Commercial 

Airplanes 757

Service Bulletin

ALERT

Number: 757-27A0153

Original Issue: May 09, 2012

ATA System: 2721

SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod

Bolt Replacement

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 © 2012 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, DreamlinerTM,

BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing

liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection

with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management

Company.

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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

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

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

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

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

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

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

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 23

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN

AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER

RUDDER PEDAL ARM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER

PEDAL ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE

BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING

TWO BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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BLANK PAGE
Commercial 

Airplanes 757

Service Bulletin

ALERT

Summary Number: 757-27A0153

Original Issue: May 09, 2012

ATA System: 2721

SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod

Bolt Replacement

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

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

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

THE NEW OWNER.

CONCURRENT REQUIREMENTS

Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND

This service bulletin gives the instructions and a kit of parts to inspect the rudder pedal arm assembly holes,

install stronger rudder pedal pushrod bolt, and provides an option to replace the rudder pedal assembly or repair

the rudder pedal arm assembly if the holes are worn. If the change in this service bulletin is not done, a bolt

fracture under heavy braking during a high-speed takeoff (RTO) may result in a loss of control of the airplane

and subsequent runway excursion.

Boeing received three reports of fractured rudder pedal pushrod bolts in the rudder pedal assembly on 757

aircraft. In one incident, the operator found a fractured bolt during the airplane pushback when the captain

applied brakes. The operator reported that the rudder pedal shifted when applying brakes and the rudder moved

to the hard left. The left rudder sudden movement occurred after the bolt fractured. Investigation and analysis

of the three incidents has shown that the rudder pedal pushrod bolts are under strength for high loading

applications.

Accomplishment of this service bulletin installs new stronger rudder pedal pushrod bolts. The installation of the

new bolts will prevent runway excursion under heavy braking during a high-speed takeoff (RTO) due to bolt

fracture.

Boeing Service Related Problem (SRP) 757-SRP-27-0209 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 757 FTD 27-09004 is related to this service bulletin.

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

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Planning Data Affected Reference

AD Related No Paragraph 1.E., Compliance

Weight and Balance Change No 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 Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION (PRR 54530-295RS)

Get access to the rudder pedal assembly for the captain and first officer and remove the rudder pedal pushrod

bolt, washer, nut, and cotter pin. Inspect the rudder pedal arm assembly holes for wear. If holes are worn, replace

the rudder pedal assembly or repair the rudder pedal arm assembly by installing bushings as necessary. Install

the new rudder pedal pushrod bolt, washer, nut, and cotter pin.

EFFECTIVITY

All 757 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of October 16, 1997. Please refer to

Paragraph 2.B., Industry Support Information.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 757

Service Bulletin

ALERT

Number: 757-27A0153

Original Issue: May 09, 2012

ATA System: 2721

SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod

Bolt Replacement

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

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

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

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplane(s) shown below. Refer to PRR 54530-295RS for data about

this change.

GROUP CONFIGURATION DESCRIPTION

1 - All 757 airplanes line numbers 1 through 1050.

Airplane Models:

757-200, 757-200CB, 757-200PF, 757-300

Variable Number Group

NA001 - NA028 1

NA191 - NA199 1

NA201 - NA239 1

NA301 - NA305 1

NA341 - NA352 1

NA391 - NA399 1

NA401 - NA408 1

NA441 - NA447 1

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Variable Number Group

NA501 - NA586 1

NB001 - NB004 1

NB021 - NB023 1

NB036 - NB041 1

NB051 - NB053 1

NB061 - NB073 1

NB079 1

NB131 - NB148 1

NB161 - NB162 1

NB166 - NB168 1

NB201 - NB204 1

NB221 - NB228 1

NB230 1

NB236 1

NB239 1

NB261 - NB267 1

NB291 - NB299 1

NB301 - NB302 1

NB311 - NB312 1

NB321 - NB331 1

NB421 - NB438 1

NB446 1

NB451 - NB454 1

NB501 - NB523 1

NB561 1

NB571 1

NB581 - NB583 1

NC001 - NC033 1

NC041 - NC042 1

NC051 - NC052 1

NC056 - NC062 1

NC066 - NC084 1

NC091 - NC094 1

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Variable Number Group

NC151 1

NC161 1

NC901 - NC951 1

NC971 - NC974 1

ND001 - ND007 1

ND011 - ND059 1

ND111 - ND113 1

ND161 - ND199 1

ND201 - ND203 1

ND221 - ND225 1

ND241 - ND248 1

ND301 - ND322 1

ND401 1

ND891 1

ND895 1

NE001 - NE008 1

NE011 - NE088 1

NE091 - NE094 1

NE141 - NE150 1

NE161 - NE177 1

NE201 - NE204 1

NE301 - NE302 1

NE311 - NE325 1

NJ001 - NJ004 1

NJ031 - NJ032 1

NJ551 - NJ555 1

NL001 - NL002 1

NL006 - NL017 1

NL101 - NL109 1

NL141 1

NL601 - NL616 1

NN001 - NN002 1

NN051 - NN052 1

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Variable Number Group

NP901 - NP904 1

NS601 - NS616 1

NT001 - NT009 1

NT201 - NT202 1

NT231 - NT234 1

NT237 - NT240 1

NT242 1

NT245 - NT248 1

NT281 - NT289 1

NT341 - NT347 1

NT351 - NT360 1

NT371 - NT373 1

NT375 - NT379 1

NT381 - NT386 1

NT401 - NT409 1

NT411 - NT412 1

NT426 - NT427 1

NT431 - NT432 1

NT436 - NT438 1

NT441 - NT442 1

NT446 1

NT701 - NT769 1

NT791 - NT796 1

NT861 - NT862 1

NT881 - NT885 1

NT901 - NT916 1

NT971 - NT985 1

NU031 - NU038 1

NU701 - NU705 1

NU721 - NU728 1

NU731 - NU732 1

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BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives the instructions and a kit of parts to inspect the rudder pedal arm assembly

holes, install stronger rudder pedal pushrod bolt, and provides an option to replace the rudder pedal

assembly or repair the rudder pedal arm assembly if the holes are worn. If the change in this service

bulletin is not done, a bolt fracture under heavy braking during a high-speed takeoff (RTO) may result

in a loss of control of the airplane and subsequent runway excursion.

Boeing received three reports of fractured rudder pedal pushrod bolts in the rudder pedal assembly on

757 aircraft. In one incident, the operator found a fractured bolt during the airplane pushback when the

captain applied brakes. The operator reported that the rudder pedal shifted when applying brakes and

the rudder moved to the hard left. The left rudder sudden movement occurred after the bolt fractured.

Investigation and analysis of the three incidents has shown that the rudder pedal pushrod bolts are

under strength for high loading applications.

Accomplishment of this service bulletin installs new stronger rudder pedal pushrod bolts. The installation

of the new bolts will prevent runway excursion under heavy braking during a high-speed takeoff (RTO)

due to bolt fracture.

Boeing Service Related Problem (SRP) 757-SRP-27-0209 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 757 FTD 27-09004 is related to this service bulletin.

D. Description

Get access to the rudder pedal assembly for the captain and first officer and remove the rudder pedal

pushrod bolt, washer, nut, and cotter pin. Inspect the rudder pedal arm assembly holes for wear. If

holes are worn, replace the rudder pedal assembly or repair the rudder pedal arm assembly by installing

bushings as necessary. Install the new rudder pedal pushrod bolt, washer, nut, and cotter pin.

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

Affected Maintenance Zones

Model Zone

757-200, 757-200CB, 757- 113, 114, 211, 212

200PF, 757-300

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

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BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
Accomplish the required action(s), based on the applicable condition(s) in Table(s) 1, in accordance

with Paragraph 3. Accomplishment Instructions.

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BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
Table 1: INSPECTION AND REPAIR OF THE RUDDER PEDAL ARM ASSEMBLIES

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 60 months 15000 flight cycles

from the original issue date on this

service bulletin.

