Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 141

Commercial

Airplanes 767

Service Bulletin

Number: 767-57A0094

Original Issue: June 02, 2005

Revision 2: December 17, 2009

ATA System: 5740 2781 2811

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat 

Track Housing Drain Tube Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2005 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable 

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third 

parties. Treatment of the document and the information it contains is governed by contract with Boeing. For 

more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, 

MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or 

its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document 

or otherwise.
 BLANK PAGE

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 141

BOEING SERVICE BULLETIN 767-57A0094

BLANK PAGE
 Table of Contents

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 141

BOEING SERVICE BULLETIN 767-57A0094

Table of Contents

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

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 33

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 33

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 33

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 36

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 39

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 1

AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 2

AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

FIGURE 3: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 3

AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

FIGURE 4: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 4

AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

FIGURE 5: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 1

AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

FIGURE 6: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 2
 Table of Contents

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 141

BOEING SERVICE BULLETIN 767-57A0094

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

FIGURE 7: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 3

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

FIGURE 8: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 4

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

FIGURE 9: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE

GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

FIGURE 10: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE

GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 135
Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 141

Commercial

Airplanes 767

Service Bulletin

Number: 767-57A0094 Revision Transmittal Sheet

Original Issue: June 02, 2005

Revision 2: December 17, 2009

ATA System: 5740 2781 2811

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat 

Track Housing Drain Tube Replacement

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive AD 2001-14-19, is related to this service bulletin.

No more work is necessary on airplanes changed in accordance with the original issue or revision 1 of this 

service bulletin.

REASON FOR REVISION

This revision is sent to add the option for operators to make their own drain tubes and add some optional 

materials to the service bulletin. A cross reference table is added to the special tooling section to show the 

equivalent part numbers for operators who want to order special tools from the Boeing Parts Page. This revision 

also adds a female 3/8 inch square drive socket as an alternative to the wrench. In addition to these changes, 

the term "as given in" is changed to "Refer to, as an accepted procedure" to comply with the latest SB standards 

on non-FAA approved manuals. Figure references are also updated to say "in accordance with" instead of "as 

given in" to comply with latest SB standards.

The changes to this service bulletin are as follows:

— Summary - Compliance - Information related to the future release of Airworthiness Directive related to this 

service bulletin is updated.

— Paragraph 1.E., Compliance - Information related to the future release of Airworthiness Directive related to 

this service bulletin is updated.

— Paragraph 1.F., Approval - FAA Approval statement updated.

— Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added.

— Paragraph 1.B., Concurrent Requirements - Second last sentence deleted from the paragraph for Group 3 

Instructions.

— Paragraph 2.A., Material - Price and Availability - Pricing information updated.

— Paragraph 2.C.1., Kits/Parts - New footnote (d) is added to 015T1772-2 drain tube in top kit table to give 

operators the option to make the drain tube.

— Paragraph 2.C.2., Parts and Materials Supplied by the Operator - BMS 3-33 is added as an option to BMS 

3-24. Also the name for "MIL-C-5541 Class 1A (Alodine 600)" changed to "Alodine 600 (Alodine 1600/1660 

Optional)"

— Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Footnote (b) is added to show optional 

automotive engine oils to SAE No 10.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 141

BOEING SERVICE BULLETIN 767-57A0094

— Paragraph 2.E., Special Tooling - Price and Availability - Special tooling cross-reference chart added to 

show the required special tooling part numbers to use when ordering from Boeing Part Page. 

— Paragraph 3.A., General Information, Step 10 - Last sentence deleted from the paragraph for Group 3 

airplanes.

— Figure 9 and Figure 10, Sheet 2, View A - Tolerance added to the 0.30 dimensions.

— Figure 9 and Figure 10, Step 7 - "MIL-C-5541, Class 1A" changed to "Alodine 600 (Alodine 1600/1660 

Optional)".

— Figure 9 and Figure 10, Note (e) - Note updated by adding "0.30". 

— Figure 11 thru Figure 18, Step 3 and 5 - BMS 3-33 is added as an optional to BMS 3-24.

— Figure 11 thru Figure 18, Step 22 - "MIL-C-5541, Class 1A" changed to "Alodine 600 (Alodine 1600/1660 

Optional)".

— Figure 18, Step 22 changed to step 21 which was previously a typo.

— Appendix A, Sheet 4 - A 3/8 inch square drive socket is added to the illustration. 

— Appendix A, Sheet 5 - Wrench P/N is changed from ST877W-77A-5 to ST2580-77A-5 in the special tooling 

table and footnote (e) is added to give tool compatibility information.

— Appendix A, Step 11 - A note is added to show optional automotive engine oils to SAE No 10.

— Appendix A, Step 15 - A female 3/8 inch square drive socket is added as an alternative to the wrench.

— Appendix A, Step 16 - A female 3/8 inch square drive socket is added as an alternative to the wrench.

The data given in Information Notice 767-57A0094 IN-01, IN-02 and IN-03 is included in this revision

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity 

paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location 

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: June 02, 2005

Revision 1: December 19, 2006

Revision 2: December 17, 2009
Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 141

Commercial

Airplanes 767

Service Bulletin

Number: 767-57A0094 Summary

Original Issue: June 02, 2005

Revision 2: December 17, 2009

ATA System: 5740 2781 2811

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat 

Track Housing Drain Tube Replacement

CONCURRENT REQUIREMENTS

Group 1-2: You cannot make the changes in accordance with this service bulletin unless the changes in 

accordance with Part III - Terminating Action of either Boeing service bulletin 767-57A0060 Revision 1, dated 

December 31, 1998, or 767-57A0060 Revision 2, dated January 31, 2002, are made. Part III - Terminating 

Action of either Boeing service bulletin 767-57A0060 Revision 1 or 767-57A0060 Revision 2, provides 

instructions to install new number 5 and number 8 slat track housing drain tube assemblies, to prevent possible 

fuel leakage near an engine or exhaust nozzle, when the airplane is on the ground.

Group 2: You cannot make the changes in accordance with this service bulletin unless the changes in 

accordance with Part IV - Additional Work of either Boeing service bulletin 767-57A0060 Revision 1, dated 

December 31, 1998, or 767-57A0060 Revision 2, dated January 31, 2002, are made. Part IV - Additional Work 

installs an additional electrostatic bond path for the number 5 and 8 inboard slat track drain tube assemblies.

Group 3: You cannot make the changes in accordance with this service bulletin unless the changes in 

accordance with Boeing service bulletin 767-57-0068 Revision 1, dated May 09, 2002, are made. Service 

bulletin 767-57-0068 Revision 1, dated May 09, 2002, gives instructions to make a better electrostatic bond for 

the number 5 and number 8 slat track housing drain tube assemblies.

Group 4: These airplanes are not affected by either Boeing service bulletin 767-57A0060 or 767-57-0068.

Refer to service bulletin Paragraph 1.B., Concurrent Requirements, for more information.

BACKGROUND

Accomplishment of this service bulletin prevents cracks in the number 5 and number 8 slat track housing drain 

tubes. Cracks in these drain tubes could let fuel drain from the main fuel tanks into the dry bay area of the wings. 

Fuel from the dry bay areas could subsequently drain on to hot Main Landing Gear (MLG) brakes and possibly 

result in a fire.

One operator told Boeing of a fuel leak on to the MLG as a result of a cracked drain tube at the number 8 slat 

track housing, no fire was reported. The crack was in a drain tube on a 767 airplane that had incorporated a rerouted drain tube with a flexible part, in accordance with Boeing service bulletin 767-57A0060. An investigation 

by Boeing found that the drain tube with a flexible part had cracked as a result of a high intensity engine 

vibration, which was more than the design of the tube permitted.
Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 141

Boeing was told of a second occurrence of a cracked drain tube at the number 8 slat track housing. The crack 

in the flexible part of the drain tube was found after an airplane had a high intensity engine vibration. During 

flight, an airplane had vibration from the number 2 engine (Pratt & Whitney PW4000) as a result of a second 

stage turbine blade failure. The engine was subsequently shut-down and the airplane was diverted. After the 

airplane had landed fuel leakage was seen from the pylon area by maintenance personnel.

This problem affects airplane line numbers 1 thru 921. Airplanes after line number 921 have a production design 

change which installs the new drain tube without a flexible part.

This service bulletin gives instructions to replace a drain tube assembly which has a flexible part with a new 

aluminum drain tube without a flexible part, at the number 5 and number 8 slat track housing. Boeing tests have 

shown that the new aluminum drain tubes are stronger and more resistant to damage during high intensity 

engine vibrations. 

Boeing Service Related Problem (SRP) 767-SRP-57-0160 is related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane VR084 after the initial 

release of this service bulletin. The change completed on airplane VR084 is equivalent to the change given in 

Revision 1 of this service bulletin. Airplane VR084 has the configuration of a Group 4 airplane.

ACTION (PRR B12901-53S)

Defuel the left and right wing main tanks. Open the applicable left and right wing main tank access panels to get 

access to the number 5 and number 8 slat track housing drain tubes. Remove the existing drain tube assemblies 

that have a flexible part. Prepare and install new aluminum drain tubes without a flexible part at the two 

locations. Close the left and right wing main tank fuel bay access panels. Refuel the left and right wing main 

tanks. Inspect the left and right wing main tank dry bay to make sure there is no fuel leakage from the new drain 

tube installations. Close the left and right wing main tank dry bay access panels.

EFFECTIVITY

767-200/300/300F Airplanes. Refer to service bulletin Paragraph 1.A.1 for effectivity.

COMPLIANCE

Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date of this 

service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2001-14-19 is related to this service bulletin.

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

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

mandatory.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 141

BOEING SERVICE BULLETIN 767-57A0094

MANPOWER

MATERIAL INFORMATION

Boeing Supplied Kits.

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

Airplanes Total Task Hours Elapsed Hours

Group 1 and Group 2 45 22

Group 3 and Group 4 43 20
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

WITHOUT A FLEXIBLE PART.

AN ALUMINUM DRAIN TUBE

SLAT TRACK HOUSING, WITH

NUMBER 5 AND NUMBER 8

FLEXIBLE PART AT THE

ASSEMBLY THAT HAS A

REPLACE THE DRAIN TUBE

(NUMBER 8 SLAT TRACK HOUSING OPPOSITE)

TYPICAL NUMBER 5 SLAT TRACK HOUSING SHOWN

RIB NO. 9

LOWER

SKIN

HOUSING

SLAT TRACK

FRONT SPAR

A

SEE A

383964
Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 141

Commercial

Airplanes 767

Service Bulletin

Number: 767-57A0094

Original Issue: June 02, 2005

Revision 2: December 17, 2009

ATA System: 5740 2781 2811

SUBJECT: WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat 

Track Housing Drain Tube Replacement

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line 

Number, and Serial Number data. 

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

production airplanes. Refer to PRR B12901-53S for data about this change.

GROUP CONFIGURATION DESCRIPTION

1 - 767-200/300/300F airplanes, Line Numbers 1 

thru 671, that have a drain tube with a flexible 

part installed at the no.5 and no.8 slat track 

housing. Two doublers are installed at rib no.9 

and there is a 3 jumper electrostatic bond 

configuration.

2 - 767-200 airplane, Variable Number VE066, that 

has a drain tube with a flexible part installed at 

the no.5 and no.8 slat track housing. One 

doubler is installed at rib no.9 and there is a 3 

jumper electrostatic bond configuration.

3 - 767-300/300F airplanes, Line Numbers 672 thru 

757, that have a drain tube with a flexible part 

installed at the no.5 and no.8 slat track housing. 

One doubler is installed at rib no.9 and there is a 

2 jumper electrostatic bond configuration.

4 - 767-200/300/300F airplanes, Line Numbers 759 

thru 921, that have a drain tube with a flexible 

part installed at the no.5 and no.8 slat track 

housing. Two doublers are installed at rib no.9 

and there is 2 jumper electrostatic bond 

configuration.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 141

BOEING SERVICE BULLETIN 767-57A0094

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AA 767 LLC (SVX)

1 VE067

ABX AIR (ABX)

1 VA301 VA303–VA306 VA309–VA315 VA508

VA803 VA807–VA809 VB101–VB123 VB125

VB302 VE064

AEROFLOT (ARO)

1 VL896–VL897 VN471–VN472

3 VS216

4 VS217 VS321–VS324 VS392

AEROMEXICO (AMX)

1 VF071 VF093 VF162 VN166

VN531

3 VS211

AEROSVIT (UKA)

1 VN154–VN155 VN157

3 VS206

AEROTURBINE (AUB)

1 VB051 VB054–VB055 VB321 VB331–VB332

AIR ALGERIE (ALG)

1 VK131–VK133

AIR ASTANA (AKZ)

1 VL899–VL900

AIR CANADA (ACN)

1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202

VN051–VN054 VN056–VN062 VN541 VN546–VN547

VN751–VN752 VN811–VN812 VN931–VN936

4 VS381–VS382 VS546–VS549

AIR CHINA (BEJ)

1 VE085–VE086 VK161–VK164

4 VS208 VS274

AIR DO (HIA)

3 VS176–VS177

AIR EUROPA (ARE)

4 VS292–VS293
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 141

BOEING SERVICE BULLETIN 767-57A0094

AIR ITALY (RIT)

1 VF001–VF002 VL913

AIR MADAGASCAR (MAD)

1 VN167 VN556

AIR NEW ZEALAND (ANZ)

1 VN653 VN655–VN657

3 VN658

AIR PACIFIC (APC)

1 VN676

AIR SEYCHELLES (ASY)

1 VB301 VE104 VL941

4 VS526

AIR TRANSPORT INTERNATIONAL (TIN)

1 VA509 VA511–VA512

AIR ZIMBABWE (ZMB)

1 VF061–VF062

ALITALIA (ALI)

1 VN424 VN427

3 VS366

ALITALIA COMPAGNIA AEREA ITALIANA SPA (ILQ)

1 VL701–VL702 VN426 VN732 VN813

ALL NIPPON AIRWAYS (ANA)

1 VK081–VK113 VN191–VN198

3 VR401

4 VS721–VS730 VT501

AMERICAN AIRLINES (AAL)

1 VA501–VA505 VA514–VA523 VA525 VA527–VA530

VN001–VN041

3 VS196–VS203

4 VS751–VS759

AMIRI FLIGHT (ABD)

4 VS391

ARAMCO ASSOCIATED COMPANY (RAS)

4 VR084

ARKEFLY (HXL)

1 VN156 VN164–VN165

ASIANA AIRLINES (AAR)

1 VK143–VK148 VW851

3 VR426
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 141

BOEING SERVICE BULLETIN 767-57A0094

ATLANT-SOYUZ (AYZ)

