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.

ECCN: 9E991

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Unpublished Work.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.

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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

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connection with this document unless provided in writing by Boeing.

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BLANK PAGE
Table 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

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FIGURE 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

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ALERT ALERT
Commercial 

Airplanes 777

Service Bulletin

ALERT

Revision 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.

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7. 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.

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Pages with no vertical lines have no changes.

REVISION HISTORY

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BLANK PAGE
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

Model Flight Cycles Flight Hours Crack Location Crack Length (Inches)

777-200 31,384 39,142 Left Side 1.4 and 3.3

Right Side 2.93

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Service History

Model Flight Cycles Flight Hours Crack Location Crack Length (Inches)

777-200 31,504 39,797 Left Side 2.3

Right Side 2.2

777-200 32,181 38,758 Left Side 2.5

Right Side 2.3

777-200 29,383 37,182 Left Side 2.5

Right Side 2.5

777-300 24,653 34,291 Left Side 2.2

Right Side 2.2

777-200 35,011 40,074 Left Side 2.25

Right Side 2.2

777-300 24,251 33,568 Left Side 2.5

Right Side 2.03

777-200 30,462 38,455 Left Side 2.35

Right Side 2.2

777-200 30,826 39,166 Left Side 2.2

Right Side 2.4

777-200 33,809 40,588 Left Side 2.5

Right Side 2.4

777-300 17,530 63,940 Left Side 1.2

Right Side 1.65

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.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

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Planning Data Affected Reference

Weight and Balance Change Yes (a) Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected Yes Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

(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.

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MANPOWER

Airplanes Total Task Hours Elapsed Hours

All Airplanes - Inspection 14.50 10.50

Group 1 Airplanes - Small Crack Repair 44.85 24.05

- One Side of the airplane

Group 2 Airplanes - Small Crack Repair 43.10 22.30

- One Side of the airplane

All Airplanes - Post-Repair Inspection 10.50 8.50

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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT

BLANK PAGE
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.

GROUP CONFIGURATION DESCRIPTION

1 - 777 Airplanes, line numbers 1 through 40

2 - 777 Airplanes, line numbers 41 through 244

Airplane Models:

777-200, 777-300

Variable Number Group

WA001 - WA017 1

WA076 - WA080 1

WA086 - WA087 1

WA088 - WA093 2

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Variable Number Group

WA101 - WA104 1

WA116 - WA117 1

WA118 - WA119 2

WA131 - WA135 1

WA136 - WA137 2

WA171 - WA173 1

WA174 - WA175 2

WA196 - WA197 1

WA198 2

WA206 - WA212 2

WA221 - WA223 2

WA231 - WA232 2

WA241 - WA245 2

WB001 - WB020 2

WB031 2

WB051 - WB072 2

WB101 - WB106 2

WB121 - WB125 2

WB131 - WB133 2

WB151 - WB153 2

WB161 - WB171 2

WB181 - WB188 2

WB231 - WB235 2

WB271 - WB272 2

WB276 - WB286 2

WB291 - WB297 2

WB306 - WB307 2

WB311 - WB318 2

WB336 - WB337 2

WB366 2

WB371 - WB383 2

WB406 2

WB411 - WB413 2

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Variable Number Group

WB416 - WB426 2

WB446 - WB448 2

WB501 - WB506 2

WB531 - WB535 2

WB551 - WB553 2

WB591 - WB595 2

WB601 - WB602 2

WB611 - WB615 2

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

Model Flight Cycles Flight Hours Crack Location Crack Length (Inches)

777-200 31,384 39,142 Left Side 1.4 and 3.3

Right Side 2.93

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ALERT ALERT
Service History

Model Flight Cycles Flight Hours Crack Location Crack Length (Inches)

777-200 31,504 39,797 Left Side 2.3

Right Side 2.2

777-200 32,181 38,758 Left Side 2.5

Right Side 2.3

777-200 29,383 37,182 Left Side 2.5

Right Side 2.5

777-300 24,653 34,291 Left Side 2.2

Right Side 2.2

777-200 35,011 40,074 Left Side 2.25

Right Side 2.2

777-300 24,251 33,568 Left Side 2.5

Right Side 2.03

777-200 30,462 38,455 Left Side 2.35

Right Side 2.2

777-200 30,826 39,166 Left Side 2.2

Right Side 2.4

777-200 33,809 40,588 Left Side 2.5

Right Side 2.4

777-300 17,530 63,940 Left Side 1.2

Right Side 1.65

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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
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.

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 Zones

Model Zone

777-200 313, 314

Group 2:

Affected Maintenance Zones

Model Zone

777-200, 777-300 313, 314

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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
The 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)

Condition Action

Within 4,000 -

flight cycles or

1,125 days,

whichever occurs first, after

the 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

CONDITION 1: NO FOR- OPTION 1: - 12,000 flight cycles

WARD CHORD CRACK IS

FOUND

Repeat PART 1: STA- (a)

TION 2370 PIVOT

BULKHEAD FORWARD

CHORD - DET AND

HFEC INSPECTION for

any crack.

OPTION 2: Before further flight (a)

Do the terminating modification in accordance with

Boeing Service Bulletin

777-53-0076. (a)

CONDITION 2: ANY FOR- OPTION 2: Before further flight -

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)

OPTION 3 (ACTION 1): Before further flight -

Do PART 2: STATION

2370 PIVOT BULKHEAD

FORWARD CHORD -

SMALL CRACK REPAIR.

OPTION 3 (ACTION 2): Refer to Table 2 -

Do PART 3: STATION

2370 PIVOT BULKHEAD

FORWARD CHORD -

POST-REPAIR DET AND

HFEC INSPECTION.

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ALERT ALERT
Table 1: Detailed and HFEC Inspection of the Station 2370 Pivot Bulkhead Forward Chord:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Do the terminating modifi- Before further flight -

cation in accordance with

Boeing Service Bulletin

777-53-0076. (a)

CONDITION 3: ANY FORWARD CHORD CRACK

FOUND IS GREATER

THAN 0.160 INCH.

Continue to do the small Before further flight -

crack repair in accordance with PART 2:

STATION 2370 PIVOT

BULKHEAD FORWARD

CHORD - SMALL

CRACK REPAIR.

CONDITION 6: NO FORWARD CHORD UPPER

LOCATION OR ADJACENT STRUCTURE

CRACK IS FOUND

ACTION 1: Contact The Before further flight -

Boeing Company for repair instructions and do

the repair.

CONDITION 7: ANY FORWARD CHORD UPPER

LOCATION OR ADJACENT STRUCTURE

CRACK IS FOUND ACTION 2: Continue to Before further flight -

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)

Condition Action Compliance Time

Within 12,000 flight -

cycles after installation of the repair in

accordance with

PART 2: STATION

2370 PIVOT

BULKHEAD 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 2370

PIVOT BULKHEAD FORWARD CHORD - SMALL

CRACK REPAIR

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Table 2: Post-Repair Detailed and HFEC Inspection of the STA 2370 Pivot Bulkhead Forward

Chord:

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

OPTION 4: Repeat PART - 12,000 flight cycles

3: STATION 2370 PIVOT

BULKHEAD FORWARD

CHORD -POST-REPAIR

DET AND HFEC INSPECTION for any crack.

CONDITION 4: NO FORWARD CHORD CRACK IS

FOUND DURING POSTREPAIR INSPECTION

(a)

OPTION 2: Do the termi- Before further flight (a)

nating modification in accordance with Boeing

Service Bulletin 777-53-

0076. (a)

Do the terminating modifi- Before further flight -

cation in accordance with

Boeing Service Bulletin

777-53-0076. (a)

CONDITION 5: ANY FORWARD CHORD CRACK IS

FOUND 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

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

Task Number of Persons Task Hours Elapsed Hours

Open Access

FIGURE 1 1 2.00 2.00

FIGURE 2 1 2.00 2,00

PART 1: STATION 2370 PIVOT BULKHEAD FORWARD CHORD - DET AND

HFEC INSPECTION

FIGURE 3 1 1.25 1.25

FIGURE 4 1 1.25 1.25

Close Access

FIGURE 5 2 4.00 2.00

FIGURE 6 2 4.00 2.00

TOTAL FOR EACH AIRPLANE 14.50 10.50

Group 1:

Table 2: Manpower Information for PART 2: STATION 2370 PIVOT BULKHEAD FORWARD

CHORD - SMALL CRACK REPAIR

Task Number of Persons Task Hours Elapsed Hours

FIGURE 7 (or FIG- 2 8.00 4.00

URE 8) (a)

FIGURE 11 (or FIG- 1 1.50 1.50

URE 12) (a)

FIGURE 13 (or FIG- 1 1.75 1.75

URE 14) (a)

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ALERT ALERT
Group 1:

Table 2: Manpower Information for PART 2: STATION 2370 PIVOT BULKHEAD FORWARD

CHORD - SMALL CRACK REPAIR

Task Number of Persons Task Hours Elapsed Hours

FIGURE 15 (or FIG- 2 29.60 14.80

URE 16) (a)

FIGURE 23 (or FIG- 2 4.00 2.00

URE 24) (a)

TOTAL FOR ONE SIDE OF THE AIRPLANE 44.85 24.05

(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

Task Number of Persons Task Hours Elapsed Hours

FIGURE 9 (or FIG- 2 8.00 4.00

URE 10) (a)

FIGURE 11 (or FIG- 1 1.50 1.50

URE 12) (a)

FIGURE 17 (or FIG- 2 29.60 14.80

URE 18) (a)

FIGURE 23 (or FIG- 2 4.00 2.00

URE 24) (a)

TOTAL FOR ONE SIDE OF THE AIRPLANE 43.10 22.30

(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.

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ALERT ALERT
Group 2:

Table 3: Manpower Information for PART 2: STATION 2370 PIVOT BULKHEAD FORWARD

CHORD - SMALL CRACK REPAIR

Task Number of Persons Task Hours Elapsed Hours

(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 INSPECTION

Task Number of Persons Task Hours Elapsed Hours

Open Access

FIGURE 25 1 2.00 2.00

FIGURE 26 1 2.00 2.00

DET and HFEC Inspection

FIGURE 19 1 1.25 1.25

FIGURE 20 1 1.25 1.25

Close Access

FIGURE 21 2 2.00 2.00

FIGURE 22 2 2,00 2.00

TOTAL FOR EACH AIRPLANE 10.50 8.50

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.

