Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-57A0079

Original Issue: June 20, 2002

Revision 1: May 06, 2010

ATA System: 5750

SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting

Lug Inspection and Replacement

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ALERT ALERT

BLANK PAGE
Table of Contents

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

Summary ...................................................... 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 18

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 20

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 21

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES . . . . . . . 27

FIGURE 2: HINGE FITTING - DETAILED INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 3: HINGE FITTING - DETAILED - EDDY CURRENT INSPECTION . . . . . . . . . . . . . . 31

FIGURE 4: HINGE FITTING - REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 767-57A0079

Original Issue: June 20, 2002

Revision 1: May 06, 2010

ATA System: 5750

SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting

Lug Inspection and Replacement

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01, is related to this service bulletin.

No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.

REASON FOR REVISION

This revision is sent to:

1. To reduce the initial compliance time and repeat interval based on service reports. Subsequent to the original

issue of this service bulletin, operators have reported finding 3 fractured hinge fitting assemblies. The

fractured hinge fitting assemblies had accumulated less flight-cycles than the initial compliance threshold

and in 1 case, the hinge fitting assembly fractured after the original inspection and prior to the next repeat

inspection. Boeing Service Related Problem (SRP) 767-SRP-57-0233 was issued to address this issue.

2. Add instructions to transfer the stainless steel filler and the shims for the mid fairing roller from the old hinge

fitting assembly to the new hinge fitting assembly.

3. Revise inspection area to show inspection from the center of the lug forward, not the end of the lug forward.

This moves the inspection forward to inspect additional area where cracking has been found, not the lug

bore where cracking has not been found.

4. Add reference to the existing AD, add an AMOC to the existing AD, and reference the possible new AD

which would make the compliance tasks and times in Revision 1 of this service bulletin mandatory.

5. Update the format of the service bulletin to meet current service bulletin standards.

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These sections were changed:

1. Summary:

a. Background - Add the new reports of fracture and reference to the new Boeing Service Related Problem

(SRP) 767-SRP-57-0233.

b. Compliance - Add reference to the existing AD and the possible new AD which would make the

compliance tasks and times in Revision 1 of this service bulletin mandatory.

2. 1., Planning:

a. C., Reason - Add new reports of fracture and reference to the new Boeing Service Related Problem

(SRP) 767-SRP-57-0233.

b. D., Description - Add Compliance information related to the revision and Affected Maintenance Zone

Table.

c. E., Compliance - Add reference to the existing the AD and the possible new AD which would make the

compliance tasks and times in Revision 1 of this service bulletin mandatory.

d. F., Approval - Add AMOC statement for the existing AD.

e. J., References - Add reference to new SRP number. Add Reference to existing FAA AD.

3. 2., Material Information

a. A., Material - Price and Availability - Updated price data.

4. 3., Accomplishment Instructions:

a. A., General Notes:

(1) Note 6 - Revise note to remove the one grip length variance and refer to the SRM for installation

standards. Operators have reported grip length variances greater than the 1 grip length.

b. B., Work Instructions:

c. Figure 1 - Revise the inital threshold and the repeat interval for the Part 2 - Detailed - Eddy Current

Inspection due to reports of cracks.

d. Figure 3 - Illustration - Revise inspection area to show inspection from the center of the lug forward,

not the end of the lug forward.

e. Figure 4:

(1) Illustration: Revise inspection area to show inspection from the center of the lug forward, not the

end of the lug forward.

(2) Step Table: Add new steps 7 and 8 to transfer the stainless steel filler and the shims for the mid

fairing roller from the old hinge fitting assembly to the new hinge fitting assembly.

(3) Fastener Table: Change "reference" to "refer to as an accepted procedure" to meet current service

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BOEING SERVICE BULLETIN 767-57A0079

ALERT ALERT
bulletin standards.

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 20, 2002

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BOEING SERVICE BULLETIN 767-57A0079

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-57A0079

Original Issue: June 20, 2002

Revision 1: May 06, 2010

ATA System: 5750

SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting

Lug Inspection and Replacement

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Accomplishment of this service bulletin will detect cracks, prevent fractures and ensure the structural integrity

of the inboard trailing edge main flap outboard hinge fittings. Fracture of the hinge fittings could result in the

inboard aft flap becoming unrestrained potentially striking the aircraft upon departure, resulting in significant

damage to the surrounding structure and cause potential personal injury.

