### Commercial Airplanes 

# 777 Service Bulletin ALERT Number: 777-53A0075 Original Issue: January 14, 2015 Revision 1: December 14, 2015 ATA System: 5380 SUBJECT:FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair 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 Unpublished Work.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: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 1 of 248 2.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 2 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT

BLANK PAGETable of Contents Revision Transmittal Sheet............................................ 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 27 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 34 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 35 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . 43 FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL. . . . . . . . . . . . . . . . . . . . . 47 FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION. . . . . . . . . . . . . . . . . . . 59 FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION. . . . . . . . . . . . . . . . . . . 64 FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 3 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 FIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 109 FIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 114 FIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION [Group 1]. . . . . . . . . . 119 FIGURE 14: RIGHT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION [Group 1]. . . . . . . . . 122 FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 1] . 125 FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 1] . 147 FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 2] . 167 FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 2] . 187 FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . 235 FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL. . . . . . . . . . . . . . . . . . . . . 239 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD. . . . 243 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: POST-REPAIR DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 APPENDIX C: BOEING PART DEMAND INTENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 4 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT

### Commercial Airplanes 

# 777 Service Bulletin ALERTRevision Transmittal Sheet Number: 777-53A0075 Original Issue: January 14, 2015 Revision 1: December 14, 2015 ATA System: 5380 SUBJECT:FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2015-NM-026-AD, is related to this service bulletin. Effects of this Revision on airplanes on which Original Issue was previously done: None. REASON FOR REVISION This revision is sent to make changes identified during the validation of the Original Issue of this service bulletin and to clarify or correct issues identified by operators since the Original Issue. As a part of a service bulletin validation program, this inspection was completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue before the release of Revision 1 of this service bulletin. The inspection completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WA174 has the configuration of a Group 2 airplane. These sections were changed: 1. In Summary, Background, revised the description of the unsafe condition, revised the number of operator reports, added a service history table, added a description of the completed service bulletin validation. 2. In Summary, Action, revised the paragraph. 3. In Summary, Compliance, added FAA Notice of Proposed Rule Making (NPRM) reference. 4. In Summary, Manpower, added a reference to Paragraph 1.G., Manpower. 5. In Summary, Material Information, added "Operator Supplied Parts/Materials". 6. In Summary, revised the summary illustration.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 5 of 2487. In Paragraph 1.C., Reason, revised the description of the unsafe condition, revised the number of operator reports, added a service history table, added paragraphs to give a description of the completed service bulletin validation and to give the reason for this revision. 8. In Paragraph 1.D., Description, revised the paragraph, added paragraph to give the effects of this revision on airplanes on which Original Issue was previously done. 9. In Paragraph 1.E., Compliance, added NPRM reference, revised the paragraph above Table 1, revised Table 1 and Table 2. 10. In Paragraph 1.G., Manpower, revised the tables. 11. In Paragraph 1.H., Weight and Balance Changes, revised the table to give weight and balance changes. 12. In Paragraph 1.J., References, revised the reference list. 13. In Paragraph 2.A., Material - Price and Availability, revised top kit dates and quantities, added Reorder Lead Time (ROLT) and revised price information. 14. In Paragraph 2.C.1., Kits/Parts, revised the top kit parts lists. 15. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, deleted the duplicate paragraph above the table. 16. In Paragraph 2.C.3., Parts Modified and Reidentified, added table for Group 1 airplanes, added paragraph for Group 2 airplanes. 17. In Paragraph 3.A., General Information, deleted notes that are not applicable, revised note 17. and note 18. 18. In Paragraph 3.B., Work Instructions, revised the work instructions. 19. In Figure 5 and Figure 6, revised the illustrations and the fastener code table. 20. In Figure 7, Figure 8, Figure 9 and Figure 10, revised the illustrations and the step table. 21. In Figure 11, Figure 12, Figure 13 and Figure 14, revised the illustrations. 22. In Figure 15, Figure 16, Figure 17, Figure 18, Figure 21, Figure 22, Figure 23 and Figure 24, revised the illustrations, the step table and the fastener code table. 23. Added Figure 25 and Figure 26 to give instructions for skin panel removal after the small crack repair was installed. 24. In Appendix A, revised the table and the flag note, revised the logic diagram. 25. In Appendix B, revised the table and the flag note. 26. In Appendix C, revised Part Demand Intent. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 6 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTPages with no vertical lines have no changes. REVISION HISTORY January 14, 2015 Original Issue: December 14, 2015 Revision 1:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 7 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTExport Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 8 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT

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### Commercial Airplanes 

# 777 Service Bulletin ALERT Summary Number: 777-53A0075 Original Issue: January 14, 2015 Revision 1: December 14, 2015 ATA System: 5380 SUBJECT:FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. CONCURRENT REQUIREMENTS None. BACKGROUND This service bulletin is sent to give instructions for inspections of the left and right side forward outer chords of the Body Station (STA) 2370 pivot bulkhead for cracks. Cracks in the STA 2370 pivot bulkhead forward outer chords that are not found and repaired can become large and result in a severed forward outer chord. Since the horizontal stabilizer is attached to the STA 2370 bulkhead at two pivot locations, this damage could cause the loss of horizontal stabilizer control, resulting in loss of controllability of the airplane. Two operators have reported finding cracks in the outer flanges of the left and right side forward outer chords of the STA 2370 pivot bulkhead on a total of eleven airplanes. The cracks were fatigue cracks caused by a stress concentration which is generated at the transition radius of the forward outer flange of the chord prior to the chord splice at the upper longeron. Accomplishment of the inspections in this service bulletin will help ensure that STA 2370 pivot bulkhead forward outer chord cracks are found and repaired before they can become large and result in damage that could result in the loss of horizontal stabilizer control. Boeing Service Bulletin (SB) 777-53-0076 gives instructions for a modification that is terminating action to the repeat inspections given in this service bulletin. The table below shows the crack findings and related service data that have been reported to Boeing. Service History Crack Length (Inches) Crack Location Flight Hours Flight Cycles Model 1.4 and 3.3 Left Side 39,142 31,384 777-200 2.93 Right Side

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 9 of 248Service History Crack Length (Inches) Crack Location Flight Hours Flight Cycles Model 2.3 Left Side 39,797 31,504 777-200 2.2 Right Side2.5 Left Side 38,758 32,181 777-200 2.3 Right Side 2.5 Left Side 37,182 29,383 777-200 2.5 Right Side 2.2 Left Side 34,291 24,653 777-300 2.2 Right Side2.25 Left Side 40,074 35,011 777-200 2.2 Right Side 2.5 Left Side 33,568 24,251 777-300 2.03 Right Side2.35 Left Side 38,455 30,462 777-200 2.2 Right Side2.2 Left Side 39,166 30,826 777-200 2.4 Right Side 2.5 Left Side 40,588 33,809 777-200 2.4 Right Side 1.2 Left Side 63,940 17,530 777-300 1.65 Right Side Boeing Fleet Team Digest (FTD) 777 FTD 53-13001 is related to this service bulletin. Boeing Service Related Problem (SRP) 777-SRP-53-0455 is related to this service bulletin. As a part of a service bulletin validation program, this inspection was completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue before the release of Revision 1 of this service bulletin. The inspection completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WA174 has the configuration of a Group 2 airplane. 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., Compliance and Paragraph 1.F., Approval Yes AD Related

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 10 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTReference Affected Planning Data Paragraph 1.H., Weight and Balance Changes Yes (a) Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected Yes 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 Yes 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 (a) Only if the repair was done. ACTION (PRR 62777-97S) Do a Detailed and HFEC inspection of the Station 2370 pivot bulkhead forward chord in accordance with PART 1, for any crack. If any crack is found, and no crack found is greater than 0.160 inch, do one of the following options on the affected side of the airplane: 1. Do the terminating action in accordance with SB 777-53-0076. 2. Do the repair of the Station 2370 pivot bulkhead forward chord in accordance with PART 2 and the post-repair Detailed and HFEC inspection in accordance with PART 3. If any crack found is greater than 0.160 inch, do the terminating action in accordance with SB 777-53-0076. If no crack is found, repeat PART 1, or do the terminating action in accordance with SB 777-53-0076. EFFECTIVITY 777-200/-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2015-NM-026-AD, is related to this service bulletin. Refer to Paragraph 1.E., Compliance. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of November 20, 2013. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 11 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMANPOWER Elapsed Hours Total Task Hours Airplanes 10.50 14.50 All Airplanes - Inspection 24.05 44.85 Group 1 Airplanes - Small Crack Repair - One Side of the airplane 22.30 43.10 Group 2 Airplanes - Small Crack Repair - One Side of the airplane 8.50 10.50 All Airplanes - Post-Repair Inspection Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability. Operators are encouraged to complete the survey provided in APPENDIX C of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 12 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTExport Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 13 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTExport Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 14 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT

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### Commercial Airplanes 

# 777 Service Bulletin ALERT Number: 777-53A0075 Original Issue: January 14, 2015 Revision 1: December 14, 2015 ATA System: 5380 SUBJECT:FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair 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 777-200/-300 Airplanes, line numbers 1-244 in 2 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-97S for data about this change. Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTION CONFIGURATION GROUP 777 Airplanes, line numbers 1 through 40

- 1 777 Airplanes, line numbers 41 through 244

- 2

Airplane Models: 777-200, 777-300 Group Variable Number1 WA001 - WA0171 WA076 - WA0801 WA086 - WA0872 WA088 - WA093

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 15 of 248Group Variable Number1 WA101 - WA1041 WA116 - WA1172 WA118 - WA1191 WA131 - WA1352 WA136 - WA1371 WA171 - WA1732 WA174 - WA1751 WA196 - WA1972 WA198 2 WA206 - WA2122 WA221 - WA2232 WA231 - WA2322 WA241 - WA2452 WB001 - WB0202 WB031 2 WB051 - WB0722 WB101 - WB1062 WB121 - WB1252 WB131 - WB1332 WB151 - WB1532 WB161 - WB1712 WB181 - WB1882 WB231 - WB2352 WB271 - WB2722 WB276 - WB2862 WB291 - WB2972 WB306 - WB3072 WB311 - WB3182 WB336 - WB3372 WB366 2 WB371 - WB3832 WB406 2 WB411 - WB413

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 16 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTGroup Variable Number2 WB416 - WB4262 WB446 - WB4482 WB501 - WB5062 WB531 - WB5352 WB551 - WB5532 WB591 - WB5952 WB601 - WB6022 WB611 - WB615 2. Spares Affected None. B. Concurrent Requirements None. C. Reason This service bulletin is sent to give instructions for inspections of the left and right side forward outer chords of the Body Station (STA) 2370 pivot bulkhead for cracks. Cracks in the STA 2370 pivot bulkhead forward outer chords that are not found and repaired can become large and result in a severed forward outer chord. Since the horizontal stabilizer is attached to the STA 2370 bulkhead at two pivot locations, this damage could cause the loss of horizontal stabilizer control, resulting in loss of controllability of the airplane. Two operators have reported finding cracks in the outer flanges of the left and right side forward outer chords of the STA 2370 pivot bulkhead on a total of eleven airplanes. The cracks were fatigue cracks caused by a stress concentration which is generated at the transition radius of the forward outer flange of the chord prior to the chord splice at the upper longeron. Accomplishment of the inspections in this service bulletin will help ensure that STA 2370 pivot bulkhead forward outer chord cracks are found and repaired before they can become large and result in damage that could result in the loss of horizontal stabilizer control. Boeing Service Bulletin (SB) 777-53-0076 gives instructions for a modification that is terminating action to the repeat inspections given in this service bulletin. The table below shows the crack findings and related service data that have been reported to Boeing. Service History Crack Length (Inches) Crack Location Flight Hours Flight Cycles Model 1.4 and 3.3 Left Side 39,142 31,384 777-200 2.93 Right Side

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 17 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTService History Crack Length (Inches) Crack Location Flight Hours Flight Cycles Model 2.3 Left Side 39,797 31,504 777-200 2.2 Right Side2.5 Left Side 38,758 32,181 777-200 2.3 Right Side 2.5 Left Side 37,182 29,383 777-200 2.5 Right Side 2.2 Left Side 34,291 24,653 777-300 2.2 Right Side2.25 Left Side 40,074 35,011 777-200 2.2 Right Side 2.5 Left Side 33,568 24,251 777-300 2.03 Right Side2.35 Left Side 38,455 30,462 777-200 2.2 Right Side2.2 Left Side 39,166 30,826 777-200 2.4 Right Side 2.5 Left Side 40,588 33,809 777-200 2.4 Right Side 1.2 Left Side 63,940 17,530 777-300 1.65 Right Side Boeing Fleet Team Digest (FTD) 777 FTD 53-13001 is related to this service bulletin. Boeing Service Related Problem (SRP) 777-SRP-53-0455 is related to this service bulletin. As a part of a service bulletin validation program, this inspection was completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue before the release of Revision 1 of this service bulletin. The inspection completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WA174 has the configuration of a Group 2 airplane. Revision 1 is sent to make changes identified during the validation of the Original Issue of this service bulletin and to clarify or correct issues identified by operators since the Original Issue. D. Description Do a Detailed and HFEC inspection of the Station 2370 pivot bulkhead forward chord in accordance with PART 1, for any crack.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 18 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTIf any crack is found, and no crack found is greater than 0.160 inch, do one of the following options on the affected side of the airplane: 1. Do the terminating action in accordance with SB 777-53-0076. 2. Do the repair of the Station 2370 pivot bulkhead forward chord in accordance with PART 2 and the post-repair Detailed and HFEC inspection in accordance with PART 3. If any crack found is greater than 0.160 inch, do the terminating action in accordance with SB 777-53-0076. If no crack is found, repeat PART 1, or do the terminating action in accordance with SB 777-53-0076. Revision 1 - Effects of this Revision on airplanes on which Original Issue was previously done: None. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1:
Affected Maintenance ZonesZone Model 313, 314 777-200 Group 2:
Affected Maintenance ZonesZone Model 313, 314 777-200, 777-300 E. Compliance Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2015-NM-026-AD, is related to this service bulletin. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. Logic diagrams showing compliance tasks and compliance times are included as aids in APPENDIX A and APPENDIX B.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 19 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe conditions and associated actions given in the compliance tables below can be different on the left and right sides of the airplane. The actions done must obey the compliance times shown in the compliance tables for each side of the airplane. Because the conditions found may not be the same on both sides of the airplane, the required actions may be different between the left and right side of the airplane and can be done independently. Table 1: Detailed and HFEC Inspection of the Station 2370 Pivot Bulkhead Forward Chord: Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) Action Condition

- Within 4,000 flight cycles or 1,125 days,whichever occurs first, afterthe Original Issue date of this Service Bulletin. Before 16,000 total flight cycles Do PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD -DET AND HFEC INSPECTION for any crack. All Airplanes

12,000 flight cycles

- OPTION 1: CONDITION 1: NO FOR- WARD CHORD CRACK IS FOUND (a) Repeat PART 1: STA- TION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION for any crack. (a) Before further flight OPTION 2:Do the terminating modification in accordance with Boeing Service Bulletin 777-53-0076. (a)

- Before further flight OPTION 2: CONDITION 2: ANY FOR- WARD CHORD CRACK IS FOUND, AND NO CRACK FOUND IS GREATER THAN 0.160 INCH Do the terminating modification in accordance with Boeing Service Bulletin 777-53-0076. (a)

- Before further flight OPTION 3 (ACTION 1): Do PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR.

