Commercial 

Airplanes 757

Service Bulletin

Number: 757-57-0061

Original Issue: February 06, 2003

Revision 3: December 07, 2012

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)

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

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

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

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2003 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, DreamlinerTM,

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 Boeing

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BOEING SERVICE BULLETIN 757-57-0061

BLANK PAGE
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 2 AND GROUP

3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FIGURE 2: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1 AND GROUP 3,

CONFIGURATION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FIGURE 4: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1 AND GROUP 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1 AND GROUP

3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

FIGURE 6: INSPECTION AND APPLICATION OF THE SECONDARY FUEL BARRIER - GROUP 2 . 51

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Appendix A: RECORD OF THICKNESS MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . 54

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BOEING SERVICE BULLETIN 757-57-0061
Commercial 

Airplanes 757

Service Bulletin

Revision Transmittal Sheet Number: 757-57-0061

Original Issue: February 06, 2003

Revision 3: December 07, 2012

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

Federal Aviation Administration (FAA) Notice of Proposed Rule Making: NPRM 2011-NM-070-AD, is related to

this service bulletin.

No more work is necessary on the airplane(s) changed in accordance with the Revision 1 or 2, of this service

bulletin.

REASON FOR REVISION

This revision is sent to change the quantity of locations listed in Figure 5, Sheet 5 of 5, Step 2 in order to match

the view shown in Figure 5, sheet 1 of 5 and the Upper Panel (TP) Table in Appendix A.

These sections were changed:

1. In Summary Compliance, Added NPRM.

2. In Paragraph 1.C. Reason, Added Revision 3 description.

3. In Paragraph 1.E. Compliance, Added NPRM.

4. In Paragraph 1.J. References, Added NPRM.

5. In Paragraph 3.A. Updated General Notes.

6. In Figure 5, Added new View F-F and changed Step 2. PRT and LTP quantity to match locations shown

in the Figure and listed in Appendex A, Inspection Worksheet.

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.

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REVISION HISTORY

Original Issue: February 06, 2003

Revision 1: May 24, 2007

Revision 2: May 04, 2012

Revision 3: December 07, 2012

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BOEING SERVICE BULLETIN 757-57-0061
Commercial 

Airplanes 757

Service Bulletin

Summary Number: 757-57-0061

Original Issue: February 06, 2003

Revision 3: December 07, 2012

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.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected No Paragraph 1.K., Publications Affected

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Planning Data Affected Reference

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required No Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required Yes

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

Federal Aviation Administration (FAA) Notice of Proposed Rule Making:NPRM 2011-NM-070-AD, is related to

this service bulletin.

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 757 airplanes. 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

BLANK PAGE
Commercial 

Airplanes 757

Service Bulletin

Number: 757-57-0061

Original Issue: February 06, 2003

Revision 3: December 07, 2012

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.

GROUP CONFIGURATION DESCRIPTION

1 - 757-300 Airplanes that must complete the whole bulletin

757-300 Airplanes that only require inspection of the front spar center

section.

2 -

757-300 Airplanes previously in Group 1 that could have fuel vapor

barrier material applied that was thinned with lacquer thinner.

3 -

Group 3 Airplanes that have not incorporated the previous release

of service bulletin 757-57-0061.

1

Group 3 Airplanes that have incorporated the previous release of

service bulletin 757-57-0061.

2

Airplane Models:

757-300

Variable Number Group

NL001 - NL002 2

NU701 - NU705 1

NU721 - NU723 1

NU724 - NU727 3

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Variable Number Group

NU728 1

NU731 - NU732 3

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.

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

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.

Revision 2 is sent to reference possibly release an Airworthiness Directive, to revise the Industry

Support information, to add Damage Tolerance Information, to remove the title of Part III, and the Group

2 from the title of Part III, IV, and V, to delete "and upper panel" from step 1 of Part VI of the work

Instructions and to correct a typographical error from Part VI and Part V.

Revision 3 is sent to change the quantity of locations listed in Figure 5, Sheet 5 of 5, Step 2 in order

to match the view shown in Figure 5, sheet 1 of 5 and the Upper Panel (TP) Table in Appendix A.

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.

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BOEING SERVICE BULLETIN 757-57-0061
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

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

Affected Maintenance Zones

Model Zone

757-300 133, 134

E. Compliance

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-070-AD, is

related to this service bulletin.

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.

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

Index, Part 1.

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BOEING SERVICE BULLETIN 757-57-0061
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

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 13.0 6.5

Inspection 2 8.0 4.0

Thickness Measurement 1 6.0 6.0

Secondary Fuel Barrier Ap- 1 6.5 6.5

plication

Close Access 2 15.0 7.5

TOTAL FOR EACH AIRPLANE 48.5 30.5

Group 2 ONLY

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 4.0 2.0

Inspection 2 8.0 4.0

Secondary Fuel Barrier Ap- 1 6.5 6.5

plication

Close Access 2 6.0 3.0

TOTAL FOR EACH AIRPLANE 24.5 15.5

Group 3, Configuration 2 ONLY

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 13.0 6.5

Thickness Measurement 1 6.0 6.0

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BOEING SERVICE BULLETIN 757-57-0061
Number of Per- Task-Hours Elapsed Hours

sons

Task

Secondary Fuel Barrier Ap- 1 6.5 6.5

plication

Close Access 2 15.0 7.5

TOTAL FOR EACH AIRPLANE 40.5 26.5

H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

(Pounds)

Airplane

757-300 + 1 + 1, 000

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

k. Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM

2011-NM-070-AD, is related to this service bulletin.

