Commercial 

Airplane

Group 767

Service Bulletin

Number: 767-27-0203

Date: June 25, 2007

Revision 1: February 21, 2008

ATA System: 2731

SUBJECT: FLIGHT CONTROLS - Elevator - Repetitive Mis-Rig Check

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2007 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Unpublished Work - All Rights Reserved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

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

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2.0
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BOEING SERVICE BULLETIN 767-27-0203

BLANK PAGE
Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 13

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 15

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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BOEING SERVICE BULLETIN 767-27-0203

BLANK PAGE
Commercial 

Airplane

Group 767

Service Bulletin

Revision Transmittal Sheet Number: 767-27-0203

Date: June 25, 2007

Revision 1: February 21, 2008

ATA System: 2731

SUBJECT: FLIGHT CONTROLS - Elevator - Repetitive Mis-Rig Check

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed as shown in the original issue of this service bulletin.

REASON FOR REVISION

This revision is sent to clarify Paragraph 1.E., Compliance.

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 25, 2007

Revision 1: February 21, 2008

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BLANK PAGE
Commercial 

Airplane

Group 767

Service Bulletin

Summary Number: 767-27-0203

Date: June 25, 2007

Revision 1: February 21, 2008

ATA System: 2731

SUBJECT: FLIGHT CONTROLS - Elevator - Repetitive Mis-Rig Check

CONCURRENT REQUIREMENTS

Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND

This service bulletin gives instructions to do repetitive checks of the elevator Power Control Actuator (PCA)

rigging to determine if there is a mis-rig condition. As an alternative to Boeing Alert Service Bulletin 767-27A0169,

the incorporation of Boeing Service Bulletin 767-27-0187 to replace or rework elevator PCA bellcranks combined

with the repetitive check of the elevator PCA input rod assemblies recommended in Boeing Service Bulletin

767-27-0201 and the repetitive check of the elvator PCA rigging recommended in this service bulletin will prevent

continued operation with yielded or failed shear rivets in a bellcrank assembly for the elevator PCA and will also

allow for longer inspection intervals. Operators are currently required by the Federal Aviation Administration

(FAA) Airworthiness Directive (AD) 2001-04-09 to do the 400 flight-hour repetitive check recommended in Boeing

Alert Service Bulletin 767-27A0169.

One operator reported the left elevator drooping during a preflight check. Examination of the elevator control

system found sheared rivets in the left-inboard and center Power Control Actuator (PCA) bellcrank assemblies.

The elevator single hydraulic system check required by a Certification Maintenance Requirement (CMR) may

not detect yielded or failed shear rivets in the bellcrank assemblies for the elevator PCA. As a result, the FAA

issued AD 2000-17-05 to mandate the accomplishment of the actions specified in Boeing Alert Service Bulletin

767-27A0166, dated August 17, 2000.

Since the issuance of AD 2000-17-05, the FAA has received reports that several 767-200, 767-300, and 767-300F

airplanes failed the one-time functional check of the shear rivets required by the AD. As a result, the FAA issued

AD 2001-04-09 to mandate the accomplishment of the actions specified in Boeing Alert Service Bulletin

767-27A0169, dated November 21, 2000.

A detailed design review found that the override device incorporated into the elevator PCA input rod assembly

provides protection against malfunctions and non-normal PCA operation.This design review also found that the

shear rivets are not needed.The completion of Boeing Service Bulletin 767-27-0187 to replace or rework elevator

PCA bellcranks combined with the repetitive check of the elevator PCA input rod assemblies recommended in

Boeing Service Bulletin 767-27-0201 and the repetitive check of the elevator PCA rigging recommended in this

service bulletin is an alternative to the 400 flight-hour repetitive check recommended in Boeing Alert Service

Bulletin 767-27A0169.

Boeing Service Related Problem (SRP) 767-SRP-27-0128 is related to this service bulletin.

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ACTION (PRR B12901-35S)

Do a check of the elevator power control actuator (PCA) rigging.

EFFECTIVITY

767-400ER Airplanes. Refer to Paragraph 1.A.1 Airplanes, for the list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive 2001-04-09 is related to this service bulletin. The

FAA will possibly release a new Airworthiness Directive related to this service bulletin. The new Airworthiness

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

See Service Bulletin Paragraph 1.E. for compliance information.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service

bulletin.

MANPOWER

Total Task Hours Elapsed Hours

2.0 1.0

MATERIAL INFORMATION

None.

