### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-53A0251**  Original Issue: August 07, 2013 ATA System: 5300 **SUBJECT:** FUSELAGE - Section 41 - Skins - Stringer 37 Lap Splice Inspection Between Body Stations 428 and 431 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2013 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: August 07, 2013 767-53A0251 1 of 31 6.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 2 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 14 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 15 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 16 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FIGURE 1: SKIN INSPECTION FOR MISSING FASTENERS . . . . . . . . . . . . . . . . . . . . . . 21 FIGURE 2: SKIN DETAILED AND OPEN-HOLE INSPECTION . . . . . . . . . . . . . . . . . . . . . 24 FIGURE 3: FASTENER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 3 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 4 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Summary**  **Number: 767-53A0251** Original Issue: August 07, 2013 ATA System: 5300 **SUBJECT:** FUSELAGE - Section 41 - Skins - Stringer 37 Lap Splice Inspection Between Body Stations 428 and 431 THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** This service bulletin gives instructions to do inspections of the stringer 37 (S-37) left and right lap splice just forward of the Body Station (STA) 434 circumferential splice for missing fasteners. Missing fasteners can result in cracks in the fuselage skin, which could adversely affect the structural integrity of the airplane. Boeing has discovered that six fasteners may not have been installed in the left and right S-37 lap splices on some airplanes during production. Accomplishment of the inspections and fastener installations, if necessary, in this service bulletin will help ensure the structural integrity of the S-37 lap splices. Boeing Service Related Problem (SRP) 767-53-0424 is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 5 of 31**Reference Affected**  **Planning Data** Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**ACTION** Do external general visual inspections of the left and right S-37 lap splices for missing fasteners. If no fasteners are found to be missing, no more work is required. If fasteners are found to be missing, get internal access and remove fasteners adjacent to the missing fastener locations. Do internal and external detailed inspections in the area for any crack or corrosion, or any other discrepancy, such as broken sealant,. Also do open-hole High Frequency Eddy Current (HFEC) inspections of the skin at the open fastener holes for cracks. If no crack or corrosion is found, install fasteners in accordance with this service bulletin. If any crack or corrosion is found, determine if the damage is within the repair limits in the SRM. If all cracking and corrosion is within the repair limits in the SRM, do repairs in accordance with the SRM. If any crack or corrosion is found that is beyond the repair limits in the SRM, contact Boeing for repair instructions and do the repair. **EFFECTIVITY** 767-200, 767-300, 767-300F, and 767-400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s). **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. This service bulletin affects SSI 53-10-I07C and 53-10-I07D of MPD 622T009 Section 9. Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of September 11, 2012. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  0.10 0.10 Inspection for missing fasteners

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 6 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT Elapsed Hours**  **Total Task Hours Airplanes**  7.25 12.75 Additional inspections and fastener instal-lation if fasteners are found to be missing Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 7 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 8 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-53A0251**  Original Issue: August 07, 2013 ATA System: 5300 **SUBJECT:** FUSELAGE - Section 41 - Skins - Stringer 37 Lap Splice Inspection Between Body Stations 428 and 431 THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplane(s) shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-200, 767-300, 767-300F and 767-400ER airplanes line number 929 through 1028. - 1

Airplane Models: 767-200, 767-300, 767-300F, 767-400ER **Group Variable Number**  1 VQ111 1 VR087 - VR089 1 VR106 - VR109 1 VR266 - VR283 1 VS712 - VS720 1 VS732 - VS736

