### Commercial **Airplanes** 

# 767

Service Bulletin **ALERT Number:**  **767-53A0266** Original Issue: April 20, 2015 ATA System: 5380 **SUBJECT:** FUSELAGE - Aft Pressure Bulkhead - STA 1582 Aft Pressure Bulkhead Web Inspection

Under Pressure Chord Splice Plate Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2015 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: April 20, 2015 767-53A0266 1of 41 5.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 2of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**

BLANK PAGE**Table of Contents**

Summary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1. PLANNING INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Effectivity

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1. Airplanes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. Spares Affected

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Concurrent Requirements

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Reason

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Compliance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Approval

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 H. Weight and Balance Changes

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

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

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

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 M. Software Accomplishment Summary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2. MATERIAL INFORMATION

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Parts Necessary for Each Airplane

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Kits/Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Parts and Materials Supplied by the Operator

. . . . . . . . . . . . . . . . . . . . . . . . 25 3. Parts Modified and Reidentified

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4. Parts Removed and Not Replaced

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Parts Necessary to Change Spares

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

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

. . . . . . . . . . . . . . . . . . . . . . . 26 3. ACCOMPLISHMENT INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FIGURE 1: AFT PRESSURE BULKHEAD WEB COMMON TO PRESSURE CHORD SPLICE PLATE -

FASTENER REMOVAL AND WEB INSPECTION[Group 2, Configuration 1; Group 3]

. . 32 FIGURE 2: AFT PRESSURE BULKHEAD WEB COMMON TO PRESSURE CHORD SPLICE PLATE -

FASTENER REMOVAL AND WEB INSPECTION[Group 1; Group 2, Configuration 2; Group 4]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 3: AFT PRESSURE BULKHEAD - PRESSURE CHORD SPLICE PLATES - FASTENER

INSTALLATION[Group 2, Configuration 1; Group 3]

. . . . . . . . . . . . . . . . . . . . . 36 FIGURE 4: AFT PRESSURE BULKHEAD - PRESSURE CHORD SPLICE PLATES - FASTENER

INSTALLATION[Group 1; Group 2, Configuration 2; Group 4]

. . . . . . . . . . . . . . . 38 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: AFT PRESSURE

BULKHEAD WEB INSPECTIONS AT PRESSURE CHORD JOINT.[Group 2, Configuration 1; Group 3-4]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 3of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: AFT PRESSURE BULKHEAD WEB INSPECTIONS AT PRESSURE CHORD JOINT.[Group 1; Group 2, Configuration 2]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 4of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767

Service Bulletin **ALERT Summary**  **Number: 767-53A0266**  Original Issue: April 20, 2015 ATA System: 5380 **SUBJECT:** FUSELAGE - Aft Pressure Bulkhead - STA 1582 Aft Pressure Bulkhead Web Inspection

Under Pressure Chord Splice Plate THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Accomplishment of the inspection described in this service bulletin will enable detection and repair of cracks if they should occur, in the areas under splice plates at the Station (STA) 1582 aft pressure bulkhead web to pressure chord joint. If a crack is present in the aft pressure bulkhead web and not found and repaired, crack growth can result in possible rapid decompression and loss of structural integrity. The aft pressure bulkhead web is attached to the pressure chords with a double row of fasteners and the pressure chord segments are spliced using pressure chord splice plates. At these splice plate locations, the aft pressure bulkhead web is hidden and cannot be inspected in accordance with existing 767 MPD Section 9or Service Bulletin (SB)767-53A0087and do not provide sufficient crack detection probability of the aft pressure bulkhead web under splice plates. Boeing Service Related Problem (SRP) 767-SRP-53-0470is related to this service bulletin. Boeing SB 767-53A0087and 767-53A0139are related to this service bulletin. Boeing 767 MPD SSI 53-80-I01Ais related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Complianceand Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 5of 41**Reference Affected**  **Planning Data** Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**ACTION** Get access to the forward and aft sides of the aft pressure bulkhead at STA 1582. Locate the splice plates that splice pressure chords on the circumference of the forward side of the aft pressure bulkhead. Remove the aft row of fasteners from each splice plate and do an open hole High Frequency Eddy Current (HFEC) inspection for any crack in the aft pressure bulkhead web. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, install new fasteners, close access to the area and repeat the inspection at the time specified in Paragraph 1.E., Compliance

. **EFFECTIVITY** All 767-200/-300/-300F/-400ER airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an additional 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 DirectiveAD 2004-05-16is related to this service bulletin. The effective date ofAD 2004-05-16is April 13, 2004. Federal Aviation Administration (FAA) Airworthiness DirectiveAD 2012-09-08is related to this service bulletin. The effective date ofAD 2012-09-08is June 18, 2012. Federal Aviation Administration (FAA) Airworthiness DirectiveAD 2014-14-04is related to this service bulletin. The effective date ofAD 2014-14-04is September 5, 2014. This service bulletin is related to 767 MPD SSI 53-80-I01A, which is mandated byAD 2014-14-04. All other MPD inspections outside of the affected area are not affected and must continue. Refer to Paragraph 1.E., Compliance

. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 6of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT MANPOWER**  **Elapsed Hours**  **Total Task Hours**  **Airplanes**
12.60 45.20 Group 1, Configuration 1 Airplanes 13.35 46.70 Group 1, Configuration 2 Airplanes 12.60 45.20 Group 2, Configuration 1 Passenger Airplanes 8.60 17.20 Group 2, Configuration 1 Converted Freighters 13.35 46.70 Group 2, Configuration 2 Passenger Airplanes 9.35 18.70 Group 2, Configuration 2 Converted Freighters 12.60 45.20 Group 3 Passenger Airplanes 8.60 17.20 Group 3 Freighters and Converted Freighters 13.35 46.70 Group 4 Passenger Airplanes 9.35 18.70 Group 4 Freighters and Converted Freighters
Refer to Paragraph 1.G., Manpower

. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability

.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 7of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 8of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767

Service Bulletin **ALERT Number:**  **767-53A0266** Original Issue: April 20, 2015 ATA System: 5380 **SUBJECT:** FUSELAGE - Aft Pressure Bulkhead - STA 1582 Aft Pressure Bulkhead Web Inspection

Under Pressure Chord Splice Plate THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A.**  **Effectivity** 1. Airplanes This service bulletin is applicable to all 767 Airplanes, in 4 Groups. The Variable Numbers and Group Information for the applicable airplanes are given below. Refer toService Bulletin Index D624T001Part 3 for Airplane Variable Number, Line Number, and Serial Number data. **NOTE:** The Variable Number table below includes all affected airplanes up to Line Number 1097. Affected airplanes after Line Number 1097 will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page.
**DESCRIPTION CONFIGURATION**  **GROUP** Airplanes from line number 1 to 175 with aft pressure bulkhead replaced in accordance with SB 767-53A0139, with four pressure chord splice plates. - 1

Airplanes from line number 176 to 423.

- 2 Airplanes with original production bulkhead installed with three pressure chord splice plates. 1
Airplanes with aft pressure bulkhead replaced in accordance with a

Boeing Organization Design Authorization (ODA) approval via FAA Form 8100-9, with four pressure chord splice plates. 2

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 9of 41**DESCRIPTION CONFIGURATION**  **GROUP** Airplanes from line number 424 to 926 installed with three pressure chord splice plates. - 3
Airplanes from line number 927 and on installed with four pressure chord splice plates. - 4

Airplane Models: 767-200, 767-300, 767-300F, 767-400ER **Group Variable Number**  1 VA001 - VA020 1 VA301 - VA315 1 VA501 - VA526 2 VA527 - VA530 1 VA701 - VA712 2 VA713 - VA719 1 VA801 - VA810 1 VB001 - VB002 1 VB051 - VB055 1 VB101 - VB125 1 VB201 - VB202 1 VB251 - VB253 1 VB281 - VB284 1 VB301 - VB302 1 VB321 - VB324 2 VB325 - VB332 1 VB371 - VB373 1 VB401 3 VB441 - VB444 1 VE001 - VE002 2 VE003 1 VE021 - VE023 1 VE041 - VE043 1 VE061 - VE068

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 10of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group**  **Variable Number** 2 VE069 1 VE083 - VE084 2 VE085 - VE086 1 VE101 - VE103 2 VE104 1 VE116 - VE117 2 VE118 1 VE121 - VE123 2 VE124 - VE126 1 VE141 - VE142 2 VE143 - VE151 3 VE152 2 VE171 - VE172 2 VF001 - VF002 2 VF041 - VF042 2 VF051 2 VF061 - VF062 2 VF071 - VF072 2 VF091 - VF093 2 VF101 - VF102 2 VF161 3 VF162 3 VF171 - VF172 3 VF180 - VF184 3 VF251 1 VK001 - VK004 2 VK005 - VK011 3 VK012 - VK016 2 VK021 - VK022 1 VK031 - VK037 2 VK038 - VK053 3 VK054 - VK056 2 VK081 - VK099

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 11of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group**  **Variable Number** 3 VK100 - VK113 2 VK131 - VK133 2 VK141 - VK142 3 VK143 - VK148 3 VK161 - VK164 3 VK171 3 VK181 3 VK186 1 VL001 2 VL002 - VL006 1 VL011 3 VL701 - VL703 3 VL751 - VL755 3 VL806 - VL807 3 VL871 - VL873 3 VL891 - VL900 3 VL911 - VL914 3 VL931 - VL932 3 VL941 2 VN001 - VN019 3 VN020 - VN041 2 VN051 - VN062 3 VN063 - VN064 2 VN081 - VN092 3 VN093 - VN099 2 VN111 - VN124 3 VN125 - VN127 2 VN130 - VN132 3 VN133 - VN137 2 VN151 - VN158 2 VN163 - VN168 2 VN171 - VN173 3 VN174