One operator of a 767-300 reported lug fractures on both the inboard and outboard hinge fittings of the outboard

hinge assembly mounted to the main flap. The hinge assembly provides one of two primary attachment points

of the inboard trailing edge aft flap assembly. The inboard fitting was fractured through the lug hole. The outboard

fitting was fractured just above the lug hole. The fractured fittings were found during a routine maintenance

inspection. The airplane had accumulated 9,598 flight-hours and 5,393 flight cycles.

During root cause analysis of the fractured hinge fitting it was discovered that an optional tool runout was not

present on the damaged fitting assemblies. The tool runout option allows the part to be machined thicker within

the area reported to be fractured. Boeing has received no reports of cracks or fractures on fitting that have the

additional material area of the optional tool runout. Service bulletin 767-57A0076 was released to inspect and

replace the suspect hinge fittings if and as required on all 767-200, 767-300 and 767-300F airplanes line numbers

1 through 825. The inboard trailing edge main flap outboard hinge fittings on the 767-400 are similar in design

to the 767-200, 767-300 and 767-300F fittings. The 767-400 fittings are wider and thicker however higher fatigue

loads are associated with the 767-400 in this area. Analysis indicates the 767-400 fittings could be susceptible

to early fatigue cracking and or fractures as a result of these higher loads.

Subsequent to the original issue of this service bulletin, 3 reports of hinge assembly fracture have been received.

The fractures all occurred at approximately 9,100 flight-cycles and in 1 case fracture at approximately 1,400

flight-cycles after the last detailed - eddy current inspection. Based on the reports of the fractured hinge fitting

assemblies prior to the initial threshold and the repeat interval, the initial threshold and repeat interval have been

reduced.

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Replacement of the outboard hinge fitting with a more robust designed fitting will ensure the structural integrity

of the aft flap, prevent damage to the surrounding structure and the potential for personal injury.

Boeing Service Related Problem (SRP) 767-SRP-57-0119 is related to this service bulletin.

Boeing Service Related Problem (SRP) 767-SRP-57-0233 is related to this service bulletin.

ACTION

Inspect the inboard trailing edge fitting assemblies for cracks and or fractures. If damaged fittings are found,

complete terminating action. If damaged fittings are not found, repeat the inspections at the intervals in accordance

with Figure 1 until terminating action is completed.

EFFECTIVITY

767-400 Airplanes. Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin.

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 Revision 1 of this service

bulletin mandatory.

Refer to Figure 1 Logic Diagram for Inspection and Maintenance Alternatives.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures

given in this service bulletin.

MANPOWER

Refer to Paragraph 1.G. Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-57A0079

Original Issue: June 20, 2002

Revision 1: May 06, 2010

ATA System: 5750

SUBJECT: WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting

Lug Inspection and Replacement

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-24T001 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent

production airplanes. Refer to PRR12901-9S for data about this change.

GROUP CONFIGURATION DESCRIPTION

1 - 767-400 airplanes line numbers 758 through 877.

Airplane Models:

767-400ER

Variable Number Group

VQ001 - VQ021 1

VQ071 - VQ085 1

2. Spares Affected

Examine your 767-400 inboard trailing edge main flap spares supply for the 113T2271-401 and

113T2271-402 outboard hinge fitting assemblies. If any parts are found, refer to Paragraph 2.C.

and 2.D. for the recommended use.

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B. Concurrent Requirements

None.

C. Reason

Accomplishment of this service bulletin will detect cracks, prevent fractures and ensure the structural

integrity of the inboard trailing edge main flap outboard hinge fittings. Fracture of the hinge fittings could

result in the inboard aft flap becoming unrestrained potentially striking the aircraft upon departure,

resulting in significant damage to the surrounding structure and cause potential personal injury.

One operator of a 767-300 reported lug fractures on both the inboard and outboard hinge fittings of

the outboard hinge assembly mounted to the main flap. The hinge assembly provides one of two primary

attachment points of the inboard trailing edge aft flap assembly. The inboard fitting was fractured

through the lug hole. The outboard fitting was fractured just above the lug hole. The fractured fittings

were found during a routine maintenance inspection. The airplane had accumulated 9,598 flight-hours

and 5,393 flight cycles.

