Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 94 ALERT ALERT 

### Commercial **Airplanes** 

# 777

**ALERT ALERT**  

# Service Bulletin

**Number: 777-78A0065** Original Issue: June 23, 2008 Revision 2: May 06, 2010 ATA System: 7800 7831 5430
**SUBJECT:** EXHAUST (RB211 Trent Engine) - Thrust Reverser System - Inner Wall Thermal Insulation Blanket and Panel Inspection - Sealant, Fasteners, Fittings, and Wall Panel Condition 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.**BLANK PAGE** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

BLANK PAGE**Table of Contents** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**Table of Contents** Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 36 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 36 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 36 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 38 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 42 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 APPENDIX A: INSPECTION EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 APPENDIX B: DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 APPENDIX C: SEALANT REMOVAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 77 APPENDIX D: PDOS FITTING - SEALANT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 78 APPENDIX E: SEALANT RTV106 AND BMS 5-63 TYPE 1 - ACCELERATED CURE PROCESSES . 79 APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS . . . . . . . . . . . . . . . . . . . . . . 81 APPENDIX G: THRUST REVERSER INNER WALL - FIREWALL ZONE. . . . . . . . . . . . . . . . 87 APPENDIX H: PDOS LUG HOLE AND BUSHING DIAMETERS . . . . . . . . . . . . . . . . . . . . 88 APPENDIX I: PROCEDURES TO ESTABLISH THE DISTANCE BETWEEN OVERLAPPED BLANKET FACE SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 9 APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS . . . . . . . . . . . . . . 91**Table of Contents** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

BLANK PAGEOriginal Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 94 ALERT ALERT 

### Commercial **Airplanes** 

# 777

**ALERT ALERT**  

# Service Bulletin

**Number: 777-78A0065** 

### Revision Transmittal Sheet Original Issue: June 23, 2008 Revision 2: May 06, 2010 ATA System: 7800 7831 5430
**SUBJECT:** EXHAUST (RB211 Trent Engine) - Thrust Reverser System - Inner Wall Thermal Insulation Blanket and Panel Inspection - Sealant, Fasteners, Fittings, and Wall Panel Condition

This Revision includes all pages of the service bulletin.
**COMPLIANCE INFORMATION RELATED TO THIS REVISION** Airplanes WC571 thru WC574 were added to this service bulletin effectivity. No more work is necessary on airplanes changed as shown in Revision 1 or the original issue of this service bulletin.
**REASON FOR REVISION** This revision is sent to reference the Structural Repair Manual (SRM) for repairs of the inner wall. The repair information that was previously contained in Appendix B of this service bulletin is now in 777-200 SRM 54-32-01 and 777-300 SRM 54-32-01. Additional changes have been made based on input from operators. These sections were changed: 1. In Description, Section 1.D., maintenance zone information is added. 2. In Compliance, Section 1.E., the following is changed:

A. The related AD information is added. B. Tables 1 and 4 are changed to add the necessary actions for the condition where an inner wall panel bolt hole has been repaired with a titanium bushing. 3. In References, Paragraph 1.J., 777-200 SRM 54-32-01 and 777-300 SRM 54-32-01 is added and the publications that were referenced in Appendix B are removed. Also reference to a Boeing Program Letter and Boeing Service Bulletins are added. 4. Damage Tolerance Based Structural Inspections, Paragraph 1.K.2., is added. 5. The Industry Support Information, Paragraph 2.B., has changed.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** 6. In Work Instructions, Section 3.B., the following is changed: A. A general visual inspection is added for inner wall panel bolt holes that have been repaired with a titanium bushing. B. Reference to the SRM is added for repair of the inner wall. C. The statement "remove all BMS 5-63 Type 2 sealant" is expanded to clarify the intent. D. Reference to CMM 78-31-76 for replacement of inner wall panels is removed. E. A NOTE is added to clarify the intent of the dispatch limits referenced in Work Package 1, Part B. 7. In Appendix B, the inner wall repair information is removed. This repair information is now contained in 777-200 SRM 54-32-01 and 777-300 SRM 54-32-01. 8. In Appendix I, another method to determine the overlapped blanket face sheet distance is added. Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. 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: June 23, 2008 Revision 1: January 29, 2009 Revision 2: May 6, 2010Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 94 ALERT ALERT 

### Commercial **Airplanes** 

# 777

**ALERT ALERT**  

# Service Bulletin

**Number: 777-78A0065** 

### Summary Original Issue: June 23, 2008 Revision 2: May 06, 2010 ATA System: 7800 7831 5430
**SUBJECT:** EXHAUST (RB211 Trent Engine) - Thrust Reverser System - Inner Wall Thermal Insulation Blanket and Panel Inspection - Sealant, Fasteners, Fittings, and Wall Panel Condition

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** This service bulletin tells the operator to do inspections. The inspections are of the Thrust Reverser (T/R) inner wall insulation blanket sealant, insulation blanket attachment studs, inner wall panel structural integrity, and fittings. The inspections will make sure that hot air does not infiltrate to the composite inner wall panel to cause disbondments and delaminations in the wall area and weaken the fittings. A T/R inner wall panel could have structural degradation from heat migration through insulation blanket gaps that are not correctly sealed. A degraded T/R inner wall panel could let structural pieces separate from an airplane in flight. A separated T/R piece in flight could cause damage to other airplane areas, or cause injury to persons on the ground. A separated T/R piece at departure could cause a runway excursion because of thrust asymmetry from forward thrust on a Refused Take Off (RTO). Eight 777 Rolls Royce T/R events related to thermal damage of the T/R inner wall have occurred since 2003. The events have included such things as Air Turn Backs (ATB), In Flight Shut Downs (IFSD), T/R inner wall panel sections and parts liberated from the airplane, T/R inner wall panel collapse, and engine fire loop fault messages. No hull loss or personal injury has occurred from these events. Service Bulletins (SB) 777-78A0059 and 777-78-0060 were released in 2005 to inspect the T/R inner wall panel structure and seal the insulation blankets to prevent hot, under cowl air, from contact with the T/R inner wall panel. There have been four events since the release of the 777-78A0059 and 777-78-0060 service bulletins. Two of the post-SB 777-78A0059 and 777-78-0060 events had T/Rs that had not fully accomplished the bulletins. One of the post-SB 777-78A0059 and 777-78-0060 event T/R had not done the bulletins. The fourth post-SB 777-78A0059 and 777-78-0060 event T/R had fully accomplished the bulletins.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** Boeing Service Related Problem (SRP) 777-SRP-78-0052 is related to this service bulletin.

**ACTION** Do a detailed inspection of the T/R insulation blanket sealant at the edges, grommet holes, penetrations, and seams (Work Package 1.A). Do a general visual inspection of the T/R insulation blanket click bond studs, blanket studs, and temporary fasteners (Work Package 1.B). Do an NDT of the full T/R inner wall panel area (Work Package 2). Or, do an NDT of limited areas of the T/R inner wall panel (Work Package 6). Do a detailed inspection of the number 1 compression pad fitting Powered Door Opening System (PDOS) lugs (Work Package 3). Do an NDT of the number 1 upper and number 1 and 2 lower compression pad fittings (Work Package 4). Do a general visual inspection on the perforated side of the T/R inner wall aft of the Intermediate Pressure compressor 8th Stage (IP8) duct and High Pressure compressor 3rd Stage (HP3) duct (Work Package 5). It is necessary to remove and install (and seal) insulation blankets on the inner wall panel to do Work Package 2, 4, and 6. It may be necessary to remove blankets in Work Package 1A, 1B, and 3. Each work package can be done independently or together. The T/R must be opened to do the work for all work packages except Work Package 5. The work packages must be done and repeated as given in the compliance tables given in Paragraph 1.E, Compliance. **Service History Year of Event//Cycles//Hours Data**  2003 // 5,871 // 17,982 Engine 2 LH TR half. Shorted fire loop fault messages (intermittent) received during descent. Extensive delamination found during ground inspection. 2004 // 4,600 // 13,100 Engine 1 LH TR half. Extensive delamination found during ground inspection during a planned engine change. 2004 // 6,160 // 15,472 Engine 2 LH TR half. Damage seen on arrival. Large portion of inner wall missing. Debris on runway. Nozzle outer sleeve not found. 2004 // 6,600 // 16,600 Engine 1 LH TR half. Panel collapsed during takeoff. Parts liberated. ATB performed. Nozzle outer sleeve landed on vehicle. 2006 // 2,450 // 13,124 Engine 2 Right Hand (RH) TR half. Exhaust Gas Temperature (EGT) fluctuation during climb out and fire loop fault messages. Flight continued, damage found during ground inspection. 2006 // 5,782 // 37,687 Engine 1 RH TR half. Panel collapsed during takeoff. Parts liberated. ATB performed. 2007 // 7,627 // 26,963 Engine 2 RH TR half. Engine fire warning after takeoff. IFSD and ATB performed. Extensive delamination found during ground inspection. 2007 // 9,770 // 34,895 Engine 2 RH TR half. Intermittent status message "LOOP 1 ENG R" and "OVERHEAT CIRCUIT R," but no warning messages. Damage seen on arrival. Large portion of inner wall missing. Debris on takeoff runwayOriginal Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** AMM 78-31-06 gives limited use of sealant in grommet holes when fasteners are missing. The detailed inspection of grommet holes is limited to those grommets filled with sealant as a temporary replacement for missing T/R insulation blanket click bond studs, blanket studs, and temporary fasteners. Replacement of BMS 5-63 Type 2 sealant with BMS 5-63 Type 1 is necessary in the firewall zone areas where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, replacement of BMS 5-63 Type 2 sealant with BMS 5-63 Type 1 is necessary in the firewall zone where blanket edges do not overlap other blankets, such as on the forward, upper, or aft edges of the T/R. In other areas, satisfactory sealant is covered with RTV106. It is also necessary to seal the PDOS rod end and number 1 compression pad lugs. Inspection results can make it necessary to: — repair and/or replace sealant — remove and install insulation blankets — NDT inspect inner wall panel areas — NDT inspect compression pad fittings, and PDOS fitting or bushings — repair inner wall panel areas — replace compression pads, and PDOS fitting or bushings — replace click bonds or other blanket attachments
**EFFECTIVITY** 777-200 and 777-300 airplanes with Rolls-Royce RB211 Trent 800 engines. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
**COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. See Service Bulletin Paragraph 1.E. for compliance information.
**INDUSTRY SUPPORT INFORMATION** Boeing Industry Support information is provided in Program Letter M-1151-777-PGM-187, dated October 13, 2008. Additional copies of program letters are available from Boeing Commercial Airplanes Group - Warranties.

**MANPOWER** The following estimate does not include repair or sealant cure time. **Each Engine Thrust Reverser Half Work Total Task Hours Elapsed Hours**  Package 1, Part A (a) 2.50 2.00

Package1, Part B 2.00 1.50 Package 2 28.55 18.65 Package 3 4.00 4.00 Package 4 7.00 6.00Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability. Package 5 2.00 2.00 Package 6 27.35 17.95 (a) A one time manpower charge for BMS 5-63 Type 2 removal

and installation of sealant BMS 5-63 Type 1 or RTV 106, is acceptable. Add 27.50 Total Task Hours and 14.50 Elapsed Hours for the one time manpower charge. **Each Engine Thrust Reverser Half Work Total Task Hours Elapsed Hours** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 94 ALERT ALERT 

### Commercial **Airplanes** 

# 777

**ALERT ALERT**  

# Service Bulletin

**Number: 777-78A0065** Original Issue: June 23, 2008 Revision 2: May 06, 2010 ATA System: 7800 7831 5430
**SUBJECT:** EXHAUST (RB211 Trent Engine) - Thrust Reverser System - Inner Wall Thermal Insulation Blanket and Panel Inspection - Sealant, Fasteners, Fittings, and Wall Panel Condition

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 D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.

Airplane models:

777-200 777-300
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AIR NEW ZEALAND (ANZ) 1 WC486–WC493 AMERICAN AIRLINES (AAL) 1 WB416–WB439 WC051–WC073 BRITISH AIRWAYS (BAB) 1 WB031–WB046 WC571–WC574 **GROUP CONFIGURATION DESCRIPTION**1 - 777-200 and 777-300 airplanes with RollsRoyce RB211 Trent 800 enginesOriginal Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** CATHAY PACIFIC AIRWAYS (CAT) 1 WA001 WA101–WA104 WB501–WB512 DELTA AIR LINES (DAL) 1 WB446–WB453 EL AL ISRAEL AIRLINES (ELA) 1 WC101–WC104 WC566–WC567 EMIRATES (EAD) 1 WA196–WA198 WB101–WB106 WB631–WB638 WB646–WB649 KENYA AIRWAYS (KEN) 1 WC456–WC459 MALAYSIA AIRLINES (MAS) 1 WB161–WB177 SINGAPORE AIRLINES (SIA) 1 WB181–WB194 WB201–WB215 WB231–WB247 WB611–WB622 THAI AIRWAYS INTERNATIONAL (TII) 1 WA086–WA093 WB601–WB606 WC531–WC536
IDENTIFICATION BY VARIABLE NUMBER
**Variable Group** WA001 1 WA086–WA093 1 WA101–WA104 1 WA196–WA198 1 WB031–WB046 1 WB101–WB106 1 WB161–WB177 1 WB181–WB194 1 WB201–WB215 1 WB231–WB247 1 WB416–WB439 1 WB446–WB453 1 WB501–WB512 1 WB601–WB606 1 WB611–WB622 1 WB631–WB638 1 WB646–WB649 1 WC051–WC073 1 WC101–WC104 1Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

2. Spares Affected It is necessary to include this service bulletin on spare Thrust Reversers. **B. Concurrent Requirements**

None.
**C. Reason** This service bulletin tells the operator to do inspections. The inspections are of the Thrust Reverser (T/R) inner wall insulation blanket sealant, insulation blanket attachment studs, inner wall panel structural integrity, and fittings. The inspections will make sure that hot air does not infiltrate to the composite inner wall panel to cause disbondments and delaminations in the wall area and weaken the fittings. A T/R inner wall panel could have structural degradation from heat migration through insulation blanket gaps that are not correctly sealed. A degraded T/R inner wall panel could let structural pieces separate from an airplane in flight. A separated T/R piece in flight could cause damage to other airplane areas, or cause injury to persons on the ground. A separated T/R piece at departure could cause a runway excursion because of thrust asymmetry from forward thrust on a Refused Take Off (RTO). Eight 777 Rolls Royce T/R events related to thermal damage of the T/R inner wall have occurred since 2003. The events have included such things as Air Turn Backs (ATB), In Flight Shut Downs (IFSD), T/R inner wall panel sections and parts liberated from the airplane, T/R inner wall panel collapse, and engine fire loop fault messages. No hull loss or personal injury has occurred from these events. Service Bulletins (SB) 777-78A0059 and 777-78-0060 were released in 2005 to inspect the T/R inner wall panel structure and seal the insulation blankets to prevent hot, under cowl air, from contact with the T/R inner wall panel. There have been four events since the release of the 777-78A0059 and 777- 78-0060 service bulletins. Two of the post-SB 777-78A0059 and 777-78-0060 events had T/Rs that had not fully accomplished the bulletins. One of the post-SB 777-78A0059 and 777-78-0060 event T/ R had not done the bulletins. The fourth post-SB 777-78A0059 and 777-78-0060 event T/R had fully accomplished the bulletins. WC456–WC459 1 WC486–WC493 1 WC531–WC536 1 WC566–WC567 1 WC571–WC574 1 **Variable Group**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

Boeing Service Related Problem (SRP) 777-SRP-78-0052 is related to this service bulletin.