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ALERT ALERT
H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

777-200 - Repaired +0.5 +1,183.5

on one side

777-200 - Repaired +1.0 +2,367.0

on both sides

777-300 - Repaired +0.5 +1,278.0

on one side

777-300 - Repaired +1.0 +2,556.0

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.

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BOEING SERVICE BULLETIN 777-53A0075

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

Drawing Number Title

148W2010 Bulkhead Instl - Upr, Pivot and Skin, STA 2370

148W2910 Fairing Instl - Stabilizer Seal, UPR

148W9700 Bulkhead Instl - Pivot, Integration, STA 2370

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:

Publication Chapter-Section

777 Structural Repair Manual 53-80

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.

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ALERT ALERT
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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT

BLANK PAGE
2. 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 1

date of this Service Bulletin (US

Dollars)

ROLT as of the

Revision 1 date of

this Service Bulletin (Calendar

Days)

Kit Number Name Date QTY

January 12, 11 266 241.00

2016

Top Kit - STA 2370

Pivot Bulkhead Forward

Outer Chord - Inspection Restoration

005W0016-10

February 9, 10

2016

March 8, 2016 10

January 12, 10 525 13,574.00

2016

Top Kit - STA 2370

Pivot Bulkhead Forward

Outer Chord, Left -

Small Crack

005W0016-11

(a)

January 12, 10 790 13,574.00

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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
B. 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

Existing Part Notes

Number

New Part Number Qty Name

-10 -11 -12

Top Kit - STA 2370 - (a)

Pivot Bulkhead

Forward Outer

Chord - Inspection

Restoration

005W0016-10 - . .

Top Kit - STA 2370 - (b)

Pivot Bulkhead

Forward Outer

Chord, Left - Small

Crack Repair

005W0016-11 . - .

Top Kit - STA 2370 - (c)

Pivot Bulkhead

Forward Outer

Chord, Right- Small

Crack Repair

005W0016-12 . . -

148W0015-12 . 1 1 SHIM - -

148W0015-13 . 1 1 SHIM - -

148W0015-14 . 2 2 SHIM - -

(d) (e)

(f)

148W2204-1

(Group 1)

148W2204-5 . 1 . SPLICE ANGLE

148W2204-3

(Group 2)

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ALERT ALERT
ALL

Kit 005W0016

Existing Part Notes

Number

New Part Number Qty Name

-10 -11 -12

(d) (e)

(f)

148W2204-2

(Group 1)

148W2204-6 . . 1 SPLICE ANGLE

148W2204-4

(Group 2)

148W7143-5 . 1 1 SHIM LAMINATED - -

148W7143-6 . 1 1 SHIM LAMINATED - -

148W7143-7 . 1 1 SHIM LAMINATED - -

148W7143-11 . 1 1 SHIM LAMINATED - -

148W7143-13 . 1 1 SHIM LAMINATED - -

148W9710-15 . 1 1 RADIUS FILLER - -

BOLT, PROTRUD- - (g)

ING HD

BACB30MY10K10X . 6 6

BOLT, PROTRUD- - (g)

ING HD

BACB30MY10K13X . 6 6

BOLT, PROTRUD- - (g)

ING HD

BACB30MY10K7X . 8 8

BOLT, PROTRUD- - (g)

ING HD

BACB30MY8K11X . 14 14

BOLT, PROTRUD- - (g)

ING HD

BACB30MY8K4X . 11 16

BOLT, PROTRUD- - (g)

ING HD

BACB30MY8K5X . 11 8

BOLT, PROTRUD- - (g)

ING HD

BACB30MY8K6X . 18 18

BOLT, PROTRUD- - (g)

ING HD

BACB30MY8K7X . 8 8

BOLT, PROTRUD- - (g)

ING HD

BACB30MY8K8X . 5 5

BOLT, PROTRUD- - (g)

ING HD

BACB30MY8K9X . 1 1

BOLT, 100 DEG - (g)

HEX DR

BACB30NW6K5X 4 2 2

BOLT, 100 DEG - (g)

HEX DR

BACB30NW8K10X . 28 28

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ALERT ALERT
ALL

Kit 005W0016

Existing Part Notes

Number

New Part Number Qty Name

-10 -11 -12

BOLT, 100 DEG - (g)

HEX DR

BACB30NW8K12X . 4 4

BOLT, 100 DEG - (g)

HEX DR

BACB30NW8K5X 14 3 3

BOLT, 100 DEG - (g)

HEX DR

BACB30NW8K6X 2 1 1

BOLT, 100 DEG - (g)

HEX DR

BACB30NW8K7X . 3 3

BOLT, 100 DEG - (g)

HEX DR

BACB30NW8K8X . 5 5

BOLT, 100 DEG - (g)

HEX DR

BACB30NW8K9X 8 31 31

BOLT, PROTRUD- - (g)

ING HD

BACB30NX10K11X . 3 3

BOLT, PROTRUD- - (g)

ING HD

BACB30NX10K14X . 13 13

BOLT, PROTRUD- - (g)

ING HD

BACB30NX6K5X . 4 4

BOLT, 100 DEG - (g)

HEX D

BACB30NZ10K15X . 12 12

BOLT, 100 DEG - (g)

HEX DR

BACB30NZ10K16X . 16 16

BOLT, 100 DEG - (g)

HEX DR

BACB30NZ8K12X . 10 10

BACB30YN10K15X . 12 12 BOLT, HEX DRIVE - (g)

BACB30YN10K16X . 16 16 BOLT, HEX DRIVE - (g)

BACB30YN8K12X . 8 8 BOLT, HEX DRIVE - (g)

BACC30BH10 . 44 44 COLLAR - -

BACC30BH8 . 10 10 COLLAR - -

BACC30M10 . 20 20 COLLAR - -

BACC30M6 4 6 6 COLLAR - -

BACC30M8 24 132 132 COLLAR - -

SELF-LOCKING - -

NUT

BACN10HR12CD . 2 2

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ALERT ALERT
ALL

Kit 005W0016

Existing Part Notes

Number

New Part Number Qty Name

-10 -11 -12

SELF-LOCKING - -

NUT

BACN10HR162CD . 2 2

SELF-LOCKING - -

NUT

BACN10HR6CD . 5 5

BACN10HR8CD . 3 3 NUT - -

BACN10YR4CD . 16 16 NUT - -

BACN10YR5CD . 28 28 NUT - -

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

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

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

BACR15FV81KE13 . 27 27 RIVET - (g)

SHIM, LAMINAT- - -

ED

BACS40R007B064F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R007B077F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R008B041F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R008B062F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R016B037F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R017B037F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R019B056F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R021B049F . 1 1

SHIM, LAMINAT- - -

ED

BACS40R023B053F . 1 1

BACS40R029B065F . 1 1 SHIM,LAMINATED - -

BACS40R033B052F . 1 1 SHIM-LAMINATED - -

BACW10BP12CD . 2 2 WASHER, PLAIN - -

BACW10BP12DP . 2 2 WASHER, PLAIN - -

BACW10BP16CD . 2 2 WASHER, PLAIN - -

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ALERT ALERT
ALL

Kit 005W0016

Existing Part Notes

Number

New Part Number Qty Name

-10 -11 -12

BACW10BP16DP . 2 2 WASHER, PLAIN - -

BACW10BP41DP . 8 8 WASHER, PLAIN - -

BACW10BP6CD . 5 5 WASHER, PLAIN - -

BACW10BP6DP . 5 5 WASHER - -

BACW10BP8CD . 3 3 WASHER - -

BACW10BP8DP . 3 3 WASHER - -

NAS1149D0432J . 8 8 WASHER - -

NAS1149D0463J . 8 8 WASHER - -

NAS1149D0532J . 28 28 WASHER - -

NAS1149D0563J . 28 28 WASHER - -

(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.

Part Number / QTY Name Notes

Specification

BMS 3-23 (BMS 3- 1 pint Corrosion Inhibiting Compound (a)

29 and BMS 3-35

optional)

BMS 5-95 1 pint Sealant (a)

BMS 10-11, Type I 1 pint Primer (a)

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ALERT ALERT
Part Number / QTY Name Notes

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:

Existing Part Number QTY Name New Part Number Notes

148W2204-5 (a) 1 SPLICE ANGLE (d) (c) (e)

148W2204-6 (b) 1 SPLICE ANGLE (d) (c) (e)

(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.

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ALERT ALERT
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ALERT ALERT

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. 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.

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ALERT ALERT
7. 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

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ALERT ALERT
and 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:

Left Side Right Side

FIGURE 1 FIGURE 2

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.

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ALERT ALERT
2) 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:

Left Side Right Side

FIGURE 5 FIGURE 6

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:

Left Side Right Side

FIGURE 3 FIGURE 4

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.

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ALERT ALERT
2. Group 1:

Get access to the repair area in accordance with the figures below:

Left Side Right Side

FIGURE 7 FIGURE 8

3. Group 2:

Get access to the repair area in accordance with the figures below:

Left Side Right Side

FIGURE 9 FIGURE 10

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:

Left Side Right Side

FIGURE 13 FIGURE 14

6. Group 1:

RC - Repair the Station 2370 pivot bulkhead forward chord in accordance with the figures below:

Left Side Right Side

FIGURE 15 FIGURE 16

7. Group 2:

RC - Repair the Station 2370 pivot bulkhead forward chord in accordance with the figures below:

Left Side Right Side

FIGURE 17 FIGURE 18

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8. RC - Install the skin panels in accordance with the figures below:

Left Side Right Side

FIGURE 23 FIGURE 24

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:

Left Side Right Side

FIGURE 25 FIGURE 26

2. RC - Do the DET and HFEC inspection in accordance with the figures below:

Left Side Right Side

FIGURE 19 FIGURE 20

3. RC - Install the skin panels in accordance with the figures below:

Left Side Right Side

FIGURE 21 FIGURE 22

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:

Left Side Right Side

FIGURE 11 FIGURE 12

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ALERT ALERT
FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 1 OF 4)

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FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 2 OF 4)

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FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 3 OF 4)

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Remove FASTENER - 24

2 Remove/Keep FASTENER - 3

SKIN 148W2912-1 1

SKIN 148W2912-3 1

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

FILLER BACF3T03M14S8B 1

SPLICE PLATE 148W2918-3 1

BRACKET 148W2920-1 1

FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 4 OF 4)

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FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 1 OF 4)

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FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 3 OF 4)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Remove FASTENER - 24

2 Remove/Keep FASTENER - 3

SKIN 148W2912-2 1

SKIN 148W2912-4 1

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

FILLER BACF3T03M14S8B 1

SPLICE PLATE 148W2918-4 1

BRACKET 148W2920-2 1

FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC

INSPECTION

(SHEET 1 OF 4)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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Original Issue: January 14, 2015

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52 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

CHORD - FOR- 148W7102-( ) 1 Do a DET for any crack.