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 12of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group**  **Variable Number** 2 VN191 - VN193 3 VN194 - VN198 2 VN211 - VN212 2 VN221 - VN224 3 VN225 2 VN231 - VN234 2 VN241 3 VN242 - VN243 2 VN251 - VN259 3 VN260 - VN276 2 VN291 3 VN292 - VN293 2 VN301 - VN306 3 VN307 - VN314 2 VN371 - VN372 2 VN376 2 VN381 3 VN382 - VN388 3 VN421 - VN427 3 VN436 2 VN471 - VN472 2 VN491 - VN496 3 VN497 - VN513 2 VN531 - VN532 2 VN536 - VN537 2 VN541 - VN542 3 VN546 - VN547 2 VN551 3 VN556 - VN557 3 VN561 - VN562 2 VN631 - VN633 3 VN634 - VN638 2 VN651 - VN652

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 13of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group**  **Variable Number** 3 VN653 - VN658 2 VN671 - VN672 3 VN676 2 VN681 - VN683 3 VN684 - VN691 2 VN731 3 VN732 2 VN751 - VN753 3 VN791 - VN792 3 VN811 - VN813 3 VN921 - VN922 3 VN931 - VN936 3 VN951 - VN953 3 VN966 - VN972 3 VQ001 - VQ021 3 VQ071 - VQ086 4 VQ111 3 VR051 - VR060 3 VR081 3 VR084 3 VR086 4 VR087 - VR089 4 VR106 - VR109 3 VR201 - VR211 3 VR251 3 VR256 - VR260 4 VR266 - VR292 3 VR401 3 VR421 - VR423 3 VR426 3 VR441 3 VR461 3 VR471 - VR472

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 14of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group**  **Variable Number** 3 VS051 - VS056 3 VS061 3 VS066 - VS070 3 VS073 - VS078 3 VS091 - VS104 3 VS111 - VS113 3 VS131 - VS133 3 VS136 - VS137 3 VS176 - VS177 3 VS186 - VS187 3 VS196 - VS203 3 VS206 - VS208 3 VS211 3 VS216 - VS217 3 VS231 3 VS246 - VS248 3 VS261 - VS263 3 VS266 - VS274 3 VS291 - VS293 3 VS301 - VS303 3 VS306 - VS311 3 VS316 3 VS321 - VS324 3 VS331 - VS333 3 VS336 - VS337 3 VS366 - VS367 3 VS381 - VS382 3 VS391 - VS392 3 VS401 3 VS426 - VS428 3 VS466 - VS472 3 VS486 3 VS496 - VS497

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 15of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group**  **Variable Number** 3 VS506 - VS507 3 VS526 3 VS546 - VS549 3 VS701 - VS710 4 VS711 - VS720 3 VS721 - VS731 4 VS732 - VS736 3 VS751 - VS759 3 VS821 - VS825 3 VS841 - VS844 3 VS861 3 VS881 - VS882 4 VS883 3 VS891 4 VS896 4 VS901 - VS912 4 VS916 4 VS921 - VS928 4 VS931 - VS933 4 VS941 4 VS951 - VS954 4 VS961 - VS969 4 VS971 - VS977 4 VS981 - VS984 4 VT001 - VT013 4 VT021 4 VT031 - VT033 3 VT501 4 VT511 - VT513 4 VT521 - VT523 4 VT531 - VT533 4 VT541 - VT546 4 VT551 - VT552

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 16of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group**  **Variable Number** 4 VT556 - VT585 3 VV001 3 VW701 - VW721 3 VW851
2. Spares Affected None. **B. Concurrent Requirements**  None. **C. Reason**  Accomplishment of the inspection described in this service bulletin will enable detection and repair of cracks if they should occur, in the areas under splice plates at the STA 1582 aft pressure bulkhead web to pressure chord joint. If a crack is present in the aft pressure bulkhead web and not found and repaired, crack growth can result in possible rapid decompression and loss of structural integrity. The aft pressure bulkhead web is attached to the pressure chords with a double row of fasteners and the pressure chord segments are spliced using pressure chord splice plates. At these splice plate locations, the aft pressure bulkhead web is hidden and cannot be inspected in accordance with existing 767 MPD Section 9or SB767-53A0087and do not provide sufficient crack detection probability of the aft pressure bulkhead web under splice plates. Boeing Service Related Problem 767-SRP-53-0470is related to this service bulletin. Boeing Service Bulletins 767-53A0087and 767-53A0139are related to this service bulletin. Boeing 767 MPD SSI 53-80-I01Ais related to this service bulletin. **D. Description**  Get access to the forward and aft sides of the aft pressure bulkhead at STA 1582. Locate the splice plates that splice pressure chords on the circumference of the forward side of the aft pressure bulkhead. Remove the aft row of fasteners from each splice plate and do an open hole HFEC inspection for any crack in the aft pressure bulkhead web. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, install new fasteners, close access to the area and repeat the inspection at the time specified in Paragraph 1.E., Compliance

