February 06, 2003

Revision 1: May 24, 2007 757-57-0061

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 55

Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0061

Date: February 06, 2003

Revision 1 May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel (-300 Series)

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2003 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Unpublished Work - All Rights Reserved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, BBJ, DC-8, DC-9, 

DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery 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.
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 Table of Contents

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BOEING SERVICE BULLETIN 757-57-0061

Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 16

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 17

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 18

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

FIGURE 1: Open Access - Air Conditioning Duct Removal - Group 1, Group 2 and Group 3 . . . . . . 29

FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1 . 30

FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1 35

FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3 . . . . . . . . 42

FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3 . . . . . . . 45

FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2 . . . . . . . . . . . . 50

FIGURE 7: Close Access - Air Conditioning Duct Installation - Group 1, Group 2 and Group 3. . . . . 52

APPENDIX A: Record of Thickness Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
 Table of Contents

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BOEING SERVICE BULLETIN 757-57-0061

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Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0061 Revision Transmittal Sheet

Date: February 06, 2003

Revision 1: May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel (-300 Series)

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes changed as shown in the initial release of this service bulletin.

REASON FOR REVISION

Revision 1 is sent to add a group of airplanes that may have been delivered with improperly mixed secondary 

fuel vapor barrier sealant and to provide new thickness measurement inspection limits. This revision also 

corrects and clarifies inspection points on the front spar and top surface of the Center Wing Box.

Paragraph 1.E., Compliance, has been changed from 4 years to 5 years in order to align better with heavy 

maintenance checks.

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

paragraph for changes.

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

of important changes.

Pages with no vertical lines have no important changes.

The data given in Information Notice 757-57-0061 R00 IN01 is included in this revision. The Information Notice 

advised operators about the errors in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.

REVISION HISTORY

Original Issue: February 6, 2003

Revision 1: May 24, 2007
 

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Revision 1: May 24, 2007 757-57-0061

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 55

Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0061 Summary

Date: February 06, 2003

Revision 1 May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel (-300 Series)

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied to the outboard 

corners of the front spar. More inspections found defective examples of the Secondary Fuel Barrier applied 

along the front spar and the upper panel.

The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure. When 

the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from fuel leaks or 

fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener holes or cracks in the 

structure and pass into the passenger compartment. There are no reports of fuel leaks or fumes in the 

passenger compartment.

This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front spar and 

upper panel. The inspections will identify locations where the secondary fuel barrier is not satisfactory. A new 

layer of secondary fuel barrier will be applied if it is necessary. A satisfactory secondary fuel barrier will keep 

fuel leaks or fumes out of the pressurized cabin.

Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin.
 

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BOEING SERVICE BULLETIN 757-57-0061

ACTION

Get access to the front spar and the top of the Wing Center Section by removal of the seats, floor covers, floor 

panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If necessary, remove the bulkhead 

lining for more access.

Examine the specified locations where the Secondary Fuel Barrier is applied. Look for examples of missing, 

peeled, non-continuous or non-transparent secondary fuel barrier. Make sure the applied thickness of the 

secondary fuel barrier is between the specified limits. Remove the corrosion inhibitor compound if it is 

necessary, then clean the area where the new layer of secondary fuel barrier will be applied. Install all the 

components that were removed for access. Do system tests as necessary.

EFFECTIVITY

Airplane Model 757-300; Line numbers 804 thru 964; divided into three groups.

COMPLIANCE

Boeing recommends the inspection of the Secondary Fuel Barrier at the next regularly scheduled heavy 

maintenance check. Apply the secondary fuel barrier, if it is necessary, no later than five years after the release 

of this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of September 22, 2000. Please refer to 

Paragraph 2.B., Industry Support Information.

MANPOWER

See Paragraph 1.G Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 757-57-0061

900

STA

1040

STA

NEW LAYER OF SECONDARY FUEL BARRIER.

IF DEFECTIVE, REMOVE AND APPLY A

SECONDARY FUEL BARRIER.

SPAR FOR DEFECTIVE APPLICATION OF

EXAMINE THE UPPER PANEL AND FRONT

V87883
 

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BLANK PAGE
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Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0061

Date: February 06, 2003

Revision 1: May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel (-300 Series)

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-24N001 Part 3 for Airplane Variable Number, Line 

Number, and Serial Number data.

Airplane models:

757-300

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

ARKIA ISRAELI AIRLINES (ARK)

3 NU731–NU732

GROUP CONFIGURATION DESCRIPTION

1 - 757-300 Airplanes that must complete the whole 

bulletin

2 - 757-300 Airplanes that only require inspection 

of the front spar center section.

3 - 757-300 Airplanes previously in Group 1 that 

could have fuel vapor barrier material applied 

that was thinned with lacquer thinner.

1 Group 3 Airplanes that have not incorporated 

the previous release of service bulletin 757-57-

0061.

2 Group 3 Airplanes that have incorporated the 

previous release of service bulletin 757-57-

0061.
 

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BOEING SERVICE BULLETIN 757-57-0061

CONDOR (CDF)

1 NU701–NU705 NU721–NU723 NU728

3 NU724–NU727

THOMAS COOK AIRLINES UK (JMA)

2 NL001–NL002

IDENTIFICATION BY VARIABLE NUMBER

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied to 

the outboard corners of the front spar. More inspections found defective examples of the Secondary 

Fuel Barrier applied along the front spar and the upper panel.

The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure. 

When the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from 

fuel leaks or fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener 

holes or cracks in the structure and pass into the passenger compartment. There are no reports of 

fuel leaks or fumes in the passenger compartment.

This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front 

spar and upper panel. The inspections will identify locations where the secondary fuel barrier is not 

satisfactory. A new layer of secondary fuel barrier will be applied if it is necessary. A satisfactory 

secondary fuel barrier will keep fuel leaks or fumes out of the pressurized cabin.

NOTE: A satisfactory secondary fuel barrier is described in the Accomplishment Instructions, 

Part III - Inspection of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3 -

Configuration 1.

Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin.

Variable Group

NL001–NL002 2

NU701–NU705 1

NU721–NU723 1

NU724–NU727 3

NU728 1

NU731–NU732 3
 

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BOEING SERVICE BULLETIN 757-57-0061

Revision 1 is sent to add a group of airplanes that may have been delivered with improperly mixed 

secondary fuel vapor barrier sealant and to provide new thickness measurement inspection limits. 

This revision includes the correct special tooling requirements for the accomplishment of the service 

bulletin, and provides clarifications and corrections to inspection points on the Front Spar and Upper 

Panel. 

