Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-52A0038

Original Issue: June 18, 2009

Revision 1: June 24, 2010

ATA System: 5234

SUBJECT: DOORS - Forward Large Cargo Door - Lower Sill Latch Pin Fitting (LPF) No. 1 through

8 - Latch Pin Retention Bolt Inspection

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 © 2009 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Unpublished Work - All Rights Reserved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, 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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the

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connection with this document unless provided in writing by Boeing.

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2.0
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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT

BLANK PAGE
Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 23

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 26

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

FIGURE 1: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSPECTION . . 30

FIGURE 2: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSTALLATION . 33

FIGURE 3: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN MIGRATION INSPECTION . . . . . . 36

FIGURE 4: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN FITTING ASSEMBLY REPLACEMENT . 38

FIGURE 5: LATCH PIN FITTING NO. 1 THRU 8 - FUSELAGE AND CARGO DOOR INSPECTION . 42

FIGURE 6: TERMINATING ACTION - LATCH PIN FITTING NO. 1 THRU 8 - INCONEL BOLT INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

FIGURE 7: LATCH PIN FITTING NO. 1 THRU 8 - BOLT HEAD DIRECTION CHANGE AND TORQUE

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 777-52A0038

Original Issue: June 18, 2009

Revision 1: June 24, 2010

ATA System: 5234

SUBJECT: DOORS - Forward Large Cargo Door - Lower Sill Latch Pin Fitting (LPF) No. 1 through

8 - Latch Pin Retention Bolt Inspection

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes inspected and changed in accordance with the original issue of this service

bulletin. Accomplish terminating action, or alternatively, do repeat Detailed Inspections and torque check for

loose bolts until terminating action is accomplished.

Airplane line numbers 718, 727, 731-734 and 738-825 were added to this service bulletin.

REASON FOR REVISION

This revision is sent to give instruction for a terminating action and to give instruction to do alternative repeat

Detailed Inspections and torque check for loose bolts until the terminating action is accomplished. This revision

is also sent to extend the effectivity of this service bulletin to include all applicable airplanes built before a

production change (equivalent to the terminating action given in this service bulletin) was incorporated.

These sections were changed:

1. Summary Action: Revised text to incorporate terminating action and alternative repeat Detail Inspections

and torque check for loose bolts.

2. Planning Information:

a. 1.D. Description: revised text to incorporate terminating action and alternative repeat Detail Inspections

and torque check for loose bolts.

b. 1.E. Compliance: revised compliance tables to incorporate terminating action and alternative repeat

Detail Inspections and torque check for loose bolts.

c. 1.G. Manpower: added manpower data for the terminating action and change of existing bolt installed

direction.

3. Material Information, 2.C.2. Parts and Materials Supplied by the Operator table: added parts for the

terminating action and Latch Pin Fitting replacement.

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4. Accomplishment Instructions: incorporated instruction for the terminating action, alternative repeat Detail

Inspection and torque check, and revised presentation to clarify the instruction.

5. Figure 1: revised figure step table to clarify work steps.

6. Figure 2: revised figure to add optional bolt part number.

7. Figure 4: revised figure title and revised Latch Pin Fitting replacement step table, added notes and rigging

instructions after a latch pin fitting replacement.

8. Added new Figure 6 to give instruction for the terminating action.

9. Added new Figure 7 to give instruction to change the existing bolt installed direction and torque check for

loose bolts.

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 18, 2009

Revision 1: June 24, 2010

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Commercial 

Airplanes 777

Service Bulletin

ALERT

Summary Number: 777-52A0038

Original Issue: June 18, 2009

Revision 1: June 24, 2010

ATA System: 5234

SUBJECT: DOORS - Forward Large Cargo Door - Lower Sill Latch Pin Fitting (LPF) No. 1 through

8 - Latch Pin Retention Bolt Inspection

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Accomplishment of this service bulletin will inspect the forward large cargo door lower sill Latch Pin Fitting (LPF)

No. 1 through 8 at Station 509.10, 522.75, 537.50, 554.30, 562.90, 579.70, 591.25 and 604.90 for loose, fractured

or missing latch pin retention bolts. A fractured retention bolt can become separated from the LPF and latch pin,

which could lead to migration of the latch pin. A latch pin that migrates and becomes disengaged from the main

cam latch can result in increased loads on adjacent LPFs, which may cause damage to the cargo door latch

mechanism and/or lower sill structure. The migration of two or more latch pins can result in the inability of the

cargo door to carry limit loads which may cause loss of the cargo door and catastrophic depressurization of the

airplane.

The forward large cargo door LPFs are attached to the door lower sill and numbered 1 through 8 forward to aft.

LPFs and latch pins are an integral component of the large forward cargo door latching mechanism that carry

structural and pressurization loads during flight.

Two operators have reported missing and fractured LPF latch pin retention bolts. One report indicated that on

a 777-200 airplane at LPF No. 1 and 2, Stations 509.10 and 522.75, one retention bolt was found on the ground

during closure of the forward cargo door and after further inspection a second bolt was noticed to be missing

from the adjacent fitting. In addition it was found that one of the latch pins had migrated away from engagement

with the corresponding cargo door main cam latch. Based on this report, Boeing requested a limited survey of

the 777 fleet for missing and/or fractured latch pin retention bolts. In response to this request an operator reported

that after applying a 15 in-lb test torque to all eight retention bolts on a 777-300, one retention bolt fractured at

LPF No. 2, Station 522.75. In both cases no further damage was reported as a result of the missing and fractured

retention bolts. All bolts were replaced and the airplanes were returned to normal service.

Boeing has developed terminating action for the Latch Pin Fitting (LPF) latch pin retention bolt inspection and

replacement that was given in the original issue of this service bulletin. In addition, repeat LPF latch pin retention

bolt inspections are added to this revision as optional action for terminating action.

