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Revision 2: May 06, 2010 777-78A0065

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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Unpublished Work - All Rights Reserved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 

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This document includes proprietary information owned by The Boeing Company and/or one or more third 

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more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

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 Table of Contents

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS . . . . . . . . . . . . . . 91
 Table of Contents

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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.
 

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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, 2010
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ALERT ALERT

Commercial

Airplanes 777

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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.
 

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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 runway
 

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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 6.00
 

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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
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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 engines
 

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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 1
 

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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
 

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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 runway
 

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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, 426
 

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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

 -
 

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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)
 

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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)
 

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BOEING SERVICE BULLETIN 777-78A0065

ALERT ALERT

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.

Assume the damaged or 

missing sealant is less than or 

equal to 0.100 inch across. 

Therefore, replace damaged 

or missing sealant as given in 

the accomplishment instructions of 3.B.WORK PACKAGE 

1, PART A.

 Before further flight -

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.

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)
 

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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)
 

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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 bolt 

hole 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)
 

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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)
 

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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)
 

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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 cycles
 

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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)
 

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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)
 

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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)
 

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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 disbonded 

areas 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)
 

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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 -
 

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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 bolt 

hole as given in the accomplishment instructions of 

3.B.WORK PACKAGE 1, 

PART A, or WORK PACKAGE 1, PART B.

Before further flight -
 

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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)
 

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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.
 

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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.
 

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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 0.50
 

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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
 

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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, 78-30
 

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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.
 

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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)
 

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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
 

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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
 

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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 ribbon 

direction. 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
 

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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 Tester 
 

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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 the 
 

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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:
 

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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. 
 

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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.
 

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(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. 
 

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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. 
 

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{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 0.208
 

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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.
 

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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:
 

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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:
 

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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.
 

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(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.
 

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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. 
 

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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.
 

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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. 
 

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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 0.208
 

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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.
 

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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.
 

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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.
 

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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. 
 

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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.
 

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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.
 

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(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 0.208
 

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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 (Tap 

Test 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.
 

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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.
 

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(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

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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

CLICKBOND

1422180
 APPENDIX A: INSPECTION EXAMPLES

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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 WALL

1422186
 APPENDIX A: INSPECTION EXAMPLES

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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 WALL

1422192
 APPENDIX A: INSPECTION EXAMPLES

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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 REVERSER

1663900
 APPENDIX A: INSPECTION EXAMPLES

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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

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 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

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 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

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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

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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

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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

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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

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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

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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

5 13 13 13 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

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 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

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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

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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

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 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

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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

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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. 

LEFT THRUST REVERSER HALF RIGHT THRUST REVERSER HALF

UP

FWD

A

SEE A SEE B

FWD

UP

B

BOTTOM BOUNDARY

(INSULATION BLANKET SEAM)

FIREWALL

ZONE

FIREWALL

ZONE

1463120
 APPENDIX H: PDOS LUG HOLE AND BUSHING DIAMETERS

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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

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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

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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

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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

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ALERT ALERT

FWD

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

FIREWALL

ZONE

RTV 106 SEALANT (b) LEFT THRUST REVERSER HALF

BMS 5-63, TYPE 1 OR RTV 106 SEALANT,

AS APPLICABLE (c)

1663629
 APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS

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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

ZONE

1663891
 APPENDIX J: THRUST REVERSER - SEALANT TYPE REQUIREMENTS

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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.