Revision 1 is sent to tell operators that this service bulletin is approved as an alternative method of compliance (AMOC) to Airworthiness Directive (AD) 2005-07-24. Also, this revision is sent to correct errors in the service bulletin and to further clarify information based on operator input. The data given in Information Notice 777-78A0065 IN 01 is included in Revision 1. Revision 2 is sent to reference the Structural Repair Manual (SRM) for repairs of the inner wall. The repair information that was previously contained in Appendix B of this service bulletin is now in 777-200 SRM 54-32-01 and 777-300 SRM 54-32-01. Additional changes have been made based on input from operators. **Service History Year of Event//Cycles//Hours Data**  2003 // 5,871 // 17,982 Engine 2 LH TR half. Shorted fire loop fault messages (intermittent) received during descent. Extensive delamination found during ground inspection. 2004 // 4,600 // 13,100 Engine 1 LH TR half. Extensive delamination found during ground inspection during a planned engine change. 2004 // 6160 // 15,472 Engine 2 LH TR half. Damage seen on arrival. Large portion of inner wall missing. Debris on runway. Nozzle outer sleeve not found. 2004 // 6,600 // 16,600 Engine 1 LH TR half. Panel collapsed during takeoff. Parts liberated. ATB performed. Nozzle outer sleeve landed on vehicle. 2006 // 2,450 // 13,124 Engine 2 Right Hand (RH) TR half. Exhaust Gas Temperature (EGT) fluctuation during climb out and fire loop fault messages. Flight continued, damage found during ground inspection. 2006 // 5,782 // 37,687 Engine 1 RH TR half. Panel collapsed during takeoff. Parts liberated. ATB performed. 2007 // 7,627 // 26,963 Engine 2 RH TR half. Engine fire warning after takeoff. IFSD and ATB performed. Extensive delamination found during ground inspection. 2007 // 9,770 // 34,895 Engine 2 RH TR half. Intermittent status message "LOOP 1 ENG R" and "OVERHEAT CIRCUIT R," but no warning messages. Damage seen on arrival. Large portion of inner wall missing. Debris on takeoff runwayOriginal Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT D. Description**  Do a detailed inspection of the T/R insulation blanket sealant at the edges, grommet holes, penetrations, and seams (Work Package 1.A). Do a general visual inspection of the T/R insulation blanket click bond studs, blanket studs, and temporary fasteners (Work Package 1.B). Do an NDT of the full T/R inner wall panel area (Work Package 2). Or, do an NDT of limited areas of the T/R inner wall panel (Work Package 6). Do a detailed inspection of the number 1 compression pad fitting Powered Door Opening System (PDOS) lugs (Work Package 3). Do an NDT of the number 1 upper and number 1 and 2 lower compression pad fittings (Work Package 4). Do a general visual inspection on the perforated side of the T/R inner wall aft of the Intermediate Pressure compressor 8th Stage (IP8) duct and High Pressure compressor 3rd Stage (HP3) duct (Work Package 5). It is necessary to remove and install (and seal) insulation blankets on the inner wall panel to do Work Package 2, 4, and 6. It may be necessary to remove blankets in Work Package 1A, 1B, and 3. Each work package can be done independently or together. The T/R must be opened to do the work for all work packages except Work Package 5. The work packages must be done and repeated as given in the compliance tables given in Paragraph 1.E, Compliance.

**NOTE:** AMM 78-31-06 gives limited use of sealant in grommet holes when fasteners are missing. The detailed inspection of grommet holes is limited to those grommets filled with sealant as a temporary replacement for missing T/R insulation blanket click bond studs, blanket studs, and temporary fasteners. Replacement of BMS 5-63 Type 2 sealant with BMS 5-63 Type 1 is necessary in the firewall zone areas where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, replacement of BMS 5-63 Type 2 sealant with BMS 5-63 Type 1 is necessary in the firewall zone where blanket edges do not overlap other blankets, such as on the forward, upper, or aft edges of the T/R. In other areas, satisfactory sealant is covered with RTV106. It is also necessary to seal the PDOS rod end and number 1 compression pad lugs. Inspection results can make it necessary to: — repair and/or replace sealant — remove and install insulation blankets — NDT inspect inner wall panel areas — NDT inspect compression pad, and PDOS fitting or bushings — repair inner wall panel areas — replace compression pad fittings, and PDOS fitting or bushings — replace click bonds or other blanket attachments Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. Revision 2 - No more work is necessary on airplanes changed as shown in Revision 1 or the original issue of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.

**Affected Maintenance Zones Model Zone**  777-200, 777-300 415, 416, 425, 426Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **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. Federal Aviation Administration (FAA) Airworthiness Directive 2005-07-24 is related to service bulletins 777-78A0059 and 777-78-0060, which are related to this service bulletin. Boeing recommends to do the inspections and repeat inspection on all airplanes, each T/R half, as given in Tables 1 thru 4. Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)** All airplanes, each T/R half Check maintenance records for sealant added because of Multi Operator Message 1- 397934790-1. Within 1,500 flight hours after the date on the original issue of this service bulletin -Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

Sealant was added to insulation blankets around compression pads because of Multi Operator Message 1- 397934790-1 For areas where sealant was added, do the work described in 3.B.WORK PACKAGE 1, PART A, for sealant cracks larger than 0.100 inch. Within 1,500 flight hours after the date on the original issue of this service bulletin. -

Do a detailed inspection of inner wall insulation blanket edges, grommet holes (a), penetrations, and seams, for sealant that has cracks, gaps, is loose, or missing as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Within 1,500 flight hours after the date on the original issue of this service bulletin. 1,500 flight hours

General visual inspection of click bond studs, blanket studs, and temporary fasteners as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART B. Within 1,500 flight hours after the date on the original issue of this service bulletin 1,500 flight hours

In the firewall zone, replace BMS 5-63 Type 2 sealant with BMS 5-63 Type 1 sealant, as applicable.

And
In other areas, remove unsatisfactory BMS 5-63 Type 2 sealant. Cover satisfactory BMS 5-63 Type 2 sealant with RTV106. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Within 1,500 flight hours after the date on the original issue of this service bulletin - Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

No sealant was added to insulation blankets around compression pads because of Multi Operator Message 1- 397934790-1 Do a detailed inspection of inner wall insulation blanket edges, grommet holes (a), penetrations, and seams, for sealant that has cracks, gaps, is loose, or missing as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Within 1,500 flight hours after the date on the original issue of this service bulletin 1,500 flight hours

General visual inspection of click bond studs, blanket studs, and temporary fasteners as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART B. Within 1,500 flight hours after the date on the original issue of this service bulletin 1,500 flight hours

In the firewall zone, replace BMS 5-63 Type 2 sealant with BMS 5-63 Type 1 sealant, as applicable.

And
In other areas, remove unsatisfactory BMS 5-63 Type 2 sealant. Cover satisfactory BMS 5-63 Type 2 sealant with RTV106 sealant. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Within 1,500 flight hours after the date on the original issue of this service bulletin -

T/R insulation blanket edge, grommet hole (a), penetration, or seam, has sealant cracks, gaps, is loose, or is missing sections greater than 0.100 inch. Measure the distance between the overlapped blanket face sheets on a blanket seam or the distance between the inner wall and the insulation blanket on a blanket edge adjacent to the damaged or missing sealant. (d) Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Before further flight - Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

The overlapped blanket facesheet distance or the distance between the inner wall and the insulation blanket adjacent to the damaged or missing sealant is less than or equal to 0.100 inch. Assume the damaged or missing sealant is less than or equal to 0.100 inch across. Therefore, replace damaged or missing sealant as given inthe accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Before further flight -

The overlapped blanket facesheet distance or the distance between the inner wall and the insulation blanket adjacent to the damaged or missing sealant is more than 0.100 inch. Remove the insulation blanket(s) adjacent to crack, gap, loose, or missing sealant. (d)

And Do an NDT and general visual inspection for thermal degradation of the exposed T/R inner wall panel area that is within 12 inches of the crack, gap, loose, or missing sealant.

And

Do an NDT of an uncovered compression pad if it is within 12 inches of the crack, gap, loose, or missing sealant. (c) Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Before further flight -

T/R insulation blanket edge, grommet hole (a), penetration, or seam, has sealant cracks, gaps, is loose, or is missing sections that are equal to, or less than 0.100 inch Replace damaged or missing sealant as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A. Before further flight - Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

Click bond stud, blanket stud, or temporary fastener is loose, damaged, or missing more than dispatch limits. (b) Remove insulation blankets as necessary.
And Do an NDT and general visual inspection for thermal degradation of the exposed T/R inner wall panel area that is within 12 inches of the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener.

And

Do an NDT of an uncovered compression pad if it is within 12 inches of the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener. (c)

And Install replacement click bonds, blanket studs, or temporary fasteners. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART B. Before further flight - Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

Unsatisfactory compression pad found. (c) Remove unsatisfactory compression pad, NDT the T/R inner wall panel where fitting was installed.

And Do a general visual inspection for areas of thermal degradation.

And Do a detailed inspection of the T/R inner wall panel bolt holes for elongation.

And

Install serviceable compression pad fitting. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 1, PART A, or WORK PACKAGE 1, PART B. Before further flight -

Inner wall panel bolt hole for the unsatisfactory and removed compression pad fitting has been repaired with a titanium bushing. Do a general visual inspection of the bushing for migration or looseness as given in the accomplishment instructions of 3.B.WORK PACKAGE 1,PART A, or WORK PACKAGE 1, PART B. Before further flight -

Bushing migration or looseness is found. Remove the bushing and repair the inner wall panel bolthole as given in the accomplishment instructions of 3.B.WORK PACKAGE 1,PART A, or WORK PACKAGE 1, PART B. Before further flight -

Bushing migration or looseness is not found. None - - Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

Area of thermal degradation is found. Do a Barcol hardness test of the area as given in the accomplishment instructions of 3.B. WORK PACKAGE 1, PART A, or WORK PACKAGE 1, PART B. Before further flight -

Delaminated, disbonded, soft areas, or elongated bolt holes are found on the T/R inner wall panel. Repair T/R inner wall panel, and install removed insulation blankets and fittings.
Or Contact Boeing for repair instructions and do repair, and install removed insulation blankets and fittings.
Or Replace the T/R inner wall panel with a serviceable one, and install the removed insulation blankets and fittings. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 1, PART A, or WORK PACKAGE 1, PART B. Before further flight -

No delaminated, disbonded, thermally degraded, soft areas, or elongated bolt holes are found on the T/R inner wall panel. Install removed insulation blankets and fittings as given in accomplishment instructions of 3.B.WORK PACKAGE 1, PART A, or WORK PACKAGE 1, PART B. Before further flight -

Compression pad fittings are satisfactory from NDT. (c) Install removed insulation blankets as given in accomplishment instructions of 3.B.WORK PACKAGE 1, PART A, or WORK PACKAGE 1, PART B. Before further flight -

Sealant and click bond studs, blanket attachments, and temporary fasteners are satisfactory. None - - Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

(a) AMM 78-31-06 gives limited use of sealant in grommet holes when fasteners are missing. The detailed inspection of grommet holes is limited to those grommets filled with sealant as a temporary replacement for missing T/R insulation blanket click bond studs, blanket studs, and temporary fasteners. (b) 777 AMM 78-31-06 has dispatch limits for insulation blanket attachments. (c) It is only necessary to inspect the number 1 upper and number 1 and 2 lower compression pad fittings. If a blanket that covers a different compression pad fitting is removed, it is not necessary to inspect the compression pad fitting. (d) For the initial inspection of each T/R, it is not necessary to remove insulation blankets due to damaged or missing sealant on the forward, upper, or aft edges of the thrust reverser. Damaged or missing sealant found on the forward, upper, or aft edges of the T/R during the initial inspection can be assumed to be less than or equal to 0.100 inch across. Table 1: Thrust Reverser - Inspections and Repair - Insulation Blanket Sealant, Insulation Blanket Attachments, and PDOS lug Sealant

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** Table 2: Thrust Reverser - Inspections and Repair - Inner Wall Panel

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)** All airplanes, each T/R half that has been inspected before the date on this service bulletin based on the inspections described in the accomplishment instructions of 3.B. WORK PACKAGE 2 and 3.B.WORK PACKAGE 5. Do a full inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 2.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 2,000 flight cycles after the date of the operator’s own inspections based on the inspections described in the accomplishment instructions of 3.B. WORK PACKAGE 2 and 3.B. WORK PACKAGE 5. 2,000 flight cycles

Or Do a limited inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 6.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 2,000 flight cycles after the date of the operator’s own inspections based on the inspections described in the accomplishment instructions of 3.B. WORK PACKAGE 2 and 3.B. WORK PACKAGE 5. 700 flight cyclesOriginal Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

All airplanes, each T/R half with more than 10,000 total flight cycles, and was not inspected before the date on this service bulletin based on the inspections described in the accomplishment instructions of 3.B. WORK PACKAGE 2 and 3.B. WORK PACKAGE 5. Do a full inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 2.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 600 flight cycles after the date on the original issue of this service bulletin 2,000 flight cycles

Or Do a limited inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 6.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 600 flight cycles after the date on the original issue of this service bulletin 700 flight cycles Table 2: Thrust Reverser - Inspections and Repair - Inner Wall Panel

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

All airplanes, each T/R half with 5,000 or more total flight cycles, but with less than or equal to 10,000 total flight cycles, and was not inspected before the date on this service bulletin based on the inspections described in the accomplishment instructions of 3.B. WORK PACKAGE 2 and 3.B. WORK PACKAGE 5. Do a full inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 2.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 1,000 flight cycles after the date on the original issue of this service bulletin 2,000 flight cycles

Or Do a limited inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 6.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 1,000 flight cycles after the date on the original issue of this service bulletin 700 flight cycles Table 2: Thrust Reverser - Inspections and Repair - Inner Wall Panel

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

All airplanes, each T/R half with less than 5,000 total flight cycles, and was not inspected before the date on this service bulletin based on the inspections described in the accomplishment instructions of 3.B. WORK PACKAGE 2 and 3.B. WORK PACKAGE 5. Do a full inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 2.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 1,700 flight cycles after the date on the original issue of this service bulletin 2,000 flight cycles

Or Do a limited inner wall panel NDT of each T/R half, and do a general visual inspection for areas of thermal degradation. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 6.