1 VF051

AUSTRIAN AIRLINES AG (AUL)

1 VN242–VN243 VN671

3 VS301

4 VS302–VS303

AVIANCA (AVI)

1 VE171–VE172 VF072 VF092 VF161

VN152 VN532

AWAS (AWW)

1 VB325

4 VS308

BELAIR AIRLINES (BLB)

1 VL932

BELLVIEW AIRLINES (BEB)

1 VE125–VE126

BLUE CITY HOLDING (BCY)

1 VE069

BLUE PANORAMA AIRLINES (BPA)

1 VN174 VN681

3 VS061

BOEING (TBC)

1 VA001

BOEING CAPITAL CORPORATION (ZMF)

1 VE117

BRISTOL AIR LIMITED (BMD)

1 VA804

BRITISH AIRWAYS (BAB)

1 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137

3 VS246–VS248

CAMEROON AIRLINES (CAM)

1 VA801

CARGOJET AIRWAYS LTD. (WNT)

1 VA510 VA513

CHILEAN AIR FORCE (CHF)

1 VN561

CHINA EASTERN AIRLINES (CEA)

1 VL871–VL873
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 141

BOEING SERVICE BULLETIN 767-57A0094

CONDOR (CDF)

1 VN683–VN691

CONTINENTAL AIRLINES (CAL)

4 VR051–VR060

CROCUS CORPORATION (CCS)

4 VS825

CSDS AVIATION (CSO)

1 VA506–VA507

DELTA AIR LINES (DAL)

1 VA302 VK036 VK039–VK056 VL753

VN251–VN273 VN301–VN306

3 VN274–VN276 VR471–VR472 VS066–VS070 VS073–VS078

VS266–VS272

4 VS273 VS466–VS472

EL AL ISRAEL AIRLINES (ELA)

1 VB281 VB283–VB284 VF101–VF102 VN537

VN682 VN972

ERITREAN AIR LINES (ERJ)

2 VE066

ETHIOPIAN AIRLINES (ETH)

1 VL898 VN388

3 VS306

4 VS496–VS497 VS506–VS507 VS881

EUROATLANTIC AIRWAYS (MAE)

1 VN055 VN151 VN551 VN562

EVERGREEN MAINTENANCE CENTER (EAC)

1 VE061

FLORIDA WEST INTERNATIONAL (PAI)

4 VR260

FLYGLOBESPAN.COM (FGS)

1 VN654

4 VS112–VS113

GABON AIRLINES (GBO)

1 VA017–VA018

GECAS (GEF)

1 VN731

3 VS367

GENERIC CUSTOMER/SUPPLIER (XXX)

1 VA004–VA005 VE002 VE041 VE063
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 141

BOEING SERVICE BULLETIN 767-57A0094

GOL AIRLINES (GOT)

1 VF171 VN163 VN225 VN557

VN637 VN753

4 VS307

GUGGENHEIM AVIATION PARTNERS (GPR)

1 VN153

GULF AIR (GUL)

1 VN310 VN314

HAINAN AIRLINES (HNA)

4 VS426–VS428

HAWAIIAN AIRLINES (HWI)

1 VK031–VK034 VN171–VN173 VN381

4 VS309–VS311 VS821–VS824 VS841–VS843

HEWA BORA AIRWAYS (EXD)

1 VE021

HIS MAJESTY THE SULTAN'S FLIGHT (BWN)

1 VF180

ICELANDAIR (ICE)

1 VN158 VN211

ILFC (ILF)

1 VL891 VL893

3 VS401

4 VS291

INTEGRATED DEFENSE SYSTEMS (BAC)

1 VA806

ITALIAN AIR FORCE (ZSV)

4 VR086

ITOCHU CORPORATION (CIT)

1 VF181–VF184

JAL INTERNATIONAL (JAL)

1 VB371–VB373 VK001–VK015 VK021–VK022 VK181

3 VK016 VK186 VR461

4 VR441 VS701–VS709

JETAIRFLY (TLB)

1 VN234

JORDAN AVIATION (JOR)

1 VB327 VB329–VB330
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 141

BOEING SERVICE BULLETIN 767-57A0094

KALAIR (BERMUDA) (KLB)

1 VN311

KAM AIR (KMC)

1 VA019

KENYA AIRWAYS (KEN)

1 VK141 VL003 VN421

4 VS331–VS333

KRASAIR (ZXD)

1 VE001 VE022–VE023

LAN AIRLINES (LAN)

1 VL703 VN063–VN064 VN168 VN966–VN969

VN971

3 VN970 VR251 VS111 VS131–VS133

4 VR256–VR259

LOT POLISH AIRLINES (LOT)

1 VN233 VN291–VN293 VN652

LUZAIR TRANSPORTES AEREOS S.A. (LUZ)

1 VN635

MALEV HUNGARIAN AIRLINES LTD. (HGA)

1 VF172

MARTINAIR HOLLAND (MTH)

1 VN221–VN224 VN385 VN672

MEXICANA (CMA)

1 VF041–VF042 VL001–VL002

MID EAST JET (SKL)

1 VF251

NEOS (NEO)

1 VL892 VL894

NORTH AMERICAN AIRLINES (NNA)

1 VL755 VL895 VL911 VN634

VN922

3 VS316

OCEANAIR AIRLINES (OAL)

1 VN376 VN495 VN500

PACE AIRLINES (PIE)

1 VB053

PAI AVIATION, INC. (PSS)

1 VL931
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 141

BOEING SERVICE BULLETIN 767-57A0094

PHOENIX AIRCRAFT LEASING, INC. (PLB)

1 VA810

PLUNA (PLU)

1 VN651

PRIVATAIR (PTS)

4 VS137

PTC AEROSPACE (PTE)

1 VB282

QANTAS (QAN)

1 VN081–VN099 VN115–VN117 VN123 VN130–VN132

3 VS186–VS187

4 VS486

ROSSIYA RUSSIAN AIRLINES (STG)

3 VS261–VS262

4 VS263

ROYAL AIR MAROC (RAM)

1 VN636

4 VS336–VS337

ROYAL BRUNEI AIRLINES (RBA)

1 VN372 VN382–VN384 VN386–VN387

RYAN INTERNATIONAL AIRLINES (RYN)

1 VK035 VK038 VL011

S7 AIRLINES (SBR)

1 VN436 VN638

3 VS136

SAFI AIRWAYS (FFI)

1 VE084

SALAMIS AVIATION (LMV)

1 VE068

SHANGHAI AIRLINES (SHA)

1 VK171

3 VR421 VS207

4 VR422–VR423

SKYMARK AIRLINES (SKM)

4 VS231 VS861

SKYSTAR (SYW)

1 VA008 VA011–VA012 VA020
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 141

BOEING SERVICE BULLETIN 767-57A0094

SMARTLYNX AIRLINES (LCH)

1 VN536 VN542

STAR AIR (SBJ)

1 VA307–VA308 VB323 VB328 VB441–VB444

VE101–VE103

STATE AIR COMPANY "BERKUT" (ORE)

4 VR081

TAA (TNL)

1 VA002–VA003 VA007 VA014–VA015

TAM (TPR)

1 VN422–VN423 VN425

TAMPA CARGO (TMP)

1 VE121–VE124

TEEBAH AIRLINES (EBH)

1 VA710

THOMAS COOK AIRLINES UK (JMA)

1 VN951–VN953

THOMSON AIRWAYS (BRI)

1 VL751–VL752 VL754 VL914 VN791–VN792

VN921

3 VS051–VS054

4 VS055–VS056

TRANSAERO AIRLINES (TRX)

1 VE116 VE118 VE143 VN307–VN309

VN313 VN371 VN631–VN633

TRANSATLANTIC INTL AIRLINES (TIB)

1 VA016

TUIFLY NORDIC (TNS)

1 VL912

UNITED AIR LINES (UAL)

1 VN491–VN494 VN496–VN499 VN501–VN513

3 VS091–VS096

4 VS097–VS104

UPS (UPS)

1 VW701–VW718

3 VR201–VR207 VW719–VW721

4 VR208–VR211

US AIRWAYS (USA)

1 VE141–VE142 VE144–VE149 VE151–VE152
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 141

BOEING SERVICE BULLETIN 767-57A0094

UZBEKISTAN AIRWAYS (UZB)

1 VL806–VL807

4 VS844

VARIG AIRLINES (VAR)

1 VN231–VN232

VISION AIR (VEG)

1 VA006 VA009–VA010

VIVA MACAU (VMC)

1 VF091 VK142

WELLS FARGO (FSB)

1 VL004–VL006

WEST DOVER LLC (WDR)

1 VK037

XL AIRWAYS (SBE)

1 VB326

YONA (IOP)

1 VN312

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

VA001–VA020 1

VA301–VA315 1

VA501–VA530 1

VA701–VA719 1

VA801–VA810 1

VB001–VB002 1

VB051–VB055 1

VB101–VB125 1

VB201–VB202 1

VB251–VB253 1

VB281–VB284 1

VB301–VB302 1

VB321–VB332 1

VB371–VB373 1

VB401 1

VB441–VB444 1

VE001–VE003 1

VE021–VE023 1
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 141

BOEING SERVICE BULLETIN 767-57A0094

VE041–VE043 1

VE061–VE065 1

VE066 2

VE067–VE069 1

VE083–VE086 1

VE101–VE104 1

VE116–VE118 1

VE121–VE126 1

VE141–VE152 1

VE171–VE172 1

VF001–VF002 1

VF041–VF042 1

VF051 1

VF061–VF062 1

VF071–VF072 1

VF091–VF093 1

VF101–VF102 1

VF161–VF162 1

VF171–VF172 1

VF180–VF184 1

VF251 1

VK001–VK015 1

VK016 3

VK021–VK022 1

VK031–VK056 1

VK081–VK113 1

VK131–VK133 1

VK141–VK148 1

VK161–VK164 1

VK171 1

VK181 1

VK186 3

VL001–VL006 1

VL011 1

VL701–VL703 1

VL751–VL755 1

VL806–VL807 1

VL871–VL873 1

VL891–VL900 1

Variable Group
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 141

BOEING SERVICE BULLETIN 767-57A0094

VL911–VL914 1

VL931–VL932 1

VL941 1

VN001–VN041 1

VN051–VN064 1

VN081–VN099 1

VN111–VN127 1

VN130–VN137 1

VN151–VN158 1

VN163–VN168 1

VN171–VN174 1

VN191–VN198 1

VN211–VN212 1

VN221–VN225 1

VN231–VN234 1

VN241–VN243 1

VN251–VN273 1

VN274–VN276 3

VN291–VN293 1

VN301–VN314 1

VN371–VN372 1

VN376 1

VN381–VN388 1

VN421–VN427 1

VN436 1

VN471–VN472 1

VN491–VN513 1

VN531–VN532 1

VN536–VN537 1

VN541–VN542 1

VN546–VN547 1

VN551 1

VN556–VN557 1

VN561–VN562 1

VN631–VN638 1

VN651–VN657 1

VN658 3

VN671–VN672 1

VN676 1

Variable Group
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 141

BOEING SERVICE BULLETIN 767-57A0094

VN681–VN691 1

VN731–VN732 1

VN751–VN753 1

VN791–VN792 1

VN811–VN813 1

VN921–VN922 1

VN931–VN936 1

VN951–VN953 1

VN966–VN969 1

VN970 3

VN971–VN972 1

VR051–VR060 4

VR081 4

VR084 4

VR086 4

VR201–VR207 3

VR208–VR211 4

VR251 3

VR256–VR260 4

VR401 3

VR421 3

VR422–VR423 4

VR426 3

VR441 4

VR461 3

VR471–VR472 3

VS051–VS054 3

VS055–VS056 4

VS061 3

VS066–VS070 3

VS073–VS078 3

VS091–VS096 3

VS097–VS104 4

VS111 3

VS112–VS113 4

VS131–VS133 3

VS136 3

VS137 4

VS176–VS177 3

Variable Group
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 141

BOEING SERVICE BULLETIN 767-57A0094

VS186–VS187 3

VS196–VS203 3

VS206–VS207 3

VS208 4

VS211 3

VS216 3

VS217 4

VS231 4

VS246–VS248 3

VS261–VS262 3

VS263 4

VS266–VS272 3

VS273–VS274 4

VS291–VS293 4

VS301 3

VS302–VS303 4

VS306 3

VS307–VS311 4

VS316 3

VS321–VS324 4

VS331–VS333 4

VS336–VS337 4

VS366–VS367 3

VS381–VS382 4

VS391–VS392 4

VS401 3

VS426–VS428 4

VS466–VS472 4

VS486 4

VS496–VS497 4

VS506–VS507 4

VS526 4

VS546–VS549 4

VS701–VS709 4

VS721–VS730 4

VS751–VS759 4

VS821–VS825 4

VS841–VS844 4

VS861 4

Variable Group
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 141

BOEING SERVICE BULLETIN 767-57A0094

2. Spares Affected

None.

B. Concurrent Requirements

Group 1-2: You cannot make the changes in accordance with this service bulletin unless the changes 

in accordance with Part III - Terminating Action of either Boeing service bulletin 767-57A0060 

Revision 1, dated December 31, 1998, or 767-57A0060 Revision 2, dated January 31, 2002, are 

made. Part III - Terminating Action of either Boeing service bulletin 767-57A0060 Revision 1 or 

767-57A0060 Revision 2, provides instructions to install new number 5 and number 8 slat track 

housing drain tube assemblies, to prevent possible fuel leakage near an engine or exhaust nozzle, 

when the airplane is on the ground.

Group 1-2: If Part III - Terminating Action of either Boeing service bulletin 767-57A0060 Revision 1 

or 767-57A0060 Revision 2 is accomplished concurrently with this service bulletin, do not do either 

the tasks in accordance with the service bulletin to install the 200-030-0001-501 drain tube (with a 

flexible part) or the tasks to install the bonding clamps, bonding jumpers and related fasteners on the 

200-030-0001-501 drain tube. These tasks are not necessary as the 200-030-0001-501 drain tube is 

replaced by the work instructions in accordance with this service bulletin. Keep the bonding clamps, 

bonding jumpers and related fasteners in accordance with service bulletin 767-57A0060 that would 

have been installed on the 200-030-0001-501 drain tube. These parts are required to complete the 

installation of the new drain tube in accordance with this service bulletin.

Group 1: If Part III - Terminating Action of either Boeing service bulletin 767-57A0060 Revision 1 or 

767-57A0060 Revision 2 was previously accomplished on the airplane, do the work instructions in 

accordance with this service bulletin.