Do a detailed inspection

on both holes in each of

the captain and the first

officer rudder pedal arm

assemblies in accordance

with Paragraph 3.B.,

Work Instructions, step 7.

All Airplanes

Replace the rudder pedal Before further flight -

pushrod bolt, nut, washer,

and cotter pin in accordance with Paragraph

3.B., Work Instructions,

Condition 1.

Pedal arm assemblies with

the diameter of both holes

are within 0.3120-0.3140

inches.

Replace the rudder pedal Before further flight -

assembly in accordance

with Paragraph 3.B.,

Work Instructions, Condition 2. Or

Pedal arm assemblies with

the diameter of one hole is

greater than 0.3140 inches.

Repair the rudder pedal Before further flight -

arm assembly by installing one bushing as

necessary in accordance

with Paragraph 3.B.,

Work Instructions, Condition 3. Or

Replace the rudder pedal Before further flight -

assembly in accordance

with Paragraph 3.B.,

Work Instructions, Condition 2. Or

Pedal arm assemblies with

the diameter of two holes

are greater than 0.3140

inches.

Repair the rudder pedal Before further flight -

arm assembly by installing two bushings as

necessary in accordance

with Paragraph 3.B.,

Work Instructions, Condition 4.

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

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ALERT ALERT
changes.

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

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

before incorporating this service bulletin.

G. Manpower

The table below shows an estimate of the task hours necessary to do this change 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: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT AND INSPECTION OF THE

HOLE IN THE RUDDER PEDAL ARM ASSEMBLIES

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.90 0.90

Figure 1 1 1.00 1.00

Close Access 1 0.90 0.90

Test 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 3.30 3.30

TABLE 2: CONDITION 1, INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLTS

Task Number of Persons Task Hours Elapsed Hours

Figure 2 1 0.25 0.25

TOTAL FOR EACH AIRPLANE (a) 0.25 0.25

(a) Estimate shown is per one rudder pedal arm assembly that requires only

rudder pedal pushrod bolt installation. Multiply the number of rudder pedal

arm assemblies replaced by the estimate shown to reach the total for each

airplane.

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BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
TABLE 3: CONDITION 2, REPLACEMENT OF THE RUDDER PEDAL ASSEMBLY

Task Number of Persons Task Hours Elapsed Hours

Remove Rudder 1 1.00 1.00

Pedal assembly

Install Rudder Pedal 1 1.00 1.00

assembly

TOTAL FOR EACH AIRPLANE (a) 2.00 2.00

(a) Estimate shown is per one rudder pedal assembly removed and replaced.

Multiply the number of rudder pedal assemblies replaced by the estimate

shown to reach the total for each airplane.

TABLE 4: CONDITION 3, REPAIR OF THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING

ONE BUSHING

Task Number of Persons Task Hours Elapsed Hours

Remove Rudder 1 1.00 1.00

Pedal assembly

Figure 3 1 1.00 1.00

Install Repaired Rud- 1 1.00 1.00

der Pedal assembly

TOTAL FOR EACH AIRPLANE (a) 3.00 3.00

(a) Estimate shown is per rudder pedal arm assembly requiring only one hole to

be repaired. Multiply the number of the rudder pedal arm assemblies repaired

by the estimate shown to reach the total for each Airplane.

TABLE 5: CONDITION 4, REPAIR OF THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING

TWO BUSHINGS

Task Number of Persons Task Hours Elapsed Hours

Remove Rudder 1 1.00 1.00

Pedal assembly

Figure 4 1 2.00 2.00

Install Repaired Rud- 1 1.00 1.00

der Pedal assembly

TOTAL FOR EACH AIRPLANE (a) 4.00 4.00

(a) Estimate shown is per rudder pedal arm assembly requiring both holes to be

repaired. Multiply the number of the rudder pedal arm assemblies repaired by

the estimate shown to reach the total for each Airplane.