And
Do a General Visual Inspection of the T/R perforated wall aft of the IP8 and the HP3 bleed port exits as given in the accomplishment instructions of 3.B.WORK PACKAGE 5. Within 1,700 flight cycles after the date on the original issue of this service bulletin 700 flight cycles

Area of thermal degradation is found. Do a Barcol hardness test of the area as given in the accomplishment instructions of 3.B. WORK PACKAGE 2, or 3.B. WORK PACKAGE 6. Before further flight - Table 2: Thrust Reverser - Inspections and Repair - Inner Wall Panel

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

Delaminated, disbonded, or soft areas are found on the T/R inner wall panel. Repair T/R inner wall panel, and install insulation blankets.
Or Contact Boeing for repair instructions and do repair, and install insulation blankets.
Or Replace the T/R inner wall panel with a serviceable one, and install insulation blankets. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 2, or 3.B. WORK PACKAGE 6. Before further flight -

No delaminated, disbonded, thermally degraded or soft areas are found on the T/R inner wall panel. Install insulation blankets as given in accomplishment instructions of 3.B. WORK PACKAGE 2, or WORK PACKAGE 6. Before further flight -

Different wall color than normal perforated side wall color is found Do an NDT of the area of different color as given in 3.B.WORK PACKAGE 5. Before further flight -

Delaminated or disbondedareas are found on the perforated side wall Contact Boeing for repair instructions and do the repair. Before further flight -

Different wall color is not found None. - - Table 2: Thrust Reverser - Inspections and Repair - Inner Wall Panel

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** Table 3: Thrust Reverser - Inspection and Repair - PDOS Lugs

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)** All airplanes, each T/R half with more than 10,000 total flight cycles Do a detailed inspection of the PDOS lug bushings on the upper number 1 compression pad fittings as given in he accomplishment instructions of 3.B.WORK PACKAGE 3. Within 600 flight cycles after the date on the original issue of this service bulletin 2,000 flight cycles

All airplanes, each T/R half with 5,000 or more total flight cycles, but with less than or equal to 10,000 total flight cycles Do a detailed inspection of the PDOS lug bushings on the upper number 1 compression pad fittings as given in he accomplishment instructions of 3.B.WORK PACKAGE 3. Within 1,000 flight cycles after the date on the original issue of this service bulletin 2,000 flight cycles

All airplanes, each T/R half with less than 5,000 total flight cycles Do a detailed inspection of the PDOS lug bushings on the upper number 1 compression pad fittings as given in he accomplishment instructions of 3.B.WORK PACKAGE 3. Within 1,700 flight cycles after the date on the original issue of this service bulletin 2,000 flight cycles

The upper number 1 compression pad fitting PDOS lug bushings are unsatisfactory. Remove the bushings and inspect the fitting PDOS lugs. Do this work as given in the accomplishment instructions of 3.B, WORK PACKAGE 3. Before further flight -

The upper number 1 compression pad fitting PDOS lugs are unsatisfactory. Replace unserviceable upper number 1 compression pad fitting and bushings with serviceable ones, and install the PDOS actuator rod and sealant. Do this work as given in the accomplishment instructions of 3.B, WORK PACKAGE 3. Before further flight -

The upper number 1 compression pad fitting PDOS lugs are satisfactory. Replace unserviceable bushings with serviceable ones, and install PDOS actuator rod and sealant. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 3. Before further flight -

The upper number 1 compression pad fitting PDOS lug bushings are satisfactory. Install PDOS actuator rod and sealant as given in the accomplishment instructions of 3.B. WORK PACKAGE 3. Before further flight -Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** Table 4: Thrust Reverser - Inspections and Repair - Compression Pad Fittings

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)** All airplanes, each T/R half Do an NDT of the number 1 upper and number 1 and 2 lower compression pad fittings as given in the accomplishment instructions of 3.B.WORK PACKAGE 4. Within 2,000 flight cycles after the date on the original issue of this service bulletin 2,000 flight cycles

Unsatisfactory compression pad fitting is found. Remove unsatisfactory compression pad fitting.

And
Do an NDT of the T/R inner wall panel where fitting was installed.

And Do a general visual inspection for areas of thermal degradation.

And Do a detailed inspection of the T/R inner wall panel bolt holes for elongation. Do this work as given in the accomplishment instructions of 3.B.WORK PACKAGE 4. Before further flight -

Area of thermal degradation is found. Do a Barcol hardness test of the area as given in the accomplishment instructions of 3.B.WORK PACKAGE 4. Before further flight -

Inner wall panel bolt hole for the unsatisfactory and removed compression pad fitting has been repaired with a titanium bushing. Do a general visual inspection of the bushing for migration or looseness as given in the accomplishment instructions of 3.B.WORK PACKAGE 1,PART A, or WORK PACKAGE 1, PART B. Before further flight -

Bushing migration or looseness is found. Remove the bushing and repair the inner wall panel bolthole as given in the accomplishment instructions of 3.B.WORK PACKAGE 1,PART A, or WORK PACKAGE 1, PART B. Before further flight -Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

**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.Bushing migration or looseness is not found. None - -
Delaminated, disbonded, soft areas, or elongated bolt holes are found on the T/R inner wall panel. Repair T/R inner wall panel, and install removed insulation blankets and serviceable compression pad fittings.
Or Contact Boeing for repair instructions and do repair, and install removed insulation blankets and serviceable compression pad fittings.
Or Replace the T/R inner wall panel with a serviceable one, and install removed insulation blankets and serviceable compression pad fittings. Do this work as given in the accomplishment instructions of 3.B. WORK PACKAGE 4. Before further flight -

No delaminated, disbonded, thermally degraded, soft areas, or elongated bolt holes are found on the T/R inner wall panel. Install removed insulation blankets and serviceable compression pad fittings as given in the accomplishment instructions of 3.B.WORK PACKAGE 4. Before further flight -

Compression pad fittings are satisfactory. Install insulation blankets as given in the accomplishment instructions of 3.B.WORK PACKAGE 4. Before further flight - Table 4: Thrust Reverser - Inspections and Repair - Compression Pad Fittings

**Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

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. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (h) of AD 2005-07- 24. All provisions of AD 2005-07-24 that are not specifically referenced in the above statement remain fully applicable and must be complied with. **G. Manpower** The table below shows an estimate of the task hours necessary to do this service bulletin for each T/ R half. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to inspect the work — Time to cure the materials — Time to make the parts — Time to find the tools.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

**NOTE:** The below estimates do not include the necessary time to make repairs. Work Package 1, Part A - Detailed Inspection Of Insulation Blanket and PDOS Lug Sealant

**Task Number of**  **Persons Task Hours Elapsed Hours** Open Access 2 0.50 0.25 Detailed Inspection 1 1.50 1.50 Close 2 0.50 0.25 TOTAL FOR EACH T/R HALF: 2.50 2.00 TOTAL FOR EACH T/R HALF with one time charge(a) 27.50 14.50
(a) A one time manpower charge is acceptable for: 1) Replacement of BMS 5-63 Type 2 sealant with BMS 5-63 Type 1 in areas of the firewall zone. 2) Application of RTV106 sealant over satisfactory BMS 5-63 Type 2. Work Package 1, Part B - General Visual Inspection Of Insulation Blanket Attachments

**Task Number of**  **Persons Task Hours Elapsed Hours** Open Access 2 0.50 0.25 General Visual Inspection 1 1.00 1.00

Close 2 0.50 0.25 TOTAL FOR EACH T/R HALF: 2.00 1.50 Work Package 2 - NDT Of Inner Wall

**Task Number of**  **Persons Task Hours Elapsed Hours** Open Access 1 0.50 0.50 Remove Insulation Blankets 1 3.25 3.25
NDT 2 19.80 (a) 9.9 (a) Install Insulation Blankets 1 4.50 4.50

Close 1 0.50 0.50 TOTAL FOR EACH T/R HALF: 28.55 (b) 18.65 (b) (a) Estimate does not include time to perform NDT hardness test on areas that show signs of heat distress. If heat distressed areas are found, more time will be necessary to do an NDT hardness test. (b) Estimate does not include time to perform repairs. If repairs are required, more time will be necessary.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** Work Package 3 - Detailed Inspection of PDOS lugs

**Task Number of**  **Persons Task Hours Elapsed Hours** Open Access 1 1.75 1.75 Detailed Inspect 1 0.50 0.50 Restore 1 1.75 1.75 TOTAL FOR EACH T/R HALF: 4.00 4.00 Work Package 4 - NDT Of Compression Pad Fittings

**Task Number of**  **Persons Task Hours Elapsed Hours** Open Access 1 1.50 1.50 Remove Insulation Blankets 1 1.00 1.00

NDT 2 2.00 1.00 Install Insulation Blankets 1 1.00 1.00

Close 1 1.50 1.50 TOTAL FOR EACH T/R HALF: 7.00 6.00 Work Package 5 - Perforated Side Wall Inspection

**Task Number of**  **Persons Task Hours Elapsed Hours** Access 1 0.50 0.50 General Visual Inspection 1 1.00 1.00

Close Access 1 0.50 0.50 TOTAL FOR EACH T/R HALF: 2.00 2.00 Work Package 6 - Limited NDT Of Inner Wall

**Task Number of**  **Persons Task Hours Elapsed Hours** Open Access 1 0.50 0.50 Remove Insulation Blankets 1 3.15 3.15
NDT 2 18.80 (a) 9.40 (a) Install Insulation Blankets 1 4.40 4.40

Close Access 1 0.50 0.50Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

**H. Weight and Balance Changes**

None.

**I. Electrical Load Data** Not changed.
**J. References** 1. Existing Data: a. 777-200 Structural Repair Manual (SRM) 54-32-01 b. 777-300 Structural Repair Manual (SRM) 54-32-01 c. 777 Aircraft Maintenance Manual (AMM) 78-31-00, 78-31-01, 78-31-06 d. 777 Boeing Maintenance Tip (MTIP) 78-016 e. 777 Non-Destructive Testing (NDT) Manual, Part 1, 51-05-01, Part 4, 78-30-01, Part 4, 78-30-02, Part 4, 78-30-03 f. Boeing Drawing 012W6100 g. Boeing Muti-Operator Message (MOM) 1-397934790-1 h. Boeing Parts Standards Document D-590

i. FAA Airworthiness Directive 2005-07-24 j. Service Related Problem (SRP) 777-SRP-78-0052 k. Standard Overhaul Practices Manual (SOPM) 20-10-09, 20-30-03, 20-50-03, 20-50-10, 20-50-19 l. Boeing Program Letter M-1151-777-PGM-187, dated October 13, 2008 m. Boeing Service Bulletin 777-78A0059, 777-78-0060 TOTAL FOR EACH T/R HALF: 27.35 (b) 17.95 (b) (a) Estimate does not include time to perform NDT hardness test on areas that show signs of heat distress. If heat distressed areas are found, more time will be necessary to do an NDT hardness test. (b) Estimate does not include time to perform repairs. If repairs are required, more time will be necessary. Work Package 6 - Limited NDT Of Inner Wall

**Task Number of**  **Persons Task Hours Elapsed Hours**Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

2. Data supplied with this Service Bulletin:

None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:

None.

**K. Publications Affected**

1. Publications:

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 does not affect FCS, therefore DTIs are not necessary. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. **Publication Chapter-Section** 777 Aircraft Maintenance Manual 78-31 777 Non-Destructive Testing (NDT) Manual, Part 4, 78-30Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**2. MATERIAL INFORMATION A. Material - Price and Availability** 

None. **B. Industry Support Information** Boeing Industry Support information is provided in Program Letter M-1151-777-PGM-187, dated October 13, 2008. Additional copies of program letters are available from Boeing Commercial Airplanes Group - Warranties. **C. Parts Necessary For Each Airplane**
1. Kits/Parts:

None.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

2. Parts and Materials Supplied by the Operator:

**NOTE:** Necessary Parts, Materials, and Quantities will change from airplane to airplane because of inspection results. Repair materials can be necessary.

Parts and Materials listed below should be available. Possible damage when insulation blankets are removed, inspection of the inner wall panel, and inspection of the compression pad fittings, and PDOS fitting, could make these materials and parts necessary. **Part Number / Specification QTY Name Notes**  BMS 1-68 1 sheet Filler, Foam, Grade A, Form III or II, 3ft x 3ft (a) (b)

BMS 5-63 1 gallon Sealant, Type 1, Class B-4 (a) (b) (c)

RTV106 1 gallon Sealant (b)
Aluminum Tape 1 roll High Temperature Aluminum - 3M 363 Tape (b)
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Any available source. Refer to AMM consumables list. (c) BMS 5-63, Type 1 sealant is available as a pre-mix frozen (PMF) from the following supplier: PRC-DeSoto International, Inc., Application Support Center - Seattle, 14126 NE 190th Street, Woodinville, WA 98072.

**Part Number / Specification QTY Name Notes**  3M 764 or equivalent 1 Roll Tape, Vacuum Bag
BACB28AK08-044 1 Bushing, PDOS Actuator Rod End BACB30US8C21 1 Bolt, PDOS Actuator Rod End BACN10HR8C 1 Nut, PDOS Actuator Rod End BACW10BP8ACU 1 Washer, PDOS Actuator Rod End BACW10BP8APU 1 Washer, PDOS Actuator Rod End BACB28AP08P020 1 Bushing, PDOS BACB28AT11C020C 1 Bushing, PDOS BMS 4-25 - Aluminum Core, Type 6-30, Class 3, Grade 1, Low Density, 3/8 Cell Size, Drain Slots (a)(b)(f)

BMS 5-137 - Adhesive, Type 2, Class 1, GR 10 (a)(b) BMS 5-137 - Adhesive, Type 2, Class 2, GR 5 (a)(b) BMS 5-28 - Potting Compound, Type 6 or Type 7 (a)(b)
BMS 8-125 - Fiberglass Core, Type III, Class 2, GR 19.5, Style C (a)(b)Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

BMS 8-139 - Sheet, Style 108, Fiberglass (a)(b) BMS 8-297 - Sheet, Type 4, Class 2, ST 3K-70- PW for 0/90 Deg oriented plies (a)(b)(c)(d)
BMS 8-297-2 - Sheet, Type 4, Class 2, ST 3K-70- PX for +/-45 Deg plies (a)(b)(c)
BMS 8-339 - Core, Pitch, Low Density, 3/8 Cell Size (a)(b)
BMS 8-342 - Pan Core, Type 3, Class 2, GR 15 (a)(b) CB4017C3CRA8R - Stud, Composite Base (e) CB4017C3CRA12R - Stud, Composite Base (e) CB4017C3CRA14R - Stud, Composite Base (e) CB4017C3CRA16R - Stud, Composite Base (e) CB4017C3CRA18R - Stud, Composite Base (e) CB4017C3CRA20R - Stud, Composite Base (e) 315W5009-115 2 Flame Shield, Left and Right Side 315W5010-100 1 Blanket, Right Side 315W5010-104 1 Blanket, Right Side 315W5010-123 1 Blanket, Left Side 315W5010-124 1 Blanket, Right Side 315W5010-125 1 Blanket, Left Side 315W5010-126 1 Blanket, Right Side 315W5010-127 1 Blanket, Left Side 315W5010-128 1 Blanket, Right Side 315W5010-129 1 Blanket, Left Side 315W5010-130 1 Blanket, Right Side 315W5010-135 1 Blanket, Left Side 315W5010-136 1 Blanket, Right Side 315W5010-137 1 Blanket, Left Side 315W5010-138 1 Blanket, Right Side 315W5010-141 2 Blanket, Left Side 315W5010-142 2 Blanket, Right Side 315W5010-143 2 Blanket, Left Side 315W5010-144 2 Blanket, Right Side 315W5010-145 1 Blanket, Left Side 315W5010-146 1 Blanket, Right Side 315W5010-147 1 Blanket, Left Side 315W5010-148 1 Blanket, Right Side 315W5010-149 1 Blanket, Left Side 315W5010-150 1 Blanket, Right Side **Part Number / Specification QTY Name Notes** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

315W5010-151 1 Blanket, Right Side 315W5010-153 1 Blanket, Left Side 315W5010-154 1 Blanket, Right Side 315W5010-155 1 Blanket, Left Side 315W5010-157 1 Blanket, Left Side 315W5010-158 1 Blanket, Right Side 315W5010-81 1 Blanket, Left Side 315W5010-82 1 Blanket, Right Side 315W5010-83 1 Blanket, Left Side 315W5010-84 1 Blanket, Right Side 315W5010-85 1 Blanket, Left Side 315W5010-86 1 Blanket, Right Side 315W5010-88 1 Blanket, Right Side 315W5010-93 1 Blanket, Left Side 315W5010-94 1 Blanket, Right Side 315W5010-95 1 Blanket, Left Side 315W5010-96 1 Blanket, Right Side 315W5010-97 1 Blanket, Left Side 315W5010-98 1 Blanket, Right Side 315W5010-99 1 Blanket, Left Side 315W5113-17 1 Blanket, Left Side 315W5113-18 1 Blanket, Right Side 315W5113-3 1 Blanket, Left Side 315W5113-4 1 Blanket, Right Side 315W5113-5 1 Blanket, Left Side 315W5113-6 1 Blanket, Right Side 315W5113-7 1 Blanket, Left Side 315W5113-8 1 Blanket, Right Side 315W5181-11 (-13 optional) 1 No. 1 Upper Compression Pad Fitting, Left Side 315W5181-12 (-14 optional) 1 No. 1 Upper Compression Pad Fitting, Right Side 315W5191-1 (-3 optional) 1 No. 1 Lower Compression Pad Fitting, Left Side 315W5191-2 (-4 optional) 1 No. 1 Lower Compression Pad Fitting, Right Side 315W5195-1 (-3 optional) 1 No. 2 Lower Compression Pad Fitting, Left Side **Part Number / Specification QTY Name Notes** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

