### 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. 9E991 ECCN: 

## 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 Unpublished Work.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.

Original Issue: May 09, 2012 757-27A0153 1 of 45 5.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 2 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**

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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 3 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 4 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**

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### 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.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 5 of 45**Reference Affected**  **Planning Data** Paragraph 1.E., Compliance No AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected Yes Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts Yes Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 6 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 7 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 8 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**

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### 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.
**DESCRIPTION CONFIGURATION**  **GROUP** All 757 airplanes line numbers 1 through 1050.

- 1

Airplane Models: 757-200, 757-200CB, 757-200PF, 757-300 **Group Variable Number**  1 NA001 - NA028 1 NA191 - NA199 1 NA201 - NA239 1 NA301 - NA305 1 NA341 - NA352 1 NA391 - NA399 1 NA401 - NA408 1 NA441 - NA447

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 9 of 45**Group Variable Number**  1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 10 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 11 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT Group**  **Variable Number** 1 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 12 of 45 **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 Zone**  **Model** 113, 114, 211, 212 757-200, 757-200CB, 757- 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 13 of 45 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 14 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT Table 1: INSPECTION AND REPAIR OF THE RUDDER PEDAL ARM ASSEMBLIES**  **Repeat Interval (Not to Exceed)**  **Compliance Time Action**  **Condition** 15000 flight cycles Within 60 monthsfrom 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

- Before further flight Replace the rudder pedal 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.

- Before further flight Replace the rudder pedal 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.

- Before further flight Repair the rudder pedalarm assembly by installing one bushing as necessary in accordance with Paragraph 3.B.,Work Instructions, Condition 3. Or

- Before further flight Replace the rudder pedal 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.

- Before further flight Repair the rudder pedalarm 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 15 of 45 **BOEING SERVICE BULLETIN 757-27A0153 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**  **Elapsed Hours Task Hours**  **Number of Persons Task**  0.90 0.90 1 Open Access 1.00 1.00 1 Figure 1 0.90 0.90 1 Close Access 0.50 0.50 1 Test 3.30 3.30 TOTAL FOR EACH AIRPLANE **TABLE 2: CONDITION 1, INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLTS Elapsed Hours**  **Task Hours Number of Persons**  **Task** 0.25 0.25 1 Figure 2 0.25 0.25 TOTAL FOR EACH AIRPLANE (a) (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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 16 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT TABLE 3: CONDITION 2, REPLACEMENT OF THE RUDDER PEDAL ASSEMBLY**  **Elapsed Hours Task Hours**  **Number of Persons Task**  1.00 1.00 1 Remove Rudder Pedal assembly 1.00 1.00 1 Install Rudder Pedal assembly 2.00 2.00 TOTAL FOR EACH AIRPLANE (a) (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**  **Elapsed Hours Task Hours**  **Number of Persons Task**  1.00 1.00 1 Remove Rudder Pedal assembly 1.00 1.00 1 Figure 3 1.00 1.00 1 Install Repaired Rud- der Pedal assembly 3.00 3.00 TOTAL FOR EACH AIRPLANE (a) (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**  **Elapsed Hours Task Hours**  **Number of Persons Task**  1.00 1.00 1 Remove Rudder Pedal assembly 2.00 2.00 1 Figure 4 1.00 1.00 1 Install Repaired Rud- der Pedal assembly 4.00 4.00 TOTAL FOR EACH AIRPLANE (a) (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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 17 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT H. Weight and Balance Changes**  **Change in Moment (Pound-Inches)**  **Change in Weight (Pounds)**  **Airplane** Negligible Negligible Group 1
**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:
**Title Drawing Number**  Arm assy - rudder pedal 251N3140 Pedal instl - rudder 251N3013 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: **Chapter-Section Publication**  27-21 757 Aircraft Maintenance Manual

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 18 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT Chapter-Section**  **Publication** 27-21 757 Illustrated Parts Catalog 27-21 Component Maintenance Manual 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 19 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 20 of 45 **BOEING SERVICE BULLETIN 757-27A0153 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 Ser vice Bulletin (US**  **Dollars) ROLT as of the**  **original issue date of this Ser** **vice Bulletin (Cal endar Days)**  **QTY Date**  **Name Kit Number** 

217.00 245 7 09/22/11 TOP KIT, RETROFIT - RUDDER PEDALPUSHROD BOLT REPLACEMENT 012N8932-21 2 01/25/12 189 03/12/12 **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 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -21**  (a) AN970-5 WASHER 4 AN970-5

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 21 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT Kit 012N8932**  **Notes Existing Part**  **Number Name**  **QTY New Part Number** **-21** No substitution isallowed for thisfastener. (a) BACB30NM5DK47 BOLT 4 BACB30UU5K48D

(a) BACN11N5CD NUT, CASTELLAT- ED 4 BACN11N5CD (a) BACP18BC02A05P PIN 4 BACP18BC02A06P (b) WASHER 4 NAS1149D0416J (b) WASHER 4 NAS1149D0432J (b) WASHER 4 NAS1149D0463J (a) Discard existing part. (b) There are more parts than are necessary. 2. Parts and Materials Supplied by the Operator
**Notes Name**  **QTY Part Number/ Specifica-**  **tion** (a) ARM ASSY - RUDDER PEDAL - 251N3140-( )

CONVERSION COATING

- ALODINE TYPE 2, CLASS A OR C (b) PRIMER

- BMS10-11 TYPE 1 (a) BUSHING-REPAIR, RUD- DER PEDAL PUSHROD 4 001N0004-1 (b) SEALANT

- BMS5-95(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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 22 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT Notes**  **New Part Number Name**  **QTY Existing Part**  **Number** (a) (b)

