Original Issue: June 02, 2005 Revision 2: December 17, 2009 767-57A0094 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 141 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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PAGE** Original Issue: June 02, 2005 Revision 2: December 17, 2009 767-57A0094 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 141 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of Contents** Original Issue: June 02, 2005 Revision 2: December 17, 2009 767-57A0094 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 141 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 . . . . . . . . . . . . . . . . . . . 135Original 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, 2009Original 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 slattrack 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 20Original 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 A SEE383964Original 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–VS293Original 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 VR426Original 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–VL873Original 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 VE063Original 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–VB330Original 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 VL931Original 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 VA020Original 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–VE152Original 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 1Original 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 necessaryOriginal 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 57-21Original 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 PAGEOriginal 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 9Original 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**  **Name Existing Part Number Notes -1**  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 TANKOriginal 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 BAYOriginal 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 TANKOriginal 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 BAYOriginal 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 TANKOriginal 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 BAYOriginal 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 TANKOriginal 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 A SEE

RIB NO. 9



### A D SEE

LOWER SKIN NUMBER 5 SLAT TRACK HOUSING FRONT SPAR

C SEE B SEE421354

**(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 3 2



### B 17 DOUBLER ASSEMBLY STIFFENER421361

**(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 6421494

**(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 A SEE

RIB NO. 9



### A D SEE

LOWER SKIN HOUSING SLAT TRACK FRONT SPAR

C SEE B SEE NUMBER 5421499

**(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 3 2



### B 17 DOUBLER ASSEMBLY STIFFENER421500

**(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 6421511

**(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 A SEE

RIB NO. 9

LOWER SKIN HOUSING SLAT TRACK FRONT SPAR

C SEE B SEE



### A NUMBER 5421517

**(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 9 2



### B 16 DOUBLER ASSEMBLY STIFFENER421519

**(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

8421530

**(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 A SEE

RIB NO. 9



### A LOWER SKIN HOUSING SLAT TRACK NUMBER 5 FRONT SPAR

C SEE B SEE421550

**(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 STIFFENER421551

**(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 8421552

**(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** 

FWD INBD UP A SEE

RIB NO. 9



### A D SEE

LOWER SKIN NUMBER 8 SLAT TRACK HOUSING FRONT SPAR

C SEE B SEE421557

**(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 3 2



### B 17 11 DOUBLER ASSEMBLY
STIFFENER421675

**(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 6421676

**(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** 

A SEE

RIB NO. 9



### A D SEE

LOWER SKIN NUMBER 8 SLAT TRACK HOUSING FRONT SPAR

C SEE B SEE

FWD INBD UP421679

**(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 3 2



### B 17 11 DOUBLER ASSEMBLY
STIFFENER421680

**(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 6421681

**(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** 

FWD INBD UP A SEE

RIB NO. 9

WING LOWER SKIN HOUSING SLAT TRACK NUMBER 8 FRONT SPAR

C SEE B SEE



### A421683

**(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 9 2



### B 16 11 DOUBLER ASSEMBLY
STIFFENER421684

**(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

8421685

**(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** 

FWD INBD UP A SEE

RIB NO. 9



### A LOWER SKIN HOUSING SLAT TRACK NUMBER 8 FRONT SPAR

C SEE B SEE421691

**(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
STIFFENER421696

**(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 7421698

**(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

A SEE

SKIN LOWER WING HOUSING SLAT TRACK NUMBER 5 FRONT WING SPAR

428.683

OFSS

1421706

**(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)

5 7 9 10 4



### 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-D421730

**(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 SL AT TRACK HOUSING - PREPARE - ALL AIRPLANE**  **GROUPS**

FWD INBD 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 A SEE421956

**(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 9 10 4

0.050

3 (2 LOCATIONS, BEFORE SWAGE) TYPICAL DOUBLER ASSEMBLY 2

0.085

3 RIB NO.9 DRAIN TUBE

0.335 8

7 5

0.050

0.085 0.205 0.300

0.170 0.30 +

- 0.05 0.30 +

- 0.05



### B-B C-C D-D421958

**(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 AIR**  **PLANES** 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

B SEE C SEE 1

A SEE 21 22 428.683

OFSS422009

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

9422039

**(SHEET 2 OF 6) FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIR**  **PLANES** 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 20484579 16 9

**(SHEET 3 OF 6) FIGURE 11: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIR**  **PLANES** 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 2422227 STIFFENER ASSEMBLY DOUBLER