3. Parts Modified and Reidentified:

None. 4. Parts Removed and Not Replaced:

None. **D. Parts Necessary to Change Spares** Same as paragraph 2.C.2. Parts and Material Supplied by the Operator **E. Special Tooling - Price and Availability** Boeing can supply a quantity of 4 for each operator, of the tools shown in Paragraph 2.F.Special Tooling Necessary to do this Service Bulletin, at no cost to the operator. Send a request to the Director of Spares. Give this service bulletin number and the date the tools are necessary. Reference this service bulletin number when the order is submitted. Order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA (Service Bulletin 777-78A0065) 315W5195-2 (-4 optional) 1 No. 2 Lower Compression Pad Fitting, Right Side (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Any available source. (c) BMS 8-297-2, Type 3 or 4, Class 2, Style 3K-70-PW is optional to BMS 8-297, Type 4, Class 2, Style 3K-70-PW or BMS 8-297-2, Type 4, Class 2, Style 3K-70-PX. (d) BMS 8-297-2, Type 4, Class 2, Style 3K-70-PX is optional to the BMS 8-297, Type 4, Class 2, Style 3K-70-PW for the 0/90 Deg oriented plies when the BMS 8-297-2, Type 4, Class 2, Style 3K-70-PX is applied at a 45 degree bias relative to the roll direction. (e) Click Bond Inc. (V66530) 2151 Lockheed Way, Carson City, NV 89706(f) BMS 4-25, Class 3 material is available in two drain slot orientations. Slots run either parallel or perpendicular to the ribbon direction. BMS 4-25 core that is used in the upper and lower bifurcations of the thrust reverser has slots that run perpendicular to the ribbon direction. BMS 4-25 core that is used in the barrel of the thrust reverser has slots that run parallel to the ribbondirection. If BMS 4-25 core is removed, replace with BMS 4-25, Class 3 core that has slots oriented the same as the removed material. **Part Number / Specification QTY Name Notes** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

**NOTE:** Refills of consumables used in the kit are supplied by the operator. **F. Special Tooling Necessary to do this Service Bulletin** To get the tool 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:** Make sure tools necessary for ultrasonic and eddy current inspections, and repair of disbonded and delaminated composite material are available.

**NOTE:** A durometer value will be required if the accelerated cure processes are used. If a durometer measurement device is not available, contact the following: Rex Gauge Company, 1250 Busch Pkwy., Buffalo Grove, IL 60089 USA. **Tool Kit Number Name** MIT315W5100 Tool Kit - Hardness TesterOriginal Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**3. ACCOMPLISHMENT INSTRUCTIONS**

**A. GENERAL INFORMATION**
**CAUTION:** USE CAUTION WHEN REMOVING INSULATION BLANKETS FROM THE THRUST REVERSER. THE INSULATION BLANKETS CAN BEND AND CRACK IF NOT PROPERLY SUPPORTED DURING AND AFTER REMOVAL. DAMAGED BLANKETS MUST BE REPAIRED OR REPLACED. REFER TO 777 AMM 78-31-01 AS AN ACCEPTED PROCEDURE FOR REPAIR OF DAMAGED INSULATION BLANKETS.
**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. Work instructions are given in Work Package 1 Part A, 1 Part B, 2, 3, 4, 5, and 6. Task Hours and Elapsed Hours for each package are given in Paragraph 1.G., Manpower. You can do each Work Package independently or at the same time. Refer to Service Bulletin Paragraph 1.E, Compliance, for when to do the work packages. 3. Obey all of the warnings and cautions given in the specified manual sections. 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. — Torque limits to tighten nuts and bolts are given in 777 Structural Repair Manual, Chapter 51. 5. For approved fastener and process material substitutions, refer to 777 SRM, Chapter 51, Alternate fasteners are given in 777 SRM Chapter 51 and Boeing Drawing 012W6100. 6. 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. 7. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to theOriginal Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** area being checked. 8. These work instructions refer to procedures included on 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 "as given in" are included in the instruction, the procedure in the Boeing document must be used. 9. This service bulletin is done on each Thrust Reverser (T/R) half. Each engine has two T/R halves, one on each side of the engine. 10. A general summary of the bulletin work follows: — Work package 1, Part A: Look for sealant condition. If sealant gaps are more than 0.1 inch, measure the blanket seam or edge, which may have a gap less than or equal to 0.1 inch. Gaps less than or equal to 0.1 inch are sealed with new sealant. Gaps more than 0.1 inch have possibly let hot air degrade the inner wall panel. A Non Destructive Test (NDT) inspection of the inner wall panel area is necessary if gaps more than 0.1 inch are found. If the number 1 upper or number 1 and 2 lower compression pad fittings are exposed by blanket removal and within 12 inches of the damaged or missing sealant, NDT (eddy current conductivity test) them. Repair or replace unsatisfactory inner wall panel areas and compression pad fittings. In the firewall zone where the overlapped blanket face sheet distance is greater than 0.100 inch, replace BMS 5-63 Type 2 sealant with BMS 5-63 Type 1. Also, in the firewall zone where blanket edges do not overlap other blankets, such as on the forward, upper, or aft edges of the T/R, replace BMS 5-63 Type 2 sealant with BMS 5-63 Type 1. In other areas, remove loose, flaky, non-adherent sealant and apply RTV106. Cover satisfactory BMS 5-63 Type 2 sealant with RTV106. — Work package 1, Part B: Look for loose, damaged, or missing click bond studs, blanket studs, or temporary fasteners that could indicate the inner wall panel has degraded. An NDT inspection is necessary of the inner wall panel area if blanket attachments are missing or loose. This does not apply for the dispatch limits given in 777 AMM 78-31-06 for attachment fasteners. If the number 1 upper or number 1 and 2 lower compression pad fittings are exposed by blanket removal and within 12 inches of the loose, damaged, or missing click bond studs, blanket studs, or temporary fasteners, NDT (eddy current conductivity test) them. Repair or replace unsatisfactory inner wall panel areas and compression pads fittings. — Work package 2: Remove all T/R insulation blankets that cover the inner wall panel. Do an NDT inspection of the inner wall panel to make sure it is satisfactory. Repair or replace unsatisfactory inner wall panel areas. Install and seal blankets and PDOS fitting. — Work package 3: Remove sealant and foam around the PDOS fitting. Do a detailed inspection of the number 1 compression pad PDOS lugs and bushing. Repair or replace an unsatisfactory number 1 compression pad PDOS fitting. — Work package 4: Remove insulation blankets as necessary to uncover the number 1 upper and number 1 and 2 lower compression pad fittings. NDT (eddy current conductivity test) the number 1 upper and number 1 and 2 lower compression pad fittings. Replace unsatisfactory compression pad fittings. NDT the inner wall panel area under compression pad fittings that are removed. Repair unsatisfactory inner wall panel areas. — Work Package 5:Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** Do a general visual inspection aft of the forward edge of the Intermediate Pressure compressor 8th Stage (IP8) duct and High Pressure compressor 3rd Stage (HP3) duct on the perforated side of the T/R. — Work Package 6: Remove insulation blankets that cover the inner wall panel in the barrel of the T/R, aft of the blocker door drag link fittings. Do an NDT inspection of the inner wall panel to make sure it is satisfactory. Repair or replace unsatisfactory inner wall panel areas. Install and seal removed blankets. 11. Appendixes have been added to the bulletin to give procedures and information that are not available in Boeing maintenance documents.
**B. WORK INSTRUCTIONS WORK PACKAGE 1, PART A - T/R INSULATION BLANKET SEALANT INSPECTION**  1. Check maintenance records for sealant repair done because of Multi Operator Message (MOM) 1-397934790-1. If a compression pad fitting has repaired or added sealant, follow the same work instructions as if a crack or gap larger than 0.100 inch across is found in the insulation blanket that covers the compression pad fitting.

**NOTE:** MOM 1-397934790-1 directed operators to add sealant around the PDOS fitting, and compression pads fittings. If new sealant was added because of MOM 1-397934790-1, it could have covered a crack, gap, loose, or is missing sealant that is larger than 0.100 inch. Thus, any area adjacent to new sealant, added because of MOM 1-397934790-1, must be inspected like a crack, gap, loose, or is missing sealant that is larger than 0.100 inch, in instruction 3.B.3.a.

**WARNING:** DO NOT MOVE BETWEEN THE ENGINE AND THE OPEN THRUST REVERSER UNTIL THE HOLD-OPEN ROD IS ENGAGED AND LOCKED. THE THRUST REVERSER IS HEAVY AND CAN CLOSE QUICKLY IF THE PDOS HAS A FAILURE. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT. 2. Open T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to open the T/R half. 3. Do a detailed inspection of all T/R inner wall insulation blanket edges, grommet holes, penetrations, and seams for sealant that is cracked, has a gap, is loose, or is missing sealant. Refer to 777 AMM 78-31-06 for data on blanket edges, grommet holes, penetrations, and seams. This detailed inspection must also include sealant around all compression pad fittings, HP3 ducts, PDOS fitting, and the actuator end on the number 1 upper compression pad fitting.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** MOM 1-397934790-1 directed operators to add sealant around the PDOS fitting, and compression pads fittings. If new sealant was added because of MOM 1-397934790-1, it could have covered a crack, gap, loose, or is missing sealant that is larger than 0.100 inch. Thus, any area adjacent to new sealant, added because of MOM 1-397934790-1, must be inspected like a crack, gap, loose, or is missing sealant that is larger than 0.100 inch, in instruction 3.B.3.a.

**NOTE:** AMM 78-31-06 gives limited use of sealant in grommet holes when fasteners are missing. The detailed inspection of grommet holes is limited to those grommets filled with sealant as a temporary replacement for missing T/R insulation blanket click bond studs, blanket studs, and temporary fasteners. a. If a crack, gap, loose, or missing sealant is more than 0.100 inch across (opening is measured perpendicular to the length):

**NOTE:** Do not push on an insulation blanket or sealant to make the measured crack, gap, loose, or missing sealant larger. (1) FOR THE INITIAL INSPECTION OF EACH T/R ONLY: If damaged or missing sealant is found on the forward, upper, or aft edges of the T/R, it is not necessary to remove blankets due to this condition. Any missing or damaged sealant found on the forward, upper, or aft edges of the T/R can be assumed to be less than or equal to 0.100 inch across. If damaged or missing sealant is found on the forward, upper, or aft edges of the T/R during the first inspection, go to step 3.b. of Work Package 1, Part A.

**NOTE:** Sealant may not have been installed on the forward, upper, or aft edges of the T/ R. It is not necessary to remove the blankets adjacent to these edges if this condition is found during the initial inspection of each T/R. If sealant is found missing or damaged greater than 0.100 inch in areas other than the forward, upper, or aft edges of the T/R, removal of the blankets will be necessary. For each repeat inspection, removal of blankets is necessary if any damaged or missing sealant greater than 0.100 inch is found, including on the forward, upper, or aft edges of the T/R. (2) For overlapping blanket seams, measure the distance between the overlapped blanket face sheets adjacent to the damaged or missing sealant. For blanket edges that do not overlap other blankets, measure the distance between the inner wall and the insulation blanket adjacent to the damaged or missing sealant. Remove damaged sealant if necessary to measure the blanket edge or seam.

**NOTE:** Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets. (a) If the overlapped blanket face sheet distance or the distance between the inner wall and the insulation blanket adjacent to the damaged or missing sealant is less than or equal to 0.100 inch, it is not necessary to remove the adjacent insulation blankets. Assume that the crack, gap, loose, or missing sealant is less than or equal to 0.100 inch across. Go to step 3.b. of Work Package 1, Part A. (b) If the overlapped blanket face sheet distance or the distance between the inner wall and the insulation blanket adjacent to the damaged or missing sealant is more than 0.100 inch, the adjacent insulation blankets must be removed. Continue with the subsequent step.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** (3) Except as specified in step 3.B.3.a.(1), remove insulation blanket(s) adjacent to the crack, gap, loose, or missing sealant. Refer to 777 AMM 78-31-06 as an accepted procedure to remove the insulation blankets. Refer to Appendix A for examples of insulation blankets to be removed for a found condition.

**NOTE:** The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. (4) Do a General Visual Inspection and an NDT of the inner wall panel: (a) Solvent clean the inner wall panel. Refer to SOPM 20-30-03 as an accepted procedure to solvent clean the inner wall.

**NOTE:** In addition to the acceptable solvents found in SOPM 20-30-03, Isopropyl Alcohol can also be used. 1) Do not remove marks on the inner wall that have recorded information that should be kept for inspectors or other personnel. (b) Do an NDT for delamination and disbonding of the exposed inner wall panel area that is within 12 inches of the crack, gap, loose, or missing sealant. Use a one inch grid pattern to scan the applicable inner wall panel areas.

**NOTE:** It is only necessary to inspect the applicable inner wall panel area that is exposed by removal of the insulation blankets that are adjacent to the damaged or missing sealant. It is not necessary to remove additional blankets in order to inspect all of the inner wall panel that is within 12 inches of the damaged or missing sealant. 1) For an NDT of field core areas (four ply areas) refer to 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), or Low Frequency Bond Test, 777 NDT, Part 4, 78-30-03, as accepted procedures to NDT field core areas. Refer to Appendix F for locations of ply build up areas. 2) For an NDT of ply build-up areas (greater than 4 plies) refer to 777 NDT, Part 4, 78-30-01 (High Frequency Bond Test), or 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), as accepted procedures for the NDT of ply build-up areas. Refer to Appendix F for locations of ply build up areas. (c) Do a general visual inspection of the exposed inner wall panel area that is within 12 inches of the crack, gap, loose, or missing sealant for areas of thermal degradation. These areas show wall color that appears different than the normal wall. See 777-MTIP-78-016 for examples of areas of thermal degradation.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** It is only necessary to inspect the applicable inner wall panel area that is exposed by removal of the insulation blankets that are adjacent to the damaged or missing sealant. It is not necessary to remove additional blankets in order to inspect all of the inner wall panel that is within 12 inches of the damaged or missing sealant. 1) Do a Barcol hardness inspection of the inner wall panel in areas that are thought to have thermal degradation. Use Barcol hardness tester GYZJ934- 1. Use a 0.5 inch grid pattern to scan the entire area that is thought to have thermal degradation.

**NOTE:** Acceptable hardness for the T/R inner wall is greater than or equal to 50 Barcol hardness units.

**NOTE:** The Barcol hardness tester, calibration disks, and test disks are supplied in tool MIT315W5100. {a} If an indication of less than 50 Barcol hardness units is measured, test a different location within 0.25 inches of the initial low indication. {b} If the second indication is greater than or equal to 50 Barcol hardness units, neglect the initial low indication. {c} If the second indication is less than 50 Barcol hardness units, test the surrounding area to define the full area of softness. Soft areas with a diameter larger than 0.25 inches must be repaired.

