. Assemble the HSTA. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 311, 312 777-200, 777-200LR, 777-300, 777-300ER **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: Inspection of Karon Lined Bushings and Pins Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever**  **Occurs Later ) Action**  **Condition**

- Within 24 months after the original issuedate of this service bulletin. Before 32,000total flight cycles. Do a Detailed Inspectionof the Karon lined bushings for a disbond or tear and measure the ID of the Karon lined bushings for wear in accordancewith PART 1 of Paragraph 3.B., Work Instructions, All airplanes.

- Before further flight. Do a Karon lined bushingreplacement in accordance with PART 1 ofParagraph 3.B., Work Instructions, as applicable Any disbond or tear found, or the ID is greater than theallowable MAXIMUM DIAMETER on the Karon lined bushings. AND Install HSTA that is in aknown serviceable condition or has been overhauled in accordancewith PART 2 of Paragraph 3.B., Work Instructions.(a)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 15 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Table 1: Inspection of Karon Lined Bushings and Pins**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- Before further flight. Install HSTA that is in aknown serviceable condition or has been overhauled in accordancewith PART 2 of Paragraph 3.B., Work Instructions.(a) No disbond and tear found, and the ID is less than or equal to the allowable MAXIMUM DIAMETER on the Karon lined bushings.

16,000 flight cycles. Within 16,000 flight cycles from the initial inspection. Do a Detailed Inspectionof the Karon lined bushings for a disbond or tear and measure the ID of the Karon lined bushings for wear in accordancewith PART 1 of Paragraph 3.B., Work Instructions. Accomplished PART 1 ofParagraph 3.B., Work Instructions, and installed HSTA that is in a known serviceable condition or has been overhauled in accordance with PART 2 of Paragraph 3.B., Work Instructions. (a) If the replacement HSTA is not in a known serviceable condition, then do a Detailed Inspection and measurement of the Karon lined bushings and pins; and a Detailed Inspection of the fail-safe components of the HSTA in accordance with PART 2 of Paragraph 3.B., Work Instructions, before further flight. Refer to Paragraph 3.A., General Information, for the descriptions of HSTA's that are in a known serviceable conditions. **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 16 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**• Time to cure the materials • Time to make the parts • Time to find the tools. **Table 1: Airplane Work - Inspection and Measurement of Karon Lined Bushings Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 

1.80 3.60 2 PART 1: Prepara- tion, Open Access,and Actuator Removal 0.75 0.75 1 PART 1: BULK- HEAD SUPPORTJACKSCREW FITTING Karon lined bushings (FIGURE 1) 0.75 0.75 1 PART 1: HORIZON- TAL STABILIZERJACKSCREW FITTING Karon lined bushings (FIGURE 2) 2.8 5.6 2 PART 6: HSTA In-stallation, HSTA Installation Test, and Close Access. 6.10 10.70 TOTAL FOR EACH AIRPLANE Note: More time is needed if bushing replacement is necessary. Refer to Table 3 for additional hours for bushing replacement. **Table 2: Component (Horizontal Stabilizer Trim Actuator, HSTA) Work - Inspection and Measurement of Karon Lined Bushings and Pins**  **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task**

0.50 0.50 1 PART 2: UPPER GIMBAL - BRAKE HOUSING Karon lined bushings (FIGURE 3) 0.50 0.50 1 PART 2: UPPERGIMBAL - BULKHEAD SUPPORTKaron lined bushings (FIGURE 3)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 17 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Table 2: Component (Horizontal Stabilizer Trim Actuator, HSTA) Work - Inspection and**  **Measurement of Karon Lined Bushings and Pins Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 

0.50 0.50 1 PART 2: TRIM AC- TUATOR PRIMARY BRAKE HOUSINGKaron lined bushings (FIGURE 4) 0.75 0.75 1 PART 2: LOWER GIMBAL Karon lined bushings (FIGURE 5) 0.50 0.50 1 PART 2: Pins (FIG- URE 6) 2.75 2.75 TOTAL FOR EACH COMPONENT Note: More time is needed if bushing and/or pin replacement/refurbishment are necessary. Refer to Table 3 for additional hours for bushing replacement. **Table 3: Karon Lined Bushing Replacement Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 