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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 17of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group 1-2:** 

**Affected Maintenance Zones Zone**  **Model** 165, 166, 251, 252, 253, 254, 311, 312 767-200, 767-300 **Group 3-4:**
**Affected Maintenance Zones Zone**  **Model** 165, 166, 251, 252, 253, 254, 311, 312 767-200, 767-300, 767-300F, 767-400ER
**E. Compliance**  The Federal Aviation Administration (FAA) will possibly release an additional 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 DirectiveAD 2004-05-16is related to this service bulletin. The effective date ofAD 2004-05-16is April 13, 2004. Federal Aviation Administration (FAA) Airworthiness DirectiveAD 2012-09-08is related to this service bulletin. The effective date ofAD 2012-09-08is June 18, 2012. Federal Aviation Administration (FAA) Airworthiness DirectiveAD 2014-14-04is related to this service bulletin. The effective date ofAD 2014-14-04is September 5, 2014. This service bulletin is related to767 MPD SSI 53-80-I01Aof767 MPD 622T001-9, which is mandated byAD 2014-14-04. All other MPD inspections outside of the affected area are not affected and must continue. Logic diagrams showing compliance tasks and compliance times are included as an aid inAPPENDIX AandAPPENDIX B

. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 18of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group 2, Configuration 1; Group 3-4:** 

**Table 1: Open Hole High Frequency Eddy Current (HFEC) Inspection at STA 1582 Aft Pressure Bulkhead Web Under the Pressure Splice Plates**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 

- Within 3,000flight cycles after the original issue date ofthis service bulletin. Before 50,000total flight cycles. Do PART 2: FASTENER REMOVAL AND OPENHOLE HFEC INSPECTION of the aft pressure bulkhead web for any crack. All airplanes.

(a)

- Before further flight. Contact The BoeingCompany for repair instructions and do the repair. CONDITION 1: ANY CRACK FOUND IN THEAFT PRESSURE BULKHEAD WEB. 12,000 flight cycles. - - Repeat PART 2: FASTEN- ER REMOVAL ANDOPEN HOLE HFEC INSPECTION of the aft pressure bulkhead web for any crack. CONDITION 2: NO CRACK FOUND IN THEAFT PRESSURE BULKHEAD WEB.
(a) (a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs approved by Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage tolerance inspection instructions specified in approval for existing repairs must continue. Inspection outside of the repaired area must continue in accordance with this service bulletin. **Group 1; Group 2, Configuration 2: Table 2: Open Hole High Frequency Eddy Current (HFEC) Inspection at STA 1582 Aft Pressure Bulkhead**  **Web Under the Pressure Splice Plates Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever**  **Occurs Later) Action**  **Condition**

- Within 3,000flight cycles after the original issue date ofthis service bulletin. Within 37,500flight cycles after replacementof the aft pressure bulkhead. Do PART 2: FASTENER REMOVAL AND OPENHOLE HFEC INSPECTION of the aft pressure bulkhead web for any crack. All airplanes.

(a)

- Before further flight. Contact The BoeingCompany for repair instructions and do the repair. CONDITION 1: ANY CRACK FOUND IN THEAFT PRESSURE BULKHEAD WEB.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 19of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group 1; Group 2, Configuration 2:** 