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 9 of 31**Group Variable Number**  1 VS883 1 VS901 - VS912 1 VS916 1 VS921 - VS928 1 VS931 - VS933 1 VS941 1 VS951 - VS954 1 VS961 - VS969 1 VS971 - VS976 1 VS981 - VS982 1 VT511 - VT513 1 VT521 - VT523 1 VT531 - VT533 1 VT541 - VT543 1 VT551 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** This service bulletin gives instructions to do inspections of the stringer 37 (S-37) left and right lap splice just forward of the Body Station (STA) 434 circumferential splice for missing fasteners. Missing fasteners can result in cracks in the fuselage skin, which could adversely affect the structural integrity of the airplane. Boeing has discovered that six fasteners may not have been installed in the left and right S-37 lap splices on some airplanes during production. Accomplishment of the inspections and fastener installations, if necessary, in this service bulletin will help ensure the structural integrity of the S-37 lap splices. Boeing Service Related Problem (SRP) 767-53-0424 is related to this service bulletin. **D. Description** Do external general visual inspections of the left and right S-37 lap splices for missing fasteners. If no fasteners are found to be missing, no more work is required.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 10 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**If fasteners are found to be missing, get internal access and remove fasteners adjacent to the missing fastener locations. Do internal and external detailed inspections in the area for any crack or corrosion, or any other discrepancy, such as broken sealant,. Also do open-hole High Frequency Eddy Current (HFEC) inspections of the skin at the open fastener holes for cracks. If no crack or corrosion is found, install fasteners in accordance with this service bulletin. If any crack or corrosion is found, determine if the damage is within the repair limits in the SRM. If all cracking and corrosion is within the repair limits in the SRM, do repairs in accordance with the SRM. If any crack or corrosion is found that is beyond the repair limits in the SRM, contact Boeing for repair instructions and do the repair. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 123, 124 767-200, 767-300, 767-300F, 767-400ER **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. This service bulletin affects SSI 53-10-I07C and 53-10-I07D of MPD 622T009 Section 9. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. **Table 1: S-37 Lap Splice Inspection for Missing Fasteners Between STA 428 and 431 Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever**  **Occurs First) Action**  **Condition**

- Within 2 years after the original issue date ofthis service bulletin. Within 3,000flight-cycles after the original issue date ofthis service bulletin. Do an external General Visual Inspection of the Stringer 37 (S-37) lap splice, just forward of the circumferential splice at Body Station (STA) 434, for missing fasteners. All affected airplanes.

- - No more work is neces- sary.CONDITION 1: NO MISSING FASTENERS

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 11 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT Table 1: S-37 Lap Splice Inspection for Missing Fasteners Between STA 428 and 431**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs First)**  **Action Condition** 

- Before further flight. Remove fasteners adja-cent to the missing fastener locations. Do detailed inspections for any crack, any corrosion, and any other discrepancy, such as broken sealant. Doopen-hole HFEC inspections for cracks at the open fastener holes. CONDITION 2: ANY MISSING FASTENERS

- Before further flight. Install fasteners. CONDITION 3: NO CRACK, CORROSION OR OTHER DISCREPANCY FOUND

- Before further flight. Determine if the crack,corrosion or other discrepancy is within the repair limits in the SRM. CONDITION 4: ANY CRACK, CORROSION OR OTHER DISCREPANCY FOUND

- Before further flight. Repair in accordance with the SRM. CONDITION 5: ALL CRACKING, CORROSIONOR OTHER DISCREPANCY FOUND IS WITHIN SRM LIMITS