Group 2: You cannot make the changes in accordance with this service bulletin unless the changes 

in accordance with Part IV - Additional Work of either Boeing service bulletin 767-57A0060 Revision 

1, dated December 31, 1998, or 767-57A0060 Revision 2, dated January 31, 2002, are made. Part IV 

- Additional Work installs an additional electrostatic bond path for the number 5 and 8 inboard slat 

track drain tube assemblies.

Group 2: If Part III - Terminating Action of either Boeing service bulletin 767-57A0060 Revision 1 or 

767-57A0060 Revision 2, was previously accomplished on the airplane, do not perform the work 

instructions in accordance with this service bulletin, unless the changes in accordance with Part IV - 

Additional Work of either Boeing service bulletin 767-57A0060 Revision 1, dated December 31, 1998, 

or 767-57A0060 Revision 2, dated January 31, 2002, are also made.

VS881 4

VT501 4

VW701–VW718 1

VW719–VW721 3

VW851 1

Variable Group
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 141

BOEING SERVICE BULLETIN 767-57A0094

Group 2: If Part IV - Additional Work of either Boeing service bulletin 767-57A0060 Revision 1 or 

767-57A0060 Revision 2 is accomplished concurrently with this service bulletin, do not do the tasks 

to install the bonding clamps, bonding jumpers and related fasteners on the 200-030-0001-501 drain 

tube. These tasks are not necessary as the 200-030-0001-501 drain tube is replaced by the work 

instructions in accordance with this service bulletin. Keep the bonding clamps, bonding jumpers and 

related fasteners in accordance with service bulletin 767-57A0060 that would have been installed on 

the 200-030-0001-501 drain tube. These parts are required to complete the installation of the new 

drain tube in accordance with this service bulletin.

Group 2: If both Part III - Terminating Action and Part IV - Additional Work of either Boeing service 

bulletin 767-57A0060 Revision 1 or 767-57A0060 Revision 2, were previously accomplished on the 

airplane, do the work instructions in accordance with this service bulletin.

Group 3: You cannot make the changes in accordance with this service bulletin unless the changes 

in accordance with Boeing service bulletin 767-57-0068 Revision 1, dated May 09, 2002, are made. 

Service bulletin 767-57-0068 Revision 1, dated May 09, 2002, gives instructions to make a better 

electrostatic bond for the number 5 and number 8 slat track housing drain tube assemblies.

Group 3: If Boeing service bulletin 767-57-0068 Revision 1 is accomplished concurrently with this 

service bulletin, do not do the tasks in accordance with service bulletin 767-57-0068 Revision 1 to 

install the bonding clamps, bonding jumpers and related fasteners on the 200-030-0001-501 drain 

tube (with a flexible part). These tasks are not necessary as the 200-030-0001-501 drain tube is 

replaced by the work instructions in accordance with this service bulletin. 

Group 3: If Boeing service bulletin 767-57-0068 Revision 1 was previously accomplished on the 

airplane, do the work instructions in accordance with this service bulletin.

Group 4: These airplanes are not affected by either Boeing service bulletin 767-57A0060 or 

767-57-0068.

C. Reason

Accomplishment of this service bulletin prevents cracks in the number 5 and number 8 slat track 

housing drain tubes. Cracks in these drain tubes could let fuel drain from the main fuel tanks into the 

dry bay area of the wings. Fuel from the dry bay areas could subsequently drain on to hot Main 

Landing Gear (MLG) brakes and possibly result in a fire.

One operator told Boeing of a fuel leak on to the MLG as a result of a cracked drain tube at the number 

8 slat track housing, no fire was reported. The crack was in a drain tube on a 767 airplane that had 

incorporated a re-routed drain tube with a flexible part, in accordance with Boeing service bulletin 

767-57A0060. An investigation by Boeing found that the drain tube with a flexible part had cracked as 

a result of a high intensity engine vibration, which was more than the design of the tube permitted. 

Boeing was told of a second occurrence of a cracked drain tube at the number 8 slat track housing. 

The crack in the flexible part of the drain tube was found after an airplane had a high intensity engine 

vibration. During flight, an airplane had vibration from the number 2 engine (Pratt & Whitney PW4000) 

as a result of a second stage turbine blade failure. The engine was subsequently shut-down and the 

airplane was diverted. After the airplane had landed fuel leakage was seen from the pylon area by 

maintenance personnel. 

This problem affects airplane line numbers 1 thru 921. Airplanes after line number 921 have a 

production design change which installs the new drain tube without a flexible part.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 141

BOEING SERVICE BULLETIN 767-57A0094

This service bulletin gives instructions to replace a drain tube assembly which has a flexible part with 

a new aluminum drain tube without a flexible part, at the number 5 and number 8 slat track housing. 

Boeing tests have shown that the new aluminum drain tubes are stronger and more resistant to 

damage during high intensity engine vibrations. 

Boeing Service Related Problem (SRP) 767-SRP-57-0160 is related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane VR084 after 

the initial release of this service bulletin. The change completed on airplane VR084 is equivalent to 

the change given in Revision 1 of this service bulletin. Airplane VR084 has the configuration of a 

Group 4 airplane.

Revision 1 was sent to make changes to the sequence of the work instructions and to change the 

safety wire part number, as a result of the airplane validation. The validation found that the step to 

close the main wing tank access panels was incorrectly located after the refuel step. It also found that 

the minimum fuel quantity note was incorrectly located after the dry bay inspection step. Special tools 

required to roller swage the drain tubes onto the ferrules, are specified in this revision.

The changes in Revision 1 of this service bulletin are as follows:

— The Summary, Background paragraph and Paragraph 1.C., Reason, are changed to include the 

airplane validation data.

— The Summary, Compliance paragraph and Paragraph 1.E., Compliance, are revised to provide 

additional information on the concurrent requirements for each group of airplanes, relative to 

Boeing service bulletins 767-57A0060 and 767-57-0068.

— The Summary, Compliance paragraph and Paragraph 1.E., Compliance, are revised to change 

the recommended compliance time from 24 months after the initial release of this service bulletin, 

to 24 months after the Revision 1 release of this service bulletin. The compliance time is changed 

due to the special roller swage tools required to accomplish this service bulletin, and the difficulty 

operators have experienced with special roller swage tool procurement.

— Paragraph 1.G., Manpower, is changed to agree with the resequenced steps to close the main 

wing tank fuel bay access panels prior to the refuel step, in Paragraph 3.B., Work Instructions.

— Paragraph 2.C.2., Parts and Materials Supplied by the Operator, is changed to correct the safety 

wire part number from NASM20995AB32 to MS20995AB32, and to delete the BACT11SD08 

tape.

— Paragraph 2.E., Special Tooling - Price and Availability, is changed to include the special roller 

swage tools data.

— Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin, is changed to include the 

special roller swage tools data.

— Paragraph 3.B., Work Instructions, for all airplane groups, are changed to resequence the steps 

to close the main wing tank fuel bay access panels prior to the refuel step, and to move the 

minimum fuel quantity note for the fuel leakage inspection to the refuel step.

— Figures 9 and 10, are changed to delete the BACT11SD08 tape and the reference to BAC5001.

— Figures 11 thru 18, are changed to correct the safety wire part number from NASM20995AB32 

to MS0995AB32.

— Appendix A, Roller Swaging - Wiggins Type Ferrules, is changed to: switch the heading from 

Roller Swaging - Wiggins Type Ferrules to Roller Swage Instructions; identify the required 

special roller swage tools, add illustrations to depict special roller swage tools usage, and delete 

the groove fill acceptance criteria.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 141

BOEING SERVICE BULLETIN 767-57A0094

Revision 2 is sent to add the option for operators to make their own drain tubes and add some optional 

materials to the service bulletin. A cross reference table is added to the special tooling section to show 

the equivalent part numbers for operators who want to order special tools from the Boeing Parts Page. 

This revision also adds a female 3/8 inch square drive socket as an alternative to the wrench. In 

addition to these changes, the term "as given in" is changed to "Refer to, as an accepted procedure" 

to comply with the latest SB standards on non-FAA approved manuals. Figure references are also 

updated to say "in accordance with" instead of "as given in" to comply with latest SB standards.

The changes to this service bulletin are as follows:

— Summary - Compliance - Information related to the future release of Airworthiness Directive 

related to this service bulletin is updated.

— Paragraph 1.E., Compliance - Information related to the future release of Airworthiness Directive 

related to this service bulletin is updated.

— Paragraph 1.F., Approval - FAA Approval statement updated.

— Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added.

— Paragraph 1.B., Concurrent Requirements - Second last sentence deleted from the paragraph 

for Group 3 Instructions.

— Paragraph 2.A., Material - Price and Availability - Pricing information updated.

— Paragraph 2.C.1., Kits/Parts - New footnote (d) is added to 015T1772-2 drain tube in top kit table 

to give operators the option to make the drain tube.

— Paragraph 2.C.2., Parts and Materials Supplied by the Operator - BMS 3-33 is added as an 

option to BMS 3-24. Also the name for "MIL-C-5541 Class 1A (Alodine 600)" changed to "Alodine 

600 (Alodine 1600/1660 Optional)"

— Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Footnote (b) is added to show 

optional automotive engine oils to SAE No 10.

— Paragraph 2.E., Special Tooling - Price and Availability - Special tooling cross-reference chart 

added to show the required special tooling part numbers to use when ordering from Boeing Part 

Page. 

— Paragraph 3.A., General Information, Step 10 - Last sentence deleted from the paragraph for 

Group 3 airplanes.

— Figure 9 and Figure 10, Sheet 2, View A - Tolerance added to the 0.30 dimensions.

— Figure 9 and Figure 10, Step 7 - "MIL-C-5541, Class 1A" changed to "Alodine 600 (Alodine 1600/

1660 Optional)".

— Figure 9 and Figure 10, Note (e) - Note updated by adding "0.30". 

— Figure 11 thru Figure 18, Step 3 and 5 - BMS 3-33 is added as an optional to BMS 3-24.

— Figure 11 thru Figure 18, Step 22 - "MIL-C-5541, Class 1A" changed to "Alodine 600 (Alodine 

1600/1660 Optional)".

— Figure 18, Step 22 changed to step 21 which was previously a typo.

— Appendix A, Sheet 4 - A 3/8 inch square drive socket is added to the illustration. 

— Appendix A, Sheet 5 - Wrench P/N is changed from ST877W-77A-5 to ST2580-77A-5 in the 

special tooling table and footnote (e) is added to give tool compatibility information.

— Appendix A, Step 11 - A note is added to show optional automotive engine oils to SAE No 10.

— Appendix A, Step 15 - A female 3/8 inch square drive socket is added as an alternative to the 

wrench.

— Appendix A, Step 16 - A female 3/8 inch square drive socket is added as an alternative to the 

wrench.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 141

BOEING SERVICE BULLETIN 767-57A0094

D. Description

Defuel the left and right wing main fuel tanks. Open the applicable left and right wing fuel tank access 

panels to get access to the number 5 and number 8 slat track housing drain tubes. Remove the 

existing drain tube assemblies that have a flexible part. Prepare and install new aluminum drain tubes 

without a flexible part at the two locations. Close the left and right wing main tank fuel bay access 

panels. Refuel the left and right wing main tanks. Inspect the left and right wing main tank dry bay to 

make sure there is no fuel leakage from the new drain tube installations. Close the left and right wing 

main tank dry bay access panels.

Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this 

service bulletin.

Revision 2 - No more work is necessary on airplanes changed in accordance with the original issue 

or revision 1 of this service bulletin.

E. Compliance

Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date 

of this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2001-14-19 is related to this service 

bulletin.

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

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

this service bulletin mandatory.

F. Approval

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

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

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

JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval 

were based on the airplane in its original Boeing delivery configuration or as modified by other 

approved Boeing changes.

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

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

approval before incorporating this service bulletin.

This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle 

Aircraft Certification Office approves the installation of new aluminum drain tubes without a flexible 

part at the number 5 and number 8 slat track housing, as described in this service bulletin, as an 

alternative method of compliance with the requirements of paragraphs (a), (b) and (c) of FAA AD 

2001-14-19 for Boeing Model 767-200/300/300F series airplanes. All provisions of FAA AD 

2001-14-19 that are not specifically referenced in the above statement remain fully applicable and 

must be met.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 141

BOEING SERVICE BULLETIN 767-57A0094

G. Manpower

The table below shows an estimate of the task-hours necessary to do this service bulletin for each 

airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with 

operator task-hour data if necessary. The estimate does not include lost time. These are some 

examples of lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Group 1: 

Task

Number of 

Persons Task-Hours Elapsed Hours

Defuel 4 20.0 5.0

Prepare for Fuel 

Tank Access

2 6.0 3.0

Open Panels 2 2.0 1.0

Figure 1 1 2.0 2.0

Figure 5 1 2.0 2.0

Figure 9 as necessary

Figure 10 as necessary

Figure 11 1 2.5 2.5

Figure 15 1 2.5 2.5

Close Wing Main 

Tank Panels

2 1.0 0.5

Refuel 2 4.0 2.0

Inspect 2 2.0 1.0

Close Wing Dry 

Bay Panels

2 1.0 0.5

TOTAL FOR EACH AIRPLANE 45.0 22.0

Group 2: 

Task

Number of 

Persons Task-Hours Elapsed Hours

Defuel 4 20.0 5.0

Prepare for Fuel 

Tank Access

2 6.0 3.0

Open Panels 2 2.0 1.0

Figure 2 1 2.0 2.0

Figure 6 1 2.0 2.0

Figure 9 as necessary

Figure 10 as necessary
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 141

BOEING SERVICE BULLETIN 767-57A0094

Figure 12 1 2.5 2.5

Figure 16 1 2.5 2.5

Close Wing Main 

Tank Panels

2 1.0 0.5

Refuel 2 4.0 2.0

Inspect 2 2.0 1.0

Close Wing Dry 

Bay Panels

2 1.0 0.5

TOTAL FOR EACH AIRPLANE 45.0 22.0

Group 3: 

Task

Number of 

Persons Task-Hours Elapsed Hours

Defuel 4 20.0 5.0

Prepare for Fuel 

Tank Access

2 6.0 3.0

Open Panels 2 2.0 1.0

Figure 3 1 1.5 1.5

Figure 7 1 1.5 1.5

Figure 9 as necessary

Figure 10 as necessary

Figure 13 1 2.0 2.0

Figure 17 1 2.0 2.0

Close Wing Main 

Tank Panels

2 1.0 0.5

Refuel 2 4.0 2.0

Inspect 2 2.0 1.0

Close Wing Dry 

Bay Panels

2 1.0 0.5

TOTAL FOR EACH AIRPLANE 43.0 20.0

Group 4: 

Task

Number of 

Persons Task-Hours Elapsed Hours

Defuel 4 20.0 5.0

Prepare for Fuel 

Tank Access

2 6.0 3.0

Open Panels 2 2.0 1.0

Figure 4 1 1.5 1.5

Figure 8 1 1.5 1.5

Group 2: 

Task

Number of 

Persons Task-Hours Elapsed Hours
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 141

BOEING SERVICE BULLETIN 767-57A0094

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR B12901-53S.

b. Service Related Problem (SRP) 767-SRP-57-0160.

c. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 12-11-01, 28-11-00, 28-26-00.

d. Boeing Standard Wiring Practices Manual (SWPM) 20-20-00.

e. Boeing Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-43-03, 

20-50-02, 20-50-07, 20-50-10, 20-50-19, 20-60-02.

f. Boeing Service Bulletin 767-57A0060.

g. Boeing Service Bulletin 767-57-0068.

h. FAA Airworthiness Directive (AD) FAA AD 2001-14-19.

i. Boeing Parts Standards Document D-590.

j. Boeing Drawing 012W6100.

