### Commercial **Airplanes** 

# 777

Service Bulletin **Number: 777-57A0097**  Original Issue: January 10, 2014 Revision 1: May 04, 2015 ATA System: 5720 **SUBJECT:** WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection

and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 1of49 4.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 2of49 **BOEING SERVICE BULLETIN 777-57A0097**

BLANK PAGE**Table of Contents**

Revision Transmittal Sheet

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 H. Weight and Balance Changes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 I. Electrical Load Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 J. References

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Existing Data:

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L. Interchangeability and Intermixability of Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 M. Software Accomplishment Summary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2. MATERIAL INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. Material - Price and Availability

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Industry Support Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Parts Necessary for Each Airplane

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1. Kits/Parts

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

. . . . . . . . . . . . . . . . . . . . . . . . 19 3. Parts Modified and Reidentified

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4. Parts Removed and Not Replaced

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Parts Necessary to Change Spares

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

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

. . . . . . . . . . . . . . . . . . . . . . . 20 3. ACCOMPLISHMENT INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION[Group 1, 3]

. . . . . . 26 FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION[Group 2-3]

. . . . . . 30 FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR[Group 1, 3]

. . . . . . . . . 34 FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR[Group 2-3]

. . . . . . . . . 37 FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION[Group 1, 3]

. . . . 40 FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION[Group 2-3]

. . . . 43 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED INSPECTION

INTERVALS FOR MISSING SEALANT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 APPENDIX B: SEALANT REMOVAL TOOLS AND PROCEDURES

. . . . . . . . . . . . . . . . . . . . . 48

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 3of49 **BOEING SERVICE BULLETIN 777-57A0097**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 4of49 **BOEING SERVICE BULLETIN 777-57A0097**

BLANK PAGE

### Commercial **Airplanes** 

# 777

Service Bulletin **Revision Transmittal Sheet Number:**  **777-57A0097** Original Issue: January 10, 2014 Revision 1: May 04, 2015 ATA System: 5720 **SUBJECT:** WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection

and Repair This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** Effects of this Revision on airplanes on which Original Issue was previously done: None. **REASON FOR REVISION** This revision is sent to add the reference to the related Notice of Proposed Rule Making (NPRM), clarify the method of sealant removal from the wing skin panel gaps using solvent and add compliance logic diagram. These sections were changed: 1. Summary Compliance - deleted the Airworthiness Directive (AD) statement and added the reference to the related Notice of Proposed Rule Making (NPRM). 2. Paragraph 1.A.1., Airplanes - listed the affected line numbers. 3. Paragraph 1.C., Reason - added Revision 1 information. 4. Paragraph 1.D., Description - added Revision 1 information. 5. Paragraph 1.E., Compliance - deleted the Airworthiness Directive (AD) statement and added the reference to the related Notice of Proposed Rule Making (NPRM). 6. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - added ketone solvent. 7. Paragraph 1.J.1., Existing Data - updated the reference list. 8. Figures 1 and 2 - deleted the procedure reference from the More Data column in steps 1 and 2, specified the use of ketone solvent in footnote (a), and corrected a typographical error in footnote (b). 9. Figures 3 and 4 - added missing "-" in the QTY column in steps 3, 5 and 6. 10. Figures 5 and 6 - deleted the procedure reference from the More Data column in step 1, deleted the reference to borescope and Remote Visual Inspection, and changed "borescope" to "inspection tool" in the More Data column in step 2, and specified the use of ketone solvent in footnote (a).

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 5of4911. Appendix A - added new Appendix A with compliance logic diagram.

12. Appendix B - clarified that the information in this appendix is optional. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes. Pages with no vertical lines have no changes. **REVISION HISTORY** January 10, 2014 Original Issue: May 04, 2015 Revision 1:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 6of49 **BOEING SERVICE BULLETIN 777-57A0097**

### Commercial **Airplanes** 

# 777

Service Bulletin

**Summary Number:**  **777-57A0097** Original Issue: January 10, 2014 Revision 1: May 04, 2015 ATA System: 5720 **SUBJECT:** WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection

and Repair **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Accomplishment of this service bulletin will find if sealant was applied to the wing skin panel gaps above the underwing fittings. Missing sealant in the wing skin panel gaps above the underwing fittings can allow undetected corrosion to develop in the wing skin panels above the underwing fittings. Undetected corrosion in the wing skin panels above the underwing fittings can result in undetected fatigue cracks in the wing skin panels. Undetected fatigue cracks in the wing skin panels can result in the loss of limit load capability of the wing skins and structural failure of the wings. Boeing found that sealant may not have been applied in production to the wing skin panel gaps above the underwing fittings on certain underwing fittings on certain 777 airplanes. Sealant is required to be applied to the wing skin panel gaps above the underwing fittings prior to installation of the underwing fittings. A review of Boeing installation records found that sealant may not have been applied above certain underwing fittings on certain previously delivered and in-production 777 airplanes. The affected in-production 777 airplanes have been inspected to make sure sealant is applied to the wing skin panel gaps above the underwing fittings. Production installation procedures have also been addressed to make sure sealant is applied to the wing skin panel gaps above the underwing fittings on future 777 production airplanes. This service bulletin gives instructions to inspect and restore the sealant in the wing skin panel gaps above the underwing fittings. If sealant is missing, this service bulletin also gives instructions to inspect for corrosion in the wing skin panels gaps to prevent possible fatigue cracks in the wing skin panels, loss of limit load capability of the wing skins and potential subsequent structural failure of the wings. Boeing Fleet Team Digest (FTD)777 FTD 57-13003is related to this service bulletin. Boeing Service Related Problem (SRP) 777-SRP-57-0265is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information. **Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 7of49**Reference Affected**  **Planning Data** Paragraph 1.E., Complianceand Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service BulletinandAPPENDIX Bfor additional optional tool information. No Special Tooling Required

**ACTION** Do a Detailed Inspection (DET) of the wing skin panel gaps above the underwing fittings for any missing sealant, on the left wing (applicable to Groups 1,3) and on the right wing (applicable to Groups 2-3). If sealant is missing, do a DET of the wing skin panel gaps above the underwing fittings for corrosion. If any corrosion is found, contact Boeing for repair instructions, do the repair, and restore the missing sealant and the sealant that was previously removed to gain inspection access. If no corrosion is found, restore the missing sealant and the sealant that was previously removed to gain inspection access. If sealant is not missing, restore the sealant that was previously removed to gain inspection access. **EFFECTIVITY** 777-200/-200LR/-300ER, 777F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. **COMPLIANCE** Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2014-NM-033-ADis related to this service bulletin. Refer to Paragraph 1.E., Compliance

. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of August 7, 2013. Please refer toParagraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 8of49 **BOEING SERVICE BULLETIN 777-57A0097 MANPOWER**  **Elapsed Hours**  **Total Task**  **Hours Airplanes** 

15.85 51.85 Group 1 and Group 2 Airplanes 19.70 103.70 Group 3 Airplanes **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability

.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 9of49 **BOEING SERVICE BULLETIN 777-57A0097**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 10of49 **BOEING SERVICE BULLETIN 777-57A0097**

### Commercial **Airplanes** 

# 777

Service Bulletin **Number: 777-57A0097**  Original Issue: January 10, 2014 Revision 1: May 04, 2015 ATA System: 5720 **SUBJECT:** WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection

and Repair **1. PLANNING INFORMATION A.**  **Effectivity** 1. Airplanes This service bulletin is applicable to 777-200/-200LR/-300ER, 777F Airplanes, line numbers 1038-1042, 1045-1047, 1049-1055, 1057-1059, 1064-1068, 1070-1071, 1073, 1075-1076, 1078, 1080-1082, 1084-1086, 1088-1094, 1096, 1098-1099, 1101, 1103-1106, 1108-1109, 1111, 1114-1116, 1119 in 3 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below. Refer toService Bulletin Index D624W001Part 3 for Airplane Variable Number, Line Number, and Serial Number data. **DESCRIPTION CONFIGURATION**  **GROUP** 777-200/-200LR/-300ER and 777F airplanes that require inspection for missing sealant on the left wing only. - 1 777-300ER and 777F airplanes that require inspection for missing sealant on the right wing only. - 2 777-300ER and 777F airplanes that require inspection for missing sealant on both the left and the right wings. - 3

Airplane Models: 777-200, 777-200LR, 777-300ER, 777F **Group Variable Number**  1 WC593 1 WD106 2 WD889

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 11of49**Group Variable Number**  1 WD890 - WD892 1 WD918 1 WD923 - WD925 1 WD927 2 WD928 1 WD941 - WD943 1 WD956 - WD957 1 WD993 1 WE094 1 WE141 1 WE159 - WE164 1 WE203 3 WE206 1 WE207 - WE208 1 WE240 1 WE242 - WE243 2 WE262 1 WE263 - WE265 1 WE272 3 WE273 1 WE274 1 WE276 1 WE301 1 WE303 - WE304 1 WE307 1 WE331 1 WE333 1 WE351 1 WE416 1 WF035 3 WF037 1 WF038 2 WF062

