### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-53A0261**  Original Issue: August 12, 2014 ATA System: 5300 5380 5530 **SUBJECT:** FUSELAGE - Section 48 - Vertical Stabilizer Attachment Barrel Nut Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.

Original Issue: August 12, 2014 767-53A0261 1 of 40 3.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 2 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 16 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 18 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 19 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FIGURE 1: ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 2: INTERNAL AND EXTERNAL DETAILED INSPECTION. . . . . . . . . . . . . . . . . . . 27 FIGURE 3: TORQUE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 4: MAGNETIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 5: BARREL NUT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 APPENDIX A: COMPLIANCE TASKS AND COMPLIANCE TIMES LOGIC DIAGRAM. . . . . . . . . . . 39 APPENDIX B: INPUT SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 3 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 4 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Summary**  **Number: 767-53A0261** Original Issue: August 12, 2014 ATA System: 5300 5380 5530 **SUBJECT:** FUSELAGE - Section 48 - Vertical Stabilizer Attachment Barrel Nut 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 this service bulletin will make sure H-11 steel barrel nuts that attach the vertical stabilizer to body section 48 are found and replaced. If H-11 steel barrel nuts are not found and replaced, galvanic corrosion can occur if moisture is present. Corroded H-11 steel barrel nuts could fail due to stress corrosion cracking which can cause departure of the vertical stabilizer and the loss of rudder control. During a C-check, an operator reported finding of H-11 steel barrel nuts installed on an airplane not included in the effectivity of the Service Bulletin SB 767-53A0085. The SB 767-53A0085 provides instructions to inspect and replace H-11 steel barrel nuts at the Vertical Fin, Section 48, attachment points with Inconel barrel nuts. Further investigation has discovered that airplanes with line numbers 575 to 681, allowed an optional installation of H-11 steel or Inconel barrel nuts at the 16 vertical fin attachment points. Production incorporation of only Inconel barrel nuts begins with line number 682 and on. Boeing Service Related Problem (SRP) 767-SRP-53-0453 is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 5 of 40**Reference Affected**  **Planning Data** Paragraph 1.K., Publications Affected Yes Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts Yes Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**ACTION** Get internal and external access to Section 48 and to the area of the vertical fin attachment joint. Do the following steps for each of the 16 attachment points. Do Internal and External Detailed Inspection of the barrel nut holes and sealant for cracked/damaged sealant, corrosion, or cracked/broken barrel nut. If cracked/damaged sealant, corrosion, or cracked/broken barrel nut is found, consider the barrel nut to be corroded. Replace the barrel nut with a new Inconel barrel nut. If no cracked/damaged sealant, corrosion, or cracked/broken barrel nut is found, do a Torque Check on each affected vertical fin attachment bolt. If the Torque Check finds that a bolt can be turned, consider the barrel nut to be damaged. Replace the barrel nut with a new Inconel barrel nut. If the Torque Check does not find that a bolt can be turned, put the airplane back to a serviceable condition. Continue to do Internal and External Detailed Inspection, and Torque Check on each affected vertical fin attachment bolt unless the correct nut type is installed. As an alternative, do the Magnetic Check to identify H-11 steel barrel nuts. If H-11 steel barrel nut is found, replace the barrel nut with a new Inconel barrel nut. If no H-11 steel barrel nut is found, no further action is required. Put the airplane back to a serviceable condition. **EFFECTIVITY** 767-200/-300/-300F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. **COMPLIANCE** Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of September 11, 1997. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 6 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT MANPOWER**  Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. Operators are encouraged to complete the survey provided in the Appendix of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 7 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 8 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-53A0261**  Original Issue: August 12, 2014 ATA System: 5300 5380 5530 **SUBJECT:** FUSELAGE - Section 48 - Vertical Stabilizer Attachment Barrel Nut 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 Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-200/-300/-300F Airplanes. Line number 575 through 681, which have optional H-11 steel or Inconel barrel nuts installed at the vertical stabilizer attachment points. - 1