2.00 2.00 1 PART 1: BULK- HEAD SUPPORTJACKSCREW FITTING, Bushing Removal (FIGURE 7)(a) 2.15 2.15 1 PART 1: BULK- HEAD SUPPORTJACKSCREW FITTING, IntermediateSleeve Replacement (FIGURE 8)(a) (b) (c) 1.00 1.00 1 PART 1: BULK- HEAD SUPPORTJACKSCREW FITTING, Bushing Installation (FIGURE 9)(a) (c)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 18 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Table 3: Karon Lined Bushing Replacement**  **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task**

3.00 3.00 1 PART 1: HORIZON- TAL STABILIZERJACKSCREW FITTING, Bushing Replacement(a) (c) 1.75 1.75 1 PART 2: UPPER GIMBAL - UPPER BRAKE, Bushing Replacement(a) (c) 1.75 1.75 1 PART 2: UPPERGIMBAL - BULKHEAD SUPPORT,Bushing Replacement(a) (c) 1.75 1.75 1 PART 2: TRIM AC- TUATOR PRIMARY BRAKE HOUSING,Bushing Replacement(a) (c) 3.00 3.00 1 PART 2: LOWER GIMBAL, Bushing Replacement(a) (c) (a) Hours given are for a typical in-line set replacement. (b) Replacement of the intermediate sleeve is necessary if a damage is found on the sleeve. (c) More time will be necessary to perform machining steps. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data a. Boeing Service Related Problem (SRP) 777-SRP-55-0042 b. Component Maintenance Manual (CMM) 27-41-03 c. Standard Overhaul Practices Manual (SOPM) 20-10-02, 20-20-02, 20-30-03, 20-50-03

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 19 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**d. 777 Aircraft Maintenance Manual (AMM) 27-41-13 e. 777 Fleet Team Digest (FTD) 55-07001 f. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-04 g. 777-200 Structural Repair Manual (SRM) 51-20-01, 55-10-90, REPAIR 1 h. 777-300 Structural Repair Manual (SRM) 51-20-01, 55-10-90, REPAIR 1 i. 777 Maintenance Planning Document (MPD) 27-290-00, 55-507-00 2. Data supplied with this Service Bulletin None. 3. Installation Drawings Used in the Preparation of this Service Bulletin
**Title Drawing Number**  SUPPORT ASSEMBLY - HORIZONTAL STABILIZER JACKSCREW, STA 2245.70 148W9100
SPLICE ASSEMBLY - FRONT SPAR, HORIZONTAL STABILIZER 182W7400 UPPER GIMBAL ASSEMBLY - STABILIZER TRIM 251W4170 HOUSING ASSEMBLY - PRIMARY BRAKE, STABILIZER TRIM 251W4140 GIMBAL ASSEMBLY - LOWER, ACTUATOR, STABILIZER TRIM 251W4180 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** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 20 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the parts shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. Parts availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.
**Unit Price thru 12/31/2010**  **ROLT (Weeks)**  **Name Part Number** 
$541.00 31 BUSHING - JACKSCREW, SUPPORT 148W9106-2 $1,135.00 23 BUSHING - JACKSCREW, HORIZONTAL STABILIZER 182W7404-1
$985.00 33 BUSHING - GIMBAL, UPPER BRAKE HOUSING 251W4172-3 $1,072.00 23 BUSHING - GIMBAL, LOWER HORIZONTAL STABILIZER 251W4172-4 $1,029.00 23 BUSHING - GIMBAL, UPPER SUPPORT 251W4172-5 $1,001.00 23 BUSHING - GIMBAL, BRAKE HOUSING 251W4172-6 $1,187.00 86 PIN - UPPER GIMBAL, STABI- LIZER TRIM, BRAKE HOUSING 251W4173-3 $3,191.00 76 PIN - UPPER GIMBAL, STABI- LIZER TRIM, SUPPORT 251W4175-3 $7,791.00 45 PIN ASSEMBLY - NUT GIM- BAL, STABILIZER TRIM251W4187-7 (ALTERNATIVE SUBSTITUTE, -9) $839.00 58 SHAFT-SAFETY, UPPER GIM- BAL, STABILIZER TRIM (SAFETY SHAFT) 251W4188-1