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Boeing Service Related Problem (SRP) 777-SRP-52-0090 is related to this service bulletin.

ACTION (PRR 62777-68S)

INSPECTION

Do a Detailed Inspection and torque check of the forward large cargo door lower sill Latch Pin Fitting (LPF) No.

1 through 8 at Station 509.10, 522.75, 537.50, 554.30, 562.90, 579.70, 591.25 and 604.90 for loose, fractured

and/or missing latch pin retention bolts.

If no retention bolts are fractured or missing do terminating action, or alternatively, change the installed bolt

head direction of existing bolts if necessary or if bolt head direction is unchanged apply a torque to check for

loose bolts. If no retention bolt is found loose, do repeat Detailed Inspections and torque check for loose bolts.

If any retention bolt is found loose, apply the specified full torque. If any bolt is found fractured during the initial

inspection and has not separated from the LPF and latch pin, carefully remove the bolt and do a Detailed

Inspection of the LPF latch pin retention bolt hole for cracks and/or surface depressions. If no cracks and/or

surface depressions are found do terminating action, or alternatively, install a new retention bolt (same type as

the removed bolt or Inconel bolt.) Do repeat Detailed Inspections and torque check for loose bolts. If any crack

and/or surface depression is found in the LPF, more work is required as specified.

If any retention bolt is missing and the associated latch pin has not migrated more than a specified distance, do

a Detailed Inspection of the LPF latch pin retention bolt hole for cracks and/or surface depressions. If no cracks

and/or surface depressions are found, do terminating action, or alternatively, install a new retention bolt (same

type as the removed bolt or Inconel bolt.) Do repeat Detailed Inspections and torque check for loose bolts. If

any crack and/or surface depression is found in the LPF, more work is required as specified.

If any retention bolt is missing and the associated latch pin has migrated more than a specified distance, do a

Detailed Inspection of the forward large cargo door lower sill, fuselage frames and internal/external skin, cargo

door frames and main cam latch mechanism for damage. If any damage is found remove the associated LPF

and repair the fuselage and/or cargo door in accordance with applicable 777 Structural Repair Manual (SRM)

or contact Boeing for repair data and do the repair. Then do a Detailed Inspection of the LPF latch pin retention

bolt hole for cracks and/or surface depressions. If no cracks and/or surface depressions are found do terminating

action, or alternatively, install a new retention bolt (same type as the missing bolt or Inconel bolt.) Do repeat

Detailed Inspections and torque check for loose bolts. If any crack and/or surface depression is found in the

LPF, more work is required as specified.

TERMINATING ACTION

Terminating action is not complete until titanium bolts have been removed and replaced with new Inconel bolts

at all LPF No. 1 through 8 locations.

To accomplish terminating action, do a Detailed Inspection of LPF No. 1 through 8 for fractured or missing latch

pin retention bolts. If no retention bolts are fractured or missing, remove the existing titanium bolts and replace

with new Inconel bolts. No further action is required. If any existing retention bolt is found fractured and has not

separated from the LPF and latch pin, carefully remove the bolt and do a Detailed Inspection of the LPF latch

pin retention bolt hole for cracks and/or surface depressions. If no cracks and/or surface depressions are found,

replace with a new Inconel bolt. If any crack and/or surface depression is found in the LPF, more work is required

as specified.

If any existing retention bolt is missing and the associated latch pin has not migrated more than a specified

distance, do a Detailed Inspection of the LPF latch pin retention bolt hole for cracks and/or surface depressions.

If no cracks and/or surface depressions are found, replace with a new Inconel bolt. If any crack and/or surface

depression is found in the LPF, more work is required as specified.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
If any existing retention bolt is missing and the associated latch pin has migrated more than a specified distance,

do a Detailed Inspection of the forward large cargo door lower sill, fuselage frames and internal/external skin,

cargo door frames and main cam latch mechanism for damage. If any damage is found remove the associated

LPF and repair the fuselage and/or cargo door in accordance with applicable 777 Structural Repair Manual

(SRM) or contact Boeing for repair data and do the repair. Then do a Detailed Inspection of the LPF latch pin

retention bolt hole for cracks and/or surface depressions. If no cracks and/or surface depressions are found,

replace with a new Inconel bolt. If any crack and/or surface depression is found in the LPF, more work is required

as specified.

EFFECTIVITY

777-200/-200LR/-300/-300ER/777F Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected

airplanes.

COMPLIANCE

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

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

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

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

bulletin.

MANPOWER

Inspection

Airplanes Total Task Hours Elapsed Hours

Group 1 1.25 1.25

Terminating Action

Airplanes Total Task Hours Elapsed Hours

Group 1 1.20 1.20

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-52A0038

Original Issue: June 18, 2009

Revision 1: June 24, 2010

ATA System: 5234

SUBJECT: DOORS - Forward Large Cargo Door - Lower Sill Latch Pin Fitting (LPF) No. 1 through

8 - Latch Pin Retention Bolt Inspection

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

GROUP CONFIGURATION DESCRIPTION

1 - 777 airplanes with a forward large cargo door, line numbers 001-825.

