Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-54A0101

Original Issue: September 23, 1999

Revision 5: June 29, 2010

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, 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.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 1999 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Unpublished Work - All Rights Reserved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.

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4.0
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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT

BLANK PAGE
Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

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

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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

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

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

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

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

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 28

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FIGURE 1: INSPECTION THRESHOLD AND REINSPECTION INTERVALS . . . . . . . . . . . . . . 37

FIGURE 2: MIDSPAR FITTING INSPECTION (DETAILED) . . . . . . . . . . . . . . . . . . . . . . . 41

FIGURE 3: MIDSPAR FITTING FASTENER HOLE INSPECTION (HFEC) . . . . . . . . . . . . . . . 44

FIGURE 4: MIDSPAR FITTING FASTENER HOLE REWORK . . . . . . . . . . . . . . . . . . . . . . 46

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 767-54A0101

Original Issue: September 23, 1999

Revision 5: June 29, 2010

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, and

Replacement

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on the airplanes changed in accordance with previous revisions of this service bulletin.

Operators must do Part 1 inspection at the reduced threshold and repeat intervals in accordance with Paragraph

1. E., Compliance.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-19-23 is related to this service bulletin.

REASON FOR REVISION

This revision is sent to:

1. Revise Part 1 inspection threshold and repeat intervals. The inspection threshold reduction is based on

fleet history. Subsequent to the release of Revision 4 of this service bulletin, one operator reported two

incidents of cracks in the midspar fitting tangs. The first report found severed upper and lower tangs at the

aft two fastener locations in the Number 1 pylon inboard midspar fitting. The cracks were found during a

routine check of a 767-300 airplane at approximately 92,205 flight hours and 14,969 cycles. This airplane

had incurred 408 flight cycles from the previous inspection. The second report found cracks in the Number

1 pylon inboard midspar fitting lower tang, between the aft two fastener holes, on a 767-300 airplane at

approximately 94176 flight hours and 15405 cycles. This airplane had incurred 830 cycles from the previous

inspection.

2. Delete the requirement for cap sealing the fasteners in the outboard midspar fitting after performing the

detailed inspection.

3. Update the service bulletin to the current format.

These sections were changed:

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1. In Summary Compliance and paragraph 1.E., Compliance, added compliance information for Federal

Aviation Administration (FAA) Airworthiness Directive, and updated the affected maintenance zones and

the reference to FAA Airworthiness Directive AD 2005-19-23.

2. In Summary Industry Support Information, updated the reference to Program Letter BPL

6-1151-757/767PGM-120 R4.

3. In Summary Background and paragraph 1.C, Reason, updated the reference to Service Related Problem

(SRP) 767-SRP-54-0133.

4. In Paragraph 3.A., General Information, added new general notes.

5. In Paragraph 3.B, Work Instructions, Part 2 - Open Hole HFEC Inspection, made the strut removal optional.

6. In Figure 1, changed the inspection threshold and repeat interval for Part 1 inspection, and deleted the MPD

references in Table 1, flag note 1.

7. In Figure 2 and Figure 4, deleted the requirement for cap sealing the bolts at the outboard midspar fitting,

and added requirement for the application of plating and primer to the bare surfaces, as required.

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

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: September 23, 1999

Revision 1: February 03, 2000

Revision 2: January 10, 2002

Revision 3: September 05, 2002

Revision 4: February 10, 2005

Revision 5: June 29, 2010

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-54A0101

Original Issue: September 23, 1999

Revision 5: June 29, 2010

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, 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

For Part 4 - Terminating Action the related service bulletins are 767-54-0080, 767-54-0081, 767-54-0052,

767-54-0061, 767-54A0062, 767-54-0069, 767-57-0063, 767-54-0072, 767-54-0074, 767-54A0094.

BACKGROUND

Accomplishment of this service bulletin will ensure early detection of cracks in the horizontal tangs of the strut

midspar fitting. A cracked midspar fitting could result in a fractured fitting which could lead to strut and engine

separation.

One operator has reported a cracked inboard midspar fitting on a number two pylon of a General Electric powered

airplane. The crack was found during a midspar fitting bushing replacement. The airplane had accumulated

21,375 hours and 11,563 cycles. This crack was due to fatigue and occurred much earlier than predicted by

Boeing analysis.

The midspar fittings are part of the redundant strut-to-wing load path. More frequent inspections of the midspar

fittings are necessary to ensure the structural integrity required for damage tolerance. Without early detection,

a cracked midspar fitting could eventually result in separation of an engine and strut.

Subsequent to the initial release of this service bulletin, six operators have reported finding cracks in seven

midspar fittings on airplanes with approximately 27,914 to 61,347 hours and 11,640 to 23,826 flight cycles. One

of the cracks was next to the third row of fasteners in the upper tang of a midspar fitting. Therefore, the inspection

and rework requirements have changed to include the aft most eight (8) fastener locations common to the upper

and lower tangs of the midspar fittings, instead of the aft most two (2) fastener locations. The Federal Aviation

Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service

bulletin.

Subsequent to the release of Revision 3 of this service bulletin, one operator has reported finding a crack in the

closeout angle common to the aft most row of fasteners for the midspar fitting. An eddy current inspection of

the fastener holes revealed that the midspar fitting lower tang was also cracked in the area under the closeout

angle.

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Subsequent to the release of Revision 4 of this service bulletin, one operator reported two incidents of cracks

in the midspar fitting tangs. The first report found severed upper and lower tangs at the aft two fastener locations

in the Number 1 pylon inboard midspar fitting. The cracks were found during a routine check of a 767-300

airplane at approximately 92,205 flight hours and 14,969 cycles. This airplane had incurred 408 flight cycles

from the previous inspection. The second report found cracks in the Number 1 pylon inboard midspar fitting

lower tang, between the aft two fastener holes, on a 767-300 airplane at approximately 94176 flight hours and

15405 cycles. This airplane had incurred 830 cycles from the previous inspection.

Boeing Service Related Problems (SRP) 767-SRP-54-0107 and 767-SRP-54-0133 are related to this service

bulletin.

ACTION

For each midspar fitting, do a Detailed Inspection of the tangs at the aft most eight (8) fastener locations for

cracks. Also do a surface High Frequency Eddy Current (HFEC) Inspection of the close out angle around the

two fasteners common to the closeout angle and the midspar fitting. If no cracks are found, repeat the inspection

at the intervals specified in Figure 1. If cracks are found in the closeout angle, remove the two fasteners common

to the closeout angle and the midspar fitting, and do the PART 2 - OPEN HOLE HFEC INSPECTION. Contact

Boeing for repair instructions if cracks are only found in the closeout angle.

Optional to Detailed Inspection: Do a HFEC Inspection of the fastener holes. If no cracks are found, rework the

holes as necessary and repeat the inspection at the intervals specified in Figure 1. If cracks are found or any

of the fastener holes are larger than 0.5322 inch, do Part 4 - Terminating Action or contact Boeing for rework

instructions.

The terminating action for this service bulletin is to do Part 4, which replaces the midspar fittings as specified

by the 767 Strut Improvement Program (SIP) service bulletins or contact Boeing for additional inspection

instructions.

EFFECTIVITY

All 767 airplanes line numbers 1 to 663 powered by General Electric and Pratt-Whitney engines.

COMPLIANCE

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

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

5 of this service bulletin mandatory.

See Figure 1 for compliance recommendations and maintenance alternatives.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-19-23 is related to this service bulletin.

INDUSTRY SUPPORT INFORMATION

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

The inspection and repair procedures given in this service bulletin are not covered by Program Letter BPL

6-1151-757/767PGM-120 R4 .