**Table 2: Open Hole High Frequency Eddy Current (HFEC) Inspection at STA 1582 Aft Pressure Bulkhead Web Under the Pressure Splice Plates**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition**  12,000 flight cycles. - - Repeat PART 2: FASTEN- ER REMOVAL ANDOPEN HOLE HFEC INSPECTION of the aft pressure bulkhead web for any crack. CONDITION 2: NO CRACK FOUND IN THEAFT PRESSURE BULKHEAD WEB.
(a) (a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs approved by Boeing ODA via FAA 8100-9 form cover the affected inspection areas. Damage tolerance inspection instructions specified in approval for existing repairs must continue. Inspection outside of the repaired area must continue in accordance with this service bulletin.
**F. Approval**  This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. The Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the accomplishment of inspections defined in this Service Bulletin (SB) along with the corresponding compliance times specified in Paragraph 1.E., Complianceof this SB, Original Issue, as an Alternative Method Of Compliance (AMOC) to the inspections defined in D622T001-DTR Structural Significant Item (SSI) 53-80-I01A and Section 9 of the Maintenance Planning Document (MPD) D622T001-9, required by paragraphs (i) and (k) of Airworthiness Directive (AD) 2014-14-04. This AMOC only applies to the areas inspected in accordance with this SB. All other inspections outside of this SB inspection region are not affected and must continue. All provisions ofAD 2014-14-04that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. In Addition, the Manager of the FAA SACO approves the accomplishment of inspections defined in this SB along with the corresponding compliance times specified in Paragraph 1.E., Complianceof this SB, Original Issue, as an AMOC to the inspections defined in SB767-53A0087required by paragraphs (a) and (b) ofAD 2004-05-16. This AMOC only applies to the areas inspected in accordance with this SB. All other inspections outside of this SB inspection region are not affected and must continue. All provisions ofAD 2004-05-16that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 20of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**In addition, the Manager of the FAA SACO approves the accomplishment of inspections, after Replacement of an Aft Pressure Bulkhead, defined in this SB along with the corresponding compliance times specified in Paragraph 1.E., Complianceof this SB, Original Issue, as an AMOC to the inspections defined in SB 767-53A0139required by paragraph (h) ofAD 2012-09-08. This AMOC only applies to the areas inspected in accordance with this service bulletin. All other inspections outside of this service bulletin inspection region are not affected and must continue. All provisions ofAD 2012-09-08that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. **G. Manpower**  The tables below show estimates of the task hours necessary to do the inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimates do 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. **Group 2, Configuration 1; Group 3: Passenger Airplanes Only**  **Elapsed Hours Task Hours**  **Number of Persons Task**  5.00 20.00 4 Open Access 2.35 4.70 2 FIGURE 1 0.25 0.50 2 FIGURE 3 5.00 20.00 4 Close Access 12.60 45.20 TOTAL FOR EACH AIRPLANE **Group 2, Configuration 1; Group 3: Freighters and Converted Freighters Only**  **Elapsed Hours Task Hours**  **Number of Persons Task**  3.00 6.00 2 Open Access 2.35 4.70 2 FIGURE 1 0.25 0.50 2 FIGURE 3 3.00 6.00 2 Close Access 8.60 17.20 TOTAL FOR EACH AIRPLANE

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 21of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT Group 1; Group 2, Configuration 2; Group 4:**  **Passenger Airplanes Only Elapsed Hours**  **Task Hours Number of Persons**  **Task** 5.00 20.00 4 Open Access 3.00 6.00 2 FIGURE 2 0.35 0.70 2 FIGURE 4 5.00 20.00 4 Close Access 13.35 46.70 TOTAL FOR EACH AIRPLANE **Group 1; Group 2, Configuration 2; Group 4: Freighters and Converted Freighters Only**  **Elapsed Hours Task Hours**  **Number of Persons Task**  3.00 6.00 2 Open Access 3.00 6.00 2 FIGURE 2 0.35 0.70 2 FIGURE 4 3.00 6.00 2 Close Access 9.35 18.70 TOTAL FOR EACH AIRPLANE
**H. Weight and Balance Changes**  None. **I. Electrical Load Data**  Not changed. **J. References**  1. Existing Data:

a. Boeing Service Bulletin 767-53A0087, 767-53A0139 b. Boeing Service Letter 767-SL-51-036

c. Boeing Service Related Problem (SRP) 767-SRP-53-0470 d. Federal Aviation Administration (FAA) Airworthiness Directive (AD)2004-05-16,2012-09-08, 2014-14-04

e. Service Bulletin Index D624T001 f. Standard Overhaul Practices Manual (SOPM) 20-50-01

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 22of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**g. 767 Aircraft Maintenance Manual (AMM)25-31-04,25-52-01,25-52-03,25-55-01,25-59-01, 25-59-05, 27-41-00, 38-11-01, 38-32-11 h. 767 Maintenance Planning Data (MPD) 622T001-9, Section 9, SSI 53-80-I01A i. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-04, Part 6, 51-00-11 j. 767-200 Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05 k. 767-200SF Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05 l. 767-300 Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05

m. 767-300BCF Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05

n. 767-300F Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05

o. 767-400 Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:

**Title Drawing Number**  Splice Plate - Press Bulkhead STA 1582 148T2620 Bulkhead End Item Pressure Dome, Station 1582.0 148T2610 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected**  1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

**L. Interchangeability and Intermixability of Parts**  Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 23of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT M.**  **Software Accomplishment Summary**

Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 24of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability**  None. **B. Industry Support Information**  Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. **C. Parts Necessary for Each Airplane**  1. Kits/Parts None. 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. **Group 2, Configuration 1; Group 3:**
**Notes Name**  **QTY Part Number /**  **Specification**

- Rivet 18 BACR15FT6D8C **Group 1; Group 2, Configuration 2; Group 4:**
**Notes Name**  **QTY Part Number /**  **Specification**

- Rivet 24 BACR15FT6D8C
3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. **D. Parts Necessary to Change Spares**  None. **E. Special Tooling - Price and Availability**  None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 25of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT F.**  **Special Tooling Necessary to do this Service Bulletin**

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 26of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch

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

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 767 Structural Repair Manual, Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 767 Aircraft Maintenance Manual (AMM).