WARD, PIVOT

BULKHEAD, MID

1 Inspect

FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC

INSPECTION

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

CHORD - FOR- 148W7102-( ) 1 Do a DET for any crack.

WARD, PIVOT

BULKHEAD, MID

2 Inspect

Do an open hole HFEC inspection for

any crack, in accordance with 777 NDT

Manual Part 6, 51-00-02.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

3 Inspect

Do a surface HFEC inspection for any

crack, in accordance with 777 NDT

Manual Part 6, 51-00-01.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

4 Inspect

FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC

INSPECTION

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 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

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55 of 248

BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

56 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

CHORD - FOR- 148W7102-( ) 1 Do a DET for any crack.

WARD, PIVOT

BULKHEAD, MID

1 Inspect

FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC

INSPECTION

(SHEET 3 OF 4)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

CHORD - FOR- 148W7102-( ) 1 Do a DET for any crack.

WARD, PIVOT

BULKHEAD, MID

2 Inspect

Do an open hole HFEC inspection for

any crack, in accordance with 777 NDT

Manual Part 6, 51-00-02.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

3 Inspect

Do a surface HFEC inspection for any

crack, in accordance with 777 NDT

Manual Part 6, 51-00-01.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

4 Inspect

FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC

INSPECTION

(SHEET 4 OF 4)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION

(SHEET 1 OF 5)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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Original Issue: January 14, 2015

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION

(SHEET 2 OF 5)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION

(SHEET 3 OF 5)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

1 Put/Hold

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-1 1

SKIN 148W2912-3 1

Drill/Ream HOLE - 14 Refer to the fastener table.

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

Remove/Keep2

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-1 1

SKIN 148W2912-3 1

Deburr HOLE - -

Install FILLER 148W2917-9 1 (a)

(Kept)

3

FILLER 148W2917-11 1 (a)

FILLER 148W2917-7 1 (a)

SPLICE PLATE 148W2918-3 1 (a)

BRACKET 148W2920-1 1 (a)

ANGLE - FAIRING 148W2914-( ) 1 (a)

ASSY, UPPER

FILLER BACF3T03M14S8B 1 (a)

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-1 1

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-3 1

FASTENER - 3

Install FASTENER - 24

(New)

4

FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

(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.

Code Name Identification Qty Hole Dia More Data

0.2026 - (a)

0.2036

BOLT, 100 DEG HEX BACB30NW6K5X 2

DR

D

COLLAR BACC30M6 2 -

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K5X 7

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K6X 1

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K9X 4

DR

COLLAR BACC30M8 12 -

H RIVET, 100 DEG BACR15CE5KE5 3 -

RIVET, 100 DEG BACR15CE5KE6 6 -

RIVET, 100 DEG BACR15CE5KE8 1 -

J BOLT BACB30VF3K4 2 -

BOLT BACB30VF3K5 1 -

Install bolts into existing

nutplates on the horizontal

stabilizer seal fairing.

NUTPLATE BACN10YF33CD - -

(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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION

(SHEET 1 OF 5)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION

(SHEET 2 OF 5)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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66 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

1 Put/Hold

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-2 1

SKIN 148W2912-4 1

Drill/Ream HOLE - 14 Refer to the fastener table.

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

Remove/Keep2

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-2 1

SKIN 148W2912-4 1

Deburr HOLE - -

Install FILLER 148W2917-9 1 (a)

(Kept)

3

FILLER 148W2917-11 1 (a)

FILLER 148W2917-7 1 (a)

SPLICE PLATE 148W2918-4 1 (a)

BRACKET 148W2920-2 1 (a)

ANGLE - FAIRING 148W2914-( ) 1 (a)

ASSY, UPPER

FILLER BACF3T03M14S8B 1 (a)

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-2 1

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-4 1

FASTENER - 3

Install FASTENER - 24

(New)

4

FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

(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.

Code Name Identification Qty Hole Dia More Data

0.2026 - (a)

0.2036

BOLT, 100 DEG HEX BACB30NW6K5X 2

DR

D

COLLAR BACC30M6 2 -

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K5X 7

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K6X 1

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K9X 4

DR

COLLAR BACC30M8 12 -

H RIVET, 100 DEG BACR15CE5KE5 3 -

RIVET, 100 DEG BACR15CE5KE6 6 -

RIVET, 100 DEG BACR15CE5KE8 1 -

J BOLT BACB30VF3K4 2 -

BOLT BACB30VF3K5 1 -

Install bolts into existing

nutplates on the horizontal

stabilizer seal fairing.

NUTPLATE BACN10YF33CD - -

(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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
This 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 2 OF 10)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 4 OF 10)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 5 OF 10)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 7 OF 10)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Make a note of the location

of each removed fastener.

1 Remove/Keep FASTENER - 12

2 Remove FASTENER - 210

SHIM - 18

SPLICE ANGLE 148W2204-( ) 1

3 Remove/Keep END FITTING 148W2379-( ) 1

FILLER BACF3H14NP017HN 2 FILLER A

FILLER BACF33C105-410F 1 FILLER B

FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 9 OF 10)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

4 Remove/Keep END FITTING 148W2369-( ) 1

FILLER BACF33C105-620F 1 FILLER C

SPLICE FITTING - 148W2514-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, UPR

5 Remove/Keep

BRACKET 287W4809-291 1

SPLICE FITTING - 148W2515-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, FWD

6 Remove/Keep

FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 10 OF 10)

Export Controlled ECCN: 9E991 - BOEING

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ALERT ALERT
This 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 5 OF 10)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

86 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Make a note of the location

of each removed fastener.

1 Remove/Keep FASTENER - 12

2 Remove FASTENER - 210

SHIM - 18

SPLICE ANGLE 148W2204-( ) 1

3 Remove/Keep END FITTING 148W2379-( ) 1

FILLER BACF3H14NP017HN 2 FILLER A

FILLER BACF33C105-410F 1 FILLER B

FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 9 OF 10)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

4 Remove/Keep END FITTING 148W2369-( ) 1

FILLER BACF33C105-620F 1 FILLER C

SPLICE FITTING - 148W2514-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, UPR

5 Remove/Keep

SPLICE FITTING - 148W2515-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, FWD

6 Remove/Keep

FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 10 OF 10)

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ALERT ALERT
This 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 2 OF 10)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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ALERT ALERT
FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 4 OF 10)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Make a note of the location

of each removed fastener.

1 Remove/Keep FASTENER - 12

2 Remove FASTENER - 202

SHIM - 19

SPLICE ANGLE 148W2204-( ) 1

3 Remove/Keep END FITTING 148W2379-( ) 1

FILLER BACF3H14NP017HN 2 FILLER A

FILLER 148W2328-1 1 FILLER D

FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 9 OF 10)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

4 Remove/Keep END FITTING 148W2369-( ) 1

FILLER 148W2328-2 1 FILLER E

SPLICE FITTING - 148W2514-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, UPR

5 Remove/Keep

BRACKET 287W4809-291 1

SPLICE FITTING - 148W2515-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, FWD

6 Remove/Keep

FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 10 OF 10)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
This 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

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99 of 248

BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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ALERT ALERT
FIGURE 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.

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ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Make a note of the location

of each removed fastener.

1 Remove/Keep FASTENER - 12

2 Remove FASTENER - 202

SHIM - 19

SPLICE ANGLE 148W2204-( ) 1

3 Remove/Keep END FITTING 148W2379-( ) 1

FILLER BACF3H14NP017HN 2 FILLER A

FILLER 148W2328-1 1 FILLER D

FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 9 OF 10)

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

4 Remove/Keep END FITTING 148W2369-( ) 1

FILLER 148W2328-2 1 FILLER E

SPLICE FITTING - 148W2514-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, UPR

5 Remove/Keep

SPLICE FITTING - 148W2515-( ) 1

UPR LONGERON,

STA 2370, OUTBOARD, FWD

6 Remove/Keep

FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL

(SHEET 10 OF 10)

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ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

112 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

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.

1 Inspect HOLE - 4

Do a Detailed Inspection (DET) of the

upper aft longeron extension fittings between STA 2370 and STA 2380, for any

crack.

2 Inspect FITTING 148W5126-( ) 1

Do a Detailed Inspection (DET) of the

upper aft longeron extension fittings between STA 2370 and STA 2380, for any

crack.

3 Inspect FITTING 148W5127-( ) 1

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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

114 of 248

BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

115 of 248

BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

116 of 248

BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

117 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

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.

1 Inspect HOLE - 4

Do a Detailed Inspection (DET) of the

upper aft longeron extension fittings between STA 2370 and STA 2380, for any

crack.

2 Inspect FITTING 148W5126-( ) 1

Do a Detailed Inspection (DET) of the

upper aft longeron extension fittings between STA 2370 and STA 2380, for any

crack.

3 Inspect FITTING 148W5127-( ) 1

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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
This 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION

(SHEET 2 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Cut to the dimensions shown.

Maximum surface roughness

125RA.

1 Cut SPLICE ANGLE 148W2204-5 1

Break all sharp

edges.

Deburr SPLICE ANGLE 148W2204-5 1

Roto peen cut

edges. Refer to

SOPM 20-10-03

as an accepted

procedure.

Shot Peen SPLICE ANGLE 148W2204-5 1

Apply to the cut

surfaces. Refer

to SOPM 20-43-

03 as an accepted procedure.