2. Data Supplied with this Service Bulletin:

None.

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BOEING SERVICE BULLETIN 757-57-0061
3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

Seal Application - Secondary Fuel Barrier Coating, Wing, Center

Section

110N0004

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

144N2101 Bulkhead Installation, Front Spar Body Station 900

140N3002 Corrosion Inhibiting Compound Instl - Fuselage

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

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

L. Interchangeability and Intermixability of Parts

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

M. Software Accomplishment Summary

Not affected.

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BOEING SERVICE BULLETIN 757-57-0061
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are available for Group 1, Group 2, and Group 3 - Configuration 1, 757

airplanes in warranty as of September 22, 2000. Boeing warranty remedies are available for Group 3-

Configuration 2, 757 airplanes in warranty as of October 8, 2004. 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:

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)

Advanced Organic Corrosion Inhibiting Com- (a)

pounds (CIC)

BMS 3-29 1 Pint

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

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

Pressure and Environmental Sealant - Chro- (a) (b)

mate Type

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

B-2 or B-4

(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

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

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D. Parts Necessary to Change Spares

None.

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) (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) (b) Fisher Technology (9U437) 750 Marshall Phelps Rd. Windsor, CT 06095-2199

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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. 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 and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque limits to tighten nuts and bolts are in SRM Chapter 51

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

SRM Chapter 51.

6. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

7. The necessary conditions for selection of clamp type and size are included in SWPM

20-10-12. If any wire bundle support clamp specified in this service bulletin does not

make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted

procedure to select a clamp that fits correctly.

8. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

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

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

9. 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.

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10. 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 "as

given" or "in accordance with" are included in the instruction, the procedure in the

Boeing document must be used.

11. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

12. Refer to Appendix A for Thickness Measurments- Upper Panel -Group 1 and Group

3 Airplanes.

13. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

14. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

15. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

16. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

17. Some Boeing parts are supplied in a temporary configuration. Those parts are

identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is

permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'

(dash) part number. Boeing Drawing 005W0900 contains more data.

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 757 AMM 24-41-00.

2. Release the pressure from the pneumatic system; refer to 757 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

757 AMM 21-00-00.

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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 757 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 757 AMM 25-25-01.

(2) The floor covering, as referenced in 757 AMM 25-27-01.

(3) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(4) The sidewall lining (panels and carpet risers), as referenced in 757 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 757

AMM 25-50-03.

PART II - Open Access - Group 2

1. Supply external power to the airplane, as given in 757 AMM 24-41-00.

2. Release the pressure from the pneumatic system; refer to 757 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

757 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 757 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 757

AMM 25-50-03.

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

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, 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, 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, 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 V - Repair of the Secondary Fuel Barrier - Group 1, 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, 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, and Group 3, Configuration 1; and in Part IV - Thickness Measurement

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

1.

a. Remove the secondary fuel barrier as given in 757 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 757 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 to ensure that the application covers the minimum

area specified in Figure 6.

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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.

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

757 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 757 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 757 AMM

25-50-03.

d. Between BS 900 and 1040, install:

(1) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.

(2) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(3) The floor covering, as referenced in 757 AMM 25-27-01.

(4) The passenger seats, as referenced in 757 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 757 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 757 AMM 36-00-00.

5. Put the electrical power back to service condition, as given in 757 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.

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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 757 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 757 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 757 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 757

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 757 AMM 36-00-00.

5. Put the electrical power back to service condition, as given in 757 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 757 AMM 24-41-00.

4. Release the pressure from the pneumatic system; refer to 757 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

757 AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

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

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6. Set the L And R RECIRC FAN switch-lights to the OFF position, on the pilot's overhead panel P5.

Refer to 757 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.

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 757 AMM 25-25-01.

(2) The floor covering, as referenced in 757 AMM 25-27-01.

(3) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(4) The sidewall lining (panels and carpet risers), as referenced in 757 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 757

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.

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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.

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

a. Remove the secondary fuel barrier as given in 757 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 757 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 757 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 757 AMM

25-50-03.

d. Between BS 900 and 1040, install:

(1) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.

(2) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(3) The floor covering, as referenced in 757 AMM 25-27-01.

(4) The passenger seats, as referenced in 757 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 757 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 757

AMM 21-00-00.

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

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BOEING SERVICE BULLETIN 757-57-0061
b. Make sure the PACK OFF lights go off.