- Refer to Table 2 OPTION 3 (ACTION 2): Do PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 20 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTTable 1: Detailed and HFEC Inspection of the Station 2370 Pivot Bulkhead Forward Chord: Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) Action Condition

- Before further flight Do the terminating modifi- cation in accordance with Boeing Service Bulletin 777-53-0076. (a)CONDITION 3: ANY FORWARD CHORD CRACK FOUND IS GREATER THAN 0.160 INCH.

- Before further flight Continue to do the smallcrack repair in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR.CONDITION 6: NO FORWARD CHORD UPPERLOCATION OR ADJACENT STRUCTURE CRACK IS FOUND

- Before further flight ACTION 1: Contact TheBoeing Company for repair instructions and do the repair.CONDITION 7: ANY FORWARD CHORD UPPERLOCATION OR ADJACENT STRUCTURE CRACK IS FOUND

- Before further flight ACTION 2: Continue to do the small crack repair in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR. (a) Modification in accordance with Boeing Service Bulletin 777-53-0076 is terminating action to the repeat inspections in this service bulletin.

Table 2: Post-Repair Detailed and HFEC Inspection of the STA 2370 Pivot Bulkhead Forward Chord: Repeat Interval (Not to Exceed) Compliance Time Action Condition

- Within 12,000 flightcycles after installation of the repair in accordance with PART 2: STATION 2370 PIVOTBULKHEAD FORWARD CHORD - SMALL CRACK REPAIR Do PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION for any crack.All airplanes previously repaired in accordance with PART 2: STATION 2370PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 21 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTTable 2: Post-Repair Detailed and HFEC Inspection of the STA 2370 Pivot Bulkhead Forward Chord: Repeat Interval (Not to Exceed) Compliance Time Action Condition 12,000 flight cycles

- OPTION 4: Repeat PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD -POST-REPAIRDET AND HFEC INSPECTION for any crack.CONDITION 4: NO FORWARD CHORD CRACK ISFOUND DURING POSTREPAIR INSPECTION (a)

(a) Before further flight OPTION 2: Do the termi-nating modification in accordance with Boeing Service Bulletin 777-53- 0076. (a)

- Before further flight Do the terminating modifi- cation in accordance with Boeing Service Bulletin 777-53-0076. (a)CONDITION 5: ANY FORWARD CHORD CRACK ISFOUND DURING POSTREPAIR INSPECTION (a) Modification in accordance with Boeing Service Bulletin 777-53-0076 is terminating action to the repeat inspections in this service bulletin.
NOTE:PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION is for both sides of the airplane. PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR is for one side of the airplane. It is possible to have an airplane with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR done on both sides. PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION is for one side of the airplane. It is possible to have an airplane with PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION done on both sides. PART 4: STATION 2370 PIVOT BULKHEAD FORWARD CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION is for one side of the airplane. It is possible to have an airplane with PART 4: STATION 2370 PIVOT BULKHEAD FORWARD CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION done on both sides. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 22 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTIf 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. G. Manpower The tables below show an estimate of the task hours necessary to do this 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 estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. Table 1: Manpower Information for PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION Elapsed Hours Task Hours Number of Persons Task Open Access 2.00 2.00 1 FIGURE 1 2,00 2.00 1 FIGURE 2 PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION 1.25 1.25 1 FIGURE 3 1.25 1.25 1 FIGURE 4 Close Access 2.00 4.00 2 FIGURE 5 2.00 4.00 2 FIGURE 6 10.50 14.50 TOTAL FOR EACH AIRPLANE Group 1: Table 2: Manpower Information for PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR Elapsed Hours Task Hours Number of Persons Task 4.00 8.00 2 FIGURE 7 (or FIG- URE 8) (a) 1.50 1.50 1 FIGURE 11 (or FIG- URE 12) (a) 1.75 1.75 1 FIGURE 13 (or FIG- URE 14) (a)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 23 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTGroup 1: Table 2: Manpower Information for PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR Elapsed Hours Task Hours Number of Persons Task 14.80 29.60 2 FIGURE 15 (or FIG- URE 16) (a) 2.00 4.00 2 FIGURE 23 (or FIG- URE 24) (a) 24.05 44.85 TOTAL FOR ONE SIDE OF THE AIRPLANE (b) (a) Figure 7, Figure 11, Figure 13, Figure 15 and Figure 23 are for the left side of the airplane. Figure 8, Figure 12, Figure 14, Figure 16 and Figure 24 are for the right side of the airplane. (b) This table shows the manpower information for small crack repair in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD -SMALL CRACK REPAIR, on one side of the airplane. If both sides of the airplane are repaired in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR, multiply the total manpower information by two, to obtain the total manpower for both sides of the airplane. Group 2: Table 3: Manpower Information for PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR Elapsed Hours Task Hours Number of Persons Task 4.00 8.00 2 FIGURE 9 (or FIG- URE 10) (a) 1.50 1.50 1 FIGURE 11 (or FIG- URE 12) (a) 14.80 29.60 2 FIGURE 17 (or FIG- URE 18) (a) 2.00 4.00 2 FIGURE 23 (or FIG- URE 24) (a) 22.30 43.10 TOTAL FOR ONE SIDE OF THE AIRPLANE (b) (a) Figure 9, Figure 11, Figure 17 and Figure 23 are for the left side of the airplane.Figure 10, Figure 12, Figure 18 and Figure 24 are for the right side of the airplane.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 24 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTGroup 2: Table 3: Manpower Information for PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR Elapsed Hours Task Hours Number of Persons Task (b) This table shows the manpower information for small crack repair in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD -SMALL CRACK REPAIR, on one side of the airplane. If both sides of the airplane are repaired in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR, multiply the total manpower information by two, to obtain the total manpower for both sides of the airplane. Table 4: Manpower Information for PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTIONElapsed Hours Task Hours Number of Persons Task Open Access 2.00 2.00 1 FIGURE 25 2.00 2.00 1 FIGURE 26 DET and HFEC Inspection 1.25 1.25 1 FIGURE 19 1.25 1.25 1 FIGURE 20 Close Access 2.00 2.00 2 FIGURE 21 2.00 2,00 2 FIGURE 22 8.50 10.50 TOTAL FOR EACH AIRPLANE
NOTE:PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION is for both sides of the airplane. PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR is for one side of the airplane. It is possible to have an airplane with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR done on both sides. PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION is for one side of the airplane. It is possible to have an airplane with PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION done on both sides. PART 4: STATION 2370 PIVOT BULKHEAD FORWARD CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION is for one side of the airplane. It is possible to have an airplane with PART 4: STATION 2370 PIVOT BULKHEAD FORWARD CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION done on both sides.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 25 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTH. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +1,183.5 +0.5 777-200 - Repaired on one side +2,367.0 +1.0 777-200 - Repaired on both sides +1,278.0 +0.5 777-300 - Repaired on one side +2,556.0 +1.0 777-300 - Repaired on both sides
I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 62777-97S b. Boeing Service Bulletin 777-53-0076 c. Boeing Service Letter 777-SL-51-013 d. Boeing Service Related Problem (SRP) 777-SRP-53-0455 e. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM) 2015-NM-026-AD f. Service Bulletin Index D624W001 g. Standard Overhaul Practices Manual (SOPM) 20-10-03, 20-41-02, 20-41-05, 20-43-03, 20-50-01, 20-50-10, 20-50-19 h. 777 Aircraft Maintenance Manual (AMM) 07-11-01, 55-17-01 i. 777 Fleet Team Digest (FTD) 53-13001 j. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-02 k. 777-200 Structural Repair Manual (SRM) 51-10-02, 51-20-01 l. 777-300 Structural Repair Manual (SRM) 51-10-02, 51-20-01 2. Data Supplied with this Service Bulletin: None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 26 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT3. Installation Drawings Used in the Preparation of this Service Bulletin:
Title Drawing NumberBulkhead Instl - Upr, Pivot and Skin, STA 2370 148W2010 Fairing Instl - Stabilizer Seal, UPR 148W2910 Bulkhead Instl - Pivot, Integration, STA 2370 148W9700 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: Chapter-Section

Publication 53-80 777 Structural Repair Manual 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. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. M. Software Accomplishment Summary Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 27 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTExport Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 28 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT

BLANK PAGE2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of the Revision 1date of this Service Bulletin (US Dollars) ROLT as of the Revision 1 date ofthis Service Bulletin (Calendar Days) QTY Date Name Kit Number

241.00 266 11 January 12, 2016 Top Kit - STA 2370 Pivot Bulkhead ForwardOuter Chord - Inspection Restoration 005W0016-10
10 February 9, 2016 10 March 8, 2016 13,574.00 525 10 January 12, 2016 Top Kit - STA 2370 Pivot Bulkhead Forward Outer Chord, Left - Small Crack 005W0016-11 (a)

13,574.00 790 10 January 12, 2016 Top Kit - STA 2370 Pivot Bulkhead Forward Outer Chord, Right - Small Crack 005W0016-12 (b)

(a) This top kit is for the repair on the left side of the airplane. (b) This top kit is for the repair on the right side of the airplane. Operators are encouraged to complete the survey provided in APPENDIX C of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 29 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTB. Industry Support Information Boeing warranty remedies are available for 777 airplanes in warranty as of November 20, 2013. For task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Fleet Support Contracts - Warranty. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Material Management. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. The warranty remedies will expire eight years from the original issue date of this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE:One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane, except as noted in Paragraph 2.A., Material - Price and Availability. ALL
Kit 005W0016 Notes Existing Part Number Name Qty New Part Number -12 -11 -10 (a)

- Top Kit - STA 2370 Pivot Bulkhead Forward Outer Chord - Inspection Restoration . . - 005W0016-10

(b)

- Top Kit - STA 2370 Pivot Bulkhead Forward Outer Chord, Left - Small Crack Repair . - . 005W0016-11

(c)

- Top Kit - STA 2370 Pivot Bulkhead Forward Outer Chord, Right- Small Crack Repair - . . 005W0016-12

- - SHIM 1 1

. 148W0015-12

- - SHIM 1 1

. 148W0015-13

- - SHIM 2 2

. 148W0015-14 (d) (e) (f) 148W2204-1 (Group 1) SPLICE ANGLE

. 1

. 148W2204-5 148W2204-3 (Group 2)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 30 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTALL
Kit 005W0016 Notes Existing Part Number Name Qty New Part Number -12 -11 -10 (d) (e) (f) 148W2204-2 (Group 1) SPLICE ANGLE 1

. . 148W2204-6 148W2204-4 (Group 2)

- - SHIM LAMINATED 1 1

. 148W7143-5

- - SHIM LAMINATED 1 1

. 148W7143-6

- - SHIM LAMINATED 1 1

. 148W7143-7

- - SHIM LAMINATED 1 1

. 148W7143-11

- - SHIM LAMINATED 1 1

. 148W7143-13

- - RADIUS FILLER 1 1

. 148W9710-15 (g)

- BOLT, PROTRUD- ING HD 6 6

. BACB30MY10K10X (g)

- BOLT, PROTRUD- ING HD 6 6

. BACB30MY10K13X (g)

- BOLT, PROTRUD- ING HD 8 8

. BACB30MY10K7X (g)

- BOLT, PROTRUD- ING HD 14 14

. BACB30MY8K11X (g)

- BOLT, PROTRUD- ING HD 16 11

. BACB30MY8K4X (g)

- BOLT, PROTRUD- ING HD 8 11

. BACB30MY8K5X (g)

- BOLT, PROTRUD- ING HD 18 18

. BACB30MY8K6X (g)