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BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

Group 1 Negligible Negligible

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 54530-295RS

b. Boeing Service Related Problem (SRP) 757-SRP-27-0209

c. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-02, 20-50-03

d. 757 Aircraft Maintenance Manual (AMM) 27-21-02, 29-11-00

e. 757 Fleet Team Digest (FTD) 27-09004

f. Component Maintenance Manual (CMM) CMM 27-21-47

g. Boeing Parts Standards Document D-590

2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

251N3140 Arm assy - rudder pedal

251N3013 Pedal instl - rudder

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

757 Aircraft Maintenance Manual 27-21

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ALERT ALERT
Publication Chapter-Section

757 Illustrated Parts Catalog 27-21

Component Maintenance Manual 27-21

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary

Not affected.

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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 original issue

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name Date QTY

TOP KIT, RETROFIT - 09/22/11 7 245 217.00

RUDDER PEDAL

PUSHROD BOLT REPLACEMENT

012N8932-21

01/25/12 2

03/12/12 189

B. Industry Support Information

Boeing warranty remedies are available for 757 airplanes in warranty as of October 16, 1997. For task

hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Commercial Airplanes Group - Warranties. 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 Spares. Please refer to this service

bulletin number and reference the airplane variable number in your purchase order.

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.

Kit 012N8932

Existing Part Notes

Number

New Part Number QTY Name

-21

AN970-5 4 WASHER AN970-5 (a)

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ALERT ALERT
Kit 012N8932

Existing Part Notes

Number

New Part Number QTY Name

-21

No substitution is

allowed

for this

fastener. (a)

BACB30UU5K48D 4 BOLT BACB30NM5DK47

NUT, CASTELLAT- BACN11N5CD (a)

ED

BACN11N5CD 4

BACP18BC02A06P 4 PIN BACP18BC02A05P (a)

NAS1149D0416J 4 WASHER (b)

NAS1149D0432J 4 WASHER (b)

NAS1149D0463J 4 WASHER (b)

(a) Discard existing part.

(b) There are more parts than are necessary.

2. Parts and Materials Supplied by the Operator

Part Number/ Specifica- QTY Name Notes

tion

ARM ASSY - RUDDER (a)

PEDAL

251N3140-( ) -

ALODINE TYPE 2, CLASS - CONVERSION COATING

A OR C

BMS10-11 TYPE 1 - PRIMER (b)

BUSHING-REPAIR, RUD- (a)

DER PEDAL PUSHROD

001N0004-1 4

BMS5-95 - SEALANT (b)

(a) Boeing Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA.

(b) See 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.

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ALERT ALERT
Existing Part QTY Name New Part Number Notes

Number

RUDDER PEDAL ARM - (a) (b)

ASSY

251N3140-() -

(a) Make the change in accordance with this service bulletin.

(b) There is no equivalent Boeing part number for the changed part. Identify on the part that

the change done in accordance with this service bulletin was made.

4. Parts Removed and Not Replaced

Existing Part Name QTY Notes

Number

BACB30NM5DK47 BOLT 4

BACP18BC02A05P PIN 4

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

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 limits to tighten nuts and bolts are in SRM Chapter 51

4. Use the approved fastener and process 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.

6. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

7. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

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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. 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.

10. 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.

11. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

B. WORK INSTRUCTIONS

1. Get access to the flight compartment.

2. Remove pressure from the main hydraulic system. Refer to the 757 AMM 29-11-00 as an accepted

procedure.

3. At the P61 right side panel, move the FLT CONTROL SHUTOFF switches L, C, and R to OFF

position.

NOTE: Attach DO-NOT-OPERATE tags and make sure that the amber switch-position legend

lights come ON.

4. At the overhead circuit breaker panel, P11, open these circuit breakers and install safety tags.

Row Col Number Name

FLT CONT SHUTOFF

TAIL L

H 17 C04033

FLT CONT SHUTOFF

TAIL C

H 18 C04035

H 28 C04034 FLT/CONT S/O TAIL R

5. Open the forward access door 113AL.

6. Move the towing lever to the tow position and install the NLG towing lever pin, SPL-1499 in the

nose gear.