MANPOWER

Refer to Paragraph 1.G., Manpower.

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
MATERIAL INFORMATION

Operator Supplied Parts/Materials for Part 3 - Hole Rework.

Boeing Supplied Kits for Part 4 - Terminating Action. Refer to Paragraph 2.A., Material - Price and Availability.

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ALERT ALERT
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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-54A0101

Original Issue: September 23, 1999

Revision 5: June 29, 2010

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Attach Fittings - Midspar Fitting Inspection, Rework, 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 Document D6-24T001 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

767-200 airplanes, line numbers 1 thru 123, powered by Pratt and

Whitney JT9D engines.

1 -

767-200 and -300 airplanes, line numbers 124 thru 379, powered by

Pratt and Whitney JT9D engines.

2 -

767-200 and -300 airplanes, line numbers 165 thru 663, powered by

Pratt and Whitney PW4000 engines.

3 -

767-200 airplanes, line numbers 6 thru 123, powered by General

Electric CF6-80A engines.

4 -

767-200 and -300 airplanes, line numbers 124 thru 427, powered by

General Electric CF6-80A engines.

5 -

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GROUP CONFIGURATION DESCRIPTION

767-200, -300, and -300F airplanes, line numbers 158 thru 663,

powered by General Electric CF6-80C2 engines.

6 -

Airplane Models:

767-200, 767-300, 767-300F

Variable Number Group

VA001 - VA020 1

VA301 - VA315 4

VA501 - VA513 4

VA514 - VA530 5

VA701 - VA712 1

VA713 - VA719 2

VA801 - VA810 1

VB001 - VB002 1

VB051 - VB055 4

VB101 - VB121 4

VB122 - VB125 5

VB201 - VB202 1

VB251 - VB253 4

VB281 - VB284 1

VB301 - VB302 1

VB321 - VB324 4

VB325 - VB330 5

VB331 - VB332 6

VB371 - VB373 1

VB401 5

VB441 - VB444 6

VE001 - VE002 1

VE003 2

VE021 - VE023 1

VE041 - VE043 2

VE061 - VE062 1

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
Variable Number Group

VE063 - VE069 2

VE083 - VE084 2

VE085 - VE086 3

VE101 - VE104 5

VE116 - VE118 5

VE121 - VE126 6

VE141 - VE152 6

VE171 - VE172 3

VF001 - VF002 6

VF041 - VF042 6

VF051 6

VF061 - VF062 3

VF071 - VF072 3

VF091 - VF093 3

VF101 - VF102 3

VF161 - VF162 3

VF171 - VF172 6

VF180 - VF184 6

VF251 6

VK001 - VK011 2

VK012 - VK015 6

VK021 - VK022 2

VK031 - VK054 5

VK055 - VK056 3

VK081 - VK112 6

VK131 - VK133 6

VK141 - VK147 6

VK161 - VK164 3

VK171 3

VL001 - VL006 6

VL011 3

VL701 - VL703 6

VL751 - VL755 6

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
Variable Number Group

VL806 - VL807 3

VL891 - VL900 6

VL911 - VL914 6

VL931 - VL932 3

VL941 6

VN001 - VN041 6

VN051 - VN064 6

VN081 - VN098 6

VN151 - VN158 3

VN163 - VN168 3

VN171 - VN174 3

VN191 - VN198 6

VN211 - VN212 3

VN221 - VN225 3

VN231 - VN234 6

VN241 - VN243 3

VN251 - VN271 3

VN291 - VN293 6

VN301 - VN314 6

VN371 - VN372 3

VN376 3

VN381 - VN388 3

VN421 - VN427 6

VN436 6

VN471 - VN472 6

VN491 - VN513 3

VN531 - VN532 3

VN536 - VN537 3

VN541 - VN542 3

VN546 - VN547 6

VN551 3

VN556 - VN557 3

VN561 - VN562 3

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
Variable Number Group

VN631 - VN633 3

VN634 - VN638 6

VN651 - VN657 6

VN671 - VN672 3

VN676 6

VN681 - VN691 3

VN731 - VN732 6

VN751 - VN753 6

VN791 - VN792 6

VN811 - VN813 6

VN921 - VN922 6

VN931 - VN936 3

VN951 - VN953 6

VN966 - VN967 3

VN968 - VN969 6

VN971 - VN972 3

VW701 - VW716 6

VW851 6

2. Spares Affected

None.

B. Concurrent Requirements

For Part 4 - Terminating Action the related service bulletins are 767-54-0080, 767-54-0081, 767-54-0052,

767-54-0061, 767-54A0062, 767-54-0069, 767-57-0063, 767-54-0072, 767-54-0074, 767-54A0094.

C. Reason

Accomplishment of this service bulletin will ensure early detection of cracks in the horizontal tangs of

the strut midspar fitting. A cracked midspar fitting could result in a fractured fitting and drooping of the

strut at the strut-to-wing interface, or result in strut and engine separation.

One operator has reported a cracked inboard midspar fitting on a number two pylon of a General

Electric powered airplane. The crack was found during a midspar fitting bushing replacement. The

airplane had accumulated 21,375 hours and 11,563 cycles. This crack was due to fatigue and occurred

much earlier than predicted by Boeing analysis.

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Revision 5: June 29, 2010 767-54A0101

15 of 49

BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
The midspar fittings are part of the redundant strut-to-wing load path. More frequent inspections of the

midspar fittings are necessary to ensure the structural integrity required for damage tolerance. Without

early detection, a cracked midspar fitting could eventually result in separation of an engine and strut.

Subsequent to the initial release of this service bulletin, six operators have reported finding cracks in

seven midspar fittings on airplanes with approximately 27,914 to 61,347 hours and 11,640 to 23,826

flight cycles. One of the cracks was next to the third row of fasteners in the upper tang of a midspar

fitting. Therefore, the inspection and rework requirements have changed to include the aft most eight

(8) fastener locations common to the upper and lower tangs of the midspar fittings, instead of the aft

most two (2) fastener locations.

Subsequent to the release of Revision 3 of this service bulletin, one operator has reported finding a

crack in the closeout angle common to the aft most row of fasteners for the midspar fitting. An eddy

current inspection of the fastener holes revealed that the midspar fitting lower tang was also cracked

in the area under the closeout angle.

Subsequent to the release of Revision 4 of this service bulletin, one operator reported two incidents of

cracks in the midspar fitting tangs. The first report found severed upper and lower tangs at the aft two

fastener locations in the Number 1 pylon inboard midspar fitting. The cracks were found during a routine

check of a 767-300 airplane at approximately 92,205 flight hours and 14,969 cycles. This airplane had

incurred 408 flight cycles from the previous inspection. The second report found cracks in the Number

1 pylon inboard midspar fitting lower tang, between the aft two fastener holes, on a 767-300 airplane

at approximately 94176 flight hours and 15405 cycles. This airplane had incurred 830 cycles from the

previous inspection.

Boeing Service Related Problem (SRP) 767-SRP-54-0107 and 767-SRP-54-0133 are related to this

service bulletin.

Revision 1 was sent to inform the operators of the following changes:

1. Add the surface HFEC 767 NDT Part 6, 51-00-21 and MPD D622T001, item 5450-433-02I,

5450-443-02I, 5450-437-03I, 5450-447-03I to paragraph J.1. Existing Data.

2. Revise the Accomplishment Instructions, Part 1 - Detailed Visual Inspection to add the activation

of thrust reverser and the leading edge slats.