Airplane Models:

777-200, 777-200LR, 777-300, 777-300ER, 777F

Variable Number Group

WA001 - WA017 1

WA076 - WA080 1

WA086 - WA093 1

WA101 - WA104 1

WA116 - WA119 1

WA131 - WA137 1

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Variable Number Group

WA171 - WA175 1

WA196 - WA198 1

WA206 - WA212 1

WA221 - WA223 1

WA231 - WA232 1

WA241 - WA250 1

WA261 - WA266 1

WA281 - WA283 1

WA301 - WA304 1

WB001 - WB021 1

WB031 - WB046 1

WB051 - WB088 1

WB101 - WB106 1

WB121 - WB125 1

WB131 - WB148 1

WB151 - WB155 1

WB161 - WB177 1

WB181 - WB194 1

WB201 - WB215 1

WB231 - WB247 1

WB271 - WB273 1

WB276 - WB286 1

WB291 - WB302 1

WB306 - WB307 1

WB311 - WB337 1

WB341 - WB342 1

WB366 - WB368 1

WB371 - WB388 1

WB406 1

WB411 - WB413 1

WB416 - WB439 1

WB446 - WB453 1

WB476 1

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Variable Number Group

WB481 - WB484 1

WB501 - WB512 1

WB531 - WB537 1

WB551 - WB554 1

WB591 - WB597 1

WB601 - WB606 1

WB611 - WB622 1

WB631 - WB638 1

WB646 - WB649 1

WC051 - WC073 1

WC101 - WC104 1

WC111 - WC120 1

WC221 - WC222 1

WC241 - WC243 1

WC281 - WC290 1

WC301 - WC308 1

WC361 - WC364 1

WC371 - WC374 1

WC381 - WC395 1

WC441 1

WC446 - WC449 1

WC456 - WC459 1

WC486 - WC493 1

WC506 - WC508 1

WC521 - WC522 1

WC531 - WC536 1

WC546 - WC548 1

WC556 1

WC566 - WC567 1

WC571 - WC574 1

WD001 - WD002 1

WD011 - WD018 1

WD031 - WD036 1

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Variable Number Group

WD046 - WD055 1

WD066 - WD073 1

WD081 - WD083 1

WD501 - WD513 1

WD521 - WD541 1

WD546 - WD554 1

WD561 - WD573 1

WD581 - WD599 1

WD606 - WD609 1

WD621 - WD632 1

WD651 - WD664 1

WD671 - WD675 1

WD691 - WD709 1

WD741 - WD752 1

WD761 - WD771 1

WD786 - WD788 1

WD796 - WD807 1

WD826 - WD834 1

WD846 - WD858 1

WD871 - WD878 1

WD911 - WD914 1

WD936 - WD939 1

WD946 - WD948 1

WD966 - WD969 1

WD981 - WD982 1

WF001 - WF003 1

WF016 - WF019 1

WF031 - WF032 1

WF046 1

WF076 - WF077 1

WF081 - WF082 1

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for

the recommended use.

B. Concurrent Requirements

None.

C. Reason

Accomplishment of this service bulletin will inspect the forward large cargo door lower sill Latch Pin

Fitting (LPF) No. 1 through 8 at Station 509.10, 522.75, 537.50, 554.30, 562.90, 579.70, 591.25 and

604.90 for loose, fractured or missing latch pin retention bolts. A fractured retention bolt can become

separated from the LPF and latch pin, which could lead to migration of the latch pin. A latch pin that

migrates and becomes disengaged from the main cam latch can result in increased loads on adjacent

LPFs, which may cause damage to the cargo door latch mechanism and/or lower sill structure. The

migration of two or more latch pins can result in the inability of the cargo door to carry limit loads which

may cause loss of the cargo door and catastrophic depressurization of the airplane.

The forward large cargo door LPFs are attached to the door lower sill and numbered 1 through 8 forward

to aft. LPFs and latch pins are an integral component of the large forward cargo door latching mechanism

that carry structural and pressurization loads during flight.

Two operators have reported missing and fractured LPF latch pin retention bolts. One report indicated

that on a 777-200 airplane at LPF No. 1 and 2, Stations 509.10 and 522.75, one retention bolt was

found on the ground during closure of the forward cargo door and after further inspection a second bolt

was noticed to be missing from the adjacent fitting. In addition it was found that one of the latch pins

had migrated away from engagement with the corresponding cargo door main cam latch. Based on

this report, Boeing requested a limited survey of the 777 fleet for missing and/or fractured latch pin

retention bolts. In response to this request an operator reported that after applying a 15 in-lb test torque

to all eight retention bolts on a 777-300, one retention bolt fractured at LPF No. 2, Station 522.75. In

both cases no further damage was reported as a result of the missing and fractured retention bolts. All

bolts were replaced and the airplanes were returned to normal service.

Boeing has developed terminating action for the Latch Pin Fitting (LPF) latch pin retention bolt inspection

and replacement that was given in the original issue of this service bulletin. In addition, repeat LPF

latch pin retention bolt inspections are added to this revision as optional action for terminating action.

Boeing Service Related Problem (SRP) 777-SRP-52-0090 is related to this service bulletin.

D. Description

INSPECTION

Do a Detailed Inspection and torque check of the forward large cargo door lower sill Latch Pin Fitting

(LPF) No. 1 through 8 at Station 509.10, 522.75, 537.50, 554.30, 562.90, 579.70, 591.25 and 604.90

for loose, fractured and/or missing latch pin retention bolts.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: June 18, 2009

Revision 1: June 24, 2010 777-52A0038

15 of 51

BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
If no retention bolts are fractured or missing do terminating action, or alternatively, change the installed

bolt head direction of existing bolts if necessary or if bolt head direction is unchanged apply a torque

to check for loose bolts. If no retention bolt is found loose, do repeat Detailed Inspections and torque

check for loose bolts. If any retention bolt is found loose, apply the specified full torque. If any bolt is

found fractured during the initial inspection and has not separated from the LPF and latch pin, carefully

remove the bolt and do a Detailed Inspection of the LPF latch pin retention bolt hole for cracks and/or

surface depressions. If no cracks and/or surface depressions are found do terminating action, or

alternatively, install a new retention bolt (same type as the removed bolt or Inconel bolt.) Do repeat

Detailed Inspections and torque check for loose bolts. If any crack and/or surface depression is found

in the LPF, more work is required as specified.