Figure 9 as necessary

Figure 10 as necessary

Figure 14 1 2.0 2.0

Figure 18 1 2.0 2.0

Close Wing Main 

Tank Panels

2 1.0 0.5

Refuel 2 4.0 2.0

Inspect 2 2.0 1.0

Close Wing Dry 

Bay Panels

2 1.0 0.5

TOTAL FOR EACH AIRPLANE 43.0 20.0

Group 4: 

Task

Number of 

Persons Task-Hours Elapsed Hours
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 141

BOEING SERVICE BULLETIN 767-57A0094

2. Data supplied with this Service Bulletin:

None.

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

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

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

applicable to all airplane configurations or operators.

K. Publications Affected

1. Damage Tolerance Based Structural Inspections:

 Boeing has evaluated the 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.

Drawing Number Title

112T2019 DRAIN TUBE INSTL - SLAT TRACK HOUSING, WING

Publication Chapter-Section

767 Illustrated Parts Catalog 57-21
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 141

BOEING SERVICE BULLETIN 767-57A0094

BLANK PAGE
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 141

BOEING SERVICE BULLETIN 767-57A0094

2. MATERIAL INFORMATION

A. Material - Price and Availability

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

below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. 

More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the 

date Boeing gets the purchase order.

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

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

United States dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of the methods that follow:

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

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

Kit Number Name Date QTY

ROLT 

(Weeks)

Unit Price thru

Dec 31/09

015T1772-1 Top Kit - Slat Track 

Housing - Drain Tube 

Replacement

Aug 18/04 1 20 $1,117.00

Oct 14/04 25

Nov 11/04 25

Dec 13/04 25

Jan 19/05 25

Feb 16/05 25

Mar 16/05 25

Apr 13/05 25

May 11/05 9
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 141

BOEING SERVICE BULLETIN 767-57A0094

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.

2. Parts and Materials Supplied by the Operator:

Kit 015T1772

New Part 

Number

QTY

-1 Name Existing Part Number Notes

015T1772-1 - Top Kit - Slat Track Housing 

- Drain Tube Replacement

-

015T1772-2 2 Drain Tube 200-030-0001-501 (a) (d)

AS1716D08 4 Ferrule - Flexible AS1716D08

AN735DC8 2 Clamp, Loop AN735C8 or AN735D8 

or AN735DC8

AS1712D08 2 Coupling - Flexible 305B387S8

AS1713D08 2 Coupling - Half 355B387S8

BACJ40A20-8 4 Bonding Jumper BACJ40AC44-6 or 

BACJ40AC44-8

BACN10YR3CD 6 Nut BACN10YR3CD

BACS12HN3-9 2 Screw BACS12GU3K6 or 

BACS12GU3K9

(b)

MS29513-114 6 Packing, Preformed MS29513-114 (c)

NAS1149D0316H 16 Washer NAS1149D0316H or 

NAS1149D0316R or

NAS1149D0316J

NAS1149D0332H 2 Washer - Plain -

NAS1149D0363H 2 Washer NAS1149D0363H or 

NAS1149D0363R

(a) Discard the existing part. 

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

length longer than indicated. Also, if any fasteners part numbers listed are not available or 

have been superseded, substitute fasteners may be supplied in kits. Boeing Document 

D590 and Boeing Drawing 012W6100 are used to determine the part numbers used as 

substitutes.

(c) There are more parts than are necessary.

(d) Optional to make drain tube, operators can make the drain tube from raw stock tubing 

material 6061-T6 in accordance with WW-T-700/6 or AMS 4083 or AMS-T-7081, with a 

nominal Outer Diameter of 0.5 inch, and a nominal wall thickness of 0.035 inch.

Part Number / Specification QTY Name Notes

Alodine 600 (Alodine 1600/1660 Optional) 1/2 pint Chemical Conversion Coating (c)

BMS 10-20, Type II 1/2 pint Corrosion Resistant Finish (a)

MS20995AB32 12 inches Safety Wire

BMS 3-24

(BMS 3-33 Optional)

1/4 pint Grease (a)
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 141

BOEING SERVICE BULLETIN 767-57A0094

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

The operator can supply the special tools shown in Paragraph 2.F., Special Tooling Necessary to do 

this Service Bulletin. The special tools may be purchased from the suppliers shown below. Tool price 

and availability data are not given.

Denatured Alcohol 1/2 pint Solvent

SAE No. 10 Automotive Motor Oil 

(Masterdraw B1767C Optional)

1/4 pint Lubricant (b)

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

supplier data.

(b) Any SAE "10W-xx" (10W-20, 10W-30, 10W-40, etc.) automotive engine oil is an acceptable 

substitute for SAE No.10 automotive engine oil.

(c) Refer to SOPM 20-43-03 as an accepted procedure for the application of Chemical 

Conversion Coating.

Tool Part Number QTY Name Notes

ST2580-77A-5 1 Wrench (b)(c)

ST877W-F 1 Frame (a)(b)(c)

ST877W-DF-D-08-1-1 1 Die Block (a)(b)(c)

ST877W-DF-D-08-1-2 (Optional) 1 Die Block (a)(b)(c)

DB6305H8 (Optional) 1 Swage Block (e)(h)

ST877W-DH-1 1 Die Block Holder (a)(b)(c)

DH6305-1 (Optional) 1 Swage Block Holder (e)(g)

ST877W-E-8-035 1 Tube Expander (a)(d)

B9108-35 (Optional) 1 Tube Expander (a)(f)

B8308-35 (Optional) 1 Tube Expander (e)(f)

Part Number / Specification QTY Name Notes
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 141

BOEING SERVICE BULLETIN 767-57A0094

Tool Part Number QTY Name Notes

(a) This tool can be purchased from:

 Monaghan & Associates, Inc.

 Elliot Tool Technologies

 1760 Tuttle Avenue

 P.O. Box 1165-45401

 Dayton, Ohio 45403-3428 

 Phone: 937-253-7706

 Toll Free: 800-332-0447

 Fax: 937-259-9241

 Contact: Ken MacDonald, Sales Engineer

 Email: sales@monaghaninc.com

(b) This tool can be purchased from:

 New Tech Industries, Inc.

 7911 44th Avenue West

 Mukilteo, Washington 98275

 Phone: 425-778-1200

 Fax: 425-743-3566

 Contact: Tom Bigelow, President

 Email: tom@newtechind.com

(c) This tool can be purchased from:

 Precise Tool and Gage Co., Inc.

 30540 S.E. 84th St., Unit 2

 Preston, Washington 98050

 Phone: 206-623-1120, 425-222-9567

 Fax: 425-222-9568

 Contact: Brad Schulz, Sales Rep.

 Email: ptg@precisetoolco.com

(d) This tool can be purchased from:

 E.F. Bailey Company

 5610 Fourth Avenue South

 Seattle, Washington 98108 

 Phone: 206-607-4840

 Fax: 206-607-5440

 Contact: Ted McBurney, Sales Rep.

(e) This tool can be purchased from:

 Adel Wiggins Group

 Transdigm, Inc.

 5000 Triggs Street

 Los Angeles, California 90022

 Phone: 323-881-7654

 Contact: Terri Roane, Boeing Account Rep.

 Email: TRoane@AdelWiggins.com

(f) This tool is equivalent to the ST877W-E-8-035 Tube Expander.

(g) This tool is equivalent to the ST877W-DH-1 Die Block Holder.

(h) This tool is equivalent to the ST877W-DF-D-08-1-1 Die Block.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 141

BOEING SERVICE BULLETIN 767-57A0094

Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service 

Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the 

date the tools will be used. If there is a limit in the quantity of available tools, a supply sequence is 

given by Spares.

The tools are subject to the terms and conditions of the Boeing standard purchase order 

acknowledgement. After the Price data, new price data is applicable. Prices are in United States 

dollars. Terms: Net 30 days.

Reference this service bulletin number and submit purchase order by one of the methods that follow:

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

(Service Bulletin 767-57A0094)

F. Special Tooling Necessary to do this Service Bulletin

To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. 

Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be 

necessary. Examine operator tool supply to make sure all necessary tools are available.

Purchase Data

Tool Kit Number Boeing Part Page Number (a) Name

ST2580-77A-5 ST2580-77A5 Wrench

ST877W-F ST877WF Frame

ST877W-DH-1 ST877WDH1 (DH6305-1Optional) Die Block Holder 

(Swage Block Holder)

ST877W-DF-D-08-1-1 ST877WDFD08-1-1 (ST877WDFD08-1-2 or 

DB6305H8 Optional)

Die Block (Swage Block)

ST877W-E-8-035 ST877WE8-035 (B9108-35 or B8308-35 

Optional)

Tube Expander

(a) Use the special Boeing part page number when ordering from the Boeing Part Page. The Boeing 

Part Page only lets entries with dashes "-" between numbers be entered. The user will be alerted to 

this, if the unmodified, tool part number is entered.

Tool Part Number QTY Name Notes

ST2580-77A-5 1 Wrench

ST877W-F 1 Frame (a)

ST877W-DH-1 

(DH6305-1Optional)

1 Die Block Holder 

(Swage Block Holder)

(b)

ST877W-DF-D-08-1-1 

(ST877W-DF-D-08-1-2 

or DB6305H8 Optional)

1 Die Block 

(Swage Block)

(c)
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 141

BOEING SERVICE BULLETIN 767-57A0094

NOTE: The above special tools are reusable. The special tools may be used to accomplish this

service bulletin on multiple airplanes, with correct use and care.

ST877W-E-8-035 

(B9108-35 or B8308-35 

Optional)

1 Tube Expander (d)

(a) This tool is optional. The ST877W-DH-1 die block holder (or DH6305-1swage

 block holder) may be installed in a sturdy bench vise, for the roller swage

 process.

(b) A DH6305-1 swage block holder may be used in place of the ST877W-DH-1

 die block holder.

(c) Either a ST877W-DF-D-08-1-2 die block (no link installed) or a DB6305H8

 swage block may be used in place of the ST877W-DF-D-08-1-1 die block.

(d) Either a B9108-35 tube expander or a B8308-35 tube expander may be

 used in place of the ST877W-E-8-035 tube expander.

Tool Part Number QTY Name Notes
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 141

BOEING SERVICE BULLETIN 767-57A0094

3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED

MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES

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

SPARKS OR OTHER ELECTRICAL DAMAGE.

NOTE:

1. The instructions identified in Paragraph 3.B. Work Instructions and the Figures give the 

recommended sequence of steps. The sequence of steps to do this service bulletin can 

be changed.

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

definition of the acronyms.

3. Obey all of the warnings and cautions given in the specified manual sections.

4. Unless shown differently, these dimensions and tolerances are used:

— Linear dimensions are in inches.

— Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or 

minus 0.03 inch.

— Angular tolerance is plus or minus 2 degrees.

— Torque limits to tighten nuts and bolts are in 767-200/300/300F Structural Repair 

Manual, Chapter 51.

5. Use the approved fastener and process material substitutions, in accordance with 767-

200/300/300F Structural Repair Manual, Chapter 51. Alternate fasteners are listed in 

767-200/300/300F Structural Repair Manual Chapter 51 and Boeing Drawing 

012W6100.

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

installation standards in 767-400 Structural Repair Manual, Chapter 51, then a fastener 

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

installation standards in 767-400 Structural Repair Manual, Chapter 51 may be used.

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 ensure visual access to all surfaces in the inspection area. This 

level of inspection is made under normal 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.

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.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 141

BOEING SERVICE BULLETIN 767-57A0094

9. For Group 1 and Group 2 airplanes, if Part III - Terminating Action of either Boeing 

service bulletin 767-57A0060 Revision 1 or 767-57A0060 Revision 2 is accomplished 

concurrently with this service bulletin, do not do either the tasks in accordance with the 

service bulletin to install the 200-030-0001-501 drain tube (with a flexible part) or the 

tasks to install the bonding clamps, bonding jumpers and related fasteners on the 200-

030-0001-501 drain tube. These tasks are not necessary as the 200-030-0001-501 

drain tube is replaced by the work instructions in accordance with this service bulletin. 

Keep the bonding clamps, bonding jumpers and related fasteners in accordance with 

service bulletin 767-57A0060 that would have been installed on the 200-030-0001-501 

drain tube. These parts are required to complete the installation of the new drain tube in 

accordance with this service bulletin.

10. For Group 2 airplanes, If Part IV - Additional Work of either Boeing service bulletin 

767-57A0060 Revision 1 or 767-57A0060 Revision 2, is accomplished concurrently with 

this service bulletin, do not do the tasks to install the bonding clamps, bonding jumpers 

and related fasteners on the 200-030-0001-501 drain tube. These tasks are not 

necessary as the 200-030-0001-501 drain tube is replaced by the work instructions in 

accordance with this service bulletin. Keep the bonding clamps, bonding jumpers and 

related fasteners in accordance with service bulletin 767-57A0060 that would have been 

installed on the 200-030-0001-501 drain tube. These parts are required to complete the 

installation of the new drain tube in accordance with this service bulletin.

11. For Group 3 airplanes, if Boeing service bulletin 767-57-0068 Revision 1 is 

accomplished concurrently with this service bulletin, do not do the tasks in accordance 

with service bulletin 767-57-0068 Revision 1 to install the bonding clamps, bonding 

jumpers and related fasteners on the 200-030-0001-501 drain tube (with a flexible part). 

These tasks are not necessary as the 200-030-0001-501 drain tube is replaced by the 

work instructions in accordance with this service bulletin.