During root cause analysis of the fractured hinge fitting it was discovered that an optional tool runout

was not present on the damaged fitting assemblies. The tool runout option allows the part to be machined

thicker within the area reported to be fractured. Boeing has received no reports of cracks or fractures

on fitting that have the additional material area of the optional tool runout. Service bulletin 767-57A0076

was released to inspect and replace the suspect hinge fittings if and as required on all 767-200, 767-300

and 767-300F airplanes line numbers 1 through 825. The inboard trailing edge main flap outboard

hinge fittings on the 767-400 are similar in design to the 767-200, 767-300 and 767-300F fittings. The

767-400 fittings are wider and thicker however higher fatigue loads are associated with the 767-400 in

this area. Analysis indicates the 767-400 fittings could be susceptible to early fatigue cracking and or

fractures as a result of these higher loads.

Subsequent to the original issue of this service bulletin, 3 reports of hinge assembly fracture have been

received. The fractures all occurred at approximately 9,100 flight-cycles and in 1 case fracture at

approximately 1,400 flight-cycles after the last detailed - eddy current inspection. Based on the reports

of the fractured hinge fitting assemblies prior to the initial threshold and the repeat interval, the initial

threshold and repeat interval have been reduced.

Replacement of the outboard hinge fitting with a more robust designed fitting will ensure the structural

integrity of the aft flap, prevent damage to the surrounding structure and the potential for personal

injury.

Boeing Service Related Problem (SRP) 767-SRP-57-0119 is related to this service bulletin.

Boeing Service Related Problem (SRP) 767-SRP-57-0233 is related to this service bulletin.

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BOEING SERVICE BULLETIN 767-57A0079

ALERT ALERT
Revision 1 is sent to

1. To reduce the initial compliance time and repeat interval based on service reports. Subsequent

to the original issue of this service bulletin, operators have reported finding 3 fractured hinge fitting

assemblies. The fractured hinge fitting assemblies had accumulated less flight-cycles than the

initial compliance threshold and in 1 case, the hinge fitting assembly fractured after the original

inspection and prior to the next repeat inspection. Boeing Service Related Problem (SRP)

767-SRP-57-0233 was issued to address this issue.

2. Add instructions to transfer the stainless steel filler and the shims for the mid fairing roller from the

old hinge fitting assembly to the new hinge fitting assembly.

3. Revise inspection area to show inspection from the center of the lug forward, not the end of the

lug forward. This moves the inspection forward to inspect additional area where cracking has been

found, not the lug bore where ctracking has not been found.

4. Add reference to the existing AD, add an AMOC to the existing AD, and reference the possible

new AD which would make the compliance tasks and times in Revision 1 of this service bulletin

mandatory.

5. Update the format of the service bulletin to meet current service bulletin standards.

D. Description

Inspect the inboard trailing edge fitting assemblies for cracks and or fractures. If damaged fittings are

found, complete terminating action. If damaged fittings are not found, repeat the inspections at the

intervals in accordance with Figure 1 until terminating action is completed.

Revision 1 - No more work is necessary on airplanes changed in accordance with 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

767-400ER 555, 655

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service

bulletin.

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

Revision 1 of this service bulletin mandatory.

Refer to Figure 1 Logic Diagram for Inspection and Maintenance Alternatives.

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BOEING SERVICE BULLETIN 767-57A0079

ALERT ALERT
F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

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 Seattle Aircraft

Certification Office approves the inspections, follow-on and corrective actions, and terminating action

with the corresponding compliance times specified in paragraph 1.E., "Compliance," of SB 767-57A0079,

Revision 1, as an AMOC to the inspections, follow-on and corrective actions, and terminating action

with the corresponding compliance times specified in paragraph 1.E., "Compliance," of SB 767-57A0079,

Initial Release, dated June 20, 2002, required by paragraphs (a), (b) and (f) of AD 2003-13-01. All

provisions of AD 2003-13-01 that are not specifically referenced in this paragraph remain fully applicable

and must be complied with.