$725.00 52 INTERMEDIATE SLEEVE 148W9107-1 The parts are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. **REFERENCE THIS SERVICE BULLETIN AND SUBMIT YOUR PURCHASE ORDER BY ONE OF THE METHODS THAT FOLLOW:**  1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 21 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **B. Industry Support Information** Boeing warranty remedies are available for 777 airplanes in warranty as of March 7, 2007. For inspection task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours are required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. **C. Parts Necessary For Each Airplane** 1. Kits/Parts
**Notes Name**  **QTY Part Number /**  **Specification**

- BUSHING - JACKSCREW, SUP- PORT 4 148W9106-2

- BUSHING - JACKSCREW, HORI- ZONTAL STABILIZER 4 182W7404-1

- BUSHING - GIMBAL, UPPER BRAKE HOUSING 4 251W4172-3

- BUSHING - GIMBAL, LOWER HORIZONTAL STABILIZER 4 251W4172-4

- BUSHING - GIMBAL, UPPER SUP- PORT 4 251W4172-5

- BUSHING - GIMBAL, BRAKE HOUSING 4 251W4172-6

- PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING 2 251W4173-3

- PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT 2 251W4175-3

- PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM 2 251W4187-7 (AL-TERNATIVE SUBSTITUTE, -9)

- SHAFT-SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT) 1 251W4188-1

- INTERMEDIATE SLEEVE 2 148W9107-1 2. Parts and Materials Supplied by the Operator None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 22 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 23 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 24 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. The work instructions are divided into work packages. Task Hours and Elapsed Hours for each package are given in Paragraph 1.G., Manpower. You can do each work package independently. 5. 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 – Torque limits to tighten nuts and bolts are in 777 SRM, Chapter 51. 6. Use the approved fastener and process material substitutions in accordance with 777 SRM, Chapter 51. Alternate fasteners are listed in 777 SRM, Chapter 51 and Boeing Drawing 012W6100. 7. 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. 8. 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. 9. The Detailed inspection and measurement of Karon lined bushings and pins in the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) and HSTA attachment locations on the airplane structure are necessary at the following joint locations: – BULKHEAD SUPPORT JACKSCREW FITTING – HORIZONTAL STABILIZER JACKSCREW FITTING – UPPER GIMBAL - BRAKE HOUSING