D. Description

Get access to the front spar and the top of the Wing Center Section by removal of the seats, floor 

covers, floor panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If 

necessary, remove the bulkhead lining for more access.

Examine the specified locations where the Secondary Fuel Barrier is applied. Look for examples of 

missing, peeled, non-continuous or non-transparent secondary fuel barrier. Make sure the applied 

thickness of the secondary fuel barrier is between the specified limits. Remove the corrosion inhibitor 

compound if it is necessary, then clean the area where the new layer of secondary fuel barrier will be 

applied. Install all the components that were removed for access. Do system tests as necessary.

The airplane effectivity is divided into three groups. The airplanes in Group 1 and Group 3, 

Configuration 1 must complete all of the service bulletin. The airplanes in Group 2 will only do work 

on the Front Spar. The airplanes in Group 3, Configuration 2 must be checked to determine if the 

vapor barrier meets the new thickness requirements. 

Revision 1 - More work is necessary on airplanes changed as shown in the initial release of this 

service bulletin. The airplanes in Group 3, Configuration 2 must be checked to determine if the vapor 

barrier meets the new thickness requirements. 

PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION 

RESULTS WHEN EACH INSPECTION IS COMPLETE

Send your report to:

BOEING COMMERCIAL AIRPLANES GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT

E. Compliance

Boeing recommends the inspection of the Secondary Fuel Barrier at the next regularly scheduled 

heavy maintenance check. Apply the secondary fuel barrier, if it is necessary, no later than five years 

after the release of this service bulletin.

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.
 

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BOEING SERVICE BULLETIN 757-57-0061

NOTE: Joint Airworthiness Requirements (JAR) compliance status may be found in the Service

Bulletin Index, Part 1.

G. Manpower

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

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

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

lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Group 1 and Group 3, Configuration 1 ONLY

Group 2 ONLY

Group 3, Configuration 2 ONLY

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 13.0 6.5

Inspection 2 8.0 4.0

Thickness Measurement 1 6.0 6.0

Secondary Fuel Barrier 

Application

1 6.5 6.5

Close Access 2 15.0 7.5

TOTAL FOR EACH AIRPLANE 48.5 30.5

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 4.0 2.0

Inspection 2 8.0 4.0

Secondary Fuel Barrier 

Application

1 6.5 6.5

Close Access 2 6.0 3.0

TOTAL FOR EACH AIRPLANE 24.5 15.5

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 13.0 6.5

Thickness Measurement 1 6.0 6.0
 

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BOEING SERVICE BULLETIN 757-57-0061

H. Weight and Balance Changes

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Miscellaneous Retrofit Requirement (MRR) MRR 5574-1067

b. Service Related Problem (SRP) 757-SRP-28-0067

c. Boeing Document D6-56722, Customer Cost Benefit Methodology Guide

d. 757 Maintenance Manual (AMM) Subjects 20-10-11, 20-10-12, 21-00-00, 21-00-01,

21-21-00, 21-23-06, 24-41-00, 25-21-02, 25-25-01, 25-27-01, 25-50-03, 25-50-04,

28-11-00, 36-00-00 and 53-01-01.

e. 757 Structural Repair Manual (SRM) Subject 57-10-10

f. Boeing Standard Overhaul Practices Manual (BSOPM) 20-41-05, 20-50-19 and 20-60-01

g. 757 Maintenance Planning Document (MPD) Item Number CP53-124-01I

h. FAA Airworthiness Directive 98-19-05, Amendment 39-10747

i. Boeing Parts Standards Document D-590

j. Boeing Drawing 65-88700 

2. Data supplied with this Service Bulletin:

None.

Secondary Fuel Barrier 

Application

1 6.5 6.5

Close Access 2 15.0 7.5

TOTAL FOR EACH AIRPLANE 40.5 26.5

Airplane

Change in Weight 

(Pounds)

Change in Moment 

(Pound-Inches)

757-300 + 1 + 1, 000

Task

Number of 

Persons Task-Hours Elapsed Hours
 

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BOEING SERVICE BULLETIN 757-57-0061

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.

K. Publications Affected

None.

L. Interchangeability and Intermixability of Parts

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

Drawing Number Title

110N0004 Seal Application - Secondary Fuel Barrier Coating, Wing, Center 

Section

112N2010 Terminal Fitting Installation - Wing / Body Joint, Front Spar

144N2101 Bulkhead Installation, Front Spar Body Station 900

140N3002 Corrosion Inhibiting Compound Instl - Fuselage
 

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2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are available for 757 airplanes in warranty as of September 22, 2000. For 

inspection man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim 

to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin 

is found during the inspection for airplanes in warranty as of that date and additional man-hours and 

kits, parts, and/or special tools are required, send a warranty claim to Boeing Commercial Airplanes 

Group - Warranties. Please refer to this service bulletin number and reference the airplane variable 

numbers in your purchase order.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

Part Number / Specification QTY Name Notes

180 to 400 grit 20 Sheets Abrasive Paper, Aluminum Oxide

BMS 5-81, Type II 40 oz. Sealant, Secondary Fuel Barrier (a)

BMS 3-23, Type II, Class 2 1 Pint Organic Corrosion Inhibiting Compound (a)

BMS 3-29 1 Pint Advanced Organic Corrosion Inhibiting 

Compounds (CIC)

(a)

BMS 3-35 1 Pint Heavy Duty Corrosion Inhibiting Compound (a)

BMS 10-11, Type I 1 Pint Chemical and Solvent Resistant Finish (a)

BMS 5-95, Type 1, Class B-1/2, 

B-2 or B-4

1 Pint Pressure and Environmental Sealant - 

Chromate Type

(a) (b)

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

data.

(b) Refer to BSOPM 20-50-19
 

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BOEING SERVICE BULLETIN 757-57-0061

E. Special Tooling - Price and Availability

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

Service Bulletin. Tool price and supply data are not given.

F. Special Tooling Necessary to do this Service Bulletin

To get the Non-Conductive Coating Thickness Gage shown below, refer to Paragraph 2.E., Special 

Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 

1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary 

tools are available.

Tool Number Name

602-816 Dualscope MP20 (a) (b)

602-128 ETA 3.3H Probe (a) (b)

(a) The Dualscope with probe are an example of a Non-Conductive Coating 

Thickness Gage (NCCTG). The use of any NCCTG is permitted, but it must 

have a thickness range from 0.001 - 0.045 inches.

(b) Fisher Technology (9U437)

750 Marshall Phelps Rd.

Windsor, CT 06095-2199
 

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BOEING SERVICE BULLETIN 757-57-0061

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. 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.

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

— Linear dimensions are in inches

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

minus 0.03 inch.