Airplane Models: 767-200, 767-300, 767-300F **Group Variable Number**  1 VF182 - VF184 1 VF251 1 VK015 - VK016 1 VK113 1 VK144 - VK148

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 9 of 40**Group Variable Number**  1 VK181 1 VK186 1 VL754 - VL755 1 VL806 - VL807 1 VL871 - VL873 1 VL891 - VL900 1 VL911 - VL914 1 VL931 - VL932 1 VL941 1 VN096 - VN099 1 VN136 - VN137 1 VN174 1 VN197 - VN198 1 VN225 1 VN265 - VN276 1 VN292 - VN293 1 VN388 1 VN424 - VN427 1 VN436 1 VN637 - VN638 1 VN657 - VN658 1 VN932 - VN936 1 VN953 1 VN966 - VN972 1 VW701 - VW721 1 VW851 2. Spares Affected None. **B. Concurrent Requirements** None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 10 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT C. Reason**  Accomplishment of this service bulletin will make sure H-11 steel barrel nuts that attach the vertical stabilizer to body section 48 are found and replaced. If H-11 steel barrel nuts are not found and replaced, galvanic corrosion can occur if moisture is present. Corroded H-11 steel barrel nuts could fail due to stress corrosion cracking which can cause departure of the vertical stabilizer and the loss of rudder control. During a C-check, an operator reported finding of H-11 steel barrel nuts installed on an airplane not included in the effectivity of the Service Bulletin SB 767-53A0085. The SB 767-53A0085 provides instructions to inspect and replace H-11 steel barrel nuts at the Vertical Fin, Section 48, attachment points with Inconel barrel nuts. Further investigation has discovered that airplanes with line numbers 575 to 681, allowed an optional installation of H-11 steel or Inconel barrel nuts at the 16 vertical fin attachment points. Production incorporation of only Inconel barrel nuts begins with line number 682 and on. Boeing Service Related Problem (SRP) 767-SRP-53-0453 is related to this service bulletin. **D. Description** Get internal and external access to Section 48 and to the area of the vertical fin attachment joint. Do the following steps for each of the 16 attachment points. Do Internal and External Detailed Inspection of the barrel nut holes and sealant for cracked/damaged sealant, corrosion, or cracked/broken barrel nut. If cracked/damaged sealant, corrosion, or cracked/broken barrel nut is found, consider the barrel nut to be corroded. Replace the barrel nut with a new Inconel barrel nut. If no cracked/damaged sealant, corrosion, or cracked/broken barrel nut is found, do a Torque Check on each affected vertical fin attachment bolt. If the Torque Check finds that a bolt can be turned, consider the barrel nut to be damaged. Replace the barrel nut with a new Inconel barrel nut. If the Torque Check does not find that a bolt can be turned, put the airplane back to a serviceable condition. Continue to do Internal and External Detailed Inspection, and Torque Check on each affected vertical fin attachment bolt unless the correct nut type is installed. As an alternative, do the Magnetic Check to identify H-11 steel barrel nuts. If H-11 steel barrel nut is found, replace the barrel nut with a new Inconel barrel nut. If no H-11 steel barrel nut is found, no further action is required. Put the airplane back to a serviceable condition. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 311, 312, 313, 314, 322, 323, 324, 325 767-200, 767-300, 767-300F

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 11 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT 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. 1. Compliance Time Exceptions: If a vertical stabilizer attachment barrel nut has been inspected and no H-11 steel barrel nut found, and/or replaced, and meets 1 of the requirements shown below, then no further action is required at that attachment point location. The inspections and/or H-11 steel barrel nut replacement of the non-repaired attachment points do not change. a. Previously installed H-11 barrel nut was replaced with drawing configuration barrel nut made from alternate material to H-11 steel. b. Previously installed H-11 barrel nut was replaced with barrel nut approved by FAA or by a Boeing Company Authorized Representative. The replacement barrel nut is made from alternate material to H-11 steel. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX A. **Table 1: Vertical Stabilizer Attachment Barrel Nut Inspection Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever**  **Occurs Later) Action**  **Condition**