CHEMICAL - -

CONVERSION

COATING

Apply

Apply two coats

to the cut surfaces. Refer to

SOPM 20-41-02

as an accepted

procedure.

BMS 10-11, -

TYPE I

PRIMER

Identify on the

part that this service bulletin

change has been

made. Refer to

SOPM 20-50-10

rubber stamp

method as an accepted procedure.

2 Identify SPLICE ANGLE 148W2204-5 1

FIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
This 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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

Revision 1 December 14, 2015 777-53A0075

123 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Cut to the dimensions shown.

Maximum surface roughness

125RA.

1 Cut SPLICE ANGLE 148W2204-6 1

Break all sharp

edges.

Deburr SPLICE ANGLE 148W2204-6 1

Roto peen cut

edges. Refer to

SOPM 20-10-03

as an accepted

procedure.

Shot Peen SPLICE ANGLE 148W2204-6 1

Apply to the cut

surfaces. Refer

to SOPM 20-43-

03 as an accepted procedure.

CHEMICAL -

CONVERSION

COATING

Apply

Apply two coats

to the cut surfaces. Refer to

SOPM 20-41-02

as an accepted

procedure.

BMS 10-11, -

TYPE I

PRIMER

Identify on the

part that this service bulletin

change has been

made. Refer to

SOPM 20-50-10

rubber stamp

method as an accepted procedure.

2 Identify SPLICE ANGLE 148W2204-6 1

FIGURE 14: RIGHT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
This 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

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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ALERT ALERT
FIGURE 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.

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ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 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.

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ALERT ALERT
FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 11 OF 22)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

modified in accordance with FIGURE

13.

1 Put / Hold SPLICE ANGLE 148W2204-5 1

Put / Hold SHIM LAMINATED 148W7143-11 1 SHIM A

Put / Hold SHIM LAMINATED 148W7143-13 1 SHIM B

Put / Hold SHIM LAMINATED 148W7143-7 1 SHIM C

Put / Hold SHIM LAMINATED 148W7143-6 1 SHIM D

Put / Hold SHIM LAMINATED 148W7143-5 1 SHIM E

2 Put / Hold SHIM, LAMINATED BACS40R017B037F 1 SHIM F

Put / Hold FILLER BACF3H14NP017HN 2 FILLER A

This is a kept part.

Put / Hold SHIM, LAMINATED BACS40R007B064F 1 SHIM G

Put / Hold SHIM, LAMINATED BACS40R008B041F 1 SHIM H

Put / Hold FILLER BACF33C105-410F 1 FILLER B

This is a kept part.

Put / Hold END FITTING 148W2379-() 1

Put / Hold SHIM, LAMINATED BACS40R023B053F 1 SHIM I

Put / Hold SHIM, LAMINATED BACS40R007B077F 1 SHIM J

Put / Hold SHIM, LAMINATED BACS40R008B062F 1 SHIM K

Put / Hold FILLER BACF33C105-620F 1 FILLER C

This is a kept part.

Put / Hold END FITTING 148W2369-() 1

3 Put / Hold FITTING 148W2515-() 1

Put / Hold SHIM,LAMINATED BACS40R029B065F 1 SHIM L

Put / Hold SHIM 148W0015-13 1 SHIM M

Put / Hold SHIM 148W0015-14 1 SHIM O

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 12 OF 22)

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ALERT ALERT
Step Task Name Identification Qty More Data

4 Put / Hold FITTING 148W2514-() 1

Put / Hold SHIM 148W0015-12 1 SHIM Q

Put / Hold SHIM 148W0015-14 1 SHIM O

Put / Hold SHIM, LAMINATED BACS40R021B049F 1 SHIM R

Put / Hold SHIM, LAMINATED BACS40R019B056F 1 SHIM S

Put / Hold BRACKET 287W4809-291 1 This is a kept part.

Match drill the holes

common to the skin,

splice angle and forward outer chord.

5 Drill HOLE - 27

6 Drill / Ream HOLE - 195

7 Remove / Keep PART - -

8 Deburr HOLE - -

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 13 OF 22)

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ALERT ALERT
Step Task Name Identification Qty More Data

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 detected

crack, and not to exceed 0.160 inch.

9 Cut CHORD 148W7102-() 1

Deburr CHORD 148W7102-() 1

Do a surface High

Frequency Eddy

Current (HFEC) inspection of the cut

edge, to make sure

any crack was removed, in accordance with 777 NDT

Manual Part 6, 51-

00-01. (a)

Inspect CHORD 148W7102-() 1

0.04 inch insurance

cut. Maximum edge

trim out is 0.200

inch. Blend the edge

to a minimum radius

of 1.50 inch. Maintain a shoulder slope

of runout of minimum 1.0 inch.

Cut CHORD 148W7102-() 1

Deburr the cut edge.

The surface roughness of the cut edge

is 63 Ra or better.

Deburr CHORD 148W7102-() 1

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 14 OF 22)

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ALERT ALERT
Step Task Name Identification Qty More Data

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 Shot

Peening, as an accepted procedure.

10 Shot Peen CHORD 148W7102-() 1

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

11 Apply

two coats, on the cut

surface. Refer to

SOPM 20-41-02 as

an accepted procedure.

Apply PRIMER BMS 10-11, TYPE I -

modified in accordance with FIGURE

13.

12 Install (New) SPLICE ANGLE 148W2204-5 1

(f)

Install (New) SHIM LAMINATED 148W7143-11 1 SHIM A

(e) (f)

Install (New) SHIM LAMINATED 148W7143-13 1 SHIM B

(e) (f)

Install (New) SHIM LAMINATED 148W7143-7 1 SHIM C

(e) (f)

Install (New) SHIM LAMINATED 148W7143-6 1 SHIM D

(e) (f)

Install (New) SHIM LAMINATED 148W7143-5 1 SHIM E

(e) (f)

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 15 OF 22)

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ALERT ALERT
Step Task Name Identification Qty More Data

13 Install (New) SHIM, LAMINATED BACS40R017B037F 1 SHIM F

(d) (f)

Install (Kept) FILLER BACF3H14NP017HN 2 FILLER A

(f)

Install (New) SHIM, LAMINATED BACS40R007B064F 1 SHIM G

(b) (f)

Install (New) SHIM, LAMINATED BACS40R008B041F 1 SHIM H

(b) (f)

Install (Kept) FILLER BACF33C105-410F 1 FILLER B

(f)

(f) End fitting pad

must remain

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2379-() 1

Install (New) SHIM, LAMINATED BACS40R023B053F 1 SHIM I

(d) (f)

Install (New) SHIM, LAMINATED BACS40R007B077F 1 SHIM J

(b) (f)

Install (New) SHIM, LAMINATED BACS40R008B062F 1 SHIM K

(b) (f)

Install (Kept) FILLER BACF33C105-620F 1 FILLER C

(f)

(f) End fitting pad

must remain

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2369-() 1

14 Install (Kept) FITTING 148W2515-() 1 (f)

Install (New) SHIM,LAMINATED BACS40R029B065F 1 SHIM L

(b) (f)

Install (New) SHIM 148W0015-13 1 SHIM M

(b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O

(b) (f)

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 16 OF 22)

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ALERT ALERT
Step Task Name Identification Qty More Data

15 Install (Kept) FITTING 148W2514-() 1 (f)

Install (New) SHIM 148W0015-12 1 SHIM Q

(b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O

(b) (f)

Install (New) SHIM, LAMINATED BACS40R021B049F 1 SHIM R

(b) (f)

Install (New) SHIM, LAMINATED BACS40R019B056F 1 SHIM S

(b) (f)

Install (Kept) BRACKET 287W4809-291 1 (f)

16 Install (Kept) FASTENER - 12 (g)

17 Install (New) FASTENER - 210 (g)

(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.

Name Identification Qty More Data

SHIM-LAMINATED BACS40R033B052F 1 SHIM T

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 17 OF 22)

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ALERT ALERT
The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

Flagnote Description

Make 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)

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ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

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.

A BOLT, 12 PT HEAD BACB30US6K14 2 0.376 - 0.379

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.

BOLT, 12 PT HEAD BACB30US6K19 3 0.376 - 0.379

WASHER, PLAIN BACW10BP6CD 5 - Under bolt head

WASHER BACW10BP6DP 5 - Under the nut

Tighten to 300 to 500 inlb.SELF-LOCKING NUT BACN10HR6CD 5 -

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.

BOLT, 12 PT HEAD BACB30US8K28 1 0.501 - 0.505

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.

BOLT, 12 PT HEAD BACB30US8K33 2 0.501 - 0.505

WASHER BACW10BP8CD 3 - Under bolt head

WASHER BACW10BP8DP 3 - Under the nut

Tighten to 870 to 1300 inlb.NUT BACN10HR8CD 3 -

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.

BOLT, 12 PT HEAD BACB30US12K36 2 0.751 - 0.757

WASHER, PLAIN BACW10BP12CD 2 - Under bolt head

WASHER, PLAIN BACW10BP12DP 2 - Under the nut

Tighten to 3300 to 4300

in-lb.

SELF-LOCKING NUT BACN10HR12CD 2 -

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 19 OF 22)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

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.

BACB30US16K45 1 1.028 - 1.047

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.

BOLT, 12 PT HEAD BACB30US16K46 1 1.028 - 1.047

WASHER, PLAIN BACW10BP16CD 2 - Under bolt head

WASHER, PLAIN BACW10BP16DP 2 - Under the nut

Tighten to 7000 to 10900

in-lb.