**WARNING:** MAKE SURE THAT THE T/R IS OPEN IN A PLACE THAT NO WIND CAN BLOW ON IT IF A COMPRESSION PAD FITTING IS REPLACED ON-WING. IF A PERSON ENTERS THE FAN DUCT COWL WHEN THE T/R IS OPEN, AND THE WIND BLOWS, TOO MUCH PRESSURE WILL BE PUT ON THE HOLD-OPEN ROD WHICH CAN FAIL. A T/R CAN FALL TO THE CLOSED POSITION QUICKLY, WHICH CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. (d) If a removed blanket covered the number 1 upper or number 1 and 2 lower compression pad fitting, and if the crack, gap, loose, or missing sealant was within 12 inches of the number 1 upper or number 1 and 2 lower compression pad fitting, do an NDT (eddy current conductivity test) of the compression pad fitting. Refer to 777 AMM 78-31-06 page block 600 as an accepted procedure to NDT a compression pad fitting. If the compression pad fitting is white, it must still have an eddy current conductivity test NDT.

**NOTE:** If the fitting does not pass the conductivity test, it is unsatisfactory. 1) Remove unsatisfactory compression pad fitting. Refer to 777 AMM 78-31-01 page block 800, as an accepted procedure. 2) Do an NDT for delamination and disbonding of the inner wall panel under the unsatisfactory compression pad. Use a one inch grid pattern to scan the inner wall panel areas.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** {a} For an NDT of ply build-up areas (greater than 4 plies) refer to 777 NDT, Part 4, 78-30-01 (High Frequency Bond Test), or 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), as accepted procedures for the NDT of ply build-up areas. 3) Do a general visual inspection of the inner wall panel under the unsatisfactory compression pad for areas of thermal degradation. These areas show wall color that appears different than the normal wall. See 777-MTIP-78-016 for examples of areas of thermal degradation. {a} Do a Barcol hardness inspection of the inner wall panel in areas that are thought to have thermal degradation. Use Barcol hardness tester GYZJ934-1. Use a 0.5 inch grid pattern to scan the entire area that is thought to have thermal degradation.

**NOTE:** Acceptable hardness for the T/R inner wall is greater than or equal to 50 Barcol hardness units.

**NOTE:** The Barcol hardness tester, calibration disks, and test disks are supplied in tool MIT315W5100.

1} If an indication of less than 50 Barcol hardness units is measured, test a different location within 0.25 inches of the initial low indication. 2} If the second indication is greater than or equal to 50 Barcol hardness units, neglect the initial low indication. 3} If the second indication is less than 50 Barcol hardness units, test the surrounding area to define the full area of softness. Soft areas with a diameter larger than 0.25 inches must be repaired. 4) Do a detailed inspection of the inner wall panel bolt holes for the removed unsatisfactory compression pad fitting. Look for unsatisfactory elongation of the holes. Refer to the table below for acceptable bolt hole diameters. Diameters that exceed the maximum hole diameter given are unsatisfactory.

{a} If an inner wall panel bolt hole for the unsatisfactory compression pad fitting has been repaired with a titanium bushing, do a general visual inspection for migration or looseness of the bushing. 1} If bushing migration or looseness is found, remove the bushing. Repair the inner wall panel bolt hole as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. **Removed Fastener Maximum Hole Diameter**  BACB30NY6K* 0.194 BACB30NY8K* 0.254 ASPFF-V06-22AC 0.208Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** 2} If bushing migration or looseness is not found, no action is necessary. (e) Repair the inner wall panel where disbonds, delaminations, areas of softness, and elongated holes are found as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. Or, replace the inner wall panel assembly with a serviceable one. (f) Install a serviceable compression pad fitting for an unsatisfactory one. Refer to 777 AMM 78-31-01 page block 800 as an accepted procedure. (5) Prepare and install the removed insulation blankets. (a) If it is in the firewall zone, remove all BMS 5-63 Type 2 sealant from the removed blanket such that new sealant can adequately bond to the blanket surface and form the firewall for the blanket seam. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area.

**NOTE:** BMS 5-63 Type 2 starts out light grey but will have a light pink color when aged in service. RTV106 remains red when aged in service. BMS 5-63 Type 1 starts out dark gray but turns dark red in service.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. (b) Remove loose, flaky, and non-adherent sealant and sand to smooth so that sealant can be satisfactorily applied. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area. (c) Install removed insulation blankets. Refer to 777 AMM 78-31-06 as an accepted procedure to install the insulation blankets. BMS 1-68 foam can be used in gaps larger than 0.2 inches. Use only BMS 5-63 Type 1 sealant in areas of the firewall zone where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, use only BMS 5-63 Type 1 sealant on blanket edges in the firewall zone that do not overlap other blankets, such as on the forward, upper, and aft edges of the T/R. For other areas, use RTV106 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant application procedure. Refer to Appendix E for optional accelerated sealant cure time processes. Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, BMS 5-63 Type 1 sealant should be used in all areas of the firewall zone.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. (d) OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** Make sure the sealant is cured before the T/R is put into service. b. If a crack, gap, loose, or missing sealant is less than or equal to 0.100 inch across: (1) If it is in the firewall zone and the distance between the overlapped blanket face sheets is greater than 0.100 inch, or if it is in the firewall zone and it is on a blanket edge that does not overlap another blanket, such as on the forward, upper, or aft edges of the T/ R:

**NOTE:** Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, the distance should be assumed to be greater than 0.100 inch. In areas of the firewall zone where the overlapped blanket face sheet distance is not known, BMS 5-63 Type 1 sealant should be used. (a) Remove all BMS 5-63 Type 2 sealant such that new sealant can adequately bond to the surface and form the firewall for the blanket seam. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area.
**NOTE:** BMS 5-63 Type 2 starts out light grey but will have a light pink color when aged in service. RTV106 remains red when aged in service. BMS 5-63 Type 1 starts out dark gray but turns dark red in service. (b) Remove loose, flaky, and non-adherent sealant and sand to smooth so that new BMS5-63 Type 1 sealant can be satisfactorily applied. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area. (c) Apply BMS 5-63 Type 1 to the crack or gap, or to replace the removed BMS 5-63 Type 2, or missing sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant procedure. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. (2) If it is in the firewall zone and the distance between the overlapped blanket face sheets is equal to or less than 0.100 inch:Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, the distance should be assumed to be greater than 0.100 inch. In areas of the firewall zone where the overlapped blanket face sheet distance is not known, BMS 5-63 Type 1 sealant should be used. (a) Remove loose, flaky, and non-adherent sealant and sand to smooth so that new RTV106 sealant can be satisfactorily applied. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area. (b) Apply RTV106 to the crack or gap, or missing sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant procedure. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. (3) If it is external to the firewall zone: (a) Remove loose, flaky, and non-adherent sealant and sand to smooth so that new RTV106 sealant can be satisfactorily applied. Refer to Appendix C as an accepted procedure for removal of sealant. (b) Apply RTV106 to the crack or gap, or missing sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant procedure. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant.

**NOTE:** Make sure the sealant is cured before the T/R is put into service. (4) OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets. c. If no crack, gap, loose, or missing sealant is found: (1) If BMS 5-63 Type 2 sealant is found in the firewall zone and the distance between the overlapped blanket face sheets is greater than 0.100 inch, or if it is in the firewall zone and it is on a blanket edge that does not overlap another blanket, such as on the forward, upper, or aft edges of the T/R:Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** BMS 5-63 Type 2 starts out light grey but will have a light pink color when aged in service. RTV106 remains red when aged in service. BMS 5-63 Type 1 starts out dark gray but turns dark red in service.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, the distance should be assumed to be greater than 0.100 inch. In areas of the firewall zone where the overlapped blanket face sheet distance is not known, BMS 5-63 Type 1 sealant should be used. (a) Remove all BMS 5-63 Type 2 sealant such that new sealant can adequately bond to the surface and form the firewall for the blanket seam. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area. (b) Remove loose, flaky, and non-adherent sealant and sand to smooth so that new BMS5-63 Type 1 sealant can be satisfactorily applied. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area. (c) Apply BMS 5-63 Type 1 to replace the removed BMS 5-63 Type 2. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant procedure. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. (2) If BMS 5-63 Type 2 sealant is found in the firewall zone and the distance between the overlapped blanket face sheets is equal to or less than 0.100 inch:

**NOTE:** Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** BMS 5-63 Type 2 starts out light grey but will have a light pink color when aged in service. RTV106 remains red when aged in service. BMS 5-63 Type 1 starts out dark gray but turns dark red in service.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, the distance should be assumed to be greater than 0.100 inch. In areas of the firewall zone where the overlapped blanket face sheet distance is not known, BMS 5-63 Type 1 sealant should be used. (a) Remove loose, flaky, and non-adherent BMS 5-63 Type 2 sealant and sand to smooth so that new RTV106 sealant can be satisfactorily applied. Refer to Appendix C as an accepted procedure for removal of sealant. Refer to Appendix G for the firewall zone area.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** (b) Apply RTV106 over good BMS 5-63 Type 2 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant procedure. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. (3) If BMS 5-63 Type 2 sealant is found external to the firewall zone:

**NOTE:** BMS 5-63 Type 2 starts out light grey but will have a light pink color when aged in service. RTV106 remains red when aged in service. BMS 5-63 Type 1 starts out dark gray but turns dark red in service. (a) Remove loose, flaky, and non-adherent sealant BMS 5-63 Type 2 and sand to smooth so that new RTV106 sealant can be satisfactorily applied. Refer to Appendix C as an accepted procedure for removal of sealant. (b) Apply RTV106 over good BMS 5-63 Type 2 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant procedure. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant.

**NOTE:** Make sure the sealant is cured before the T/R is put into service. (4) No action is necessary if BMS 5-63 Type 2 is not found. (5) OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets. 4. Make sure the PDOS fitting and actuator end that is attached to it is sealed. The sealed area is inside the number 1 upper compression pad fitting blanket. Use only BMS 5-63 Type 1 sealant. Refer to Appendix D as an accepted procedure to seal the PDOS fitting. a. OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure all sealant is cured before the T/R is put into service. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets. 5. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number and the work package completed to show the inspection was done. Refer to SOPM 20-50-10 as an accepted procedure. 6. Close the T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to close the T/R half.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

7. Put the airplane back to a serviceable condition. **WORK PACKAGE 1, PART B - T/R INSULATION BLANKET ATTACHMENT STUD INSPECTION**

**WARNING:** DO NOT MOVE BETWEEN THE ENGINE AND THE OPEN THRUST REVERSER UNTIL THE HOLD-OPEN ROD IS ENGAGED AND LOCKED. THE THRUST REVERSER IS HEAVY AND CAN CLOSE QUICKLY IF THE PDOS HAS A FAILURE. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT. 1. Open T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to open the T/R half. 2. Do a general visual inspection for loose, damaged, or missing click bond studs, blanket studs, or temporary fasteners.

**NOTE:** Dispatch limits for missing or damaged click bond studs are provided in 777 AMM 78-31-06. Removal of the insulation blankets and/or inspection of the inner wall is not necessary if within dispatch limits. Replacement of temporary fasteners and sealed grommet holes is necessary within the time limit specified in 777 AMM 78-31-06. a. If a click bond stud, blanket stud, or temporary fastener is loose, damaged, or missing beyond the dispatch limits given in 777 AMM 78-31-06: (1) Remove insulation blanket(s) that have a loose, damaged, or missing click bond stud, blanket stud, or temporary fastener. Refer to 777 AMM 78-31-06 as an accepted procedure to remove the insulation blankets. Refer to Appendix A for examples of insulation blankets to be removed for a found condition.

**NOTE:** The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. (2) Do a general visual inspection and NDT of the inner wall panel: (a) Solvent clean the inner wall panel. Refer to SOPM 20-30-03 as an accepted procedure to solvent clean the inner wall.

**NOTE:** In addition to the acceptable solvents found in SOPM 20-30-03, Isopropyl Alcohol can also be used. 1) Do not remove marks on the inner wall that have recorded information that should be kept for inspectors or other personnel. (b) Do an NDT for delamination and disbonding of the inner wall panel area that is within 12 inches of the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener. Use a one inch grid pattern to scan the applicable inner wall panel areas.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** It is only necessary to inspect the applicable inner wall panel area that is exposed by removal of the insulation blankets that are adjacent to the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener. It is not necessary to remove additional blankets in order to inspect all of the inner wall panel that is within 12 inches of the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener. 1) For an NDT of field core areas (four ply areas) refer to 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)),or Low Frequency Bond Test, 777 NDT, Part 4, 78-30-03, as accepted procedures to NDT field core areas. Refer to Appendix F for locations of ply build up areas. 2) For an NDT of ply build-up areas (greater than 4 plies) refer to 777 NDT, Part 4, 78-30-01 (High Frequency Bond Test), or 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), as accepted procedures for the NDT of ply build-up areas. Refer to Appendix F for locations of ply build up areas. (c) Do a general visual inspection of the inner wall panel area that is within 12 inches of the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener for areas of thermal degradation. These areas show wall color that appears different than the normal wall. See 777-MTIP-78-016 for examples of areas of thermal degradation.

**NOTE:** It is only necessary to inspect the applicable inner wall panel area that is exposed by removal of the insulation blankets that are adjacent to the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener. It is not necessary to remove additional blankets in order to inspect all of the inner wall panel that is within 12 inches of the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener. 1) Do a Barcol hardness inspection of the inner wall panel in areas that are thought to have thermal degradation. Use Barcol hardness tester GYZJ934- 1. Use a 0.5 inch grid pattern to scan the entire area that is thought to have thermal degradation.

**NOTE:** Acceptable hardness for the T/R inner wall is greater than or equal to 50 Barcol hardness units.

**NOTE:** The Barcol hardness tester, calibration disks, and test disks are supplied in tool MIT315W5100. {a} If an indication of less than 50 Barcol hardness units is measured, test a different location within 0.25 inches of the initial low indication. {b} If the second indication is greater than or equal to 50 Barcol hardness units, neglect the initial low indication. {c} If the second indication is less than 50 Barcol hardness units, test the surrounding area to define the full area of softness. Soft areas with a diameter larger than 0.25 inches must be repaired.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**WARNING:** MAKE SURE THAT THE T/R IS OPEN IN A PLACE THAT NO WIND CAN BLOW ON IT IF A COMPRESSION PAD FITTING IS REPLACED ON-WING. IF A PERSON ENTERS THE FAN DUCT COWL WHEN THE T/R IS OPEN, AND THE WIND BLOWS, TOO MUCH PRESSURE WILL BE PUT ON THE HOLD-OPEN ROD WHICH CAN FAIL. A T/R CAN FALL TO THE CLOSED POSITION QUICKLY, WHICH CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. (d) If a removed blanket covered the number 1 upper or number 1 and 2 lower compression pad fitting, and if the loose, damaged, or missing click bond stud, blanket stud, or temporary fastener is within 12 inches of the number 1 upper or number 1 and 2 lower compression pad fitting, do an NDT (eddy current conductivity test) of the compression pad fitting. Refer to 777 AMM 78-31-06 page block 600 as an accepted procedure to NDT a compression pad fitting. If the compression pad fitting is white, it must still have an eddy current conductivity test NDT.

**NOTE:** If the fitting does not pass the conductivity test, it is unsatisfactory. 1) Remove unsatisfactory compression pad fitting. Refer to 777 AMM 78-31-01 page block 800, as an accepted procedure. 2) Do an NDT for delamination and disbonding of the inner wall panel under the unsatisfactory compression pad. Use a one inch grid pattern to scan the inner wall panel areas. {a} For an NDT of ply build-up areas (greater than 4 plies) refer to 777 NDT, Part 4, 78-30-01 (High Frequency Bond Test), or 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), as accepted procedures for the NDT of ply build-up areas. Refer to Appendix F for locations of ply build up areas. 3) Do a general visual inspection of the inner wall panel under the unsatisfactory compression pad for areas of thermal degradation. These areas show wall color that appears different than the normal wall. See 777-MTIP-78-016 for examples of areas of thermal degradation. {a} Do a Barcol hardness inspection of the inner wall panel in areas that are thought to have thermal degradation. Use Barcol hardness tester GYZJ934-1. Use a 0.5 inch grid pattern to scan the entire area that is thought to have thermal degradation.