- Within 36 months after the last TorqueCheck inspection in accordance with 767 MPD Section 2, Task 53-734-00. Within 24 months after the Original Issuedate of this Service Bulletin. OPTION 1: Do PART 2: INTERNALAND EXTERNAL DETAILED INSPECTION of the barrel nut holes andsealant for signs of corrosion. Do PART 3: TORQUE CHECK for any loose bolt (e.g., the bolt can be turned). All Airplanes.

(a) OPTION 2: Do PART 4: MAGNETIC CHECK to identify H-11 steel barrel nuts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 12 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT Table 1: Vertical Stabilizer Attachment Barrel Nut Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 
18 months.

- - CONDITION 1 (ACTION 1): Repeat CONDITION 1: No signs of corrosion AND no loosebolt found during any OPTION 1 inspection. (b) PART 2: INTERNAL AND EXTERNAL DETAILEDINSPECTION of the barrel nut holes and sealant for signs of corrosion. PART 3: TORQUE CHECK for any loose bolt (e.g., the bolt can be turned).

- Within 36 months after the Original Issue date of this Service Bulletin. CONDITION 1 (ACTION 2): Do PART 5: BARREL NUT REPLACEMENT. (b)

- Before further flight. Do PART 5: BARREL NUT REPLACEMENT. CONDITION 2: Corrosion OR any loose bolt foundduring any OPTION 1 inspection. (b)

- - - No further action is re- quired. CONDITION 3: No H-11steel barrel nut found during any OPTION 2 inspection.

- Before further flight. Do PART 2: INTERNALAND EXTERNAL DETAILED INSPECTION of the barrel nut holes andsealant for signs of corrosion. CONDITION 4: H-11 steel barrel nut found during any OPTION 2 inspection.

Do PART 3: TORQUE CHECK for any loose bolt (e.g., the bolt can be turned). (a) (b)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 13 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT Table 1: Vertical Stabilizer Attachment Barrel Nut Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 
18 months.

- - CONDITION 5 (ACTION 1): Repeat CONDITION 5: H-11 steel barrel nut found during any OPTION 2 inspection. No signs of corrosion AND no loose bolt found during any OPTION 2 inspection. (b) PART 2: INTERNAL AND EXTERNAL DETAILEDINSPECTION of the barrel nut holes and sealant for signs of corrosion. PART 3: TORQUE CHECK for any loose bolt (e.g., the bolt can be turned).

- Within 36 months after the Original Issue date of this Service Bulletin. CONDITION 5 (ACTION 2): Do PART 5: BARREL NUT REPLACEMENT. (b)

- Before further flight. Do PART 5: BARREL NUT REPLACEMENT. CONDITION 6: H-11 steel barrel nut found during anyOPTION 2 inspection. Corrosion OR any loose bolt found during any OPTION 2 inspection. (b)

(a) Signs of corrosion include but not limited to sealant cracks, sealant bulging and powder residue. (b) Accomplishment of PART 5: BARREL NUT REPLACEMENT is terminating action to the repeat inspection at that attachment point location only. **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 and replacement 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:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 14 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**• 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. **Elapsed Hours Task Hours**  **Number of Persons Task**  0.75 1.50 2 OPEN ACCESS 1.60 1.60 1 FIGURE 2 - INTERNAL AND EXTERNAL DETAILED INSPECTION 1.60 1.60 1 FIGURE 3 - TORQUE CHECK 2.00 4.00 2 FIGURE 4 - MAGNETIC CHECK (a) 0.75 0.75 1 FIGURE 5 - BARREL NUT REPLACEMENT (b) 0.75 1.50 2 CLOSE ACCESS 4.70 6.20 TOTAL FOR EACH AIRPLANE (a) Add labor estimates to total as required if optional inspection is accomplished in accordance with Paragraph 3.B., Work Instructions - PART 4: MAGNETIC CHECK. (b) Labor estimates are for one (1) barrel nut replacement. Multiply the number of barrel nut replacement and add labor estimates to total as required if barrel nut replacement is accomplished in accordance with Paragraph 3.B., Work Instructions - PART 5: BARREL NUT REPLACEMENT.