- BOLT, PROTRUD- ING HD 8 8

. BACB30MY8K7X (g)

- BOLT, PROTRUD- ING HD 5 5

. BACB30MY8K8X (g)

- BOLT, PROTRUD- ING HD 1 1

. BACB30MY8K9X (g)

- BOLT, 100 DEG HEX DR 2 2 4 BACB30NW6K5X (g)

- BOLT, 100 DEG HEX DR 28 28

. BACB30NW8K10X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 31 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTALL
Kit 005W0016 Notes Existing Part Number Name Qty New Part Number -12 -11 -10 (g)

- BOLT, 100 DEG HEX DR 4 4

. BACB30NW8K12X (g)

- BOLT, 100 DEG HEX DR 3 3 14 BACB30NW8K5X (g)

- BOLT, 100 DEG HEX DR 1 1 2 BACB30NW8K6X (g)

- BOLT, 100 DEG HEX DR 3 3

. BACB30NW8K7X (g)

- BOLT, 100 DEG HEX DR 5 5

. BACB30NW8K8X (g)

- BOLT, 100 DEG HEX DR 31 31 8 BACB30NW8K9X (g)

- BOLT, PROTRUD- ING HD 3 3

. BACB30NX10K11X (g)

- BOLT, PROTRUD- ING HD 13 13

. BACB30NX10K14X (g)

- BOLT, PROTRUD- ING HD 4 4

. BACB30NX6K5X (g)

- BOLT, 100 DEG HEX D 12 12

. BACB30NZ10K15X (g)

- BOLT, 100 DEG HEX DR 16 16

. BACB30NZ10K16X (g)

- BOLT, 100 DEG HEX DR 10 10

. BACB30NZ8K12X (g)

- BOLT, HEX DRIVE 12 12

. BACB30YN10K15X (g)

- BOLT, HEX DRIVE 16 16

. BACB30YN10K16X (g)

- BOLT, HEX DRIVE 8 8

. BACB30YN8K12X

- - COLLAR 44 44

. BACC30BH10

- - COLLAR 10 10

. BACC30BH8

- - COLLAR 20 20

. BACC30M10

- - COLLAR 6 6 4 BACC30M6

- - COLLAR 132 132 24 BACC30M8

- - SELF-LOCKING NUT 2 2

. BACN10HR12CD

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 32 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTALL
Kit 005W0016 Notes Existing Part Number Name Qty New Part Number -12 -11 -10

- - SELF-LOCKING NUT 2 2

. BACN10HR162CD

- - SELF-LOCKING NUT 5 5

. BACN10HR6CD

- - NUT 3 3

. BACN10HR8CD

- - NUT 16 16

. BACN10YR4CD

- - NUT 28 28

. BACN10YR5CD (g)

- RIVET, 100 DEG 3 3 6 BACR15CE5KE5 (g)

- RIVET, 100 DEG 6 6 12 BACR15CE5KE6 (g)

- RIVET, 100 DEG 1 1 2 BACR15CE5KE8 (g)

- RIVET 27 27

. BACR15FV81KE13

- - SHIM, LAMINAT- ED 1 1

. BACS40R007B064F

- - SHIM, LAMINAT- ED 1 1

. BACS40R007B077F

- - SHIM, LAMINAT- ED 1 1

. BACS40R008B041F

- - SHIM, LAMINAT- ED 1 1

. BACS40R008B062F

- - SHIM, LAMINAT- ED 1 1

. BACS40R016B037F

- - SHIM, LAMINAT- ED 1 1

. BACS40R017B037F

- - SHIM, LAMINAT- ED 1 1

. BACS40R019B056F

- - SHIM, LAMINAT- ED 1 1

. BACS40R021B049F

- - SHIM, LAMINAT- ED 1 1

. BACS40R023B053F

- - SHIM,LAMINATED 1 1

. BACS40R029B065F

- - SHIM-LAMINATED 1 1

. BACS40R033B052F

- - WASHER, PLAIN 2 2

. BACW10BP12CD

- - WASHER, PLAIN 2 2

. BACW10BP12DP

- - WASHER, PLAIN 2 2

. BACW10BP16CD

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 33 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTALL
Kit 005W0016 Notes Existing Part Number Name Qty New Part Number -12 -11 -10

- - WASHER, PLAIN 2 2

. BACW10BP16DP

- - WASHER, PLAIN 8 8

. BACW10BP41DP

- - WASHER, PLAIN 5 5

. BACW10BP6CD

- - WASHER 5 5

. BACW10BP6DP

- - WASHER 3 3

. BACW10BP8CD

- - WASHER 3 3

. BACW10BP8DP

- - WASHER 8 8

. NAS1149D0432J

- - WASHER 8 8

. NAS1149D0463J

- - WASHER 28 28

. NAS1149D0532J

- - WASHER 28 28

. NAS1149D0563J (a) This top kit is for access restoration after inspection and no crack findings. (b) This top kit is for the repair on the left side of the airplane. (c) This top kit is for the repair on the right side of the airplane. (d) Discard the existing part. (e) This part is used in production. (f) You cannot use the existing part to replace the new or changed part. (g) 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. 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.
Notes Name QTY Part Number / Specification (a) Corrosion Inhibiting Compound 1 pint BMS 3-23 (BMS 3- 29 and BMS 3-35 optional) (a) Sealant 1 pint BMS 5-95 (a) Primer 1 pint BMS 10-11, Type I

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 34 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTNotes Name QTY Part Number / Specification (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
3. Parts Modified and Reidentified The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane. Group 1:
Notes New Part Number Name QTY Existing Part Number (c) (e) (d) SPLICE ANGLE 1 148W2204-5 (a) (c) (e) (d) SPLICE ANGLE 1 148W2204-6 (b) (a) This part is included in top kit 005W0016-11. (b) This part is included in top kit 005W0016-12. (c) Make the change in accordance with this service bulletin. (d) There is no equivalent Boeing part number for the changed part. Identify on the part that the change in accordance with this service bulletin was made. (e) This part is not used in production. Group 2: None. 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares None. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 35 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTExport Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 36 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT

BLANK PAGE3. 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 777 Structural Repair Manual, Chapter 51. — Values for airframe maintenance tasks are included in Chapter 20 of 777 Airplane Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). — Values for engine maintenance tasks are included in Chapter 70 of 777 Airplane Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step.
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 to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 6. 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. may be necessary. Surface cleaning and elaborate procedures may be required.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 37 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT7. HFEC is used for a High Frequency Eddy Current Inspection. 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. Boeing Service Letter 777-SL-51-013, 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. 10. Refer to APPENDIX A and APPENDIX B for logic diagram(s). 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. 11. 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. 12. 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. 13. 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. 14. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 15. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 16. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 17. The conditions and associated actions given in Paragraph 3.B., Work Instructions can be different on the left and right sides of the airplane. Because the conditions found may not be the same on both sides of the airplane, the required actions may be different between the left and right side of the airplane and can be done independently. 18. Some steps in the Work Instructions are labeled as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps labeled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including sub-steps

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 38 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTand identified figures. Steps not labeled as RC may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC. This is provided that the RC steps, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. B. WORK INSTRUCTIONS 1. Remove the skin panels in accordance with the figures below: Right Side Left Side FIGURE 2 FIGURE 1
2. Do PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION, for any crack. a. CONDITION 1: NO FORWARD CHORD CRACK IS FOUND (1) OPTION 1: Repeat PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION for any crack. (2) OPTION 2: Do the terminating modification in accordance with Boeing Service Bulletin 777-53-0076. b. CONDITION 2: ANY FORWARD CHORD CRACK IS FOUND, AND NO CRACK FOUND IS GREATER THAN 0.160 INCH (1) OPTION 2: Do the terminating modification in accordance with Boeing Service Bulletin 777-53-0076. (2) OPTION 3: (a) OPTION 3 (ACTION 1): Do PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR. NOTE:PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR can be done on the left and right side of the airplane at the same time. (b) OPTION 3 (ACTION 2): Do PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION. 1) CONDITION 4: NO FORWARD CHORD CRACK IS FOUND DURING POST-REPAIR INSPECTION a) OPTION 4: Repeat PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION. b) OPTION 2: Do the terminating modification in accordance with Boeing Service Bulletin 777-53-0076.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 39 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT2) CONDITION 5: ANY FORWARD CHORD CRACK IS FOUND DURING POST-REPAIR INSPECTION a) Do the terminating modification in accordance with Boeing Service Bulletin 777-53-0076. c. CONDITION 3: ANY FORWARD CHORD CRACK FOUND IS GREATER THAN 0.160 INCH (1) Do the terminating modification in accordance with Boeing Service Bulletin 777-53-0076. 3. If not previously installed, install the skin panels in accordance with the figures below: Right Side Left Side FIGURE 6 FIGURE 5 4. Put the airplane back to a serviceable condition. PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION 1. RC - Do an inspection of the Pivot Bulkhead Forward Outer Chord, for any crack, in accordance with the figures below: Right Side Left Side FIGURE 4 FIGURE 3
PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR 1. Support the airplane using one of the options below: OPTION 1: a. Support the airplane on its landing gear. b. Remove the load from the pivot pin assembly on the side of the airplane where the small crack repair is done. Refer to 777 AMM 55-17-01 as an accepted procedure. Removal of the pivot pin assembly or pivot fitting bearing is not necessary. If the small crack repair is done on the left and right side of the airplane at the same time, make sure that the pivot pin assemblies are unloaded on the left and right side of the airplane at the same time. OPTION 2: a. Lift the airplane on the primary jacks A, B and C. Refer to 777 AMM 07-11-01 as an accepted procedure. b. Remove the load from the pivot pin assembly on the side of the airplane where the small crack repair is done. Refer to 777 AMM 55-17-01 as an accepted procedure. Removal of the pivot pin assembly or pivot fitting bearing is not necessary. If the small crack repair is done on the left and right side of the airplane at the same time, make sure that the pivot pin assemblies are unloaded on the left and right side of the airplane at the same time.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 40 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT2.Group 1: Get access to the repair area in accordance with the figures below: Right Side Left Side FIGURE 8 FIGURE 7
3.Group 2: Get access to the repair area in accordance with the figures below: Right Side Left Side FIGURE 10 FIGURE 9
4. RC - Do PART 4: STATION 2370 PIVOT BULKHEAD FORWARD CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION, for any crack. a. CONDITION 6: NO FORWARD CHORD UPPER LOCATION OR ADJACENT STRUCTURE CRACK IS FOUND (1) RC - Continue to do the small crack repair in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR. b. CONDITION 7: ANY FORWARD CHORD UPPER LOCATION OR ADJACENT STRUCTURE CRACK IS FOUND (1) RC - ACTION 1: Contact The Boeing Company for repair instructions and do the repair. (2) RC - ACTION 2: Continue to do the small crack repair in accordance with PART 2: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR.
5.Group 1: RC - Modify the splice angle in accordance with the figures below: Right Side Left Side FIGURE 14 FIGURE 13
6.Group 1: RC - Repair the Station 2370 pivot bulkhead forward chord in accordance with the figures below: Right Side Left Side FIGURE 16 FIGURE 15
7.Group 2: RC - Repair the Station 2370 pivot bulkhead forward chord in accordance with the figures below: Right Side Left Side FIGURE 18 FIGURE 17

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 41 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT8. RC - Install the skin panels in accordance with the figures below: Right Side Left Side FIGURE 24 FIGURE 23 9. Apply finish to the repaired area to match adjacent structure. Apply BMS 3-23 (BMS 3-29 and BMS 3-35 optional) corrosion inhibiting compound to the repaired area. Refer to SOPM 20-41-05 as an accepted procedure. 10. If the airplane was stabilized using OPTION 1, remove the horizontal stabilizer jacking equipment. Refer to 777 AMM 55-17-01 as an accepted procedure. 11. If the airplane was stabilized using OPTION 2, a. Remove the horizontal stabilizer jacking equipment. Refer to 777 AMM 55-17-01 as an accepted procedure. b. Lower the airplane off of the jacks. Refer to 777 AMM 07-11-01 as an accepted procedure. PART 3: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION 1. Remove the skin panels in accordance with the figures below: Right Side Left Side FIGURE 26 FIGURE 25 2. RC - Do the DET and HFEC inspection in accordance with the figures below: Right Side Left Side FIGURE 20 FIGURE 19 3. RC - Install the skin panels in accordance with the figures below: Right Side Left Side FIGURE 22 FIGURE 21 4. Put the airplane back to a serviceable condition. PART 4: STATION 2370 PIVOT BULKHEAD FORWARD CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION 1. RC - Inspect the pivot bulkhead forward chord and adjacent structure in accordance with the figures below: Right Side Left Side FIGURE 12 FIGURE 11

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1: December 14, 2015 42 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 1 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 43 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 2 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 44 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 45 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 24
- FASTENER Remove 1 3
- FASTENER Remove/Keep 2 1 148W2912-1 SKIN 1 148W2912-3 SKIN 1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER 1 BACF3T03M14S8B FILLER 1 148W2918-3 SPLICE PLATE 1 148W2920-1 BRACKET

FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 46 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 1 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 47 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 2 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 48 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 49 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 24
- FASTENER Remove 1 3
- FASTENER Remove/Keep 2 1 148W2912-2 SKIN 1 148W2912-4 SKIN 1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER 1 BACF3T03M14S8B FILLER 1 148W2918-4 SPLICE PLATE 1 148W2920-2 BRACKET

FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 50 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 1 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 51 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 2 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 52 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Do a DET for any crack. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 1

FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 53 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step Do a DET for any crack. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 2

Do an open hole HFEC inspection for any crack, in accordance with 777 NDT Manual Part 6, 51-00-02. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 3

Do a surface HFEC inspection for any crack, in accordance with 777 NDT Manual Part 6, 51-00-01. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 4

FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 54 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 1 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 55 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 2 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 56 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Do a DET for any crack. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 1

FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 57 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step Do a DET for any crack. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 2

Do an open hole HFEC inspection for any crack, in accordance with 777 NDT Manual Part 6, 51-00-02. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 3

Do a surface HFEC inspection for any crack, in accordance with 777 NDT Manual Part 6, 51-00-01. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 4

FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 58 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 1 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 59 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 2 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 60 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 3 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 61 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER Put/Hold 1

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-1 SKIN 1 148W2912-3 SKIN Refer to the fastener table. 14
- HOLE Drill/Ream 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPERRemove/Keep 2

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-1 SKIN 1 148W2912-3 SKIN

- - HOLE Deburr (a) 1 148W2917-9 FILLER Install (Kept) 3 (a) 1 148W2917-11 FILLER (a) 1 148W2917-7 FILLER (a) 1 148W2918-3 SPLICE PLATE (a) 1 148W2920-1 BRACKET (a) 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER (a) 1 BACF3T03M14S8B FILLER (a) Do not seal the exterior gap around this skin panel. 1 148W2912-1 SKIN (a) Do not seal the exterior gap around this skin panel. 1 148W2912-3 SKIN
3
- FASTENER 24
- FASTENER Install (New) 4

FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 62 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step (a) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.