7. Remove the rudder pedal pushrod bolt, washer, nut, and cotter pin from each of the captain and

the first officer rudder pedal assemblies and do a detailed inspection on both holes to make sure

that the diameter of the holes are within 0.3120-0.3140 inches in each of the captain and the first

officer rudder pedal assemblies in accordance with FIGURE 1.

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a. If the diameter of both holes are within 0.3120-0.3140 inches in each rudder pedal arm

assembly, then install the new rudder pedal pushrod bolt, washers, nut, and cotter pin in

accordance with condition 1.

b. If the diameter of one hole is greater than 0.3140 inches in any rudder pedal arm assembly,

then do one of the options below:

(1) Remove and replace the rudder pedal assembly in accordance with condition 2. Or

(2) Repair the rudder pedal arm assembly in accordance with condition 3.

c. If the diameter of both holes are greater than 0.3140 inches in any rudder pedal arm assembly,

then do one of the options below:

(1) Remove and replace the rudder pedal assembly in accordance with condition 2. Or

(2) Repair the rudder pedal arm assembly in accordance with condition 4.

Condition 1: The diameter of both holes are within 0.3120-0.3140 inches.

1. Install the new rudder pedal pushrod bolt, washers, nut, and cotter pin for each rudder pedal arm

assembly in accordance with FIGURE 2.

NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already

installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin

included in the top kit 012N8932-21. Use a combination of the different sizes of washers

that were included in the top kit to meet the torque specification of 110-150 inch-pounds,

while allowing installation of the cotter pin without disturbing the nut torque.

WARNING: KEEP PERSONS AND EQUIPMENT AWAY FROM ALL CONTROL SURFACES WHEN

HYDRAULIC POWER IS SUPPLIED. AILERONS, ELEVATORS, RUDDER, FLAPS,

SLATS, SPOILERS, AND STABILIZER ARE FULLY POWERED SURFACES. INJURY

TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC

POWER IS SUPPLIED.

2. Supply the power from the left, right, and center hydraulic systems. Refer to the 757 AMM 29-11-00

as an accepted procedure.

3. At the overhead circuit breaker panel, P11, close these circuit breakers.

Row Col Number Name

FLT CONT SHUTOFF

TAIL L

H 17 C04033

FLT CONT SHUTOFF

TAIL C

H 18 C04035

H 28 C04034 FLT/CONT S/O TAIL R

4. At the P61 right side panel, Remove the DO-NOT-OPERATE tags and move the FLT CONTROL

SHUTOFF switches L, C, and R to ON position.

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ALERT ALERT
5. Do the rudder pedal operation test as follows:

a. Push the STATUS switch on the P9 Display Select Panel to show the control surface position

indicator on the bottom EICAS display.

b. Operate the rudder pedals through their full travel range and make sure the following:

(1) The rudder operates smoothly and correctly when the pedals are moved through their

full sweep from both the captain's and first officer's pedals.

(2) The rudder position indicator operates correctly and shows full rudder travel in each

direction.

(3) The rudder goes back to its neutral position when the pedals are released slowly.

6. Make sure that the nose wheels are in their center position and remove the towing lever lockpin

from the nose gear.

WARNING: STAY AWAY FROM THE NOSE WHEELS WHEN THE LOCKPIN IS REMOVED. THE

WHEELS CAN TURN TO THE CENTER POSITION QUICKLY, AND CAN CAUSE INJURY

TO PERSONS AND DAMAGE TO EQUIPMENT.

7. Close the forward access door 113AL.

8. Remove the power from the left, right, and center hydraulic systems. Refer to the 757 AMM 29-11-00

as an accepted procedure.

9. Put the airplane back to a serviceable condition.

Condition 2 : The diameter of any hole is greater than 0.3140 inches, replace the rudder pedal

assembly.

1. Remove the rest of the rudder pedal assembly. Refer to 757 AMM 27-21-02 as an accepted

procedure.

2. Install and test the new rudder pedal assembly. Refer to 757 AMM 27-21-02 as an accepted

procedure.

NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already

installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin

included in the top kit 012N8932-21. Use a combination of the different sizes of washers

that were included in the top kit to meet the torque specification of 110 - 150 inch-pounds,

while allowing installation of the cotter pin without disturbing the nut torque.