SELF-LOCKING NUT BACN10HR162CD 2 -

BOLT, PROTRUDING BACB30NX6K5X 4 0.200 - 0.203

HD

B

COLLAR BACC30M6 4 -

BOLT, PROTRUDING BACB30NX10K11X 3 0.327 - 0.331

HD

BOLT, PROTRUDING BACB30NX10K14X 13 0.327 - 0.331

HD

COLLAR BACC30BH10 16 -

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 20 OF 22)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30MY8K4X 11 0.263 - 0.266

HD

C

BOLT, PROTRUDING BACB30MY8K5X 11 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K6X 16 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K7X 8 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K8X 5 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K9X 1 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K11X 14 0.263 - 0.266

HD

COLLAR BACC30M8 66 -

BOLT, PROTRUDING BACB30MY10K7X 8 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K10X 6 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K13X 6 0.325 - 0.328

HD

COLLAR BACC30M10 20 -

BOLT, 100 DEG HEX BACB30NW8K7X 3 0.263 - 0.266

DR

D

BOLT, 100 DEG HEX BACB30NW8K8X 5 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K9X 3 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K10X 28 0.263 - 0.266

DR

COLLAR BACC30M8 39 -

E RIVET BACR15FV81KE13 27 0.268 - 0.272

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 21 OF 22)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, 100 DEG HEX BACB30NZ8K12X 10 0.263 - 0.266

DR

F

COLLAR BACC30BH8 10 -

BOLT, 100 DEG HEX BACB30NZ10K15X 12 0.325 - 0.328

D

BOLT, 100 DEG HEX BACB30NZ10K16X 16 0.325 - 0.328

DR

COLLAR BACC30BH10 28 -

FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 22 OF 22)

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ALERT ALERT
This Figure applies only to: Group 1.

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 1 OF 20)

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ALERT ALERT
FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 2 OF 20)

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FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 3 OF 20)

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FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 4 OF 20)

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ALERT ALERT
FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 5 OF 20)

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ALERT ALERT
FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 6 OF 20)

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ALERT ALERT
FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 7 OF 20)

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FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 8 OF 20)

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FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 9 OF 20)

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FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 10 OF 20)

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FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 11 OF 20)

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

modified in accordance with FIGURE

14.

1 Put / Hold SPLICE ANGLE 148W2204-6 1

Put / Hold SHIM LAMINATED 148W7143-11 1 SHIM A

Put / Hold SHIM LAMINATED 148W7143-13 1 SHIM B

Put / Hold SHIM LAMINATED 148W7143-7 1 SHIM C

Put / Hold SHIM LAMINATED 148W7143-6 1 SHIM D

Put / Hold SHIM LAMINATED 148W7143-5 1 SHIM E

2 Put / Hold SHIM, LAMINATED BACS40R017B037F 1 SHIM F

Put / Hold FILLER BACF3H14NP017HN 2 FILLER A

This is a kept part.

Put / Hold SHIM, LAMINATED BACS40R007B064F 1 SHIM G

Put / Hold SHIM, LAMINATED BACS40R008B041F 1 SHIM H

Put / Hold FILLER BACF33C105-410F 1 FILLER B

This is a kept part.

Put / Hold END FITTING 148W2379-() 1

Put / Hold SHIM, LAMINATED BACS40R023B053F 1 SHIM I

Put / Hold SHIM, LAMINATED BACS40R007B077F 1 SHIM J

Put / Hold SHIM, LAMINATED BACS40R008B062F 1 SHIM K

Put / Hold FILLER BACF33C105-620F 1 FILLER C

This is a kept part.

Put / Hold END FITTING 148W2369-() 1

3 Put / Hold FITTING 148W2515-() 1

Put / Hold SHIM,LAMINATED BACS40R029B065F 1 SHIM L

Put / Hold SHIM 148W0015-13 1 SHIM M

Put / Hold SHIM 148W0015-14 1 SHIM O

4 Put / Hold FITTING 148W2514-() 1

Put / Hold SHIM 148W0015-12 1 SHIM Q

Put / Hold SHIM 148W0015-14 1 SHIM O

Put / Hold SHIM, LAMINATED BACS40R021B049F 1 SHIM R

Put / Hold SHIM, LAMINATED BACS40R019B056F 1 SHIM S

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 12 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

Match drill the holes

common to the skin,

splice angle and forward outer chord.

5 Drill HOLE - 27

6 Drill / Ream HOLE - 195

7 Remove / Keep PART - -

8 Deburr HOLE - -

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 detected

crack, and not to exceed 0.160 inch.

9 Cut CHORD 148W7102-() 1

Deburr CHORD 148W7102-() 1

Do a surface High

Frequency Eddy

Current (HFEC) inspection of the cut

edge, to make sure

any crack was removed, in accordance with 777 NDT

Manual Part 6, 51-

00-01. (a)

Inspect CHORD 148W7102-() 1

0.04 inch insurance

cut. Maximum edge

trim out is 0.200

inch. Blend the edge

to a minimum radius

of 1.50 inch. Maintain a shoulder slope

of runout of minimum 1.0 inch.

Cut CHORD 148W7102-() 1

Deburr the cut edge.

The surface roughness of the cut edge

is 63 Ra or better.

Deburr CHORD 148W7102-() 1

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 13 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

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 Shot

Peening, as an accepted procedure.

10 Shot Peen CHORD 148W7102-() 1

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

11 Apply

two coats, on the cut

surface. Refer to

SOPM 20-41-02 as

an accepted procedure.

Apply PRIMER BMS 10-11, TYPE I -

modified in accordance with FIGURE

14.

12 Install (New) SPLICE ANGLE 148W2204-6 1

(f)

Install (New) SHIM LAMINATED 148W7143-11 1 SHIM A (e) (f)

Install (New) SHIM LAMINATED 148W7143-13 1 SHIM B (e) (f)

Install (New) SHIM LAMINATED 148W7143-7 1 SHIM C (e) (f)

Install (New) SHIM LAMINATED 148W7143-6 1 SHIM D (e) (f)

Install (New) SHIM LAMINATED 148W7143-5 1 SHIM E (e) (f)

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 14 OF 20)

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Step Task Name Identification Qty More Data

13 Install (New) SHIM, LAMINATED BACS40R017B037F 1 SHIM F (d) (f)

Install (Kept) FILLER BACF3H14NP017HN 2 FILLER A (f)

Install (New) SHIM, LAMINATED BACS40R007B064F 1 SHIM G (b) (f)

Install (New) SHIM, LAMINATED BACS40R008B041F 1 SHIM H (b) (f)

Install (Kept) FILLER BACF33C105-410F 1 FILLER B (f)

(f) End fitting pad

must remain

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2379-() 1

Install (New) SHIM, LAMINATED BACS40R023B053F 1 SHIM I (d) (f)

Install (New) SHIM, LAMINATED BACS40R007B077F 1 SHIM J (b) (f)

Install (New) SHIM, LAMINATED BACS40R008B062F 1 SHIM K (b) (f)

Install (Kept) FILLER BACF33C105-620F 1 FILLER C (f)

(f) End fitting pad

must remain

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2369-() 1

14 Install (Kept) FITTING 148W2515-() 1 (f)

Install (New) SHIM,LAMINATED BACS40R029B065F 1 SHIM L (b) (f)

Install (New) SHIM 148W0015-13 1 SHIM M (b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O (b) (f)

15 Install (Kept) FITTING 148W2514-() 1 (f)

Install (New) SHIM 148W0015-12 1 SHIM Q (b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O (b) (f)

Install (New) SHIM, LAMINATED BACS40R021B049F 1 SHIM R (b) (f)

Install (New) SHIM, LAMINATED BACS40R019B056F 1 SHIM S (b) (f)

16 Install (Kept) FASTENER - 12 (g)

17 Install (New) FASTENER - 210 (g)

(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)

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ALERT ALERT
Step Task Name Identification Qty More Data

(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.

Name Identification Qty More Data

SHIM-LAMINATED BACS40R033B052F 1 SHIM T

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

Flagnote Description

Make 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)

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ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

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.

A BOLT, 12 PT HEAD BACB30US6K14 2 0.376 - 0.379

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.

BOLT, 12 PT HEAD BACB30US6K19 3 0.376 - 0.379

WASHER, PLAIN BACW10BP6CD 5 - Under bolt head

WASHER BACW10BP6DP 5 - Under the nut

Tighten to 300 to 500 inlb.SELF-LOCKING NUT BACN10HR6CD 5 -

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.

BOLT, 12 PT HEAD BACB30US8K28 1 0.501 - 0.505

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.

BOLT, 12 PT HEAD BACB30US8K33 2 0.501 - 0.505

WASHER BACW10BP8CD 3 - Under bolt head

WASHER BACW10BP8DP 3 - Under the nut

Tighten to 870 to 1300 inlb.NUT BACN10HR8CD 3 -

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.

BOLT, 12 PT HEAD BACB30US12K36 2 0.751 - 0.757

WASHER, PLAIN BACW10BP12CD 2 - Under bolt head

WASHER, PLAIN BACW10BP12DP 2 - Under the nut

Tighten to 3300 to 4300

in-lb.

SELF-LOCKING NUT BACN10HR12CD 2 -

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 17 OF 20)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

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.

BACB30US16K45 1 1.028 - 1.047

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.

BOLT, 12 PT HEAD BACB30US16K46 1 1.028 - 1.047

WASHER, PLAIN BACW10BP16CD 2 - Under bolt head

WASHER, PLAIN BACW10BP16DP 2 - Under the nut

Tighten to 7000 to 10900

in-lb.

SELF-LOCKING NUT BACN10HR162CD 2 -

BOLT, PROTRUDING BACB30NX6K5X 4 0.200 - 0.203

HD

B

COLLAR BACC30M6 4 -

BOLT, PROTRUDING BACB30NX10K11X 3 0.327 - 0.331

HD

BOLT, PROTRUDING BACB30NX10K14X 13 0.327 - 0.331

HD

COLLAR BACC30BH10 16 -

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 18 OF 20)

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BOLT, PROTRUDING BACB30MY8K4X 14 0.263 - 0.266

HD

C

BOLT, PROTRUDING BACB30MY8K5X 8 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K6X 16 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K7X 8 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K8X 5 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K9X 1 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K11X 14 0.263 - 0.266

HD

COLLAR BACC30M8 66 -

BOLT, PROTRUDING BACB30MY10K7X 8 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K10X 6 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K13X 6 0.325 - 0.328

HD

COLLAR BACC30M10 20 -

BOLT, 100 DEG HEX BACB30NW8K7X 3 0.263 - 0.266

DR

D

BOLT, 100 DEG HEX BACB30NW8K8X 5 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K9X 3 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K10X 28 0.263 - 0.266

DR

COLLAR BACC30M8 39 -

E RIVET BACR15FV81KE13 27 0.268 - 0.272

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 19 OF 20)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, 100 DEG HEX BACB30NZ8K12X 10 0.263 - 0.266

DR

F

COLLAR BACC30BH8 10 -

BOLT, 100 DEG HEX BACB30NZ10K15X 12 0.325 - 0.328

D

BOLT, 100 DEG HEX BACB30NZ10K16X 16 0.325 - 0.328

DR

COLLAR BACC30BH10 28 -

FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 20 OF 20)

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This Figure applies only to: Group 2.

