### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Number: 757-54A0047**  Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 1 of 62 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 2 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 26 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 29 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 30 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 FIGURE 1: ACCESS FOR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE. . . . . . . . . . . . . . 38 FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD . . . 40 FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE. . . . . . . . . . . . 43 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE. . . . . . . . . . 46 FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE. . . . . . . . 48 FIGURE 7: THIS FIGURE HAS BEEN DELETED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND. . . . . . . . . . . . . . . . . . . . . 52 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE. . . . . . . . . . . . . . . . . . . . . 54 FIGURE 10: SEAL COVER PLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS. . . . . . . 58

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 3 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**FIGURE 12: NACELLE/PYLONS - ALTERNATIVE ACCESS TO THE CRITICAL HORIZONTAL FLANGE FASTENERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS . . 61

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 4 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 757-54A0047** Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** More work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2 or Revision 3 of this service bulletin. On airplanes without conclusive records of previous inspections, do a one time open hole High Frequency Eddy Current (HFEC) inspection or ultrasonic inspection of the four critical fastener holes in the horizontal flange as given in this service bulletin. No airplanes ware added or removed from this service bulletin effectivity. **REASON FOR REVISION** This revision is sent to revise the compliance information and to give an alternative method of accessing the critical fasteners at the strut-to-diagonal brace fitting. It is also sent to add more instructions for inspecting the aft torque bulkhead. The following sections were changed: 1. More information is added to the Background and Reason sections. 2. Paragraph 1.D., Description - Affected maintenance zones are added. 3. Paragraph 1.E., Compliance - The compliance information is revised. 4. Paragraph 1.F., Approval - An Alternative Method of Compliance (AMOC) statement is added, and the Federal Aviation Administration (FAA) Airworthiness Directives (AD) reference is changed. 5. Paragraph 1.G., Manpower - Added a new manpower table and changed manpower information. 6. Paragraph 1.J.1., Existing Data - Service Related Problem (SRP), Nondestructive Test (NDT) and the FAA (AD) reference is changed. 7. Paragraph 1.K., Publications Affected - A Damage Tolerance Based Structural Inspection statement is added. 8. Paragraph 3.A., General Information - Added new standard Note 1 and Note 7.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 5 of 629. Paragraph 3.B., Work Instructions - More inspection instructions are added to Part II and Part IV. 10. FIGURE 3 - A new view and more inspection instructions are added. 11. FIGURE 12 and FIGURE 13 are added. The data given in Information Notice 757-54A0047 R03 IN-01 is included in this revision. 757-54A0047 R03 IN-01 was sent to inform operators about the Federal Aviation Administration (FAA) approval of an Alternative Method of Compliance (AMOC) to paragraph (g) of Airworthiness Directive (AD) 2007-16-13. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** November 13, 2003 Original Issue: March 24, 2005 Revision 1: January 31, 2007 Revision 2: June 27, 2007 Revision 3: June 24, 2010 Revision 4:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 6 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Summary**  **Number: 757-54A0047** Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting 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 the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and to do an inspection and repair of the four critical fastener holes on the horizontal flange. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. **Service History Report**  **Strut Cycles**  **Hours Date**  One bolt sheared in horizontal flange. Four bolts loose in vertical flange. - 10,284 29,451 12/93 Four bolts loose in vertical flange of both struts. No. 1 & 2 9,358 25,768 11/96 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. No. 1 & 2

- - 06/98 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. No. 1 & 2 21,749 55,789 11/99

Sixteen bolts loose in horizontal flange. No. 1 & 2 20,161 46,459 01/01 Two bolts loose in vertical flange. No. 1 13,662 49,019 09/01

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 7 of 62**Service History Report**  **Strut Cycles**  **Hours Date**  Two bolt heads cracked.

- 14,633 23,423 01/02 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. No. 1 & 2 12,493 16,601 04/02 Migrated shim between bulkhead and vertical flange of fitting. No. 1 & 2 15,522 43,822 05/02 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. No. 2 15,900 46,758 06/02 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. No. 1 20,090 49,807 12/02

Two loose bolts in vertical flange.