3. Put the airplane back to a serviceable condition.

Condition 3: The diameter of one hole is greater than 0.3140 inches, repair the rudder pedal arm

assembly by installing one bushing.

1. Remove and keep the rest of the rudder pedal assembly. Refer to 757 AMM 27-21-02 as an

accepted procedure.

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ALERT ALERT
2. Install one bushing at the worn hole for any rudder pedal arm assembly in accordance with FIGURE

3.

3. Install and test the repaired rudder pedal arm assembly along with the rest of the kept rudder pedal

assembly components and the rudder pedal pushrod bolt, washers, nut, and cotter pin. Refer to

757 AMM 27-21-02 as an accepted procedure.

NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already

installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin

included in the top kit 012N8932-21. Use a combination of the different sizes of washers

that were included in the top kit to meet the torque specification of 110 - 150 inch-pounds,

while allowing installation of the cotter pin without disturbing the nut torque.

4. Put the airplane back to a serviceable condition.

Condition 4: The diameter of two holes are greater than 0.3140 inches, repair the rudder pedal

arm assembly by installing two bushings.

1. Remove and keep the rest of the rudder pedal assembly. Refer to 757 AMM 27-21-02 as an

accepted procedure.

2. Install two bushings at the two worn holes for any rudder pedal arm assembly in accordance with

FIGURE 4.

3. Install and test the repaired rudder pedal arm assembly along with the rest of the kept rudder pedal

assembly components and the rudder pedal pushrod bolt, washers, nut, and cotter pin. Refer to

757 AMM 27-21-02 as an accepted procedure.

NOTE: Make sure to discard the existing bolt, nut, washer, and cotter pin that were already

installed and install the new rudder pedal pushrod bolt, washers, nut, and cotter pin

included in the top kit 012N8932-21. Use a combination of the different sizes of washers

that were included in the top kit to meet the torque specification of 110 - 150 inch-pounds,

while allowing installation of the cotter pin without disturbing the nut torque.

4. Put the airplane back to a serviceable condition.

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FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN

AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL

ARM ASSEMBLIES

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN

AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL

ARM ASSEMBLIES

(SHEET 2 OF 4)

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ALERT ALERT
Step Task Name Identification Qty More Data

Move one pedal forward and the other

pedal aft to create

clearance for the

fasteners replacement.

1 Move RUDDER PEDAL - -

2 Remove / Keep RETAINER 251A3131-( ) 8 If installed.

Remove / Keep SCREW BACS12GU08K8 8

Remove / Keep WASHER NAS1149CN832R 8

Remove / Keep NUT PLH508CD 8

3 Remove COTTER PIN BACP18BC02A05P 4

FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN

AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL

ARM ASSEMBLIES

(SHEET 3 OF 4)

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Step Task Name Identification Qty More Data

4 Remove NUT BACN11N5CD 4

Remove WASHER AN970-( ) 4

Remove BOLT BACB30NM5DK47 4

Verify that the diameter of each hole is

within 0.3120-0.3140

inches.

5 Inspect HOLE - -

FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN

AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL

ARM ASSEMBLIES

(SHEET 4 OF 4)

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FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL

ARM ASSEMBLY

(SHEET 1 OF 4)

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FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL

ARM ASSEMBLY

(SHEET 2 OF 4)

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FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL

ARM ASSEMBLY

(SHEET 3 OF 4)

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ALERT ALERT
Step Task Name Identification Qty More Data

No substitution is allowed for this fastener.1 Install (New) BOLT BACB30UU5K48D 1

Install (New) WASHER AN970-5 1

Install (New) WASHER NAS1149D0416J 1 (a)

Install (New) WASHER NAS1149D0432J 1 (a)

Install (New) WASHER NAS1149D0463J 1 (a)

Torque specification

is 110 - 150 inchpounds.

Install (New) NUT, CASTELLATED BACN11N5CD 1

Refer to the SOPM

20-50-02 as an accepted procedure.