**NOTE:** If Boeing tools PME148T0010 (PLATFORM ASSEMBLY) and 2MIT100T3480 (TORQUE MULTIPLIER AND ADAPTER) are used, further removal of equipment will be necessary for access. The time required for the removal and reinstallation of equipment has not been accounted for in this estimate of man-hours. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Boeing Service Bulletin 767-53A0085 b. Boeing Service Related Problem (SRP) 767-SRP-53-0453 c. Service Bulletin Index D624T001

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 15 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**d. Standard Overhaul Practices Manual (SOPM) 20-50-01 e. 767 Aircraft Maintenance Manual (AMM) 24-22-00, 29-11-00, 55-31-03, 55-30-03 f. 767 Illustrated Parts Catalog (IPC) 53-80-52 g. 767 Maintenance Planning Data (MPD) Section 2, Task 53-734-00 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  SECTION 48/72 INTEGRATION 100T3480 SEALANT APPLICATION - SECTION 48 INTEGRATION 140T4800 PROTECTIVE FINISH INSTL 140T5000 CORROSION INHIBITING COMPOUND INSTL - FUSELAGE 140T6000 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: **Chapter-Section Publication**  55-30 767 Aircraft Maintenance Manual 55-00, 55-30 767 Corrosion Prevention Manual 53-80 767 Illustrated Parts Catalog 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. **M. Software Accomplishment Summary** Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 16 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits/parts are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 **REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION** 
**Unit Price as of the original issue** **date of this Ser vice Bulletin (US**  **Dollars) ROLT as of the**  **original issue date of this Ser** **vice Bulletin (Cal endar Days)**  **Name Kit Number** 

Kit - Barrel Nut Replacement 015T1900-1 Kit - Bolt Replacement 015T1900-2 Operators are encouraged to complete the survey provided in the APPENDIX of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. **B. Industry Support Information** Boeing warranty remedies are available for airplanes in warranty as of September 11, 1997. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin. **C. Parts Necessary for Each Airplane** 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **NOTE:** A barrel nut replacement kit 015T1900-1 and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. If the fin attachment bolts that exist are found to be damaged, a bolt replacement kit 015T1900-2 would also be necessary and should also be ordered. To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 17 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT ALL** 
**Kit 015T1900 Notes**  **Existing Part Number**  **Name Qty**  **New Part Number -2**  **-1** (a) Kit - Barrel Nut Re- placement . - 015T1900-1 (a) Kit - Bolt Replace- ment - . 015T1900-2
BOLT, 12 PT HEAD 4

. BACB30US16K47
BOLT, 12 PT HEAD 4

. BACB30US16K48
BOLT, 12 PT HEAD 2

. BACB30US16K50
BOLT, 12 PT HEAD 2

. BACB30US16K51
BOLT, 12 PT HEAD 4

. BACB30US18K52
BARREL NUT

. 12 BACN11B16CS BARREL NUT

. 4 BACN11B18CS RETAINER, BARREL NUT . 12 BACR10AL16B
RETAINER, BARREL NUT . 4 BACR10AL18B
WASHER, PLAIN

. 12 BACW10BP16CD WASHER, PLAIN

. 4 BACW10BP18CD WASHER

. 12 NAS1149E1632P WASHER

. 4 NAS1149E1832P (a) The kit may have more parts than are necessary for installation. Discard parts that are not used or keep the parts for spares. 2. Parts and Materials Supplied by the Operator: The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available.
**Notes Name**  **Qty Part Number/ Specification**  (a) Corrosion Inhibiting Compound 8 Oz BMS 3-23, TYPE II