4. Use the approved fastener, process and material substitutions in accordance with

SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer toSOPM 20-50-01for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 6. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.
7. Boeing Service Letter 767-SL-51-036, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 27of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**8. Refer to Appendices A and B for logic diagrams. Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 9. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 10. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 11. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 12. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 13. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance

. 14. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC must be done to comply with the AD. Alternative procedures for steps not identified with RC can be used if the RC steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. **B. WORK INSTRUCTIONS**  1. Do PART 1: OPEN ACCESS. 2. RC - Do PART 2: FASTENER REMOVAL AND OPEN HOLE HFEC INSPECTION.

a. CONDITION 1: ANY CRACK FOUND IN THE AFT PRESSURE BULKHEAD WEB. (1) RC - Contact The Boeing Company for repair instructions and do the repair. b. CONDITION 2: NO CRACK FOUND IN THE AFT PRESSURE BULKHEAD WEB. (1) RC - Repeat PART 2: FASTENER REMOVAL AND OPEN HOLE HFEC INSPECTION. 3. Do PART 3: FASTENER INSTALLATION. 4. Do PART 4: CLOSE ACCESS. 5. Put the airplane back to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 28of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT PART 1: OPEN ACCESS**  1. For passenger airplanes only:

a. Remove and keep the aft galley. Refer to 767 AMM 25-31-04as an accepted procedure. 2. For freighter airplanes (including Boeing Converted Freighters) only:

a. Remove and keep the cargo lining panels from the aft pressure bulkhead in the main deck cargo compartment. Refer to 767 AMM 25-59-01as an accepted procedure. 3. Remove and keep insulation from around splice plates that splice pressure chords on the aft pressure bulkhead in the main deck cargo compartment. Refer to 767 AMM 25-59-05as an accepted procedure. 4. Remove and keep the end wall in the bulk cargo compartment. Refer to767 AMM 25-52-01as an accepted procedure. 5. For passenger airplanes only:

a. Remove and keep the right side potable water tank. If installed, remove and keep the left side potable water tank. Refer to 767 AMM 38-11-01as an accepted procedure. b. If necessary for access, remove and keep the waste tank. On some affected airplanes, the waste tanks are installed forward of the affected area. On these airplanes, waste tank removal is not necessary for access to the aft pressure bulkhead. Refer to 767 AMM 38-32-11as an accepted procedure. 6. Remove and keep insulation from around splice plates that splice pressure chords on the aft pressure bulkhead in the bulk cargo compartment. Refer to 767 AMM 25-52-03as an accepted procedure. **WARNING:** MAKE SURE THAT PERSONNEL AND EQUIPMENT ARE CLEAR OF THE HORIZONTAL

STABILIZER AND ELEVATOR SURFACES BEFORE MOVING THE STABILIZER. INJURY TO PERSONNEL AND DAMAGE TO EQUIPMENT COULD OCCUR.
7. Position the horizontal stabilizer to neutral and deactivate controls. Refer to 767 AMM 27-41-00 as an accepted procedure. **WARNING:** DO NOT STAND ON ACCESS DOOR 312AR. THE WEIGHT OF PERSONNEL COULD

CAUSE THE SPRING LOADED LATCH TO RELEASE, AND PERSONNEL MAY BE INJURED BY FALLING THROUGH THE OPENING. 8. Open access door 312AR for access to the aft side of the aft pressure bulkhead. Use a suitable platform or cover over the access door while working inside the tail section. **PART 2: FASTENER REMOVAL AND OPEN HOLE HFEC INSPECTION CAUTION:**  TO PREVENT ANY MOVEMENT OF THE PRESSURE DOME, PERFORM PART 2 ON

ONE SPLICE PLATE AT A TIME.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 29of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**IF DRILLING OF FASTENERS IS REQUIRED, HOLD STEEL SHEETS TO THOSE FASTENERS ON THE AFT SIDE OF THE AFT PRESSURE BULKHEAD. 1. **Group 2, Configuration 1; Group 3:** Remove the aft row of fasteners from splice plates that splice pressure chords and do open hole HFEC inspections for any crack in the aft pressure bulkhead web in accordance with FIGURE 1

. 2. **Group 1; Group 2, Configuration 2; Group 4:** Remove the aft row of fasteners from splice plates that splice pressure chords and do open hole HFEC inspections for any crack in the aft pressure bulkhead web in accordance with FIGURE 2

. **PART 3: FASTENER INSTALLATION** 1. **Group 2, Configuration 1; Group 3:** Install the aft row of fasteners on splice plates that splice pressure chords in accordance with FIGURE 3