**NOTE:** Acceptable hardness for the T/R inner wall is greater than or equal to 50 Barcol hardness units.

**NOTE:** The Barcol hardness tester, calibration disks, and test disks are supplied in tool MIT315W5100.

1} If an indication of less than 50 Barcol hardness units is measured, test a different location within 0.25 inches of the initial low indication.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** 2} If the second indication is greater than or equal to 50 Barcol hardness units, neglect the initial low indication. 3} If the second indication is less than 50 Barcol hardness units, test the surrounding area to define the full area of softness. Soft areas with a diameter larger than 0.25 inches must be repaired. 4) Do a detailed inspection of the inner wall panel bolt holes for the removed unsatisfactory compression pad fitting. Look for unsatisfactory elongation of the holes. Refer to the table below for acceptable bolt hole diameters. Diameters that exceed the maximum hole diameter given are unsatisfactory.

{a} If an inner wall panel bolt hole for the unsatisfactory compression pad fitting has been repaired with a titanium bushing, do a general visual inspection for migration or looseness of the bushing. 1} If bushing migration or looseness is found, remove the bushing. Repair the inner wall panel bolt hole as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. 2} If bushing migration or looseness is not found, no action is necessary. (e) Repair the inner wall panel where disbonds, delaminations, and elongated holes are found as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. Or, replace the inner wall panel assembly with a serviceable one. (f) Install a serviceable compression pad fitting for an unsatisfactory one. Refer to 777 AMM 78-31-01 pageblock 800 as an accepted procedure. (3) Install replacement click bonds, blanket studs, or temporary fasteners. Refer to 777 AMM 78-31-01 and 777 AMM 78-31-06 as an accepted procedure to install click bonds, blanket studs, or temporary fasteners. **Removed Fastener Maximum Hole Diameter**  BACB30NY6K* 0.194 BACB30NY8K* 0.254 ASPFF-V06-22AC 0.208Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** (4) Install removed insulation blankets. Refer to 777 AMM 78-31-06 as an accepted procedure to install the insulation blankets. BMS 1-68 foam can be used in gaps larger than 0.2 inches. Use BMS 5-63 Type 1 or RTV106 sealant, as applicable. Use only BMS 5-63 Type 1 sealant in areas of the firewall zone where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, use only BMS 5-63 Type 1 sealant on blanket edges in the firewall zone that do not overlap other blankets, such as on the forward, upper, and aft edges of the T/R. For other areas, use RTV106 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant application procedure. Refer to Appendix E for optional accelerated sealant cure time processes. Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, BMS 5-63 Type 1 sealant should be used in all areas of the firewall zone.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. (a) Make sure the PDOS fitting and actuator end that is attached to it is sealed. The sealed area is inside the number 1 upper compression pad fitting blanket. Use only BMS 5-63 Type 1 sealant. Refer to Appendix D as an accepted procedure to seal the PDOS fitting. (5) OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure the sealant is cured before the T/R is put into service. b. If no loose, damaged, or missing click bond stud, blanket stud, or temporary fastener is found, no action is required. 3. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number and the work package completed to show the inspection was done. Refer to SOPM 20-50-10 as an accepted procedure. 4. Close the T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to close the T/R half. 5. Put the airplane back to a serviceable condition.
**WORK PACKAGE 2 - T/R INNER WALL PANEL - FULL AREA NDT** 1. Open T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to open the T/R half.
2. Remove the insulation blankets attached to the T/R half inner wall. Refer to 777 AMM 78-31-06 as an accepted procedure to remove the insulation blankets.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. 3. Solvent clean the inner wall panel. Refer to SOPM 20-30-03 as an accepted procedure to solvent clean the inner wall.

**NOTE:** In addition to the acceptable solvents found in SOPM 20-30-03, Isopropyl Alcohol can also be used. a. Do not remove marks on the inner wall that have recorded information that should be kept for inspectors or other personnel. 4. Do an NDT for delamination and disbonding of the inner wall panel. Use a one inch grid pattern to scan the inner wall panel areas. a. For an NDT of field core areas (four ply areas) refer to 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)),or Low Frequency Bond Test, 777 NDT, Part 4, 78-30-03, as accepted procedures to NDT field core areas. Refer to Appendix F for locations of ply build up areas. b. For an NDT of ply build-up areas (greater than 4 plies) refer to 777 NDT, Part 4, 78-30-01 (High Frequency Bond Test), or 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), as accepted procedures for the NDT of ply build-up areas. Refer to Appendix F for locations of ply build up areas. 5. Do a general visual inspection of the inner wall panel for areas of thermal degradation. These areas show wall color that appears different than the normal wall. See 777-MTIP-78-016 for examples of areas of thermal degradation. a. Do a Barcol hardness inspection of the inner wall panel in areas that are thought to have thermal degradation. Use Barcol hardness tester GYZJ934-1. Use a 0.5 inch grid pattern to scan the entire area that is thought to have thermal degradation.

**NOTE:** Acceptable hardness for the T/R inner wall is greater than or equal to 50 Barcol hardness units.

**NOTE:** The Barcol hardness tester, calibration disks, and test disks are supplied in tool MIT315W5100. (1) If an indication of less than 50 Barcol hardness units is measured, test a different location within 0.25 inches of the initial low indication. (2) If the second indication is greater than or equal to 50 Barcol hardness units, neglect the initial low indication. (3) If the second indication is less than 50 Barcol hardness units, test the surrounding area to define the full area of softness. Soft areas with a diameter larger than 0.25 inches must be repaired.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

6. Repair the inner wall panel where disbonds, delaminations, and areas of softness are found as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. Or, replace the inner wall panel assembly with a serviceable one. 7. Install insulation blankets. Refer to 777 AMM 78-31-06 as an accepted procedure to install the insulation blankets. BMS 1-68 foam can be used in gaps larger than 0.2 inches. Use BMS 5-63 Type 1 or RTV106 sealant, as applicable. Use only BMS 5-63 Type 1 sealant in areas of the firewall zone where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, use only BMS 5-63 Type 1 sealant on blanket edges in the firewall zone that do not overlap other blankets, such as on the forward, upper, and aft edges of the T/R. For other areas, use RTV106 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant application procedure. Refer to Appendix E for optional accelerated sealant cure time processes. Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, BMS 5-63 Type 1 sealant should be used in all areas of the firewall zone.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. a. Make sure the PDOS fitting and actuator end that is attached to it is sealed. The sealed area is inside the number 1 upper compression pad fitting blanket. Use only BMS 5-63 Type 1 sealant. Refer to Appendix D as an accepted procedure to seal the PDOS fitting. 8. OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure sealant is cured before the T/R is put into service. 9. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number and the work package completed to show the inspection was done. Refer to SOPM 20-50-10 as an accepted procedure. 10. Close the T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to close the T/R half. 11. Put the airplane back to a serviceable condition.
**WORK PACKAGE 3 - T/R PDOS FITTING INSPECTION**

**WARNING:** DO NOT MOVE BETWEEN THE ENGINE AND THE OPEN THRUST REVERSER UNTIL THE HOLD-OPEN ROD IS ENGAGED AND LOCKED. THE THRUST REVERSER IS HEAVY AND CAN CLOSE QUICKLY IF THE PDOS HAS A FAILURE. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT. 1. Open T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to open the T/R half.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 62 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** It is best to open the T/R half using the sling method. The PDOS actuator rod end must be disconnected from the number 1 compression pad fitting in an instruction below. 2. Remove all sealant and foam around the PDOS rod end and lugs of the number 1 compression pad fitting.

**WARNING:** MAKE SURE THAT THE HOLD OPEN ROD IS ENGAGED AND LOCKED AND ONE OR MORE HOLD OPEN DEVICE SECURES THE T/R HALF BEFORE THE PRESSURE IN THE PDOS ACTUATOR IS REMOVED. A T/R CAN FALL TO THE CLOSED POSITION QUICKLY, WHICH CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. 3. Remove the PDOS actuator rod end from the number 1 compression pad fitting. a. Push the T/R PDOS DOWN switch for 30 seconds to bleed the pressure from the actuator. b. Remove and keep the nut, washers, bolt, and bushing that holds the rod end to the number 1 compression pad fitting. c. Move the rod end away from the number 1 compression pad fitting. Secure the actuator as necessary.
**WARNING:** IF A COMPRESSION PAD FITTING IS REPLACED ON-WING, MAKE SURE THAT THE T/R IS OPEN IN A PLACE THAT NO WIND CAN BLOW ON IT. IF A PERSON ENTERS THE FAN DUCT COWL WHEN THE T/R IS OPEN, AND THE WIND BLOWS, TOO MUCH PRESSURE WILL BE PUT ON THE HOLD-OPEN ROD WHICH CAN FAIL. A T/R CAN FALL TO THE CLOSED POSITION QUICKLY, WHICH CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. 4. Do a detailed inspection of the removed bushing and the inner diameter of the number 1 compression pad fitting PDOS lug bushings for hole elongation, deformation, and contact with the PDOS actuator.

**NOTE:** Refer to Appendix H for PDOS lug bushing and hole acceptable diameters. A satisfactory diameter is in the specified limits. If a diameter is outside the specified limits, it is unsatisfactory. a. If the inner diameter of the PDOS lug bushings is unsatisfactory, remove the bushings and inspect the PDOS fitting lugs. b. If the number 1 compression pad fitting PDOS lugs are unsatisfactory, replace the number 1 compression pad fitting with a serviceable one. Refer to 777 AMM 78-31-01 pageblock 800 as an accepted procedure to install the number 1 compression pad fitting. (1) Remove insulation blankets as necessary to uncover the number 1 compression pad fitting. Refer to 777 AMM 78-31-06 as an accepted procedure to remove insulation blankets. c. Replace bushings that were found unsatisfactory. Install the bushings using BMS 5-63 sealant. Refer to SOPM 20-50-03 as an accepted procedure. Once installed, new bushings must be reamed to the acceptable diameters given in Appendix H. Refer to SOPM 20-10-09 copper beryllium.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

5. If insulation blanket(s) were removed, install them. Refer to 777 AMM 78-31-06 as an accepted procedure to install insulation blankets. BMS 1-68 foam can be used in gaps larger than 0.2 inches. Use BMS 5-63 Type 1 or RTV106 sealant, as applicable. Use only BMS 5-63 Type 1 sealant in areas of the firewall zone where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, use only BMS 5-63 Type 1 sealant on blanket edges in the firewall zone that do not overlap other blankets, such as on the forward, upper, and aft edges of the T/R. For other areas, use RTV106 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant application procedure. Refer to Appendix E for optional accelerated sealant cure time processes. Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, BMS 5-63 Type 1 sealant should be used in all areas of the firewall zone.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. 6. Install the PDOS actuator rod end to the number 1 upper compression pad fitting PDOS lugs with a serviceable nut, washers, bushing, and bolt. 7. Make sure the PDOS fitting and actuator end that is attached to it is sealed. The sealed area is inside the number 1 upper compression pad fitting blanket. Use only BMS 5-63 Type 1 sealant. Refer to Appendix D as an accepted procedure to seal the PDOS fitting. 8. OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure sealant is cured before the T/R is put into service. 9. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number and the work package completed to show the inspection was done. Refer to SOPM 20-50-10 as an accepted procedure. 10. Close the T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to close the T/R half. 11. Put the airplane back to a serviceable condition.
**WORK PACKAGE 4 - T/R COMPRESSION PAD NDT**

**WARNING:** DO NOT MOVE BETWEEN THE ENGINE AND THE OPEN THRUST REVERSER UNTIL THE HOLD-OPEN ROD IS ENGAGED AND LOCKED. THE THRUST REVERSER IS HEAVY AND CAN CLOSE QUICKLY IF THE PDOS HAS A FAILURE. THIS CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT. 1. Open the T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to open the T/R half. 2. Remove insulation blankets as necessary to uncover the number 1 upper and number 1 and 2 lower compression pad fittings. Refer to 777 AMM 78-31-06 as an accepted procedure to remove the insulation blankets.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. 3. Remove all sealant and foam around the PDOS rod end and lugs of the number 1 compression pad fitting.

**WARNING:** IF A COMPRESSION PAD FITTING IS REPLACED ON-WING, MAKE SURE THAT THE T/R IS OPEN IN A PLACE THAT NO WIND CAN BLOW ON IT. IF A PERSON ENTERS THE FAN DUCT COWL WHEN THE T/R IS OPEN, AND THE WIND BLOWS, TOO MUCH PRESSURE WILL BE PUT ON THE HOLD-OPEN ROD WHICH CAN FAIL. A T/R CAN FALL TO THE CLOSED POSITION QUICKLY, WHICH CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. 4. Do an eddy current conductivity test NDT of the number 1 upper and number 1 and 2 lower compression pad fittings. Refer to 777 AMM 78-31-06 page block 600 as an accepted procedure to NDT a compression pad. If the compression pad fitting is white, it must still have an eddy current conductivity test NDT.

**NOTE:** If the fitting does not pass the conductivity test, it is unsatisfactory. a. Remove unsatisfactory compression pad fitting. Refer to 777 AMM 78-31-01 page block 800, as an accepted procedure to remove compression pad fittings. b. Do an NDT for delamination and disbonding of the inner wall panel under the unsatisfactory compression pad. Use a one inch grid pattern to scan the inner wall panel areas. (1) For an NDT of ply build-up areas (greater than 4 plies) refer to 777 NDT, Part 4, 78-30-01 (High Frequency Bond Test), or 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)), as accepted procedures for the NDT of ply build-up areas. Refer to Appendix F for locations of ply build up areas. c. Do a general visual inspection of the inner wall panel for areas of thermal degradation. These areas show wall color that appears different than the normal wall. See 777-MTIP-78-016 for examples of areas of thermal degradation. (1) Do a Barcol hardness inspection of the inner wall panel in areas that are thought to have thermal degradation. Use Barcol hardness tester GYZJ934-1. Use a 0.5 inch grid pattern to scan the entire area that is thought to have thermal degradation.

**NOTE:** Acceptable hardness for the T/R inner wall is greater than or equal to 50 Barcol hardness units.

**NOTE:** The Barcol hardness tester, calibration disks, and test disks are supplied in tool MIT315W5100. (a) If an indication of less than 50 Barcol hardness units is measured, test a different location within 0.25 inches of the initial low indication. (b) If the second indication is greater than or equal to 50 Barcol hardness units, neglect the initial low indication.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** (c) If the second indication is less than 50 Barcol hardness units, test the surrounding area to define the full area of softness. Soft areas with a diameter larger than 0.25 inches must be repaired. d. Do a detailed inspection of the inner wall panel bolt holes for the removed unsatisfactory compression pad fitting. Look for unsatisfactory elongation of the holes. Refer to the table below for acceptable bolt hole diameters. Diameters that exceed the maximum hole diameter given are unsatisfactory.