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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code (a) 0.2026 - 0.2036 2 BACB30NW6K5X BOLT, 100 DEG HEX DR D

- 2 BACC30M6 COLLAR (a) 0.2651 - 0.2661 7 BACB30NW8K5X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 1 BACB30NW8K6X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 4 BACB30NW8K9X BOLT, 100 DEG HEX DR

- 12 BACC30M8 COLLAR

- 3 BACR15CE5KE5 RIVET, 100 DEG H

- 6 BACR15CE5KE6 RIVET, 100 DEG

- 1 BACR15CE5KE8 RIVET, 100 DEG

- 2 BACB30VF3K4 BOLT J

- 1 BACB30VF3K5 BOLT Install bolts into existing nutplates on the horizontal stabilizer seal fairing. - - BACN10YF33CD NUTPLATE

(a) Install fasteners with BMS 5-95 sealant. Refer to SOPM 20-50-19, Method 2 as an accepted procedure.

FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 63 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 1 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 64 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 2 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 65 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 3 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 66 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER Put/Hold 1

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-2 SKIN 1 148W2912-4 SKIN Refer to the fastener table. 14
- HOLE Drill/Ream 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPERRemove/Keep 2

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-2 SKIN 1 148W2912-4 SKIN

- - HOLE Deburr (a) 1 148W2917-9 FILLER Install (Kept) 3 (a) 1 148W2917-11 FILLER (a) 1 148W2917-7 FILLER (a) 1 148W2918-4 SPLICE PLATE (a) 1 148W2920-2 BRACKET (a) 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER (a) 1 BACF3T03M14S8B FILLER (a) Do not seal the exterior gap around this skin panel. 1 148W2912-2 SKIN (a) Do not seal the exterior gap around this skin panel. 1 148W2912-4 SKIN
3
- FASTENER 24
- FASTENER Install (New) 4

FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 67 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step (a) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.

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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code (a) 0.2026 - 0.2036 2 BACB30NW6K5X BOLT, 100 DEG HEX DR D

- 2 BACC30M6 COLLAR (a) 0.2651 - 0.2661 7 BACB30NW8K5X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 1 BACB30NW8K6X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 4 BACB30NW8K9X BOLT, 100 DEG HEX DR

- 12 BACC30M8 COLLAR

- 3 BACR15CE5KE5 RIVET, 100 DEG H

- 6 BACR15CE5KE6 RIVET, 100 DEG

- 1 BACR15CE5KE8 RIVET, 100 DEG

- 2 BACB30VF3K4 BOLT J

- 1 BACB30VF3K5 BOLT Install bolts into existing nutplates on the horizontal stabilizer seal fairing. - - BACN10YF33CD NUTPLATE

(a) Install fasteners with BMS 5-95 sealant. Refer to SOPM 20-50-19, Method 2 as an accepted procedure.

FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 68 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 1.

FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 1 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 69 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 2 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 70 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 3 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 71 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 4 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 72 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 5 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 73 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 6 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 74 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 7 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 75 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 8 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 76 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Make a note of the location of each removed fastener. 12
- FASTENER Remove/Keep 1
210
- FASTENER Remove 2 18
- SHIM 1 148W2204-( ) SPLICE ANGLE 1 148W2379-( ) END FITTING Remove/Keep 3 FILLER A 2 BACF3H14NP017HN FILLER FILLER B 1 BACF33C105-410F FILLER

FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 9 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 77 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step 1 148W2369-( ) END FITTING Remove/Keep 4 FILLER C 1 BACF33C105-620F FILLER 1 148W2514-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, UPR Remove/Keep 5

1 287W4809-291 BRACKET 1 148W2515-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, FWD Remove/Keep 6

FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 10 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 78 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 1.

FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 1 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 79 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 2 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 80 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 3 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 81 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 4 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 82 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 5 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 83 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 6 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 84 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 7 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 85 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 8 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 86 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Make a note of the location of each removed fastener. 12
- FASTENER Remove/Keep 1
210
- FASTENER Remove 2 18
- SHIM 1 148W2204-( ) SPLICE ANGLE 1 148W2379-( ) END FITTING Remove/Keep 3 FILLER A 2 BACF3H14NP017HN FILLER FILLER B 1 BACF33C105-410F FILLER

FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 9 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 87 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step 1 148W2369-( ) END FITTING Remove/Keep 4 FILLER C 1 BACF33C105-620F FILLER 1 148W2514-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, UPR Remove/Keep 5

1 148W2515-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, FWD Remove/Keep 6

FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 10 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 88 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 2.

FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 1 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 89 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 2 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 90 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 3 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 91 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 4 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 92 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 5 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 93 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 6 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 94 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 7 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 95 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 8 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 96 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Make a note of the location of each removed fastener. 12
- FASTENER Remove/Keep 1
202
- FASTENER Remove 2 19
- SHIM 1 148W2204-( ) SPLICE ANGLE 1 148W2379-( ) END FITTING Remove/Keep 3 FILLER A 2 BACF3H14NP017HN FILLER FILLER D 1 148W2328-1 FILLER

FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 9 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 97 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step 1 148W2369-( ) END FITTING Remove/Keep 4 FILLER E 1 148W2328-2 FILLER 1 148W2514-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, UPR Remove/Keep 5

1 287W4809-291 BRACKET 1 148W2515-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, FWD Remove/Keep 6

FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 10 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 98 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 2.

FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 1 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 99 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 2 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 100 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 3 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 101 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 4 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 102 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 5 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 103 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 6 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 104 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 7 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 105 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 8 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 106 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Make a note of the location of each removed fastener. 12
- FASTENER Remove/Keep 1
202
- FASTENER Remove 2 19
- SHIM 1 148W2204-( ) SPLICE ANGLE 1 148W2379-( ) END FITTING Remove/Keep 3 FILLER A 2 BACF3H14NP017HN FILLER FILLER D 1 148W2328-1 FILLER

FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 9 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 107 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step 1 148W2369-( ) END FITTING Remove/Keep 4 FILLER E 1 148W2328-2 FILLER 1 148W2514-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, UPR Remove/Keep 5

1 148W2515-( ) SPLICE FITTING - UPR LONGERON,STA 2370, OUTBOARD, FWD Remove/Keep 6

FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL (SHEET 10 OF 10) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 108 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 1 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 109 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 2 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 110 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 3 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 111 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 112 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Do an open hole High Frequency Eddy Current (HFEC) inspection for any crack,of the holes common to the pivot bulkhead web, the upper forward chord and the aft chord, and of the holes common to the skin and the bulkhead assembly, in accordance with 777 NDT Manual Part 6, 51-00-02. 4
- HOLE Inspect 1

Do a Detailed Inspection (DET) of theupper aft longeron extension fittings between STA 2370 and STA 2380, for any crack. 1 148W5126-( ) FITTING Inspect 2

Do a Detailed Inspection (DET) of theupper aft longeron extension fittings between STA 2370 and STA 2380, for any crack. 1 148W5127-( ) FITTING Inspect 3

FIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 113 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 1 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 114 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 2 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 115 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 3 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 116 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 117 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Do an open hole High Frequency Eddy Current (HFEC) inspection for any crack,of the holes common to the pivot bulkhead web, the upper forward chord and the aft chord, and of the holes common to the skin and the bulkhead assembly, in accordance with 777 NDT Manual Part 6, 51-00-02. 4
- HOLE Inspect 1

Do a Detailed Inspection (DET) of theupper aft longeron extension fittings between STA 2370 and STA 2380, for any crack. 1 148W5126-( ) FITTING Inspect 2

Do a Detailed Inspection (DET) of theupper aft longeron extension fittings between STA 2370 and STA 2380, for any crack. 1 148W5127-( ) FITTING Inspect 3

FIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 118 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 1.

FIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION (SHEET 1 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 119 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 120 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Cut to the dimensions shown.Maximum surface roughness 125RA. 1 148W2204-5 SPLICE ANGLE Cut 1

Break all sharp edges. 1 148W2204-5 SPLICE ANGLE Deburr Roto peen cut edges. Refer to SOPM 20-10-03 as an accepted procedure. 1 148W2204-5 SPLICE ANGLE Shot Peen

Apply to the cut surfaces. Refer to SOPM 20-43-03 as an accepted procedure. - - CHEMICAL CONVERSION COATING Apply

Apply two coatsto the cut surfaces. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE I PRIMER

Identify on thepart that this service bulletin change has been made. Refer to SOPM 20-50-10 rubber stampmethod as an accepted procedure. 1 148W2204-5 SPLICE ANGLE Identify 2

FIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 121 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 1.

FIGURE 14: RIGHT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION (SHEET 1 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 122 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 14: RIGHT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 123 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Cut to the dimensions shown.Maximum surface roughness 125RA. 1 148W2204-6 SPLICE ANGLE Cut 1

Break all sharp edges. 1 148W2204-6 SPLICE ANGLE Deburr Roto peen cut edges. Refer to SOPM 20-10-03 as an accepted procedure. 1 148W2204-6 SPLICE ANGLE Shot Peen

Apply to the cut surfaces. Refer to SOPM 20-43-03 as an accepted procedure. - CHEMICAL CONVERSION COATING Apply

Apply two coatsto the cut surfaces. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE I PRIMER

Identify on thepart that this service bulletin change has been made. Refer to SOPM 20-50-10 rubber stampmethod as an accepted procedure. 1 148W2204-6 SPLICE ANGLE Identify 2

FIGURE 14: RIGHT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 124 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 1.

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 1 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 125 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 2 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 126 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 3 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 127 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 4 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 128 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 5 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 129 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 6 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 130 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 7 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 131 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 8 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 132 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 9 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 133 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 10 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 134 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 11 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 135 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step modified in accordance with FIGURE 13. 1 148W2204-5 SPLICE ANGLE Put / Hold 1

SHIM A 1 148W7143-11 SHIM LAMINATED Put / Hold SHIM B 1 148W7143-13 SHIM LAMINATED Put / Hold SHIM C 1 148W7143-7 SHIM LAMINATED Put / Hold SHIM D 1 148W7143-6 SHIM LAMINATED Put / Hold SHIM E 1 148W7143-5 SHIM LAMINATED Put / Hold SHIM F 1 BACS40R017B037F SHIM, LAMINATED Put / Hold 2 FILLER A 2 BACF3H14NP017HN FILLER Put / Hold This is a kept part. SHIM G 1 BACS40R007B064F SHIM, LAMINATED Put / Hold SHIM H 1 BACS40R008B041F SHIM, LAMINATED Put / Hold FILLER B 1 BACF33C105-410F FILLER Put / Hold This is a kept part. 1 148W2379-() END FITTING Put / Hold SHIM I 1 BACS40R023B053F SHIM, LAMINATED Put / Hold SHIM J 1 BACS40R007B077F SHIM, LAMINATED Put / Hold SHIM K 1 BACS40R008B062F SHIM, LAMINATED Put / Hold FILLER C 1 BACF33C105-620F FILLER Put / Hold This is a kept part. 1 148W2369-() END FITTING Put / Hold 1 148W2515-() FITTING Put / Hold 3 SHIM L 1 BACS40R029B065F SHIM,LAMINATED Put / Hold SHIM M 1 148W0015-13 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 12 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 136 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step 1 148W2514-() FITTING Put / Hold 4 SHIM Q 1 148W0015-12 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold SHIM R 1 BACS40R021B049F SHIM, LAMINATED Put / Hold SHIM S 1 BACS40R019B056F SHIM, LAMINATED Put / Hold This is a kept part. 1 287W4809-291 BRACKET Put / Hold Match drill the holes common to the skin,splice angle and forward outer chord. 27
- HOLE Drill 5

195
- HOLE Drill / Ream 6

- - PART Remove / Keep 7

- - HOLE Deburr 8

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 13 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 137 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step the damaged edge in accordance with 777-200 SRM 51- 10-02 or 777-300 SRM 51-10-02, as applicable. Minimum material removed equals the length of the longest detectedcrack, and not to exceed 0.160 inch. 1 148W7102-() CHORD Cut 9