B. WORK INSTRUCTIONS

Group 1: 

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR WEATHER RADAR

DURING THE DEFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR.

1. Defuel the main tank of the left and right wing. Refer to 767 AMM 28-26-00 as an accepted 

procedure.

WARNING: OBEY THE PURGING AND FUEL TANK ENTRY PRECAUTIONS. FAILURE TO OBEY

THE PURGING AND FUEL TANK ENTRY PRECAUTIONS CAN CAUSE SERIOUS

INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO EQUIPMENT.

2. Prepare to go into the main fuel tank, inboard of rib no.10, of the left and right wing. Refer to 767 

AMM 28-11-00 as an accepted procedure.
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT USE AIRPLANE ELECTRICAL POWER WHEN FUEL TANK ACCESS

DOORS ARE REMOVED. A FIRE OR EXPLOSION CAN OCCUR IF FUEL VAPOR IS

IGNITED BY SPARK(S) FROM ELECTRICAL EQUIPMENT. A FIRE OR EXPLOSION

CAN CAUSE SERIOUS INJURY OR DEATH TO PERSONS AND CAN CAUSE

DAMAGE TO EQUIPMENT.

3. Open the left and right wing main tank and dry bay access panels listed below, to get access to 

the number 5 and number 8 slat track housing drain tube assemblies. Refer to 767 AMM 

06-44-00.

4. Remove the existing drain tube assembly that has a flexible part at the number 5 slat track 

housing in accordance with Figure 1.

5. Remove the existing drain tube assembly that has a flexible part at the number 8 slat track 

housing in accordance with Figure 5.

6. Prepare the new drain tube for installation at the number 5 slat track housing in accordance with 

Figure 9.

7. Prepare the new drain tube for installation at the number 8 slat track housing in accordance with 

Figure 10.

8. Install the new drain tube at the number 5 slat track housing in accordance with Figure 11.

9. Install the new drain tube at the number 8 slat track housing in accordance with Figure 15.

10. Close the left and right wing main tank access panels listed below. Refer to 767 AMM 06-44-00.

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK

Panel Number Location

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT PUT GROUND EQUIPMENT UNDER THE WINGTIPS DURING THE REFUEL

PROCEDURES. THE WINGS MOVE DOWN UNDER THE WEIGHT OF THE FUEL

AND THE WINGTIPS MOVE THE MOST. BECAUSE THE FUEL TANKS ARE VENTED

THROUGH THE WINGTIPS, A DANGEROUS AND EXPLOSIVE MIXTURE AROUND

THE WINGTIPS CAN OCCUR.

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR THE WEATHER

RADAR DURING THE REFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR.

11. Refuel the main tank of the left and right wing. Refer to 767 AMM 12-11-01 as an accepted 

procedure.

NOTE: A minimum of 4400 U.S. gallons of fuel is necessary in the main tanks to do a

satisfactory inspection for leakage.

12. Do a General Visual Inspection of the left and right wing dry bay areas, to make sure there is no 

fuel leakage from the new drain tube installations.

13. Close the left and right wing dry bay access panels listed below. Refer to 767 AMM 06-44-00. 

14. Put the airplane back to a serviceable condition.

Group 2: 

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR WEATHER RADAR

DURING THE DEFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR.

1. Defuel the main tank of the left and right wing. Refer to 767 AMM 28-26-00 as an accepted 

procedure.

WARNING: OBEY THE PURGING AND FUEL TANK ENTRY PRECAUTIONS. FAILURE TO OBEY

THE PURGING AND FUEL TANK ENTRY PRECAUTIONS CAN CAUSE SERIOUS

INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO EQUIPMENT.

2. Prepare to go into the main fuel tank, inboard of rib no.10, of the left and right wing. Refer to 767 

AMM 28-11-00 as an accepted procedure.

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT USE AIRPLANE ELECTRICAL POWER WHEN FUEL TANK ACCESS

DOORS ARE REMOVED. A FIRE OR EXPLOSION CAN OCCUR IF FUEL VAPOR IS

IGNITED BY SPARK(S) FROM ELECTRICAL EQUIPMENT. A FIRE OR EXPLOSION

CAN CAUSE SERIOUS INJURY OR DEATH TO PERSONS AND CAN CAUSE

DAMAGE TO EQUIPMENT.

3. Open the left and right wing main tank and dry bay access panels listed below, to get access to 

the number 5 and number 8 slat track housing drain tube assemblies. Refer to 767 AMM 

06-44-00.

4. Remove the existing drain tube assembly that has a flexible part at the number 5 slat track 

housing in accordance with Figure 2.

5. Remove the existing drain tube assembly that has a flexible part at the number 8 slat track 

housing in accordance with Figure 6.

6. Prepare the new drain tube for installation at the number 5 slat track housing in accordance with 

Figure 9.

7. Prepare the new drain tube for installation at the number 8 slat track housing in accordance with 

Figure 10.

8. Install the new drain tube at the number 5 slat track housing in accordance with Figure 12.

9. Install the new drain tube at the number 8 slat track housing in accordance with Figure 16.

10. Close the left and right wing main tank access panels listed below. Refer to 767 AMM 06-44-00. 

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK

Panel Number Location

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT PUT GROUND EQUIPMENT UNDER THE WINGTIPS DURING THE REFUEL

PROCEDURES. THE WINGS MOVE DOWN UNDER THE WEIGHT OF THE FUEL

AND THE WINGTIPS MOVE THE MOST. BECAUSE THE FUEL TANKS ARE VENTED

THROUGH THE WINGTIPS, A DANGEROUS AND EXPLOSIVE MIXTURE AROUND

THE WINGTIPS CAN OCCUR.

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR THE WEATHER

RADAR DURING THE REFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR

11. Refuel the main tank of the left and right wing. Refer to 767 AMM 12-11-01 as an accepted 

procedure.

NOTE: A minimum of 4400 U.S. gallons of fuel is necessary in the main tanks to do a

satisfactory inspection for leakage.

12. Do a General Visual Inspection of the left and right wing dry bay areas, to make sure there is no 

fuel leakage from the new drain tube installations.

13. Close the left and right wing dry bay access panels listed below. Refer to 767 AMM 06-44-00. 

14. Put the airplane back to a serviceable condition.

Group 3: 

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR WEATHER RADAR

DURING THE DEFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR.

1. Defuel the main tank of the left and right wing. Refer to 767 AMM 28-26-00 as an accepted 

procedure.

WARNING: OBEY THE PURGING AND FUEL TANK ENTRY PRECAUTIONS. FAILURE TO OBEY

THE PURGING AND FUEL TANK ENTRY PRECAUTIONS CAN CAUSE SERIOUS

INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO EQUIPMENT.

2. Prepare to go into the main fuel tank, inboard of rib no.10, of the left and right wing. Refer to 767 

AMM 28-11-00 as an accepted procedure.

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT USE AIRPLANE ELECTRICAL POWER WHEN FUEL TANK ACCESS

DOORS ARE REMOVED. A FIRE OR EXPLOSION CAN OCCUR IF FUEL VAPOR IS

IGNITED BY SPARK(S) FROM ELECTRICAL EQUIPMENT. A FIRE OR EXPLOSION

CAN CAUSE SERIOUS INJURY OR DEATH TO PERSONS AND CAN CAUSE

DAMAGE TO EQUIPMENT.

3. Open the left and right wing main tank and dry bay access panels listed below, to get access to 

the number 5 and number 8 slat track housing drain tube assemblies. Refer to 767 AMM 

06-44-00. 

4. Remove the existing drain tube assembly that has a flexible part at the number 5 slat track 

housing in accordance with Figure 3.

5. Remove the existing drain tube assembly that has a flexible part at the number 8 slat track 

housing in accordance with Figure 7.

6. Prepare the new drain tube for installation at the number 5 slat track housing in accordance with 

Figure 9.

7. Prepare the new drain tube for installation at the number 8 slat track housing in accordance with 

Figure 10.

8. Install the new drain tube at the number 5 slat track housing in accordance with Figure 13.

9. Install the new drain tube at the number 8 slat track housing in accordance with Figure 17.

10. Close the left and right wing main tank access panels listed below. Refer to 767 AMM 06-44-00. 

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK

Panel Number Location

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT PUT GROUND EQUIPMENT UNDER THE WINGTIPS DURING THE REFUEL

PROCEDURES. THE WINGS MOVE DOWN UNDER THE WEIGHT OF THE FUEL

AND THE WINGTIPS MOVE THE MOST. BECAUSE THE FUEL TANKS ARE VENTED

THROUGH THE WINGTIPS, A DANGEROUS AND EXPLOSIVE MIXTURE AROUND

THE WINGTIPS CAN OCCUR.

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR THE WEATHER

RADAR DURING THE REFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR

11. Refuel the main tank of the left and right wing. Refer to 767 AMM 12-11-01 as an accepted 

procedure.

NOTE: A minimum of 4400 U.S. gallons of fuel is necessary in the main tanks to do a

satisfactory inspection for leakage.

12. Do a General Visual Inspection of the left and right wing dry bay areas, to make sure there is no 

fuel leakage from the new drain tube installations.

13. Close the left and right wing dry bay access panels listed below. Refer to 767 AMM 06-44-00. 

14. Put the airplane back to a serviceable condition.

Group 4: 

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR WEATHER RADAR

DURING THE DEFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR.

1. Defuel the main tank of the left and right wing. Refer to 767 AMM 28-26-00 as an accepted 

procedure.

WARNING: OBEY THE PURGING AND FUEL TANK ENTRY PRECAUTIONS. FAILURE TO OBEY

THE PURGING AND FUEL TANK ENTRY PRECAUTIONS CAN CAUSE SERIOUS

INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO EQUIPMENT.

2. Prepare to go into the main fuel tank, inboard of rib no.10, of the left and right wing. Refer to 767 

AMM 28-11-00 as an accepted procedure.

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT USE AIRPLANE ELECTRICAL POWER WHEN FUEL TANK ACCESS

DOORS ARE REMOVED. A FIRE OR EXPLOSION CAN OCCUR IF FUEL VAPOR IS

IGNITED BY SPARK(S) FROM ELECTRICAL EQUIPMENT. A FIRE OR EXPLOSION

CAN CAUSE SERIOUS INJURY OR DEATH TO PERSONS AND CAN CAUSE

DAMAGE TO EQUIPMENT.

3. Open the left and right wing main tank and dry bay access panels listed below, to get access to 

the number 5 and number 8 slat track housing drain tube assemblies. Refer to 767 AMM 

06-44-00. 

4. Remove the existing drain tube assembly that has a flexible part at the number 5 slat track 

housing in accordance with Figure 4.

5. Remove the existing drain tube assembly that has a flexible part at the number 8 slat track 

housing in accordance with Figure 8.

6. Prepare the new drain tube for installation at the number 5 slat track housing in accordance with 

Figure 9.

7. Prepare the new drain tube for installation at the number 8 slat track housing in accordance with 

Figure 10.

8. Install the new drain tube at the number 5 slat track housing in accordance with Figure 14.

9. Install the new drain tube at the number 8 slat track housing in accordance with Figure 18.

10. Close the left and right wing main tank access panels listed below. Refer to 767 AMM 06-44-00. 

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK

Panel Number Location

532FB LEFT WING MAIN TANK

632FB RIGHT WING MAIN TANK
 

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 141

BOEING SERVICE BULLETIN 767-57A0094

WARNING: DO NOT PUT GROUND EQUIPMENT UNDER THE WINGTIPS DURING THE REFUEL

PROCEDURES. THE WINGS MOVE DOWN UNDER THE WEIGHT OF THE FUEL

AND THE WINGTIPS MOVE THE MOST. BECAUSE THE FUEL TANKS ARE VENTED

THROUGH THE WINGTIPS, A DANGEROUS AND EXPLOSIVE MIXTURE AROUND

THE WINGTIPS CAN OCCUR.

WARNING: DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR THE WEATHER

RADAR DURING THE REFUEL PROCEDURES. THE OPERATION OF THE HF

COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN

EXPLOSION TO OCCUR.

11. Refuel the main tank of the left and right wing. Refer to 767 AMM 12-11-01 as an accepted 

procedure.

NOTE: A minimum of 4400 U.S. gallons of fuel is necessary in the main tanks to do a

satisfactory inspection for leakage.

12. Do a General Visual Inspection of the left and right wing dry bay areas, to make sure there is no 

fuel leakage from the new drain tube installations.

13. Close the left and right wing dry bay access panels listed below. Refer to 767 AMM 06-44-00. 

14. Put the airplane back to a serviceable condition.

Panel Number Location

533AB LEFT WING DRY BAY

633AB RIGHT WING DRY BAY
 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

FWD INBD

UP

SEE A

RIB NO. 9

A

SEE D

LOWER

SKIN

NUMBER 5

SLAT TRACK

HOUSING

FRONT SPAR

SEE C

SEE B

421354

(SHEET 1 OF 4)
 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

15

11

2 3

B

17

DOUBLER

ASSEMBLY STIFFENER

421361

(SHEET 2 OF 4)
 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 141

BOEING SERVICE BULLETIN 767-57A0094

14

D

12

16

C

DRAIN TUBE

ATTACHED TO

SLAT TRACK

HOUSING

NUMBER 5 SLAT

TRACK HOUSING

FWD

UP

DRAIN TUBE

6

9

7

7

5

1 3

3

11

4

3

2 10

17

8

13

5 7

7

9

8

7

6

421494

(SHEET 3 OF 4)
 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Screw BACS12GU3K6 or 

BACS12GU3K( )

1 A longer screw could be 

installed.

2 Remove Nut BACN10YR3CD 2

3 Remove Washer NAS1149D0316H 4

4 Remove Washer NAS1149D0363H 4

5 Remove/Keep Screw BACS12GU3K6 or 

BACS12GU3K( )

2 A longer screw could be 

installed.

6 Remove/Keep Nut BACN10YR3CD 2

7 Remove/Keep Washer NAS1149D0316H 6

8 Remove/Keep Washer NAS1149D0363H 4

9 Remove/Keep Bonding Jumper BACJ40A20-8 1

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

13 Remove/Keep Bonding Clamp AN735DC8 1

14 Remove/Keep Bonding Clamp AN735DC56 1

15

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1 Loosen 

16

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

17 Remove Drain Tube 

Assembly

200-030-0001-501 1

(SHEET 4 OF 4)
 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

FWD INBD

UP

SEE A

RIB NO. 9

A

SEE D

LOWER

SKIN

HOUSING

SLAT TRACK

FRONT SPAR

SEE C

SEE B

NUMBER 5

421499

(SHEET 1 OF 4)
 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

15

11

2 3

B

17

DOUBLER

ASSEMBLY STIFFENER

421500

(SHEET 2 OF 4)
 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 141

BOEING SERVICE BULLETIN 767-57A0094

14

D

12

16

DRAIN TUBE

ATTACHED TO

SLAT TRACK

HOUSING

NUMBER 5 SLAT

TRACK HOUSING

FWD

UP

DRAIN TUBE

6

9

7

7

5

1 3

3

11

4

3

2 10

17

8

C

13

5 7

7

9

8

7

6

421511

(SHEET 3 OF 4)
 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Screw BACS12GU3K6 or 

BACS12GU3K( )

1 A longer screw could be 

installed.