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 25 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**– UPPER GIMBAL - BULKHEAD SUPPORT – TRIM ACTUATOR PRIMARY BRAKE HOUSING – LOWER GIMBAL 10. The fail-safe components in the six joint locations of the HSTA are SHAFT-SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT) and the inner pin of PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM. 11. Each joint location has four (4) Karon lined bushings in the in-line set; 2 bushings per side. If Karon lined bushing replacement is necessary for a joint, it is recommended to replace the bushings in a set of 4. However, as a minimum replace Karon lined bushings as a pair on either side of the joint. 12. The instructions identified in Paragraph 3.B., Work Instructions, and Figure(s) are for a typical in-line set. 13. A replacement Horizontal Stabilizer Trim Actuator (HSTA) is in a known serviceable condition if your records agree with one these conditions: – The HSTA is new. – The HSTA is overhauled as specified in the applicable CMM 27-41-03. – The condition of the HSTA is found satisfactory with the tests and checks as specified in CMM 27-41-03. **B. WORK INSTRUCTIONS PART 1 - AIRPLANE WORK**  1. Preparation, Open Access, and HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) Removal a. Remove hydraulic pressure, hydraulic power, and install safety tags to the HSTA. Refer to 777 AMM 27-41-13 as an accepted procedure. b. Gain access to the HSTA through service access door 311BL. c. Remove the HSTA. Refer to 777 AMM 27-41-13 as an accepted procedure. 2. Inspection and Measurement of Karon Lined Bushings a. Do a Detailed Inspection and measure the internal diameter (ID) of the BUSHING - JACKSCREW, SUPPORT in the BULKHEAD SUPPORT JACKSCREW FITTING in accordance with FIGURE 1. (1) Condition 1: If any disbond or tear is found, or the ID is greater than the allowable MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined bushings; then do bushing replacement as follows: (a) Remove the Karon lined bushings in accordance with FIGURE 7. 1) Condition 1: If any damage is found or the ID is greater than the allowable hole diameter in accordance with FIGURE 7 on the intermediate sleeve, then replace the intermediate sleeve in accordance with FIGURE 8. Do the following when replacing the intermediate sleeve:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 26 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**a) Condition 1: If any damage is found or the ID is greater than the allowable hole diameter in accordance with FIGURE 8 on the fitting, then contact Boeing for alternative repair instructions. b) Condition 2: If no damage is found and the ID is within the allowable hole diameter in accordance with FIGURE 8 on the fitting, then continue with the repair in accordance with FIGURE 8. 2) Condition 2: If no damage is found and the ID is within the allowable hole diameter in accordance with FIGURE 7 on the intermediate sleeve, then replacement of the intermediate sleeve is not necessary. (b) Install the new Karon lined bushings in accordance with FIGURE 9. (2) Condition 2: If no disbond and tear are found, and the ID is less than or equal to the allowable MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined bushings; then bushing replacement is not necessary. b. Do a Detailed Inspection and measure the ID of the BUSHING - JACKSCREW, HORIZONTAL STABILIZER in the HORIZONTAL STABILIZER JACKSCREW FITTING in accordance with FIGURE 2. (1) Condition 1: If any disbond or tear is found, or the ID is greater than the allowable MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined bushings; then do bushing replacement and finish the repair area of the fitting as necessary in accordance with Structural Repair Manual 777-200 SRM 55-10-90, REPAIR 1 or 777-300 SRM 55-10-90, REPAIR 1. (2) Condition 2: If no disbond and tear are found, and the ID is less than or equal to the allowable MAXIMUM DIAMETER in accordance with FIGURE 10 on the Karon lined bushings; then bushing replacement is not necessary. 3. Installation of the HSTA a. Option 1: If the replacement HSTA is in a known serviceable condition, then install the HSTA. Refer to 777 AMM 27-41-13 as an accepted procedure. **NOTE:** If the replacement HSTA is not in a known serviceable condition, then do the Detailed Inspection and measurement of the Karon lined bushings, pins, and fail-safe components of the replacement HSTA as applicable in accordance with PART 2 of Paragraph 3.B., Work Instructions. Refer to Paragraph 3.A., General Information, for the descriptions of HSTA's that are in a known serviceable conditions. b. Option 2: If the replacement or the existing HSTA is not in a known serviceable condition, then do PART 2. 4. Do the Horizontal Stabilizer Trim Actuator Test. Refer to 777 AMM 27-41-13 as an accepted procedure. 5. Close access and put the airplane back to a serviceable condition. 6. Repeat the Detailed Inspection and measurement of the Karon lined bushings at the time in accordance with Paragraph 1.E., Compliance.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 27 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT PART 2 - COMPONENT (HORIZONTAL STABILIZER TRIM ACTUATOR, HSTA) WORK**  1. Disassemble the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) as necessary. Refer to CMM 27-41-03 as an accepted procedure. 2. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, UPPER BRAKE HOUSING in the UPPER GIMBAL - BRAKE HOUSING in accordance with FIGURE 3. a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then do bushing replacement and refinish the repair area of the gimbal as necessary. Refer to Components Maintenance Manual CMM 27-41-03, REPAIR 8-1 and CMM 27-41-03, REPAIR 8-2; respectively as an accepted procedure. b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then bushing replacement is not necessary. 3. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, UPPER SUPPORT in the UPPER GIMBAL - BULKHEAD SUPPORT in accordance with FIGURE 3. a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then do bushing replacement and refinish the repair area of the gimbal as necessary. Refer to CMM 27-41-03, REPAIR 8-1 and CMM 27-41-03, REPAIR 8-2; respectively as an accepted procedure. b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then bushing replacement is not necessary. 4. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, BRAKE HOUSING in the TRIM ACTUATOR PRIMARY BRAKE HOUSING in accordance with FIGURE 4. a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then do bushing replacement and refinish the repair area of the housing as necessary. Refer to CMM 27-41-03, REPAIR 3-1 and CMM 27-41-03, REPAIR 3-2; respectively as an accepted procedure. b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then bushing replacement is not necessary. 5. Do a Detailed Inspection and measure the ID of the BUSHING - GIMBAL, LOWER HORIZONTAL STABILIZER in the LOWER GIMBAL in accordance with FIGURE 5.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 28 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**a. Condition 1: If any disbond or tear is found, or the ID is greater than MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then do bushing replacement and refinish the repair area of the gimbal as necessary. Refer to CMM 27-41-03, REPAIR 16-1 as an accepted procedure. b. Condition 2: If no disbond and tear are found, and the ID is less than or equal to MAXIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the Karon lined bushings; then bushing replacement is not necessary. 6. Do a Detailed Inspection of the pins and the safety shaft; and measure the outer diameter (OD) of the pins in accordance with FIGURE 6. a. Condition 1: If any crack is found, do the following as applicable: (1) For the PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING in the UPPER GIMBAL, replace the pin. (2) For the PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT in the UPPER GIMBAL, replace the pin. Also do a magnetic particle inspection of the SHAFT-SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT) for a crack. Refer to SOPM 20-20-01 as an accepted procedure for magnetic particle inspection. (a) Condition 1: If any crack is found, replace the safety shaft. (b) Condition 2: If no crack is found, then refurbish the safety shaft as necessary. Refer to CMM 27-41-03, REPAIR 10-1, as an accepted procedure for refurbishment of the safety shaft. (3) For the PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM in the LOWER GIMBAL, replace the outer pin or the entire assembly. If the outer pin is replaced, do a magnetic particle inspection of the inner pin. Refer to SOPM 20-20-01 as an accepted procedure for magnetic particle inspection. (a) Condition 1: If any crack is found, replace the inner pin. (b) Condition 2: If no crack is found, then refurbish the pin assembly as necessary. Refer to CMM 27-41-03, REPAIR 1-1, as an accepted procedure for refurbishment of the pins. (4) For the SHAFT-SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT), replace the safety shaft. b. Condition 2: If any gouge is found, do the following as applicable:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 29 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**(1) For the PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING in the UPPER GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an accepted procedure for refurbishment of the pins. (2) For the PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT in the UPPER GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an accepted procedure for refurbishment of the pins. (3) For the PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM in the LOWER GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 1-1, as an accepted procedure for refurbishment of the pins. (4) For the SHAFT, SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT), replace or refurbish the safety shaft. Refer to CMM 27-41-03, REPAIR 10-1, as an accepted procedure for the refurbishment of the safety shaft. c. Condition 3: If OD is less than MINIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the pins; then do the following as applicable: (1) For the PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING in the UPPER GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an accepted procedure for refurbishment of the pins. (2) For the PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT in the UPPER GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 17-1 as an accepted procedure for refurbishment of the pins. (3) For the PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM in the LOWER GIMBAL, replace or refurbish the pins. Refer to CMM 27-41-03, REPAIR 1-1, as an accepted procedure for refurbishment of the pins. d. Condition 4: If no gouge, crack and wear are found on any of the pins and safety shaft as applicable; and the OD is greater than or equal to MINIMUM DESIGN DIMENSION as specified in FITS AND CLEARANCES of CMM 27-41-03 on the pins as applicable; then a replacement or refurbishment is not necessary. 7. Assemble the HSTA. Refer to CMM 27-41-03 as an accepted procedure.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 30 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 1: INSPECTION AND MEASUREMENT OF BULKHEAD SUPPORT JACKSCREW FITTING KARON**  **LINED BUSHINGS (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 31 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a Detailed Inspection of the Karon liner for any disbond or tear. 4 148W9106-2 BUSHING -JACKSCREW, SUPPORT Inspect 1