1 148W7102-() CHORD Deburr Do a surface High Frequency EddyCurrent (HFEC) inspection of the cut edge, to make sureany crack was removed, in accordance with 777 NDT Manual Part 6, 51- 00-01. (a) 1 148W7102-() CHORD Inspect

0.04 inch insurance cut. Maximum edge trim out is 0.200 inch. Blend the edge to a minimum radiusof 1.50 inch. Maintain a shoulder slopeof runout of minimum 1.0 inch. 1 148W7102-() CHORD Cut

Deburr the cut edge.The surface roughness of the cut edge is 63 Ra or better. 1 148W7102-() CHORD Deburr

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 14 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 138 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step The indicated inboard and outboard surface of the chord. Shot intensity is 0.010A, shot size is 330, and coverage is 100%. Refer to SOPM 20-10-03, Self-Contained ShotPeening, as an accepted procedure. 1 148W7102-() CHORD Shot Peen 10

to the cut surface, in accordance with 777-200 SRM 51- 20-01 or 777-300 SRM 51-20-01, as applicable. - - CHEMICAL CONVER- SION COATING Apply 11

two coats, on the cut surface. Refer to SOPM 20-41-02 asan accepted procedure. - BMS 10-11, TYPE I PRIMER Apply

modified in accordance with FIGURE 13. 1 148W2204-5 SPLICE ANGLE Install (New) 12
(f) SHIM A 1 148W7143-11 SHIM LAMINATED Install (New) (e) (f) SHIM B 1 148W7143-13 SHIM LAMINATED Install (New) (e) (f) SHIM C 1 148W7143-7 SHIM LAMINATED Install (New) (e) (f) SHIM D 1 148W7143-6 SHIM LAMINATED Install (New) (e) (f) SHIM E 1 148W7143-5 SHIM LAMINATED Install (New) (e) (f)

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 15 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 139 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step SHIM F 1 BACS40R017B037F SHIM, LAMINATED Install (New) 13 (d) (f) FILLER A 2 BACF3H14NP017HN FILLER Install (Kept) (f) SHIM G 1 BACS40R007B064F SHIM, LAMINATED Install (New) (b) (f) SHIM H 1 BACS40R008B041F SHIM, LAMINATED Install (New) (b) (f) FILLER B 1 BACF33C105-410F FILLER Install (Kept) (f) (f) End fitting pad must remain clamped to chord until the sealant is cured. 1 148W2379-() END FITTING Install (Kept)

SHIM I 1 BACS40R023B053F SHIM, LAMINATED Install (New) (d) (f) SHIM J 1 BACS40R007B077F SHIM, LAMINATED Install (New) (b) (f) SHIM K 1 BACS40R008B062F SHIM, LAMINATED Install (New) (b) (f) FILLER C 1 BACF33C105-620F FILLER Install (Kept) (f) (f) End fitting pad must remain clamped to chord until the sealant is cured. 1 148W2369-() END FITTING Install (Kept)

(f) 1 148W2515-() FITTING Install (Kept) 14 SHIM L 1 BACS40R029B065F SHIM,LAMINATED Install (New) (b) (f) SHIM M 1 148W0015-13 SHIM Install (New) (b) (f) SHIM O 1 148W0015-14 SHIM Install (New) (b) (f)

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 16 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 140 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step (f) 1 148W2514-() FITTING Install (Kept) 15 SHIM Q 1 148W0015-12 SHIM Install (New) (b) (f) SHIM O 1 148W0015-14 SHIM Install (New) (b) (f) SHIM R 1 BACS40R021B049F SHIM, LAMINATED Install (New) (b) (f) SHIM S 1 BACS40R019B056F SHIM, LAMINATED Install (New) (b) (f) (f) 1 287W4809-291 BRACKET Install (Kept) (g) 12
- FASTENER Install (Kept) 16 (g) 210
- FASTENER Install (New) 17 (a) If crack indications exist after this surface HFEC inspection, remove additional material, a maximum of 0.160 inch total, to remove the crack indication. If crack indications still exist after a total of 0.160 inch of material has been removed, this repair cannot be done. Do the modification in Boeing Service Bulletin 777-53-0076.(b) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.04 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (c) Fit shim by removing 0.003 inch laminations as required. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (d) Fit shim by removing 0.003 inch laminations as required. Maximum gap after shimming is 0.003 inch. Step tapering may be necessary. Shim must pick up minimum of one bolt. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (e) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.033 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (f) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure. (g) Install fasteners with BMS 5-95. Refer to SOPM 20-50-19, Method 2, as an accepted procedure. The parts shown in the table below are provided as extra parts for this figure.
More Data Qty Identification Name SHIM T 1 BACS40R033B052F SHIM-LAMINATED

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 17 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 141 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. Description FlagnoteMake sure the space between the stringer end fitting and the adjacent structure is free of sealant for sufficient drainage. 1

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 18 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 142 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 2 BACB30US6K14 BOLT, 12 PT HEAD A

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 3 BACB30US6K19 BOLT, 12 PT HEAD

Under bolt head

- 5 BACW10BP6CD WASHER, PLAIN Under the nut

- 5 BACW10BP6DP WASHER Tighten to 300 to 500 inlb. - 5 BACN10HR6CD SELF-LOCKING NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 1 BACB30US8K28 BOLT, 12 PT HEAD

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 2 BACB30US8K33 BOLT, 12 PT HEAD

Under bolt head

- 3 BACW10BP8CD WASHER Under the nut

- 3 BACW10BP8DP WASHER Tighten to 870 to 1300 inlb. - 3 BACN10HR8CD NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.751 - 0.757 2 BACB30US12K36 BOLT, 12 PT HEAD

Under bolt head

- 2 BACW10BP12CD WASHER, PLAIN Under the nut

- 2 BACW10BP12DP WASHER, PLAIN Tighten to 3300 to 4300 in-lb. - 2 BACN10HR12CD SELF-LOCKING NUT

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 19 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 143 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name CodeBOLT, 12 PT HEAD This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 1.028 - 1.047 1 BACB30US16K45

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 1.028 - 1.047 1 BACB30US16K46 BOLT, 12 PT HEAD

Under bolt head

- 2 BACW10BP16CD WASHER, PLAIN Under the nut

- 2 BACW10BP16DP WASHER, PLAIN Tighten to 7000 to 10900 in-lb. - 2 BACN10HR162CD SELF-LOCKING NUT
0.200 - 0.203 4 BACB30NX6K5X BOLT, PROTRUDING HD B

- 4 BACC30M6 COLLAR 0.327 - 0.331 3 BACB30NX10K11X BOLT, PROTRUDING HD 0.327 - 0.331 13 BACB30NX10K14X BOLT, PROTRUDING HD

- 16 BACC30BH10 COLLAR

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 20 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 144 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 11 BACB30MY8K4X BOLT, PROTRUDING HD C
0.263 - 0.266 11 BACB30MY8K5X BOLT, PROTRUDING HD 0.263 - 0.266 16 BACB30MY8K6X BOLT, PROTRUDING HD 0.263 - 0.266 8 BACB30MY8K7X BOLT, PROTRUDING HD 0.263 - 0.266 5 BACB30MY8K8X BOLT, PROTRUDING HD 0.263 - 0.266 1 BACB30MY8K9X BOLT, PROTRUDING HD 0.263 - 0.266 14 BACB30MY8K11X BOLT, PROTRUDING HD

- 66 BACC30M8 COLLAR 0.325 - 0.328 8 BACB30MY10K7X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K10X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K13X BOLT, PROTRUDING HD

- 20 BACC30M10 COLLAR 0.263 - 0.266 3 BACB30NW8K7X BOLT, 100 DEG HEX DR D
0.263 - 0.266 5 BACB30NW8K8X BOLT, 100 DEG HEX DR 0.263 - 0.266 3 BACB30NW8K9X BOLT, 100 DEG HEX DR 0.263 - 0.266 28 BACB30NW8K10X BOLT, 100 DEG HEX DR

- 39 BACC30M8 COLLAR 0.268 - 0.272 27 BACR15FV81KE13 RIVET E

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 21 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 145 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 10 BACB30NZ8K12X BOLT, 100 DEG HEX DR F

- 10 BACC30BH8 COLLAR 0.325 - 0.328 12 BACB30NZ10K15X BOLT, 100 DEG HEX D 0.325 - 0.328 16 BACB30NZ10K16X BOLT, 100 DEG HEX DR

- 28 BACC30BH10 COLLAR

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 22 OF 22) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 146 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 1.

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 1 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 147 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 2 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 148 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 3 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 149 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 4 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 150 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 5 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 151 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 6 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 152 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 7 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 153 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 8 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 154 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 9 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 155 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 10 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 156 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 11 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 157 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step modified in accordance with FIGURE 14. 1 148W2204-6 SPLICE ANGLE Put / Hold 1

SHIM A 1 148W7143-11 SHIM LAMINATED Put / Hold SHIM B 1 148W7143-13 SHIM LAMINATED Put / Hold SHIM C 1 148W7143-7 SHIM LAMINATED Put / Hold SHIM D 1 148W7143-6 SHIM LAMINATED Put / Hold SHIM E 1 148W7143-5 SHIM LAMINATED Put / Hold SHIM F 1 BACS40R017B037F SHIM, LAMINATED Put / Hold 2 FILLER A 2 BACF3H14NP017HN FILLER Put / Hold This is a kept part. SHIM G 1 BACS40R007B064F SHIM, LAMINATED Put / Hold SHIM H 1 BACS40R008B041F SHIM, LAMINATED Put / Hold FILLER B 1 BACF33C105-410F FILLER Put / Hold This is a kept part. 1 148W2379-() END FITTING Put / Hold SHIM I 1 BACS40R023B053F SHIM, LAMINATED Put / Hold SHIM J 1 BACS40R007B077F SHIM, LAMINATED Put / Hold SHIM K 1 BACS40R008B062F SHIM, LAMINATED Put / Hold FILLER C 1 BACF33C105-620F FILLER Put / Hold This is a kept part. 1 148W2369-() END FITTING Put / Hold 1 148W2515-() FITTING Put / Hold 3 SHIM L 1 BACS40R029B065F SHIM,LAMINATED Put / Hold SHIM M 1 148W0015-13 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold 1 148W2514-() FITTING Put / Hold 4 SHIM Q 1 148W0015-12 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold SHIM R 1 BACS40R021B049F SHIM, LAMINATED Put / Hold SHIM S 1 BACS40R019B056F SHIM, LAMINATED Put / Hold

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 12 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 158 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step Match drill the holes common to the skin,splice angle and forward outer chord. 27
- HOLE Drill 5

195
- HOLE Drill / Ream 6

- - PART Remove / Keep 7

- - HOLE Deburr 8 the damaged edge in accordance with 777-200 SRM 51- 10-02 or 777-300 SRM 51-10-02, as applicable. Minimum material removed equals the length of the longest detectedcrack, and not to exceed 0.160 inch. 1 148W7102-() CHORD Cut 9

1 148W7102-() CHORD Deburr Do a surface High Frequency EddyCurrent (HFEC) inspection of the cut edge, to make sureany crack was removed, in accordance with 777 NDT Manual Part 6, 51- 00-01. (a) 1 148W7102-() CHORD Inspect

0.04 inch insurance cut. Maximum edge trim out is 0.200 inch. Blend the edge to a minimum radiusof 1.50 inch. Maintain a shoulder slopeof runout of minimum 1.0 inch. 1 148W7102-() CHORD Cut

Deburr the cut edge.The surface roughness of the cut edge is 63 Ra or better. 1 148W7102-() CHORD Deburr

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 13 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 159 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step The indicated inboard and outboard surface of the chord. Shot intensity is 0.010A, shot size is 330, and coverage is 100%. Refer to SOPM 20-10-03, Self-Contained ShotPeening, as an accepted procedure. 1 148W7102-() CHORD Shot Peen 10

to the cut surface, in accordance with 777-200 SRM 51- 20-01 or 777-300 SRM 51-20-01, as applicable. - - CHEMICAL CONVER- SION COATING Apply 11

two coats, on the cut surface. Refer to SOPM 20-41-02 asan accepted procedure. - BMS 10-11, TYPE I PRIMER Apply

modified in accordance with FIGURE 14. 1 148W2204-6 SPLICE ANGLE Install (New) 12
(f) SHIM A (e) (f) 1 148W7143-11 SHIM LAMINATED Install (New) SHIM B (e) (f) 1 148W7143-13 SHIM LAMINATED Install (New) SHIM C (e) (f) 1 148W7143-7 SHIM LAMINATED Install (New) SHIM D (e) (f) 1 148W7143-6 SHIM LAMINATED Install (New) SHIM E (e) (f) 1 148W7143-5 SHIM LAMINATED Install (New)

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 14 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 160 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step SHIM F (d) (f) 1 BACS40R017B037F SHIM, LAMINATED Install (New) 13 FILLER A (f) 2 BACF3H14NP017HN FILLER Install (Kept) SHIM G (b) (f) 1 BACS40R007B064F SHIM, LAMINATED Install (New) SHIM H (b) (f) 1 BACS40R008B041F SHIM, LAMINATED Install (New) FILLER B (f) 1 BACF33C105-410F FILLER Install (Kept) (f) End fitting pad must remain clamped to chord until the sealant is cured. 1 148W2379-() END FITTING Install (Kept)

SHIM I (d) (f) 1 BACS40R023B053F SHIM, LAMINATED Install (New) SHIM J (b) (f) 1 BACS40R007B077F SHIM, LAMINATED Install (New) SHIM K (b) (f) 1 BACS40R008B062F SHIM, LAMINATED Install (New) FILLER C (f) 1 BACF33C105-620F FILLER Install (Kept) (f) End fitting pad must remain clamped to chord until the sealant is cured. 1 148W2369-() END FITTING Install (Kept)

(f) 1 148W2515-() FITTING Install (Kept) 14 SHIM L (b) (f) 1 BACS40R029B065F SHIM,LAMINATED Install (New) SHIM M (b) (f) 1 148W0015-13 SHIM Install (New) SHIM O (b) (f) 1 148W0015-14 SHIM Install (New) (f) 1 148W2514-() FITTING Install (Kept) 15 SHIM Q (b) (f) 1 148W0015-12 SHIM Install (New) SHIM O (b) (f) 1 148W0015-14 SHIM Install (New) SHIM R (b) (f) 1 BACS40R021B049F SHIM, LAMINATED Install (New) SHIM S (b) (f) 1 BACS40R019B056F SHIM, LAMINATED Install (New) (g) 12
- FASTENER Install (Kept) 16 (g) 210
- FASTENER Install (New) 17 (a) If crack indications exist after this surface HFEC inspection, remove additional material, maximum of 0.160 inch total, to remove the crack indication. If crack indications still exist after a total of 0.160 inch of material has been removed, this repair cannot be done. Do the modification in Boeing Service Bulletin 777-53-0076.