(1) If an inner wall panel bolt hole for the unsatisfactory compression pad fitting has been repaired with a titanium bushing, do a general visual inspection for migration or looseness of the bushing. (a) If bushing migration or looseness is found, remove the bushing. Repair the inner wall panel bolt hole as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. (b) If bushing migration or looseness is not found, no action is necessary. e. Repair the inner wall panel where disbonds, delaminations, areas of softness, and elongated holes are found as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. Or, replace the inner wall panel assembly with a serviceable one. f. Install a serviceable compression pad fitting for unsatisfactory ones. Refer to 777 AMM 78-31-01 pageblock 800 as an accepted procedure to install compression pad fittings. 5. Install insulation blankets. Refer to 777 AMM 78-31-06 as an accepted procedure to install the insulation blankets. BMS 1-68 foam can be used in gaps larger than 0.2 inches. Use BMS 5-63 Type 1 or RTV106 sealant, as applicable. Use only BMS 5-63 Type 1 sealant in areas of the firewall zone where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, use only BMS 5-63 Type 1 sealant on blanket edges in the firewall zone that do not overlap other blankets, such as on the forward, upper, and aft edges of the T/R. For other areas, use RTV106 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant application procedure. Refer to Appendix E for optional accelerated sealant cure time processes. Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets. **Removed Fastener Maximum Hole Diameter**  BACB30NY6K* 0.194 BACB30NY8K* 0.254 ASPFF-V06-22AC 0.208Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, BMS 5-63 Type 1 sealant should be used in all areas of the firewall zone.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. a. Make sure the PDOS fitting and actuator end that is attached to it is sealed. The sealed area is inside the number 1 upper compression pad fitting blanket. Use only BMS 5-63 Type 1 sealant. Refer to Appendix D as an accepted procedure to seal the PDOS fitting. 6. OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure sealant is cured before the T/R is put into service. 7. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number and the work package completed to show the inspection was done. Refer to SOPM 20-50-10 as an accepted procedure. 8. Close the T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to close the T/R half. 9. Put the airplane back to a serviceable condition.
**WORK PACKAGE 5 - PERFORATED WALL SIDE INSPECTION** 1. Deactivate the T/R for ground maintenance. Refer to 777 AMM 78-31-00 as an accepted procedure to deactivate the T/R. 2. Do a general visual inspection of the perforated side of the T/R wall, aft of the Intermediate Pressure compressor 8th Stage (IP8) and High Pressure compressor 3rd Stage (HP3) bleed port exits. a. Inspect 12 inches circumferentially on either side of the IP8/HP3 bleed port exits and at least 36 inches aft. Look for color that is different then the general area, this can be an indication of an overheat condition. b. If a different color is found, do an NDT inspection of the discolored area for delamination and disbonding on the perforated side of the inner wall. Refer to 777 NDT, Part 1, 51-05-01 (TapTest of Honeycomb Sandwich Structure), or 777 NDT, Part 4, 78-30-02ThroughTransmission Ultrasonic (TTU)) as an accepted procedure. (1) If disbonded or delaminated areas are found, contact Boeing for repair procedures and do the repair. (2) If no disbonded or delaminated areas are found, no action is necessary. c. If no color differences are found, no action is necessary. 3. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number and the work package completed to show the inspection was done. Refer to SOPM 20-50-10 as an accepted procedure.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 67 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

4. Activate the T/R. Refer to 777 AMM 78-31-00 as an accepted procedure to activate the T/R. 5. Put the airplane back into a serviceable condition.
**WORK PACKAGE 6 - T/R INNER WALL PANEL - LIMITED AREA NDT** 1. Open T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to open the T/R half. 2. Remove the insulation blankets attached to the T/R half inner wall. It is only necessary to remove insulation blankets that cover the field core areas (four ply areas) in the barrel of the T/R, aft of the blocker door drag link fittings. Refer to 777 AMM 78-31-06 as an accepted procedure to remove the insulation blankets. Refer to Appendix F for locations of ply build up areas.

**NOTE:** The aft most upper blanket stud can rotate like a defective bonded stud when the nut is turned. Make sure the head of the bolt is held, if necessary, to remove the nut and washer. The blanket can be damaged if this blanket attachment is not removed correctly. 3. Solvent clean the inner wall panel. Refer to SOPM 20-30-03 as an accepted procedure to solvent clean the inner wall.

**NOTE:** In addition to the acceptable solvents found in SOPM 20-30-03, Isopropyl Alcohol can also be used. a. Do not remove marks on the inner wall that have recorded information that should be kept for inspectors or other personnel. 4. Do an NDT for delamination and disbonding of the inner wall panel. Use a one inch grid pattern to scan the inner wall panel areas. It is only necessary to NDT field core areas (four ply areas) in the barrel of the T/R, aft of the blocker door drag link fittings. Inspection of the upper and lower bifurcation walls is not required. Refer to 777 NDT, Part 4, 78-30-02 (Through Transmission Ultrasonic, (TTU)),or Low Frequency Bond Test, 777 NDT, Part 4, 78-30-03, as accepted procedures to NDT field core areas. Refer to Appendix F for locations of ply build up areas. 5. Do a general visual inspection of the inner wall panel for areas of thermal degradation. These areas show wall color that appears different than the normal wall. See 777-MTIP-78-016 for examples of areas of thermal degradation. a. Do a Barcol hardness inspection of the inner wall panel in areas that are thought to have thermal degradation. Use Barcol hardness tester GYZJ934-1. Use a 0.5 inch grid pattern to scan the entire area that is thought to have thermal degradation.

**NOTE:** Acceptable hardness for the T/R inner wall is greater than or equal to 50 Barcol hardness units.

**NOTE:** The Barcol hardness tester, calibration disks, and test disks are supplied in tool MIT315W5100. (1) If an indication of less than 50 Barcol hardness units is measured, test a different location within 0.25 inches of the initial low indication. (2) If the second indication is greater than or equal to 50 Barcol hardness units, neglect the initial low indication.Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 68 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** (3) If the second indication is less than 50 Barcol hardness units, test the surrounding area to define the full area of softness. Soft areas with a diameter larger than 0.25 inches must be repaired. 6. Repair the inner wall panel where disbonds, delaminations, and areas of softness are found as given in 777-200 SRM 54-32-01 or 777-300 SRM 54-32-01. For damage that exceeds the SRM limits, or for repairs not in the SRM, contact Boeing for repair instructions and do the repair. Or, replace the inner wall panel assembly with a serviceable one. 7. Install insulation blankets. Refer to 777 AMM 78-31-06 as an accepted procedure to install the insulation blankets. BMS 1-68 foam can be used in gaps larger than 0.2 inches. Use BMS 5-63 Type 1 or RTV106 sealant, as applicable. Use only BMS 5-63 Type 1 sealant in areas of the firewall zone where the overlapped blanket face sheet distance is greater than 0.100 inch. Also, use only BMS 5-63 Type 1 sealant on blanket edges in the firewall zone that do not overlap other blankets, such as on the forward, upper, and aft edges of the T/R. For other areas, use RTV106 sealant. Refer to Appendix G for the area of the firewall zone. Refer to SOPM 20-50-19 as an accepted sealant application procedure. Refer to Appendix E for optional accelerated sealant cure time processes. Refer to Appendix I as an accepted procedure to establish the distance between overlapped blanket face sheets.

**NOTE:** If the overlapped blanket face sheet distance is not measured or cannot be determined, BMS 5-63 Type 1 sealant should be used in all areas of the firewall zone.

**NOTE:** Make sure to apply new sealant over adjacent good sealant and make a gradual transition from old to new sealant. a. Make sure the PDOS fitting and actuator end that is attached to it is sealed. The sealed area is inside the number 1 upper compression pad fitting blanket. Use only BMS 5-63 Type 1 sealant. Refer to Appendix D as an accepted procedure to seal the PDOS fitting. 8. OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.

**NOTE:** Make sure sealant is cured before the T/R is put into service. 9. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number and the work package completed to show the inspection was done. Refer to SOPM 20-50-10 as an accepted procedure. 10. Close the T/R half. Refer to 777 AMM 78-31-00 as an accepted procedure to close the T/R half. 11. Put the airplane back to a serviceable condition.**APPENDIX A: INSPECTION EXAMPLES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 69 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX A: INSPECTION EXAMPLES**



### EXAMPLE 1 THRUST REVERSER INNER WALL (LEFT SIDE SHOWN RIGHT SIDE SIMILAR) PDOS FITTING

NUMBER 1 UPPER COMPRESSION PAD

FWD



### A SEE A B C D REMOVE INSULATION BLANKET AND DO AN NDT INSPECTION OF INNER WALL

EXAMPLE AREA OF MISSING OR LOOSE CLICKBOND1422180**APPENDIX A: INSPECTION EXAMPLES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 70 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

EXAMPLE 2 THRUST REVERSER INNER WALL (LEFT SIDE SHOWN RIGHT SIDE SIMILAR) PDOS FITTING

NUMBER 1 UPPER COMPRESSION PAD

EXAMPLE AREA OF CRACK OR GAP LARGER THAN 0.100.

FWD



### B REMOVE INSULATION BLANKET AND DO AN NDT INSPECTION OF INNER WALL1422186**APPENDIX A: INSPECTION EXAMPLES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 71 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

EXAMPLE AREA OF CRACK OR GAP LARGER THAN 0.100 OR MISSING OR LOOSE CLICK BOND



### EXAMPLE 3 THRUST REVERSER INNER WALL (LEFT SIDE SHOWN RIGHT SIDE SIMILAR) PDOS FITTING

NUMBER 1 UPPER COMPRESSION PAD

FWD



### C REMOVE INSULATION BLANKET AND DO AN NDT INSPECTION OF INNER WALL1422192**APPENDIX A: INSPECTION EXAMPLES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 72 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

EXAMPLE 4 THRUST REVERSER INNER WALL (LEFT SIDE SHOWN RIGHT SIDE SIMILAR) PDOS FITTING

NUMBER 1 UPPER COMPRESSION PAD

FWD



### D EXAMPLE AREA OF GAP OR MISSING SEALANT LARGER THAN 0.100 FOR THE INITIAL INSPECTION OF EACH T/R, DO NOT NEED TO REMOVE BLANKET DUE TO DAMAGED OR MISSING SEALANT ON AFT EDGE OF THRUST REVERSER1663900**APPENDIX A: INSPECTION EXAMPLES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 73 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** The example numbers shown below agree with the example numbers shown in the Appendix A figures. The Condition and Action gives a description for the Example shown. **Example Condition Action** 1 Missing or loose click bond, in a blanket. Remove the affected blanket and do an NDT of the inner wall panel area that is within 12 inches of the missing or loose click bond.**APPENDIX A: INSPECTION EXAMPLES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 74 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

2 Sealant crack or gap larger than 0.100 inch in the seam of adjacent blankets covering the number 1 and 2 lower compression pad fittings. Measure the distance between the overlapped blanket face sheets adjacent to the damaged or missing sealant. If the distance is less than or equal to 0.100 inch, assume the sealant crack or gap is less than 0.100 inch. Removal of the insulation blankets is not necessary.
If the distance is more than 0.100 inch, remove the affected adjacent blankets. Do an NDT of the inner wall panel area that is within 12 inches of the damaged sealant. Also, do an NDT of the number 2 lower compression pad fittings if it is within 12 inches of the damaged sealant. 3 Sealant crack or gap larger than 0.100 inch, or missing or loose click bond in adjacent blankets. For a missing or loose click bond, remove the affected adjacent blankets. Do an NDT of the inner wall panel area that is within 12 inches of the missing or loose click bond. For a sealant crack or gap larger than 0.100, measure the distance between the overlapped blanket face sheets adjacent to the damaged or missing sealant. If the distance is less than or equal to 0.100 inch, assume the sealant crack or gap is less than 0.100 inch. Removal of the insulation blankets is not necessary.
If the distance is more than 0.100 inch, remove the affected adjacent blankets. Do an NDT of the inner wall panel area that is within 12 inches of the damaged sealant. **Example Condition Action APPENDIX A: INSPECTION EXAMPLES**  Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 75 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

4 Damaged or missing sealant larger than 0.100 inch on aft edge of the thrust reverser. For the initial inspection only, blanket removal due to missing or damaged sealant on the forward, upper, or aft edge of the thrust reverser. Apply sealant as given in the accomplishment instructions. For each repeat inspection, measure the distance between the inner wall and the blanket at the blanket edge adjacent to the damaged or missing sealant. If the distance is less than or equal to 0.100 inch, assume the sealant crack or gap is less than 0.100 inch. Removal of the insulation blankets is not necessary.
If the distance is more than 0.100 inch, remove the affected adjacent blanket and do an NDT of the inner wall panel area that is within 12 inches of the damaged or missing sealant. **Example Condition Action APPENDIX B: DELETED**  Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 76 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX B: DELETED** This appendix has been deleted. The inner wall repair information that was previously in this appendix are now in 777-200 SRM 54-32-01 and 777-300 SRM 54-32-01.**APPENDIX C: SEALANT REMOVAL INSTRUCTIONS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 77 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX C: SEALANT REMOVAL INSTRUCTIONS** 1. Clean a width wider than the width of the applied sealant. 2. Abrade surface area that will have sealant applied with 150 grit, or finer abrasive paper, until all unsatisfactory sealant is removed from area to be sealed. Do not damage the facesheet of the insulation blanket. 3. Remove loose particles or foreign matter from surface to be sealed by wiping with clean white cotton cleaning wipers, dampened in hand wipe cleaner solvent. Use solvent, or equivalent, given in SOPM 20-50-19, surface preparation section, as accepted solvents for cleaning the surface. 4. Dry area immediately with clean, dry white cotton cleaning wipers.**APPENDIX D: PDOS FITTING - SEALANT INSTRUCTIONS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 78 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX D: PDOS FITTING - SEALANT INSTRUCTIONS**

Insulate the Powered Door Opening System (PDOS) fitting using BMS1-68 Grade A, Form III or II Silicone Foam and BMS5-63 Type 1, Class B-4 Sealant. 1. Measure the sides of the void to cut a block of foam or to build up a block from foam layers. 2. Cut the block or build up a block of foam to the dimensions taken. 3. Cut the block as necessary to wrap around the fitting and actuator rod. 4. Cut out the approximate shape of the fittings and actuator rod, from the cut block, such that it can be installed in the void and enclose the fittings and rod. 5. Place the cut foam block in the void, around the fittings and actuator rod, until they contact the T/R inner wall panel. 6. Apply BMS5-63 Type 1, Class B-4 sealant to the exposed surface of the foam. Make sure that the sealant covers the foam surface and cut edge and encases the actuator rod end. Make sure the sealant fillet seals the edges of the insulation blanket. Do not compress the foam.