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 1 OF 20)

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FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 2 OF 20)

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FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 3 OF 20)

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FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 4 OF 20)

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FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 5 OF 20)

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ALERT ALERT
FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 6 OF 20)

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FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 7 OF 20)

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ALERT ALERT
FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 8 OF 20)

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FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 9 OF 20)

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FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 10 OF 20)

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Put / Hold SPLICE ANGLE 148W2204-5 1

Put / Hold SHIM LAMINATED 148W7143-11 1 SHIM A

Put / Hold SHIM LAMINATED 148W7143-13 1 SHIM B

Put / Hold SHIM LAMINATED 148W7143-7 1 SHIM C

Put / Hold SHIM LAMINATED 148W7143-6 1 SHIM D

Put / Hold SHIM LAMINATED 148W7143-5 1 SHIM E

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 11 OF 20)

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Step Task Name Identification Qty More Data

2 Put / Hold SHIM, LAMINATED BACS40R016B037F 1 SHIM U

Put / Hold FILLER BACF3H14NP017HN 2 FILLER A

This is a kept part.

Put / Hold SHIM, LAMINATED BACS40R007B064F 1 SHIM G

Put / Hold SHIM, LAMINATED BACS40R008B041F 1 SHIM H

Put / Hold FILLER 148W2328-1 1 FILLER D

This is a kept part.

Put / Hold END FITTING 148W2379-() 1

Put / Hold SHIM, LAMINATED BACS40R023B053F 1 SHIM I

Put / Hold SHIM, LAMINATED BACS40R007B077F 1 SHIM J

Put / Hold SHIM, LAMINATED BACS40R008B062F 1 SHIM K

Put / Hold FILLER 148W2328-2 1 FILLER E

This is a kept part.

Put / Hold END FITTING 148W2369-() 1

3 Put / Hold FITTING 148W2515-() 1

Put / Hold SHIM,LAMINATED BACS40R029B065F 1 SHIM L

Put / Hold SHIM 148W0015-13 1 SHIM M

Put / Hold SHIM 148W0015-14 1 SHIM O

4 Put / Hold FITTING 148W2514-() 1

Put / Hold SHIM 148W0015-12 1 SHIM Q

Put / Hold SHIM 148W0015-14 1 SHIM O

Put / Hold SHIM, LAMINATED BACS40R021B049F 1 SHIM R

Put / Hold SHIM, LAMINATED BACS40R019B056F 1 SHIM S

Put / Hold SHIM-LAMINATED BACS40R033B052F 1 SHIM T

Put / Hold BRACKET 287W4809-291 1 This is a kept part.

5 Drill / Ream HOLE - 214

6 Remove / Keep PART - -

7 Deburr HOLE - -

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 12 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

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 detected

crack, and not to exceed 0.160 inch.

8 Cut CHORD 148W7102-() 1

Deburr CHORD 148W7102-() 1

Do a surface High

Frequency Eddy

Current (HFEC) inspection of the cut

edge, to make sure

any crack was removed, in accordance with 777 NDT

Manual Part 6, 51-

00-01. (a)

Inspect CHORD 148W7102-() 1

0.04 inch insurance

cut. Maximum edge

trim out is 0.200

inch. Blend the edge

to a minimum radius

of 1.50 inch. Maintain a shoulder slope

of runout of minimum 1.0 inch.

Cut CHORD 148W7102-() 1

Deburr the cut edge.

The surface roughness of the cut edge

is 63 Ra or better.

Deburr CHORD 148W7102-() 1

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 13 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

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 Shot

Peening, as an accepted procedure.

9 Shot Peen CHORD 148W7102-() 1

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

10 Apply

two coats, on the cut

surface. Refer to

SOPM 20-41-02 as

an accepted procedure.

Apply PRIMER BMS 10-11, TYPE I -

11 Install (New) SPLICE ANGLE 148W2204-5 1 (f)

Install (New) SHIM LAMINATED 148W7143-11 1 SHIM A (e) (f)

Install (New) SHIM LAMINATED 148W7143-13 1 SHIM B (e) (f)

Install (New) SHIM LAMINATED 148W7143-7 1 SHIM C (e) (f)

Install (New) SHIM LAMINATED 148W7143-6 1 SHIM D (e) (f)

Install (New) SHIM LAMINATED 148W7143-5 1 SHIM E (e) (f)

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 14 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

12 Install (New) SHIM, LAMINATED BACS40R016B037F 1 SHIM U (d) (f)

Install (Kept) FILLER BACF3H14NP017HN 2 FILLER A (f)

Install (New) SHIM, LAMINATED BACS40R007B064F 1 SHIM G (b) (f)

Install (New) SHIM, LAMINATED BACS40R008B041F 1 SHIM H (b) (f)

Install (Kept) FILLER 148W2328-1 1 FILLER D (f)

(f) End fitting pad

must remained

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2379-() 1

Install (New) SHIM, LAMINATED BACS40R023B053F 1 SHIM I (d) (f)

Install (New) SHIM, LAMINATED BACS40R007B077F 1 SHIM J (b) (f)

Install (New) SHIM, LAMINATED BACS40R008B062F 1 SHIM K (b) (f)

Install (Kept) FILLER 148W2328-2 1 FILLER E (f)

(f) End fitting pad

must remained

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2369-() 1

13 Install (Kept) FITTING 148W2515-() 1 (f)

Install (New) SHIM,LAMINATED BACS40R029B065F 1 SHIM L (b) (f)

Install (New) SHIM 148W0015-13 1 SHIM M (b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O (b) (f)

14 Install (Kept) FITTING 148W2514-() 1 (f)

Install (New) SHIM 148W0015-12 1 SHIM Q (b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O (b) (f)

Install (New) SHIM, LAMINATED BACS40R021B049F 1 SHIM R (b) (f)

Install (New) SHIM, LAMINATED BACS40R019B056F 1 SHIM S (b) (f)

Install (New) SHIM-LAMINATED BACS40R033B052F 1 SHIM T (c) (f)

Install (Kept) BRACKET 287W4809-291 1 (f)

15 Install (Kept) FASTENER - 12 (g)

16 Install (New) FASTENER - 202 (g)

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 15 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

(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.

Flagnote Description

Make 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)

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ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

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.

A BOLT, 12 PT HEAD BACB30US6K14 2 0.376 - 0.379

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.

BOLT, 12 PT HEAD BACB30US6K19 3 0.376 - 0.379

WASHER, PLAIN BACW10BP6CD 5 - Under bolt head

WASHER BACW10BP6DP 5 - Under the nut

Tighten to 300 to 500 inlb.SELF-LOCKING NUT BACN10HR6CD 5 -

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.

BOLT, 12 PT HEAD BACB30US8K28 1 0.501 - 0.505

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.

BOLT, 12 PT HEAD BACB30US8K* 2 0.501 - 0.505

WASHER BACW10BP8CD 3 - Under bolt head

WASHER BACW10BP8DP 3 - Under the nut

Tighten to 870 to 1300 inlb.NUT BACN10HR8CD 3 -

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.

BOLT, 12 PT HEAD BACB30US12K36 2 0.751 - 0.757

WASHER, PLAIN BACW10BP12CD 2 - Under bolt head

WASHER, PLAIN BACW10BP12DP 2 - Under the nut

Tighten to 3300 to 4300

in-lb.

SELF-LOCKING NUT BACN10HR12CD 2 -

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 17 OF 20)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

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.

BACB30US16K46 2 1.028 - 1.047

WASHER, PLAIN BACW10BP16CD 2 - Under bolt head

WASHER, PLAIN BACW10BP16DP 2 - Under the nut

Tighten to 7000 to 10900

in-lb.

SELF-LOCKING NUT BACN10HR162CD 2 -

BOLT, PROTRUDING BACB30NX6K5X 4 0.200 - 0.203

HD

B

COLLAR BACC30M6 4 -

BOLT, PROTRUDING BACB30NX10K11X 3 0.327 - 0.331

HD

BOLT, PROTRUDING BACB30NX10K14X 13 0.327 - 0.331

HD

COLLAR BACC30BH10 16 -

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 18 OF 20)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30MY8K4X 11 0.263 - 0.266

HD

C

BOLT, PROTRUDING BACB30MY8K5X 9 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K6X 18 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K7X 6 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K8X 5 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K9X 1 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K11X 14 0.263 - 0.266

HD

COLLAR BACC30M8 64 -

BOLT, PROTRUDING BACB30MY10K7X 8 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K10X 6 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K13X 6 0.325 - 0.328

HD

COLLAR BACC30M10 20 -

BOLT, 100 DEG HEX BACB30NW8K7X 2 0.263 - 0.266

DR

D

BOLT, 100 DEG HEX BACB30NW8K8X 5 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K9X 17 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K10X 28 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K12X 2 0.263 - 0.266

DR

COLLAR BACC30M8 54 -

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 19 OF 20)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

G BOLT, HEX DRIVE BACB30YN8K12X 8 0.263 - 0.266

WASHER NAS1149D0432J 8 - -

WASHER NAS1149D0463J 8 - -

NUT BACN10YR4CD 8 - Tighten to 60 to 80 in-lb.

BOLT, HEX DRIVE BACB30YN10K15X 12 0.325 - 0.328

BOLT, HEX DRIVE BACB30YN10K16X 16 0.325 - 0.328

WASHER NAS1149D0532J 28 - -

WASHER NAS1149D0563J 28 - -

Tighten to 130 to 160 inlb.NUT BACN10YR5CD 28 -

0.2616 -

0.2636

BOLT, 100 DEG HEX BACB30NW8K9X 8

DR

I

WASHER, PLAIN BACW10BP41DP 8 -

NUT BACN10YR4CD 8 - Tighten to 60 to 80 in-lb.

FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 20 OF 20)

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ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 1 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 2 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 3 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 4 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 5 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 6 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 7 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 8 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 9 OF 20)

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ALERT ALERT
FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 10 OF 20)

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Put / Hold SPLICE ANGLE 148W2204-6 1

Put / Hold SHIM LAMINATED 148W7143-11 1 SHIM A

Put / Hold SHIM LAMINATED 148W7143-13 1 SHIM B

Put / Hold SHIM LAMINATED 148W7143-7 1 SHIM C

Put / Hold SHIM LAMINATED 148W7143-6 1 SHIM D

Put / Hold SHIM LAMINATED 148W7143-5 1 SHIM E

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 11 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

2 Put / Hold SHIM, LAMINATED BACS40R016B037F 1 SHIM U

Put / Hold FILLER BACF3H14NP017HN 2 FILLER A

This is a kept part.

Put / Hold SHIM, LAMINATED BACS40R007B064F 1 SHIM G

Put / Hold SHIM, LAMINATED BACS40R008B041F 1 SHIM H

Put / Hold FILLER 148W2328-1 1 FILLER D

This is a kept part.

Put / Hold END FITTING 148W2379-() 1 BLUE

Put / Hold SHIM, LAMINATED BACS40R023B053F 1 SHIM I

Put / Hold SHIM, LAMINATED BACS40R007B077F 1 SHIM J

Put / Hold SHIM, LAMINATED BACS40R008B062F 1 SHIM K

Put / Hold FILLER 148W2328-2 1 FILLER E

This is a kept part.

Put / Hold END FITTING 148W2369-() 1

3 Put / Hold FITTING 148W2515-() 1

Put / Hold SHIM,LAMINATED BACS40R029B065F 1 SHIM L

Put / Hold SHIM 148W0015-13 1 SHIM M

Put / Hold SHIM 148W0015-14 1 SHIM O

4 Put / Hold FITTING 148W2514-() 1

Put / Hold SHIM 148W0015-12 1 SHIM Q

Put / Hold SHIM 148W0015-14 1 SHIM O

Put / Hold SHIM, LAMINATED BACS40R021B049F 1 SHIM R

Put / Hold SHIM, LAMINATED BACS40R019B056F 1 SHIM S

Put / Hold SHIM-LAMINATED BACS40R033B052F 1 SHIM T

5 Drill / Ream HOLE - 214

6 Remove / Keep PART - -

7 Deburr HOLE - -

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 12 OF 20)

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ALERT ALERT
Step Task Name Identification Qty More Data

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 detected

crack, and not to exceed 0.160 inch.

8 Cut CHORD 148W7102-() 1

Deburr CHORD 148W7102-() 1

Do a surface High

Frequency Eddy

Current (HFEC) inspection of the cut

edge, to make sure

any crack was removed, in accordance with 777 NDT

Manual Part 6, 51-

00-01. (a)

Inspect CHORD 148W7102-() 1

0.04 inch insurance

cut. Maximum edge

trim out is 0.200

inch. Blend the edge

to a minimum radius

of 1.50 inch. Maintain a shoulder slope

of runout of minimum 1.0 inch.

Cut CHORD 148W7102-() 1

Deburr the cut edge.

The surface roughness of the cut edge

is 63 Ra or better.

Deburr CHORD 148W7102-() 1

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 13 OF 20)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

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 Shot

Peening, as an accepted procedure.

9 Shot Peen CHORD 148W7102-() 1

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

10 Apply

two coats, on the cut

surface. Refer to

SOPM 20-41-02 as

an accepted procedure.

Apply PRIMER BMS 10-11, TYPE I -

11 Install (New) SPLICE ANGLE 148W2204-6 1 (f)

Install (New) SHIM LAMINATED 148W7143-11 1 SHIM A (e) (f)

Install (New) SHIM LAMINATED 148W7143-13 1 SHIM B (e) (f)

Install (New) SHIM LAMINATED 148W7143-7 1 SHIM C (e) (f)

Install (New) SHIM LAMINATED 148W7143-6 1 SHIM D (e) (f)

Install (New) SHIM LAMINATED 148W7143-5 1 SHIM E (e) (f)

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 14 OF 20)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

12 Install (New) SHIM, LAMINATED BACS40R016B037F 1 SHIM U (d) (f)

Install (Kept) FILLER BACF3H14NP017HN 2 FILLER A (f)

Install (New) SHIM, LAMINATED BACS40R007B064F 1 SHIM G (b) (f)

Install (New) SHIM, LAMINATED BACS40R008B041F 1 SHIM H (b) (f)

Install (Kept) FILLER 148W2328-1 1 FILLER D (f)

(f) End fitting pad

must remain

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2379-() 1

Install (New) SHIM, LAMINATED BACS40R023B053F 1 SHIM I (d) (f)

Install (New) SHIM, LAMINATED BACS40R007B077F 1 SHIM J (b) (f)

Install (New) SHIM, LAMINATED BACS40R008B062F 1 SHIM K (b) (f)

Install (Kept) FILLER 148W2328-2 1 FILLER E (f)

(f) End fitting pad

must remain

clamped to chord

until the sealant is

cured.

Install (Kept) END FITTING 148W2369-() 1

13 Install (Kept) FITTING 148W2515-() 1 (f)

Install (New) SHIM,LAMINATED BACS40R029B065F 1 SHIM L (b) (f)

Install (New) SHIM 148W0015-13 1 SHIM M (b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O (b) (f)

14 Install (Kept) FITTING 148W2514-() 1 (f)

Install (New) SHIM 148W0015-12 1 SHIM Q (b) (f)

Install (New) SHIM 148W0015-14 1 SHIM O (b) (f)

Install (New) SHIM, LAMINATED BACS40R021B049F 1 SHIM R (b) (f)

Install (New) SHIM, LAMINATED BACS40R019B056F 1 SHIM S (b) (f)

Install (New) SHIM-LAMINATED BACS40R033B052F 1 SHIM T (c) (f)

15 Install (Kept) FASTENER - 12 (g)

16 Install (New) FASTENER - 202 (g)

(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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

(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.

Flagnote Description

Make 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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

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.

A BOLT, 12 PT HEAD BACB30US6K14 2 0.376 - 0.379

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.

BOLT, 12 PT HEAD BACB30US6K19 3 0.376 - 0.379

WASHER, PLAIN BACW10BP6CD 5 - Under bolt head

WASHER BACW10BP6DP 5 - Under the nut

Tighten to 300 to 500 inlb.SELF-LOCKING NUT BACN10HR6CD 5 -

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.

BOLT, 12 PT HEAD BACB30US8K28 1 0.501 - 0.505

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.

BOLT, 12 PT HEAD BACB30US8K* 2 0.501 - 0.505

WASHER BACW10BP8CD 3 - Under bolt head

WASHER BACW10BP8DP 3 - Under the nut

Tighten to 870 to 1300 inlb.NUT BACN10HR8CD 3 -

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.

BOLT, 12 PT HEAD BACB30US12K36 2 0.751 - 0.757

WASHER, PLAIN BACW10BP12CD 2 - Under bolt head

WASHER, PLAIN BACW10BP12DP 2 - Under the nut

Tighten to 3300 to 4300

in-lb.

SELF-LOCKING NUT BACN10HR12CD 2 -

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 17 OF 20)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Code Name Identification Qty Hole Dia More Data

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.

BACB30US16K46 2 1.028 - 1.047

WASHER, PLAIN BACW10BP16CD 2 - Under bolt head

WASHER, PLAIN BACW10BP16DP 2 - Under the nut

Tighten to 7000 to 10900

in-lb.

SELF-LOCKING NUT BACN10HR162CD 2 -

BOLT, PROTRUDING BACB30NX6K5X 4 0.200 - 0.203

HD

B

COLLAR BACC30M6 4 -

BOLT, PROTRUDING BACB30NX10K11X 3 0.327 - 0.331

HD

BOLT, PROTRUDING BACB30NX10K14X 13 0.327 - 0.331

HD

COLLAR BACC30BH10 16 -

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 18 OF 20)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30MY8K4X 16 0.263 - 0.266

HD

C

BOLT, PROTRUDING BACB30MY8K5X 4 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K6X 18 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K7X 6 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K8X 5 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K9X 1 0.263 - 0.266

HD

BOLT, PROTRUDING BACB30MY8K11X 14 0.263 - 0.266

HD

COLLAR BACC30M8 64 -

BOLT, PROTRUDING BACB30MY10K7X 8 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K10X 6 0.325 - 0.328

HD

BOLT, PROTRUDING BACB30MY10K13X 6 0.325 - 0.328

HD

COLLAR BACC30M10 20 -

BOLT, 100 DEG HEX BACB30NW8K7X 2 0.263 - 0.266

DR

D

BOLT, 100 DEG HEX BACB30NW8K8X 5 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K9X 17 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K10X 28 0.263 - 0.266

DR

BOLT, 100 DEG HEX BACB30NW8K12X 2 0.263 - 0.266

DR

COLLAR BACC30M8 54 -

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 19 OF 20)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

G BOLT, HEX DRIVE BACB30YN8K12X 8 0.263 - 0.266

WASHER NAS1149D0432J 8 -

WASHER NAS1149D0463J 8 -

NUT BACN10YR4CD 8 - Tighten to 60 to 80 in-lb.

BOLT, HEX DRIVE BACB30YN10K15X 12 0.325 - 0.328

BOLT, HEX DRIVE BACB30YN10K16X 16 0.325 - 0.328

WASHER NAS1149D0532J 28 -

WASHER NAS1149D0563J 28 -

Tighten to 130 to 160 inlb.NUT BACN10YR5CD 28 -

0.2616 -

0.2636

BOLT, 100 DEG HEX BACB30NW8K9X 8

DR

I

WASHER, PLAIN BACW10BP41DP 8 -

NUT BACN10YR4CD 8 - Tighten to 60 to 80 in-lb.

FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR

(SHEET 20 OF 20)

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ALERT ALERT
FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND

HFEC INSPECTION

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND

HFEC INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Do a surface

High Frequency

Eddy Current

(HFEC) inspection for any

crack, in accordance with 777

NDT Manual Part

6, 51-00-01.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

1 Inspect

Do an open hole

HFEC inspection

for any crack, in

accordance with

777 NDT Manual

Part 6, 51-00-02.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

2 Inspect

Do a DET for any

crack.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

3 Inspect

FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND

HFEC INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND

HFEC INSPECTION

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND

HFEC INSPECTION

(SHEET 2 OF 3)

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211 of 248

BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

Do a surface

High Frequency

Eddy Current

(HFEC) inspection for any

crack, in accordance with 777

NDT Manual Part

6, 51-00-01.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

1 Inspect

Do an open hole

HFEC inspection

for any crack, in

accordance with

777 NDT Manual

Part 6, 51-00-02.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

2 Inspect

Do a DET for any

crack.

CHORD - FOR- 148W7102-( ) 1

WARD, PIVOT

BULKHEAD, MID

3 Inspect

FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND

HFEC INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION

- SKIN PANEL INSTALLATION

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION

- SKIN PANEL INSTALLATION

(SHEET 2 OF 5)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION

- SKIN PANEL INSTALLATION

(SHEET 3 OF 5)

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Install (Kept) FILLER 148W2917-9 1 (a)

FILLER 148W2917-11 1 (a)

FILLER 148W2917-7 1 (a)

ANGLE - FAIR- 148W2914-( ) 1 (a)

ING ASSY, UPPER

FILLER BACF3T03M14S8B 1 (a)

SPLICE PLATE 148W2918-3 1 (a)

BRACKET 148W2920-1 1 (a)

(a) Do not seal

the exterior gap

around this skin

panel.

SKIN 148W2912-1 1

(a) Do not seal

the exterior gap

around this skin

panel.

SKIN 148W2912-2 1

RADIUS FILLER 148W9710-15 1 (a)

FASTENER - 3

2 Install (New) FASTENER - 24

(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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

0.2026 - (a)

0.2036

BOLT, 100 DEG HEX BACB30NW6K5X 2

DR

D

COLLAR BACC30M6 2 -

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K5X 3

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K6X 1

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K9X 6

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K12X 2

DR

COLLAR BACC30M8 12 -

H RIVET, 100 DEG BACR15CE5KE5 3 -

RIVET, 100 DEG BACR15CE5KE6 6 -

RIVET, 100 DEG BACR15CE5KE8 1 -

J BOLT BACB30VF3K4 2 -

BOLT BACB30VF3K5 - -

Install bolts into existing

nutplates on the horizontal

stabilizer seal fairing.

NUTPLATE BACN10YF33CD - -

(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)

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ALERT ALERT
FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION

- SKIN PANEL INSTALLATION

(SHEET 1 OF 5)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION

- SKIN PANEL INSTALLATION

(SHEET 2 OF 5)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION

- SKIN PANEL INSTALLATION

(SHEET 3 OF 5)

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Install (Kept) FILLER 148W2917-9 1 (a)

FILLER 148W2917-11 1 (a)

FILLER 148W2917-7 1 (a)

ANGLE - FAIR- 148W2914-( ) 1 (a)

ING ASSY, UPPER

FILLER BACF3T03M14S8B 1 (a)

SPLICE PLATE 148W2918-4 1 (a)

BRACKET 148W2920-2 1 (a)

(a) Do not seal

the exterior gap

around this skin

panel.

SKIN 148W2912-2 1

(a) Do not seal

the exterior gap

around this skin

panel.

SKIN 148W2912-4 1

RADIUS FILLER 148W9710-15 1 (a)

FASTENER - 3

2 Install (New) FASTENER - 24

(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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

0.2026 - (a)

0.2036

BOLT, 100 DEG HEX BACB30NW6K5X 2

DR

D

COLLAR BACC30M6 2 -

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K5X 3

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K6X 1

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K9X 6

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K12X 2

DR

COLLAR BACC30M8 12 -

H RIVET, 100 DEG BACR15CE5KE5 3 -

RIVET, 100 DEG BACR15CE5KE6 6 -

RIVET, 100 DEG BACR15CE5KE8 1 -

J BOLT BACB30VF3K4 2 -

BOLT BACB30VF3K5 - -

Install bolts into existing

nutplates on the horizontal

stabilizer seal fairing.

NUTPLATE BACN10YF33CD - -

(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)

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ALERT ALERT
FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 3 OF 6)

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

1 Put/Hold

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-1 1

SKIN 148W2912-3 1

RADIUS FILLER 148W9710-15 1

Drill/Ream HOLE - 14

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

Remove/Keep2

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-1 1

SKIN 148W2912-3 1

RADIUS FILLER 148W9710-15 1

Deburr HOLE - -

FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 4 OF 6)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

Install FILLER 148W2917-9 1 (a)

(Kept)

3

FILLER 148W2917-11 1 (a)

FILLER 148W2917-7 1 (a)

SPLICE PLATE 148W2918-3 1 (a)

BRACKET 148W2920-1 1 (a)

ANGLE - FAIRING 148W2914-( ) 1 (a)

ASSY, UPPER

FILLER BACF3T03M14S8B 1 (a)

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-1 1

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-3 1

RADIUS FILLER 148W9710-15 1 (a)

FASTENER - 3

Install FASTENER - 24

(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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

0.2026 - (a)

0.2036

BOLT, 100 DEG HEX BACB30NW6K5X 2

DR

D

COLLAR BACC30M6 2 -

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K5X 3

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K6X 1

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K9X 6

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K12X 2

DR

COLLAR BACC30M8 12 -

H RIVET, 100 DEG BACR15CE5KE5 3 -

RIVET, 100 DEG BACR15CE5KE6 6 -

RIVET, 100 DEG BACR15CE5KE8 1 -

J BOLT BACB30VF3K4 2 -

BOLT BACB30VF3K5 - -

Install bolts into existing

nutplates on the horizontal

stabilizer seal fairing.

NUTPLATE BACN10YF33CD - -

(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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 2 OF 6)

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ALERT ALERT
FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 3 OF 6)

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BOEING SERVICE BULLETIN 777-53A0075

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

1 Put/Hold

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-2 1

SKIN 148W2912-4 1

RADIUS FILLER 148W9710-15 1

Drill/Ream HOLE - 14

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

Remove/Keep2

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

SKIN 148W2912-2 1

SKIN 148W2912-4 1

RADIUS FILLER 148W9710-15 1

Deburr HOLE - -

FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL

INSTALLATION

(SHEET 4 OF 6)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Step Task Name Identification Qty More Data

Install FILLER 148W2917-9 1 (a)

(Kept)

3

FILLER 148W2917-11 1 (a)

FILLER 148W2917-7 1 (a)

SPLICE PLATE 148W2918-4 1 (a)

BRACKET 148W2920-2 1 (a)

ANGLE - FAIRING 148W2914-( ) 1 (a)

ASSY, UPPER

FILLER BACF3T03M14S8B 1 (a)

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-2 1

(a) Do not seal the exterior gap around

this skin panel.

SKIN 148W2912-4 1

RADIUS FILLER 148W9710-15 1 (a)

FASTENER - 3

Install FASTENER - 24

(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)

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ALERT ALERT
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.

Code Name Identification Qty Hole Dia More Data

0.2026 - (a)

0.2036

BOLT, 100 DEG HEX BACB30NW6K5X 2

DR

D

COLLAR BACC30M6 2 -

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K5X 3

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K6X 1

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K9X 6

DR

0.2651 - (a)

0.2661

BOLT, 100 DEG HEX BACB30NW8K12X 2

DR

COLLAR BACC30M8 12 -

H RIVET, 100 DEG BACR15CE5KE5 3 -

RIVET, 100 DEG BACR15CE5KE6 6 -

RIVET, 100 DEG BACR15CE5KE8 1 -

J BOLT BACB30VF3K4 2 -

BOLT BACB30VF3K5 - -

Install bolts into existing

nutplates on the horizontal

stabilizer seal fairing.

NUTPLATE BACN10YF33CD - -

(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)

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FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 1 OF 4)

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FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 2 OF 4)

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FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 3 OF 4)

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Remove FASTENER - 24

Remove / FASTENER - 3

Keep

2

RADIUS FILLER 148W9710-15 1

SKIN 148W2912-1 1

SKIN 148W2912-3 1

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

FILLER BACF3T03M14S8B 1

SPLICE PLATE 148W2918-3 1

BRACKET 148W2920-1 1

FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 4 OF 4)

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FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 1 OF 4)

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FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 2 OF 4)

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FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 3 OF 4)

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

numbers shown below are the number of parts necessary for this figure.

Step Task Name Identification Qty More Data

1 Remove FASTENER - 24

2 Remove/Keep FASTENER - 3

RADIUS FILLER 148W9710-15 1

SKIN 148W2912-2 1

SKIN 148W2912-4 1

FILLER 148W2917-9 1

FILLER 148W2917-11 1

FILLER 148W2917-7 1

ANGLE - FAIRING 148W2914-( ) 1

ASSY, UPPER

FILLER BACF3T03M14S8B 1

SPLICE PLATE 148W2918-4 1

BRACKET 148W2920-2 1

FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL

(SHEET 4 OF 4)

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ALERT ALERT
Logic 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.

Title Description

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

CONDITION 1 NO FORWARD CHORD CRACK IS FOUND

ANY FORWARD CHORD CRACK IS FOUND, AND NO CRACK FOUND IS

GREATER THAN 0.160 INCH

CONDITION 2

CONDITION 3 ANY FORWARD CHORD CRACK FOUND IS GREATER THAN 0.160 INCH

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.

Flag Note Letter Description

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)

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ALERT ALERT
APPENDIX 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)

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ALERT ALERT
APPENDIX 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)

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BOEING SERVICE BULLETIN 777-53A0075

ALERT ALERT
Logic 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.

Title Description

STATION 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR

DET AND HFEC INSPECTION

PART 3

NO FORWARD CHORD CRACK IS FOUND DURING POST-REPAIR INSPECTIONSCONDITION 4

ANY FORWARD CHORD CRACK IS FOUND DURING POST-REPAIR INSPECTIONSCONDITION 5

2. The table below gives the description for the flag notes called out in the logic diagram.

Flag Note Letter Description

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)

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ALERT ALERT
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 2 OF 2)

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APPENDIX C: BOEING PART DEMAND INTENT

(SHEET 1 OF 1)

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ALERT ALERT