If any retention bolt is missing and the associated latch pin has not migrated more than a specified

distance, do a Detailed Inspection of the LPF latch pin retention bolt hole for cracks and/or surface

depressions. If no cracks and/or surface depressions are found, do terminating action, or alternatively,

install a new retention bolt (same type as the removed bolt or Inconel bolt.) Do repeat Detailed

Inspections and torque check for loose bolts. If any crack and/or surface depression is found in the

LPF, more work is required as specified.

If any retention bolt is missing and the associated latch pin has migrated more than a specified distance,

do a Detailed Inspection of the forward large cargo door lower sill, fuselage frames and internal/external

skin, cargo door frames and main cam latch mechanism for damage. If any damage is found remove

the associated LPF and repair the fuselage and/or cargo door in accordance with applicable 777

Structural Repair Manual (SRM), Component Maintenance Manual (CMM) or contact Boeing for repair

data and do the repair. Then do a Detailed Inspection of the LPF latch pin retention bolt hole for cracks

and/or surface depressions. If no cracks and/or surface depressions are found do terminating action,

or alternatively, install a new retention bolt (same type as the missing bolt or Inconel bolt.) Do repeat

Detailed Inspections and torque check for loose bolts. If any crack and/or surface depression is found

in the LPF, more work is required as specified.

TERMINATING ACTION

Terminating action is not complete until titanium bolts have been removed and replaced with new

Inconel bolts at all LPF No. 1 through 8 locations.

To accomplish terminating action, do a Detailed Inspection of LPF No. 1 through 8 for fractured or

missing latch pin retention bolts. If no retention bolts are fractured or missing, remove the existing

titanium bolts and replace with new Inconel bolts. No further action is required. If any existing retention

bolt is found fractured and has not separated from the LPF and latch pin, carefully remove the bolt and

do a Detailed Inspection of the LPF latch pin retention bolt hole for cracks and/or surface depressions.

If no cracks and/or surface depressions are found, replace with a new Inconel bolt. If any crack and/or

surface depression is found in the LPF, more work is required as specified.

If any existing retention bolt is missing and the associated latch pin has not migrated more than a

specified distance, do a Detailed Inspection of the LPF latch pin retention bolt hole for cracks and/or

surface depressions. If no cracks and/or surface depressions are found, replace with a new Inconel

bolt. If any crack and/or surface depression is found in the LPF, more work is required as specified.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
If any existing retention bolt is missing and the associated latch pin has migrated more than a specified

distance, do a Detailed Inspection of the forward large cargo door lower sill, fuselage frames and

internal/external skin, cargo door frames and main cam latch mechanism for damage. If any damage

is found remove the associated LPF and repair the fuselage and/or cargo door in accordance with

applicable 777 Structural Repair Manual (SRM), Component Maintenance Manual (CMM) or contact

Boeing for repair data and do the repair. Then do a Detailed Inspection of the LPF latch pin retention

bolt hole for cracks and/or surface depressions. If no cracks and/or surface depressions are found,

replace with a new Inconel bolt. If any crack and/or surface depression is found in the LPF, more work

is required as specified.

Revision 1 is sent to give instruction for a terminating action and to give instruction to do repeat Detailed

Inspections and torque checks until the terminating modification is accomplished. Also, with Revision

1, the effectivity of this service bulletin is extended to include all applicable airplanes built before a

production change (equivalent to the terminating action given in this service bulletin) was incorporated.

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777-300, 122

777-300ER, 777F

E. Compliance

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

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

service bulletin mandatory.

Table 1: Forward Large Cargo Door Lower Sill Latch Pin Fitting (LPF) No. 1 through 8 - Retention

Bolt Inspection

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 12 months -

after the Revision

1 date of this service bulletin.

At Stations 509.10,

522.75, 537.50, 554.30,

562.90, 579.70, 591.25

and 604.90 do a Detailed

Inspection of the forward

large cargo door lower sill

Latch Pin Fitting (LPF)

No. 1 through 8 for fractured and/or missing latch

pin retention bolts in accordance with Accomplishment Instructions

3.B.2.

All airplanes.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Table 1: Forward Large Cargo Door Lower Sill Latch Pin Fitting (LPF) No. 1 through 8 - Retention

Bolt Inspection

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do terminating action in

accordance with Accomplishment Instructions

3.B.6.

No fractured or missing retention bolts and installed

bolt head direction is facing

inboard.

OR

Change installed bolt

head direction in accordance with Accomplishment Instructions

3.B.2.(a).

Before further -

flight.

Do terminating action in

accordance with Accomplishment Instructions

3.B.6.

No fractured or missing retention bolts and installed

bolt head direction is facing

outboard.

OR

Apply a torque to check

for loose bolts in accordance with Accomplishment Instructions

3.B.2.(a).

No further action re- - -

quired.

Terminating action accomplished.

1,000 flight cycles.

(a)

Within 1,000 flight

cycles after the

previous inspection

in this service bulletin.

At Stations 509.10,

522.75, 537.50, 554.30,

562.90, 579.70, 591.25

and 604.90 do a Detailed

Inspection of the forward

large cargo door lower sill

Latch Pin Fitting (LPF)

No. 1 through 8 for fractured, loose and/or missing latch pin retention

bolts in accordance with

Accomplishment Instructions 3.B.2.

Any existing installed bolt

head direction changed

OR

Any existing installed bolt

head direction not changed

and no loose bolt found or

any loose bolt torqued.

Proceed in accor- -

dance with Table

2.

Remove fractured bolt in

accordance with Accomplishment Instruction

3.B.3, then proceed in

accordance with Table 2.

Any retention bolt found

fractured and is engaged

with the LPF and latch pin.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Table 1: Forward Large Cargo Door Lower Sill Latch Pin Fitting (LPF) No. 1 through 8 - Retention

Bolt Inspection

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Measure the linear distance between the LPF

and latch pin forward/aft

end to determine if the

pin has migrated in accordance with Accomplishment Instructions 3.B.4.

Any missing retention bolt.

Proceed in accor- -

dance with Table

2.

