### Commercial Airplanes 

# 777 Service Bulletin Number: 777-54-0030 Original Issue: May 27, 2014 Revision 1: September 30, 2015 ATA System: 5452 SUBJECT:NACELLES/PYLONS - Aft Fairing - Strut Aft Fairing Lower Spar Heat Shield Insulation Blankets Replacement 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 © 2014 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 Unpublished Work.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: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 1 of 81 3.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 2 of 81 BOEING SERVICE BULLETIN 777-54-0030

BLANK PAGETable 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 17 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 23 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 25 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FIGURE 1: LEFT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL. . . . . . . . . . . . 30 FIGURE 2: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL. . . . . . . . . . . 36 FIGURE 3: LEFT STRUT - VELCRO STRIPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . 42 FIGURE 4: RIGHT STRUT - VELCRO STRIPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . 45 FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT [Group 1]. . . . . . . . . . . . . . . . . . 48 FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT [Group 1]. . . . . . . . . . . . . . . . . 56 FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION. . . . . . . . . 64 FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION. . . . . . . . . 72 APPENDIX A: MASTER FASTENER CODE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 APPENDIX B: PART DEMAND INTENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 3 of 81 BOEING SERVICE BULLETIN 777-54-0030Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 4 of 81 BOEING SERVICE BULLETIN 777-54-0030

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### Commercial Airplanes 

# 777 Service Bulletin Revision Transmittal Sheet Number: 777-54-0030 Original Issue: May 27, 2014 Revision 1: September 30, 2015 ATA System: 5452 SUBJECT:NACELLES/PYLONS - Aft Fairing - Strut Aft Fairing Lower Spar Heat Shield Insulation Blankets Replacement 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 2014-NM-178-AD is related to this service bulletin. Effects of this Revision on airplanes on which Original Issue was previously done: None. REASON FOR REVISION This revision is sent to change access instructions, update illustrations and revision level of the concurrent requirement. The data given in Information Notice 777-54-0030 IN 01 is included in this revision. These sections were changed: 1. In Summary, Compliance, added NPRM reference. 2. In Summary, Material Information, added Boeing Supplied Kits/Parts ordering information request and information for Operator Supplied Kits/Parts. 3. In Summary Figure, changed the locator illustration. 4. In Paragraph 1.B., Concurrent Requirements, added a new revision to an existing bulletin reference. 5. In Paragraph 1.C., Reason, added reason for revision and included statement about Information Notice. 6. In Paragraph 1.D., Description, added information for effects of this revision. 7. In Paragraph 1.E., Compliance, added NPRM reference. 8. In Paragraph 1.G., Manpower, updated task-hours. 9. In Paragraph 1.J.1., Existing Data, updated the reference list. 10. In Paragraph 1.L., Interchangeability and Intermixability of Parts, added reference for part interchangeability and intermixability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 5 of 8111. In Paragraph 2.A., Material - Price and Availability, added reference to Boeing Supplied Kits/Parts survey. 12. In Paragraph 2.C.1., Kits/Parts, added of part interchangeability and intermixability information. 13. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added new operator supplied parts. 14. In Paragraph 3.B., Work Instructions, added access doors. 15. In FIGURE 1, changed access instructions and updated illustrations. 16. In FIGURE 2, changed access instructions and updated illustrations. 17. In FIGURE 3, changed engine locator illustration. 18. In FIGURE 4, changed engine locator illustration. 19. In FIGURE 5, changed access instructions and updated illustrations. 20. In FIGURE 6, changed access instructions and updated illustrations. 21. In FIGURE 7, changed instructions to restore access to the aircraft and updated illustrations. 22. In FIGURE 8, changed instructions to restore access to the aircraft and updated illustrations. 23. In APPENDIX A, added a new fastener code. 24. Added APPENDIX B, PART DEMAND INTENT, for Service Bulletin kit planning information. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes. Pages with no vertical lines have no changes. REVISION HISTORY May 27, 2014 Original Issue: September 30, 2015 Revision 1:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 6 of 81 BOEING SERVICE BULLETIN 777-54-0030

### Commercial Airplanes 

# 777 Service Bulletin Summary Number: 777-54-0030 Original Issue: May 27, 2014 Revision 1: September 30, 2015 ATA System: 5452 SUBJECT:NACELLES/PYLONS - Aft Fairing - Strut Aft Fairing Lower Spar Heat Shield Insulation Blankets Replacement CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements. BACKGROUND Accomplishment of this service bulletin will increase the thermal capability and improve the durability of the strut aft fairing lower spar heat shield insulation blankets. Airflow into the cavity between the strut and strut aft fairing heat shield is forced upon the forward blanket face and through the heat shield cavity, which results in accelerated wear damage to the heat shield insulation blankets. Wear damage to insulation blankets could lead to damage of the aft fairing lower spar web, which could result in unscheduled airplane maintenance and downtime for repair. Multiple operators have reported multiple cases of damage to strut aft fairing high temperature seals and heat shield insulation blankets. Boeing performed a root cause evaluation and found that continuous exposure to turbulent air can cause a degradation of the front face of the #1 heat shield insulation blanket and heat shield primary seal. The degradation exposes the strut aft fairing lower spar web structure and heat shield insulation blankets to high temperature air. New insulation blankets will provide improved durability and thermal protection. The new design of the insulation blankets includes changes to the insulation material that improved the insulation blankets to be resistant to higher temperatures and higher velocity air. The #1 heat shield insulation blanket nose piece material was changed from silicone and quartz to nextel fabric, which demonstrates better performance to resist damage from turbulent air during testing. In addition to the changes to the insulation blankets, a Nitronic 60 rub strip will be added to the seal depressor. The Nitronic 60 rub strip has improved friction characteristics that allow for free movement and reduces wear damage to the primary seal. This service bulletin provides instructions to replace heat shield insulation blankets and install Nitronic 60 rub strips. Due to the new configuration of the insulation blankets, some airplanes will need new aft fairing lower spar web drain sumps when replacing insulation blankets. Replacement of the insulation blankets will reduce blanket wear damage due to turbulent airflow. Installation of the rub strip will provide better seal compression and wear resistance to extend the life of the strut aft fairing lower spar primary seal. Incorporation of the changes in accordance with this service bulletin, and a final one time inspection and corrective actions in accordance with Service Bulletin (SB) 777-54A0031 is terminating action to the repeat inspections in accordance with SB 777-54A0031. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to SB 777-54A0031. Boeing Fleet Team Digest (FTD) 777 FTD 54-11003 is related to this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 7 of 81Boeing Service Related Problem (SRP) 777-SRP-54-0137 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 Yes Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected Yes Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts Yes 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 (PRR 62777-92S) Group 1: Get access to the upper and lower aft fairing structure. Replace insulation blankets, drain sump, and velcro. Install new rub strips to seal depressor. Close access to the upper and lower aft fairing structure. Group 2: Get access to the upper and lower aft fairing structure. Replace insulation blankets and velcro. Install new rub strips to seal depressor. Close access to the upper and lower aft fairing structure. EFFECTIVITY 777-200, -300 Airplanes with Rolls Royce Engines. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2014-NM-178-AD is related to this service bulletin. No compliance time is given. Boeing recommends this service bulletin be done to introduce improvements.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 8 of 81 BOEING SERVICE BULLETIN 777-54-0030INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of June 8, 2011. 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 Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. 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: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 9 of 81 BOEING SERVICE BULLETIN 777-54-0030Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 10 of 81 BOEING SERVICE BULLETIN 777-54-0030