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 15 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 161 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step(b) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.04 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure.(c) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.04 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (d) Fit shim by removing 0.003 inch laminations as required. Maximum gap after shimming is 0.003 inch. Step tapering may be necessary. Shim must pick up minimum of one bolt. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (e) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.033 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (f) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure. (g) Install fasteners with BMS 5-95. Refer to SOPM 20-50-19, Method 2, as an accepted procedure. The parts shown in the table below are provided as extra parts for this figure.
More Data Qty Identification Name SHIM T 1 BACS40R033B052F SHIM-LAMINATED The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. Description FlagnoteMake sure the space between the stringer end fitting and the adjacent structure is free of sealant for sufficient drainage. 1

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 16 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 162 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 2 BACB30US6K14 BOLT, 12 PT HEAD A

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 3 BACB30US6K19 BOLT, 12 PT HEAD

Under bolt head

- 5 BACW10BP6CD WASHER, PLAIN Under the nut

- 5 BACW10BP6DP WASHER Tighten to 300 to 500 inlb. - 5 BACN10HR6CD SELF-LOCKING NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 1 BACB30US8K28 BOLT, 12 PT HEAD

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 2 BACB30US8K33 BOLT, 12 PT HEAD

Under bolt head

- 3 BACW10BP8CD WASHER Under the nut

- 3 BACW10BP8DP WASHER Tighten to 870 to 1300 inlb. - 3 BACN10HR8CD NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.751 - 0.757 2 BACB30US12K36 BOLT, 12 PT HEAD

Under bolt head

- 2 BACW10BP12CD WASHER, PLAIN Under the nut

- 2 BACW10BP12DP WASHER, PLAIN Tighten to 3300 to 4300 in-lb. - 2 BACN10HR12CD SELF-LOCKING NUT

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 17 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 163 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name CodeBOLT, 12 PT HEAD This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 1.028 - 1.047 1 BACB30US16K45

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 1.028 - 1.047 1 BACB30US16K46 BOLT, 12 PT HEAD

Under bolt head

- 2 BACW10BP16CD WASHER, PLAIN Under the nut

- 2 BACW10BP16DP WASHER, PLAIN Tighten to 7000 to 10900 in-lb. - 2 BACN10HR162CD SELF-LOCKING NUT
0.200 - 0.203 4 BACB30NX6K5X BOLT, PROTRUDING HD B

- 4 BACC30M6 COLLAR 0.327 - 0.331 3 BACB30NX10K11X BOLT, PROTRUDING HD 0.327 - 0.331 13 BACB30NX10K14X BOLT, PROTRUDING HD

- 16 BACC30BH10 COLLAR

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 18 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 164 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 14 BACB30MY8K4X BOLT, PROTRUDING HD C
0.263 - 0.266 8 BACB30MY8K5X BOLT, PROTRUDING HD 0.263 - 0.266 16 BACB30MY8K6X BOLT, PROTRUDING HD 0.263 - 0.266 8 BACB30MY8K7X BOLT, PROTRUDING HD 0.263 - 0.266 5 BACB30MY8K8X BOLT, PROTRUDING HD 0.263 - 0.266 1 BACB30MY8K9X BOLT, PROTRUDING HD 0.263 - 0.266 14 BACB30MY8K11X BOLT, PROTRUDING HD

- 66 BACC30M8 COLLAR 0.325 - 0.328 8 BACB30MY10K7X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K10X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K13X BOLT, PROTRUDING HD

- 20 BACC30M10 COLLAR 0.263 - 0.266 3 BACB30NW8K7X BOLT, 100 DEG HEX DR D
0.263 - 0.266 5 BACB30NW8K8X BOLT, 100 DEG HEX DR 0.263 - 0.266 3 BACB30NW8K9X BOLT, 100 DEG HEX DR 0.263 - 0.266 28 BACB30NW8K10X BOLT, 100 DEG HEX DR

- 39 BACC30M8 COLLAR 0.268 - 0.272 27 BACR15FV81KE13 RIVET E

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 19 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 165 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 10 BACB30NZ8K12X BOLT, 100 DEG HEX DR F

- 10 BACC30BH8 COLLAR 0.325 - 0.328 12 BACB30NZ10K15X BOLT, 100 DEG HEX D 0.325 - 0.328 16 BACB30NZ10K16X BOLT, 100 DEG HEX DR

- 28 BACC30BH10 COLLAR

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 20 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 166 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 2.

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 1 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 167 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 2 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 168 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 3 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 169 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 4 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 170 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 5 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 171 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 6 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 172 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 7 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 173 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 8 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 174 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 9 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 175 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 10 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 176 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 1 148W2204-5 SPLICE ANGLE Put / Hold 1 SHIM A 1 148W7143-11 SHIM LAMINATED Put / Hold SHIM B 1 148W7143-13 SHIM LAMINATED Put / Hold SHIM C 1 148W7143-7 SHIM LAMINATED Put / Hold SHIM D 1 148W7143-6 SHIM LAMINATED Put / Hold SHIM E 1 148W7143-5 SHIM LAMINATED Put / Hold

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 11 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 177 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step SHIM U 1 BACS40R016B037F SHIM, LAMINATED Put / Hold 2 FILLER A 2 BACF3H14NP017HN FILLER Put / Hold This is a kept part. SHIM G 1 BACS40R007B064F SHIM, LAMINATED Put / Hold SHIM H 1 BACS40R008B041F SHIM, LAMINATED Put / Hold FILLER D 1 148W2328-1 FILLER Put / Hold This is a kept part. 1 148W2379-() END FITTING Put / Hold SHIM I 1 BACS40R023B053F SHIM, LAMINATED Put / Hold SHIM J 1 BACS40R007B077F SHIM, LAMINATED Put / Hold SHIM K 1 BACS40R008B062F SHIM, LAMINATED Put / Hold FILLER E 1 148W2328-2 FILLER Put / Hold This is a kept part. 1 148W2369-() END FITTING Put / Hold 1 148W2515-() FITTING Put / Hold 3 SHIM L 1 BACS40R029B065F SHIM,LAMINATED Put / Hold SHIM M 1 148W0015-13 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold 1 148W2514-() FITTING Put / Hold 4 SHIM Q 1 148W0015-12 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold SHIM R 1 BACS40R021B049F SHIM, LAMINATED Put / Hold SHIM S 1 BACS40R019B056F SHIM, LAMINATED Put / Hold SHIM T 1 BACS40R033B052F SHIM-LAMINATED Put / Hold This is a kept part. 1 287W4809-291 BRACKET Put / Hold 214
- HOLE Drill / Ream 5

- - PART Remove / Keep 6

- - HOLE Deburr 7

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 12 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 178 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step the damaged edge in accordance with 777-200 SRM 51- 10-02 or 777-300 SRM 51-10-02, as applicable. Minimum material removed equals the length of the longest detectedcrack, and not to exceed 0.160 inch. 1 148W7102-() CHORD Cut 8

1 148W7102-() CHORD Deburr Do a surface High Frequency EddyCurrent (HFEC) inspection of the cut edge, to make sureany crack was removed, in accordance with 777 NDT Manual Part 6, 51- 00-01. (a) 1 148W7102-() CHORD Inspect

0.04 inch insurance cut. Maximum edge trim out is 0.200 inch. Blend the edge to a minimum radiusof 1.50 inch. Maintain a shoulder slopeof runout of minimum 1.0 inch. 1 148W7102-() CHORD Cut

Deburr the cut edge.The surface roughness of the cut edge is 63 Ra or better. 1 148W7102-() CHORD Deburr

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 13 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 179 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step The indicated inboard and outboard surface of the chord. Shot intensity is 0.010A, shot size is 330, and coverage is 100%. Refer to SOPM 20-10-03, Self-Contained ShotPeening, as an accepted procedure. 1 148W7102-() CHORD Shot Peen 9

to the cut surface, in accordance with 777-200 SRM 51- 20-01 or 777-300 SRM 51-20-01, as applicable. - - CHEMICAL CONVER- SION COATING Apply 10

two coats, on the cut surface. Refer to SOPM 20-41-02 asan accepted procedure. - BMS 10-11, TYPE I PRIMER Apply

(f) 1 148W2204-5 SPLICE ANGLE Install (New) 11 SHIM A (e) (f) 1 148W7143-11 SHIM LAMINATED Install (New) SHIM B (e) (f) 1 148W7143-13 SHIM LAMINATED Install (New) SHIM C (e) (f) 1 148W7143-7 SHIM LAMINATED Install (New) SHIM D (e) (f) 1 148W7143-6 SHIM LAMINATED Install (New) SHIM E (e) (f) 1 148W7143-5 SHIM LAMINATED Install (New)

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 14 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 180 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step SHIM U (d) (f) 1 BACS40R016B037F SHIM, LAMINATED Install (New) 12 FILLER A (f) 2 BACF3H14NP017HN FILLER Install (Kept) SHIM G (b) (f) 1 BACS40R007B064F SHIM, LAMINATED Install (New) SHIM H (b) (f) 1 BACS40R008B041F SHIM, LAMINATED Install (New) FILLER D (f) 1 148W2328-1 FILLER Install (Kept) (f) End fitting pad must remained clamped to chord until the sealant is cured. 1 148W2379-() END FITTING Install (Kept)

SHIM I (d) (f) 1 BACS40R023B053F SHIM, LAMINATED Install (New) SHIM J (b) (f) 1 BACS40R007B077F SHIM, LAMINATED Install (New) SHIM K (b) (f) 1 BACS40R008B062F SHIM, LAMINATED Install (New) FILLER E (f) 1 148W2328-2 FILLER Install (Kept) (f) End fitting pad must remained clamped to chord until the sealant is cured. 1 148W2369-() END FITTING Install (Kept)

(f) 1 148W2515-() FITTING Install (Kept) 13 SHIM L (b) (f) 1 BACS40R029B065F SHIM,LAMINATED Install (New) SHIM M (b) (f) 1 148W0015-13 SHIM Install (New) SHIM O (b) (f) 1 148W0015-14 SHIM Install (New) (f) 1 148W2514-() FITTING Install (Kept) 14 SHIM Q (b) (f) 1 148W0015-12 SHIM Install (New) SHIM O (b) (f) 1 148W0015-14 SHIM Install (New) SHIM R (b) (f) 1 BACS40R021B049F SHIM, LAMINATED Install (New) SHIM S (b) (f) 1 BACS40R019B056F SHIM, LAMINATED Install (New) SHIM T (c) (f) 1 BACS40R033B052F SHIM-LAMINATED Install (New) (f) 1 287W4809-291 BRACKET Install (Kept) (g) 12
- FASTENER Install (Kept) 15 (g) 202
- FASTENER Install (New) 16

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 15 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 181 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step (a) If crack indications exist after this surface HFEC inspection, remove additional material, maximum of 0.160 inch total, to remove the crack indication. If crack indications still exist after a total of 0.160 inch of material has been removed, this repair cannot be done. Do the modification in Boeing Service Bulletin 777-53-0076.(b) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.04 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (c) Fit shim by removing 0.003 inch laminations as required. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (d) Fit shim by removing 0.003 inch laminations as required. Maximum gap after shimming is 0.003 inch. Step tapering may be necessary. Shim must pick up minimum of one bolt. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (e) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.033 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (f) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure. (g) Install fasteners with BMS 5-95. Refer to SOPM 20-50-19, Method 2, as an accepted procedure. The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. Description FlagnoteMake sure the space between the stringer end fitting and the adjacent structure is free of sealant for sufficient drainage. 1

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 16 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 182 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 2 BACB30US6K14 BOLT, 12 PT HEAD A

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 3 BACB30US6K19 BOLT, 12 PT HEAD

Under bolt head

- 5 BACW10BP6CD WASHER, PLAIN Under the nut

- 5 BACW10BP6DP WASHER Tighten to 300 to 500 inlb. - 5 BACN10HR6CD SELF-LOCKING NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 1 BACB30US8K28 BOLT, 12 PT HEAD

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 2 BACB30US8K* BOLT, 12 PT HEAD