G. Manpower

The table below shows an estimate of the task-hours necessary to do the fitting inspections and

replacement for each airplane. This estimate is for direct labor only, done by an experienced crew.

Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time.

These are some examples of lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Part 1 - Detailed Inspection

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 2.0 1.0

Examine 1 1.0 1.0

Close Access 2 2.0 1.0

TOTAL FOR EACH WING 5.0 3.0

TOTAL FOR EACH AIRPLANE 10.0 6.0

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BOEING SERVICE BULLETIN 767-57A0079

ALERT ALERT
Part 2 - Detailed Inspection - Eddy Current Inspection

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 2.0 1.0

Examine 1 2.5 2.5

Close Access 2 2.0 1.0

TOTAL FOR EACH WING 6.5 4.5

TOTAL FOR EACH AIRPLANE 13.0 9.0

Part 3 - Terminating Action

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 2.0 1.0

Replace Fitting 2 12.0 6.0

Close Access 2 2.0 1.0

TOTAL FOR EACH WING 16.0 8.0

TOTAL FOR EACH AIRPLANE 32.0 16.0

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR12901-9S

b. Boeing Service Bulletin 767-57A0076

c. Boeing Service Related Problem (SRP) 767-SRP-57-0119, 767-SRP-57-0233

d. Component Maintenance Manual (CMM) 57-53-27

e. Federal Aviation Administration (FAA) Airworthiness Directive 2003-13-01

f. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-50-10, 20-50-19

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g. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 27-51-00

h. 767 Non-Destructive Testing (NDT) Manual Part 6, Subject 51-00-01, Part 6, Subject 51-00-19

i. Boeing Drawing 012W6100

2. Data supplied with this Service Bulletin:

None.

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

Drawing Number Title

113T2000 Flap Instl - Inbd T.E. Flap

This drawing was used to prepare this service bulletin. This drawing is not necessary to make the

specified changes, and is not supplied with this service bulletin. This drawing may not be applicable

to all airplane configurations or operators.

K. Publications Affected

Publication Chapter-Section

767 Illustrated Parts Catalog 27-51

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability

information.

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

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

2.D., Parts Necessary to Change Spares, as shown below. If there is a limit to the quantity (QTY) of

available kits, a supply sequence is given by Spares. More kits become available as shown in the

Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

Unit Price thru

Mar 31/11

ROLT

(Weeks)

Number Name Date QTY

015T1689-1 Top Kit May 06/02 1 $ 45,400.00

Jun 27/02 2

Nov 15/02 8 19

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

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

Terms: Net 30 days.

REFERENCE THIS SERVICE BULLETIN AND SUBMIT YOUR PURCHASE 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

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes, inspection and/or repair

procedures given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

Kit 015T1689

Existing Part Notes

Number

New Part Number QTY Name

-3 -2 -1

015T1689-1 . . - Subkit, Top Kit

015T1689-2 . - 1 Subkit, Hinge Fitting

015T1689-3 - . 1 Subkit, Hinge Fitting

113T2271-419 1 . . Hinge Fitting Assembly - Left 113T2271-401 (a)(b)(c)(f)

113T2271-420 . 1 . Hinge Fitting Assembly - Right 113T2271-402 (a)(b)(c)(g)

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Kit 015T1689

Existing Part Notes

Number

New Part Number QTY Name

-3 -2 -1

BACB30LE5K19 2 2 . Bolt (d)

BACB30LE5K19X 2 2 . Bolt (optional 1/64 oversize) (d)

BACB30LE5K20 2 2 . Bolt (d)

BACB30LE5K20X 2 2 . Bolt (optional 1/64 oversize) (d)

BACS40R015D015F 2 2 . Shim (e)

BACS40R015D017F 2 2 . Shim (e)

BACW10BP5CD 4 4 . Washer

BACW10BP51CD 4 4 . Washer (optional 1/64 oversize)

BACW10BP5DP 4 4 . Washer

BACW10BP51DP 4 4 . Washer (optional 1/64 oversize)

NAS1805-5L 4 4 . Nut

(a) Discard the existing part.

(b) This part is used in production.

(c) You cannot use the existing part to replace the new or changed part.

(d) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer

than indicated. Also, if any fasteners part numbers listed are not available or have been superseded,

substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 012W6100

are used to determine the part numbers used as substitutes.