### Commercial Airplanes 

# 777 Service Bulletin Number: 777-54-0030 Original Issue: May 27, 2014 Revision 1: September 30, 2015 ATA System: 5452 SUBJECT:NACELLES/PYLONS - Aft Fairing - Strut Aft Fairing Lower Spar Heat Shield Insulation Blankets Replacement 1. PLANNING INFORMATION A. Effectivity 1. Airplanes This service bulletin is applicable to 777-200 and 777-300 Airplanes with Rolls Royce engines, line numbers 1-796 in 2 Group(s). The Variable Numbers and Group Information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-92S for data about this change. Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. DESCRIPTION CONFIGURATION GROUP 777-200, 777-300 Airplanes with Rolls Royce Engines, line number 14-126, delivered with Drain Sump Assembly, Part Number 313W5816-1 - 1
777-200, 777-300 Airplanes with Rolls Royce Engines, line number 1, 128 through 796, delivered with Drain Sump Assembly, Part Number 313W5816-5 or 313W5816-7 - 2

Airplane Models: 777-200, 777-300 Group Variable Number2 WA001 1 WA086 - WA093 1 WA101 - WA104 1 WA196 - WA198 2 WB031 - WB046

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 11 of 81Group Variable Number1 WB101 - WB104 2 WB105 - WB106 1 WB161 - WB165 2 WB166 - WB177 1 WB181 - WB186 2 WB187 - WB194 2 WB201 - WB215 2 WB231 - WB247 2 WB416 - WB439 2 WB446 - WB453 1 WB501 - WB503 2 WB504 - WB512 2 WB601 - WB606 2 WB611 - WB622 2 WB631 - WB638 2 WB646 - WB649 2 WC051 - WC0732 WC101 - WC1042 WC456 - WC4592 WC486 - WC4932 WC531 - WC5362 WC566 - WC5672 WC571 - WC574 2. Spares Affected None. B. Concurrent Requirements The service bulletin listed below must be done before or at the same time as this service bulletin:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 12 of 81 BOEING SERVICE BULLETIN 777-54-0030Description Service Bulletin Company Inspects the strut aft fairing lower spar web structure and heat shield primary seal forheat damage. Corrective actions for inspections include replacement of damaged parts and repeat inspections. Accomplishment of Service Bulletin (SB) 777-54-0030, at thesame time as SB 777-54A0031, is terminating action to the repeat inspections in accordance with SB 777-54A0031. 777-54A0031 Original Issue or Revision 1 The Boeing Compa- ny

C. Reason Accomplishment of this service bulletin will increase the thermal capability and improve the durability of the strut aft fairing lower spar heat shield insulation blankets. Airflow into the cavity between the strut and strut aft fairing heat shield is forced upon the forward blanket face and through the heat shield cavity, which results in accelerated wear damage to the heat shield insulation blankets. Wear damage to insulation blankets could lead to damage of the aft fairing lower spar web, which could result in unscheduled airplane maintenance and downtime for repair. Multiple operators have reported multiple cases of damage to strut aft fairing high temperature seals and heat shield insulation blankets. Boeing performed a root cause evaluation and found that continuous exposure to turbulent air can cause a degradation of the front face of the #1 heat shield insulation blanket and heat shield primary seal. The degradation exposes the strut aft fairing lower spar web structure and heat shield insulation blankets to high temperature air. New insulation blankets will provide improved durability and thermal protection. The new design of the insulation blankets includes changes to the insulation material that improved the insulation blankets to be resistant to higher temperatures and higher velocity air. The #1 heat shield insulation blanket nose piece material was changed from silicone and quartz to nextel fabric, which demonstrates better performance to resist damage from turbulent air during testing. In addition to the changes to the insulation blankets, a Nitronic 60 rub strip will be added to the seal depressor. The Nitronic 60 rub strip has improved friction characteristics that allow for free movement and reduces wear damage to the primary seal. This service bulletin provides instructions to replace heat shield insulation blankets and install Nitronic 60 rub strips. Due to the new configuration of the insulation blankets, some airplanes will need new aft fairing lower spar web drain sumps when replacing insulation blankets. Replacement of the insulation blankets will reduce blanket wear damage due to turbulent airflow. Installation of the rub strip will provide better seal compression and wear resistance to extend the life of the strut aft fairing lower spar primary seal. Incorporation of the changes in accordance with this service bulletin, and a final one time inspection and corrective actions in accordance with Service Bulletin (SB) 777-54A0031 is terminating action to the repeat inspections in accordance with SB 777-54A0031. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to SB 777-54A0031. Boeing Fleet Team Digest (FTD) 777 FTD 54-11003 is related to this service bulletin. Boeing Service Related Problem (SRP) 777-SRP-54-0137 is related to this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 13 of 81 BOEING SERVICE BULLETIN 777-54-0030Revision 1 is sent to change access instructions, update illustrations and revision level of the concurrent requirement. The data given in Information Notice 777-54-0030 IN 01 is included in this revision. D. Description Group 1: Get access to the upper and lower aft fairing structure. Replace insulation blankets, drain sump, and velcro. Install new rub strips to seal depressor. Close access to the upper and lower aft fairing structure. Group 2: Get access to the upper and lower aft fairing structure. Replace insulation blankets and velcro. Install new rub strips to seal depressor. Close access to the upper and lower aft fairing structure. Effects of Revision 1 on airplanes on which Original Issue was previously done: None The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance ZonesZone Model 434, 444 777-200, 777-300 E. Compliance Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2014-NM-178-AD is related to this service bulletin. No compliance time is given. Boeing recommends this service bulletin be done to introduce improvements. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. G. Manpower The table below shows an estimate of the task hours necessary to do this replacement 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:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 14 of 81 BOEING SERVICE BULLETIN 777-54-0030• 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. Group 1: Elapsed Hours Task Hours Number of Persons Task 2.50 5.00 2 Open Access Remove 6.75 27.00 4 ...Left Strut, Blankets - FIGURE 1 6.75 27.00 4 ...Right Strut, Blan- kets - FIGURE 2 Replace 3.25 6.50 2 ...Left Strut, Velcro - FIGURE 3 3.25 6.50 2 ...Right Strut, Velcro - FIGURE 4 Replace 3.50 7.00 2 ...Left Strut, Drain Sump - FIGURE 5 3.50 7.00 2 ...Right Strut, Drain Sump - FIGURE 6 Install 7.75 31.00 4 ...Left Strut, Blankets - FIGURE 7 7.75 31.00 4 ...Right Strut, Blan- kets - FIGURE 8 2.00 4.00 2 Test 2.50 5.00 2 Close Access 49.50 157.00 TOTAL FOR EACH AIRPLANE Group 2: Elapsed Hours Task Hours Number of Persons Task 2.50 5.00 2 Open Access Remove