2 Remove Nut BACN10YR3CD 2

3 Remove Washer NAS1149D0316H 4

4 Remove Washer NAS1149D0363H 4

5 Remove/Keep Screw BACS12GU3K6 or 

BACS12GU3K( )

2 A longer screw could be 

installed.

6 Remove/Keep Nut BACN10YR3CD 2

7 Remove/Keep Washer NAS1149D0316H 6

8 Remove/Keep Washer NAS1149D0363H 4

9 Remove/Keep Bonding Jumper BACJ40A20-8 1

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

13 Remove/Keep Bonding Clamp AN735DC8 1

14 Remove/Keep Bonding Clamp AN735DC56 1

15

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1

16

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

17 Remove Drain Tube 

Assembly

200-030-0001-501 1

(SHEET 4 OF 4)
 FIGURE 3: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 3: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

FWD INBD

UP

SEE A

RIB NO. 9

LOWER

SKIN

HOUSING

SLAT TRACK FRONT SPAR

SEE C

SEE B

A

NUMBER 5

421517

(SHEET 1 OF 4)
 FIGURE 3: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

14

11

2 9

B

16

DOUBLER

ASSEMBLY STIFFENER

421519

(SHEET 2 OF 4)
 FIGURE 3: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove/Keep Screw BACS12GU3K8 1

2 Remove/Keep Nut BACN10YR3CD 2

3 Remove/Keep Washer NAS1149D0316H 3

4 Remove/Keep Washer NAS1149D0363H 2

5 Remove Screw BACS12GU3K9 or 

BACS12GU3K( )

1 A longer screw could be 

installed.

6 Remove Nut BACN10YR3CM 1

7 Remove Washer NAS1149D0316R 3

8 Remove Washer NAS1149D0363R 2

9 Remove Washer NAS1149D0316H 1

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

11

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

10

1

5

4

3

C

3

3

15

2

13

16

12

7

6

10

7

7

8

421530

(SHEET 3 OF 4)
 FIGURE 3: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 62 of 141

BOEING SERVICE BULLETIN 767-57A0094

13 Remove/Keep Bonding Clamp AN735DC8 1

14

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1

15

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

16 Remove Drain Tube 

Assembly

200-030-0001-501 1

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 4 OF 4)
 FIGURE 4: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 4: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

FWD INBD

UP

SEE A

RIB NO. 9

A

LOWER

SKIN

HOUSING

SLAT TRACK

FRONT SPAR NUMBER 5

SEE C

SEE B

421550

(SHEET 1 OF 4)
 FIGURE 4: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

14

11

9

B

16

2

DOUBLER

ASSEMBLY STIFFENER

421551

(SHEET 2 OF 4)
 FIGURE 4: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove/Keep Screw BACS12GU3K8 1

2 Remove/Keep Nut BACN10YR3CD 2

3

Remove/Keep Washer NAS1149D0316H 

or 

NAS1149D0316J

3 one of the two types of 

washer could be 

installed.

4 Remove/Keep Washer NAS1149D0363H 2

5 Remove Screw BACS12GU3K9 1

6 Remove Nut BACN10YR3CM 1

7 Remove Washer NAS1149D0316R 3

8 Remove Washer NAS1149D0363R 2

9

Remove Washer NAS1149D0316H 

or 

NAS1149D0316J

1 one of the two types of 

washer could be 

installed.

11

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

10

1

5

4

3

C

3

3

15

2

13

16

12

6

10

7

7

7

8

421552

(SHEET 3 OF 4)
 FIGURE 4: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 141

BOEING SERVICE BULLETIN 767-57A0094

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

13 Remove/Keep Bonding Clamp AN735DC8 1

14

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1

15

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

16 Remove Drain Tube 

Assembly

200-030-0001-501 1

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 4 OF 4)
 FIGURE 5: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 67 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 5: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

INBD FWD

UP

SEE A

RIB NO. 9

A

SEE D

LOWER

SKIN

NUMBER 8

SLAT TRACK

HOUSING

FRONT SPAR

SEE C

SEE B

421557

(SHEET 1 OF 4)
 FIGURE 5: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 68 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

15

2 3

B

17

11

DOUBLER

ASSEMBLY

STIFFENER

421675

(SHEET 2 OF 4)
 FIGURE 5: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 69 of 141

BOEING SERVICE BULLETIN 767-57A0094

14

12

16

DRAIN TUBE

ATTACHED TO

SLAT TRACK

HOUSING

NUMBER 8 SLAT

TRACK HOUSING

FWD

UP

13

DRAIN TUBE

6

7

7

5

1 3

3

11

4

3

2 10

17

9

D

9

8

7

7

8

5

C

7

6

421676

(SHEET 3 OF 4)
 FIGURE 5: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 1 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 70 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Screw BACS12GU3K6 or 

BACS12GU3K( )

1 A longer screw could be 

installed.

2 Remove Nut BACN10YR3CD 2

3 Remove Washer NAS1149D0316H 4

4 Remove Washer NAS1149D0363H 2

5 Remove/Keep Screw BACS12GU3K6 or 

BACS12GU3K( )

2 A longer screw could be 

installed.

6 Remove/Keep Nut BACN10YR3CD 2

7 Remove/Keep Washer NAS1149D0316H 6

8 Remove/Keep Washer NAS1149D0363H 4

9 Remove/Keep Bonding Jumper BACJ40A20-8 1

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

13 Remove/Keep Bonding Clamp AN735DC8 1

14 Remove/Keep Bonding Clamp AN735DC56 1

15

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1

16

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

17 Remove Drain Tube 

Assembly

200-030-0001-501 1

(SHEET 4 OF 4)
 FIGURE 6: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 71 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 6: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

SEE A

RIB NO. 9

A

SEE D

LOWER

SKIN

NUMBER 8

SLAT TRACK

HOUSING

FRONT SPAR

SEE C

SEE B

FWD INBD

UP

421679

(SHEET 1 OF 4)
 FIGURE 6: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 72 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

15

2 3

B

17

11

DOUBLER

ASSEMBLY

STIFFENER

421680

(SHEET 2 OF 4)
 FIGURE 6: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 73 of 141

BOEING SERVICE BULLETIN 767-57A0094

14

12

16

DRAIN TUBE

ATTACHED TO

SLAT TRACK

HOUSING

NUMBER 8 SLAT

TRACK HOUSING

FWD

UP

DRAIN TUBE

6

7

7

5

1 3

3

11

4

3

2 10

17

9

D

9

8

7

7

8

5

13

C

7

6

421681

(SHEET 3 OF 4)
 FIGURE 6: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 2 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 74 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Screw BACS12GU3K6 or 

BACS12GU3K( )

1 A longer screw could be 

installed.

2 Remove Nut BACN10YR3CD 2

3 Remove Washer NAS1149D0316H 4

4 Remove Washer NAS1149D0363H 2

5 Remove/Keep Screw BACS12GU3K6 or 

BACS12GU3K( )

2 A longer screw could be 

installed.

6 Remove/Keep Nut BACN10YR3CD 2

7 Remove/Keep Washer NAS1149D0316H 6

8 Remove/Keep Washer NAS1149D0363H 4

9 Remove/Keep Bonding Jumper BACJ40A20-8 1

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

13 Remove/Keep Bonding Clamp AN735DC8 1

14 Remove/Keep Bonding Clamp AN735DC56 1

15

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1

16

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

17 Remove Drain Tube 

Assembly

200-030-0001-501 1

(SHEET 4 OF 4)
 FIGURE 7: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 75 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 7: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

INBD FWD

UP

SEE A

RIB NO. 9

WING LOWER

SKIN

HOUSING

SLAT TRACK

NUMBER 8

FRONT SPAR

SEE C

SEE B

A

421683

(SHEET 1 OF 4)
 FIGURE 7: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 76 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

14

2 9

B

16

11

DOUBLER

ASSEMBLY

STIFFENER

421684

(SHEET 2 OF 4)
 FIGURE 7: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 77 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove/Keep Screw BACS12GU3K8 1

2 Remove/Keep Nut BACN10YR3CD 2

3 Remove/Keep Washer NAS1149D0316H 3

4 Remove/Keep Washer NAS1149D0363H 2

5 Remove Screw BACS12GU3K9 or 

BACS12GU3K( )

1 A longer screw could be 

installed.

6 Remove Nut BACN10YR3CM 1

7 Remove Washer NAS1149D0316R 3

8 Remove Washer NAS1149D0363R 2

9 Remove Washer NAS1149D0316H 1

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

11

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

1

7

5

4

3

C

3

3

15

7

2

13

16

12

7

6

10

10

8

421685

(SHEET 3 OF 4)
 FIGURE 7: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 3 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 78 of 141

BOEING SERVICE BULLETIN 767-57A0094

13 Remove/Keep Bonding Clamp AN735DC8 1

14

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1

15

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

16 Remove Drain Tube 

Assembly

200-030-0001-501 1

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 4 OF 4)
 FIGURE 8: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 79 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 8: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

INBD FWD

UP

SEE A

RIB NO. 9

A

LOWER

SKIN

HOUSING

SLAT TRACK

NUMBER 8

FRONT SPAR

SEE C

SEE B

421691

(SHEET 1 OF 4)
 FIGURE 8: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 80 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

14

2

B

16

11

9

DOUBLER

ASSEMBLY

STIFFENER

421696

(SHEET 2 OF 4)
 FIGURE 8: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 81 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove/Keep Screw BACS12GU3K8 1

2 Remove/Keep Nut BACN10YR3CD 2

3

Remove/Keep Washer NAS1149D0316H 

or 

NAS1149D0316J

3 one of the two types of 

washer could be 

installed.

4 Remove/Keep Washer NAS1149D0363H 2

5 Remove Screw BACS12GU3K9 1

6 Remove Nut BACN10YR3CM 1

7 Remove Washer NAS1149D0316R 3

8 Remove Washer NAS1149D0363R 2

9

Remove Washer NAS1149D0316H 

or 

NAS1149D0316J

1 one of the two types of 

washer could be 

installed.

10

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

10

1

5

4

3

C

3

3

15

2

13

16

12

6

11

7

7

8

7

421698

(SHEET 3 OF 4)
 FIGURE 8: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE - GROUP 4 

AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 82 of 141

BOEING SERVICE BULLETIN 767-57A0094

10 Remove Bonding Jumper BACJ40AC44-6 1

11 Remove Bonding Jumper BACJ40AC44-8 1

12 Remove Bonding Clamp AN735C8 1

13 Remove/Keep Bonding Clamp AN735DC8 1

14

Remove Lockwire - -

Coupling 

Assembly

355B387S8 1

15

Remove Lockwire - -

Coupling 

Assembly

305B387S8 1

16 Remove Drain Tube 

Assembly

200-030-0001-501 1

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 4 OF 4)
 FIGURE 9: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 83 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 9: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS 

FWD INBD

UP

B

TUBE CONFIGURATION

TYPICAL DRAIN

B C

C

RIB NO. 9

SEE A

SKIN

LOWER WING

HOUSING

SLAT TRACK

NUMBER 5

FRONT WING SPAR

428.683

OFSS

1

421706

(SHEET 1 OF 4)
 FIGURE 9: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 84 of 141

BOEING SERVICE BULLETIN 767-57A0094

D

D

INBD

FWD

INBD

10.00 (REF)

4 5 7 9 10

A

6

6

(DRAIN TUBE SHOWN BENT)

DRAIN TUBE ATTACHED TO

SLAT TRACK HOUSING

FERRULE

NEW DRAIN TUBE

0.170

NEW

DRAIN TUBE

0.050

3

FERRULE

(2 LOCATIONS,

BEFORE SWAGE)

TYPICAL

DOUBLER

ASSEMBLY

2

0.085

3

RIB NO.9

DRAIN

TUBE

8

0.335

0.085

0.205

0.050

0.300

0.30

+

- 0.05

0.30

+

- 0.05

B-B C-C

D-D

421730

(SHEET 2 OF 4)
 FIGURE 9: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 85 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1

Align Drain Tube 015T1772-2 1 to make one end fully 

agree with the drain tube 

attached to the slat track 

housing.

Measure - (a)

2 Bend - (b)

3 Cut - (c)

4 Deburr - (d)

5

Clean the outer surface to 

remove oil and grease. 

Refer to SOPM 20-30-03 

as an accepted 

procedure.

6

Install (New) Ferrule - Flexible AS1716D08 2 one on each end of the 

drain tube as shown. 

Roller Swage - the drain tube onto each 

ferrule, in accordance 

with Appendix A.

7

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- to the inner and outer 

surface of the drain tube. 

Refer to SOPM 20-43-03 

as an accepted 

procedure.

8 Apply Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (e)

9 Apply Marking - - (f)

10

Apply Part Mark 015T1772-3 - with a rubber stamp to 

reidentify the drain tube. 

Refer to SOPM 20-50-10 

as an accepted 

procedure.

(a) the bend angle necessary to make the other end of the drain tube fully agree with doubler at rib 

no. 9. 

(b) with standard bend radius tools, to agree with the measurements. After the tube is bent, an 

end to end distance tolerance of + or - 0.03 inches is permitted.

(c)

to make one end parallel with the end of the drain tube attached to the slat track housing and 

one end perpendicular with the doubler at rib no. 9. Cut the tube as necessary to keep the 

clearance dimensions at each end of the tube as shown.

(SHEET 3 OF 4)
 FIGURE 9: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 86 of 141

BOEING SERVICE BULLETIN 767-57A0094

(d) Flat deburr and square both drain tube ends to within 0.005 inch. Radius all sharp edges to 

between 0.02 and 0.06 inch.

(e)

to all of the inner surface and the specified area of the outer surface of the drain tube and each 

ferrule. Refer to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures. Do not apply 

BMS 10-20, Type II to the 0.30 dimension shown at the end of the each ferrule.