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 18 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT Notes**  **Name Qty**  **Part Number/ Specification** (a) Sealant 8 Oz BMS 5-142, TYPE II (BMS 5- 95 optional) (a) Sealant 1 Pt BMS 5-95, TYPE I, CLASS B OR C (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None **E. Special Tooling - Price and Availability** Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin by e-mail to ServiceBulletinRentalLoanTools@boeing.com. The tools are subject to the terms and conditions of the Boeing standard purchase order acknowledgement. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (425) 965-8237 **Rental Data: Daily Price as of**  **the Original Issue date of this ser**  **vice bulletin (US Dollars)**  **Name Tool Kit Number** 

$209,767.00 PLATFORM ASSEMBLY PME148T0010 $272,554.00 TORQUE MULTIPLIER AND ADAPTER 2MIT100T3480
**F. Special Tooling Necessary to do this Service Bulletin** The tools referred to below can be used to improve access to the vertical fin attachment bolts and for removal and replacement of the same bolts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 19 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available.
**Name Tool Kit Number**  PLATFORM ASSEMBLY PME148T0010 TORQUE MULTIPLIER AND ADAPTER 2MIT100T3480

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 20 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT 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. 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. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values: — Values for structural fasteners are given in 767 Structural Repair Manual, Chapter 51. — Non-standard torque values for maintenance tasks are included in the applicable installation step.
5. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51. 6. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 21 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**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. Refer to APPENDIX A for logic diagram(s). Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 10. Refer to APPENDIX B for INPUT SURVEY. Operators are encouraged to complete the survey provided in the Appendix of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. 11. 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. 12. 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. 13. 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. 14. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 15. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 16. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 17. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC must be done to comply with the AD. Alternative procedures for steps not identified with RC can be used if the RC steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. 18. Boeing recommends that PLATFORM ASSEMBLY PME148T0010 or a similar suitable work platform be installed for access to the vertical fin attachment bolts. If this tool is used, fasteners from the frames at body station (BS) 1629 and BS 1654 must be removed to allow access. Install new fasteners of the same type and size after the PLATFORM ASSEMBLY is removed.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 22 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**19. Boeing TORQUE MULTIPLIER AND ADAPTER Tool 2MIT100T3480 is a tool used by Boeing during production to apply installation torque to the bolts that attach the vertical fin to the fuselage. If an operator wishes to use this tool or a similar tool, several pieces of equipment such as pulley brackets, fairlead brackets and hydraulic lines will need to be removed in order to attach the tool to BS 1654.5 and BS 1725.5 frames. Details of this equipment removal and subsequent installation are not shown in this service bulletin. 20. Compliance Time Exceptions: If a vertical stabilizer attachment barrel nut has been inspected and no H-11 steel barrel nut found, and/or replaced, and meets 1 of the requirements shown below, then no further action is required at that attachment point location. The inspections and/or H-11 steel barrel nut replacement of the non-repaired attachment points do not change. – Previously installed H-11 barrel nut was replaced with drawing configuration barrel nut made from alternate material to H-11 steel. – Previously installed H-11 barrel nut was replaced with barrel nut approved by FAA or by a Boeing Company Authorized Representative. The replacement barrel nut is made from alternate material to H-11 steel. **B. WORK INSTRUCTIONS** 1. Do PART 1: OPEN ACCESS. 2. OPTION 1: Do PART 2: INTERNAL AND EXTERNAL DETAILED INSPECTION for signs of corrosion. Do PART 3: TORQUE CHECK for any loose bolt (e.g., the bolt can be turned). **NOTE:** Signs of corrosion includes but not limited to sealant cracks, sealant bulging and powder residue. **CONDITION 1: No signs of corrosion AND no loose bolt found.** a. ACTION 1: Repeat PART 2: INTERNAL AND EXTERNAL DETAILED INSPECTION and PART 3: TORQUE CHECK. b. ACTION 2: Do PART 5: BARREL NUT REPLACEMENT. **CONDITION 2: Corrosion OR any loose bolt found.** a. Do PART 5: BARREL NUT REPLACEMENT. 3. OPTION 2: Do PART 4: MAGNETIC CHECK to identify H-11 steel barrel nuts. **CONDITION 3: No H-11 steel barrel nut found.** a. No further action is required. **CONDITION 4: H-11 steel barrel nut found.** a. Do PART 2: INTERNAL AND EXTERNAL DETAILED INSPECTION for signs of corrosion. Do PART 3: TORQUE CHECK for any loose bolt (e.g., the bolt can be turned).