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 15 of 81 BOEING SERVICE BULLETIN 777-54-0030Group 2: Elapsed Hours Task Hours Number of Persons Task 6.75 27.00 4 ...Left Strut, Blankets - FIGURE 1 6.75 27.00 4 ...Right Strut, Blan- kets - FIGURE 2 Replace 3.25 6.50 2 ...Left Strut, Velcro - FIGURE 3 3.25 6.50 2 ...Right Strut, Velcro - FIGURE 4 Install 7.75 31.00 4 ...Left Strut, Blankets - FIGURE 7 7.75 31.00 4 ...Right Strut, Blan- kets - FIGURE 8 2.50 5.00 2 Close Access 40.50 139.00 TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane + 36806.0 + 30.8 All I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 62777-92S b. Boeing Service Bulletin 777-54-0030, 777-54A0031 c. Boeing Service Letter 777-SL-00-007 d. Boeing Service Related Problem (SRP) 777-SRP-54-0137 e. Component Maintenance Manual (CMM) 54-52-17 f. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM) 2014-NM-178-AD

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 16 of 81 BOEING SERVICE BULLETIN 777-54-0030g. Service Bulletin Index D624W001 h. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-01, 20-50-12, 20-50-19 i. 777 Aircraft Maintenance Manual (AMM) 06-43-00, 54-51-01, 54-54-01, 54-55-01 j. 777 Fleet Team Digest (FTD) 54-11003 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: Title Drawing Number Lower Heat Shield Instl - Aft Fairing 313W5820 Sealing Instl - Aft Fairing 313W3410 Drain Instl - Heat Shield, Aft Fairing 313W5803 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Chapter-Section

Publication 54-54 777 Aircraft Maintenance Manual 54-54, 54-55 777 Illustrated Parts Catalog 54-52 Component Maintenance Manual 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 Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information. M. Software Accomplishment Summary Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 17 of 81 BOEING SERVICE BULLETIN 777-54-0030Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 18 of 81 BOEING SERVICE BULLETIN 777-54-0030

BLANK PAGE2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 Group 1: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Original Issue

date of this Service Bulletin (US Dollars) ROLT as of the Original Issuedate of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

$116,114.00 390 10 May 27, 2015 TOP KIT - RR STRUTAFT FAIRING INSULATION BLANKET ANDDRAIN SUMP - REPLACEMENT 005W3563-1

Group 2: REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Original Issue

date of this Service Bulletin (US Dollars) ROLT as of the Original Issuedate of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

$92,879.00 149 16 May 9, 2014 TOP KIT - RR STRUTAFT FAIRING INSULATION BLANKET - REPLACEMENT 005W3563-2

Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 19 of 81 BOEING SERVICE BULLETIN 777-54-0030B. Industry Support Information Boeing warranty remedies are available for 777 airplanes in warranty as of June 8, 2011. For task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Fleet Support Contracts - Warranty. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Material Management. 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 To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE:One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. The Top Kit is divided into Figure kits for each installation figure shown in the table below. Figure Kit 8 7 6 5 4 3 Top Kit 1 1 1 1 1 1 005W3563-1 1 1 - - 1 1 005W3563-2 Group 1: KIT 005W3563-1

Notes Existing Part Number Name Figure
New Part Number 8 7 6 5 4 3 Qty (b) RUB STRIP 1 1

. . . . 311W5585Y16 (a) (c) 313W5804-24 DRAIN SCREEN

. . 1 1

. . 313W3410-10 (a) (c) 313W5421-1 BLANKET ASSY 1 1

. . . . 313W5421-30 (a) (c) 313W5421-2 BLANKET ASSY 1 1

. . . . 313W5421-31 (a) (c) 313W5421-3 BLANKET ASSY 1 1

. . . . 313W5421-32 (a) (c) 313W5421-4 BLANKET ASSY 1 1

. . . . 313W5421-33 (a) (c) 313W5421-5 BLANKET ASSY 1 1

. . . . 313W5421-34 (a) (c) 313W5421-6 BLANKET ASSY 1 1

. . . . 313W5421-35 (a) (c) 313W5421-7 BLANKET ASSY 1 1

. . . . 313W5421-36 (a) (c) 313W5421-8 BLANKET ASSY 1 1

. . . . 313W5421-37 (a) (c) 313W5421-9 BLANKET ASSY 1 1

. . . . 313W5421-38

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 20 of 81 BOEING SERVICE BULLETIN 777-54-0030Group 1: KIT 005W3563-1

Notes Existing Part Number Name Figure
New Part Number 8 7 6 5 4 3 Qty (a) (c) 313W5804-3 DRAIN TUBE AS- SY . . 1 1