Under bolt head

- 3 BACW10BP8CD WASHER Under the nut

- 3 BACW10BP8DP WASHER Tighten to 870 to 1300 inlb. - 3 BACN10HR8CD NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.751 - 0.757 2 BACB30US12K36 BOLT, 12 PT HEAD

Under bolt head

- 2 BACW10BP12CD WASHER, PLAIN Under the nut

- 2 BACW10BP12DP WASHER, PLAIN Tighten to 3300 to 4300 in-lb. - 2 BACN10HR12CD SELF-LOCKING NUT

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 17 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 183 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name CodeBOLT, 12 PT HEAD This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 1.028 - 1.047 2 BACB30US16K46

Under bolt head

- 2 BACW10BP16CD WASHER, PLAIN Under the nut

- 2 BACW10BP16DP WASHER, PLAIN Tighten to 7000 to 10900 in-lb. - 2 BACN10HR162CD SELF-LOCKING NUT
0.200 - 0.203 4 BACB30NX6K5X BOLT, PROTRUDING HD B

- 4 BACC30M6 COLLAR 0.327 - 0.331 3 BACB30NX10K11X BOLT, PROTRUDING HD 0.327 - 0.331 13 BACB30NX10K14X BOLT, PROTRUDING HD

- 16 BACC30BH10 COLLAR

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 18 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 184 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 11 BACB30MY8K4X BOLT, PROTRUDING HD C
0.263 - 0.266 9 BACB30MY8K5X BOLT, PROTRUDING HD 0.263 - 0.266 18 BACB30MY8K6X BOLT, PROTRUDING HD 0.263 - 0.266 6 BACB30MY8K7X BOLT, PROTRUDING HD 0.263 - 0.266 5 BACB30MY8K8X BOLT, PROTRUDING HD 0.263 - 0.266 1 BACB30MY8K9X BOLT, PROTRUDING HD 0.263 - 0.266 14 BACB30MY8K11X BOLT, PROTRUDING HD

- 64 BACC30M8 COLLAR 0.325 - 0.328 8 BACB30MY10K7X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K10X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K13X BOLT, PROTRUDING HD

- 20 BACC30M10 COLLAR 0.263 - 0.266 2 BACB30NW8K7X BOLT, 100 DEG HEX DR D
0.263 - 0.266 5 BACB30NW8K8X BOLT, 100 DEG HEX DR 0.263 - 0.266 17 BACB30NW8K9X BOLT, 100 DEG HEX DR 0.263 - 0.266 28 BACB30NW8K10X BOLT, 100 DEG HEX DR 0.263 - 0.266 2 BACB30NW8K12X BOLT, 100 DEG HEX DR

- 54 BACC30M8 COLLAR

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 19 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 185 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 8 BACB30YN8K12X BOLT, HEX DRIVE G

- - 8 NAS1149D0432J WASHER

- - 8 NAS1149D0463J WASHER Tighten to 60 to 80 in-lb.

- 8 BACN10YR4CD NUT 0.325 - 0.328 12 BACB30YN10K15X BOLT, HEX DRIVE 0.325 - 0.328 16 BACB30YN10K16X BOLT, HEX DRIVE

- - 28 NAS1149D0532J WASHER

- - 28 NAS1149D0563J WASHER Tighten to 130 to 160 inlb. - 28 BACN10YR5CD NUT
0.2616 - 0.2636 8 BACB30NW8K9X BOLT, 100 DEG HEX DR I

- 8 BACW10BP41DP WASHER, PLAIN Tighten to 60 to 80 in-lb.

- 8 BACN10YR4CD NUT

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 20 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 186 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThis Figure applies only to: Group 2.

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 1 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 187 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 2 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 188 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 3 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 189 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 4 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 190 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 5 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 191 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 6 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 192 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 7 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 193 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 8 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 194 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 9 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 195 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 10 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 196 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 1 148W2204-6 SPLICE ANGLE Put / Hold 1 SHIM A 1 148W7143-11 SHIM LAMINATED Put / Hold SHIM B 1 148W7143-13 SHIM LAMINATED Put / Hold SHIM C 1 148W7143-7 SHIM LAMINATED Put / Hold SHIM D 1 148W7143-6 SHIM LAMINATED Put / Hold SHIM E 1 148W7143-5 SHIM LAMINATED Put / Hold

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 11 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 197 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step SHIM U 1 BACS40R016B037F SHIM, LAMINATED Put / Hold 2 FILLER A 2 BACF3H14NP017HN FILLER Put / Hold This is a kept part. SHIM G 1 BACS40R007B064F SHIM, LAMINATED Put / Hold SHIM H 1 BACS40R008B041F SHIM, LAMINATED Put / Hold FILLER D 1 148W2328-1 FILLER Put / Hold This is a kept part. BLUE 1 148W2379-() END FITTING Put / Hold SHIM I 1 BACS40R023B053F SHIM, LAMINATED Put / Hold SHIM J 1 BACS40R007B077F SHIM, LAMINATED Put / Hold SHIM K 1 BACS40R008B062F SHIM, LAMINATED Put / Hold FILLER E 1 148W2328-2 FILLER Put / Hold This is a kept part. 1 148W2369-() END FITTING Put / Hold 1 148W2515-() FITTING Put / Hold 3 SHIM L 1 BACS40R029B065F SHIM,LAMINATED Put / Hold SHIM M 1 148W0015-13 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold 1 148W2514-() FITTING Put / Hold 4 SHIM Q 1 148W0015-12 SHIM Put / Hold SHIM O 1 148W0015-14 SHIM Put / Hold SHIM R 1 BACS40R021B049F SHIM, LAMINATED Put / Hold SHIM S 1 BACS40R019B056F SHIM, LAMINATED Put / Hold SHIM T 1 BACS40R033B052F SHIM-LAMINATED Put / Hold 214
- HOLE Drill / Ream 5

- - PART Remove / Keep 6

- - HOLE Deburr 7

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 12 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 198 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step the damaged edge in accordance with 777-200 SRM 51- 10-02 or 777-300 SRM 51-10-02, as applicable. Minimum material removed equals the length of the longest detectedcrack, and not to exceed 0.160 inch. 1 148W7102-() CHORD Cut 8

1 148W7102-() CHORD Deburr Do a surface High Frequency EddyCurrent (HFEC) inspection of the cut edge, to make sureany crack was removed, in accordance with 777 NDT Manual Part 6, 51- 00-01. (a) 1 148W7102-() CHORD Inspect

0.04 inch insurance cut. Maximum edge trim out is 0.200 inch. Blend the edge to a minimum radiusof 1.50 inch. Maintain a shoulder slopeof runout of minimum 1.0 inch. 1 148W7102-() CHORD Cut

Deburr the cut edge.The surface roughness of the cut edge is 63 Ra or better. 1 148W7102-() CHORD Deburr

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 13 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 199 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step The indicated inboard and outboard surface of the chord. Shot intensity is 0.010A, shot size is 330, and coverage is 100%. Refer to SOPM 20-10-03, Self-Contained ShotPeening, as an accepted procedure. 1 148W7102-() CHORD Shot Peen 9

to the cut surface, in accordance with 777-200 SRM 51- 20-01 or 777-300 SRM 51-20-01, as applicable. - - CHEMICAL CONVER- SION COATING Apply 10

two coats, on the cut surface. Refer to SOPM 20-41-02 asan accepted procedure. - BMS 10-11, TYPE I PRIMER Apply

(f) 1 148W2204-6 SPLICE ANGLE Install (New) 11 SHIM A (e) (f) 1 148W7143-11 SHIM LAMINATED Install (New) SHIM B (e) (f) 1 148W7143-13 SHIM LAMINATED Install (New) SHIM C (e) (f) 1 148W7143-7 SHIM LAMINATED Install (New) SHIM D (e) (f) 1 148W7143-6 SHIM LAMINATED Install (New) SHIM E (e) (f) 1 148W7143-5 SHIM LAMINATED Install (New)

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 14 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 200 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step SHIM U (d) (f) 1 BACS40R016B037F SHIM, LAMINATED Install (New) 12 FILLER A (f) 2 BACF3H14NP017HN FILLER Install (Kept) SHIM G (b) (f) 1 BACS40R007B064F SHIM, LAMINATED Install (New) SHIM H (b) (f) 1 BACS40R008B041F SHIM, LAMINATED Install (New) FILLER D (f) 1 148W2328-1 FILLER Install (Kept) (f) End fitting pad must remain clamped to chord until the sealant is cured. 1 148W2379-() END FITTING Install (Kept)

SHIM I (d) (f) 1 BACS40R023B053F SHIM, LAMINATED Install (New) SHIM J (b) (f) 1 BACS40R007B077F SHIM, LAMINATED Install (New) SHIM K (b) (f) 1 BACS40R008B062F SHIM, LAMINATED Install (New) FILLER E (f) 1 148W2328-2 FILLER Install (Kept) (f) End fitting pad must remain clamped to chord until the sealant is cured. 1 148W2369-() END FITTING Install (Kept)

(f) 1 148W2515-() FITTING Install (Kept) 13 SHIM L (b) (f) 1 BACS40R029B065F SHIM,LAMINATED Install (New) SHIM M (b) (f) 1 148W0015-13 SHIM Install (New) SHIM O (b) (f) 1 148W0015-14 SHIM Install (New) (f) 1 148W2514-() FITTING Install (Kept) 14 SHIM Q (b) (f) 1 148W0015-12 SHIM Install (New) SHIM O (b) (f) 1 148W0015-14 SHIM Install (New) SHIM R (b) (f) 1 BACS40R021B049F SHIM, LAMINATED Install (New) SHIM S (b) (f) 1 BACS40R019B056F SHIM, LAMINATED Install (New) SHIM T (c) (f) 1 BACS40R033B052F SHIM-LAMINATED Install (New) (g) 12
- FASTENER Install (Kept) 15 (g) 202
- FASTENER Install (New) 16 (a) If crack indications exist after this surface HFEC inspection, remove additional material, a maximum of 0.160 inch total, to remove the crack indication. If crack indications still exist after a total of 0.160 inch of material has been removed, this repair cannot be done. Do the modification in Boeing Service Bulletin 777-53-0076.

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 15 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 201 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step(b) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.04 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (c) Fit shim by removing 0.003 inch laminations as required. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (d) Fit shim by removing 0.003 inch laminations as required. Maximum gap after shimming is 0.003 inch. Step tapering may be necessary. Shim must pick up minimum of one bolt. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (e) Fit shim by removing 0.003 inch laminations as required. Maximum shim thickness is 0.033 inch. Step tapering may be necessary. Maximum gap after shimming is 0.005 inch before fastener installation. Install with BMS 10-11, Type I primer. Refer to SOPM 20-41-02 as an accepted procedure. (f) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure. (g) Install fasteners with BMS 5-95. Refer to SOPM 20-50-19, Method 2, as an accepted procedure. The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. Description FlagnoteMake sure the space between the stringer end fitting and the adjacent structure is free of sealant for sufficient drainage. 1

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 16 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 202 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 2 BACB30US6K14 BOLT, 12 PT HEAD A

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.376 - 0.379 3 BACB30US6K19 BOLT, 12 PT HEAD

Under bolt head

- 5 BACW10BP6CD WASHER, PLAIN Under the nut

- 5 BACW10BP6DP WASHER Tighten to 300 to 500 inlb. - 5 BACN10HR6CD SELF-LOCKING NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 1 BACB30US8K28 BOLT, 12 PT HEAD

This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.501 - 0.505 2 BACB30US8K* BOLT, 12 PT HEAD

Under bolt head

- 3 BACW10BP8CD WASHER Under the nut

- 3 BACW10BP8DP WASHER Tighten to 870 to 1300 inlb. - 3 BACN10HR8CD NUT This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 0.751 - 0.757 2 BACB30US12K36 BOLT, 12 PT HEAD

Under bolt head

- 2 BACW10BP12CD WASHER, PLAIN Under the nut

- 2 BACW10BP12DP WASHER, PLAIN Tighten to 3300 to 4300 in-lb. - 2 BACN10HR12CD SELF-LOCKING NUT

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 17 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 203 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name CodeBOLT, 12 PT HEAD This is a kept part. If this part is not serviceable, use a new part with the same part number. This part is not in the retrofit kit. 1.028 - 1.047 2 BACB30US16K46

Under bolt head

- 2 BACW10BP16CD WASHER, PLAIN Under the nut

- 2 BACW10BP16DP WASHER, PLAIN Tighten to 7000 to 10900 in-lb. - 2 BACN10HR162CD SELF-LOCKING NUT
0.200 - 0.203 4 BACB30NX6K5X BOLT, PROTRUDING HD B

- 4 BACC30M6 COLLAR 0.327 - 0.331 3 BACB30NX10K11X BOLT, PROTRUDING HD 0.327 - 0.331 13 BACB30NX10K14X BOLT, PROTRUDING HD

- 16 BACC30BH10 COLLAR

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 18 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 204 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 16 BACB30MY8K4X BOLT, PROTRUDING HD C
0.263 - 0.266 4 BACB30MY8K5X BOLT, PROTRUDING HD 0.263 - 0.266 18 BACB30MY8K6X BOLT, PROTRUDING HD 0.263 - 0.266 6 BACB30MY8K7X BOLT, PROTRUDING HD 0.263 - 0.266 5 BACB30MY8K8X BOLT, PROTRUDING HD 0.263 - 0.266 1 BACB30MY8K9X BOLT, PROTRUDING HD 0.263 - 0.266 14 BACB30MY8K11X BOLT, PROTRUDING HD

- 64 BACC30M8 COLLAR 0.325 - 0.328 8 BACB30MY10K7X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K10X BOLT, PROTRUDING HD 0.325 - 0.328 6 BACB30MY10K13X BOLT, PROTRUDING HD

- 20 BACC30M10 COLLAR 0.263 - 0.266 2 BACB30NW8K7X BOLT, 100 DEG HEX DR D
0.263 - 0.266 5 BACB30NW8K8X BOLT, 100 DEG HEX DR 0.263 - 0.266 17 BACB30NW8K9X BOLT, 100 DEG HEX DR 0.263 - 0.266 28 BACB30NW8K10X BOLT, 100 DEG HEX DR 0.263 - 0.266 2 BACB30NW8K12X BOLT, 100 DEG HEX DR

- 54 BACC30M8 COLLAR

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 19 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 205 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Hole Dia Qty Identification Name Code 0.263 - 0.266 8 BACB30YN8K12X BOLT, HEX DRIVE G

- 8 NAS1149D0432J WASHER

- 8 NAS1149D0463J WASHER Tighten to 60 to 80 in-lb.