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 23 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT NOTE:**  Signs of corrosion includes but not limited to sealant cracks, sealant bulging and powder residue. **CONDITION 5: H-11 steel barrel nut found. No signs of corrosion AND no loose bolt found.**  (1) ACTION 1: Repeat PART 2: INTERNAL AND EXTERNAL DETAILED INSPECTION and PART 3: TORQUE CHECK. (2) ACTION 2: Do PART 5: BARREL NUT REPLACEMENT. **CONDITION 6: H-11 steel barrel nut found. Corrosion OR any loose bolt found.** (1) Do PART 5: BARREL NUT REPLACEMENT. 4. Do PART 6: CLOSE ACCESS. **PART 1: OPEN ACCESS WARNING:**  BEFORE ENTERING SECTION 48, DEACTIVATE AND PLACARD THE HORIZONTAL STABILIZER TRIM CONTROLS WITH DO-NOT-OPERATE IDENTIFIERS. DO THIS TO PREVENT INADVERTENT STABILIZER OPERATION WHICH CAN CAUSE INJURY TO PERSONNEL AND DAMAGE TO EQUIPMENT. 1. Do the steps that follow to deactivate the horizontal stabilizer. Refer to 767 AMM 55-31-03 as an accepted procedure. a. Pressurize the center hydraulic system. Refer to 767 AMM 29-11-00 as an accepted procedure. b. Place the horizontal stabilizer at neutral (2 units of trim on position indicator) using the STAB TRIM levers. c. Depressurize the center and left hydraulic systems. Refer to 767 AMM 29-11-00 as an accepted procedure. d. Position LEFT and CENTER STAB TRIM SHUTOFF switches on control stand P10 to CUTOUT. e. Open SHUT OFF VALVE,STAB TRIM,LEFT (11C12), and SHUT OFF VALVE, STAB TRIM,C (11C13) circuit breakers on the P11 overhead circuit breaker panel and attach DO-NOT-CLOSE identifiers. 2. Do the steps that follow to deactivate the rudder. Refer to 767 AMM 55-31-03 as an accepted procedure. a. Supply electrical power. Refer to 767 AMM 24-22-00 as an accepted procedure. b. Move the FLT CONTROL SHUTOFF TAIL L, R, and C switches on the P61 right side panel to OFF. Make sure that the switch position lights come on. Attach DO-NOT-CLOSE identifiers. c. Open RUDDER RATIO (11G10), TAIL, L-FLT CONT SHUTOFF (11H17), TAIL, C-FLT CONT SHUTOFF (11H18), and TAIL, R-FLT CONT SHUTOFF (11H27) circuit breakers on the P11 overhead circuit breaker panel and attach DO-NOT-CLOSE identifiers.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 24 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**3. Get external access to the base of the vertical fin. Get internal access as shown in FIGURE 1. **PART 2: INTERNAL AND EXTERNAL DETAILED INSPECTION** 1. RC - Do Internal and External Detailed Inspection of the barrel nut holes and sealant for cracked/damaged sealant, corrosion, or cracked/broken barrel nuts in accordance with FIGURE 2. **NOTE:** Signs of corrosion include but not limited to sealant cracks, sealant bulging and powder residue. **PART 3: TORQUE CHECK** 1. RC - Do a Torque Check of the Vertical Stabilizer attachment bolts for any loose bolt (e.g., the bolt can be turned) in accordance with FIGURE 3. **NOTE:** Boeing recommends that Platform Assembly PME148T0010 or a similar suitable work platform be installed to allow access to the vertical fin attachment bolts. **PART 4: MAGNETIC CHECK** 1. RC - Do a Magnetic Check to identify H-11 steel barrel nuts in accordance with FIGURE 4. **PART 5: BARREL NUT REPLACEMENT WARNING:**  DO NOT REMOVE TWO ADJACENT BOLTS AT THE SAME TIME. ALSO, DO NOT REMOVE MORE THAN FOUR BOLTS FROM EACH SIDE OF THE FIN AT ONE TIME. DO THIS TO PREVENT INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. 1. RC - Do barrel nut replacement in accordance with FIGURE 5. **PART 6: CLOSE ACCESS** 1. Close the access doors that were opened for access as shown in FIGURE 1. 2. Remove the DO-NOT close identifiers and close SHUT OFF VALVE,STAB TRIM,LEFT (11C12), and SHUT OFF VALVE, STAB TRIM,C (11C13) circuit breakers on the P11 overhead circuit breaker panel. 3. Remove the DO-NOT close identifiers and close RUDDER RATIO (11G10), TAIL, L-FLT CONT SHUTOFF (11H17), TAIL, C-FLT CONT SHUTOFF (11H18), and TAIL, R-FLT CONT SHUTOFF (11H27) circuit breakers on the P11 overhead circuit breaker panel. 4. Put the airplane back to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 25 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step** 