— 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 are given in 757 Structural Repair 

Manual, Chapter 51

— Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, 

Chapter 51.

5. For approved fastener and process material substitutions, refer to 757 Structural Repair 

Manual, Chapter 51, Alternate fasteners are given in 757 Structural Repair Manual 

Chapter 51 and Boeing Drawing 65-88700

6. Refer to the Boeing Standard Wiring Practices Manuals 20-10-11 and 20-10-12 for the 

wire installation procedures.

7. If the length of fasteners specified in this service bulletin do not meet the installation 

standards, fasteners of the same specification, or an approved substitute, one grip 

length longer or shorter may be used.

8. Detailed Visual Inspection - 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 access procedures may be required.

B. WORK INSTRUCTIONS

1. For Group 1, Group 2 and Group 3, Configuration 1 airplanes, do Part I through Part VIII as 

applicable.

2. For Group 3, Configuration 2 airplanes, do Part IX.

PART I - Open Access - Group 1 and Group 3, Configuration 1

1. Supply external power to the airplane, as given in AMM 24-41-00.
 

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2. Release the pressure from the pneumatic system; refer to AMM 36-00-00.

3. Set the L And R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to 

AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

b. Put a DO-NOT-OPERATE tag on the selectors.

4. Set the L And R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel 

P5. Refer to AMM 21-00-01.

a. Make sure the INOP lights go on, and the ON lights go off.

b. Put a DO-NOT-OPERATE tag on the switch-lights.

5. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section.

a. Between BS 900 and 1040, remove:

(1) The passenger seats, as referenced in AMM 25-25-01.

(2) The floor covering, as referenced in AMM 25-27-01.

(3) The floor panels, as referenced in AMM 25-50-04 and 53-01-01.

(4) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02.

b. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1.

c. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in

AMM 25-50-03.

PART II - Open Access - Group 2

1. Supply external power to the airplane, as given in AMM 24-41-00.

2. Release the pressure from the pneumatic system; refer to AMM 36-00-00.

3. Set the L And R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to 

AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

b. Put a DO-NOT-OPERATE tag on the selectors.

4. Set the L And R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel 

P5. Refer to AMM 21-00-01.

a. Make sure the INOP lights go on, and the ON lights go off.

b. Put a DO-NOT-OPERATE tag on the switch-lights.
 

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5. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section.

a. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1.

b. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in

AMM 25-50-03.

Part III - Inspection of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, 

Configuration 1

1. Do a Detailed Visual Inspection of the Front Spar and the Upper Panel. Refer to Figure 2 and 

Figure 3 for the specified location of the application.

a. Look for signs of missing, peeled, non-continuous or non-transparent secondary fuel barrier. 

(1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to 

examine in Paragraph 1.b.

(2) If defective surfaces are found, the secondary fuel barrier is NOT permitted. Record 

the location. Repair as given in Part V - Repair of the Secondary Fuel Barrier - Group 

1, Group 2 and Group 3, Configuration 1.

b. Look for small air bubbles, air pockets or blister-like areas, or solid particles in the secondary 

fuel barrier or between the secondary fuel barrier and the structure.

(1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to 

examine the surface as directed in Paragraph 1.c.

(2) If some small air bubbles or non-metallic solid particles are found, they must NOT break 

the continuity of the application of the secondary fuel barrier. If there are no more than 

2 (two) occurrences in a 12 inch by 12 inch area the application is permitted. Continue 

to examine the surface as directed in Paragraph 1.c if this statement is correct.

(3) Air pockets or blister-like areas between the secondary fuel barrier and the structure 

are NOT permitted. Record the location and repair as given in Part V – Repair of the 

Secondary Fuel Barrier – Group 1, Group 2 and Group 3, Configuration 1.

NOTE: Solid metallic particles are not acceptable. Record the location and repair as

given in Part V – Repair of the Secondary Fuel Barrier – Group 1, Group 2 and

Group 3, Configuration 1.

(4) If small air bubbles, air pockets or non-metallic solid particles break the continuity of the 

application of the secondary fuel barrier, the application is NOT permitted. Record the 

location. Repair as given in Part V - Repair of the Secondary Fuel Barrier - Group 1, 

Group 2 and Group 3, Configuration 1. Continue to examine in the surface as directed 

in Paragraph 1.c.

c. Look for fillet sealant, primer, corrosion inhibiting compound or other finishes that are 

applied on top of the Secondary Fuel Barrier.

(1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to 

do the Accomplishment Instructions.
 

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(2) If defective surfaces are found, and the structure below can be seen, it is a permitted 

secondary fuel barrier. Continue to do the Accomplishment Instructions.

(3) If defective surfaces are found, but the structure below cannot be seen, it is NOT a 

permitted secondary fuel barrier. Record the location and repair as given in

Part V - Repair of the Secondary Fuel Barrier - Group 1and Group 3, Configuration 1.

d. Look for missing fillet (cap) seals common to the fastener locations shown in Figure 2,

View J-J.

(1) If all the locations are cap sealed, no work is necessary. Continue to do the 

Accomplishment Instructions.

(2) If there are locations that are not cap sealed, record the location. Repair as given in 

Part V - Repair of the Secondary Fuel Barrier - Group 1 and Group 3, Configuration 1.

Part IV - Thickness Measurement Inspection - Group 1 and Group 2 

1. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figures 

4 and 5.

2. Make sure the thickness is 0.007 - 0.022 inch. (This includes a 0.002 inch layer of primer.) Refer 

to Figure 2.

a. If the thickness is less than 0.007 inch, apply more Secondary Fuel Barrier as given in

Part X - Application of More Secondary Fuel Barrier.

b. If the thickness is more than 0.022 inch, it must have a transparent quality. A transparent 

quality makes it easy to see a crack that starts below the structure. An applied secondary 

fuel barrier that is not transparent must be removed. Repair as given in Part V - Repair of 

Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1.

c. If the thickness is more than 0.042 inch, the secondary fuel barrier is NOT permitted. Repair 

as given in Part V - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, 

Configuration 1.

NOTE: Do NOT measure on top of the other sealants. There is no limit to the thickness of

secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental

Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant).

3. Record the thickness data in the Inspection Worksheets given in Appendix A and keep the 

worksheet with the airplane maintenance records for future reference.

Part IV(a) - Thickness Measurement Inspection - Group 3, Configuration 1

1. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figure 4 

and Figure 5.

NOTE: The thickness measurements below includes a 0.002 inch layer of primer.

a. If the thickness is less than 0.007 inch, apply a minimum of 0.005 inch new Secondary Fuel 

Barrier as given in Part X - Application of More Secondary Fuel Barrier. 
 