Measure the ID of the Karon lined bushing for any wear. 4 148W9106-2 BUSHING -JACKSCREW, SUPPORT Measure 2

**FIGURE 1: INSPECTION AND MEASUREMENT OF BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHINGS**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 32 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 2: INSPECTION AND MEASUREMENT OF HORIZONTAL STABILIZER JACKSCREW FITTING**  **KARON LINED BUSHINGS (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 33 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a Detailed Inspection of the Karon liner for any disbond or tear. 4 182W7404-1 BUSHING -JACKSCREW, HORIZONTAL STABILIZER Inspect 1

Measure the ID of the Karon lined bushing for any wear. 4 182W7404-1 BUSHING -JACKSCREW, HORIZONTAL STABILIZER Measure 2

**FIGURE 2: INSPECTION AND MEASUREMENT OF HORIZONTAL STABILIZER JACKSCREW FITTING KARON LINED BUSHINGS**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 34 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 3: INSPECTION AND MEASUREMENT OF UPPER GIMBAL - BRAKE HOUSING AND UPPER**  **GIMBAL - BULKHEAD SUPPORT KARON LINED BUSHINGS (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 35 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a Detailed Inspection of the Karon liner for any disbond or tear. 4 251W4172-3 BUSHING - GIMBAL, UPPER BRAKE HOUSING Inspect 1