(e) Use original shims located between the fitting assembly and the flap skin to maintain the original hinge

line geometry of the fittings. However, if the original shims are damaged, replace shims. Maintain the

thickness and location of the original shims.

(f) The 113T2271-419 hinge fitting assembly is composed of a matched set of hinge fittings. The 113T2271-

415 and the 113T2271-417.

(g) The 113T2271-420 hinge fitting assembly is composed of a matched set of hinge fittings. The 113T2271-

416 and the 113T2271-418.

2. Parts and Materials Supplied by the Operator:

Part Number / QTY Name Notes

Specification

BMS 5-95 8 ounces Sealant (a)

BMS 10-11, Type I 4 ounces Primer (a)

MIL-G-23827 4 ounces Grease (a)

(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier

data.

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3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

To get the kit shown below, refer to Paragraph 2.A., Material - Price and Availability.

Part Number Name QTY Notes

015T1689-1 Top Kit 1 (a)

(a) The 015T1689-1 top kit consists of two 015T1689 hinge fitting sub kits. The

015T1689-2 subkit contains the parts required to rework a right inboard trailing

edge main flap assembly. The 015T1689-3 subkit contains the parts required to

rework a left inboard trailing edge main flap assembly.

E. Special Tooling - Price and Availability

None.

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.

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ALERT ALERT

BLANK PAGE
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. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s)

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

bulletin can be changed.

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

definition of the acronyms.

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

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets are in 767-400 SRM, Chapter 51

– Torque limits to tighten nuts and bolts are in 767-400 SRM, Chapter 51.

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

767-400 SRM, Chapter 51, Alternate fasteners are listed in 767-400 SRM, Chapter

51 and Boeing Drawing 012W6100.

6. If the length of any fastener specified in this service bulletin does not meet the

installation standards in 767-400 SRM, Chapter 51, then a fastener of the same

specification, or an approved substitute, with a length which meets the installation

standards in 767-400 SRM, Chapter 51 may be used.

7. A Detailed Inspection (DET) 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. maybe

necessary. Surface cleaning and elaborate procedures may be required.

8. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

9. 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.

The removed part can be discarded if a new or serviceable part is installed.

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ALERT ALERT
B. WORK INSTRUCTIONS

PART 1 - DETAILED INSPECTION

WARNING: TRAILING EDGE FLAPS ARE FAST ACTING. MAKE SURE THAT PERSONS AND

EQUIPMENT ARE CLEAR OF TRAILING EDGE FLAPS AND THE FLAP DRIVE

MECHANISMS BEFORE YOU MOVE THE FLAP CONTROL LEVER. ONCE THE

TRAILING EDGE FLAPS ARE DEPLOYED LOCKS MUST BE INSTALLED TO PREVENT

POSSIBLE INJURY DUE TO INADVERTENT OPERATION OF THE FLAPS.

1. Extend and deactivate the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted

procedure.

2. Remove the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer

to 767 AMM 06-44-00 for location of these panels.

Left Wing Right Wing

571GL 671GL

571GR 671GR

3. Do a Detailed Inspection (DET) of the inboard trailing edge main flap outboard hinge fittings for

cracks and or fractures in accordance with Figure 2.

4. If cracked or fractured fittings are found, do Part 3 - Terminating action.

5. If no damage is found, repeat the inspections at the intervals in accordance with Figure 1 until

terminating action is completed.

6. Install the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer to

767 AMM 06-44-00 for location of these panels.

Left Wing Right Wing

571GL 671GL

571GR 671GR

7. Activate and retract the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure.

8. Put the airplane back to a serviceable condition.

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ALERT ALERT
PART 2 - DETAILED - EDDY CURRENT INSPECTION

WARNING: TRAILING EDGE FLAPS ARE FAST ACTING. MAKE SURE THAT PERSONS AND

EQUIPMENT ARE CLEAR OF TRAILING EDGE FLAPS AND THE FLAP DRIVE

MECHANISMS BEFORE YOU MOVE THE FLAP CONTROL LEVER. ONCE THE

TRAILING EDGE FLAPS ARE DEPLOYED LOCKS MUST BE INSTALLED TO PREVENT

POSSIBLE INJURY DUE TO INADVERTENT OPERATION OF THE FLAPS.