- RUDDER PEDAL ARM 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
**Notes QTY**  **Name Existing Part**  **Number** 4 BOLT BACB30NM5DK47 4 PIN BACP18BC02A05P **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 23 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 24 of 45 **BOEING SERVICE BULLETIN 757-27A0153 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 25 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**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.
**Name Number**  **Col Row**  FLT CONT SHUTOFF TAIL L C04033 17 H

FLT CONT SHUTOFF TAIL C C04035 18 H

FLT/CONT S/O TAIL R C04034 28 H 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 26 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT**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.
**Name Number**  **Col Row**  FLT CONT SHUTOFF TAIL L C04033 17 H

FLT CONT SHUTOFF TAIL C C04035 18 H

FLT/CONT S/O TAIL R C04034 28 H 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 27 of 45 **BOEING SERVICE BULLETIN 757-27A0153 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 28 of 45 **BOEING SERVICE BULLETIN 757-27A0153 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 29 of 45 **BOEING SERVICE BULLETIN 757-27A0153 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 1 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 30 of 45 **BOEING SERVICE BULLETIN 757-27A0153 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)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 31 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** Move one pedal forward and the other pedal aft to create clearance for thefasteners replacement. - - RUDDER PEDAL Move 1

If installed. 8 251A3131-( ) RETAINER Remove / Keep 2 8 BACS12GU08K8 SCREW Remove / Keep 8 NAS1149CN832R WASHER Remove / Keep 8 PLH508CD NUT Remove / Keep 4 BACP18BC02A05P COTTER PIN Remove 3

**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)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 32 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** 4 BACN11N5CD NUT Remove 4 4 AN970-( ) WASHER Remove 4 BACB30NM5DK47 BOLT Remove Verify that the diameter of each hole is within 0.3120-0.3140 inches. - - HOLE Inspect 5

**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)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 33 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL**  **ARM ASSEMBLY (SHEET 1 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 34 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL**  **ARM ASSEMBLY (SHEET 2 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 35 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL**  **ARM ASSEMBLY (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 36 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** No substitution is allowed for this fastener. 1 BACB30UU5K48D BOLT Install (New) 1

1 AN970-5 WASHER Install (New) (a) 1 NAS1149D0416J WASHER Install (New) (a) 1 NAS1149D0432J WASHER Install (New) (a) 1 NAS1149D0463J WASHER Install (New) Torque specificationis 110 - 150 inchpounds. 1 BACN11N5CD NUT, CASTELLATED Install (New)

Refer to the SOPM20-50-02 as an accepted procedure. 4 BACP18BC02A06P COTTER PIN Install (New)

If installed. 2 251A3131-( ) RETAINER Install (Kept) 2 2 BACS12GU08K8 SCREW Install (Kept) 2 NAS1149CN832R WASHER Install (Kept) 2 PLH508CD NUT Install (Kept) 1

- RUDDER PEDAL Release 3 (a) Use each washer alone or in a combination with other washers provided in the kit as required to meetthe 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)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 37 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE**  **BUSHING (SHEET 1 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 38 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE**  **BUSHING (SHEET 2 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 39 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE**  **BUSHING (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 40 of 45 **BOEING SERVICE BULLETIN 757-27A0153 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** Ream the worn hole in line with the other hole. Refer to view A-A. 1 251N3140-( ) ARM ASSY - RUDDER PEDAL Ream 1

Refer to view A-A. 1 251N3140-( ) ARM ASSY - RUDDER PEDAL Machine 2

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

Refer to SOPM 20-43-03 as an accepted procedure. - ALODINE TYPE 2, CLASS A OR CCONVERSION COATING Apply 3

Use the shrink fit procedure to install the bushing. Refer to SOPM 20-50-03as an accepted procedure. Refer to view A-A. 1 001N0004-1 BUSHING-REPAIR, RUDDER PEDAL PUSHROD Install (New) 4

- BMS5-95 SEALANT Apply As necessary, refer to SOPM 20-41-02as an accepted procedure. - BMS10-11 TYPE 1 PRIMER Apply 5

Ream the hole inline. Refer to view AA. 1 251N3140-( ) ARM ASSY - RUDDER PEDAL Ream 6

Refer to SOPM 20-43-03 as an accepted procedure. - ALODINE TYPE 2, CLASS A OR CCONVERSION COATING Apply 7

**FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE BUSHING**  **(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 41 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 1 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2012 757-27A0153 42 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 2 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 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 More Data**  **Qty Identification**  **Name Task**  **Step** Ream the worn holes. Refer to view A-A. 2 251N3140-( ) ARM ASSY - RUDDER PEDAL Ream 1

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

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

Refer to SOPM 20-43-03 as an accepted procedure. - ALODINE TYPE 2, CLASS A OR CCONVERSION COATING Apply 3

Use the shrink fit procedure to install the bushing. Refer to SOPM 20-50-03as an accepted procedure. Refer to view A-A. 2 001N0004-1 BUSHING-REPAIR, RUDDER PEDAL PUSHROD Install (New) 4

- BMS5-95 SEALANT Apply As necessary, refer to SOPM 20-41-02as an accepted procedure. - BMS10-11 TYPE 1 PRIMER Apply 5

Ream both bushings in-line. Refer to view A-A. 2 251N3140-( ) ARM ASSY - RUDDER PEDAL Ream 6

Refer to SOPM 20-43-03 as an accepted procedure. - ALODINE TYPE 2, CLASS A OR CCONVERSION COATING Apply 7

**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**