Proceed in accordance

with Table 2.

Any missing retention bolt

and the latch pin did not

migrate more than the

specified distance in the

engaged or disengaged direction.

Proceed in accor- -

dance with Table

3.

Proceed in accordance

with Table 3.

Any missing retention bolt

and the latch pin did migrate more than the specified distance in the engaged or disengaged direction.

(a) To stop the repeat inspections, do terminating action in accordance with Accomplishment

Instructions 3.B.6.

Table 2: Latch Pin Fitting (LPF) No. 1 through 8 - LPF Inspection - Fitting and Retention Bolt Replacement

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do a Detailed Inspection

of the LPF latch pin retention bolt hole for any

crack or surface depression in accordance with

Accomplishment Instructions 3.B.5.

Any retention bolt found

fractured and is engaged

with the LPF and latch pin.

Or

Any missing retention bolt

and the latch pin did not

migrate more than the

specified distance in the

engaged or disengaged direction.

Before further -

flight.

Replace the LPF in accordance with Accomplishment Instructions 3.B.5,

or contact Boeing for repair data and do the repair.

Any crack or surface depression found.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Table 2: Latch Pin Fitting (LPF) No. 1 through 8 - LPF Inspection - Fitting and Retention Bolt Replacement

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do terminating action in

accordance with Accomplishment Instructions

3.B.6.

No crack(s) or surface depression(s) found

OR

new LPF installed.

OR

Install new bolt and,

change existing installed

bolt head direction or, if

bolt head direction is unchanged check for loose

bolts in accordance with

Accomplishment Instructions 3.B.5.

No further action re- - -

quired.

Terminating action accomplished.

1,000 flight cycles.

(a)

Within 1,000 flight

cycles.

At Stations 509.10,

522.75, 537.50, 554.30,

562.90, 579.70, 591.25

and 604.90 do a Detailed

Inspection of the forward

large cargo door lower sill

Latch Pin Fitting (LPF)

No. 1 through 8 for fractured, loose and/or missing latch pin retention

bolts in accordance with

Accomplishment Instructions 3.B.2.

New bolt(s) installed

AND

Any existing installed bolt

head direction changed

OR

Any existing installed bolt

head direction not changed

and no loose bolt found or

any loose bolt torqued.

(a) To stop the repeat inspections, do terminating action in accordance with Accomplishment

Instructions 3.B.6.

Table 3: Latch Pin Fitting (LPF) No. 1 through 8 - Latch Pin Migration - Forward Large Cargo Door

Lower Sill and Cargo Door Inspection / Repair

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do a Detailed Inspection

of the cargo door main

cam latch for any cut,

crack or other damage in

accordance with Accomplishment Instructions

3.B.4.(b).

Any missing retention bolt

and the latch pin did migrate in to the cargo door

main cam latch more than

the specified distance in

the engaged direction.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Table 3: Latch Pin Fitting (LPF) No. 1 through 8 - Latch Pin Migration - Forward Large Cargo Door

Lower Sill and Cargo Door Inspection / Repair

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Proceed in accordance

with Accomplishment Instructions 3.B.5.

No cut, crack or other

damage found in the cam

latch.

Before further -

flight.

Replace the cargo door

main cam latch in accordance with Accomplishment Instructions

3.B.4.(b).

Any cut, crack or other

damage found in the cam

latch.

Before further -

flight.

Do a Detailed Inspection

for cracks or other damage in the forward large

cargo door lower sill,

fuselage frames and internal/external skin, cargo

door frames, mid-span

latch cam (if installed)

and main cam latch

mechanisms in accordance with Accomplishment Instructions

3.B.4.(c).

Any missing retention bolts

and two or more latch pins

migrated away from the

cargo door main cam latch

more than the specified

distance in the disengaged

direction.

Before further -

flight.

Proceed in accordance

with Accomplishment Instructions 3.B.5.

Any missing retention bolt

and no more than one latch

pin has migrated away

from the cargo door main

cam latch more than the

specified distance in the

disengaged direction.

Within 4,000 fight -

cycles after the

LPF latch pin retention bolt inspection.

Do a Detailed Inspection

for cracks or other damage in the forward large

cargo door lower sill,

fuselage frames and internal/external skin, cargo

door frames, mid-span

latch cam and main cam

latch mechanisms in accordance with Accomplishment Instructions

3.B.4.(d).

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
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 airplane.

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

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

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

INSPECTION/TORQUE CHECK

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 1 0.10 0.10

Detailed Inspection 1 0.40 0.40

Change Installed 1 0.25 (a) 0.25 (a)

Bolt Head Direction

Torque Check 1 0.40 0.40

Close Access 1 0.10 0.10

TOTAL FOR EACH AIRPLANE 1.25 1.25

NOTE: More work will be required if bolts are fractured, loose and/or missing, or

if damage is found in the Latch Pin Fitting (LPF), forward large cargo door lower

sill, fuselage frames and internal/external skin, cargo door frames, mid-span latch

cam (if installed) or main cam latch mechanisms.

(a) Time is estimated for one bolt change.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
TERMINATING ACTION

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.10 0.10

Replace Bolts 1 1.00 1.00

Close Access 1 0.10 0.10

TOTAL FOR EACH AIRPLANE 1.20 1.20

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Engineering Change Memo PRR 62777-68S

b. Standard Overhaul Practices Manual (SOPM) 20-50-01, 20-50-19

c. 777 Aircraft Maintenance Manual (AMM) 52-34-00, 52-34-15

d. 777-200 Structural Repair Manual (SRM) 51-70-00, 53-10-15

e. 777-300 Structural Repair Manual (SRM) 51-70-00, 53-10-15

f. 777F Structural Repair Manual (SRM) 51-70-00, 53-10-15

g. Service Related Problem (SRP) 777-SRP-52-0090

h. Boeing Parts Standards Document D-590

i. Boeing Drawing 012W6100

2. Data supplied with this Service Bulletin

None.