(f) Apply an arrow that points to rib no. 9, with a rubber stamp to the drain tube outer surface, to 

identify the direction of flow. Refer to SOPM 20-50-10 as an accepted procedure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 4 OF 4)
 FIGURE 10: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 87 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 10: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS 

INBD FWD

UP

TUBE CONFIGURATION

TYPICAL DRAIN

C

C

1

B

B

RIB NO. 9

HOUSING

SLAT TRACK

NUMBER 8

FRONT WING SPAR

428.683

OFSS

SKIN

LOWER WING

SEE A

421956

(SHEET 1 OF 4)
 FIGURE 10: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 88 of 141

BOEING SERVICE BULLETIN 767-57A0094

D

D

INBD

FWD

INBD

DRAIN TUBE ATTACHED TO

SLAT TRACK HOUSING

FERRULE

NEW DRAIN TUBE

NEW

DRAIN TUBE

10.00 (REF)

A

6

6

(DRAIN TUBE SHOWN BENT)

FERRULE

4 9 10

0.050

3

(2 LOCATIONS,

BEFORE SWAGE)

TYPICAL

DOUBLER

ASSEMBLY

2

0.085

3

RIB NO.9

DRAIN

TUBE

0.335

8

5 7

0.050

0.085

0.205

0.300

0.170

0.30

+

- 0.05

0.30

+

- 0.05

B-B

C-C

D-D

421958

(SHEET 2 OF 4)
 FIGURE 10: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 89 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1

Align Drain Tube 015T1772-2 1 to make one end fully 

agree with the drain tube 

attached to the slat track 

housing.

Measure - (a)

2 Bend - (b)

3 Cut - (c)

4 Deburr - (d)

5

Clean - the outer surface to 

remove oil and grease. 

Refer to SOPM 20-30-03 

as an accepted 

procedure.

6

Install (New) Ferrule - Flexible AS1716D08 2 one on each end of the 

drain tube as shown.

Roller Swage - the drain tube onto each 

ferrule, in accordance 

with Appendix A.

7

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- to the inner and outer 

surface of the drain tube. 

Refer to SOPM 20-43-03 

as an accepted 

procedure.

8 Apply Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (e)

9 Apply Marking - - (f)

10

Apply Part Mark 015T1772-3 - with a rubber stamp to 

reidentify the drain tube. 

Refer to SOPM 20-50-10 

as an accepted 

procedure.

(a) the bend angle necessary to make the other end of the drain tube fully agree with doubler at rib 

no. 9. 

(b) with standard bend radius tools, to agree with the measurements. After the tube is bent, an 

end to end distance tolerance of + or - 0.03 inches is permitted.

(c)

to make one end parallel with the end of the drain tube attached to the slat track housing and 

one end perpendicular with the doubler at rib no. 9. Cut the tube as necessary to keep the 

clearance dimensions at each end of the tube as shown.

(SHEET 3 OF 4)
 FIGURE 10: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE - ALL AIRPLANE 

GROUPS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 90 of 141

BOEING SERVICE BULLETIN 767-57A0094

(d) Flat deburr and square both drain tube ends to within 0.005 inch. Radius all sharp edges to 

between 0.02 and 0.06 inch.

(e)

to all of the inner surface and the specified area of the outer surface of the drain tube and each 

ferrule. Refer to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures. Do not apply 

BMS 10-20, Type II to the 0.30 dimension shown at the end of the each ferrule.

(f) Apply an arrow that points to rib no. 9, with a rubber stamp to the drain tube outer surface, to 

identify the direction of flow. Refer to SOPM 20-50-10 as an accepted procedure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 4 OF 4)
 FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 91 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 

AIRPLANES

FWD INBD

UP

RIB NO. 9

SKIN

LOWER WING

HOUSING

SLAT TRACK

NUMBER 5

FRONT WING SPAR

SEE B

SEE C

1

SEE A

21

22

428.683

OFSS

422009

(SHEET 1 OF 6)
 FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 92 of 141

BOEING SERVICE BULLETIN 767-57A0094

A

TRACK HOUSING

NUMBER 5 SLAT

FWD

UP

DRAIN TUBE

17

18

17

20

18

19

15

9

422039

(SHEET 2 OF 6)
 FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 93 of 141

BOEING SERVICE BULLETIN 767-57A0094

RETAINING

7

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.47

0.59

WASHER

RETAINER

13

10

10

14

10

4

8

5 6

GAGE

12

11

8

NEW DRAIN TUBE

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

19 18

17

18

17

20

484579

16

9

(SHEET 3 OF 6)
 FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 94 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

3

8

10

C

14

6

WASHERS

RETAINING

2

422227

ASSEMBLY STIFFENER

DOUBLER

(SHEET 4 OF 6)
 FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 95 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install (New) Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install (New) Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 - to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 2

9 Install (Kept) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 2

15 Install (Kept) Bonding Clamp AN735DC56 1

16 Install (Kept) Bonding Clamp AN735DC8 1

17 Install (Kept) Washer NAS1149D0316H 6

18 Install (Kept) Washer NAS1149D0363H 4

19

Install (Kept) Screw BACS12GU3K6 or 

BACS12GU3K( )

2 Use the same length 

screw that was removed 

before. (h)

20 Install (Kept) Nut BACN10YR3CD 2 (h)

21 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 5 OF 6)
 FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 96 of 141

BOEING SERVICE BULLETIN 767-57A0094

22

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (j)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (k)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the slat track 

housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches away 

from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. 

Refer to SWPM 20-20-00 as an accepted procedure.

(j)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(k)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 6 OF 6)
 FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 97 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 

AIRPLANES

FWD INBD

UP

RIB NO. 9

SKIN

LOWER WING

HOUSING

SLAT TRACK

NUMBER 5

FRONT WING SPAR

SEE B

SEE C

1

SEE A

22

428.683

OFSS

21

422229

(SHEET 1 OF 6)
 FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 98 of 141

BOEING SERVICE BULLETIN 767-57A0094

A

TRACK HOUSING

NUMBER 5 SLAT

FWD

UP

DRAIN TUBE

17

18

17

20

18

19

15

9

422230

(SHEET 2 OF 6)
 FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 99 of 141

BOEING SERVICE BULLETIN 767-57A0094

RETAINING

7

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.47

0.59

WASHER

RETAINER

13

10

10

14

10

4

8

5 6

GAGE

12

11

8

NEW DRAIN TUBE

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

19 18

17

18

17

20

484580

16

9

(SHEET 3 OF 6)
 FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 100 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

3

8

10

C

14

6

WASHERS

RETAINING

2

422231

ASSEMBLY STIFFENER

DOUBLER

(SHEET 4 OF 6)
 FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 101 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install (New) Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install (New) Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 - to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 2

9 Install (Kept) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 2

15 Install (Kept) Bonding Clamp AN735DC56 1

16 Install (Kept) Bonding Clamp AN735DC8 1

17 Install (Kept) Washer NAS1149D0316H 6

18 Install (Kept) Washer NAS1149D0363H 4

19

Install (Kept) Screw BACS12GU3K6 or 

BACS12GU3K( )

2 Use the same length 

screw that was removed 

before. (h)

20 Install (Kept) Nut BACN10YR3CD 2 (h)

21 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 5 OF 6)
 FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 102 of 141

BOEING SERVICE BULLETIN 767-57A0094

22

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (j)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (k)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the slat track 

housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches away 

from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. 

Refer to SWPM 20-20-00 as an accepted procedure.

(j)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(k)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 6 OF 6)
 FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 103 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 

AIRPLANES

FWD INBD

UP

RIB NO. 9

SKIN

LOWER WING

FRONT WING SPAR

SEE B

SEE A

HOUSING

SLAT TRACK

NUMBER 5

428.683

OFSS

1 21

20

422235

(SHEET 1 OF 5)
 FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 104 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

3

8

10

C

19

6

RETAINING

WASHERS

2

STIFFENER

DOUBLER

ASSEMBLY

422236

(SHEET 2 OF 5)
 FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 105 of 141

BOEING SERVICE BULLETIN 767-57A0094

RETAINING

7

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.47

0.59

WASHER

RETAINER

13

10

10

14

10

4

8

5 6

GAGE

18

17

11

12

16

16

16

19

TUBE

NEW DRAIN

9

15

9

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

422234

(SHEET 3 OF 5)
 FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 106 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install (New) Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install (New) Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 - to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 1

9 Install (New) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 1

15 Install (Kept) Bonding Clamp AN735DC8 1

16 Install (Kept) Washer NAS1149D0316H 3

17 Install (Kept) Washer NAS1149D0363H 2

18

Install (Kept) Screw BACS12GU3K9 or 

BACS12GU3K( )

1 Use the same length 

screw that was removed 

before. (h)

19 Install (Kept) Nut BACN10YR3CD 2 (h)

20 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 4 OF 5)
 FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 107 of 141

BOEING SERVICE BULLETIN 767-57A0094

21

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (j)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (k)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is 

attached to the slat track housing. Make sure each of the probes of the multimeter are a 

minimum of 0.25 inches away from the bonding clamp and bracket. Electrical resistance must 

not be more than 0.010 ohms. Refer to SWPM 20-20-00 as an accepted procedure.

(j)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(k)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 5 OF 5)
 FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 108 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 

AIRPLANES

FWD INBD

UP

RIB NO. 9

SKIN

LOWER WING

FRONT WING SPAR

SEE B

SEE A

HOUSING

SLAT TRACK

NUMBER 5 428.683

OFSS

1 21

20

422241

(SHEET 1 OF 5)
 FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 109 of 141

BOEING SERVICE BULLETIN 767-57A0094

FWD INBD

UP

FWD

3

8

10

C

19

6

RETAINING

WASHERS

2

STIFFENER

DOUBLER

ASSEMBLY

422243

(SHEET 2 OF 5)
 FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 110 of 141

BOEING SERVICE BULLETIN 767-57A0094

RETAINING

7

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.47

0.59

WASHER

RETAINER

13

10

10

14

10

4

8

5 6

GAGE

18

17

11

12

16

16

16

19

9

TUBE

NEW DRAIN

15

9

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

422242

(SHEET 3 OF 5)
 FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 111 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the left wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install (New) Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install (New) Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 2 to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 1

9 Install (New) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 1

15 Install (Kept) Bonding Clamp AN735DC8 1

16

Install (Kept) Washer NAS1149D0316H 

or 

NAS1149D0316J

3

17 Install (Kept) Washer NAS1149D0363H 2

18 Install (Kept) Screw BACS12GU3K8 1

19 Install (Kept) Nut BACN10YR3CD 2

20 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 4 OF 5)
 FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 112 of 141

BOEING SERVICE BULLETIN 767-57A0094

21

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (j)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (k)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is 

attached to the slat track housing. Make sure each of the probes of the multimeter are a 

minimum of 0.25 inches away from the bonding clamp and bracket. Electrical resistance must 

not be more than 0.010 ohms. Refer to SWPM 20-20-00 as an accepted procedure.

(j)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(k)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 5 OF 5)
 FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 113 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 

AIRPLANES

INBD FWD

UP

RIB NO. 9

SKIN

LOWER WING

HOUSING

SLAT TRACK

NUMBER 8

FRONT WING SPAR

SEE B

SEE C

1

SEE A

21

22

428.683

OFSS

422605

(SHEET 1 OF 6)
 FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 114 of 141

BOEING SERVICE BULLETIN 767-57A0094

15

A

TRACK HOUSING

NUMBER 8 SLAT

FWD

UP

DRAIN TUBE

17

18

17

20

18

19

9

422606

(SHEET 2 OF 6)
 FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 115 of 141

BOEING SERVICE BULLETIN 767-57A0094

16

RETAINING

7

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.47

0.59

WASHER

RETAINER

13

10

10

14

10

4

8

5 6

GAGE

12

11

8

NEW DRAIN TUBE

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

19 18

17

18

17

20

9

484587

(SHEET 3 OF 6)
 FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 116 of 141

BOEING SERVICE BULLETIN 767-57A0094

INBD FWD

UP

FWD

3

8

10

C

14

6

WASHERS

RETAINING

2

422607

STIFFENER ASSEMBLY

DOUBLER

(SHEET 4 OF 6)
 FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 117 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install (New) Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install (New) Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 - to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 2

9 Install (Kept) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 2

15 Install (Kept) Bonding Clamp AN735DC56 1

16 Install (Kept) Bonding Clamp AN735DC8 1

17 Install (Kept) Washer NAS1149D0316H 6

18 Install (Kept) Washer NAS1149D0363H 4

19

Install (Kept) Screw BACS12GU3K6 or 

BACS12GU3K( )

2 Use the same length 

screw that was removed 

before. (h)

20 Install (Kept) Nut BACN10YR3CD 2 (h)

21 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 5 OF 6)
 FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 118 of 141

BOEING SERVICE BULLETIN 767-57A0094

22

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (j)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (k)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the slat track 

housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches away 

from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. 

Refer to SWPM 20-20-00 as an accepted procedure.

(j)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(k)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 6 OF 6)
 FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 119 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 

AIRPLANES

INBD FWD

UP

RIB NO. 9

SKIN

LOWER WING

HOUSING

SLAT TRACK

NUMBER 8

FRONT WING SPAR

SEE B

SEE C

1

SEE A

22

428.683

OFSS

21

422608

(SHEET 1 OF 6)
 FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 120 of 141

BOEING SERVICE BULLETIN 767-57A0094

15

A

TRACK HOUSING

NUMBER 8 SLAT

FWD

UP

DRAIN TUBE

17

18

17

20

18

19

9

422609

(SHEET 2 OF 6)
 FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 121 of 141

BOEING SERVICE BULLETIN 767-57A0094

16

RETAINING

7

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.47

0.59

WASHER

RETAINER

13

10

10

14

10

4

8

5 6

GAGE

12

11

8

NEW DRAIN TUBE

HOUSING

SLAT TRACK

ATTACHED TO

DRAIN TUBE

19 18

17

18

17

20

9

484588

(SHEET 3 OF 6)
 FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 122 of 141

BOEING SERVICE BULLETIN 767-57A0094

INBD FWD

UP

FWD

3

9

10

C

14

6

WASHERS

RETAINING

2

422610

STIFFENER ASSEMBLY

DOUBLER

(SHEET 4 OF 6)
 FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 123 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install (New) Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install (New) Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 2 to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 2

9 Install (Kept) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 2

15 Install (Kept) Bonding Clamp AN735DC56 1

16 Install (Kept) Bonding Clamp AN735DC8 1

17 Install (Kept) Washer NAS1149D0316H 6

18 Install (Kept) Washer NAS1149D0363H 4

19

Install (Kept) Screw BACS12GU3K6 or 

BACS12GU3K( )

2 Use the same length 

screw that was removed 

before. (h)

20 Install (Kept) Nut BACN10YR3CD 2 (h)

21 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 5 OF 6)
 FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 124 of 141

BOEING SERVICE BULLETIN 767-57A0094

22

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (l)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (m)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the slat track 

housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches away 

from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. 