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b. If the thickness is greater than 0.012 inch, but less than or equal to 0.017 inch, apply a 

minimum of 0.005 inch new Secondary Fuel Barrier as given in Part X - Application of More 

Secondary Fuel Barrier.

NOTE: Thicknesses between 0.007 inch and 0.012 inch do not require the application of

the additional 0.005 inch secondary fuel barrier. Overcoating is allowed in this

thickness range to make the repair of adjacent areas more efficient.

c. If the thickness is greater than 0.017 inch, but less than or equal to 0.037 inch it must have 

a transparent quality and it must be overcoated with a minimum of 0.005 inch of new 

Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. 

NOTE: A transparent quality makes it easy to see a crack in the structure. An applied

secondary fuel barrier that is not transparent must be removed. Repair as given in

Part V - Repair of Secondary Fuel Barrier - Group 1, Group 2 and Group 3 -

Configuration 1.

d. If the thickness is more than 0.037 inch, the secondary fuel barrier is NOT permitted. Repair 

as given in Part VI - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3 

- Configuration 1.

NOTE: Do NOT measure on top of the other sealants. There is no limit to the thickness of

secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental

Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant).

2. Record the thickness data in the Inspection Worksheets given in Appendix A and keep the 

worksheet with the airplane maintenance record for future reference.

Part V - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1

1. Repair the Secondary Fuel Barrier at the locations noted in Part III - Inspection of the Secondary 

Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1; and in Part IV - Thickness 

Measurement Inspection - Group 1 and Group 2; and in Part IV(a) - Thickness Measurement 

Inspection - Group 3, Configuration 1.

a. Remove the secondary fuel barrier as given in AMM 28-11-00..

NOTE: 757 AMM 28-11-00 does not directly address removal of large areas of BMS 5-81

sealant. It is permissible to remove the bulk of the sealant with the use of plastic or

wooden scrapers. Boeing production typically uses plastic scrapers.

b. If not already applied, apply a cap seal to the top side of the fasteners as specified in 

BSOPM 20-50-19. Refer to Figure 2, View J-J.

c. Apply the secondary fuel barrier as given in AMM 28-11-00.

Part VI - Inspection and Application of the Secondary Fuel Barrier - Group 2

1. Do a Detailed Visual Inspection of the Front spar and the Upper Panel to ensure that the 

application covers the minimum area specified in Figure 6.

a. Make sure the Secondary Fuel Barrier is applied a minimum of 1.50 inches below the lowest 

fastener that passes through the front spar web and the lower chord.
 

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b. If the Secondary Fuel Barrier does not cover the minimum specified area, apply as given in 

AMM 28-11-00.

Part VII - Close Access - Group 1 and Group 3 - Configuration 1

1. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center 

Section.

a. Install the air conditioning ducts on the mix manifold as shown in Figure 7.

b. Do a leak test of the air conditioning ducts as given in AMM 21-23-06 "Do the Riser Duct 

Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser 

duct.

c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in

AMM 25-50-03.

d. Between BS 900 and 1040, install:

(1) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02.

(2) The floor panels, as referenced in AMM 25-50-04 and 53-01-01.

(3) The floor covering, as referenced in AMM 25-27-01.

(4) The passenger seats, as referenced in AMM 25-25-01.

2. Set the L And R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. 

Refer to AMM 21-00-01.

a. Remove the DO-NOT-OPERATE tag from the switch-lights.

b. Make sure the INOP lights go off, and the ON lights go on.

3. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to 

AMM 21-00-00.

a. Remove the DO-NOT-OPERATE tag from the selectors.

b. Make sure the PACK OFF lights go off.

4. Put the pneumatic system back to service condition. Refer to AMM 36-00-00.

5. Put the electrical power back to service condition, as given in AMM 24-41-00.

6. Put the airplane back to a serviceable condition.

Part VIII - Close Access - Group 2

1. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center 

Section.

a. Install the air conditioning ducts on the mix manifold as shown in Figure 7.
 

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b. Do a leak test of the air conditioning ducts as given in AMM 21-23-06 "Do the Riser Duct 

Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser 

duct.

c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in

AMM 25-50-03.

2. Set the L And R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. 

Refer to AMM 21-00-01.

a. Remove the DO-NOT-OPERATE tag from the switch-lights.

b. Make sure the INOP lights go off, and the ON lights go on.

3. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to 

AMM 21-00-00.

a. Remove the DO-NOT-OPERATE tag from the selectors.

b. Make sure the PACK OFF lights go off.

4. Put the pneumatic system back to service condition. Refer to AMM 36-00-00.

5. Put the electrical power back to service condition, as given in AMM 24-41-00.

6. Put the airplane back to a serviceable condition.

PART IX - Thickness Measurement Inspection - Group 3 - Configuration 2 Airplanes

1. Review the maintenance records for the airplane to determine if there was a minimum of 0.005 

inch new Secondary Fuel Barrier applied. If a minimum of 0.005 inch new Secondary Fuel Barrier 

was applied, then no further action is required in that area.

2. If the thickness of the Secondary Fuel Barrier can not be determined from the maintenance 

records, or if there was not a minimum of 0.005 inch of new Secondary Fuel Barrier added, then 

go to Step 3.

3. Supply external power to the airplane, as given in AMM 24-41-00.

4. Release the pressure from the pneumatic system; refer to AMM 36-00-00.

5. Set the L And R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to 

AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

b. Put a DO-NOT-OPERATE tag on the selectors.

6. Set the L And R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel 

P5. Refer to AMM 21-00-01.

a. Make sure the INOP lights go on, and the ON lights go off.
 

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b. Put a DO-NOT-OPERATE tag on the switch-lights.

7. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section.

a. Between BS 900 and 1040, remove:

(1) The passenger seats, as referenced in AMM 25-25-01.

(2) The floor covering, as referenced in AMM 25-27-01.

(3) The floor panels, as referenced in AMM 25-50-04 and 53-01-01.

(4) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02.

b. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1.

c. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in

AMM 25-50-03.

8. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figure 4 

and Figure 5.

NOTE: The thickness measurements below includes a 0.002 inch layer of primer.

a. If the thickness is less than 0.007 inch, apply a minimum of 0.005 inch new Secondary Fuel 

Barrier as given in Part X - Application of More Secondary Fuel Barrier. 

b. If the thickness is greater than 0.012 inch, but less than or equal to 0.017 inch, apply a 

minimum of 0.005 inch new Secondary Fuel Barrier as given in Part X - Application of More 

Secondary Fuel Barrier.