. 2. **Group 1; Group 2, Configuration 2; Group 4:** Install the aft row of fasteners on splice plates that splice pressure chords in accordance with FIGURE 4

. **PART 4: CLOSE ACCESS WARNING:**  DO NOT STAND ON ACCESS DOOR 312AR. THE WEIGHT OF PERSONNEL COULD

CAUSE THE SPRING LOADED LATCH TO RELEASE, AND PERSONNEL MAY BE INJURED BY FALLING THROUGH THE OPENING. 1. Remove any platforms or covers that were used to cover access door 312AR and close the access door. **WARNING:** MAKE SURE THAT PERSONNEL AND EQUIPMENT ARE CLEAR OF THE HORIZONTAL

STABILIZER AND ELEVATOR SURFACES BEFORE MOVING THE STABILIZER. INJURY TO PERSONNEL AND DAMAGE TO EQUIPMENT COULD OCCUR. 2. Reactivate controls for the horizontal stabilizer. Refer to 767 AMM 27-41-00as an accepted procedure. 3. Install insulation to splice plates that splice pressure chords on the aft pressure bulkhead in the bulk cargo compartment. Refer to 767 AMM 25-52-03as an accepted procedure. 4. For passenger airplanes only:

a. If removed, install the waste tank. Refer to 767 AMM 38-32-11as an accepted procedure. b. Install the right side potable water tank. If removed, install the left side potable water tank. Refer to 767 AMM 38-11-01as an accepted procedure. 5. Install the end wall in the bulk cargo compartment. Refer to 767 AMM 25-55-01as an accepted procedure. 6. Install insulation to splice plates that splice pressure chords on the aft pressure bulkhead in the main deck compartment. Refer to 767 AMM 25-59-05as an accepted procedure.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 30of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**7. For passenger airplanes only:

a. Install the aft galley. Refer to 767 AMM 25-31-04as an accepted procedure. 8. For freighter airplanes (including Boeing Converted Freighters) only:

a. Install the cargo lining panels to the aft pressure bulkhead in the main deck cargo compartment. Refer to 767 AMM 25-59-01as an accepted procedure.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 31of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT This Figure applies only to: Group 2, Configuration 1; Group 3.** 

**FIGURE 1: AFT PRESSURE BULKHEAD WEB COMMON TO PRESSURE CHORD SPLICE PLATE -**  **FASTENER REMOVAL AND WEB INSPECTION**

**(SHEET 1 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 32of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step**  Six fasteners on aft row of each of three splice plates. (a) (b) 18
- Fastener Remove 1

Do a HFEC inspection of open holesfor any crack in accordance with 767 NDT Manual Part 6, 51-00-04or 767 NDT Manual Part 6, 51-00-11. (b) 3
- Aft Pressure Bulkhead Web Inspect 2

(a) Refer to 767-200 SRM 51-40-02, 767-200SF SRM 51-40-02, 767-300 SRM 51-40-02, 767-300F SRM 51-40-02, 767-300BCF SRM 51-40-02or 767-400 SRM 51-40-02as an accepted procedure. (b) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs approved by the Boeing ODA via FAA form 8100-9 cover the affected inspection areas. Damage Tolerance Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the repaired region must continue in accordance with this service bulletin.

**FIGURE 1: AFT PRESSURE BULKHEAD WEB COMMON TO PRESSURE CHORD SPLICE PLATE -**  **FASTENER REMOVAL AND WEB INSPECTION**

**(SHEET 2 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 33of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT This Figure applies only to: Group 1; Group 2, Configuration 2; Group 4.** 

**FIGURE 2: AFT PRESSURE BULKHEAD WEB COMMON TO PRESSURE CHORD SPLICE PLATE -**  **FASTENER REMOVAL AND WEB INSPECTION**

**(SHEET 1 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 34of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step**  Six fasteners on aft row of each of four splice plates. (a) (b) 24
- Fastener Remove 1

Do a HFEC inspection of open holesfor any crack in accordance with 767 NDT Manual Part 6, 51-00-04or 767 NDT Manual Part 6, 51-00-11. (b) 4
- Aft Pressure Bulkhead Web Inspect 2

(a) Refer to 767-200 SRM 51-40-02, 767-200SF SRM 51-40-02, 767-300 SRM 51-40-02, 767-300F SRM 51-40-02, 767-300BCF SRM 51-40-02or 767-400 SRM 51-40-02as an accepted procedure. (b) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs approved by the Boeing ODA via FAA form 8100-9 cover the affected inspection areas. Damage Tolerance Inspection instructions specified in approval for existing repairs must continue. Inspection outside of the repaired region must continue in accordance with this service bulletin.