- Before further flight. Contact Boeing for repair instructions and do the repair. CONDITION 6: ANY CRACK, CORROSION OR OTHER DISCREPANCY FOUND THAT IS BEYOND SRM LIMITS
**NOTE:** 1. Lap splice fastener installation and repairs will affect Structural Significant Items (SSIs) 53-10-I07C and 53-10-I07D as listed in 767 MPD Section 9, Airworthiness Limitations - Structural Inspections. 2. After accomplishment of this service bulletin, refer to the 767 MPD Section 9, Airworthiness Limitation - Structural Inspection, for inspections. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 12 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. **G. Manpower** The table below shows an estimate of the task hours necessary to do this inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **Table 1 - Inspection for Missing Fasteners Elapsed Hours**  **Task Hours Number of Persons**  **Task** 0.10 0.10 1 Inspect for missing fasteners (Figure 1) 0.10 0.10 TOTAL FOR EACH AIRPLANE **Table 2 - Additional Inspections and Fastener Installation if Fasteners are Found to be Missing**  **Elapsed Hours Task Hours**  **Number of Persons Task**  2.75 5.50 2 Open internal access 1.25 1.25 1 Detailed and eddy current inspections (Figure 2) 0.50 0.50 1 Fastener installation (Figure 3) 2.75 5.50 2 Close Access 7.25 12.75 TOTAL FOR EACH AIRPLANE
**NOTE:** More time is required for repairs if damage is found. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 13 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT J. References**  1. Existing Data: a. Boeing Service Related Problem (SRP) 767-53-0424 b. Service Bulletin Index D624T001 c. 767 Aircraft Maintenance Manual (AMM) 25-52-03, 52-33-00, 53-01-05 d. 767 Maintenance Planning Data (MPD) Section 9 e. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-04, Part 6, 51-00-11, Part 6, 51-00-16 f. 767-200 Structural Repair Manual (SRM) 53-00-01 g. 767-300 Structural Repair Manual (SRM) 53-00-01 h. 767-300F Structural Repair Manual (SRM) 53-00-01 i. 767-400 Aircraft Maintenance Manual (AMM) 25-52-03, 52-33-00, 53-01-05 j. 767-400 Structural Repair Manual (SRM) 53-00-01 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. **K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. **M. Software Accomplishment Summary** Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 14 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** None. **B. Industry Support Information** Boeing warranty remedies are available for 767 airplanes in warranty as of September 11, 2012. For inspection labor task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Warranty & Product Assurance Contracts. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours and parts are required, send a warranty claim to Boeing Warranty & Product Assurance Contracts. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. The warranty remedies will expire eight years from the original issue date of this service bulletin. **C. Parts Necessary for Each Airplane** 1. Kits/Parts None. 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available.
**Notes Name**  **QTY Part Number /**  **Specification** BACR15FV6KE7 optional. (a) Rivet 20 BACR15FV6KE6 BACR15FV6KE8 optional. (a) Rivet 10 BACR15FV6KE7 (b) Sealant 8 ounces BMS 5-95 (a) Refer to 767 Structural Repair Manual Chapter 51 for alternate fasteners. (b) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 15 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT D. Parts Necessary to Change Spares**  None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 16 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in SRM Chapter 51 4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 5. 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. 6. 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. 7. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 17 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 9. Boeing Service Letter 767-SL-51-036, 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. 10. 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. 11. 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. 12. 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. 13. Shaded areas in Figures are to separate the non-critical and non-authoritative information from the critical and authoritative information. 14. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 15. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 16. The CONDITIONS, ACTIONS and OPTIONS shown apply to each side of the airplane independently. 17. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC must be done to comply with the AD. Alternative procedures for steps not identified with RC can be used if the RC steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. **B. WORK INSTRUCTIONS** 1. RC - Do an external General Visual Inspection of the Stringer 37 (S-37) lap splice, just forward of the circumferential splice at Body Station (STA) 434, for missing fasteners in accordance with FIGURE 1.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 18 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT CONDITION 1: NO MISSING FASTENERS**  a. No more work is required. **CONDITION 2: ANY MISSING FASTENERS** a. Get internal access. Refer to PART 1 - ACCESS as an accepted procedure. b. RC - Remove fasteners adjacent to the missing fastener locations and do inspections in accordance with FIGURE 2. **CONDITION 3: NO CRACK, CORROSION OR OTHER DISCREPANCY FOUND** (1) RC - Install fasteners in accordance with FIGURE 3. **CONDITION 4: ANY CRACK, CORROSION OR OTHER DISCREPANCY FOUND** (1) RC - Determine if the crack, corrosion or other discrepancy is within the repair limits in 767-200 SRM 53-00-01, 767-300 SRM 53-00-01, 767-300F SRM 53-00-01 or 767-400 SRM 53-00-01. **CONDITION 5: ALL CRACKING, CORROSION OR OTHER DISCREPANCY FOUND IS WITHIN SRM LIMITS**  (a) RC - Repair in accordance with 767-200 SRM 53-00-01, 767-300 SRM 53-00-01, 767-300F SRM 53-00-01 or 767-400 SRM 53-00-01. **CONDITION 6: ANY CRACK, CORROSION OR OTHER DISCREPANCY FOUND THAT IS BEYOND SRM LIMITS**  (a) RC - Contact Boeing for repair instructions and do the repair. c. Apply finishes to the affected area to match adjacent structure. d. Install equipment that was removed for internal access. Refer to PART 2 - RESTORATION as an accepted procedure. 2. Put the airplane back to a serviceable condition. **PART 1: ACCESS** 1. Open the forward lower lobe cargo door. Refer to 767 AMM 52-33-00 or 767-400 AMM 52-33-00 as accepted procedures. 2. Remove and keep cargo compartment floor panels as necessary for internal access to the affected S-37 area just forward of STA 434. Refer to 767 AMM 53-01-05 or 767-400 AMM 53-01-05 as accepted procedures. 3. Remove and keep cargo compartment insulation as necessary for internal access to the affected S-37 area just forward of STA 434. Refer to 767 AMM 25-52-03 or 767-400 AMM 25-52-03 as accepted procedures.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 19 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT PART 2: RESTORATION**  1. Install cargo compartment insulation that was removed for access. Refer to 767 AMM 25-52-03 or 767-400 AMM 25-52-03 as accepted procedures. 2. Install cargo compartment floor panels that were removed for access. Refer to 767 AMM 53-01-05 or 767-400 AMM 53-01-05 as accepted procedures. 3. Close the forward lower lobe cargo door. Refer to 767 AMM 52-33-00 or 767-400 AMM 52-33-00 as accepted procedures.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 20 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 1: SKIN INSPECTION FOR MISSING FASTENERS**  **(SHEET 1 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 21 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 1: SKIN INSPECTION FOR MISSING FASTENERS**  **(SHEET 2 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 22 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.
**More Data Qty**  **Identification Name**  **Task Step**  Do an external General Visual Inspection of the S-37 lap splice for missing fasteners. - - Skin Inspect 1