NOTE: Thicknesses between 0.007 inch and 0.012 inch do not require the application of

the additional 0.005 inch secondary fuel barrier. Overcoating is allowed in this

thickness range to make the repair of adjacent areas more efficient.

c. If the thickness is greater than 0.017 inch, but less than or equal to 0.037 inch it must have 

a transparent quality and it must be overcoated with a minimum of 0.005 inch of new 

Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. 

NOTE: A transparent quality makes it easy to see a crack in the structure. An applied

secondary fuel barrier that is not transparent must be removed. Repair as given in

Step 10.

d. If the thickness is more than 0.037 inch, the secondary fuel barrier is NOT permitted. Repair 

as given in Step 10.

NOTE: Do NOT measure on top of the other sealants. There is no limit to the thickness of

secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental

Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant).

9. Record the thickness data in the Inspection Worksheets given in Appendix A and keep the 

worksheet with the airplane maintenance records for future reference.
 

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10. Repair the Secondary Fuel Barrier where removal and reapplication is required.

a. Remove the secondary fuel barrier as given in AMM 28-11-00.

NOTE: 757 AMM 28-11-00 does not directly address removal of large areas of BMS 5-81

sealant. It is permissible to remove the bulk of the sealant with the use of plastic or

wooden scrapers. Boeing production typically uses plastic scrapers.

b. If not already applied, apply a cap seal to the top side of the fasteners as specified in 

BSOPM 20-50-19. Refer to Figure 2, View J-J.

c. Apply the secondary fuel barrier as given in AMM 28-11-00.

11. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center 

Section.

a. Install the air conditioning ducts on the mix manifold as shown in Figure 7.

b. Do a leak test of the air conditioning ducts as given in AMM 21-23-06 "Do the Riser Duct 

Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser 

duct.

c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in

AMM 25-50-03.

d. Between BS 900 and 1040, install:

(1) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02.

(2) The floor panels, as referenced in AMM 25-50-04 and 53-01-01.

(3) The floor covering, as referenced in AMM 25-27-01.

(4) The passenger seats, as referenced in AMM 25-25-01.

12. Set the L And R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. 

Refer to AMM 21-00-01.

a. Remove the DO-NOT-OPERATE tag from the switch-lights.

b. Make sure the INOP lights go off, and the ON lights go on.

13. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to 

AMM 21-00-00.

a. Remove the DO-NOT-OPERATE tag from the selectors.

b. Make sure the PACK OFF lights go off.

14. Put the pneumatic system back to service condition. Refer to AMM 36-00-00.

15. Put the electrical power back to service condition, as given in AMM 24-41-00.
 

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16. Put the airplane back to a serviceable condition.

PART X - Application of More Secondary Fuel Barrier

1. Lightly sand the area with 180 grit aluminum oxide or finer abrasive paper. Remove as little of 

the sealant film as possible. Do not sand to bare metal.

2. Remove residue with clean wipers.

3. Prepare the secondary fuel barrier sealant (BMS 5-81, Type II) as given in AMM 28-11-00.

4. Apply one or two layers of BMS 5-81, Type II sealant with a flat, bristle brush. Take all reasonable 

precautions to prevent or minimize sag areas.

a. For horizontal surfaces, let the sealant dry a minimum of 1/2 hour between layers.

b. For vertical surfaces, let the sealant dry a minimum of 2 hours between layers.

5. Refer to AMM 28-11-00 for cure rates.
 FIGURE 1: Open Access - Air Conditioning Duct Removal - Group 1, Group 2 and Group 3

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FIGURE 1: Open Access - Air Conditioning Duct Removal - Group 1, Group 2 and Group 3

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Disconnect Duct Assembly 21-21-00 2 At each end; put covers 

over all open duct ends.

2 Remove Duct Assembly - 2 -

FWD

COMPARTMENT

TO PASSENGER

(2 EACH SIDE)

1 2

CONNECTOR

SERVICE

GROUND AIR

MIX MANIFOLD

V88483

(SHEET 1 OF 1)
 FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1

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FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1

FWD

900

STA

0

BL

45.50

RBL

45.50

LBL

900

STA

1 SPAR

FRONT

A

A

B B

0

BL

24.75

LBL

24.75

RBL

45.50

LBL

45.50

RBL

A-A

G

C

J J

F

70.50

RBL

70.50

LBL

3 FUEL BARRIER

SECONDARY 2

V87884

I I

D

D

C

G

E

E

F

H

H

(SHEET 1 OF 5)
 FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1

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FUEL BARRIER

SECONDARY FUEL BARRIER

SECONDARY

TYPICAL

C-C

FUEL BARRIER

SECONDARY

LOWER CHORD

CAP SEAL

TYPICAL

D-D

FUEL BARRIER

SECONDARY

SPAR WEB

FRONT

FRONT SPAR MIN

1.50

UPPER PANEL INBD

FITTING

SHEAR

2 3

2 3

MIN

1.00

TYPICAL

B-B

2 3

FWD

MIN

1.0

MIN

1.0

MIN

1.0

MIN

1.0

FITTING

SIDE 2 3

FWD

V87885

(SHEET 2 OF 5)
 FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1

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1.00

MIN

TYPICAL OUTBOARD OF BBL 45.50

E-E

FUEL BARRIER

SECONDARY

1.50

TYPICAL INBOARD OF BBL 45.50

F-F

FUEL BARRIER

SECONDARY

1.00

MIN

FUEL BARRIER

SECONDARY

TYPICAL

G-G

MIN

1.00

FRONT SPAR

SKIN

LOWER CHORD

FRONT SPAR

1.00

MIN STIFFENER

SPAR

FRONT

CHORD-BODY

2 3

FWD

STIFFENER

SPAR

FRONT

CHORD-BODY

2 3

FWD

2 3

INBD

FWD

FITTING

SIDE

0.50 MIN

V87886

(SHEET 3 OF 5)
 FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1

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FUEL BARRIER

SECONDARY

OF BBL 45.50

TYPICAL OUTBOARD

H-H

MIN

0.50

FUEL BARRIER

SECONDARY

FRONT SPAR WEB

TYPICAL

I-I

STIFFENER

1.00

MIN

1.00

MIN

FUEL BARRIER

SECONDARY

INBD

FWD

4 (7 PLACES)

CAP SEAL

TYPICAL

J-J

2 3

FWD

2 3

FWD

CHORD

ANGLE

SPLICE

SPAR

FRONT

2 3

N78545

(SHEET 4 OF 5)
 FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1

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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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Front Spar - Remove dirt/debris from 

the area

2 Identify Secondary Fuel 

Barrier

Visual Inspection - (a)

3

Examine Front Spar Detailed Visual 

Inspection

- (b) (c)

Remove Corrosion 

Inhibiting 

Compound

BMS 3-23 or 

BMS 3-29 or 

BMS 3-35

- This is only necessary if 

it is difficult to identify a 

layer of Secondary Fuel 

Barrier. Refer to 

BSOPM 20-41-05 and 

20-60-01 for removal.