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

B SEE C SEE 1

A SEE 22 428.683

OFSS

21422229

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

9422230

**(SHEET 2 OF 6) FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIR**  **PLANES** 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 20484580 16 9

**(SHEET 3 OF 6) FIGURE 12: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIR**  **PLANES** 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 2422231 STIFFENER ASSEMBLY DOUBLER

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

B SEE A SEE HOUSING SLAT TRACK NUMBER 5 428.683

OFSS

21 1

20422235

**(SHEET 1 OF 5) FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIR**  **PLANES** 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 ASSEMBLY422236

**(SHEET 2 OF 5) FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIR**  **PLANES** 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 TUBE422234

**(SHEET 3 OF 5) FIGURE 13: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIR**  **PLANES** 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 AIR**  **PLANES** 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 AIR**  **PLANES** 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

B SEE A SEE HOUSING SLAT TRACK NUMBER 5 428.683

OFSS

21 1

20422241

**(SHEET 1 OF 5) FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIR**  **PLANES** 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 ASSEMBLY422243

**(SHEET 2 OF 5) FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIR**  **PLANES** 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 TUBE422242

**(SHEET 3 OF 5) FIGURE 14: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIR**  **PLANES** 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 AIR**  **PLANES** 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 AIR**  **PLANES** 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** 

FWD INBD UP RIB NO. 9

SKIN LOWER WING HOUSING SLAT TRACK NUMBER 8 FRONT WING SPAR

B SEE C SEE 1

A SEE 21 22 428.683 OFSS422605

**(SHEET 1 OF 6) FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIR**  **PLANES** 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

9422606

**(SHEET 2 OF 6) FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIR**  **PLANES** 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 9484587

**(SHEET 3 OF 6) FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIR**  **PLANES** 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

FWD INBD UP FWD 3

8 10



### C 14

6

WASHERS RETAINING 2422607 STIFFENER ASSEMBLY DOUBLER

**(SHEET 4 OF 6) FIGURE 15: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 1 AIR**  **PLANES** 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 AIR**  **PLANES** 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 AIR**  **PLANES** 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** 

FWD INBD UP RIB NO. 9

SKIN LOWER WING HOUSING SLAT TRACK NUMBER 8 FRONT WING SPAR

B SEE C SEE 1

A SEE 22 428.683 OFSS

21422608

**(SHEET 1 OF 6) FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIR**  **PLANES** 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

9422609

**(SHEET 2 OF 6) FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIR**  **PLANES** 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 9484588

**(SHEET 3 OF 6) FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIR**  **PLANES** 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

FWD INBD UP FWD 3

9 10



### C 14

6

WASHERS RETAINING 2422610 STIFFENER ASSEMBLY DOUBLER

**(SHEET 4 OF 6) FIGURE 16: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 2 AIR**  **PLANES** 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 AIR**  **PLANES** 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 AIR**  **PLANES** 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** 

FWD INBD UP RIB NO. 9

SKIN LOWER WING FRONT WING SPAR

B SEE A SEE HOUSING SLAT TRACK NUMBER 8 428.683 OFSS

21 1

20422611

**(SHEET 1 OF 5) FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIR**  **PLANES** 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

FWD INBD UP FWD 3

8 10



### A 19

6

RETAINING WASHERS 2 STIFFENER DOUBLER ASSEMBLY422612

**(SHEET 2 OF 5) FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIR**  **PLANES** 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 15422613

**(SHEET 3 OF 5) FIGURE 17: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 3 AIR**  **PLANES** 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 AIR**  **PLANES** 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 AIR**  **PLANES** 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** 

FWD INBD UP RIB NO. 9

SKIN LOWER WING FRONT WING SPAR

B SEE A SEE HOUSING SLAT TRACK NUMBER 8 428.683 OFSS

21 1

20422615

**(SHEET 1 OF 5) FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIR**  **PLANES** 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

FWD INBD UP FWD 3

8 10



### A 19

6

RETAINING WASHERS 2 STIFFENER DOUBLER ASSEMBLY422619

**(SHEET 2 OF 5) FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIR**  **PLANES** 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 15422616

**(SHEET 3 OF 5) FIGURE 18: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - INSTALL - GROUP 4 AIR**  **PLANES** 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 AIR**  **PLANES** 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 EXPANDER1309944**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 767-57A0094FERRULEFRAMEDRAINTUBETAPEREDMANDRELWRENCHFLATSTUBE EXPANDERDIE BLOCK (OR SWAGE BLOCK) HOLDERDIE BLOCK (OR SWAGE BLOCK)WRENCH1309939**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.