- 2

- Access Door Open 1

**FIGURE 1: ACCESS (SHEET 1 OF 1)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 26 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT FIGURE 2: INTERNAL AND EXTERNAL DETAILED INSPECTION**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 27 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Barrel Nut Hole and Sealant Inspect 1 (a) Do Internal and External Detailed Inspection of the barrel nut holes and sealant for cracked/damaged sealant, corrosion, or cracked/broken barrel nuts. Signs of corrosion includes but not limited to sealant cracks, sealant bulging and powder residue.

**FIGURE 2: INTERNAL AND EXTERNAL DETAILED INSPECTION (SHEET 2 OF 2)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 28 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT FIGURE 3: TORQUE CHECK**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 29 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Torque Apply 1 (a) Torque bolt to 3,700 - 4,100 in-lbs for the torque check for any loose bolt (e.g., the bolt can be turned).

**FIGURE 3: TORQUE CHECK (SHEET 2 OF 2)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 30 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT FIGURE 4: MAGNETIC CHECK**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 31 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Sealant Remove 1 (b)

- - Barrel Nut Inspect 2 (c)

- BMS 5-142, TYPE II (BMS 5-95 optional) Sealant Apply 3 (a) Remove sealant from the barrel nut hole to expose the nut. (b) Do a magnetic check to identify H-11 steel barrel nuts. If the magnet is attracted to the nut, the nut is considered an H-11 steel nut. Doing an inspection to determine the part number is acceptable in lieu of the magnetic check if the part number of the barrel nut can be conclusively determined from that inspection. H-11 steel barrel nuts are identified with part number marking 113LH7940T or LH7940T. The part marking can be stamped or etched on either side of the barrel nut cradle. (c) Apply sealant to fill the entire barrel nut hole.