3. Revise Figure 1 to allow extension on the initial inspection threshold if MPD items 5450-433-02I,

5450-443-02I, 5450-437-03I, 5450-447-03I have been recently accomplished.

4. Revise Figure 1 to adjust the reinspection intervals for different inspection locations.

5. Revise Figure 1 and Figure 2 to add optional surface HFEC inspection of the outboard fitting, upper

tang.

6. Revise Figure 2 to clarify sealant removal and reapplication requirements.

Revision 2 was sent to incorporate the following changes:

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ALERT ALERT
1. Change inspection/rework from aft most two (2) fastener locations to the aft most eight (8) fastener

locations of each midspar fitting.

2. Add compliance information for Federal Aviation Administration (FAA) Airworthiness Directive

2004-09-14, Amendment 39-13603.

3. Add midspar fitting replacement instructions/provisions, and add related references to Paragraph

J.

4. Incorporate the data given in Information Notice 767-54A0101 IN 01.

5. Clarify figure 1, flag note 1.

6. Change representation of BACB30MY fasteners throughout bulletin.

7. Remove "if necessary" statement relative to engine/strut removal for Part 2 - HFEC inspection and

add applicable man-hours necessary for engine/strut removal.

8. The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which

requires incorporation of this service bulletin.

Revision 3 was sent to incorporate the following changes:

1. Add optional surface HFEC inspection for forward-most two fastener locations of the inspection

area if the fasteners cannot be removed for open hole HFEC inspection due to interference with

structure.

2. Correct AMM callout for removal and installation of strut access panels.

3. Incorporate format changes throughout service bulletin - no technical change.

Revision 4 was sent to incorporate the following changes:

1. Add the requirement to inspect the closeout angle for cracks during the detailed inspection shown

in Figure 2. Cracks in the closeout angle will be an indication of possible cracks in the midspar

fitting lower tang at the aft most two fasteners.

2. Update the Summary, Planning Information, and Accomplishment Instructions to reflect the added

surface HFEC inspection of the closeout angle.

3. Reduce the repeat inspection threshold from 6000 flight cycles to 1500 flight cycles for detailed

inspection of the outboard midspar fitting upper tangs in Figure 1, Table 1.

4. Revise the Accomplishment Instructions to add the option to oversize holes to remove cracks

detected during open hole HFEC inspection. Previously, if cracks were detected during open hole

HFEC inspection, Terminating Action was required.

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ALERT ALERT
5. Delete reference to FAA Airworthiness Directive 2001-07-05, Amendment 39-12170, and add

reference to FAA Airworthiness Directive 2004-09-14, Amendment 39-13603. AD 2001-07-05 has

been superseded by AD 2004-09-14.

6. Add definition of Detail Inspection to paragraph 3.A.

7. Add collar part number in Figure 4, step 9.

Revision 5 is sent to incorporate the following changes:

1. Revise Part 1 inspection threshold and repeat intervals. The inspection threshold reduction is

based on fleet history. Subsequent to the release of Revision 4 of this service bulletin, one operator

reported two incidents of cracks in the midspar fitting tangs. The first report found severed upper

and lower tangs at the aft two fastener locations in the Number 1 pylon inboard midspar fitting.

The cracks were found during a routine check of a 767-300 airplane at approximately 92,205 flight

hours and 14,969 cycles. This airplane had incurred 408 flight cycles from the previous inspection.

The second report found cracks in the Number 1 pylon inboard midspar fitting lower tang, between

the aft two fastener holes, on a 767-300 airplane at approximately 94176 flight hours and 15405

cycles. This airplane had incurred 830 cycles from the previous inspection.

2. Delete the requirement for cap sealing the fasteners in the outboard midspar fitting after performing

the detailed inspection.

3. Update the service bulletin to the current format.

D. Description

PART 1 - DETAILED INSPECTION of MIDSPAR FITTINGS and SURFACE HIGH FREQUENCY EDDY

CURRENT (HFEC) INSPECTION of CLOSEOUT ANGLE:

For each midspar fitting, do a Detailed Inspection of the tangs at the aft most eight (8) fastener locations

for cracks. Also do a surface High Frequency Eddy Current (HFEC) Inspection of the close out angle

around the two fasteners common to the closeout angle and the midspar fitting. If no cracks are found,

repeat the inspection at the intervals specified in Figure 1. If cracks are found in the closeout angle,

remove the two fasteners common to the closeout angle and the midspar fitting, and do the PART 2 -

OPEN HOLE HFEC INSPECTION. Contact Boeing for repair instructions if cracks are only found in

the closeout angle.

PART 2 - OPEN HOLE HFEC INSPECTION (Optional to Part 1 inspections)

Do a HFEC inspection of the fastener holes. If no cracks are found, do Part 3 - Hole Rework and repeat

the inspection at the intervals specified in Figure 1. If cracks are found, or any of the fastener holes

are larger than 0.5322 inch, do Part 4 - Terminating Action.

PART 3 - HOLE REWORK

If necessary, oversize the holes where HFEC inspection was done and install oversize fasteners.

PART 4 - TERMINATING ACTION

Replace the midspar fittings as specified in the 767 Strut Improvement Program (SIP) service bulletins.

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ALERT ALERT
Revision 1 - no more work is necessary on airplanes changed as shown in the initial release of this

service bulletin.

Revision 2 - more work is necessary on airplanes changed as shown in the initial release and revision

1 of this service bulletin. Subsequent inspections must be done at the aft most eight (8) fastener

locations of the upper and lower tangs of the midspar fittings instead of the aft most two (2) fastener

locations, as was specified in previous revisions.

Revision 3 - more work is necessary on airplanes inspected or changed as shown in the initial release

and revision 1 of this service bulletin. No more work is necessary on airplanes inspected or changed

as shown in revision 2 of this service bulletin.

Revision 4 - no more work is necessary on airplanes inspected or changed as shown in previous

releases of this service bulletin. However, during future Part 1 detailed inspections of the midspar

fittings, operators must also perform a surface High Frequency Eddy Current (HFEC) inspection for

cracks in the closeout angle common to the aft most two (2) fasteners of the midspar fittings.

NOTE: Inspection and maintenance alternatives are shown in a diagram in Section 3.,

ACCOMPLISHMENT INSTRUCTIONS.

1.

2. If the damaged area is more than the specified limits, write to Boeing for repair

instructions. Give the size and location of the damage. When possible, send sketches

and photographs. If the damage includes corrosion, send data on the length, width,

and largest depth of clean up.

Send to: BOEING COMMERCIAL AIRPLANE GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT

Revision 5 - more work is necessary on airplanes changed in accordance with previous revisions of

this service bulletin. Operators must do Part 1 inspection at the reduced threshold and repeat intervals

in accordance with Paragraph 1. E., Compliance.

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

Group 1, 4:

Affected Maintenance Zones

Model Zone

767-200 433, 434, 436, 443, 444, 446

Group 2-3, 5:

Affected Maintenance Zones

Model Zone

767-200, 767-300 433, 434, 436, 443, 444, 446

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ALERT ALERT
Group 6:

Affected Maintenance Zones

Model Zone

767-200, 767-300, 767-300F 433, 434, 436, 443, 444, 446

E. Compliance

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

Revision 5 of this service bulletin. The Airworthiness Directive will make the compliance tasks and

times given in Revision 5 of this service bulletin mandatory.

See Figure 1 for compliance recommendations and maintenance alternatives.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-19-23 is related to this service

bulletin.

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.