Refer to SWPM 20-20-00 as an accepted procedure.

(l)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(m)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 6 OF 6)
 FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 125 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 

AIRPLANES

INBD FWD

UP

RIB NO. 9

SKIN

LOWER WING

FRONT WING SPAR

SEE B

SEE A

HOUSING

SLAT TRACK

NUMBER 8 428.683

OFSS

1 21

20

422611

(SHEET 1 OF 5)
 FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 126 of 141

BOEING SERVICE BULLETIN 767-57A0094

INBD FWD

UP

FWD

3

8

10

A

19

6

RETAINING

WASHERS

2

STIFFENER

DOUBLER

ASSEMBLY

422612

(SHEET 2 OF 5)
 FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 127 of 141

BOEING SERVICE BULLETIN 767-57A0094

RETAINING

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.59

0.47

WASHER

RETAINER

13

10

10

14

4

8

5 6

GAGE

18

19

7

11

12

16

16

10

16

17

NEW DRAIN

TUBE

9

DRAIN TUBE

ATTACHED TO SLAT

TRACK HOUSING

9

15

422613

(SHEET 3 OF 5)
 FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 128 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install (New) Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install (New) Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 2 to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 1

9 Install (New) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 1

15 Install (Kept) Bonding Clamp AN735DC8 1

16 Install (Kept) Washer NAS1149D0316H 3

17 Install (Kept) Washer NAS1149D0363H 2

18

Install (Kept) Screw BACS12GU3K9 or 

BACS12GU3K( )

1 Use the same length 

screw that was removed 

before. (h)

19 Install (Kept) Nut BACN10YR3CD 2 (h)

20 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 4 OF 5)
 FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 129 of 141

BOEING SERVICE BULLETIN 767-57A0094

21

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (j)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (k)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is 

attached to the slat track housing. Make sure each of the probes of the multimeter are a 

minimum of 0.25 inches away from the bonding clamp and bracket. Electrical resistance must 

not be more than 0.010 ohms. Refer to SWPM 20-20-00 as an accepted procedure.

(j)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(k)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 5 OF 5)
 FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 130 of 141

BOEING SERVICE BULLETIN 767-57A0094

FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 

AIRPLANES

INBD FWD

UP

RIB NO. 9

SKIN

LOWER WING

FRONT WING SPAR

SEE B

SEE A

HOUSING

SLAT TRACK

NUMBER 8 428.683

OFSS

1 21

20

422615

(SHEET 1 OF 5)
 FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 131 of 141

BOEING SERVICE BULLETIN 767-57A0094

INBD FWD

UP

FWD

3

8

10

A

19

6

RETAINING

WASHERS

2

STIFFENER

DOUBLER

ASSEMBLY

422619

(SHEET 2 OF 5)
 FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 132 of 141

BOEING SERVICE BULLETIN 767-57A0094

RETAINING

COUPLING

BODY

COUPLING

NUT

B

WASHER

RETAINING

0.59

0.47

WASHER

RETAINER

13

10

10

14

4

8

5 6

GAGE

9

18

19

7

11

12

16

16

10

16

17

NEW DRAIN

TUBE

DRAIN TUBE

ATTACHED TO SLAT

TRACK HOUSING

9

15

422616

(SHEET 3 OF 5)
 FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 133 of 141

BOEING SERVICE BULLETIN 767-57A0094

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

numbers shown below are the number of parts necessary for the right wing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Align Drain Tube 015T1772-3 1 (a)

Install (New) (b)

2

Install Packing, 

Preformed

MS29513-114 1 (c)

3

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (d)

Install (New) Coupling 

Assembly, Half

AS1713D08 1 Engage the coupling nut 

and tighten with your 

hand.

4

Install Packing, 

Preformed

MS29513-114 2 (c)

5

Apply Grease BMS 3-24 (BMS 

3-33 Optional)

- (e)

Install (New) Coupling 

Assembly

AS1712D08 1 (f)

6

Install (New) Wire MS20995AB32 - to safety each coupling. 

Refer to SOPM 20-50-02 

as an accepted 

procedure.

7 Remove Finish - (g)

Install (New) Bonding Clamp AN735DC8 1 (h)

8 Install (New) Bonding Jumper BACJ40A20-8 1

9 Install (New) Bonding Jumper BACJ40A20-8 1

10 Install (New) Washer NAS1149D0316H 4

11 Install (New) Washer NAS1149D0332H 1

12 Install (New) Washer NAS1149D0363H 1

13 Install (New) Screw BACS12HN3-9 1

14 Install (New) Nut BACN10YR3CD 1

15 Install (Kept) Bonding Clamp AN735DC8 1

16

Install (Kept) Washer NAS1149D0316H 

or 

NAS1149D0316J

3

17 Install (Kept) Washer NAS1149D0363H 2

18 Install (Kept) Screw BACS12GU3K8 1

19 Install (Kept) Nut BACN10YR3CD 2

20 Measure Electrical 

Resistance 

Designated Bond 

(Electrostatic)

- (i)

(SHEET 4 OF 5)
 FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIRPLANES

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 134 of 141

BOEING SERVICE BULLETIN 767-57A0094

21

Apply Chemical 

Conversion 

Coating

Alodine 600 

(Alodine 1600/

1660 Optional)

- (j)

Corrosion 

Resistant Finish

BMS 10-20, 

Type II

1 layer (k)

(a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where 

it aligns with the drain tube attached to the slat track housing and the doubler.

(b)

Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube 

attached to the slat track housing and the ferrule of the new drain tube, before the coupling is 

installed.

(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the 

same configuration as shown. 

(d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) 

before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the 

coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.

(f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your 

hand. A correctly tightened coupling will agree with gage tolerance shown.

(g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 

20-20-00 as an accepted procedure.

(h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an 

accepted procedure.

(i)

between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is 

attached to the slat track housing. Make sure each of the probes of the multimeter are a 

minimum of 0.25 inches away from the bonding clamp and bracket. Electrical resistance must 

not be more than 0.010 ohms. Refer to SWPM 20-20-00 as an accepted procedure.

(j)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-43-03 as an accepted procedure.

(k)

if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the 

installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 

20-41-02 and SOPM 20-60-02 as accepted procedures.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 5 OF 5)
 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 135 of 141

BOEING SERVICE BULLETIN 767-57A0094

APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

CLAMPING

FASTENER

FRAME

DIE BLOCK (OR SWAGE BLOCK) HOLDER

STEEL FASTENER

(3 LOCATIONS)

.5000-13 X (LENGTH REQUIRED)

STEEL FASTENER

(2 LOCATIONS)

1309793
 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 136 of 141

BOEING SERVICE BULLETIN 767-57A0094

CLAMPING

FASTENER

FERRULE

SWAGE

GROOVES

FRAME

DIE BLOCK (OR SWAGE BLOCK) HOLDER

DIE BLOCK 

(OR SWAGE BLOCK)

1309931
 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 137 of 141

BOEING SERVICE BULLETIN 767-57A0094

WRENCH

FLATS

EXPANSION

ROLLER

TAPERED

MANDREL

END

TUBE EXPANDER

1309944
 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 138 of 141

BOEING SERVICE BULLETIN 767-57A0094 FERRULE FRAME

DRAINTUBE

TAPEREDMANDREL

WRENCHFLATS

TUBE EXPANDER

DIE BLOCK (OR SWAGE BLOCK) HOLDER

DIE BLOCK (OR SWAGE BLOCK)

WRENCH

1309939
 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 139 of 141

BOEING SERVICE BULLETIN 767-57A0094

The following special tooling is required to roller swage the 015T1772-2 drain tube onto the AS1716D08 

ferrules:

1. Make sure the AS1716D08 ferrule internal swage grooves are free of debris and/or lubricant.

2. Make sure the outside surface of the 015T1772-2 drain tube is free of scratches and/or gouges in the 

swaging areas. Scratches and/or gouges on the drain tube outside surface swaging areas are not 

acceptable. If the drain tube outside surface has a scratch and/or gouge in the swaging area that is deeper 

than 0.001 inch after polishing, the part must be replaced.

3. Make sure the outside surface of the 015T1772-2 drain tube is free of debris and/or lubricant in the swaging 

areas.

4. Attach the ST877W-F frame to a sturdy workbench, if the ST877W-DH-1 die block holder will be installed 

in the frame. Refer to Item 5 below.

5. Install the ST877W-DH-1 die block holder on the ST877W-F frame. Two 0.5000-13 x (length required) steel 

fasteners (operator supplied) are required to secure the die block holder to the frame. Optional to secure 

the die block holder in a sturdy bench vise, instead of on the ST877W-F frame. The 0.5000-13 x (length 

required) steel fasteners are not required if the die block holder is secured in a bench vise, instead of the 

frame. 

Quantity Part Number Description Notes

1 ST877W-F Frame (a)

1 ST877W-DH-1 

(DH6305-1 Optional)

Die Block Holder 

(Swage Block Holder)

(c)

1 ST877W-DF-D-08-1-1 

(ST877W-DF-D-08-1-2 or 

DB6305H8 Optional)

Die Block 

(Swage Block)

(b)

1 ST877W-E-8-035 

(B9108-35 or B8308-35 

Optional)

Tube Expander (d)

1 ST2580-77A-5 Wrench (e)

(a) The use of the ST877W-F Frame is optional. The ST877W-DH-1 die block

 holder (or the DH6305-1swage block holder) may be installed in a sturdy

 bench vise, instead of in the ST877W-F Frame.

(b) Either a ST877W-DF-D-08-1-2 die block (no link installed) or a DB6305H8

 swage block may be used in place of the ST877W-DF-D-08-1-1 die block.

(c) A DH6305-1 swage block holder may be used in place of the ST877W-DH-1

 die block holder.

(d) Either a B9108-35 tube expander or a B8308-35 tube expander may be

 used in place of the ST877W-E-8-035 tube expander

(e) This tool is only compatible with the ST877W-E-8-035 and the B9108-35 tube

 expander. A female 3/8 inch square drive socket can be used for the B8308-35

 expander.
 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 140 of 141

BOEING SERVICE BULLETIN 767-57A0094

6. Clean the ST877W-DF-D-08-1-1 die block halves using Denatured Alcohol and a clean cloth, to ensure the 

die block halves ferrule cavities are free of debris and/or lubricant.

7. Insert the AS1716D08 ferrule into the ST877W-DF-D-08-1-1 die block half cavity and close the die block 

halves.

8. Install the ST877W-DF-D-08-1-1 die block halves (and AS1716D08 ferrule) into the ST877W-DH-1 die 

block holder. The flanged end of the AS1716D08 ferrule must be located adjacent to the die block stop in 

the die block holder. Align the die block split lines approximately perpendicular to the die block holder split 

line.

9. Torque the ST877W-DH-1 die block holder clamping fastener to 100 foot-pounds. Make sure the ST877WDF-D-08-1-1 die block halves are fully against the die block holder stop, prior to torque application.

10. Clean the rollers and to the tapered mandrel of the ST877W-E-8-035 tube expander, using Denatured 

Alcohol solvent and a clean cloth.

11. Apply SAE No. 10 automotive engine oil lubricant to the rollers and to the tapered end of the ST877W-E8-035 tube expander. Optional to use Masterdraw B1767C lubricant.

NOTE: Any SAE "10W-xx" (10W-20, 10W-30, 10W-40, etc) automotive engine oil is an acceptable

substitute for SAE No.10 automotive engine oil.

12. Insert the 015T1772-2 drain tube into the AS1716D08 ferrule until it contacts the ferrule tube stop. Hold the 

drain tube squarely against the ferrule tube stop until the swage process is completed.

13. Insert the ST877W-E-8-035 tube expander into ST877W-DF-D-08-1-1 die block, opposite the 015T1772-

2 drain tube.

14. Push the exposed end of the mandrel towards the ST877W-E-8-035 tube expander body and rotate the 

mandrel by hand clockwise, to start the tube expander self-feeding action.

15. Install either a ST2580-77A-5 wrench or a female 3/8 inch square drive socket (as applicable), on the end 

of the tube expander mandrel.

16. Torque the ST2580-77A-5 wrench (or female 3/8 inch square drive socket) to 16 - 20 inch-pounds. The 

mandrel end will advance into the tube expander body as it rotates. Ten or more complete turns of the 

wrench may be necessary to reach the required torque.

17. Rotate the mandrel counterclockwise to loosen and remove the ST877W-E-8-035 tube expander.

18. Loosen the ST877W-DH-1 die block holder clamping fastener to remove the ST877W-DF-D-08-1-1 die 

block and swaged drain tube/ferrule.

19. Remove the swaged drain tube/ferrule from the ST877W-DF-D-08-1-1 die block halves.

20. Remove lubricant residue from the swaged drain tube/ferrule with a clean cloth.

21. Do a General Visual Inspection of the swaged joint, to check for die parting-line welts on the external 

AS1716D08 ferrule surfaces. External die parting-line welts exceeding 0.002 inch height on O-ring sealing 

areas, or 0.004 inch height in non-seal areas, are not acceptable and the parts must be replaced.
 APPENDIX A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS

Original Issue: June 02, 2005

Revision 2: December 17, 2009 767-57A0094

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 141 of 141

BOEING SERVICE BULLETIN 767-57A0094

22. Do a General Visual Inspection of the swaged joint, to check for 015T1772-2 drain tube extrusion beyond 

the AS1716D08 ferrule flange end face. Drain tube extrusion beyond the ferrule flange end face is not 

acceptable and the parts must be replaced.

23. Do a General Visual Inspection of the swaged joint, to check for signs of AS1716D08 ferrule flange 

shearing, due to linear tubing expansion from the roller swage process. Ferrule flange shearing is not 

acceptable and the parts must be replaced.

24. Do a General Visual Inspection of the swaged joint, to check for scratches and/or die marks on the 

AS1716D08 ferrule flange. Scratches and/or die marks on the ferrule flange are not acceptable and the 

parts must be replaced.

25. Do a General Visual Inspection of the swaged joint, to check for visible gaps between the AS1716D08 

ferrule tube stop and the end of the 015T1772-2 drain tube. Visible gaps between the ferrule stop and the 

end of the drain tube are not acceptable and the parts must be replaced.

26. Do a General Visual Inspection of the swaged joint, to check for longitudinal AS1716D08 ferrule cracks. 

Longitudinal ferrule cracks are not acceptable and the parts must be replaced.