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BOEING SERVICE BULLETIN 767-27-0203
Commercial 

Airplane

Group 767

Service Bulletin

Number: 767-27-0203

Date: June 25, 2007

Revision 1: February 21, 2008

ATA System: 2731

SUBJECT: FLIGHT CONTROLS - Elevator - Repetitive Mis-Rig Check

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. Refer to PRR B12901-35S for data about

this change.

NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below

is complete for airplanes through line number 965. Airplanes after line number 965 are

also affected by this service bulletin.These airplanes will be added to the service bulletin's

MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet

Profile Page.

NOTE: This Service Bulletin is for the airplanes identified below. The Effectivity list shown below

is complete for airplanes through line number 965. Airplanes after line number 965 are

also affected by this service bulletin, and are in Group(s): 1,2

GROUP CONFIGURATION DESCRIPTION

767-400ER airplanes line numbers 1-901 require incorporation of SB

767-27-0187.

1 -

767-400ER airplanes line numbers 902 and on do not require SB

767-27-0187. Intent of SB 767-27-0187 was done in production for

these airplanes.

2 -

Airplane Models:

767-400ER

Variable Number Group

VQ001 - VQ021 1

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Variable Number Group

VQ071 - VQ086 1

VQ111 2

2. Spares Affected

None.

B. Concurrent Requirements

The service bulletin listed below must be done before or at the same time as this service bulletin:

Group 1:

Company Service Bulletin Description

Elevator Power Control Actuator Bellcrank

replacement

Boeing 767-27-0187 Original Issue

Group 2:

None.The changes given in Boeing Service Bulletin 767-27-0187 were made on these airplanes before

delivery.

C. Reason

This service bulletin gives instructions to do repetitive checks of the elevator Power Control Actuator

(PCA) rigging to determine if there is a mis-rig condition. As an alternative to Boeing Alert Service

Bulletin 767-27A0169, the incorporation of Boeing Service Bulletin 767-27-0187 to replace or rework

elevator PCA bellcranks combined with the repetitive check of the elevator PCA input rod assemblies

recommended in Boeing Service Bulletin 767-27-0201 and the repetitive check of the elvator PCA

rigging recommended in this service bulletin will prevent continued operation with yielded or failed

shear rivets in a bellcrank assembly for the elevator PCA and will also allow for longer inspection

intervals. Operators are currently required by the Federal Aviation Administration (FAA) Airworthiness

Directive (AD) 2001-04-09 to do the 400 flight-hour repetitive check recommended in Boeing Alert

Service Bulletin 767-27A0169.

One operator reported the left elevator drooping during a preflight check. Examination of the elevator

control system found sheared rivets in the left-inboard and center Power Control Actuator (PCA)

bellcrank assemblies.The elevator single hydraulic system check required by a Certification Maintenance

Requirement (CMR) may not detect yielded or failed shear rivets in the bellcrank assemblies for the

elevator PCA. As a result, the FAA issued AD 2000-17-05 to mandate the accomplishment of the

actions specified in Boeing Alert Service Bulletin 767-27A0166, dated August 17, 2000.

Since the issuance of AD 2000-17-05, the FAA has received reports that several 767-200, 767-300,

and 767-300F airplanes failed the one-time functional check of the shear rivets required by the AD. As

a result, the FAA issued AD 2001-04-09 to mandate the accomplishment of the actions specified in

Boeing Alert Service Bulletin 767-27A0169, dated November 21, 2000.

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BOEING SERVICE BULLETIN 767-27-0203
A detailed design review found that the override device incorporated into the elevator PCA input rod

assembly provides protection against malfunctions and non-normal PCA operation.This design review

also found that the shear rivets are not needed.The completion of Boeing Service Bulletin 767-27-0187

to replace or rework elevator PCA bellcranks combined with the repetitive check of the elevator PCA

input rod assemblies recommended in Boeing Service Bulletin 767-27-0201 and the repetitive check

of the elevator PCA rigging recommended in this service bulletin is an alternative to the 400 flight-hour

repetitive check recommended in Boeing Alert Service Bulletin 767-27A0169.

Boeing Service Related Problem (SRP) 767-SRP-27-0128 is related to this service bulletin.

Revision 1 is sent to clarify Paragraph 1.E., Compliance.

D. Description

Do a check of the elevator power control actuator (PCA) rigging.

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

service bulletin.

Affected Maintenance Zones

Model Zone

767-400ER 336, 337, 346, 347

E. Compliance

Group 1:

Boeing recommends this check be done within 6,000 flight hours after completion of Boeing Service

Bulletin 767-27-0187.Thereafter, Boeing recommends that this check be done within every 6,000 flight

hours.