In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspections,

corrective actions and terminating actions specified in Figure 1 of Service Bulletin 767-54A0101 Revision

5 as an AMOC to the inspections, corrective actions and terminating actions required by paragraphs

(f), (h)(1), (j), (k), (l), (n) and (p) of AD 2005-19-23 . When this service bulletin specifies contacting

Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with

paragraph (q) of the AD. All provisions of AD 2005-19-23 that are not specifically referenced in this

paragraph, including but not limited to repeat inspections until the terminating action in accordance

with Service Bulletin 767-54A0101 Revision 5 is accomplished, remain fully applicable and must be

complied with.

G. Manpower

The table below shows an estimate of the man-hours necessary to do this inspection and change for

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

operator man-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 examine the work

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ALERT ALERT
— Time to cure the materials

— Time to make the parts

— Time to find the tools.

PART 1 - DETAILED INSPECTION of MIDSPAR FITTINGS and SURFACE HIGH FREQUENCY

EDDY CURRENT (HFEC) INSPECTION of CLOSEOUT ANGLE

Task Number of Persons Man-Hours Elapsed Time (Hours)

Access 2 10 5

Inspection 2 4 2

Restoration 2 12 6

TOTAL FOR EACH STRUT 26 13

PART 2 - OPEN HOLE HFEC INSPECTION

Task Number of Persons Man-Hours Elapsed Time (Hours)

Remove engine (a) 5 20 4

Remove strut (a) 4 26 6.5

Access 2 10 5

Inspect 2 3 1.5

Restoration 2 12 6

Install strut (a) 4 38 9.5

Install engine (a) 3-5 36 8

TOTAL FOR EACH STRUT 145.0 40.5

(a) If necessary.

PART 3 - HOLE REWORK

Task Number of Persons Man-Hours Elapsed Time (Hours)

Remove engine 5 20 4

Remove strut 4 26 6.5

Access 2 10 5

Rework 2 8 4

Restoration 2 12 6

Install strut 4 38 9.5

Install engine 3-5 36 8

TOTAL FOR EACH STRUT 150.0 43.0

PART 4 - TERMINATING ACTION

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ALERT ALERT
See service bulletin 767-54-0080 or 767-54-0081 for estimates of manpower requirements when

accomplishing terminating action.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable

J. References

1. Existing Data:

a. Boeing Program Letter 6-1151-757/767PGM-120 R4

b. Boeing Service Bulletin 767-54-0052, 767-54-0061, 767-54-0069, 767-54-0072, 767-54-0074,

767-54-0080, 767-54-0081, 767-54A0062, 767-54A0094, 767-57-0063

c. Boeing Service Related Problem (SRP) 767-SRP-54-0107, 767-SRP-54-0133

d. Component Maintenance Manual (CMM) 54-50-21

e. Federal Aviation Administration (FAA) Airworthiness Directive 2005-19-23

f. Standard Overhaul Practices Manual (SOPM) 20-30-03

g. 767 Aircraft Maintenance Manual (AMM) 06-43-00, 27-81-00, 51-31-01, 54-51-01, 71-00-02,

78-31-00

h. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-12, Part 6, 51-00-16,

Part 6, 51-00-17, Part 6, 51-00-19, Part 6, 51-00-21

2. Data supplied with this Service Bulletin:

None.

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

Drawing Number Title

311T1150 Midspar Installation - Nacelle Strut CF6-80

311T2150 Midspar Installation - Nacelle Strut CF6-80C

311T3150 Midspar Installation - Nacelle Strut

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.

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ALERT ALERT
K. Publications Affected

1. Publications:

Publication Chapter-Section

767 Maintenance Manual 12-21, 54-00, 54-51, 54-52, 54-54

767 Corrosion Prevention Manual 54-00

767 Structural Repair Manual 54-50, 54-51, 54-52, 54-53

767 Illustrated Parts Catalog 54-51

767 Component Maintenance Manual 54-50

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

Refer to SB 767-54-0080 or SB 767-54-0081 for information on parts changed by the midspar fitting

replacement activities of Part 4 - Terminating Action.

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ALERT ALERT
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ALERT ALERT

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown

below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares.

More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the

date Boeing gets the purchase order.

NOTE: Kits are only required for Part 4 - Terminating Action.

Unit Price thru Dec

31/02

ROLT

(Weeks)

Kit Number Name

015T1526-110 Wing Access Fastener Kit (c) 22 $ 71.50

015T1526-201 Strut Structure Subkit (a)(c) 35 $ 88,708.00

015T1526-301 Strut/Wing Structure Subkit (a)(b)(c) 27 $ 37,808.00

015T1526-302 Strut/Wing Structure Subkit (a)(b)(c) 27 $ 36,020.00

015T1526-303 Strut/Wing Structure Subkit (a)(b)(c) 43 $ 109,476.00

015T1527-110 Wing Access Fastener Kit (c) 22 $ 71.50

015T1527-201 Strut Structure Subkit (a)(c) 35 $ 125,968.00

015T1527-202 Strut Structure Subkit (a)(c) 36 $ 127,258.00

015T1527-301 Strut/Wing Structure Subkit (a)(b)(c) 29 $ 38,394.00

015T1527-302 Strut/Wing Structure Subkit (a)(b)(c) 43 $ 96,724.00

015T1527-303 Strut/Wing Structure Subkit (a)(b)(c) 53 $ 100,638.00

(a) Refer to service bulletin 767-54-0080 or service bulletin 767-54-0081 to determine the kits

needed for midspar fitting replacement.

(b) Parts needed from this kit will depend on midspar fitting condition.

(c) Refer to the applicable Strut Improvement Program service bulletin 767-54-0080 or 767-54-

0081 for individual parts contained within this kit.

The kits 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

B. Industry Support Information

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

bulletin. The inspection and repair procedures given in this service bulletin are not covered by Program

Letter BPL 6-1151-757/767PGM-120 R4 .

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ALERT ALERT
C. Parts Necessary For Each Airplane

1. Kits/Parts:

For information on the kits shown in section 2.A., refer to SB 767-54-0080 or SB 767-54-0081.

NOTE: Kits are only required for Part 4 - Terminating Action.

2. Parts and Materials Supplied by the Operator:

NOTE: The parts and materials shown below are only required for Part 3 - Hole Rework. The

quantities shown are for each airplane.

Part Number / Specification QTY Name

BACB30LE8K24 (a) (c) 8 BOLT (o)

BACB30LE8K24X (a) (d) 4 BOLT (o) (p)

BACB30LE8K24Y (a) (e) 2 BOLT (o) (q)

BACB30LE8K22 (b) (f) 8 BOLT (o)

BACB30LE8K22X (b) (g) 4 BOLT (o) (p)

BACB30LE8K22Y (b) (h) 2 BOLT (o) (q)

BACB30MY16K14 (a) (s) 8 BOLT (o)

BACB30MY16K14X (a) (t) 4 BOLT (o) (p)

BACB30MY16K14Y (a) (u) 2 BOLT (o) (q)

BACB30MY16K12 (b) (s) 8 BOLT (o)

BACB30MY16K12X (b) (t) 4 BOLT (o) (p)

BACB30MY16K12Y (b) (u) 2 BOLT (o) (q)

BACB30MY16K18 (a) (s) 16 BOLT (o)

BACB30MY16K18X (a) (t) 8 BOLT (o) (p)

BACB30MY16K18Y (a) (u) 4 BOLT (o) (q)

BACB30MY16K16 (b) (s) 16 BOLT (o)

BACB30MY16K16X (b) (t) 8 BOLT (o) (p)

BACB30MY16K16Y (b) (u) 4 BOLT (o) (q)

BACC30M16 24 COLLAR (o)

BACC30R16 6 COLLAR (o) (q)

BACN10HR8CS 8 NUT (o)

BACW10BP8ACU (i) 32 WASHER (o)

BACW10BP8DP (j) 64 WASHER (o)

BACW10BP81ACU (k) 16 WASHER (o) (p)

BACW10BP81DP (l) 32 WASHER (o) (p)

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ALERT ALERT
Part Number / Specification QTY Name

BACW10BP82ACU (m) 8 WASHER (o) (q)

BACW10BP82DP (n) 16 WASHER (o) (q)

BMS 10-79, Type III (r) 2 ounces Primer

(a) For General Electric powered airplane only.