. . 313W5804-46 (a) (c) 313W5804-2 DRAIN TUBE AS- SY . . 1 1

. . 313W5804-48 (a) (b) (c) 313W5816-1 DRAIN SUMP AS- SY . . 1 1

. . 313W5816Y7 (a) (c) 313W5820-8 VELCRO

. . . . 4 4 313W5820-54 (a) (c) 313W5820-9 VELCRO

. . . . 8 8 313W5820-55 (a) (c) 313W5820-10 VELCRO

. . . . 2 2 313W5820-56 (a) (c) 313W5820-11 VELCRO

. . . . 2 2 313W5820-57 BOLT, HEX HEAD

. . 2 2

. . BACB30LM3-4 BOLT

. . 2 2

. . BACB30LM3-5 BOLT, 100 DEG HEX DR . . 8 8

. . BACB30NW6K3X BOLT, 100 DEG HEX DR . . 2 2

. . BACB30NW8K5X BOLT, 100 DEG HEX DR . . 2 2

. . BACB30NW8K6X BOLT, PROTRUDING HD . . 10 10

. . BACB30NX6K3X BOLT, PROTRUDING HD . . 3 3

. . BACB30NX6K4X COLLAR

. . 10 10

. . BACC30BH6 COLLAR

. . 8 8

. . BACC30M6 COLLAR

. . 2 2

. . BACC30M8 NUT

. . 4 4

. . BACN11Z3CK RIVET, UNIVERSAL HD . . 7 7

. . BACR15BB7D7C RIVET, 100 DEG 24 24

. . . . BACR15CE5M5 SCREW

. . 3 3

. . BACS12CK3U7 WASHER

. . 4 4

. . BACW10BP3ACU WASHER

. . 7 7

. . NAS1149C0332R

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 21 of 81 BOEING SERVICE BULLETIN 777-54-0030Group 1: KIT 005W3563-1

Notes Existing Part Number Name Figure
New Part Number 8 7 6 5 4 3 Qty (a) Discard the existing part. (b) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the 'dash' configuration when installed as given in the Accomplishment Instructions of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Boeing Service Letter 777-SL-00-007 for more information. (c) You cannot use the existing part to replace the new or changed part. Group 2: KIT 005W3563-2

Notes Existing Part Number Name Figure
New Part Number 8 7 4 3 Qty (b) RUB STRIP 1 1

. . 311W5585Y16 (a) (c) 313W5421- 11,313W5421-21 BLANKET ASSY 1 1

. . 313W5421-30 (a) (c) 313W5421- 12,313W5421-22 BLANKET ASSY 1 1

. . 313W5421-31 (a) (c) 313W5421- 13,313W5421-23 BLANKET ASSY 1 1

. . 313W5421-32 (a) (c) 313W5421- 14,313W5421-24 BLANKET ASSY 1 1

. . 313W5421-33 (a) (c) 313W5421- 15,313W5421-25 BLANKET ASSY 1 1

. . 313W5421-34 (a) (c) 313W5421- 16,313W5421-26 BLANKET ASSY 1 1

. . 313W5421-35 (a) (c) 313W5421- 17,313W5421-27 BLANKET ASSY 1 1

. . 313W5421-36 (a) (c) 313W5421- 18,313W5421-28 BLANKET ASSY 1 1

. . 313W5421-37 (a) (c) 313W5421- 19,313W5421-29 BLANKET ASSY 1 1

. . 313W5421-38 (a) (c) 313W5820-19 VELCRO

. . 4 4 313W5820-54

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 22 of 81 BOEING SERVICE BULLETIN 777-54-0030Group 2: KIT 005W3563-2

Notes Existing Part Number Name Figure
New Part Number 8 7 4 3 Qty (a) (c) 313W5820-20 VELCRO

. . 8 8 313W5820-55 (a) (c) 313W5820-21 VELCRO

. . 2 2 313W5820-56 (a) (c) 313W5820-22 VELCRO

. . 2 2 313W5820-57 RIVET, 100 DEG 24 24

. . BACR15CE5M5 (a) Discard the existing part. (b) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the 'dash' configuration when installed as given in the Accomplishment Instructions of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Boeing Service Letter 777-SL-00-007 for more information. (c) You cannot use the existing part to replace the new or changed part.

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. Group 1: Notes Name QTY Part Number / Specification (a) ADHESIVE 1 quart BMS 5-141 (a) SEALANT 1 quart BMS 5-63 (BMS 5- 63, Type II, Class B-4 Optional) (b) LEVELING COMPOUND 1 quart DC 3110 (RTV 60 optional) (c) FOAM 1 cu-

bic feet BMS 8-133,Type 1, Class 2 Foam A-1, Grade No 10 to 15 (d) CHEMICAL CONVERSION COAT- ING 1 pint
- (a) PRIMER 1 quart BMS10-11, Type 1

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 23 of 81 BOEING SERVICE BULLETIN 777-54-0030Group 1: Notes Name QTY Part Number / Specification (e) BOLT, PROTRUDING HEAD 4 BACB30VT6K3 (e) COLLAR 4 BACC30BS6S (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Dow Corning, Corporate Center, PO Box 994, Midland, MI 48686-0994, United States (c) Material only necessary if used to displace volume when applying leveling compound. (d) Refer to SOPM 20-43-03 for a list of acceptable materials. (e) This part is related to a bracket in the aft pan casting if additional access is needed. Group 2: Notes Name QTY Part Number / Specification (a) ADHESIVE 1 quart BMS 5-141 (b) BOLT, PROTRUDING HEAD 4 BACB30VT6K3 (b) COLLAR 4 BACC30BS6S (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) This part is related to a bracket in the aft pan casting if additional access is needed. 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 24 of 81 BOEING SERVICE BULLETIN 777-54-0030F. 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: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 25 of 81 BOEING SERVICE BULLETIN 777-54-0030Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 26 of 81 BOEING SERVICE BULLETIN 777-54-0030

BLANK PAGE3. 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 Values: — Values for structural fasteners are given in 777-200/ 777-300 Structural Repair Manual, Chapter 51. — Values for airframe maintenance tasks are included in Chapter 20 of 777 Airplane Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). — Values for engine maintenance tasks are included in Chapter 70 of 777 Airplane Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step. 4. Use the approved fastener, process and 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. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 6. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 27 of 81 BOEING SERVICE BULLETIN 777-54-00307. 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. 8. 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. 9. 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. 10. 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. 11. If shading is used, shaded areas in Figures are to separate the non-critical and non-authoritative information from the critical and authoritative information. B. WORK INSTRUCTIONS 1. Prepare the strut for maintenance operations. Refer to 777 AMM 54-51-01 as an accepted procedure. 2. Open the strut aft fairing side access doors shown in the table below. Refer to 777 AMM 06-43-00 for the location of these doors. Right Wing