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 12of49 **BOEING SERVICE BULLETIN 777-57A0097 Group**  **Variable Number** 1 WF064 1 WF146 - WF147 1 WF152 2. Spares Affected None. **B. Concurrent Requirements**  None. **C. Reason**  Accomplishment of this service bulletin will find if sealant was applied to the wing skin panel gaps above the underwing fittings. Missing sealant in the wing skin panel gaps above the underwing fittings can allow undetected corrosion to develop in the wing skin panels above the underwing fittings. Undetected corrosion in the wing skin panels above the underwing fittings can result in undetected fatigue cracks in the wing skin panels. Undetected fatigue cracks in the wing skin panels can result in the loss of limit load capability of the wing skins and structural failure of the wings. Boeing found that sealant may not have been applied in production to the wing skin panel gaps above the underwing fittings on certain underwing fittings on certain 777 airplanes. Sealant is required to be applied to the wing skin panel gaps above the underwing fittings prior to installation of the underwing fittings. A review of Boeing installation records found that sealant may not have been applied above certain underwing fittings on certain previously delivered and in-production 777 airplanes. The affected in-production 777 airplanes have been inspected to make sure sealant is applied to the wing skin panel gaps above the underwing fittings. Production installation procedures have also been addressed to make sure sealant is applied to the wing skin panel gaps above the underwing fittings on future 777 production airplanes. This service bulletin gives instructions to inspect and restore the sealant in the wing skin panel gaps above the underwing fittings. If sealant is missing, this service bulletin also gives instructions to inspect for corrosion in the wing skin panels gaps to prevent possible fatigue cracks in the wing skin panels, loss of limit load capability of the wing skins and potential subsequent structural failure of the wings. Boeing Fleet Team Digest (FTD) 777 FTD 57-13003is related to this service bulletin. Boeing Service Related Problem (SRP)777-SRP-57-0265is related to this service bulletin. Revision 1 is sent to add the reference to the related Notice of Proposed Rule Making (NPRM), clarify the method of sealant removal from the wing skin panel gaps using solvent and add compliance logic diagram.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 13of49 **BOEING SERVICE BULLETIN 777-57A0097 D.**  **Description**

Do a Detailed Inspection (DET) of the wing skin panel gaps above the underwing fittings for any missing sealant, on the left wing (applicable to Groups 1,3) and on the right wing (applicable to Groups 2-3). If sealant is missing, do a DET of the wing skin panel gaps above the underwing fittings for corrosion. If any corrosion is found, contact Boeing for repair instructions, do the repair, and restore the missing sealant and the sealant that was previously removed to gain inspection access. If no corrosion is found, restore the missing sealant and the sealant that was previously removed to gain inspection access. If sealant is not missing, restore the sealant that was previously removed to gain inspection access. Effects of this Revision on airplanes on which Original Issue was previously done: None. The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1: Affected Maintenance Zones**  **Zone Model**  533 777-200, 777-200LR, 777- 300ER, 777F **Group 2: Affected Maintenance Zones**  **Zone Model**  633 777-300ER, 777F **Group 3: Affected Maintenance Zones**  **Zone Model**  533, 633 777-300ER, 777F **E. Compliance**  Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2014-NM-033-ADis related to this service bulletin. The Conditions, Actions and Compliance times shown apply to each wing panel gap location independently. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 14of49 **BOEING SERVICE BULLETIN 777-57A0097 Table 1: Detailed Inspection Intervals for Missing Sealant**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 

- Within 4000 flight cy- cles or 750 days, whichever occurs first, after the original issue date of this service bulletinWithin 6000 flight cycles or 1500 days, whichever occurs first, from the date ofissuance of the original certificate of airworthiness or theoriginal export certificate of airworthiness. Do PART 1: WING SKIN PANEL GAPS - DETAILEDSEALANT INSPECTION for missing sealant in the wing skin panel gaps above the underwing fittings. All Airplanes

- - Before further flight. Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action) CONDITION 1: NO MISSING SEALANT FOUND

- - Before further flight. Do PART 3: WING SKIN PANEL GAPS- DETAILED CORROSION INSPECTION for corrosion in the wing skin panel gaps above the underwing fittings. CONDITION 2: MISSING SEALANT FOUND

- - Before further flight. ACTION 1: ContactBoeing for repair instructions and do the repair. CONDITION 3: ANY CORROSION FOUND ACTION 2: Do PART

2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action)

- - Before further flight. Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action) CONDITION 4: NO CORROSION FOUND

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 15of49 **BOEING SERVICE BULLETIN 777-57A0097 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. **G. Manpower**  The table below shows an estimate of the task hours necessary to do this inspection for each wing panel gap location in the area of the underwing fittings. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:

• Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **Group 1: Table 1: Manpower Information for Group 1 Airplanes**  **Elapsed Hours Task Hours**  **Number of Persons Task**  6.00 24.00 4 Open Access 1.75 1.75 1 FIGURE 1 1.00 1.00 1 FIGURE 3 1.10 1.10 1 FIGURE 5 6.00 24.00 4 Close Access 15.85 51.85 TOTAL FOR EACH AIRPLANE **Group 2: Table 2: Manpower Information for Group 2 Airplanes**  **Elapsed Hours Task Hours**  **Number of Persons Task**  6.00 24.00 4 Open Access 1.75 1.75 1 FIGURE 2 1.00 1.00 1 FIGURE 4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 16of49 **BOEING SERVICE BULLETIN 777-57A0097 Group 2:**  **Table 2: Manpower Information for Group 2 Airplanes Elapsed Hours**  **Task Hours Number of Persons**  **Task** 1.10 1.10 1 FIGURE 6 6.00 24.00 4 Close Access 15.85 51.85 TOTAL FOR EACH AIRPLANE **Group 3: Table 3: Manpower Information for Group 3 Airplanes**  **Elapsed Hours Task Hours**  **Number of Persons Task**  6.00 48.00 8 Open Access 1.75 1.75 1 FIGURE 1 1.75 1.75 1 FIGURE 2 1.00 1.00 1 FIGURE 3 1.00 1.00 1 FIGURE 4 1.10 1.10 1 FIGURE 5 1.10 1.10 1 FIGURE 6 6.00 48.00 8 Close Access 19.70 103.70 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes**  None. **I. Electrical Load Data**  Not changed. **J. References**  1. Existing Data:
a. Boeing Service Letter777-SL-51-013 b. Boeing Service Related Problem (SRP)777-SRP-57-0265
c. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM) 2014-NM-033-AD d. Service Bulletin Index D624W001
e. Standard Overhaul Practices Manual (SOPM)20-30-03,20-43-03,20-50-01,20-50-19 , 20-60-01

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 17of49 **BOEING SERVICE BULLETIN 777-57A0097**f. Standard Wiring Practices Manual (SWPM)20-10-11,20-10-12,20-10-19 g. 777 Aircraft Maintenance Manual (AMM)54-52-04,78-11-02 h. 777 Fleet Team Digest (FTD)57-13003 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: **Title Drawing Number**  Nacelle Support Installation - Lower Panel 112W7000 The table above lists applicable drawing used to prepare this service bulletin. The drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. The drawing may not be applicable to all airplane configurations or operators. **K. Publications Affected**  1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary. **L. Interchangeability and Intermixability of Parts**  Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. **M. Software Accomplishment Summary**  Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 18of49 **BOEING SERVICE BULLETIN 777-57A0097 2. MATERIAL INFORMATION**  **A. Material - Price and Availability**  None. **B. Industry Support Information**  Boeing warranty remedies are available for 777 airplanes in warranty as of August 7, 2013. For inspection labor task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Warranty & Product Assurance Contracts. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours are required, send a warranty claim to Boeing Warranty & Product Assurance Contracts. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. The warranty remedies will expire eight years from the original issue date of this service bulletin. **C. Parts Necessary for Each Airplane**  1. Kits/Parts None. 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. **Notes Name**  **QTY Part Number /**  **Specification** (a) Methyl Ethyl Ketone (MEK) (or Methyl Isobutyl Ketone (MIBK) or Methyl Propyl Ketone (MPK)) - SOPM 20-60-01
(a) Sealant 1 Qt BMS 5-95 (a) Primer 8 Oz BMS 10-79, Type III (a) Corrosion Inhibiting Compound 8 Oz SOPM 20-43-03 (a) Enamel 8 Oz BMS 10-60, Type II (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 19of49 **BOEING SERVICE BULLETIN 777-57A0097 D.**  **Parts Necessary to Change Spares**

None. **E. Special Tooling - Price and Availability**  None. **F. Special Tooling Necessary to do this Service Bulletin**  No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. Refer toAPPENDIX Bfor optional tools that Boeing used to do this rework.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 20of49 **BOEING SERVICE BULLETIN 777-57A0097 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION**  **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 777 Structural Repair Manual, Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 777 Airplane Maintenance Manual (AMM).

— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).

— Values for engine maintenance tasks are included in Chapter 70 of 777 Airplane Maintenance Manual (AMM).