Group 2:

Boeing recommends this check be done at the latest of the following times:

Group 2:

1. Within 6,000 flight hours after completion of the previous mis-rig check in the original release of

this service bulletin, or

2. Within 6,000 flight hours after the bellcrank repetitive check identified in Service Bulletin

767-27A0169, or

3. Within 6,000 flight hours after the date of issuance of the original standard certificate of airworthiness

or the original export certificate of airworthiness.

Group 2:

Thereafter, Boeing recommends that this check be repeated at intervals not to exceed 6,000 flight

hours.

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BOEING SERVICE BULLETIN 767-27-0203
Federal Aviation Administration (FAA) Airworthiness Directive 2001-04-09 is related to this service

bulletin. The FAA will possibly release a new Airworthiness Directive related to this service bulletin.

The new 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 action (i.e. inspection or modification) defined in this service bulletin

combined with the actions defined in Boeing Service Bulletins 767-27-0187 and 767-27-0201 as an

alternative method of compliance to the requirements of paragraph (a) of AD 2001-04-09. All provisions

of AD 2001-04-09 that are not specifically referenced in the above statement remain fully applicable

and must be complied with.

G. Manpower

The table below shows an estimate of the task-hours necessary to do the mis-rig check 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 find the tools.

Group 1-2:

Number of Task-Hours Elapsed Hours

Persons

Work Package Task

Number

1 Check for Mis-Rig 2 1.0 0.5

TOTAL FOR WORK PACKAGE 1 1.0 0.5

2 Check for Mis-Rig 2 1.0 0.5

TOTAL FOR WORK PACKAGE 2 1.0 0.5

TOTAL FOR EACH AIRPLANE 2.0 1.0

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BOEING SERVICE BULLETIN 767-27-0203
H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR B12901-35S

b. Service Related Problem (SRP) 767-SRP-27-0128

c. 767 Aircraft Maintenance Manual (AMM) 27-31-00

d. 767 Maintenance Planning Data (MPD) 1Appendix G

e. Boeing Service Bulletin 767-27A0166

f. Boeing Service Bulletin 767-27A0169

g. Boeing Service Bulletin 767-27-0187

h. Boeing Service Bulletin 767-27-0201

i. FAA Airworthiness Directive 2000-17-05

j. FAA Airworthiness Directive 2001-04-09

2. Data supplied with this Service Bulletin:

None.

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

None.

K. Publications Affected

None.

L. Interchangeability and Intermixability of Parts

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

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BOEING SERVICE BULLETIN 767-27-0203

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

None.

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

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

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

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BOEING SERVICE BULLETIN 767-27-0203

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

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

SLATS, SPOILERS AND STABILIZER ARE FULLY POWERED SURFACES. INJURIES

TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC

POWER IS SUPPLIED.

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

3. The work instructions are divided into work packages.Task-Hours and Elapsed-Hours

for each package are given in Paragraph 1.G., Manpower.You can do each work

package independently or at the same time.The work instructions for the left and

right elevators are the same and both work packages need to be completed before

the plane is returned to service.

4. These work instructions refer to procedures included on 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 "as

given in" are included in the instruction, the procedure in the Boeing document must

be used.

B. WORK INSTRUCTIONS

WORK PACKAGE 1 - LEFT ELEVATOR MIS-RIG CHECK

1. Do a check of the elevator Power Control Actuator (PCA) rigging. Refer to "Functional Test -

Elevator PCA Mis-Rig" in 767 AMM 27-31-00 as an accepted procedure.

a. If a mis-rig condition is found, do the following steps:

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BOEING SERVICE BULLETIN 767-27-0203
(1) Adjust the PCA Input Rod Assemblies. Refer to 767 AMM 27-31-00 as an accepted

procedure.

(2) Do the Structural Inspection MPD Items 5510-335-01I and 5510-345-01I. Refer to 767

MPD 1 Appendix G as an accepted procedure.

2. Put the airplane back to a serviceable condition.

WORK PACKAGE 2 - RIGHT ELEVATOR MIS-RIG CHECK

1. Do a check of the elevator PCA rigging. Refer to "Functional Test - Elevator PCA Mis-Rig" in 767

AMM 27-31-00 as an accepted procedure.

a. If a mis-rig condition is found, do the following steps:

(1) Adjust the PCA Input Rod Assemblies. Refer to 767 AMM 27-31-00 as an accepted

procedure.

(2) Do the Structural Inspection MPD Items 5510-335-01I and 5510-345-01I. Refer to 767

MPD 1 Appendix G as an accepted procedure.

2. Put the airplane back to a serviceable condition.

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