14. Put the pneumatic system back to service condition. Refer to 757 AMM 36-00-00.

15. Put the electrical power back to service condition, as given in 757 AMM 24-41-00.

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 757 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 757 AMM 28-11-00 for cure rates.

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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

At each end; put covers

over all open duct ends.

1 Disconnect Duct Assembly 21-21-00 2

2 Remove Duct Assembly - 2 -

FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 2 AND GROUP 3

(SHEET 1 OF 1)

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FIGURE 2: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 1 OF 5)

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FIGURE 2: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 2 OF 5)

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FIGURE 2: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 3 OF 5)

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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.

FIGURE 2: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 4 OF 5)

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STEP TASK NAME REFERENCES QTY NOTES

Remove dirt/debris from

the area

1 Clean Front Spar -

Secondary Fuel Visual Inspection - (a)

Barrier

2 Identify

Detailed Visual In- - (b) (c)

spection

3 Examine Front Spar

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.

BMS 3-23 or BMS -

3-29 or BMS 3-35

Corrosion Inhibiting

Compound

Remove

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 of the Work Instructions.

FIGURE 2: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 5 OF 5)

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FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 1 OF 7)

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FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 2 OF 7)

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FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 3 OF 7)

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FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 4 OF 7)

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FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 5 OF 7)

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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.

FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 6 OF 7)

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STEP TASK NAME REFERENCES QTY NOTES

Remove dirt/debris from

the area

1 Clean Upper Panel -

Secondary Fuel Visual Inspection - (a)

Barrier

2 Identify

Detailed Visual In- - (b) (c)

spection

3 Examine Upper Panel

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.

BMS 3-23 or BMS -

3-29 or BMS 3-35

Corrosion Inhibiting

Compound

Remove

(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 - of the Work Instructions.

FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3,

CONFIGURATION 1

(SHEET 7 OF 7)

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FIGURE 4: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1 AND GROUP 3

(SHEET 1 OF 3)

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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.

FIGURE 4: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1 AND GROUP 3

(SHEET 2 OF 3)

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STEP TASK NAME REFERENCES QTY NOTES

Remove dirt/debris from

the area

1 Clean Front Spar

Secondary Fuel (a) (b) (c)

Barrier

Measure/ Make

Sure/ Record

2

Front Spar Web FSW 14 See View A-A

Front Spar Stiffen- FSS 64 See View A-A

ers

Body Frame Assy BFAW 2 See View B-B

Web

Body Frame Stiffen- BFS 4 See Views C-C and D-D

er

(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.

FIGURE 4: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1 AND GROUP 3

(SHEET 3 OF 3)

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FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1 AND GROUP 3

(SHEET 1 OF 5)

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FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1 AND GROUP 3

(SHEET 2 OF 5)

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FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1 AND GROUP 3

(SHEET 3 OF 5)

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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.

FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1 AND GROUP 3

(SHEET 4 OF 5)

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STEP TASK NAME REFERENCES QTY NOTES

Remove dirt/debris from

the area

Front Spar and

Upper Panel

1 Clean

Secondary Fuel - (a) (b) (c)

Barrier

Measure/ Make

Sure/ Record

2

10 locations each, on the

right and left side. See

View A-A and B-B

Floor Beam FB 50

10 locations each, on the

right and left side. See

Views C-C and D-D

Side of Body RSOB and LSOB 20

14 locations each, on the

right and left side. See

View E-E and View F-F

Upper Panel RTP and LTP 28

(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.

FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1 AND GROUP 3

(SHEET 5 OF 5)

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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.

FIGURE 6: INSPECTION AND APPLICATION OF THE SECONDARY FUEL BARRIER - GROUP 2

(SHEET 1 OF 2)

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STEP TASK NAME PART NUMBER QTY NOTES

It must be a minimum of

1.50 inches

Secondary Fuel BMS 5-81 -

Barrier

Measure / Make

Sure

1

FIGURE 6: INSPECTION AND APPLICATION OF THE SECONDARY FUEL BARRIER - GROUP 2

(SHEET 2 OF 2)

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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 Install Duct Assembly 21-21-00 2 -

At each end; put covers

over all open duct ends.

2 Connect Duct Assembly - 2

FIGURE 7: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 1, GROUP 2 AND

GROUP 3

(SHEET 1 OF 1)

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

FRONT SPAR - STIFFENERS (FSS)

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.

FRONT SPAR - WEB (FSW)

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.

BODY FRAME - STIFFENER (BFS)

Left Side Right Side

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

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

Appendix A: RECORD OF THICKNESS MEASUREMENTS

(SHEET 1 OF 3)

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BODY FRAME ASSEMBLY WEB (BFAW)

Left Side Right Side

BFAW 2 0. in. BFAW 1 0. in.

SIDE OF BODY (SOB)

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.

UPPER PANEL (TP)

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.

Appendix A: RECORD OF THICKNESS MEASUREMENTS

(SHEET 2 OF 3)

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Left Side Right Side

LTP 14 0. in. RTP 14 0. in.

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.

Appendix A: RECORD OF THICKNESS MEASUREMENTS

(SHEET 3 OF 3)

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