**FIGURE 4: MAGNETIC CHECK (SHEET 2 OF 2)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 32 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT FIGURE 5: BARREL NUT REPLACEMENT**  **(SHEET 1 OF 6)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 33 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT FIGURE 5: BARREL NUT REPLACEMENT**  **(SHEET 2 OF 6)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 34 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.
**More Data Qty**  **Identification Name**  **Task Step**  **WARNING:** DO NOT REMOVE TWO ADJACENT BOLTS AT THE SAME TIME. ALSO, DO NOT REMOVE MORE THAN FOUR BOLTS FROM EACH SIDE OF THE FIN AT ONE TIME. DO THIS TO PREVENT INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. (a) 1

- Bolt Remove / Keep 1

- 2

- Washer Remove 2

- 1

- Retainer Remove

- 1

- Barrel Nut Remove (b)

- BMS 5-95, TYPE I, CLASS B OR C Sealant Apply 3

**FIGURE 5: BARREL NUT REPLACEMENT (SHEET 3 OF 6)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 35 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** (d) (f) 1

- Barrel Nut Install (New) 4 (d) 1

- Retainer Install (New) (d) 1

- Washer Install (New) 5 (d) 1

- Washer Install (New) 6 (d) 1

- Bolt Install (Kept) 7 (c)

- BMS 5-142, TYPE II (BMS 5-95 optional) Sealant Apply 8 (e)

- - Finish Apply 9

- - BMS 3-23, TYPE II Corrosion Inhibiting Compound Apply 10 (a) Remove sealant from bolts. An Inconel bolt can be reinstalled if no corrosion, cracks, thread damage, or shank damage is found. If bolt corrosion, cracks, or damage is found, replace the bolt with new Inconel bolt. (b) To the areas that follow: - Bolt threads, shank and under bolt head. - Barrel nut areas that contact the vertical fin structure. - Washer mating surfaces. (c) Apply sealant to fill the entire barrel nut hole. (d) Refer to fastener table for fastener codes and torque values. (e) To bare aluminum to match adjacent structure. (f) Verify that the barrel nut locking feature is present on the new barrel nuts. Visually inspect for oval shaped threads on the upper end of the barrel nut or hand thread the matting attach fastener and verify that the bolt cannot be threaded all the way through the barrel nut by hand force. One operator has reported that new barrel nuts did not have the locking feature present on one set of barrel nuts supplied for one airplane.

**FIGURE 5: BARREL NUT REPLACEMENT (SHEET 4 OF 6)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 36 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure.
**More Data Hole Dia**  **Qty Identification**  **Name Code**  7,800 - 8,800 in-lbs torque. - 4 BACB30US16K47 BOLT, 12 PT HEAD A
7,800 - 8,800 in-lbs torque. - 4 BACB30US16K48 BOLT, 12 PT HEAD
7,800 - 8,800 in-lbs torque. - 2 BACB30US16K50 BOLT, 12 PT HEAD
7,800 - 8,800 in-lbs torque. - 2 BACB30US16K51 BOLT, 12 PT HEAD
Under bolt head.

- 12 BACW10BP16CD WASHER, PLAIN If necessary for grip length adjustment. - 12 NAS1149E1632P WASHER

- - 12 BACN11B16CS BARREL NUT

- - 12 BACR10AL16B RETAINER, BARREL NUT

**FIGURE 5: BARREL NUT REPLACEMENT (SHEET 5 OF 6)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 37 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT More Data**  **Hole Dia Qty**  **Identification Name**  **Code** 10,450 - 11,500 in-lbs torque. - 4 BACB30US18K52 BOLT, 12 PT HEAD B
Under bolt head.

- 4 BACW10BP18CD WASHER, PLAIN If necessary for grip length adjustment. - 4 NAS1149E1832P WASHER

- - 4 BACN11B18CS BARREL NUT

- - 4 BACR10AL18B RETAINER, BARREL NUT

**FIGURE 5: BARREL NUT REPLACEMENT (SHEET 6 OF 6)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 38 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance.

**APPENDIX A: COMPLIANCE TASKS AND COMPLIANCE TIMES LOGIC DIAGRAM (SHEET 1 OF 1)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 39 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT APPENDIX B: INPUT SURVEY**  **(SHEET 1 OF 1)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 12, 2014 767-53A0261 40 of 40 **BOEING SERVICE BULLETIN 767-53A0261 ALERT**  **ALERT**