- 8 BACN10YR4CD NUT 0.325 - 0.328 12 BACB30YN10K15X BOLT, HEX DRIVE 0.325 - 0.328 16 BACB30YN10K16X BOLT, HEX DRIVE

- 28 NAS1149D0532J WASHER

- 28 NAS1149D0563J WASHER Tighten to 130 to 160 inlb. - 28 BACN10YR5CD NUT
0.2616 - 0.2636 8 BACB30NW8K9X BOLT, 100 DEG HEX DR I

- 8 BACW10BP41DP WASHER, PLAIN Tighten to 60 to 80 in-lb.

- 8 BACN10YR4CD NUT

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR (SHEET 20 OF 20) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 206 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION (SHEET 1 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 207 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 208 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Do a surface High Frequency Eddy Current(HFEC) inspection for anycrack, in accordance with 777 NDT Manual Part 6, 51-00-01. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 1

Do an open hole HFEC inspection for any crack, in accordance with 777 NDT Manual Part 6, 51-00-02. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 2

Do a DET for any crack. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 3

FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 209 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION (SHEET 1 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 210 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 211 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Do a surface High Frequency Eddy Current(HFEC) inspection for anycrack, in accordance with 777 NDT Manual Part 6, 51-00-01. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 1

Do an open hole HFEC inspection for any crack, in accordance with 777 NDT Manual Part 6, 51-00-02. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 2

Do a DET for any crack. 1 148W7102-( ) CHORD - FOR- WARD, PIVOT BULKHEAD, MID Inspect 3

FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 212 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 1 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 213 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 2 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 214 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 3 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 215 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a) 1 148W2917-9 FILLER Install (Kept) 1 (a) 1 148W2917-11 FILLER (a) 1 148W2917-7 FILLER (a) 1 148W2914-( ) ANGLE - FAIR-ING ASSY, UPPER (a) 1 BACF3T03M14S8B FILLER (a) 1 148W2918-3 SPLICE PLATE (a) 1 148W2920-1 BRACKET (a) Do not seal the exterior gap around this skin panel. 1 148W2912-1 SKIN

(a) Do not seal the exterior gap around this skin panel. 1 148W2912-2 SKIN

(a) 1 148W9710-15 RADIUS FILLER 3
- FASTENER 24
- FASTENER Install (New) 2 (a) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.

FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 216 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code (a) 0.2026 - 0.2036 2 BACB30NW6K5X BOLT, 100 DEG HEX DR D

- 2 BACC30M6 COLLAR (a) 0.2651 - 0.2661 3 BACB30NW8K5X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 1 BACB30NW8K6X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 6 BACB30NW8K9X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 2 BACB30NW8K12X BOLT, 100 DEG HEX DR

- 12 BACC30M8 COLLAR

- 3 BACR15CE5KE5 RIVET, 100 DEG H

- 6 BACR15CE5KE6 RIVET, 100 DEG

- 1 BACR15CE5KE8 RIVET, 100 DEG

- 2 BACB30VF3K4 BOLT J

- - BACB30VF3K5 BOLT Install bolts into existing nutplates on the horizontal stabilizer seal fairing. - - BACN10YF33CD NUTPLATE

(a) Install fasteners with BMS 5-95 sealant. Refer to SOPM 20-50-19, Method 2 as an accepted procedure.

FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 217 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 1 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 218 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 2 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 219 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 3 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 220 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a) 1 148W2917-9 FILLER Install (Kept) 1 (a) 1 148W2917-11 FILLER (a) 1 148W2917-7 FILLER (a) 1 148W2914-( ) ANGLE - FAIR-ING ASSY, UPPER (a) 1 BACF3T03M14S8B FILLER (a) 1 148W2918-4 SPLICE PLATE (a) 1 148W2920-2 BRACKET (a) Do not seal the exterior gap around this skin panel. 1 148W2912-2 SKIN

(a) Do not seal the exterior gap around this skin panel. 1 148W2912-4 SKIN

(a) 1 148W9710-15 RADIUS FILLER 3
- FASTENER 24
- FASTENER Install (New) 2 (a) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.

FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 221 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code (a) 0.2026 - 0.2036 2 BACB30NW6K5X BOLT, 100 DEG HEX DR D

- 2 BACC30M6 COLLAR (a) 0.2651 - 0.2661 3 BACB30NW8K5X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 1 BACB30NW8K6X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 6 BACB30NW8K9X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 2 BACB30NW8K12X BOLT, 100 DEG HEX DR

- 12 BACC30M8 COLLAR

- 3 BACR15CE5KE5 RIVET, 100 DEG H

- 6 BACR15CE5KE6 RIVET, 100 DEG

- 1 BACR15CE5KE8 RIVET, 100 DEG

- 2 BACB30VF3K4 BOLT J

- - BACB30VF3K5 BOLT Install bolts into existing nutplates on the horizontal stabilizer seal fairing. - - BACN10YF33CD NUTPLATE

(a) Install fasteners with BMS 5-95 sealant. Refer to SOPM 20-50-19, Method 2 as an accepted procedure.

FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION - SKIN PANEL INSTALLATION (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 222 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 1 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 223 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 2 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 224 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 3 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 225 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER Put/Hold 1

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-1 SKIN 1 148W2912-3 SKIN 1 148W9710-15 RADIUS FILLER 14
- HOLE Drill/Ream 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPERRemove/Keep 2

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-1 SKIN 1 148W2912-3 SKIN 1 148W9710-15 RADIUS FILLER

- - HOLE Deburr

FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 4 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 226 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step (a) 1 148W2917-9 FILLER Install (Kept) 3 (a) 1 148W2917-11 FILLER (a) 1 148W2917-7 FILLER (a) 1 148W2918-3 SPLICE PLATE (a) 1 148W2920-1 BRACKET (a) 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER (a) 1 BACF3T03M14S8B FILLER (a) Do not seal the exterior gap around this skin panel. 1 148W2912-1 SKIN (a) Do not seal the exterior gap around this skin panel. 1 148W2912-3 SKIN (a) 1 148W9710-15 RADIUS FILLER 3
- FASTENER 24
- FASTENER Install (New) 4 (a) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.

FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 5 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 227 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code (a) 0.2026 - 0.2036 2 BACB30NW6K5X BOLT, 100 DEG HEX DR D

- 2 BACC30M6 COLLAR (a) 0.2651 - 0.2661 3 BACB30NW8K5X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 1 BACB30NW8K6X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 6 BACB30NW8K9X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 2 BACB30NW8K12X BOLT, 100 DEG HEX DR

- 12 BACC30M8 COLLAR

- 3 BACR15CE5KE5 RIVET, 100 DEG H

- 6 BACR15CE5KE6 RIVET, 100 DEG

- 1 BACR15CE5KE8 RIVET, 100 DEG

- 2 BACB30VF3K4 BOLT J

- - BACB30VF3K5 BOLT Install bolts into existing nutplates on the horizontal stabilizer seal fairing. - - BACN10YF33CD NUTPLATE

(a) Install fasteners with BMS 5-95 sealant. Refer to SOPM 20-50-19, Method 2 as an accepted procedure.

FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 6 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 228 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 1 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 229 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 2 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 230 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 3 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 231 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER Put/Hold 1

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-2 SKIN 1 148W2912-4 SKIN 1 148W9710-15 RADIUS FILLER 14
- HOLE Drill/Ream 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPERRemove/Keep 2

1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2912-2 SKIN 1 148W2912-4 SKIN 1 148W9710-15 RADIUS FILLER

- - HOLE Deburr

FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 4 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 232 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTMore Data Qty Identification Name Task Step (a) 1 148W2917-9 FILLER Install (Kept) 3 (a) 1 148W2917-11 FILLER (a) 1 148W2917-7 FILLER (a) 1 148W2918-4 SPLICE PLATE (a) 1 148W2920-2 BRACKET (a) 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER (a) 1 BACF3T03M14S8B FILLER (a) Do not seal the exterior gap around this skin panel. 1 148W2912-2 SKIN (a) Do not seal the exterior gap around this skin panel. 1 148W2912-4 SKIN (a) 1 148W9710-15 RADIUS FILLER 3
- FASTENER 24
- FASTENER Install (New) 4 (a) Apply BMS 5-95, Class C to all mating surfaces. Refer to SOPM 20-50-19 as an accepted procedure.

FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 5 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 233 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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. The QTY numbers shown below are the number of fasteners necessary for this figure.
More Data Hole Dia Qty Identification Name Code (a) 0.2026 - 0.2036 2 BACB30NW6K5X BOLT, 100 DEG HEX DR D

- 2 BACC30M6 COLLAR (a) 0.2651 - 0.2661 3 BACB30NW8K5X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 1 BACB30NW8K6X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 6 BACB30NW8K9X BOLT, 100 DEG HEX DR (a) 0.2651 - 0.2661 2 BACB30NW8K12X BOLT, 100 DEG HEX DR

- 12 BACC30M8 COLLAR

- 3 BACR15CE5KE5 RIVET, 100 DEG H

- 6 BACR15CE5KE6 RIVET, 100 DEG

- 1 BACR15CE5KE8 RIVET, 100 DEG

- 2 BACB30VF3K4 BOLT J

- - BACB30VF3K5 BOLT Install bolts into existing nutplates on the horizontal stabilizer seal fairing. - - BACN10YF33CD NUTPLATE

(a) Install fasteners with BMS 5-95 sealant. Refer to SOPM 20-50-19, Method 2 as an accepted procedure.

FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION (SHEET 6 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 234 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 1 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 235 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 2 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 236 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 237 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 24
- FASTENER Remove 1 3
- FASTENER Remove / Keep 2 1 148W9710-15 RADIUS FILLER 1 148W2912-1 SKIN 1 148W2912-3 SKIN 1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER 1 BACF3T03M14S8B FILLER 1 148W2918-3 SPLICE PLATE 1 148W2920-1 BRACKET

FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 238 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 1 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 239 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 2 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 240 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTFIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 241 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step 24
- FASTENER Remove 1 3
- FASTENER Remove/Keep 2 1 148W9710-15 RADIUS FILLER 1 148W2912-2 SKIN 1 148W2912-4 SKIN 1 148W2917-9 FILLER 1 148W2917-11 FILLER 1 148W2917-7 FILLER 1 148W2914-( ) ANGLE - FAIRING ASSY, UPPER 1 BACF3T03M14S8B FILLER 1 148W2918-4 SPLICE PLATE 1 148W2920-2 BRACKET

FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 242 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTLogic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information contained in Paragraph 3.B., Work Instructions is 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 diagram. Description Title STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND HFEC INSPECTION PART 1
STATION 2370 PIVOT BULKHEAD FORWARD CHORD - SMALL CRACK REPAIR PART 2
STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION PART 3
NO FORWARD CHORD CRACK IS FOUND CONDITION 1 ANY FORWARD CHORD CRACK IS FOUND, AND NO CRACK FOUND IS GREATER THAN 0.160 INCH CONDITION 2
ANY FORWARD CHORD CRACK FOUND IS GREATER THAN 0.160 INCH CONDITION 3 NO FORWARD CHORD UPPER LOCATION OR ADJACENT STRUCTURE CRACK IS FOUND CONDITION 6
ANY FORWARD CHORD UPPER LOCATION OR ADJACENT STRUCTURE CRACK IS FOUND CONDITION 7
2. The table below gives the description for the flag notes called out in the logic diagram. Description Flag Note Letter Modification in accordance with Boeing Service Bulletin 777-53-0076 is terminating action to the repeat inspections in this service bulletin. (a)

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD (SHEET 1 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 243 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTAPPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 244 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTAPPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 245 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTLogic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information contained in Paragraph 3.B., Work Instructions is 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 diagram. Description Title STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION PART 3
NO FORWARD CHORD CRACK IS FOUND DURING POST-REPAIR INSPECTIONS CONDITION 4
ANY FORWARD CHORD CRACK IS FOUND DURING POST-REPAIR INSPECTIONS CONDITION 5
2. The table below gives the description for the flag notes called out in the logic diagram. Description Flag Note Letter Modification in accordance with Boeing Service Bulletin 777-53-0076 is terminating action to the repeat inspections in this service bulletin. (a)

APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: POST-REPAIR DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD (SHEET 1 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 246 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTAPPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: POST-REPAIR DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 247 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERTAPPENDIX C: BOEING PART DEMAND INTENT (SHEET 1 OF 1) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2015 777-53A0075 Revision 1 December 14, 2015 248 of 248 BOEING SERVICE BULLETIN 777-53A0075 ALERT ALERT