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

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Drawing Number Title

141W5601 LATCH FITTING INSTL - FWD CARGO DOOR PANEL

SILL INSTL - LOWER MAIN AND AUXILIARY, FWD CARGO DOOR

PANEL

141W5808

K. Publications Affected

1. Publications:

Publication Chapter-Section

777 Maintenance Manual 52-34

777 Illustrated Parts Catalog 52-34

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

Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability

information.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

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

Part Number / QTY Name Notes

Specification

BACB30UU3K29 8 Bolt (a), (b), (d)

NAS1149E0363P 8 Washer (a), (b), (d)

BACN10JC3CD 8 Nut (a), (b), (d)

BACB30NM3K29 - Bolt (a), (b), (e)

NAS1149E0332P - Washer (a), (b), (e)

BACN11Z3CD - Nut (a), (b), (e)

141W5613-1 - Shim (Laminated) 0.062" (b)

141W5613-15 - Shim (Laminated) 0.015" (b)

141W5613-20 - Shim (Solid) 0.020" (b)

141W5613-25 - Shim (Solid) 0.025" (b)

141W5613-32 - Shim (Solid) 0.032" (b)

141W5613-40 - Shim (Solid) 0.040" (b)

141W5613-50 - Shim (Solid) 0.050" (b)

141W5613-63 - Shim (Solid) 0.063" (b)

BMS 3-38 - Corrosion Inhibiting Material (c)

BMS 5-95, Type I, - Sealant (c)

Class B

(a) Refer to 777 Structural Repair Manual Chapter 51 for alternate fasteners.

(b) Quantity required is determined at installation.

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
Part Number / QTY Name Notes

Specification

(c) See the Qualified Products List (QPL) at the end of the Boeing Material Specification

(BMS) for supplier data.

(d) These parts are to be used for terminating action, and it is allowable to use for replacement

action for repeat Detailed Inspections and torque check.

(e) These parts are NOT to be used for terminating action. It is allowable to use for replacement action for repeat Detailed Inspections and torque check only.

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 777-52A0038

ALERT ALERT
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 Figure(s)

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

– Angular tolerance is plus or minus 2 degrees

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

777 SRM, Chapter 51. Alternate fasteners are listed in 777 SRM 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 SRM Chapter 51, then a fastener of the same specification,

or an approved substitute, with a length which meets the installation standards in

SRM Chapter 51 may be used.

7. 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.

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.

B. WORK INSTRUCTIONS

1. Open the forward large cargo door. Refer to 777 AMM 52-34-00 as an accepted procedure.

2. At Station 509.10, 522.75, 537.50, 554.30, 562.90, 579.70, 591.25 and 604.90, do a Detailed

Inspection of the forward large cargo door lower sill Latch Pin Fitting (LPF) No. 1 through 8 for

fractured and/or missing latch pin retention bolts in accordance with Figure 1.

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ALERT ALERT
a. If there are no fractured or missing retention bolts, do terminating action in accordance with

paragraph 3.B.6, or alternatively, change the installed bolt head direction of existing latch pin

retention bolts or if bolt head direction is unchanged apply the specified torque to check for

loose bolts in accordance with Figure 7. At the time specified in Paragraph 1.E., Compliance,

do repeat Detailed Inspections and torque to check for loose bolts.

3. If any latch pin retention bolt is found to be fractured and is engaged with the LPF and latch pin,

remove the bolt and then go to paragraph 3.B.5.

4. If any latch pin retention bolt is missing from a LPF and latch pin, DO NOT MOVE THE LATCH

PIN FROM ITS AS FOUND POSITION. Measure the linear distance between the LPF and latch

pin forward/aft end in accordance with Figure 3 to determine if the pin has migrated.

NOTE: Ensure the forward large cargo door lower sill area and cargo door cavities do not contain

Foreign Object Debris (FOD) created by loose or broken bolts.

a. If the latch pin has not migrated or has migrated .03 inch or less in the engaged or disengaged

direction, go to paragraph 3.B.5.

b. If any latch pin has migrated more than .03 inch in to the cargo door main cam latch, engaged

direction, do a Detailed Inspection of the cam for any cut, crack or other damage.

If no cut, crack or other damage is found in the cargo door main cam latch, go to paragraph

3.B.5.

If any cut, crack or other damage is found in the cargo door main cam latch, replace the cam

in accordance with 777 AMM 52-34-15 or contact Boeing for repair data and do the repair,

then go to paragraph 3.B.5.

c. If two or more latch pins have migrated more than .03 inch away from the cargo door main

cam latch, disengaged direction, do a Detailed Inspection for cracks or other damage in the

forward large cargo door lower sill, fuselage frames and internal/external skin, cargo door

frames, mid-span latch cam (if installed) and main cam latch mechanisms in accordance with

Figure 5.

If no cracks or other damage is found in the the forward large cargo door lower sill, fuselage

frames and internal/external skin, cargo door frames, mid-span latch cam and main cam latch

mechanisms, go to paragraph 3.B.5.

If cracks or other damage is found in the forward large cargo door lower sill, fuselage frames

and/or internal/external skin, repair in accordance with 777-200 SRM 53-10-15, 777-300 SRM

53-10-15, 777F SRM 53-10-15 or contact Boeing for repair data and do the repair, then go

to paragraph 3.B.5.

If cracks or other damage is found in the cargo door frames, mid-span latch cam and/or main

cam latch mechanism, repair in accordance with 777-200 SRM 51-70-00, 777-300 SRM

51-70-00, 777F SRM 51-70-00 or contact Boeing for repair data and do the repair, then go

to paragraph 3.B.5.

d. If one latch pin has migrated more than .03 inch away from the cargo door main latch cam,

disengaged direction, go to paragraph 3.B.5. At the time specified in Paragraph 1.E.,

Compliance, do the inspection, and repair if necessary, in accordance with paragraph 3.B.4.c.