Do a Detailed Inspection of the Karon liner for any disbond or tear. 4 251W4172-5 BUSHING - GIMBAL, UPPER SUPPORT Inspect 2

Measure the ID of the Karon lined bushing for any wear. 4 251W4172-3 BUSHING - GIMBAL, UPPER BRAKE HOUSING Measure 3

Measure the ID of the Karon lined bushing for any wear. 4 251W4172-5 BUSHING - GIMBAL, UPPER SUPPORT Measure 4

**FIGURE 3: INSPECTION AND MEASUREMENT OF UPPER GIMBAL - BRAKE HOUSING AND UPPER GIMBAL - BULKHEAD SUPPORT KARON LINED BUSHINGS**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 36 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 4: INSPECTION AND MEASUREMENT OF TRIM ACTUATOR PRIMARY BRAKE HOUSING KARON**  **LINED BUSHINGS (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 37 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a Detailed Inspection of the Karon liner for any disbond or tear. 4 251W4172-6 BUSHING - GIMBAL, BRAKE HOUSING Inspect 1

Measure the ID of the Karon lined bushing for any wear. 4 251W4172-6 BUSHING - GIMBAL, BRAKE HOUSING Measure 2

**FIGURE 4: INSPECTION AND MEASUREMENT OF TRIM ACTUATOR PRIMARY BRAKE HOUSING KARON LINED BUSHINGS**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 38 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 5: INSPECTION AND MEASUREMENT OF LOWER GIMBAL KARON LINED BUSHINGS**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 39 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a Detailed Inspection of the Karon liner for any disbond or tear. 4 251W4172-4 BUSHING - GIMBAL, LOWER HORIZONTAL STABILIZER Inspect 1

Measure the ID of the Karon lined bushing for any wear. 4 251W4172-4 BUSHING - GIMBAL, LOWER HORIZONTAL STABILIZER Measure 2

**FIGURE 5: INSPECTION AND MEASUREMENT OF LOWER GIMBAL KARON LINED BUSHINGS (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 40 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 6: INSPECTION AND MEASUREMENT OF PINS**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 41 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a Detailed Inspection of the pins on the outer surface for any gouge or crack. 2 251W4173-3 PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING Inspect 1

Do a Detailed Inspection of the pins on the outer surface for any gouge or crack.(a) 2 251W4175-3 PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT Inspect 2

Do a Detailed Inspection of the outer pins on the outer surface for any gouge or crack.(b) 2 251W4187-7 (ALTER- NATIVE SUBSTITUTE, -9) PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM Inspect 3

Do a Detailed Inspection of the safety shaft on the outer surface for any gouge or crack.(a) 1 251W4188-1 SHAFT-SAFETY, UP-PER GIMBAL, STABILIZER TRIM (SAFETY SHAFT) Inspect 4

Measure the OD of the pins for any wear. 2 251W4173-3 PIN - UPPER GIMBAL, STABILIZER TRIM, BRAKE HOUSING Measure 5

Measure the OD of the pins for any wear. 2 251W4175-3 PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT Measure 6

Measure the OD of the pins for any wear. 2 251W4187-7 (ALTER- NATIVE SUBSTITUTE, -9) PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM Measure 7

(a) If any crack is found on PIN - UPPER GIMBAL, STABILIZER TRIM, SUPPORT, additional inspectionmay be necessary on SHAFT-SAFETY, UPPER GIMBAL, STABILIZER TRIM (SAFETY SHAFT) in accordance with Paragraph 3.B., Work Instructions, PART 2, Section 6. (b) The PIN ASSEMBLY - NUT GIMBAL, STABILIZER TRIM has outer and inner pins. If any crack is found on the outer pin, additional inspection may be necessary on the inner pin in accordance with Paragraph 3.B., Work Instructions, PART 2, Section 6.