Install (New) COTTER PIN BACP18BC02A06P 4

2 Install (Kept) RETAINER 251A3131-( ) 2 If installed.

Install (Kept) SCREW BACS12GU08K8 2

Install (Kept) WASHER NAS1149CN832R 2

Install (Kept) NUT PLH508CD 2

3 Release RUDDER PEDAL - 1

(a) Use each washer alone or in a combination with other washers provided in the kit as required to meet

the torque specification of 110 - 150 inch-pounds, while allowing installation of the cotter pin without disturbing the nut torque.

FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL

ARM ASSEMBLY

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE

BUSHING

(SHEET 1 OF 4)

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FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE

BUSHING

(SHEET 2 OF 4)

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FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE

BUSHING

(SHEET 3 OF 4)

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ALERT ALERT
Step Task Name Identification Qty More Data

Ream the worn hole

in line with the other

hole. Refer to view

A-A.

ARM ASSY - RUDDER 251N3140-( ) 1

PEDAL

1 Ream

ARM ASSY - RUDDER 251N3140-( ) 1 Refer to view A-A.

PEDAL

2 Machine

ARM ASSY - RUDDER 251N3140-( ) 1 Refer to view A-A.

PEDAL

Countersink

Refer to SOPM 20-

43-03 as an accepted procedure.

ALODINE TYPE 2, -

CLASS A OR C

CONVERSION COATING3 Apply

Use the shrink fit

procedure to install

the bushing. Refer

to SOPM 20-50-03

as an accepted procedure. Refer to

view A-A.

BUSHING-REPAIR, 001N0004-1 1

RUDDER PEDAL

PUSHROD

4 Install (New)

Apply SEALANT BMS5-95 -

As necessary, refer

to SOPM 20-41-02

as an accepted procedure.

5 Apply PRIMER BMS10-11 TYPE 1 -

Ream the hole in

line. Refer to view AA.

ARM ASSY - RUDDER 251N3140-( ) 1

PEDAL

6 Ream

Refer to SOPM 20-

43-03 as an accepted procedure.

ALODINE TYPE 2, -

CLASS A OR C

CONVERSION COATING7 Apply

FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE

BUSHING

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING

TWO BUSHINGS

(SHEET 1 OF 4)

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Original Issue: May 09, 2012

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BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING

TWO BUSHINGS

(SHEET 2 OF 4)

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: May 09, 2012

757-27A0153

43 of 45

BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING

TWO BUSHINGS

(SHEET 3 OF 4)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: May 09, 2012

757-27A0153

44 of 45

BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT
Step Task Name Identification Qty More Data

Ream the worn

holes. Refer to view

A-A.

ARM ASSY - RUDDER 251N3140-( ) 2

PEDAL

1 Ream

ARM ASSY - RUDDER 251N3140-( ) 2 Refer to view A-A.

PEDAL

2 Machine

ARM ASSY - RUDDER 251N3140-( ) 2 Refer to view A-A.

PEDAL

Countersink

Refer to SOPM 20-

43-03 as an accepted procedure.

ALODINE TYPE 2, -

CLASS A OR C

CONVERSION COATING3 Apply

Use the shrink fit

procedure to install

the bushing. Refer

to SOPM 20-50-03

as an accepted procedure. Refer to

view A-A.

BUSHING-REPAIR, 001N0004-1 2

RUDDER PEDAL

PUSHROD

4 Install (New)

Apply SEALANT BMS5-95 -

As necessary, refer

to SOPM 20-41-02

as an accepted procedure.

5 Apply PRIMER BMS10-11 TYPE 1 -

Ream both bushings

in-line. Refer to view

A-A.

ARM ASSY - RUDDER 251N3140-( ) 2

PEDAL

6 Ream

Refer to SOPM 20-

43-03 as an accepted procedure.

ALODINE TYPE 2, -

CLASS A OR C

CONVERSION COATING7 Apply

FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING

TWO BUSHINGS

(SHEET 4 OF 4)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: May 09, 2012

757-27A0153

45 of 45

BOEING SERVICE BULLETIN 757-27A0153

ALERT ALERT