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ALERT ALERT
5. Do a Detailed Inspection of the LPF latch pin retention bolt hole for any crack or surface depression.

a. If no crack or surface depression is found, do terminating action in accordance with paragraph

3.B.6, or alternatively, install a new bolt (same type as the removed bolt or Inconel bolt) in

accordance with Figure 2, and change the installed bolt head direction of remaining LPF latch

pin retention bolts or if bolt head direction is unchanged apply the specified torque to check

for loose bolts in accordance with Figure 7. At the time specified in Paragraph 1.E., Compliance,

do repeat Detailed Inspections and torque to check for loose bolts.

b. If any crack and/or surface depression is found, replace the LPF in accordance with Figure

4, or contact Boeing for repair data and do the repair. See Paragraph 1.E., Compliance. Then

do terminating action in accordance with paragraph 3.B.6, or alternatively, install a new bolt

(same type as the removed bolt or Inconel bolt) in accordance with Figure 2, and change the

installed bolt head direction of remaining LPF latch pin retention bolts or if bolt head direction

is unchanged apply a specified torque to check for loose bolts in accordance with Figure 7.

At the time specified in Paragraph 1.E., Compliance, do repeat Detailed Inspections and

torque to check for loose bolts.

6. At Station 509.10, 522.75, 537.50, 554.30, 562.90, 579.70, 591.25 and 604.90, Latch Pin Fitting

(LPF) No. 1 through 8, remove existing titanium latch pin retention bolts and replace with new

Inconel bolts in accordance with Figure 6.

7. Close the forward large cargo door. Refer to 777 AMM 52-34-00 as an accepted procedure.

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FIGURE 1: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSPECTION

(SHEET 1 OF 3)

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

FIGURE 1: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSPECTION

(SHEET 2 OF 3)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Bolt - 8 (a)

(a) Do a Detailed Inspection for fractured and/or missing latch pin retention bolts. If any retention bolt is

fractured or missing, more work is required.

FIGURE 1: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 2: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSTALLATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
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 component.

FIGURE 2: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSTALLATION

(SHEET 2 OF 3)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

See fastener code

table. (a)

1 Install (New) Bolt - -

See fastener code

table. (a)

Install (New) Washer - -

See fastener code

table. (a)

Install (New) Nut - -

(a) Thoroughly apply BMS 3-38 corrosion inhibiting compound to the bolt shank, threads, washer and nut

mating surfaces prior to installation. Ensure new bolt is installed with the head on the LPF outboard side

(nut on the inboard side) as shown. Refer to SOPM 20-50-01 as an accepted procedure.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

A Bolt BACB30NM3K29 - - (a), (b)

Optional substitute. (a),

(b)

Bolt BACB30UU3K29 - -

Use with

BACB30NM3K29. (a)

Washer NAS1149E0332P - -

Use with

BACB30UU3K29. (a)

Washer NAS1149E0363P - -

Use with

BACB30NM3K29. (a), (b)

Nut BACN11Z3CD - -

Use with

BACB30UU3K29. (a), (b)

Nut BACN10JC3CD - -

(a) Quantity required is determined at installation.

(b) Torque nut or bolt head side to 23-27 in-lbs, target 25 in-lbs.

FIGURE 2: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN RETENTION BOLT INSTALLATION

(SHEET 3 OF 3)

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

FIGURE 3: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN MIGRATION INSPECTION

(SHEET 1 OF 2)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Measure Latch Pin - - (a)

(a) Measure the linear distance between the LPF and latch pin forward/aft ends to determine pin migration.

Maximum 0.03 inch migration allowed in the engaged or disengaged direction. Proceed in accordance

with the instructions given in this service bulletin.

FIGURE 3: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN MIGRATION INSPECTION

(SHEET 2 OF 2)

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FIGURE 4: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN FITTING ASSEMBLY REPLACEMENT

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
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 component.

FIGURE 4: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN FITTING ASSEMBLY REPLACEMENT

(SHEET 2 OF 4)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove / Keep Nut - 4

Remove / Keep Washer - 4

Remove / Keep Bolt - 4

Remove / Keep Radius Filler - 4

2 Remove Latch Assy 141W5610-() 1 (a)

3 Install (New) Latch Assy 141W5610-() 1 (b)

Install (Kept) Radius Filler - 4 (c)

Install (Kept) Bolt - 4 (d)

Install (Kept) Washer - 4

Install (Kept) Nut - 4

4 Adjust Latch Pin Fitting - - (e)

5 Torque Bolt - 2 (f)

6 Torque Bolt - 2 (g)

(a) Mark the position of the existing latch pin fitting in relation to the serrated plate on the lower sill to facilitate

new Latch Pin Fitting installation.

(b) Ensure existing shim stack-up is maintained. Use existing shim(s) for adjustment and installation. If shim(s)

become damaged and unusable or thickness adjustments must be made, replace with new shims. Refer

to Paragraph 2.C.2, Parts and Materials Supplied by the Operator for a list of replacement parts.

(c) Apply BMS5-95 sealant to fay surfaces. Refer to SOPM 20-50-19 as an accepted procedure.

(d) Install bolts wet with BMS5-95 sealant. Refer to SOPM 20-50-19 Method 2 as an accepted procedure.

Do not apply full torque at this step.

(e) Adjust the Latch Pin Fitting(s) and cargo door rigging as necessary. Refer to TABLE 1 in this figure as an

accepted procedure.

(f) Torque from head-side 620-760 in-lb, target 690 in-lb.

(g) Torque from head-side 1320-1620 in-lb, target 1470 in-lb.

The following table describes the airplane condition and necessary Latch Pin Fitting adjustments and cargo door

rigging procedures to be accomplished during a Latch Pin Fitting replacement. Refer to 777 AMM 52-34-00 for

any special tools required to facilitate the work.