(b) For Pratt-Whitney powered airplane only.

(c) BACB30US8K24 is optional to BACB30LE8K24.

(d) BACB30US8K24X is optional to BACB30LE8K24X.

(e) BACB30US8K24Y is optional to BACB30LE8K24Y.

(f) BACB30US8K22 is optional to BACB30LE8K22.

(g) BACB30US8K22X is optional to BACB30LE8K22X.

(h) BACB30US8K22Y is optional to BACB30LE8K22Y.

(i) BACW10BP8CD, BACW10BP8CTU, BACW10BP8AC, BACW10BP8CK is optional

to BACW10BP8ACU.

(j) BACW10BP8AP, BACW10BP8PK is optional to BACW10BP8DP.

(k) BACW10BP81CD, BACW10BP81CTU, BACW10BP81AC, BACW10BP81CK is

optional to BACW10BP81ACU.

(l) BACW10BP81AP, BACW10BP81PK is optional to BACW10BP81DP.

(m) BACW10BP82CD, BACW10BP82CTU, BACW10BP82AC, BACW10BP82CK is

optional to BACW10BP82ACU.

(n) BACW10BP82AP, BACW10BP82PK is optional to BACW10BP82DP.

(o) Only required if accomplishing Part 2 - HFEC Inspection.

(p) Only required if first oversize is needed.

(q) Only required if second oversize is needed.

(r) See the Qualified Products List at the end of the Boeing Material Specification (BMS)

for supplier data.

(s) BACB30NX16K( ) is optional to BACB30MY16K( ).

(t) BACB30NX16K( )X is optional to BACB30MY16K( )X.

(u) BACB30NX16K( )Y is optional to BACB30MY16K( )Y.

3. Parts Modified and Reidentified:

Refer to SB 767-54-0080 or SB 767-54-0081 for information on parts changed by the midspar

fitting replacement activities of Part 4 - Terminating Action.

4. Parts Removed and Not Replaced:

None.

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ALERT ALERT
D. Parts Necessary to Change Spares

None

E. Special Tooling - Price and Availability

NOTE: The following tools are only required for Part 4 - Terminating Action.

Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service

Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the

date the tools will be used. If there is a limit in the quantity of available rental tools, a supply sequence

is given by Spares.

Rental Data:

Tool Kit Number Name Price

Kit - Midspar Fitting Replacement Tool Kit - (a)

General Electric (b)

015T1543-3

Kit - Midspar Fitting Replacement Tool Kit - Pratt (a)

& Whitney (c)

015T1543-4

(a) A $200.00 handling fee is added to all tool rentals. Contact Boeing Spares for rental

prices.

(b) For General Electric powered airplanes only.

(c) For Pratt & Whitney powered airplanes only.

The kits are subject to the terms and conditions of the Boeing standard purchase order

acknowledgement. After the Price date, new price data is applicable. Prices are in United States dollars.

Terms: Net 30 days.

F. Special Tooling Necessary to do this Service Bulletin

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.

NOTE: The following tools are only required for Part 4 - Terminating Action.

Tool Kit Number Name

Kit - Midspar Fitting Replacement Tool Kit -

General Electric (a)

015T1543-3

Kit - Midspar Fitting Replacement Tool Kit -

Pratt & Whitney (b)

015T1543-4

(a) For General Electric powered airplanes.

(b) For Pratt & Whitney powered airplanes.

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ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

definition of the acronyms.

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

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

— Linear dimensions are in inches

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

or minus 0.03 inch.

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

— Angular tolerance is plus or minus 2 degrees

— Hole dimensions for standard solid rivets are given in 767 Structural Repair

Manual, Chapter 51

— Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual,

Chapter 51.

4. For approved fastener and process material substitutions, refer to 767 Structural

Repair Manual, Chapter 51, Alternate fasteners are given in 767 Structural Repair

Manual Chapter 51 and Boeing Drawing 012T2100.

5. If the length of fasteners specified in this service bulletin do not meet the installation

standards, fasteners of the same specification, or an approved substitute, one grip

length longer or shorter may be used.

6. An in-situ ultrasonic (UT) inspection for this service bulletin was attempted and will

not be available due to lack of access.

7. The DETAILED INSPECTION used in this service bulletin 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 mirror, magnifying

lenses, etc. may be necessary. Surface cleaning and elaborate access 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.

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

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

additional structural repair instructions. The Service Letter describes what information

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

10. The instructions identified in Paragraph 3.B., Work Instructions, and the Figures give

the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

11. 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.

B. WORK INSTRUCTIONS

PART 1 - DETAILED INSPECTION of MIDSPAR FITTING and SURFACE HIGH FREQUENCY EDDY

CURRENT (HFEC) INSPECTION of CLOSEOUT ANGLE

WARNING: INSTALL LOCKS IN THE LEADING EDGE SLATS. ACCIDENTAL OPERATION OF THE

SLATS CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.

1. Do the deactivation procedure for the leading edge slats in the retracted position. Refer to 767

AMM 27-81-00 as an accepted procedure.

WARNING: DO THE DEACTIVATION PROCEDURE TO PREVENT THE OPERATION OF THE

THRUST REVERSER. ACCIDENTAL OPERATION OF THE THRUST REVERSER CAN

CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.

2. Do the deactivation procedure for the thrust reverser for ground maintenance. Refer to 767 AMM

78-31-00 as an accepted procedure.

3. Remove and keep the following access panels. Refer to 767 AMM 06-43-00 as an accepted

procedure.

Left Strut Right Strut

Left Side Right Side Left Side Right Side

432FL 432FR 442FL 442FR

436AL 436AR 446AL 446AR

437AL 437AR 447AL 447AR

4. Do a detailed inspection of the midspar fitting tangs for any crack and do a surface HFEC inspection

of the closeout angle for any crack in accordance with Figure 2.

a. If any crack is found in the midspar fitting tangs, do Part 4 - Terminating Action.

b. If any crack is detected during the surface HFEC inspection of the closeout angle, do the

following:

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ALERT ALERT
(1) Do Part 2 - Open Hole HFEC Inspection at the two fastener locations common to the

closeout angle and midspar fitting where the surface HFEC detected any crack.

(2) If it is not necessary to do Part 4 - Terminating Action, contact Boeing for closeout angle

repair instructions.

(3) Repeat inspections in accordance with Figure 1.

c. If no crack is found, repeat inspections in accordance with Figure 1.

5. Reinstall the following access panels. Refer to 767 AMM 06-43-00 as an accepted procedure.

Left Strut Right Strut

Left Side Right Side Left Side Right Side

432FL 432FR 442FL 442FR

436AL 436AR 446AL 446AR

437AL 437AR 447AL 447AR

6. Do the activation procedure for the thrust reverser. Refer to 767 AMM 78-31-00 as an accepted

procedure.

7. Do the activation procedure for the leading edge slats. Refer to 767 AMM 27-81-00 as an accepted

procedure.