1. Extend and deactivate the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted

procedure.

2. Remove the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer

to 767 AMM 06-44-00 for location of these panels.

Left Wing Right Wing

571GL 671GL

571GR 671GR

3. Do a Detailed Inspection (DET) and eddy current inspection of the inboard trailing edge main flap

outboard hinge fittings for cracks and or fractures in accordance with Figure 3.

4. If cracked or fractured fittings are found, do Part 3 - Terminating action.

5. If no damage is found, repeat the inspections at the intervals in accordance with Figure 1 until

terminating action is completed.

6. Install the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer to

767 AMM 06-44-00 for location of these panels.

Left Wing Right Wing

571GL 671GL

571GR 671GR

7. Activate and retract the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure.

8. Put the airplane back to a serviceable condition.

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ALERT ALERT
PART 3 - TERMINATING ACTION

WARNING: TRAILING EDGE FLAPS ARE FAST ACTING. MAKE SURE THAT PERSONS AND

EQUIPMENT ARE CLEAR OF TRAILING EDGE FLAPS AND THE FLAP DRIVE

MECHANISMS BEFORE YOU MOVE THE FLAP CONTROL LEVER. ONCE THE

TRAILING EDGE FLAPS ARE DEPLOYED LOCKS MUST BE INSTALLED TO PREVENT

POSSIBLE INJURY DUE TO INADVERTENT OPERATION OF THE FLAPS.

1. Extend and deactivate the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted

procedure.

2. Remove the number 3 and 6 trailing edge main flap fairing mid sections listed below. Refer to 767

AMM 06-44-00 for location of these fairings.

Left Wing Right Wing

571DB 671DB

3. Remove the number 3 and 6 trailing edge main flap fairing upper skin access panels listed below.

Refer to 767 AMM 06-44-00 for location of these panels.

Left Wing Right Wing

555HB 655HB

4. Replace the inboard trailing edge main flap outboard hinge fittings in accordance with Figure 4.

5. Install the number 3 and 6 trailing edge main flap fairing upper skin access panels listed below.

Refer to 767 AMM 06-44-00 for location of these panels.

Left Wing Right Wing

555HB 655HB

6. Install the number 3 and 6 trailing edge main flap fairing mid sections listed below. Refer to 767

AMM 06-44-00 for location of these fairings.

Left Wing Right Wing

571DB 671DB

7. Activate and retract the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure.

8. Put the airplane back to a serviceable condition.

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FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES

(SHEET 1 OF 1)

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FIGURE 2: HINGE FITTING - DETAILED INSPECTION

(SHEET 1 OF 3)

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

FIGURE 2: HINGE FITTING - DETAILED INSPECTION

(SHEET 2 OF 3)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

to remove loose dirt, grease and

oil. Refer to SOPM 20-30-03 as an

accepted procedure.

1 Clean Hinge Fittings - 2

Do a Detailed Inspection (DET) for

cracks or fractures within the indicated area.

2 Inspect Hinge Fittings - 2

FIGURE 2: HINGE FITTING - DETAILED INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 3: HINGE FITTING - DETAILED - EDDY CURRENT INSPECTION

(SHEET 1 OF 3)

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

FIGURE 3: HINGE FITTING - DETAILED - EDDY CURRENT INSPECTION

(SHEET 2 OF 3)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

to remove loose dirt, grease and

oil. Refer to SOPM 20-30-03 as an

accepted procedure.

1 Clean Hinge Fittings - 2

Do a Detailed Inspection (DET) for

fractures within the indicated area.

2 Inspect Hinge Fittings - 2

Do an Eddy Current inspection for

cracks within the indicated area in

accordance with 767 NDT Part 6,

Subject 51-00-01 or 767 NDT Part

6, Subject 51-00-19. Use a right

angle pencil probe with a maximum drop of 0.1 inch.