FIGURE 4: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN FITTING ASSEMBLY REPLACEMENT

(SHEET 3 OF 4)

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ALERT ALERT
TABLE 1

LATCH PIN FITTING/CARGO DOOR ADJUSTMENT

1. Do cargo door rigging procedures with the airplane in the following condition: Operating weight empty

and the airplane supported on its landing gear and stabilized with jacks. To prevent unwanted structural

deflections, limit all stabilizing jack loads to 5,000 lbs. maximum.

2. Do the following Installation Rigging adjustments. Refer to 777 AMM 52-34-00 as an accepted procedure.

(a) Lift Mechanism Adjustment

(b) Centering Roller Adjustment

(c) Pull-In Hook and Pin Adjustment

(d) Main Latch Adjustment

3. Do the following Sensor Rigging adjustments. Refer to 777 AMM 52-34-00 as an accepted procedure.

(a) Door Control Proximity Sensor Adjustment

(b) Door Indication Proximity Sensor Adjustment

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

NAME IDENTIFICATION QTY MORE DATA

FLAG

NOTE

Ensure bolt is installed with the

head on the LPF outboard side

(nut on the inboard side) as

shown. If it is necessary to remove

a bolt and change the installed direction, prior to re-installation

thoroughly apply BMS 3-38 corrosion inhibiting compound to the

bolt shank, threads, washer and

nut mating surfaces. Torque nut

or bolt head side to 23-27 in-lbs,

target 25 in-lbs. Refer to SOPM

20-50-01 as an accepted procedure.

1 Bolt - -

FIGURE 4: LATCH PIN FITTING NO. 1 THRU 8 - LATCH PIN FITTING ASSEMBLY REPLACEMENT

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 5: LATCH PIN FITTING NO. 1 THRU 8 - FUSELAGE AND CARGO DOOR INSPECTION

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 5: LATCH PIN FITTING NO. 1 THRU 8 - FUSELAGE AND CARGO DOOR INSPECTION

(SHEET 2 OF 4)

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

FIGURE 5: LATCH PIN FITTING NO. 1 THRU 8 - FUSELAGE AND CARGO DOOR INSPECTION

(SHEET 3 OF 4)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage - - (a)

2 Inspect Door - - (a)

(a) Do a Detailed Inspection for cracks or other damage in the forward large cargo door lower sill, fuselage

frames and interior/exterior skin, cargo door frames, mid-span latch cams (if installed) and main cam latch

mechanism. Do the inspection 42.0 inches in the forward, aft and inboard direction from the Latch Pin

Fitting (LPF) with the migrated latch pin. If any damage is found, more work is required.

FIGURE 5: LATCH PIN FITTING NO. 1 THRU 8 - FUSELAGE AND CARGO DOOR INSPECTION

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 6: TERMINATING ACTION - LATCH PIN FITTING NO. 1 THRU 8 - INCONEL BOLT INSTALLATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
FIGURE 6: TERMINATING ACTION - LATCH PIN FITTING NO. 1 THRU 8 - INCONEL BOLT INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Nut - 8 -

Remove Washer - 8 -

Remove Bolt - 8 -

2 Install (New) Bolt BACB30UU3K29 8 (a)

Install (New) Washer NAS1149E0363P 8 (a)

Install (New) Nut BACN10JC3CD 8 (a)

(a) Prior to installation, thoroughly apply BMS 3-38 corrosion inhibiting compound to the bolt shank, threads,

washer and nut mating surfaces. Ensure bolt is installed with the head on the LPF outboard side (nut on

the inboard side) as shown. Torque nut or bolt head side to 23-27 in-lbs, target 25 in-lbs. Refer to SOPM

20-50-01 as an accepted procedure.

FIGURE 6: TERMINATING ACTION - LATCH PIN FITTING NO. 1 THRU 8 - INCONEL BOLT INSTALLATION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 7: LATCH PIN FITTING NO. 1 THRU 8 - BOLT HEAD DIRECTION CHANGE AND TORQUE CHECK

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-52A0038

ALERT ALERT
FIGURE 7: LATCH PIN FITTING NO. 1 THRU 8 - BOLT HEAD DIRECTION CHANGE AND TORQUE CHECK

(SHEET 2 OF 3)

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Change Bolt - - (a)

2 Torque Bolt - - (b)

Inspect Bolt - - (b)

Torque Bolt - - (b)

(a) Change the installed bolt head direction of existing latch pin retention bolts as necessary. Remove any

bolt that is installed with the head on the LPF inboard side (nut on the outboard side) and re-install the

bolt(s) with the head on the LPF outboard side (nut on the inboard side) as shown. Prior to re-installation

thoroughly apply BMS 3-38 corrosion inhibiting compound to the bolt shank, threads, washer and nut

mating surfaces. Torque nut or bolt head side to 23-27 in-lbs, target 25 in-lbs. Refer to SOPM 20-50-01

as an accepted procedure.

(b) At LPF locations where the installed direction was not changed, apply a 13-15 in-lb torque to the head or

nut to check for loose bolts. Any loose bolts found, remove the nut and do a Detailed Inspection of the

nut and bolt to ensure no threads are damaged. If threads are damaged, replace with a new bolt and nut.

Thoroughly apply BMS 3-38 corrosion inhibiting compound to the bolt threads, shank, washer and nut

mating surfaces. Install nut and apply a 23-27 in-lb full torque, target 25 in-lb, to the latch pin retention

bolt head or nut. Refer to SOPM 20-50-01 as an accepted procedure.

FIGURE 7: LATCH PIN FITTING NO. 1 THRU 8 - BOLT HEAD DIRECTION CHANGE AND TORQUE CHECK

(SHEET 3 OF 3)

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ALERT ALERT