8. Return airplane to serviceable condition.

PART 2 - OPEN HOLE HFEC INSPECTION

1. Remove engine from the strut. Refer to 767 AMM 71-00-02 as an accepted procedure.

NOTE: Due to limited access, Boeing recommends removal of the engine and strut for this

procedure. However, it is acceptable to perform the open hole HFEC inspection without

removing the engine and strut as long as only two fasteners on each midspar fitting are

removed at a time. If more than two fasteners on a midspar fitting will be removed at the

same time, then the engine and strut must be removed.

2. Remove the strut if necessary. Refer to 767 AMM 54-51-01 as an accepted procedure.

3. Remove and keep the following access panels. Refer to 767 AMM 06-43-00 as an accepted

procedure.

Left Strut Right Strut

Left Side Right Side Left Side Right Side

432FL 432FR 442FL 442FR

436AL 436AR 446AL 446AR

437AL 437AR 447AL 447AR

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ALERT ALERT
4. Do an open hole HFEC inspection of each fastener hole in accordance with Figure 3.

a. If any crack is found in the midspar fitting, and the hole size is greater than 0.5322 inch, do

Part 4 - Terminating Action.

b. If any crack is found in the midspar fitting, and the hole size is less than 0.5322 inch, do the

following:

(1) Oversize the hole to remove any crack. Oversize to 0.5146 - 0.5166 inch for first oversize,

or 0.5302 - 0.5322 inch for second oversize.

(2) Inspect the fastener hole again for any crack.

(a) If the fastener hole still has any crack, do Part 4 - Terminating Action.

(b) If any crack has been removed, install the correct fastener in accordance with Figure

4.

c. If no crack is found in the midspar fitting, and fastener hole size is less than or equal to 0.5322

inch, do Part 3 - Hole Rework.

d. If no crack is found in the midspar fitting, and hole size is greater than 0.5322 inch, do Part 4

- Terminating Action or contact Boeing for repair instructions.

5. If the strut was removed, install the strut. Refer to 767 AMM 54-51-01 as an accepted procedure.

6. If the engine was removed, install the engine. Refer to 767 AMM 71-00-02 as an accepted

procedure.

7. Reinstall the following access panels. Refer to 767 AMM 06-43-00 as an accepted procedure.

Left Strut Right Strut

Left Side Right Side Left Side Right Side

432FL 432FR 442FL 442FR

436AL 436AR 446AL 446AR

437AL 437AR 447AL 447AR

8. Return airplane to serviceable condition.

PART 3 - HOLE REWORK

1. Do the hole rework in accordance with Figure 4.

PART 4 - TERMINATING ACTION

1. Do the Strut Improvement Program (SIP) service bulletins (767-54-0080 for Pratt-Whitney powered

airplanes or 767-54-0081 for General Electric powered airplanes). Boeing recommends completion

of full SIP modification if a midspar fitting is found cracked. However, it is optional to do parts of

the SIP service bulletins until the full SIP can be completed. The following work is considered the

minimum activities required for terminating action of this service bulletin.

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ALERT ALERT
Group 1-3:

Pratt and Whitney powered airplanes:

a. Do the Preparation and Access section of SB 767-54-0080, as necessary, in accordance with

the ACCOMPLISHMENT INSTRUCTIONS - WORK INSTRUCTIONS.

b. Do the following strut rework:

(1) Do SB 767-54-0080, Figures 3 through 35 as applicable to your airplane.

(2) If there is evidence of shim migration under the upper spar fitting, do the upper spar fitting

bolt replacement in accordance with SB 767-54-0080, Figure 36.

(3) If there is evidence of shim migration under the lower spar fitting, do the lower spar fitting

inspection/rework in accordance with SB 767-54-0080, Figure 37 or 38.

NOTE: If the lower spar fitting fasteners are replaced with external wrenching bolts, the

diagonal brace must be replaced with a new three piece brace. Replace

311T3730-( ) (Used on all JT9D powered airplanes except V6228 - V6230) with

311T3735-1. Replace 311T4730-() (Used on V6228 - V6230) with 311T4735-1.

Install the diagonal brace and, if necessary, adjust the length in accordance with

SB 767-54A0094, Figure 5.

(4) Do the inspection tasks and, if necessary, the corresponding repairs in accordance with

SB 767-54-0052 Strut - Aft Lower Spar - Fastener Corrosion - Inspection and Replacement.

(5) Do the inspection tasks and, if necessary, the corresponding repairs in accordance with

SB 767-54-0061 Wing to Strut Attach Fittings - Lower Spar Bushing Inspection and

Replacement.

(6) Replace sealant where necessary in accordance with SB 767-54-0080, Figure 39.

(7) Do the strut restoration in accordance with SB 767-54-0080, Figure 40.

c. Get access to the wing, as necessary, while performing the remaining work, in accordance

with SB 767-54-0080, Figure 41, 42, or 43, as applicable for your airplane.

d. Determine the remaining work required for your airplane based on group and midspar fitting

condition in accordance with the following table:

Requirements Group 1 Group 2 Group 3

with

midspar

fitting condition (b)

with

midspar

fitting condition (a)

with

midspar

fitting condition (b)

with

midspar

fitting condition (a)

with

midspar

fitting condition (b)

with

midspar

fitting condition (a)

767-54A0062 (c) x x x

767-54-0069 All Figures x x

767-57-0063 (c) x x x x x x

767-54-0072 (c) x x

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ALERT ALERT
767-54-0074 (c) x x x x x x

767-54A0094 (c) x x x x

Inspect Diagonal Brace Pins (d) x x x

Inspect Diagonal Brace (e) x x x

Replace Diagonal Brace Pins (f) x x x

Replace Midspar Fuse Pins (g) x

Inspect Upper Link Fuse Pins (h) x x x

Upper and/or lower horizontal tang cracked. Tang is not severed and crack does not extend through

two holes.

(a)

Upper and lower tang cracked. At least one tang completely severed or cracked through two fastener

holes.

(b)

(c) Do the inspection tasks and, if necessary, the corresponding repairs.

Do a high frequency eddy current (HFEC) inspection and/or a magnetic particle inspection of the diagonal brace fuse pin and secondary pin. Replace if necessary with new pins of the same part number.

Or, if the diagonal brace is being replaced in accordance with SB 767-54A0094, do the diagonal brace

fuse pin and secondary pin replacement in accordance with SB 767-54-0080, Figure 62 or 63, as applicable to your airplane.

(d)

Remove all bushings from the diagonal brace. Do a HFEC inspection or penetrant inspection of the

diagonal brace bores for cracks. Make insurance cuts and install new bushings. Refer to CMM 54-50-

21 as an accepted procedure, or replace the diagonal brace if necessary.

(e)

Replace the diagonal brace fuse pin, secondary pin, through bolts, and nuts with new parts. Or, if the

diagonal brace is being replaced in accordance with SB 767-54A0094, replace the diagonal brace fuse

pin, secondary pin, through bolts, and nuts in accordance with SB 767-54-0080, Figure 62 or 63, as

applicable to your airplane.

(f)

Replace 311T3102-() midspar fuse pins and hardware in accordance with SB 767-54-0080, Figure 62

or 63, as applicable to your airplane.

(g)

Do a HFEC and/or magnetic particle inspection of the upper link fuse pins and secondary pins. Visually

inspect for crankshafting. Replace if necessary, with pins of the same part number.

(h)

e. Do the Restoration section of SB 767-54-0080, as necessary, in accordance with the

ACCOMPLISHMENT INSTRUCTIONS - WORK INSTRUCTIONS.