3 Inspect Hinge Fittings - 2

FIGURE 3: HINGE FITTING - DETAILED - EDDY CURRENT INSPECTION

(SHEET 3 OF 3)

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FIGURE 4: HINGE FITTING - REPLACEMENT

(SHEET 1 OF 6)

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FIGURE 4: HINGE FITTING - REPLACEMENT

(SHEET 2 OF 6)

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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 one of the airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Maintain fasteners location and stackup for later installation. Refer to CMM

57-53-27 as an accepted procedure.

Remove / Fasteners - 4

Keep

1

2 Remove Fasteners - 4

3 Remove Hinge Fitting Assembly 113T2271-() 1

Maintain original location of shims. If

shims are damaged, replace shims

maintaining the original thickness. Apply BMS 10-11 Type I primer to the

replacement shims and any bare surfaces of the original shims. Refer to

SOPM 20-41-02 as an accepted procedure.

Remove / Shims "A" BACS40R015D015F 2

Keep

4

Remove / Shims "B" BACS40R015D017F 2

Keep

FIGURE 4: HINGE FITTING - REPLACEMENT

(SHEET 3 OF 6)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Locate and install hinge fitting with kept

or identical replacement shims in the

same location to maintain the original

hinge line geometry of the fitting. Refer

to CMM 57-53-27 as an accepted procedure. Fay seal shims and install

fasteners wet with BMS 5-95 common

to the fitting assembly and the main

flap. Refer to SOPM 20-50-19 as an

accepted procedure. Install kept fasteners common to the flap linkage and

hinge fittings with MIL-G-23827 grease.

Refer to CMM 57-53-27 as an accepted procedure.

5 Install Hinge Fitting Assembly 113T2271-419 LEFT 1

113T2271-420 1

RIGHT

Shims "A" (Kept) BACS40R015D015F 2

Shims "B" (Kept) BACS40R015D017F 2

Fasteners - 4

Fasteners (Kept) - 4

the incorporation of this service bulletin

on each hinge fitting assembly. Refer

to SOPM 20-50-10 as an accepted

procedure.

Rubber Stamp or Sten- - -

cil

6 Identify

BACB30LU3-20 OR 1

BACB30LH3-20

Remove / Bolt "A"

Keep

7

BACB30LU3-13 OR 1

BACB30LH3-13

Remove / Bolt "B"

Keep

BACW10BP3AP OR 2

BACW10BP3DP

Remove / Washer

Keep

BACN10JC3 OR 2

BACN10JC3CD

Remove / Nut

Keep

Remove / Shim "C" BACS40R008A026F 1

Keep

Remove / Shim "D" BACS40R008E26F 2

Keep

Remove / Filler 113T1700-9 1

Keep

FIGURE 4: HINGE FITTING - REPLACEMENT

(SHEET 4 OF 6)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Install Filler 113T1700-9 1

(Kept)

8

Install Shim "D" BACS40R008E26F 2

(Kept)

Install Shim "C" BACS40R008A026F 1

(Kept)

BACB30LU3-13 OR 1

BACB30LH3-13

Install Bolt "B"

(Kept)

BACB30LU3-20 OR 1

BACB30LH3-20

Install Bolt "A"

(Kept)

BACW10BP3AP is used with

BACB30LU3-() fasteners.

BACW10BP3DP is used with

BACB30LH3-() fasteners.

BACW10BP3AP OR 2

BACW10BP3DP

Install Washer

(Kept)

Tighten to 19-21 inch-pounds (20 target). BACN10JC3 is used with

BACB30LU3-() fasteners.

BACN10JC3CD is used with

BACB30LH3-() fasteners.

BACN10JC3 OR 2

BACN10JC3CD

Install Nut

(Kept)

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener.

FIGURE 4: HINGE FITTING - REPLACEMENT

(SHEET 5 OF 6)

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ALERT ALERT
If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to

determine the part numbers used as substitutes.

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Install bolts wet with BMS

5-95 sealant. Refer to

SOPM 20-50-19 as an

- - accepted procedure.

Bolt BACB30LE5K *

A

Opt 1/64 Oversize BACB30LE5K * X

Washer BACW10BP5CD

Opt 1/64 Oversize BACW10BP51CD

Washer BACW10BP5DP

Opt 1/64 Oversize BACW10BP51DP

Nut NAS1805-5L

FIGURE 4: HINGE FITTING - REPLACEMENT

(SHEET 6 OF 6)

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ALERT ALERT