Left Wing Outboard Inboard Inboard Outboard 444BR 444BL 434BR 434BL 444CR 444CL 434CR 434CL 444DR 444DL 434DR 434DL 444ER 444EL 434ER 434EL 3. Remove heat shield pan casting and insulation blankets in accordance with the figures below: Right Strut Left Strut FIGURE 2 FIGURE 1 4. Replace Velcro strips in accordance with the figures below: Right Strut Left Strut FIGURE 4 FIGURE 3 5.Group 1: Replace aft fairing web drain sump, drain screen, and drain tubes in accordance with the figures below:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 28 of 81 BOEING SERVICE BULLETIN 777-54-0030Right Strut Left Strut FIGURE 6 FIGURE 5 6. Install rub strips, heat shield pan casting, and insulation blankets in accordance with the figures below: Right Strut Left Strut FIGURE 8 FIGURE 7 7.Group 1: Do a test to make sure the aft fairing drain tubes are not blocked, not leaking, and drains fluid correctly. Refer to CMM 54-52-17, Repair 4-1 or 777 AMM 54-55-01 as an accepted procedure. 8. Close the strut aft fairing side access doors shown in the table below. Refer to 777 AMM 06-43-00 for the location of these doors. Right Wing

Left Wing Outboard Inboard Inboard Outboard 444BR 444BL 434BR 434BL 444CR 444CL 434CR 434CL 444DR 444DL 434DR 434DL 444ER 444EL 434ER 434EL 9. Put the strut back to its usual condition. Refer to 777 AMM 54-51-01 as an accepted procedure. 10. Put the airplane back to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1: September 30, 2015 29 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 1: LEFT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 1 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 30 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 1: LEFT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 2 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 31 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 1: LEFT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 3 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 32 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 1: LEFT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 4 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 33 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the left strut. More Data Qty Identification Name Task Step Make note of fastener location for Blanket Assembly installation. 70 - FASTENER Remove / Keep 1

FIGURE 1: LEFT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 5 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 34 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step Refer to CMM 54- 52-17, Repair 4-1 or 777 AMM 54-54-01as an accepted procedure. 5 - PAN CASTING Remove / Keep 2

7 - BLANKET ASSEMBLY Remove (a) 2 - CLAMP Remove / Keep 3 (b) 2 - FASTENER Remove 4 Make note of fastener location for Blanket Assembly installation. 14 - FASTENER Remove / Keep 5

Refer to CMM 54- 52-17, Repair 4-1 or 777 AMM 54-54-01as an accepted procedure. 1 - PAN CASTING Remove / Keep 6

2 - BLANKET ASSEMBLY Remove (a) If the clamp common to the upper drain tube cannot be removed due to limited access, remove the two fasteners common to the bracket assembly and pan casting as given in the next step and do not do this step. (b) This step is provided as an alternative method to help remove the pan casting and prevent damage to the insulation blanket and drain tubes.This step is not necessary if both clamps common to the drain tubes can be removed in step 3. The fastener and clamp common to the upper drain tube may be difficult to remove due to limited access.

FIGURE 1: LEFT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 6 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 35 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 2: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 1 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 36 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 2: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 2 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 37 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 2: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 3 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 38 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 2: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 4 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 39 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the right strut. More Data Qty Identification Name Task Step Make note of fastener location for Blanket Assembly installation. 70 - FASTENER Remove / Keep 1

FIGURE 2: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 5 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 40 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step Refer to CMM 54- 52-17, Repair 4-1 or 777 AMM 54-54-01as an accepted procedure. 5 - PAN CASTING Remove / Keep 2

7 - BLANKET ASSEMBLY Remove (a) 2 - CLAMP Remove / Keep 3 (b) 2 - FASTENER Remove 4 Make note of fastener location for Blanket Assembly installation. 14 - FASTENER Remove / Keep 5

Refer to CMM 54- 52-17, Repair 4-1 or 777 AMM 54-54-01as an accepted procedure. 1 - PAN CASTING Remove / Keep 6

2 - BLANKET ASSEMBLY Remove (a) If the clamp common to the upper drain tube cannot be removed due to limited access, remove the two fasteners common to the bracket assembly and pan casting as given in the next step and do not do this step. (b) This step is provided as an alternative method to help remove the pan casting and prevent damage to the insulation blanket and drain tubes.This step is not necessary if both clamps common to the drain tubes can be removed in step 3. The fastener and clamp common to the upper drain tube may be difficult to remove due to limited access.

FIGURE 2: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET REMOVAL (SHEET 6 OF 6) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 41 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 3: LEFT STRUT - VELCRO STRIPS REPLACEMENT (SHEET 1 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 42 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 3: LEFT STRUT - VELCRO STRIPS REPLACEMENT (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 43 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the left strut. More Data Qty Identification Name Task Step on the aft fairing lower spare web at all locations. - - VELCRO Remove 1
(a) 4 313W5820-54 VELCRO Install (New) 2 (a) 8 313W5820-55 VELCRO Install (New) 3 (a) 2 313W5820-56 VELCRO Install (New) 4 (a) 2 313W5820-57 VELCRO Install (New) 5 (a) Clean and prepare aft fairing lower spar web before installing velcro. Install velcro by bonding velcro to aft fairing lower spar web with BMS 5-141. Refer to SOPM 20-50-12, Type 111 as an accepted procedure.

FIGURE 3: LEFT STRUT - VELCRO STRIPS REPLACEMENT (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 44 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 4: RIGHT STRUT - VELCRO STRIPS REPLACEMENT (SHEET 1 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 45 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 4: RIGHT STRUT - VELCRO STRIPS REPLACEMENT (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 46 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the right strut. More Data Qty Identification Name Task Step on the aft fairing lower spare web at all locations. - - VELCRO Remove 1
(a) 4 313W5820-54 VELCRO Install (New) 2 (a) 8 313W5820-55 VELCRO Install (New) 3 (a) 2 313W5820-56 VELCRO Install (New) 4 (a) 2 313W5820-57 VELCRO Install (New) 5 (a) Clean and prepare aft fairing lower spar web before installing velcro. Install velcro by bonding velcro to aft fairing lower spar web with BMS 5-141. Refer to SOPM 20-50-12, Type 111 as an accepted procedure.

FIGURE 4: RIGHT STRUT - VELCRO STRIPS REPLACEMENT (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 47 of 81 BOEING SERVICE BULLETIN 777-54-0030This Figure applies only to: Group 1.

FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 1 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 48 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 2 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 49 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 3 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 50 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 4 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 51 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the left strut. NOTE:If Drain Sump on Left Strut Aft Fairing Lower Spar Web was replaced with a Drain Sump Part Number 313W5816-5 or 313W5816-7 prior to incorporation of this service bulletin, then the intent of this Figure has been accomplished. More Data Qty Identification Name Task Step 3 - CLAMP Remove / Keep 1 (g) 2 - CLAMP Remove / Keep 2 (g) 1 - BRACKET ASSEMBLY Remove / Keep 3 - FASTENER Remove 3 1 313W5804-24 SCREEN ASSY Remove 4 - FASTENER Remove 4 1 313W5804-2 DRAIN TUBE ASSY Remove 1 313W5804-3 DRAIN TUBE ASSY Remove 5

- - SEALANT Remove 6 27 - FASTENER Remove 1 - STIFFENER Remove / Keep (f) 1 313W5816-1 DRAIN SUMP Remove 1 313W5816Y7 DRAIN SUMP ASSY Locate 7 1 - STIFFENER Locate on aft fairing heat shield and stiffenerfor drain sump assembly installation. 27 - FASTENER HOLE Locate 8

on drain sump assembly. (a) 27 - FASTENER HOLE Drill on aft fairing heat shield and stiffenerfor drain sump assembly installation. 6 - FASTENER HOLE Locate 9

on drain sump assembly. Fastener hole size is 0.255 inch to 0.261 inch. 6 - FASTENER HOLE Drill

FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 5 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 52 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step Not shown. Clean and deburr fastener holes. 1 - DRAIN SUMP ASSEM- BLY AND STIFFENER Remove / Keep 10

to all bare metal surfaces. Not shown. Refer to SOPM 20-43-03 as an accepted procedure. - - CHEMICAL CONVER- SION COATING Apply 11

to all bare metal surfaces. Not shown. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE 1 PRIMER Apply

1 313W5816Y7 DRAIN SUMP ASSY Install (New) 12 1 - STIFFENER Install (Kept) (a) 27 - FASTENER Install (New) Fillet seal at interface of the drain sump assembly and the aft fairing frame, stiffener, and chords. (e) - BMS 5-63 SEALANT Apply 13

(d) 1 313W5804-46 DRAIN TUBE ASSY Install (New) 14 Clean bottom insideof drain sump assembly for leveling compound application. Refer to SOPM 20-50-19 as an accepted procedure. 1 313W5816Y7 DRAIN SUMP ASSY Clean 15

Refer to CMM 54-52-17 as an accepted procedure. (b) (c) - DC 3110 (RTV 60 op- tional)LEVELING COMPOUND Apply
(d) 1 313W5804-48 DRAIN TUBE ASSY Install (New) 16 Wet install by applying BMS 5-63. Refer to SOPM 20-50-19,Method 3 as an accepted procedure. 2 BACB30LM3-5 BOLT Install (New)

2 BACW10BP3ACU WASHER Install (New)

FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 6 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 53 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step Wet install by applying BMS 5-63. Refer to SOPM 20-50-19,Method 3 as an accepted procedure. 2 BACB30LM3-4 BOLT, HEX HEAD Install (New) 17

2 BACW10BP3ACU WASHER Install (New) 4 NAS1149C0332R WASHER Install (New) 18 4 BACN11Z3CK NUT Install (New) 1 313W3410-10 DRAIN SCREEN Install (New) 19 3 NAS1149C0332R WASHER Install (New) 3 BACS12CK3U7 SCREW Install (New) Wet install clamp fasteners using BMS 5-63. 3 - CLAMP Install (Kept) 20
(h) 2 - CLAMP Install (Kept) 21 (h) 1 - BRACKET ASSEMBLY Install (Kept) (a) Refer to Fastener Code Table. (b) Aft fairing structure must be oriented in aircraft ground attitude (looking FWD rotate clockwise 5.9 degrees and 1.7 degrees nose up measured from SAF STA 46.35 to SAF STA 78.85) before leveling compound can be applied. Aft fairing structure shall not be moved during working life of leveling compound. Apply leveling compound until it meets the bottom of all drain holes and not block any drain tube openings or passageways. (c) An excessive amount of leveling compound is not recommended in one pour. The use of foam to displace a large volume is optional, cut BMS 8-133,Type 1, Class 2 Foam A-1, Grade No 10 to 15, Rigid Foam to suitable size where needed to minimize leveling compound usage. Coat bottom of foam with leveling compound before installation to minimize trapped air, recommend securing foam by partially filling area with leveling compound and allowing to gel before completing pour. (d) Make sure drainage hole is clear and free of sealant. (e) It is acceptable to fay surface seal between mating surfaces using BMS 5-63, Type II, Class B-4. Clean and prime all surfaces prior to sealing. Refer to SOPM 20-50-19 as an accepted procedure. (f) It is recommended to slide the drain sump forward and then up to remove the drain sump from the fairing. Make sure not to damage the surrounding structure when removing the drain sump. Make sure to remove any remaining sealant from the area where the drain sump was removed. (g) If these parts are already removed, do not do this step. The bracket assembly may have been removed from the pan casting for additional access. If the clamps need to be removed from the bracket, remove and keep the clamps and the bracket. (h) Do not do this step if the bracket is installed on the pan casting. If the bracket is installed on the pan casting, these clamps will be installed later. Wet install clamp fasteners using BMS 5-63.

FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 7 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 54 of 81 BOEING SERVICE BULLETIN 777-54-0030The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure. More Data Hole Dia Qty Identification Name Code (a) 0.200-0.203 7 BACB30NX6K3X BOLT, PROTRUDING HD A

- 7 BACC30BH6 COLLAR (a) 0.200-0.203 3 BACB30NX6K3X BOLT, PROTRUDING HD B (a)
- 3 BACB30NX6K4X BOLT, PROTRUDING HD

- 3 BACC30BH6 COLLAR Countersink 100 degrees. (a) 0.200-0.203 8 BACB30NW6K3X BOLT, 100 DEG HEX DR C

- 8 BACC30M6 COLLAR Countersink 100 degrees. (a) 0.263-0.266 2 BACB30NW8K5X BOLT, 100 DEG HEX DR D Countersink 100 degrees. (a) - 2 BACB30NW8K6X BOLT, 100 DEG HEX DR

- 2 BACC30M8 COLLAR 0.221-0.233 7 BACR15BB7D7C RIVET, UNIVERSAL HD F (a) Wet install by applying BMS 5-63 to threads and shank.

FIGURE 5: LEFT STRUT - DRAIN SUMP REPLACEMENT (SHEET 8 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 55 of 81 BOEING SERVICE BULLETIN 777-54-0030This Figure applies only to: Group 1.

FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 1 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 56 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 2 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 57 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 3 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 58 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 4 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 59 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the right strut. NOTE:If Drain Sump on Right Strut Aft Fairing Lower Spar Web was replaced with a Drain Sump Part Number 313W5816-5 or 313W5816-7 prior to incorporation of this service bulletin, then the intent of this Figure has been accomplished. More Data Qty Identification Name Task Step 3 - CLAMP Remove / Keep 1 (g) 2 - CLAMP Remove / Keep 2 (g) 1 - BRACKET ASSEMBLY Remove / Keep 3 - FASTENER Remove 3 1 313W5804-24 SCREEN ASSY Remove 4 - FASTENER Remove 4 1 313W5804-2 DRAIN TUBE ASSY Remove 1 313W5804-3 DRAIN TUBE ASSY Remove 5

- - SEALANT Remove 6 27 - FASTENER Remove 1 - STIFFENER Remove / Keep (f) 1 313W5816-1 DRAIN SUMP Remove 1 313W5816Y7 DRAIN SUMP ASSY Locate 7 1 - STIFFENER Locate on aft fairing heat shield and stiffenerfor drain sump assembly installation. 27 - FASTENER HOLE Locate 8

on drain sump assembly. (a) 27 - FASTENER HOLE Drill on aft fairing heat shield and stiffenerfor drain sump assembly installation. 6 - FASTENER HOLE Locate 9

on drain sump assembly. Fastener hole size is 0.255 inch to 0.261 inch. 6 - FASTENER HOLE Drill

FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 5 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 60 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step Not shown. Clean and deburr fastener holes. 1 - DRAIN SUMP ASSEM- BLY AND STIFFENER Remove / Keep 10

to all bare metal surfaces. Not shown. Refer to SOPM 20-43-03 as an accepted procedure. - - CHEMICAL CONVER- SION COATING Apply 11

to all bare metal surfaces. Not shown. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11, TYPE 1 PRIMER Apply

1 313W5816Y7 DRAIN SUMP ASSY Install (New) 12 1 - STIFFENER Install (Kept) (a) 27 - FASTENER Install (New) Fillet seal at interface of the drain sump assembly and the aft fairing frame, stiffener, and chords. (e) - BMS 5-63 SEALANT Apply 13

(d) 1 313W5804-46 DRAIN TUBE ASSY Install (New) 14 Clean bottom insideof drain sump assembly for leveling compound application. Refer to SOPM 20-50-19 as an accepted procedure. 1 313W5816Y7 DRAIN SUMP ASSY Clean 15

Refer to CMM 54-52-17 as an accepted procedure. (b) (c) - DC 3110 (RTV 60 op- tional)LEVELING COMPOUND Apply
(d) 1 313W5804-48 DRAIN TUBE ASSY Install (New) 16 Wet install by applying BMS 5-63. Refer to SOPM 20-50-19,Method 3 as an accepted procedure. 2 BACB30LM3-5 BOLT Install (New)

2 BACW10BP3ACU WASHER Install (New)

FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 6 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 61 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step Wet install by applying BMS 5-63. Refer to SOPM 20-50-19,Method 3 as an accepted procedure. 2 BACB30LM3-4 BOLT, HEX HEAD Install (New) 17

2 BACW10BP3ACU WASHER Install (New) 4 NAS1149C0332R WASHER Install (New) 18 4 BACN11Z3CK NUT Install (New) 1 313W3410-10 DRAIN SCREEN Install (New) 19 3 NAS1149C0332R WASHER Install (New) 3 BACS12CK3U7 SCREW Install (New) Wet install clamp fasteners using BMS 5-63. 3 - CLAMP Install (Kept) 20
(h) 2 - CLAMP Install (Kept) 21 (h) 1 - BRACKET ASSEMBLY Install (Kept) (a) Refer to Fastener Code Table. (b) Aft fairing structure must be oriented in aircraft ground attitude (looking FWD rotate clockwise 5.9 degrees and 1.7 degrees nose up measured from SAF STA 46.35 to SAF STA 78.85) before leveling compound can be applied. Aft fairing structure shall not be moved during working life of leveling compound. Apply leveling compound until it meets the bottom of all drain holes and not block any drain tube openings or passageways. (c) An excessive amount of leveling compound is not recommended in one pour. The use of foam to displace a large volume is optional, cut BMS 8-133,Type 1, Class 2 Foam A-1, Grade No 10 to 15, Rigid Foam to suitable size where needed to minimize leveling compound usage. Coat bottom of foam with leveling compound before installation to minimize trapped air, recommend securing foam by partially filling area with leveling compound and allowing to gel before completing pour. (d) Make sure drainage hole is clear and free of sealant. (e) It is acceptable to fay surface seal between mating surfaces using BMS 5-63, Type II, Class B-4. Clean and prime all surfaces prior to sealing. Refer to SOPM 20-50-19 as an accepted procedure. (f) It is recommended to slide the drain sump forward and then up to remove the drain sump from the fairing. Make sure not to damage the surrounding structure when removing the drain sump. Make sure to remove any remaining sealant from the area where the drain sump was removed. (g) If these parts are already removed, do not do this step. The bracket assembly may have been removed from the pan casting for additional access. If the clamps need to be removed from the bracket, remove and keep the clamps and the bracket. (h) Do not do this step if the bracket is installed on the pan casting. If the bracket is installed on the pan casting, these clamps will be installed later. Wet install clamp fasteners using BMS 5-63.

FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 7 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 62 of 81 BOEING SERVICE BULLETIN 777-54-0030The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure. More Data Hole Dia Qty Identification Name Code (a) 0.200-0.203 7 BACB30NX6K3X BOLT, PROTRUDING HD A

- 7 BACC30BH6 COLLAR (a) 0.200-0.203 3 BACB30NX6K3X BOLT, PROTRUDING HD B (a)
- 3 BACB30NX6K4X BOLT, PROTRUDING HD

- 3 BACC30BH6 COLLAR Countersink 100 degrees. (a) 0.200-0.203 8 BACB30NW6K3X BOLT, 100 DEG HEX DR C

- 8 BACC30M6 COLLAR Countersink 100 degrees. (a) 0.263-0.266 2 BACB30NW8K5X BOLT, 100 DEG HEX DR D Countersink 100 degrees. (a) - 2 BACB30NW8K6X BOLT, 100 DEG HEX DR

- 2 BACC30M8 COLLAR 0.221-0.233 7 BACR15BB7D7C RIVET, UNIVERSAL HD F (a) Wet install by applying BMS 5-63 to threads and shank.