**FIGURE 2: AFT PRESSURE BULKHEAD WEB COMMON TO PRESSURE CHORD SPLICE PLATE -**  **FASTENER REMOVAL AND WEB INSPECTION**

**(SHEET 2 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 35of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT This Figure applies only to: Group 2, Configuration 1; Group 3.** 

**FIGURE 3: AFT PRESSURE BULKHEAD - PRESSURE CHORD SPLICE PLATES - FASTENER**  **INSTALLATION (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 36of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step**  Six rivets on aft row of each of three splice plates. (a) (b) 18 BACR15FT6D8C Rivet Install (New) 1

(a) Refer to 767-200 SRM 51-40-02, 767-200SF SRM 51-40-02, 767-300 SRM 51-40-02, 767-300F SRM 51-40-02, 767-300BCF SRM 51-40-02or 767-400 SRM 51-40-02as an accepted procedure. Refer to 767-200 SRM 51-40-05, 767-200SF SRM 51-40-05, 767-300 SRM 51-40-05, 767-300F SRM 51-40-05, 767-300BCF SRM 51-40-05or 767-400 SRM 51-40-05for hole quality specifications. (b) Alternative fastener installation in accordance with 767-200 SRM 51-40-03, 767-200SF SRM 51-40-03, 767-300 SRM 51-40-03, 767-300F SRM 51-40-03, 767-300BCF SRM 51-40-03or 767-400 SRM 51-40- 03is allowed. Also, installation of BACB30VT6K*X and BACC30BL6 in a transition fit hole is acceptable.

**FIGURE 3: AFT PRESSURE BULKHEAD - PRESSURE CHORD SPLICE PLATES - FASTENER**  **INSTALLATION (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 37of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT This Figure applies only to: Group 1; Group 2, Configuration 2; Group 4.** 

**FIGURE 4: AFT PRESSURE BULKHEAD - PRESSURE CHORD SPLICE PLATES - FASTENER**  **INSTALLATION (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 38of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.
**More Data Qty**  **Identification Name**  **Task Step**  Six rivets on aft row of each of four splice plates. (a) (b) 24 BACR15FT6D8C Rivet Install (New) 1

(a) Refer to 767-200 SRM 51-40-02, 767-200SF SRM 51-40-02, 767-300 SRM 51-40-02, 767-300F SRM 51-40-02, 767-300BCF SRM 51-40-02or 767-400 SRM 51-40-02as an accepted procedure. Refer to 767-200 SRM 51-40-05, 767-200SF SRM 51-40-05, 767-300 SRM 51-40-05, 767-300F SRM 51-40-05, 767-300BCF SRM 51-40-05or 767-400 SRM 51-40-05for hole quality specifications. (b) Alternative fastener installation in accordance with 767-200 SRM 51-40-03, 767-200SF SRM 51-40-03, 767-300 SRM 51-40-03, 767-300F SRM 51-40-03, 767-300BCF SRM 51-40-03or 767-400 SRM 51-40- 03is allowed. Also, installation of BACB30VT6K*X and BACC30BL6 in a transition fit hole is acceptable.

**FIGURE 4: AFT PRESSURE BULKHEAD - PRESSURE CHORD SPLICE PLATES - FASTENER**  **INSTALLATION (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 39of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT This Appendix applies only to: Group 2, Configuration 1; Group 3-4.** 

Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Complianceis the primary source for compliance times. Information contained in Paragraph 3.B., Work Instructionsis the primary source for tasks required for compliance.

1. The table below gives the description for the parts and conditions called out in the logic diagrams. **Description Title**  FASTENER REMOVAL AND OPEN HOLE HFEC INSPECTION. PART 2 ANY CRACK FOUND IN THE AFT PRESSURE BULKHEAD WEB. CONDITION 1 NO CRACK FOUND IN THE AFT PRESSURE BULKHEAD WEB. CONDITION 2

**APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: AFT PRESSURE** 

**BULKHEAD WEB INSPECTIONS AT PRESSURE CHORD JOINT. (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 40of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT This Appendix applies only to: Group 1; Group 2, Configuration 2.** 

Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Complianceis the primary source for compliance times. Information contained in Paragraph 3.B., Work Instructionsis the primary source for tasks required for compliance.

1. The table below gives the description for the parts and conditions called out in the logic diagrams. **Description Title**  FASTENER REMOVAL AND OPEN HOLE HFEC INSPECTION. PART 2 ANY CRACK FOUND IN THE AFT PRESSURE BULKHEAD WEB. CONDITION 1 NO CRACK FOUND IN THE AFT PRESSURE BULKHEAD WEB. CONDITION 2

**APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: AFT PRESSURE** 

**BULKHEAD WEB INSPECTIONS AT PRESSURE CHORD JOINT. (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 20, 2015 767-53A0266 41of 41 **BOEING SERVICE BULLETIN 767-53A0266 ALERT**  **ALERT**