**FIGURE 6: INSPECTION AND MEASUREMENT OF PINS (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 42 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 43 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 44 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  **CAUTION:** USE CARE WHEN YOU REMOVE THE BUSHINGS. THE BUSHINGS WERE INSTALLED WITH AN INTERFERENCE FIT. IF YOU DO NOT OBEY, DAMAGE TO THE BULKHEAD SUPPORT JACKSCREW FITTING CAN OCCUR.
Refer to SOPM 20-50-03 as an accepted procedure. 4 148W9106-2 BUSHING -JACKSCREW, SUPPORT Remove 1

**WARNING:** KEEP THE SOLVENTS AWAY FROM SOURCES OF HEAT, FIRE OR SPARKS. IF YOU DO NOT, AN EXPLOSION CAN OCCUR. DO NOT PERMIT THE SOLVENTS TO TOUCH YOUR SKIN, EYES OR CLOTHING. DO NOT BREATHE THE VAPORS. WEAR PROTECTIVE CLOTHING AND EYE PROTECTION. MAKE SURE THERE IS A GOOD FLOW OF CLEAN AIR. IN A CONFINED SPACE, USE MECHANICAL VENTILATION FOR RESPIRATORY PROTECTION. INJURY TO PERSONS CAN OCCUR.
**CAUTION:** USE CARE WHEN YOU WORK WITH THE INSIDE SURFACE OF THE BULKHEAD SUPPORT JACKSCREW FITTING. MECHANICAL TOOLS AND ABRASION CAN CAUSE DAMAGE TOTHE FITTING HOLE. THE RESULT CAN BE A HOLE THAT IS LARGER THAN THE ALLOWABLE MAXIMUM HOLE DIMENSIONS.

Remove all the dust and sealant from the inner surface of the hole. Refer to SOPM20-30-03 as an accepted procedure. 2 148W9107-1 INTERMEDIATE SLEEVE Clean 2

Do a surface HFEC inspection for a crack on the inner surface of the hole in accordance with 777 NDT Part 6, 51- 00-04.(a) 2 148W9107-1 INTERMEDIATE SLEEVE Inspect 3

Measure the ID of the sleeve. 2 148W9107-1 INTERMEDIATE SLEEVE Measure 4 (a) Penetrant inspection is optional to the surface HFEC inspection. Refer to SOPM 20-20-02 as an accepted procedure.

**FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 45 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 46 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 47 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. It is necessary to replace the intermediate sleeve with a damage or ID greater than the allowable hole diameter.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  **CAUTION:** USE CARE WHEN YOU REMOVE THE BUSHINGS. THE BUSHINGS WERE INSTALLED WITH AN INTERFERENCE FIT. IF YOU DO NOT OBEY, DAMAGE TO THE BULKHEAD SUPPORT JACKSCREW FITTING CAN OCCUR.
Refer to SOPM 20-50-03 as an accepted procedure. 2 148W9107-1 INTERMEDIATE SLEEVE Remove 1

**FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 48 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP WARNING:**  KEEP THE SOLVENTS AWAY FROM SOURCES OF HEAT, FIRE OR SPARKS. IF YOU DO NOT, AN EXPLOSION CAN OCCUR. DO NOT PERMIT THE SOLVENTS TO TOUCH YOUR SKIN, EYES OR CLOTHING. DO NOT BREATHE THE VAPORS. WEAR PROTECTIVE CLOTHING AND EYE PROTECTION. MAKE SURE THERE IS A GOOD FLOW OF CLEAN AIR. IN A CONFINED SPACE, USE MECHANICAL VENTILATION FOR RESPIRATORY PROTECTION. INJURY TO PERSONS CAN OCCUR.
**CAUTION:** USE CARE WHEN YOU WORK WITH THE INSIDE SURFACE OF THE BULKHEAD SUPPORT JACKSCREW FITTING. MECHANICAL TOOLS AND ABRASION CAN CAUSE DAMAGE TOTHE FITTING HOLE. THE RESULT CAN BE A HOLE THAT IS LARGER THAN THE ALLOWABLE MAXIMUM HOLE DIMENSIONS.

Remove all the dust and sealant from the inner surface of the hole. Refer to SOPM20-30-03 as an accepted procedure. 2

- BULKHEAD SUPPORT JACKSCREW FITTING Clean 2

Do a surface HFECinspection of the inner surface of the hole for a crack in accordance with 777 NDT Part 6, 51-00- 01.(a) 2

- BULKHEAD SUPPORT JACKSCREW FITTING Inspect 3

Measure the ID of the hole. 2

- BULKHEAD SUPPORT JACKSCREW FITTING Measure 4
**CAUTION:** DO NOT CONTINUE WITH THE REPAIR IF A DAMAGE IS FOUND OR THE ID IS GREATER THAN THE ALLOWABLE HOLE DIAMETER ON THE FITTING TO PREVENT MORE DAMAGE.
Refer to SOPM 20-50-03 as an accepted procedure. 2 148W9107-1 INTERMEDIATE SLEEVE Install (New) 5

Machine the ID to the diameters shown. Refer to SOPM 20-10-02 asan accepted procedure. 2 148W9107-1 INTERMEDIATE SLEEVE Ream 6

(a) Penetrant inspection is optional to the surface HFEC inspection. Refer to SOPM 20-20-02 as an accepted procedure.

**FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 49 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION**  **(SHEET 1 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 50 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 51 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Apply one layer of BMS 10-11, Type I primer to the mating surfaces of the lugface under the bushing flange. Refer to 777-200 SRM 51- 20-01 or 777-300 SRM 51-20-01 as anaccepted procedure.(a) - BMS 10-11 TYPE I PRIMER Apply 1

**FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 52 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Apply the sealant along the contact surface between the lug and bushing flange. Refer to SOPM 20-50-03 asan accepted procedure. - BMS 5-95 SEALANT Apply 2

**WARNING:** USE PROTECTION WHEN YOU DO WORK WITH LIQUID NITROGEN. MAKE SURE THATTHE AREA HAS A GOOD FLOW OF CLEAN AIR. THE TEMPERATURE FOR LIQUID NITROGEN IS APPROXIMATELY MINUS 320 F (MINUS 196 C). IF YOU DO NOT OBEY, INJURY TO PERSONS CAN BE THE RESULT. Hold the assembly in position until the assembly is at room temperature. Refer to SOPM 20-50-03as an accepted procedure. 4 148W9106-2 BUSHING -JACKSCREW, SUPPORT Install (New) 3

(b) (c) 4 148W9106-2 BUSHING -JACKSCREW, SUPPORT Ream 4

Line hone the bushing hole to the final ID dimension. Make the surface finish 32microinches (0.8 micrometers ) Ra or better.(b) (d) 4 148W9106-2 BUSHING -JACKSCREW, SUPPORT Hone

Clean the inner surface of the bushing to make sure that all the honing debris and machining oil are removed. Refer to SOPM 20-30-03as an accepted procedure. - 148W9106-2 BUSHING -JACKSCREW, SUPPORT Clean 5

**FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 53 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Apply a fillet seal on the bushing flangesand fill the gap between the bushings. Refer to SOPM 20-50-03 as an accepted procedure. - BMS 5-95 SEALANT Apply 6

(a) If necessary, apply a chemical conversion coating to the mating surfaces of the lug face under the bushing flange. Refer to 777-200 SRM 51-20-01 or 777-300 SRM 51-20-01 as an accepted procedure. (b) Use a long piloted reamer as a tool to keep all bushing holes coaxial. The pilot part of the reamer must be non-cutting to prevent damage to the bushing. Use a guide bush to slip into the adjacent bushing bore to support the reamer and protect the initial bushings. (c) Line ream the bushing hole to the inside diameter of 1.955 to 1.960 inches (49.66 to 49.78 mm). Machine the Karon liner at 1000 surface feet per minute (SFPM) minimum with a feed rate between 0.001 and 0.003 inch (0.025 and 0.076 mm) per revolution. Machining can be done dry or with a water soluble coolant. Use a diamond or carbide cutter with a 0.030 inch minimum radius. (d) If necessary hone all the replacement bushings at the same time to keep them coaxial. Use the following requirements for honing: Sunnen stone K6-A63 or equivalent (280 grit medium hard aluminum oxide), speed of 300 to 1000 RPM (revolutions per minute), and Sunnen MB30 oil base coolant or equivalent.

**FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 54 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT Service Wear Limits**  **Part Number Part Name**  **Joint Location MINIMUM DIAME**  **TER MAXIMUM DIAME**  **TER**

- ID: 2.0060 148W9106-2 BUSHING -JACKSCREW, SUPPORTBULKHEAD SUPPORT JACKSCREW FITTING

- ID: 2.0098 182W7404-1 BUSHING -JACKSCREW, HORIZONTAL STABILIZERHORIZONTAL STABILIZERJACKSCREW FITTING

**FIGURE 10: KARON LINED BUSHING SERVICE WEAR LIMITS (SHEET 1 OF 1)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 20, 2010 777-55A0017 55 of 55 **BOEING SERVICE BULLETIN 777-55A0017 ALERT**  **ALERT**