4 Verify Cap Seal 7 See View J-J

 (a) Look for a glossy finish, a clear to brown (or yellow) color, and a rubber-like texture.

 (b) Use a flashlight. Hold it 10 to 20 degrees to the inspection area.

 (c) Look for defective layers of secondary fuel barrier as specified in Part III - Inspection of the 

Secondary Fuel Barrier - Group 1, in the Work Instructions.

(SHEET 5 OF 5)
 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

FWD

900

STA

1040

STA

0

BL

24.75

RBL

45.50

RBL

70.50

RBL

24.75

LBL

45.50

LBL

70.50

LBL

900

STA

TOP PANEL 1

208.1

WL

1040

STA

V87887

B

E

E

H

H

D

D

B

C

C

A

A

G

G

M

M

O

O

P

P

N

N

(SHEET 1 OF 7)
 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

RIGHT SIDE SHOWN, LEFT SIDE SAME

A-A

TYPICAL EDGE

PANEL

CHORD UPPER

PANEL

SKIN

PLUS

MIN

1.00

STA 975.5 TO 1040

TYPICAL BEAM

B-B

LOWER CHORD

FLOOR BEAM

WEB

BEAM

FLOOR

PANEL

UPPER

C-C

ASSEMBLY

PLUG

MIN

0.50

PANEL

UPPER

TYPICAL ALL BRACKETS

D-D

PANEL

UPPER

BRACKET

SUPPORT

MIN

1.00

MIN

0.75 2 3

BEAM

CREASE

2 3

2 3

INBD

FWD

2 3

FWD

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

V87888

(SHEET 2 OF 7)
 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

E-E

F-F

RIGHT SIDE SAME

LEFT SIDE SHOWN,

G-G

SPLICE

LONGERON

AND SEALANT

COMPOUND

EXISTING

F F

BEAM

STUB

MIN

1.00

PANEL

UPPER

CHORD

PLUS

MIN

0.25

2 3

70.50

RBL

70.50

RBL

INBD

FWD

PANEL

UPPER

BEAM

STUB

CHORD

PLUS 2 3

INBD

MIN

2.00

INBD

900

STA

SKIN

BODY

CHORD

PLUS

FRAME

PANEL

UPPER

SPAR

FRONT

2 3

208.10

WL

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

SEALANT

EXISTING

V87889

(SHEET 3 OF 7)
 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

INBD

FWD

PANEL

UPPER

REAR SPAR

1.00 MIN

1.00 MIN MIN

1.00

MIN

1.00

1040

STA

FRAME

FITTING

KICK

2 3

MIN

2.00

MIN

1.00

MIN

1.00

70.50

LBL

PANEL

UPPER

KICK FITTING

FRAME

UPPER CHORD

REAR SPAR

1040

STA

2 3

70.50

LBL

45.50

LBL

24.75

LBL

0

BL

BEAM

FLOOR

CHORD

PLUS PANEL

UPPER

1024

STA

MIN

1.00

BEAM

FLOOR

BEAM

FLOOR

1040

STA

INBD

FWD

2 3

2 3

DO NOT BLOCK

DRAIN PATH -

OF KICK FITTING

TYPICAL OUTSIDE WALLS

I-I

SEALANT

EXISTING

H-H

J-J

FRAME

V87890

L

L

K

K

I

I

J J

(SHEET 4 OF 7)
 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

MIN

1.00

MIN

1.00

SPAR

REAR

1040

STA

FITTING

KICK

PANEL

UPPER

SPACER

FRAME

SEAL

INJECTION

FILLET AND

EXISTING

FWD

2 3

FWD

SPAR

PANEL REAR

UPPER

BEAM WEB

FLOOR FITTING

SEAL

PRE-PACK

DECK

PRESSURE

ANGLE

ATTACH

1040

STA

MIN

1.00

MIN

1.00

2 3

DO NOT BLOCK

DRAIN PATH -

FWD

2 3

SEAL

INJECTION

FILLET AND

EXISTING

PANEL

UPPER

PLUS CHORD

DOUBLE

MIN

1.00

MIN

0.75

SPAR

FRONT

900

STA

DO NOT BLOCK

DRAIN PATH -

RIGHT SIDE SAME

LEFT SIDE SHOWN,

M-M

OF KICK FITTING

TYPICAL, INSIDE WALLS

K-K

L-L

MIN

1.00

MIN

2.00

MIN

0.75

PANEL

UPPER

SEAL

INJECTION

FILLET AND

EXISTING 1040

STA

2 3

MIN

2.00

PLUS CHORD

DOUBLE

SPAR

REAR

RIGHT SIDE SAME

LEFT SIDE SHOWN,

N-N

FWD

V87891

(SHEET 5 OF 7)
 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

24.75

RBL

208.1

WL

MIN

1.00

BEAM

FLOOR

UPPER PANEL

TYPICAL FROM STA 900 TO STA 975.5

O-O

MIN

1.00

MIN

1.00

FITTING

TENSION

UPPER PANEL

BEAM

FLOOR

(15 PLACES)

TYPICAL AT TENSION TIE FITTINGS

P-P

2 3

2 3

N78557

(SHEET 6 OF 7)
 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Upper Panel - Remove dirt/debris from 

the area

2 Identify Secondary Fuel 

Barrier

Visual Inspection - (a)

3

Examine Upper Panel Detailed Visual 

Inspection

- (b) (c)

Remove Corrosion 

Inhibiting 

Compound

BMS 3-23 or 

BMS 3-29 or

BMS 3-35

- This is only necessary if 

it is difficult to identify a 

layer of Secondary Fuel 

Barrier. Refer to 

BSOPM 20-41-05 and 

20-60-01 for removal.

 (a) Look for a glossy finish, clear to brown (or yellow) color, and a rubber-like texture.

 (b) Use a flashlight. Hold it 10 to 20 degrees to the inspection area.

 (c) Look for defective layers of secondary fuel barrier as specified in Part III - Inspection of the 

Secondary Fuel Barrier - Group 1, in the Work Instructions.