NOTE: If the existing side links do not fit after strut modifications, do the applicable side link

replacement procedures in accordance with SB 767-54-0080, Figures 62, 63, or 64.

Group 4-6:

General Electric powered airplanes:

a. Do the Preparation and Access section of SB 767-54-0081, as necessary, in accordance with

the ACCOMPLISHMENT INSTRUCTIONS - WORK INSTRUCTIONS.

b. Do the following strut rework:

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
(1) Do SB 767-54-0081, Figures 3 through 21 as applicable to your airplane.

(2) Replace sealant where necessary in accordance with SB 767-54-0081, Figure 22.

(3) Do the strut restoration in accordance with SB 767-54-0081, Figure 23.

c. Get access to the wing, as necessary, while performing the remaining work, in accordance

with SB 767-54-0081, Figure 24, 25, or 26, as applicable to your airplane.

d. Determine the remaining work required for your airplane based on group and midspar fitting

condition in accordance with the following table:

Requirements Group 4 Group 5 Group 6

with

midspar

fitting condition (b)

with

midspar

fitting condition (a)

with

midspar

fitting condition (b)

with

midspar

fitting condition (a)

with

midspar

fitting condition (b)

with

midspar

fitting condition (a)

767-54A0062 (c) x x

767-54-0069 All Figures x x

767-57-0063 (c) x x x x x x

767-54-0072 (c) x x x

767-54-0074 (c) x x x x x x

767-54A0094 (c) x x x x

Inspect Diagonal Brace Pins (d) x x x

Inspect Diagonal Brace (e) x x x

Replace Diagonal Brace Pins (f) x x x

Replace Midspar Fuse Pins (g) x

Inspect Upper Link Fuse Pins (h) x x x

Upper and/or lower horizontal tang cracked. Tang is not severed and crack does not extend through

two holes.

(a)

Upper and lower tang cracked. At least one tang completely severed or cracked through two fastener

holes.

(b)

(c) Do the inspection tasks and, if necessary, the corresponding repairs.

Do a high frequency eddy current (HFEC) inspection and/or a magnetic particle inspection of the diagonal brace fuse pin and secondary pin. Replace if necessary with new pins of the same part number.

Or, if the diagonal brace is being replaced in accordance with SB 767-54A0094, replace the diagonal

brace fuse pin and secondary pin in accordance with SB 767-54-0081, Figure 45.

(d)

Remove all bushings from the diagonal brace. Do a HFEC inspection or penetrant inspection of the diagonal brace bores for cracks. Make insurance cuts and install new bushings. Refer to CMM 54-50-21

as an accepted procedure, or replace the diagonal brace if necessary.

(e)

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
Replace the diagonal brace fuse pin, secondary pin, through bolts, and nuts with new parts. Or, if the

diagonal brace is being replaced in accordance with SB 767-54A0094, replace the diagonal brace fuse

pin, secondary pin, through bolts, and nuts in accordance with SB 767-54-0081, Figure 45.

(f)

(g) Replace 311T3102-( ) midspar fuse pins and hardware in accordance with SB 767-54-0081, Figure 45.

Do a HFEC and/or magnetic particle inspection of the upper link fuse pins and secondary pins. Visually

inspect for crankshafting. Replace if necessary, with pins of the same part number.

(h)

e. Do the Restoration section of SB 767-54-0081, as necessary, in accordance with the

ACCOMPLISHMENT INSTRUCTIONS - WORK INSTRUCTIONS.

NOTE: If the existing side links do not fit after strut modification, do the applicable side link

replacement procedures in accordance with SB 767-54-0081, Figure 45 or 46.

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
FIGURE 1: INSPECTION THRESHOLD AND REINSPECTION INTERVALS

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 1: INSPECTION THRESHOLD AND REINSPECTION INTERVALS

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
FLAG NOTES

NOTE

1 This flag note was deleted.

Optional surface HFEC inspection can be accomplished at the outboard fitting upper tang location

to extend the repeat inspection at this location only. Refer to Table 1.

2

3 This flag note was deleted.

It is optional to do a surface HFEC inspection in accordance with 767 NDT Part 6, 51-00-12 or 767

NDT Part 6, 51-00-21, around the heads and tails of the forward most two fasteners in the inspection

area of each fitting if these fasteners cannot be removed due to interference with adjacent structure.

Shorter reinspection intervals will apply in accordance with Table 2.

4

For airplanes that are in the process of repeating the Part 1 - Detailed Inspections, do the initial surface

HFEC inspection of the closeout angle during the next scheduled Part 1 inspection. As an option to

doing surface HFEC inspections of the closeout angle, it is acceptable for operators to do open hole

HFEC inspections at the aft-most two fastener locations of each midspar fitting. If this option is done,

the repeat interval for open hole inspection of the aft-most two locations is 6,000 flight cycles, in accordance with Table 2. All other Part 1 inspection requirements remain in effect at the repeat intervals

in accordance with Table 1.

5

TABLE 1 - Reinspection Intervals for Part 1 - Detailed Inspection of Midspar Fitting and Surface High

Frequency Eddy Current (HFEC) Inspection of Closeout Angle

REPEAT INSPECTION INTERVALS

(FLIGHT CYCLES)

ENGINE TYPE INSPECTION LOCATION

400

Pratt-Whitney Inboard and Outboard Fitting, Lower Tang

Closeout Angle common to Inboard and Outboard Fitting, Lower Tang

(a)

Inboard Fitting, Upper Tang

Outboard Fitting, Upper Tang

General Electric Inboard and Outboard Fitting, Lower Tang

Closeout Angle common to Inboard and Outboard Fitting, Lower Tang

(a)

Inboard Fitting, Upper Tang

Outboard Fitting, Upper Tang

(a) Repeat inspection interval is 6,000 flight cycles at this location if open hole HFEC inspection is done in

place of surface HFEC inspection at the aft-most two fastener locations.

FIGURE 1: INSPECTION THRESHOLD AND REINSPECTION INTERVALS

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
Table 2 - Reinspection Intervals for Part 2 - Open Hole HFEC Inspection

REPEAT INSPECTION INTERVALS

(FLIGHT CYCLES)

ENGINE TYPE INSPECTION LOCATION

6,000

Pratt-Whitney Inboard and Outboard Fitting, Lower Tang

Inboard Fitting, Upper Tang

Outboard Fitting, Upper Tang

General Electric Inboard and Outboard Fitting, Lower Tang

Inboard Fitting, Upper Tang

Outboard Fitting, Upper Tang

NOTE:

Repeat inspection interval is 3,000 flight cycles at the two forward fastener locations when surface HFEC is

done as specified in flag note 4.

FIGURE 1: INSPECTION THRESHOLD AND REINSPECTION INTERVALS

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 2: MIDSPAR FITTING INSPECTION (DETAILED)

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

FIGURE 2: MIDSPAR FITTING INSPECTION (DETAILED)

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT
STEP TASK NAME PROCEDURE REFERENCES NOTES

1 Remove Sealant - - if present (a) (b)

2 Clean Midspar Fitting - SOPM 20-30-03

Use of a borescope

is recommended.

3 Inspect Midspar Fitting Detailed (c) -

around the aft most

two fasteners at the

midspar fitting lower

tang.

767 NDT Part 6, 51-

00-01 or 767 NDT Part

6, 51-00-19.

4 Inspect Closeout Angle Surface HFEC (e)

Touch-up bare surfaces as required.

Apply Low Hydrogen Embrittlement

Stylus Cadmium

Plating. Refer to

SOPM 20-42-10 as

an accepted procedure.