— Non-standard torque values for maintenance tasks are included in the applicable installation step.
4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51. 5. Refer to theSWPM 20-10-11andSWPM 20-10-12for the wire installation procedures,

andSWPM 20-10-19for the wire separation requirements, as accepted procedures. 6. The necessary conditions for selection of clamp type and size are included inSWPM 20-10-12. If any wire bundle support clamp specified in this service bulletin does not make a correct fit on the wire bundle, refer to SWPM 20-10-12as an accepted procedure to select a clamp that fits correctly. 7. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer toSOPM 20-50-01for alternate full threaded fasteners (screws) needed for installation in this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 21of49 **BOEING SERVICE BULLETIN 777-57A0097**8. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 9. 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. 10. Boeing Service Letter777-SL-51-013, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 11. Refer toAPPENDIX Bfor information on tools and procedures used by Boeing for the production rework equivalent to this Service Bulletin. 12. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 13. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 14. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 15. If shading is used, shaded areas in Figures are to separate the non-critical and non-authoritative information from the critical and authoritative information. 16. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 17. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance

. 18. The CONDITIONS, ACTIONS and OPTIONS shown apply to each wing panel gap location independently.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 22of49 **BOEING SERVICE BULLETIN 777-57A0097**19. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC must be done to comply with the AD. Alternative procedures for steps not identified with RC can be used if the RC steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. **B. WORK INSTRUCTIONS**  1. Do PART 1: WING SKIN PANEL GAPS - DETAILED SEALANT INSPECTION for missing sealant in the wing skin panel gaps above the underwing fittings.
**CONDITION 1: NO MISSING SEALANT FOUND**
a. Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action). **CONDITION 2: MISSING SEALANT FOUND**
a. Do PART 3: WING SKIN PANEL GAPS - DETAILED CORROSION INSPECTION for corrosion in the wing skin panel gaps above the underwing fittings. **CONDITION 3: ANY CORROSION FOUND** (1) ACTION 1: Contact Boeing for repair instructions and do the repair. (2) ACTION 2: Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action). **CONDITION 4: NO CORROSION FOUND** (1) Do PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION (Terminating Action). **PART 1: WING SKIN PANEL GAPS - DETAILED SEALANT INSPECTION** 1. Remove the aft fairing. Refer to 777 AMM 54-52-04as an accepted procedure. **NOTE:** It is recommended to remove the aft turbine exhaust plug before the removal of the aft fairing, to prevent any damage to the aft turbine exhaust plug. Refer to777 AMM 78-11-02 as an accepted procedure. 2. RC - Do a Detailed Inspection (DET) for missing sealant in the wing skin panel gaps above the underwing fittings in accordance with the figures below:

**Group 1: Right Wing**  **Left Wing**

- FIGURE 1

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 23of49 **BOEING SERVICE BULLETIN 777-57A0097 Group 2:**  **Right Wing Left Wing**  FIGURE 2
- **Group 3: Right Wing**  **Left Wing** FIGURE 2 FIGURE 1 **PART 2: WING SKIN PANEL GAPS - SEALANT RESTORATION** 1. RC - Restore the sealant in accordance with the figures below:

**Group 1: Right Wing**  **Left Wing**

- FIGURE 3 **Group 2: Right Wing**  **Left Wing** FIGURE 4
- **Group 3: Right Wing**  **Left Wing** FIGURE 4 FIGURE 3 2. Install the aft fairing. Refer to 777 AMM 54-52-04as an accepted procedure. **NOTE:** If the aft turbine exhaust plug was removed for access, install the aft turbine exhaust plug. Refer to777 AMM 78-11-02as an accepted procedure. 3. Put the airplane back to a serviceable condition. **PART 3: WING SKIN PANEL GAPS - DETAILED CORROSION INSPECTION** 1. RC - Do a detailed inspection for corrosion in accordance with the figures below.

**Group 1: Right Wing**  **Left Wing**

- FIGURE 5

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 24of49 **BOEING SERVICE BULLETIN 777-57A0097 Group 2:**  **Right Wing Left Wing**  FIGURE 6
- **Group 3: Right Wing**  **Left Wing** FIGURE 6 FIGURE 5

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1: May 04, 2015 25of49 **BOEING SERVICE BULLETIN 777-57A0097 This Figure applies only to: Group 1, 3.** 

**FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION**  **(SHEET 1 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 26of49 **BOEING SERVICE BULLETIN 777-57A0097 FIGURE 1:**  **LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION (SHEET 2 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 27of49 **BOEING SERVICE BULLETIN 777-57A0097**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure. **CAUTION:** USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE DAMAGE TO THE WING SKIN. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Remove sealant from the wing skinpanel gaps not covered by the underwing fittings in the area shown. - - Sealant Remove 1 (a) Remove sealant from the wing skin panel gaps covered by the underwing fittings in the area shown. - - Sealant Remove 2 (a) Do a Detailed Inspection (DET) for any void that may indicate missing sealant in the area beyond the sealant portion that was removed. - - Sealant Inspect 3
(a) (b) (a) Before sealant removal, soak and soften the sealant with Methyl Ethyl Ketone (MEK) (or Methyl Isobutyl Ketone (MIBK) or Methyl Propyl Ketone (MPK)). Use non-metallic tools to remove the sealant. Refer to SOPM 20-50-19for a list of approved non-metallic tools. It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps, which are 0.06 inch to 0.2 inch wide.Refer to APPENDIX Bfor additional optional tool information.

**FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION**  **(SHEET 3 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 28of49 **BOEING SERVICE BULLETIN 777-57A0097 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) Any solvent used for sealant removal should be allowed to dry for a minimum of 15 minutes before inspecting the remaining sealant. It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps, which are 0.06 inch to 0.2 inch wide. One method to inspect for the presence or absence of sealant is to lightly tap the remaining sealant in the wing skin panel gaps above the underwing fittings using a rubber mallet and a non-metallic tool. Another method for this inspection is to probe the sealant using a non-metallic tool by applying firm hand pressure to the existing sealant.The presence of properly applied sealant in the wing skin panel gaps above the underwing fittings is indicated by resistance against the non-metallic tool when the non-metallic tool is tapped with a rubber mallet, or when firm hand pressure is applied to it. The non-metallic tool should not advance into the existing sealant when tapped or when firm hand pressure isapplied to it. Missing sealant is indicated by reduced resistance of the sealant being tapped or manually pressed with the non-metallic tool. Obvious movement of the non-metallic tool into the existing sealant also indicates the absence of sealant. Missing sealant may also be indicated by any obvious sealant discontinuities found during the minimum of 0.5 inch sealant removal from the wing skin panel gaps, for access. The non-metallic tools used for sealant removal for access may advance suddenly, indicating incorrectly applied sealant at that location during production.

**FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION**  **(SHEET 4 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 29of49 **BOEING SERVICE BULLETIN 777-57A0097 This Figure applies only to: Group 2-3.** 

**FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION**  **(SHEET 1 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 30of49 **BOEING SERVICE BULLETIN 777-57A0097 FIGURE 2:**  **RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION (SHEET 2 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 31of49 **BOEING SERVICE BULLETIN 777-57A0097**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure. **CAUTION:** USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE DAMAGE TO THE WING SKIN. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Remove sealant from the wing skinpanel gaps not covered by the underwing fittings in the area shown. - - Sealant Remove 1 (a) Remove sealant from the wing skin panel gaps covered by the underwing fittings in the area shown. - - Sealant Remove 2 (a) Do a Detailed Inspection (DET) for any void that may indicate missing sealant in the area beyond the sealant portion that was removed. - - Sealant Inspect 3
(a) (b) (a) Before sealant removal, soak and soften the sealant with Methyl Ethyl Ketone (MEK) (or Methyl Isobutyl Ketone (MIBK) or Methyl Propyl Ketone (MPK)). Use non-metallic tools to remove the sealant. Refer to SOPM 20-50-19for a list of approved non-metallic tools. It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps, which are 0.06 inch to 0.2 inch wide.Refer to APPENDIX Bfor additional optional tool information.

**FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION**  **(SHEET 3 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 32of49 **BOEING SERVICE BULLETIN 777-57A0097 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) Any solvent used for sealant removal should be allowed to dry for a minimum of 15 minutes before inspecting the remaining sealant. It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps, which are 0.06 inch to 0.2 inch wide. One method to inspect for the presence or absence of sealant is to lightly tap the remaining sealant in the wing skin panel gaps above the underwing fittings using a rubber mallet and a non-metallic tool. Another method for this inspection is to probe the sealant using a non-metallic tool by applying firm hand pressure to the existing sealant.The presence of properly applied sealant in the wing skin panel gaps above the underwing fittings is indicated by resistance against the non-metallic tool when the non-metallic tool is tapped with a rubber mallet, or when firm hand pressure is applied to it. The non-metallic tool should not advance into the existing sealant when tapped or when firm hand pressure isapplied to it. Missing sealant is indicated by reduced resistance of the sealant being tapped or manually pressed with the non-metallic tool. Obvious movement of the non-metallic tool into the existing sealant also indicates the absence of sealant. Missing sealant may also be indicated by any obvious sealant discontinuities found during the minimum of 0.5 inch sealant removal from the wing skin panel gaps, for access. The non-metallic tools used for sealant removal for access may advance suddenly, indicating incorrectly applied sealant at that location during production.

**FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION**  **(SHEET 4 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 33of49 **BOEING SERVICE BULLETIN 777-57A0097 This Figure applies only to: Group 1, 3.** 

**FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 34of49 **BOEING SERVICE BULLETIN 777-57A0097 FIGURE 3:**  **LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 35of49 **BOEING SERVICE BULLETIN 777-57A0097**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure. **CAUTION:** USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE DAMAGE TO THE WING SKIN. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Refer toSOPM 20-30-03as an accepted procedure. - - Wing Skin Panel Gap Clean 1 (a) to any bare aluminum surface.
- - Chemical Conversion Coating Apply 2 Refer toSOPM 20-43-03as an accepted procedure.to any surface where primer was removed. - BMS 10-79, Type III Primer Apply 3 Refer toSOPM 20-50-19as an accepted procedure. - BMS 5-95 Sealant Apply 4 (a)

- BMS10-79, Type III Primer Apply 5

- BMS10-60, Type II Enamel Apply 6 (a) If the sealant was removed from the entire gap area above the underwing fitting, then clean the entire area where sealant was removed before new sealant is applied.

**FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR**  **(SHEET 3 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 36of49 **BOEING SERVICE BULLETIN 777-57A0097 This Figure applies only to: Group 2-3.** 

**FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 37of49 **BOEING SERVICE BULLETIN 777-57A0097 FIGURE 4:**  **RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 38of49 **BOEING SERVICE BULLETIN 777-57A0097**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure. **CAUTION:** USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE DAMAGE TO THE WING SKIN. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Refer toSOPM 20-30-03as an accepted procedure. - - Wing Skin Panel Gap Clean 1 (a) to any bare aluminum surface.
- - Chemical Conversion Coating Apply 2 Refer toSOPM 20-43-03as an accepted procedure.to any surface where primer was removed. - BMS 10-79, Type III Primer Apply 3 Refer toSOPM 20-50-19as an accepted procedure. - BMS 5-95 Sealant Apply 4 (a)

- BMS10-79, Type III Primer Apply 5

- BMS10-60, Type II Enamel Apply 6 (a) If the sealant was removed from the entire gap area above the underwing fitting, then clean the entire area where sealant was removed before new sealant is applied.

**FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR**  **(SHEET 3 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 39of49 **BOEING SERVICE BULLETIN 777-57A0097 This Figure applies only to: Group 1, 3.** 

**FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 40of49 **BOEING SERVICE BULLETIN 777-57A0097 FIGURE 5:**  **LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 41of49 **BOEING SERVICE BULLETIN 777-57A0097**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 each location where missing sealant was found. **CAUTION:** USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE DAMAGE TO THE WING SKIN. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  from the area directly above the underwing fitting, where sealant was not previously removed. - - Sealant Remove 1 (a) Refer toSOPM 20-30-03as an accepted procedure. - - Wing Skin Panel Gap Clean Do a DET for corrosion. Refer toAPPENDIX Bfor additional optionalinspection toolinformation. - - Wing Skin Panel Gap Inspect 2
(a) Before sealant removal, soak and soften the sealant with Methyl Ethyl Ketone (MEK) (or Methyl Isobutyl Ketone (MIBK) or Methyl Propyl Ketone (MPK)). Use non-metallic tools to abrade most of the sealant in the wing skin panel gaps without damaging the adjacent wing and underwing fitting structure and finishes. Refer to SOPM 20-50-19for a list of approved non-metallic tools. It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps, which are 0.06 inch to 0.2 inch wide. Refer toAPPENDIX Bfor additionaloptionaltool information.

**FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION**  **(SHEET 3 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 42of49 **BOEING SERVICE BULLETIN 777-57A0097 This Figure applies only to: Group 2-3.** 

**FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 43of49 **BOEING SERVICE BULLETIN 777-57A0097 FIGURE 6:**  **RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 44of49 **BOEING SERVICE BULLETIN 777-57A0097**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure. **CAUTION:** USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE DAMAGE TO THE WING SKIN. **MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  from the area directly above the underwing fitting, where sealant was not previously removed. - - Sealant Remove 1 (a) Refer toSOPM 20-30-03as an accepted procedure. - - Wing Skin Panel Gap Clean Do a DET for corrosion. Refer toAPPENDIX Bfor additional optionalinspection toolinformation. - - Wing Skin Panel Gap Inspect 2
(a) Before sealant removal, soak and soften the sealant with Methyl Ethyl Ketone (MEK) (or Methyl Isobutyl Ketone (MIBK) or Methyl Propyl Ketone (MPK)). Use non-metallic tools to abrade most of the sealant in the wing skin panel gaps without damaging the adjacent wing and underwing fitting structure and finishes. Refer to SOPM 20-50-19for a list of approved non-metallic tools. It is acceptable to modify an existing non-metallic sealant scraping tool to fit into the wing skin panel gaps, which are 0.06 inch to 0.2 inch wide. Refer toAPPENDIX Bfor additionaloptionaltool information.

**FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION**  **(SHEET 3 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 45of49 **BOEING SERVICE BULLETIN 777-57A0097**Logic diagrams are provided as an aid only. Information contained inParagraph 1.E., Complianceis the primary

source for compliance times. Information contained in Paragraph 3.B., Work Instructionsis the primary source for tasks required for compliance. 1. The table below gives the description for the parts and conditions called out in the logic diagrams. **Description Title**  WING SKIN PANEL GAPS - DETAILED SEALANT INSPECTION PART 1 WING SKIN PANEL GAPS - SEALANT RESTORATION PART 2 WING SKIN PANEL GAPS - DETAILED CORROSION INSPECTION PART 3 NO MISSING SEALANT FOUND CONDITION 1 MISSING SEALANT FOUND CONDITION 2 ANY CORROSION FOUND CONDITION 3 NO CORROSION FOUND CONDITION 4

**APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED INSPECTION**  **INTERVALS FOR MISSING SEALANT**

**(SHEET 1 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 46of49 **BOEING SERVICE BULLETIN 777-57A0097 APPENDIX A:** **LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED INSPECTION INTERVALS FOR MISSING SEALANT** 

**(SHEET 2 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 47of49 **BOEING SERVICE BULLETIN 777-57A0097**This Appendix includes information about the non-metallic tools and materials,and the inspection toolsthat

were used by Boeing for the removal of sealant and the inspection for corrosion in production. Other procedures, non-metallic tools and materials,and inspection toolsmay be used at the operators' discretion.The information in this Appendixis for reference only.
**CAUTION:** USE ONLY NON-METALLIC TOOLS TO REMOVE THE SEALANT IN THE WING SKIN PANEL

GAPS IN THE AREA OF THE UNDERWING FITTINGS. USE OF METALLIC TOOLS CAN CAUSE DAMAGE TO THE WING SKIN.
SEALANT REMOVAL TOOLS USED BY BOEING FOR THE WORK EQUIVALENT TO PART 1 DETAILED (DET) INSPECTION The following non-metallic tools were used by Boeing in production for the work equivalent to PART 1 sealant removal in this service bulletin:

– Existing non-metallic sealant scrapers modified to match the width of the wing panel gaps, which are 0.06 inch to 0.2 inch wide.

– Small manual saws fabricated from Torlon polyamide-imide stock.

– Non-metallic drill bits fabricated from polyether imide (PEI) stock to make the sealant removal more time effective. Refer to Fleet Team Digest (FTD) article 777 FTD 57-13003for additional tool photographs and information.
SEALANT REMOVAL TOOLS AND PROCEDURES USED IN PREPARATION FOR THE CORROSION INSPECTION Where missing sealant was found during the DET in Part 1, any sealant in the wing panel gap above the entire width of the affected underwing fitting was required to be removed. This was done in production in preparation for the corrosion inspection work that is equivalent to Part 3 DET in this service bulletin. The sealant removal from the remaining area above the affected underwing fitting required non-metallic tools capable to abrade most of the sealant in the wing skin panel gaps without damaging the adjacent wing and underwing fitting structure and finishes. Some tool variations that were used to remove the sealant in the wing skin panel gap above the entire width of the affected underwing fitting include, but are not limited to:

– Teflon or nylon rope that was knotted to create a rough surface that can abrade the sealant in the gap above the underwing fittings

– Wire ties connected together to create a rough surface similar to the knotted Teflon or nylon rope mentioned above

– OREGON brand Flexiblade nylon stock with 0.118 inch, 0.105 inch, and 0.099 inch cross sections (part numbers 21-602, 21-601, and 21-600, respectively). Refer to http://www.oregonproducts.com for additional information on this product.
INSPECTION TOOLS FOR CORROSION INSPECTION

**APPENDIX B: SEALANT REMOVAL TOOLS AND PROCEDURES**  **(SHEET 1 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 48of49 **BOEING SERVICE BULLETIN 777-57A0097**Boeing performed a Remote Visual Inspection (RVI) of the wing panel gap for corrosion using an Olympus

IPLEX TX 2.4 mm (0.094 inch) videoscope. This videoscope was sufficiently small to fit in the wing panel gap, which is 0.06 inch to 0.2 inch wide. Refer to http://www.olympus-ims.com for additional information on this videoscope. A borescope or other inspection tools may be used for this corrosion inspection.

**APPENDIX B: SEALANT REMOVAL TOOLS AND PROCEDURES**  **(SHEET 2 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 10, 2014 777-57A0097 Revision 1 May 04, 2015 49of49 **BOEING SERVICE BULLETIN 777-57A0097**