**FIGURE 1: SKIN INSPECTION FOR MISSING FASTENERS (SHEET 3 OF 3)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 23 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 2: SKIN DETAILED AND OPEN-HOLE INSPECTION**  **(SHEET 1 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 24 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 2: SKIN DETAILED AND OPEN-HOLE INSPECTION**  **(SHEET 2 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 25 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 2: SKIN DETAILED AND OPEN-HOLE INSPECTION**  **(SHEET 3 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 26 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.
**More Data Qty**  **Identification Name**  **Task Step**  Do internal and external detailed inspections for any crack, any corrosion, andany other discrepancy, such as broken sealant, in the area shown. (a) - - Skin Inspect 1

Adjacent to the locations where fasteners were found to be missing. 9

- Fasteners Remove 2

Do open-hole HFEC inspections for cracks at the openfastener holes in accordance with 767 NDT Manual Part 6, 51-00-04, or 767 NDT Manual Part 6, 51-00-11 or 767 NDT Manual Part 6, 51-00-16. 9

- Skin Inspect 3

(a) The area to be inspected extends one inch above the top row of fasteners in the lap splice to one inch below the bottom row of fasteners in the lap splice. The forward and aft ends of the area to be inspected are located mid-way between the columns of fasteners shown.

**FIGURE 2: SKIN DETAILED AND OPEN-HOLE INSPECTION (SHEET 4 OF 4)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 27 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 3: FASTENER INSTALLATION**  **(SHEET 1 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 28 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 3: FASTENER INSTALLATION**  **(SHEET 2 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 29 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT FIGURE 3: FASTENER INSTALLATION**  **(SHEET 3 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 30 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. **NOTE:** The driven head of the new rivets should be 1.5 times the rivet shank diameter. 1. 2. Remove and reapply any BMS 5-95 sealant found broken in the affected area.
**More Data Qty**  **Identification Name**  **Task Step**  BACR15FV7KE7 optional (a) 4 BACR15FV6KE6 Rivet Install (New) 1

BACR15FV7KE8 optional (a) 5 BACR15FV6KE7 Rivet Install (New) 2 Align the rows of new fasteners with the existing rows of fasteners in the lap splice. 6 BACR15FV6KE6 Rivet Install (New) 3

(a) Optional, if oversize is necessary due to hole quality requirements.

**FIGURE 3: FASTENER INSTALLATION (SHEET 4 OF 4)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 07, 2013 767-53A0251 31 of 31 **BOEING SERVICE BULLETIN 767-53A0251 ALERT**  **ALERT**