(SHEET 7 OF 7)
 FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3

BFAW (BODY FRAME ASSEMBLY WEB)

BFS (BODY FRAME STIFFENER)

FSS (FRONT SPAR STIFFENER)

FSW (FRONT SPAR WEB)

INSPECTION POINTS

(SEE APPENDIX A)

A

A

B

C

C

B

FWD

0

BL

70.50

RBL

70.50

LBL

900

STA

1

FSW 1

FSS 5

FSS 1

BFAW 2

FSS 10

FSS 6

BFS 4

BFS 3

FSS 15

FSS 11

FSS 20

FSS 16

FSS 25

FSS 21

FSS 26

FSS 30

FRONT SPAR

FSS 35

FSS 31

FSS 40

FSS 36

FSW INSPECTION POINTS)

(TYPICAL BETWEEN

5.0

4.0

FSS 46

FSS 41

FSS 45

FSS 50

FSS 55

FSS 51

FSS 59

14

FSW

BFS 2

FSS 64

BFS 1

BFAW 1

FSS 60

FSS 56

900

STA

V87892

(SHEET 1 OF 3)
 FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

TYPICAL FSW

(14 PLACES)

X

X/2

0.5

FRONT SPAR WEB

TYPICAL FSS

(64 PLACES)

STIFFENER

STIFFENER

TYPICAL

A-A

TYPICAL

C-C

FRAME

ASSY

SEAL

CAP

SKIN

FRONT

SPAR

TYPICAL

D-D

X

X/2

SPAR

(2 PLACES)

TYPICAL BFAW

FRONT

ASSY

FRAME

X

X/2

UPPER

PANEL

TYPICAL

B-B

(4 PLACES)

TYPICAL BFS

FRAME

FRONT

(TYPICAL)

STRINGER

ASSY

SKIN

(TYPICAL)

CAP SEAL SPAR

OF STIFFENER ONLY

INSPECT THIS SIDE

D

D

FWD

INBD FWD

1 2 1 2

1 2

1 2

V87893

(SHEET 2 OF 3)
 FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

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 one airplane. 

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Front Spar Remove dirt/debris from 

the area

2

Measure/

Make Sure/ 

Record

Secondary Fuel 

Barrier

(a) (b) (c)

Front Spar Web FSW 14 See View A-A

Front Spar 

Stiffeners

FSS 64 See View A-A

Body Frame Assy 

Web

BFAW 2 See View B-B

Body Frame 

Stiffener

BFS 4 See Views C-C and D-D

 (a) Use a Non-Conductive Coating Thickness Gage to measure the thickness of the applied secondary fuel barrier. (Refer to Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.)

 (b) Deleted - See Accomplishment Instructions for thickness limits.

 (c) Record the measurements on the Inspection Worksheets in Appendix A.

(SHEET 3 OF 3)
 FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3

FWD

E

E

A

A

C

C

900

STA

0

BL

24.75

RBL

45.50

RBL

70.50

RBL

24.75

LBL

45.50

LBL

70.50

LBL

900

STA

TOP PANEL

1040

STA

208.1

WL

1040

STA

LSOB (LEFT SIDE OF BODY)

RSOB (RIGHT SIDE OF BODY)

INSPECTION POINTS

FB (FLOOR BEAM)

LTP (LEFT TOP PANEL)

RTP (RIGHT TOP PANEL)

(SEE APPENDIX A)

LSOB 10

LSOB 1

FB 50

FB 41

LTP 8

LTP 5

FB 40

LTP 4

FB 31

LTP 1

FB 21

FB 30

RTP 14

RTP 11

FB 20

FB 11

FB 10

RTP 10

RTP 7

FB 1

RSOB 1

RSOB 10

1

RTP 1

RTP 6

LTP 9

LTP 14

V87894

(SHEET 1 OF 5)
 FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

5.0

5.0

3.0

3.0

11.0

13.0

(TYPICAL)

11.0

(TYPICAL)

13.0

TYPICAL FLOOR BEAM INSPECTION POINT

UPPER PANEL

B-B

FLOOR BEAM

0.50

OF THE WEB ONLY

INSPECT THIS SIDE

B

B

FWD

INBD

900

STA

920

STA

940

STA

960

STA

984

STA

996

STA

1020

STA

1032.3

STA

1040

STA

INSPECTION POINTS

TYPICAL FLOOR BEAM

A-A

FLOOR BEAM

10 PLACES PER

1 2

1 2

V87895

(SHEET 2 OF 5)
 FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

PANEL

UPPER

5.0

C-C

PLUS

CHORD

LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE

TYPICAL SIDE-OF-BODY INSPECTION POINTS

10 PLACES

BEAM

STUB

LSOB 1 LSOB 10

1020

STA

1000

STA

980

STA

960

STA

920

STA SPAR

FRONT REAR

SPAR

5.0

3.0

(TYPICAL)

11.0

13.0

(TYPICAL)

3.0

11.0

13.0

BEAM

CREASE

CHORD

PLUS

SKIN

BODY 0.5

CENTER SECTION

UPPER PANEL OF

D-D

940

STA

D

D

FWD

INBD

UP

INBD

1 2

1 2

V87896

(SHEET 3 OF 5)
 FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

(16 PLACES)

TYPICAL UPPER PANEL INSPECTION POINTS

FLOOR

BEAM

FLOOR

BEAM PANEL

E-E

SPAR

REAR 996

STA

984

STA

FB

UPPER TO FLOOR BEAM WEB

FLOOR BEAM WEB

TYPICAL

X/2

X

26.0

24.0

26.0

24.0

(TYPICAL)

RBL

24.75

RBL

45.50

FWD

1 2

V87897

(SHEET 4 OF 5)
 FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Front Spar and 

Upper Panel

Remove dirt/debris from 

the area

2

Measure/

Make Sure/ 

Record

Secondary Fuel 

Barrier

- (a) (b) (c)

Floor Beam FB 50 10 locations each, on the 

right and left side. See 

View A-A and B-B

Side of Body RSOB and LSOB 20 10 locations each, on the 

right and left side. See 

Views C-C and D-D

Upper Panel RTP and LTP 16 8 locations each, on the 

right and left side. See 

View E-E

 (a) Use a Non-Conductive Coating Thickness Gage to measure the thickness of the applied secondary fuel barrier. (Refer to Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.)

 (b) Deleted - See Accomplishment Instructions for thickness limits.

 (c) Record the measurements on the Inspection Worksheets in Appendix A.