5 Apply Plating - -

Primer - - BMS 10-79, Type III

For inboard and outboard fitting, upper tang, remove sealant 0.5 inch from the edge of fitting. For inboard

and outboard fitting, lower tang, remove fillet sealant between the closeout angle and midspar chord.

(a)

(b) For outboard fitting, upper tang, remove cap sealant if HFEC inspection method will be used.

Optional surface HFEC inspection at outboard fitting, upper tang only if longer reinspection intervals

is desired, in accordance with 767 NDT Part 6, 51-00-12 or 767 NDT Part 6, 51-00-21.

(c)

(d) This information was deleted.

As an option to doing surface HFEC inspections of the closeout angle, it is acceptable for operators

to do open hole HFEC inspections at the aft-most two fastener locations of each midspar fitting. If this

option is done, the repeat interval for open hole inspection of the aft-most two locations is 6,000 flight

cycles, in accordance with Figure 1, Table 2. All other Part 1 inspection requirements remain in effect

at the repeat intervals in accordance with Figure 1, Table 1.

(e)

FIGURE 2: MIDSPAR FITTING INSPECTION (DETAILED)

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 767-54A0101

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 numbers of parts necessary for one side of the airplane.

FIGURE 3: MIDSPAR FITTING FASTENER HOLE INSPECTION (HFEC)

(SHEET 1 OF 2)

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ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

Remove/ Fastener - 16

Discard

1

2 Clean Holes - 16 SOPM 20-30-03

HFEC in accordance with 767 NDT

Part 6, 51-00-16 for aluminum or 767

NDT Part 6, 51-00-17 for steel.

3 Inspect Holes - 12

HFEC in accordance with 767 NDT

Part 6, 51-00-16 for aluminum or 767

NDT Part 6, 51-00-17 for steel.

4 Inspect Holes - 4

NOTE:

It is optional to do a surface HFEC inspection around the heads and tails of the forward most two fasteners of each fitting if these fasteners cannot be removed due to interference with adjacent structure,

in accordance with HFEC in accordance with 767 NDT Part 6, 51-00-12 or 767 NDT Part 6, 51-00-21.

Shorter reinspection intervals will apply in accordance with Figure 1, Table 2.

FIGURE 3: MIDSPAR FITTING FASTENER HOLE INSPECTION (HFEC)

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-54A0101

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 numbers of parts necessary for one side of the airplane.

FIGURE 4: MIDSPAR FITTING FASTENER HOLE REWORK

(SHEET 1 OF 4)

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ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

Measure/ Hole Diameter - 16

Record

1

HOLE SIZE <= 0.5010 INCH

2 Install Bolt BACB30LE8K24 4 (a) (c) (d)

Bolt BACB30LE8K22 4 (b) (c) (d)

Washer BACW10BP8ACU 4 under bolt head. (e)

up to two (2) allowed to adjust grip length.

(f)

Washer BACW10BP8DP -

Nut BACN10HR8CS 4

3 Install Bolt BACB30MY16K18 8 (a) (c) (k)

Bolt BACB30MY16K16 8 (b) (c) (k)

one allowed under head, if necessary, to

adjust grip length (e)

Washer BACW10BP8ACU -

up to two (2) allowed under collar to adjust

grip length. (f)

Washer BACW10BP8DP -

Collar BACC30M16 8

4 Install Bolt BACB30MY16K14 4 (a) (c) (k)

Bolt BACB30MY16K12 4 (b) (c) (k)

one allowed under head, if necessary, to

adjust grip length (e)

Washer BACW10BP8ACU -

up to two (2) allowed under collar to adjust

grip length. (f)

Washer BACW10BP8DP -

Collar BACC30M16 4

0.5010 INCH < HOLE SIZE <= 0.5322 INCH

to 0.5146-0.5166 inch for first oversize or

0.5302-0.5322 inch for second oversize.

5 Oversize Hole - 16

BACB30LE8K24X or 4 (a) (c) (d)

BACB30LE8K24Y

6 Install Bolt

BACB30LE8K22X or 4 (b) (c) (d)

BACB30LE8K22Y

Bolt

BACW10BP81ACU or 4 under bolt head. (g) (i)

BACW10BP82ACU

Washer

up to two (2) is allowed to adjust grip length.

(h) (j)

BACW10BP81DP or -

BACW10BP82DP

Washer

Nut BACN10HR8CS 4

FIGURE 4: MIDSPAR FITTING FASTENER HOLE REWORK

(SHEET 2 OF 4)

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ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

BACB30MY16K18X or 8 (a) (c) (k)

BACB30MY16K18Y

7 Install Bolt

BACB30MY16K16X or 8 (b) (c) (k)

BACB30MY16K16Y

Bolt

one allowed under head, if necessary, to

adjust grip length (g) (i)

BACW10BP81ACU or -

BACW10BP82ACU

Washer

up to two (2) are allowed to adjust grip

length. (h) (j)

BACW10BP81DP or -

BACW10BP82DP

Washer

Collar BACC30R16 8

BACB30MY16K14X or 4 (a) (c) (k)

BACB30MY16K14Y

8 Install Bolt

BACB30MY16K12X or 4 (b) (c) (k)

BACB30MY16K12Y

Bolt

one allowed under head, if necessary, to

adjust grip length (g) (i)

BACW10BP81ACU or -

BACW10BP82ACU

Washer

up to two (2) are allowed to adjust grip

length. (h) (j)

BACW10BP81DP or -

BACW10BP82DP

Washer

Collar BACC30R16 4

Touch-up bare surfaces as required. Apply

Low Hydrogen Embrittlement Stylus Cadmium Plating. Refer to SOPM 20-42-10 as an

accepted procedure.

9 Apply Plating - -

Primer BMS 10-79, Type III - Touch-up bare surfaces as required.

HOLE SIZE > 0.5322 INCH

Part 4 - Termi- - - or contact Boeing for repair instructions.

nating Action

10 not Do

shown

(a) General Electric powered airplane only.

(b) Pratt-Whitney powered airplane only.

(c) Install wet with BMS 5-95 sealant.

BACB30US8K*, BACB30US8K*X, BACB30US8K*Y is optional to BACB30LE8K*, BACB30LE8K*X,

BACB30LE8K*Y respectively.

(d)

(e) BACW10BP8CD, BACW10BP8CTU, BACW10BP8AC, BACW10BP8CK is optional to BACW10BP8ACU.

(f) BACW10BP8AP, BACW10BP8PK is optional to BACW10BP8DP.

BACW10BP81CD, BACW10BP81CTU, BACW10BP81AC, BACW10BP81CK is optional to

BACW10BP81ACU.

(g)

(h) BACW10BP81AP, BACW10BP81PK is optional to BACW10BP81DP.

FIGURE 4: MIDSPAR FITTING FASTENER HOLE REWORK

(SHEET 3 OF 4)

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STEP TASK NAME PART NUMBER QTY NOTES

BACW10BP82CD, BACW10BP82CTU, BACW10BP82AC, BACW10BP82CK is optional to

BACW10BP82ACU.

(i)

(j) BACW10BP82AP, BACW10BP82PK is optional to BACW10BP82DP.

BACB30NX16K*, BACB30NX16K*X, BACB30NX16K*Y is optional to BACB30MY16K*,

BACB30MY16K*X, BACB30MY16K*Y respectively.

(k)

FIGURE 4: MIDSPAR FITTING FASTENER HOLE REWORK

(SHEET 4 OF 4)

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Original Issue: September 23, 1999

Revision 5 June 29, 2010 767-54A0101

49 of 49

BOEING SERVICE BULLETIN 767-54A0101

ALERT ALERT