**NOTE:** OPTIONAL: For improved durability of the BMS 5-63 Type 1 sealant, Operators can cover satisfactory BMS 5-63 Type 1 sealant with RTV106 sealant. Accelerated sealant cure time processes, as given in Appendix E, can be used to cure sealant on the insulation blankets.**APPENDIX E: SEALANT RTV106 AND BMS 5-63 TYPE 1 - ACCELERATED CURE PROCESSES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 79 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX E: SEALANT RTV106 AND BMS 5-63 TYPE 1 - ACCELERATED CURE PROCESSES** The accelerated cure processes outlined in this appendix are optional. As an alternative, normal cure times and processes can be used. Refer to SOPM 20-50-19 as an accepted sealant procedure. The cure times provided in the following processes are approximate. Variations in the temperature or humidity will change the cure times. The maximum temperatures that can be used to cure the sealant are provided. Monitor the sealant and surrounding structure to make sure that it stays at or below 150 degrees F, +/- 10 degrees F. If accelerated cure processes are used, a durometer measurement device must be used to ensure the sealant is fully cured before the T/R is put into service. **RTV106 over BMS 5-63 Type 1:** This cure process is permitted for application of BMS 5-63 Type 1 silicone sealant with an overcoat of RTV106 silicone sealant to the Thrust Reverser (T/R) inner wall insulation blankets: 1. Clean area of insulation blanket, equal to or greater than (1 inch greater is recommended) the area sealant is to be applied. Refer to SOPM 20-50-19 as an accepted procedure to prepare surface and for application of sealants. Also, clean two pieces of aluminum or CRES sheet metal at least 1 in. X 1 in. square (to be used as cure test samples). 2. Prime area with a thin layer of BMS5-63 Type I and cure for minimum of 30 minutes at room temperature (77 degrees F, +/- 10 degrees F). Prime the two pieces of sheet metal using the same process. 3. Apply BMS5-63 Type I sealant to insulation blanket surface(s) and cure for a minimum of 1 hour at 150F(+/ -10F). Apply same sealant to two pieces of sheet metal and cure in the same environment as the BMS 5- 63 Type I blanket sealant. Make sure that a minimum of one sample is tack free. A. If not tack free, allow an additional 30 minutes of cure time and check again. If still not tack free, the sealant mix will not cure, the process must be started again. B. If tack free, continue with the process. 4. Mist apply BMS 5-63, Type I sealant surface with deionized water. Also, mist apply on one cured sheet metal sample. 5. Apply RTV106 sealant and cure for 3 hours at 150F(+/-10F). Also, apply to the misted metal sample and cure in the same environment as the RTV106 blanket sealant. 6. Test sheet metal sample with RTV106 over BMS5-63 sealant for durometer hardness. The sheet metal sample should lay flat to support the hardness tester. The sealant is properly cured with a minimum of 26 Shore A hardness at the end of the 3 hour cure. If not fully cured, allow 1 additional hour at 150F (+/-10F). 7. If the test sample has satisfactory hardness, the insulation blanket(s) can be put into service. **BMS 5-63 Type 1 Only:** This cure process is permitted for application of BMS 5-63 Type 1 silicone sealant on the T/R inner wall insulation blankets:**APPENDIX E: SEALANT RTV106 AND BMS 5-63 TYPE 1 - ACCELERATED CURE PROCESSES** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 80 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** 1. Clean area of insulation blanket, equal to or greater than (1 inch greater is recommended) the area sealant is to be applied. Refer to SOPM 20-50-19 as an accepted procedure to prepare surface and for application of sealants. Also, clean two pieces of aluminum or CRES sheet metal at least 1 in. X 1 in. square (to be used as cure test samples). 2. Prime area with a thin layer of BMS5-63 Type I and cure for minimum of 30 minutes at room temperature (77 degrees F, +/- 10 degrees F). Prime the two pieces of sheet metal using the same process. 3. Apply BMS5-63 Type I sealant to insulation blanket surface(s) and cure for a minimum of 4 hours at 150F(+/ -10F). Apply same sealant to two pieces of sheet metal and cure in the same environment as the BMS 5- 63, Type I blanket sealant. Make sure that a minimum of one sample is tack free. A. If not tack free, allow an additional 30 minutes of cure time and check again. If still not tack free, the sealant mix will not cure, the process must be started again. B. If tack free, continue with the process. 4. Test sheet metal sample with for durometer hardness. The sheet metal sample should lay flat to support the hardness tester. The sealant is properly cured with a minimum of 26 Shore A hardness at the end of the 4 hour cure. If not fully cured, allow 1 additional hour at 150F (+/-10F). 5. If the test sample has satisfactory hardness, the insulation blanket(s) can be put into service. **RTV106 Only:** This cure process is permitted for application of RTV106 silicone sealant on the T/R inner wall insulation blankets: 1. Clean area of insulation blanket, equal to or greater than (1 inch greater is recommended) than the area sealant is to be applied. Refer to SOPM 20-50-19 as an accepted procedure to prepare surface and for application of sealants. Also, clean two pieces of aluminum or CRES sheet metal at least 1 in. X 1 in. square (to be used as cure test samples). 2. Mist apply area with an application of deionized water. Do the same to two pieces of sheet metal using the same process. 3. Apply RTV106 sealant and cure for 3 hours at 150F(+/-10F). Also, apply to the misted metal sample and cure in the same environment as the RTV106 blanket sealant. 4. Test sheet metal sample with RTV106 sealant for durometer hardness. The sheet metal sample should lay flat to support the hardness tester. The sealant is properly cured with a minimum of 26 Shore A hardness at the end of the 3 hour cure. If not fully cured, allow 1 additional hour at 150F (+/-10F). 5. If the test sample has satisfactory hardness, the insulation blanket(s) can be put into service.**APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 81 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS**



### THRUST REVERSER INNER WALL PANEL - RIGHT SIDE 1

3 2



### 13 12 13 15 12 4 4 13 4 9

13 13 13 5 13 13 13 13 17
5 13 17 7 9 13 9

5 17 15 12 4 13 13 13 5 4 7 8 13 5 9 9

TYPICAL

8

13 5

FWD 90° +45°

-45°

0°1463780**APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 82 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

PLY LAYUP AND CORE RIBBON DIRECTION VIEW IS ON THE BAG SIDE (NON-AERODYNAMIC) SURFACE The numbers shown in the circle symbols in the figures, are the number of plies on the bag side of the thrust reverser inner wall panel. 

### THRUST REVERSER INNER WALL PANEL - LEFT SIDE 1 3

13

12 13 15 12

4 4 13 9

13 13 13 13 13

12 17

13 17

13

9 17 15

13 13 4 7 13 5

9 TYPICAL

13 5 5

12 12

FWD 90° +45°

-45°

0°1469450**APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 83 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** The numbers in the flagnotes in the figures agree with the flagnotes in the below table.

More data is given in the tables below: **FLAG NOTE DATA** 1 Two plies were added to this area for Thrust Reverser (T/R) Part Number (P/N) 315W5295 -61, -62, -63, -64, -65, -66, -67, - 68, -69, -70, -71, -72, -73, -74, -75, -76, -81, -82, -83, -84 2 Four plies were added to this area for T/R P/N 315W5295 -70, - 72, -74, -76, -82, -84 3 The cross hatched area are ply build-up areas. NDT inspect these areas from the thin area to the thick area.

**T/R P/N Data** 315W5001 -23, -24, -25, -26, -45, -46, -47, -48 Ply numbers are as stated on the above figures. 315W5295 -1, -2, -3, -4, -5, -6, -7, -8, -9, -10, - 11, -12, -13, -14, -15, -16, -18, -20, -21, -22, - 23, -24, -25, -27, -28, -29, -30, -31, -32, -33, - 34, -35, -36, -41, -42, -43, -44, -49, -50, -51, - 52, -54, -53, -55, -56, -57, -58, -59, -60 Ply numbers are as stated on the above figures.

315W5317 -1, -2, -3, -4 Ply numbers are as stated on the above figures. 315W5295 -61, -62, -63, -64, -65, -66, -67, -68, -69, -71, -73, -75, -81, -83, Ply numbers are as stated on the above figures, except see Flagnote 1 for added plies. 315W5295 -70, -72, -74, -76, -82, -84 Ply numbers are as stated on the above figures, except see Flagnote 1 and 2 for added plies.

**Left Side T/R T/R P/N Inner Wall P/N [1] Drawing / Sheet Number**  315W5001 -23, -25, -45, -47 315W5101 -77 For Airplanes: WB181-WB181 315W5101 / 14

315W5001 -23, -25, -45, -47 315W5101 -1 For Airplanes: WA086-WA089 WA101-WA104 WA196-WA198 WB101-WB103 WB161-WB161 

### 315W5101 / 11

315W5295 -1,-3, 5, -7, -9, -11 315W5101 -77 315W5101 / 14 315W5317 -1, -3 315W5101 -86 315W5101 / 24 315W5295 -13, -15, -21, -23, 25, - 27, -29, -31 315W5295 -33, -35 315W5101 -87 315W5101 / 33 thru 48**APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 84 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

315W5295 -41, -43, -49, -51, -53, - 55, -57, -59 315W5101 -100 315W5101 / 49 thru 59

315W5295 -61, -63 315W5101 -201 For Airplanes: WA001-WA001 WB037-WB042 WB172-WB172 WB236-WB236 WB605-WB606 WB632-WB632 WB637-WB637 WC053-WC064 WC101-WC102 315W5101 / 73 thru 83

315W5295 -61, -63 315W5101 -301 For Airplanes: WB043-WB046 WB173-WB175 WB189-WB191 WB201-WB214 WB237-WB244 WB434-WB437 WB453-WB453 WB616-WB618 WB633-WB635 WB638-WB638 WB646-WB649 WC065-WC073 WC103-WC104 315W5101 / 97 thru 107

315W5295 -65, -67 315W5101 -201 315W5101 / 73 thru 83 315W5295 -69, -71, -73, -75, -81, - 83 315W5101 -313 315W5101 / 125, 126, 133, 134, 139 thru 141 [1] - Identification by customer variable number is given if not applicable for all airplanes effective for this bulletin. P/N is based on the airplane in its original Boeing delivery configuration. **Left Side T/R T/R P/N Inner Wall P/N [1] Drawing / Sheet Number** **APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 85 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT Right Side T/R**  **T/R P/N Inner Wall P/N[1] Drawing / Sheet Number** 315W5001 -24, -26, -46, -48 315W5102 -79 For Airplane: WB181-WB181 315W5102 / 18

315W5001 -24, -26, -46, -48 315W5102 -1 For Airplanes: WA086-WA089 WA101-WA104 WA196-WA198 WB101-WB103 WB161-WB161 

### 315W5102 / 1

315W5295 -2, -4, -6, -8, -10, -12, - 18, -20 315W5102 -79 315W5102 / 18
315W5317 -2, -4 315W5102 -86 315W5102 / 28 315W5295 -14, -16, -22, -24, 26, - 28, -30, -32 315W5295 -34, -36 315W5102 -87 315W5102 / 37 thru 53 315W5295 -42, -44, -50, -52, -54, - 56, -58, -60 315W5102 -101 315W5102 / 54 thru 65
315W5295 -66, -68 315W5102 -201 315W5102 / 80 thru 91 315W5295 -62, -64 315W5102 -201 For Airplanes: WA001-WA001 WB037-WB042 WB172-WB172 WB236-WB236 WB605-WB606 WB632-WB632 WB637-WB637 WC053-WC064 WC101-WC102 315W5102 / 80 thru 91

315W5295 -62, -64 315W5102 -301 For Airplanes: WB043-WB046 WB173-WB175 WB189-WB191 WB201-WB214 WB237-WB244 WB434-WB437 WB453-WB453 WB616-WB618 WB633-WB635 WB638-WB638 WB646-WB649 WC065-WC073 WC103-WC104 315W5102 / 106 thru 117**APPENDIX F: INNER WALL PANEL PLY BUILDUP AREAS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 86 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

315W5295 -70, -72 315W5102 -311 315W5102 / 118, 119, 126, 127, 132 thru 134 315W5295 -74, -76, -82, -84 315W5102 -313 315W5102 / 135, 136, 143, 144, 149 thru 151 [1] - Identification by customer variable number if not applicable for all airplanes effective for this bulletin. P/N is based on the airplane in its original Boeing delivery configuration. **Right Side T/R T/R P/N Inner Wall P/N[1] Drawing / Sheet Number** **APPENDIX G: THRUST REVERSER INNER WALL - FIREWALL ZONE** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 87 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX G: THRUST REVERSER INNER WALL - FIREWALL ZONE** The bottom boundary of the firewall zone is the horizontal seam of the insulation blankets as given below.



### RIGHT THRUST REVERSER HALF LEFT THRUST REVERSER HALF UP

FWD


### A B SEE SEE A

FWD UP



### B BOTTOM BOUNDARY (INSULATION BLANKET SEAM)

FIREWALL ZONE FIREWALL ZONE1463120**APPENDIX H: PDOS LUG HOLE AND BUSHING DIAMETERS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 88 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX H: PDOS LUG HOLE AND BUSHING DIAMETERS** The illustration below provides the acceptable hole and bushing diameters for the PDOS fitting lugs.

0.8132 0.8125 DIA. 0.6256 0.6250 DIA.

0.6877 0.6870 DIA.

0.5007 0.5000 DIA.1546454**APPENDIX I: PROCEDURES TO ESTABLISH THE DISTANCE BETWEEN OVERLAPPED BLANKET FACE SHEETS**  Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 89 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX I: PROCEDURES TO ESTABLISH THE DISTANCE BETWEEN OVERLAPPED BLANKET FACE SHEETS**  This appendix contains methods to determining the distance between the overlapped blanket face sheets.

A A

STEP HEIGHT D UPPER BLANKET

LOWER BLANKET

UPPER BLANKET

LOWER BLANKET SEALANT



### A-A D= DISTANCE BETWEEN OVERLAPPED BLANKET FACE SHEETS TYPICAL BLANKET OVERLAP TYPICAL BLANKET OVERLAP WITH SEALANT CRACK CRACK GREATER THAN 0.100

D D FEELER GAUGE TOOL (OR SIMILAR) METHOD 1: METHOD 2:1552368**APPENDIX I: PROCEDURES TO ESTABLISH THE DISTANCE BETWEEN OVERLAPPED BLANKET FACE SHEETS**  Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 90 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
METHOD 1: 1. Measure the step height between the overlapped blankets. 2. If the upper blanket has a Kapton face sheet, subtract 0.030 inches from the measured step height.

**NOTE:** The Kapton-faced blankets are a dark red color. 3. If the upper blanket has a CRES face sheet, subtract 0.250 inches from the measured step height.

**NOTE:** The CRES metal-faced blankets are a silver color with a textured surface. 4. The resulting value is the distance between the overlapped blanket face sheets, D.
METHOD 2: 1. Remove sealant as necessary to get access to the overlapping blanket seam. 2. Insert a feeler gauge or other similar tool into the blanket seam to determine the distance, D.

**NOTE:** Use light pressure when inserting the tool to avoid enlarging the blanket gap.**APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 91 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**
**APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS** This appendix illustrates the sealant type requirements for the different areas on the thrust reverser. Apply sealant type to the insulation blanket edges or seams as indicated. For gaps greater than 0.2 inches, BMS 1- 68 foam can be used and overcoated with the sealant type indicated.**APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 92 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

FWD

BMS 5-63, TYPE 1 SEALANT ONLY (a)

FIREWALL ZONE



### LEFT THRUST REVERSER HALF RTV 106 SEALANT (b) BMS 5-63, TYPE 1 OR RTV 106 SEALANT, AS APPLICABLE (c)1663629**APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 93 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT**

NOTE: FWD

BMS 5-63, TYPE 1 SEALANT ONLY (a) RTV 106 SEALANT (b) BMS 5-63, TYPE 1 OR RTV 106 SEALANT, AS APPLICABLE (c) 

### RIGHT THRUST REVERSER HALF FIREWALL ZONE1663891**APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS** Original Issue: June 23, 2008 Revision 2: May 06, 2010 777-78A0065 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 94 of 94 

### BOEING SERVICE BULLETIN 777-78A0065 **ALERT ALERT** (a) For areas in the firewall zone on blanket edges that do not overlap other blankets, such as on the forward, upper, and aft edges of the thrust reverser, BMS 5-63, Type 1 sealant must be used. Also, BMS 5-63, Type 1 sealant can be overcoated with RTV106 sealant for improved durability. (b) For all areas outside of the firewall zone, use RTV106 sealant. (c) For blanket seams in the firewall zone where blankets overlap, use the following criteria: — If the overlapped blanket face sheet distance is greater than 0.100, use BMS 5-63, Type 1 sealant. — If the overlapped blanket face sheet distance is equal to or less than 0.100, use RTV106 or BMS 5-63, Type 1 sealant. — If the overlapped blanket face sheet distance is not known or cannot be determined, use BMS 5-63, Type 1 sealant. — Any BMS 5-63, Type 1 sealant can be overcoated with RTV106 sealant for improved durability.