(SHEET 5 OF 5)
 FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2

FUEL BARRIER

SECONDARY

LOWER CHORD

FRONT SPAR

SPAR WEB

FRONT

MIN

1.5

TO FRONT SPAR WEB AND LOWER CHORD

TYPICAL MINIMUM COVERAGE COMMON

B-B

A-A

MIN

1.5

FWD

FWD

1

LOWER CHORD FRONT SPAR WEB

FRONT SPAR

166

WL SPAR

FRONT ALLOWED

OVERSPRAY

0

BL

24.75

RBL

45.50

RBL

70.50

RBL

24.75

LBL

45.50

LBL

70.50

LBL

900

STA

900

STA

0

BL

24.75

LBL

24.75

RBL

1

V87898

B

B

A

A

(SHEET 1 OF 2)
 FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 55

BOEING SERVICE BULLETIN 757-57-0061

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 one airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1 Measure / 

Make Sure

Secondary Fuel 

Barrier

BMS 5-81 - It must be a minimum of 

1.50 inches

(SHEET 2 OF 2)
 FIGURE 7: Close Access - Air Conditioning Duct Installation - Group 1, Group 2 and Group 3

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

FIGURE 7: Close Access - Air Conditioning Duct Installation - Group 1, Group 2 and Group 3

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Install Duct Assembly 21-21-00 2 -

2 Connect Duct Assembly - 2 At each end; put covers 

over all open duct ends.

FWD

COMPARTMENT

TO PASSENGER

(2 EACH SIDE)

1 2

CONNECTOR

SERVICE

GROUND AIR

MIX MANIFOLD

V88491

(SHEET 1 OF 1)
 APPENDIX A: Record of Thickness Measurements

February 06, 2003

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BOEING SERVICE BULLETIN 757-57-0061

APPENDIX A: Record of Thickness Measurements

Record the thickness measurements from Figures 3 and 4 on the following worksheets.

FRONT SPAR - STIFFENERS (FSS)

FRONT SPAR - WEB (FSW)

BODY FRAME - STIFFENER (BFS)

BODY FRAME ASSEMBLY WEB (BFAW)

FSS 1 0. in. FSS 17 0. in. FSS 33 0. in. FSS 49 0. in.

FSS 2 0. in. FSS 18 0. in. FSS 34 0. in. FSS 50 0. in.

FSS 3 0. in. FSS 19 0. in. FSS 35 0. in. FSS 51 0. in.

FSS 4 0. in. FSS 20 0. in. FSS 36 0. in. FSS 52 0. in.

FSS 5 0. in. FSS 21 0. in. FSS 37 0. in. FSS 53 0. in.

FSS 6 0. in. FSS 22 0. in. FSS 38 0. in. FSS 54 0. in.

FSS 7 0. in. FSS 23 0. in. FSS 39 0. in. FSS 55 0. in.

FSS 8 0. in. FSS 24 0. in. FSS 40 0. in. FSS 56 0. in.

FSS 9 0. in. FSS 25 0. in. FSS 41 0. in. FSS 57 0. in.

FSS 10 0. in. FSS 26 0. in. FSS 42 0. in. FSS 58 0. in.

FSS 11 0. in. FSS 27 0. in. FSS 43 0. in. FSS 59 0. in.

FSS 12 0. in. FSS 28 0. in. FSS 44 0. in. FSS 60 0. in.

FSS 13 0. in. FSS 29 0. in. FSS 45 0. in. FSS 61 0. in.

FSS 14 0. in. FSS 30 0. in. FSS 46 0. in. FSS 62 0. in.

FSS 15 0. in. FSS 31 0. in. FSS 47 0. in. FSS 63 0. in.

FSS 16 0. in. FSS 32 0. in. FSS 48 0. in. FSS 64 0. in.

FSW 1 0. in. FSW 8 0. in.

FSW 2 0. in. FSW 9 0. in.

FSW 3 0. in. FSW 10 0. in.

FSW 4 0. in. FSW 11 0. in.

FSW 5 0. in. FSW 12 0. in.

FSW 6 0. in. FSW 13 0. in.

FSW 7 0. in. FSW 14 0. in.

Left Side Right Side

BFS 3 0. in. BFS 1 0. in.

BFS 4 0. in. BFS 2 0. in.

Left Side Right Side

BFAW 2 0. in. BFAW 1 0. in.
 APPENDIX A: Record of Thickness Measurements

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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BOEING SERVICE BULLETIN 757-57-0061

SIDE OF BODY (SOB)

UPPER PANEL (TP)

Left Side Right Side

LSOB 1 0. in. RSOB 1 0. in.

LSOB 2 0. in. RSOB 2 0. in.

LSOB 3 0. in. RSOB 3 0. in.

LSOB 4 0. in. RSOB 4 0. in.

LSOB 5 0. in. RSOB 5 0. in.

LSOB 6 0. in. RSOB 6 0. in.

LSOB 7 0. in. RSOB 7 0. in.

LSOB 8 0. in. RSOB 8 0. in.

LSOB 9 0. in. RSOB 9 0. in.

LSOB 10 0. in. RSOB 10 0. in.

Left Side Right Side

LTP 1 0. in. RTP 1 0. in.

LTP 2 0. in. RTP 2 0. in.

LTP 3 0. in. RTP 3 0. in.

LTP 4 0. in. RTP 4 0. in.

LTP 5 0. in. RTP 5 0. in.

LTP 6 0. in. RTP 6 0. in.

LTP 7 0. in. RTP 7 0. in.

LTP 8 0. in. RTP 8 0. in.

LTP 9 0. in. RTP 9 0. in.

LTP 10 0. in. RTP 10 0. in.

LTP 11 0. in. RTP 11 0. in.

LTP 12 0. in. RTP 12 0. in.

LTP 13 0. in. RTP 13 0. in.

LTP 14 0. in. RTP 14 0. in.
 APPENDIX A: Record of Thickness Measurements

February 06, 2003

Revision 1: May 24, 2007 757-57-0061

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

BOEING SERVICE BULLETIN 757-57-0061

FLOOR BEAM (FB)

FB 1 0. FB 11 0. FB 21 0. FB 31 0. FB 41 0. 

FB 2 0. FB 12 0. FB 22 0. FB 32 0. FB 42 0. 

FB 3 0. FB 13 0. FB 23 0. FB 33 0. FB 43 0. 

FB 4 0. FB 14 0. FB 24 0. FB 34 0. FB 44 0. 

FB 5 0. FB 15 0. FB 25 0. FB 35 0. FB 45 0. 

FB 6 0. FB 16 0. FB 26 0. FB 36 0. FB 46 0. 

FB 7 0. FB 17 0. FB 27 0. FB 37 0. FB 47 0. 

FB 8 0. FB 18 0. FB 28 0. FB 38 0. FB 48 0. 

FB 9 0. FB 19 0. FB 29 0. FB 39 0. FB 49 0. 

FB 10 0. FB 20 0. FB 30 0. FB 40 0. FB 50 0.