FIGURE 6: RIGHT STRUT - DRAIN SUMP REPLACEMENT (SHEET 8 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 63 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 1 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 64 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 2 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 65 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 3 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 66 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 4 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 67 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 5 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 68 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 6 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 69 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the left strut. More Data Qty Identification Name Task Step 1 311W5585Y16 RUB STRIP Install (New) 1 24 - FASTENER HOLE Locate (b) 24 - FASTENER Install (New) (a) 1 313W5421-38 BLANKET ASSY Install (New) 2 (a) 1 313W5421-35 BLANKET ASSY Install (New) (c) 1 - PAN CASTING Install (Kept) 14 - FASTENER Install (Kept) 3 If removed, wet install clamp fasteners using BMS 5-63 2 - CLAMP Install (Kept) 4

If removed. 1 - BRACKET ASSEMBLY Install (Kept) 5 If removed. Wet install by using BMS 5-63. (b) 2 - FASTENER Install (New)
(a) 1 313W5421-34 BLANKET ASSY Install (New) 6 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 7 (a) 1 313W5421-33 BLANKET ASSY Install (New) 8 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 9 (a) 1 313W5421-32 BLANKET ASSY Install (New) 10 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 11 (a) 1 313W5421-31 BLANKET ASSY Install (New) 12 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 13 (a) 1 313W5421-30 BLANKET ASSY Install (New) 14 (a) 1 313W5421-36 BLANKET ASSY Install (New) (a) 1 313W5421-37 BLANKET ASSY Install (New) (c) 1 - PAN CASTING Install (Kept) 22 - FASTENER Install (Kept) 15

FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 7 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 70 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step (a) Refer to 777 AMM 54-54-01 as an accepted procedure. Blanket should only be installed against the web when it is in its final position to prevent loss of peel strength of velcro. Firm pressure should be applied to assure blanket is secured properly. (b) Refer to Fastener Code Table. (c) Refer to CMM 54-52-17, Repair 4-1 as an accepted procedure.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure. More Data Hole Dia Qty Identification Name Code Countersink 100 degrees. 0.159-0.167 24 BACR15CE5M5 RIVET, 100 DEG E Wet install using BMS 5- 63. - 2 BACB30VT6K3 BOLT, PROTRUDING HEAD G

- 2 BACC30BS6S COLLAR

FIGURE 7: LEFT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 8 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 71 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 1 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 72 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 2 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 73 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 3 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 74 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 4 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 75 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 5 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 76 of 81 BOEING SERVICE BULLETIN 777-54-0030FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 6 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 77 of 81 BOEING SERVICE BULLETIN 777-54-0030The 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 the right strut. More Data Qty Identification Name Task Step 1 311W5585Y16 RUB STRIP Install (New) 1 24 - FASTENER HOLE Locate (b) 24 - FASTENER Install (New) (a) 1 313W5421-38 BLANKET ASSY Install (New) 2 (a) 1 313W5421-35 BLANKET ASSY Install (New) (c) 1 - PAN CASTING Install (Kept) 14 - FASTENER Install (Kept) 3 If removed, wet install clamp fasteners using BMS 5-63 2 - CLAMP Install (Kept) 4

If removed. 1 - BRACKET ASSEMBLY Install (Kept) 5 If removed. Wet install by using BMS 5-63. (b) 2 - FASTENER Install (New)
(a) 1 313W5421-34 BLANKET ASSY Install (New) 6 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 7 (a) 1 313W5421-33 BLANKET ASSY Install (New) 8 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 9 (a) 1 313W5421-32 BLANKET ASSY Install (New) 10 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 11 (a) 1 313W5421-31 BLANKET ASSY Install (New) 12 (c) 1 - PAN CASTING Install (Kept) 12 - FASTENER Install (Kept) 13 (a) 1 313W5421-30 BLANKET ASSY Install (New) 14 (a) 1 313W5421-36 BLANKET ASSY Install (New) (a) 1 313W5421-37 BLANKET ASSY Install (New) (c) 1 - PAN CASTING Install (Kept)

FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 7 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 78 of 81 BOEING SERVICE BULLETIN 777-54-0030More Data Qty Identification Name Task Step 22 - FASTENER Install (Kept) 15 (a) Refer to 777 AMM 54-54-01 as an accepted procedure. Blanket should only be installed against the web when it is in its final position to prevent loss of peel strength of velcro. Firm pressure should be applied to assure blanket is secured properly. (b) Refer to Fastener Code Table. (c) Refer to CMM 54-52-17, Repair 4-1 as an accepted procedure.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure. More Data Hole Dia Qty Identification Name Code Countersink 100 degrees. 0.159-0.167 24 BACR15CE5M5 RIVET, 100 DEG E Wet install using BMS 5- 63. - 2 BACB30VT6K3 BOLT, PROTRUDING HEAD G

- 2 BACC30BS6S COLLAR

FIGURE 8: RIGHT STRUT - HEAT SHIELD INSULATION BLANKET INSTALLATION (SHEET 8 OF 8) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 79 of 81 BOEING SERVICE BULLETIN 777-54-0030The fastener codes in this Master Fastener Code table agree with the fastener codes given in the Figures in Paragraph 3.B, Work Instructions. This fastener code table can be used as a reference when doing the service bulletin work. If a requirement is different in a figure, than given in this table, use the requirements given in the figure. MASTER FASTENER CODE TABLE MORE DATA HOLE DIAME- TER IDENTIFICATION NAME CODE (a) 0.200-0.203 BACB30NX6K3X BOLT, PROTRUDING HD A

- BACC30BH6 COLLAR (a) 0.200-0.203 BACB30NX6K3X BOLT, PROTRUDING HD B (a) 0.200-0.203 BACB30NX6K4X BOLT, PROTRUDING HD

- BACC30BH6 COLLAR Countersink 100 degrees. (a) 0.200-0.203 BACB30NW6K3X BOLT, 100 DEG HEX DR C

- BACC30M6 COLLAR Countersink 100 degrees. (a) 0.263-0.266 BACB30NW8K5X BOLT, 100 DEG HEX DR D Countersink 100 degrees. (a) 0.263-0.266 BACB30NW8K6X BOLT, 100 DEG HEX DR

- BACC30M8 COLLAR Countersink 100 degrees. 0.159-0.167 BACR15CE5M5 RIVET, 100 DEG E 0.221-0.233 BACR15BB7D7C RIVET, UNIVERSAL HD F Bolt orientation is optional. (a) 0.190-0.218 BACB30VT6K3 BOLT, PROTRUDING HEAD G

- BACC30BS6S COLLAR (a) Wet install by applying BMS 5-63 to threads and shank .

APPENDIX A: MASTER FASTENER CODE TABLE (SHEET 1 OF 1) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 80 of 81 BOEING SERVICE BULLETIN 777-54-0030APPENDIX B: PART DEMAND INTENT (SHEET 1 OF 1) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 27, 2014 777-54-0030 Revision 1 September 30, 2015 81 of 81 BOEING SERVICE BULLETIN 777-54-0030