- 22,111 50,841 04/03 Three loose bolts in vertical flange. No. 1 9,991 30,072 09/03 Migrated shims between bulkhead and vertical flange of fitting. No. 1 & 2 26,914 60,715 09/03 Three loose bolts in vertical flange. No. 2 15,004 44,985 10/03 Three loose bolts in vertical flange. No. 2 7,922 12,368 01/04 Four loose bolts in vertical flange. No. 1 7,592 12,119 02/04 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. No. 1 13,083 44,423 04/06

In addition, one operator found a strut torque bulkhead fitting with loose fasteners and cracks at the joint common to the strut diagonal brace fitting on two airplanes with the Strut Improvement Program (SIP) incorporated during production. One airplane had been inspected for loose fasteners in 2006 per service bulletin 75-54A0047 Revision 01 with no findings. Since that inspection, the airplane had accumulated less than 3000 flight cycles. The loose fasteners and cracks were found during an engine change while the area was exposed. Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130 are related to this service bulletin. **ACTION** Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 8 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A borescope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection and repair of the four critical fastener holes on the horizontal flange. As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. **EFFECTIVITY** 757-200/-200CB and -200PF airplanes line numbers 1 thru 1048, powered by Rolls Royce engines. **COMPLIANCE** Refer to paragraph 1.E., Compliance for compliance information. Federal Aviation Administration (FAA) Airworthiness Directives (AD) 2004-12-07 and 2008-05-10, are related to this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  22.0 (a) 44.0 (a) All (a) Inspections only. Does not include time to make repairs if loose fasteners or cracks are found.
**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 9 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 10 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Number: 757-54A0047**  Original Issue: November 13, 2003 Revision 4: June 24, 2010 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting 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 Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 757-200/-200CB/-200PF airplanes line number 1 thru 735, powered by Rolls Royce engines. - 1
Airplanes without SB 757-54-0035 incorporation. 1 Airplanes with SB 757-54-0035 incorporation. 2 757-200/-200PF airplanes line number 736 thru 1048, powered by Rolls Royce engines. - 2

Airplane Models: 757-200, 757-200CB, 757-200PF **Group Variable Number**  1 NA002 - NA028

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 11 of 62**Group Variable Number**  1 NA191 - NA199 1 NA201 - NA239 1 NA301 - NA305 1 NA341 - NA352 1 NA391 - NA399 1 NA401 - NA408 1 NA441 - NA447 1 NB021 - NB023 1 NB036 - NB041 1 NB051 - NB053 1 NB061 - NB073 1 NB079 1 NB131 - NB148 1 NB161 - NB162 1 NB201 - NB204 1 NB221 - NB225 2 NB226 - NB228 2 NB230 1 NB236 1 NB239 1 NB261 - NB267 1 NB291 - NB299 1 NB301 - NB302 1 NB311 - NB312 1 NB321 - NB331 1 NB421 - NB438 1 NB446 1 NB451 - NB454 1 NB501 - NB523 1 NB561 2 NB571 2 NB581 - NB583 1 NC058 - NC061

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 12 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Group**  **Variable Number** 2 NC062 1 NC936 - NC950 1 NC971 - NC974 1 ND001 - ND007 1 ND011 - ND059 1 ND111 - ND113 1 ND161 - ND199 1 ND201 - ND203 1 ND221 - ND225 1 ND241 - ND248 1 ND301 - ND317 2 ND318 - ND322 2 ND401 1 ND891 1 ND895 2 NJ001 - NJ004 2 NJ031 - NJ032 2 NN001 - NN002 2 NN051 - NN052 1 NS601 - NS610 2 NS611 - NS616 2 NT001 - NT009 2 NT201 - NT202 2 NT231 - NT234 2 NT237 - NT240 2 NT242 2 NT245 - NT248 2 NT281 - NT289 2 NT381 - NT386 2 NT401 - NT409 2 NT411 - NT412 2 NT426 - NT427 2 NT431 - NT432

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 13 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Group**  **Variable Number** 2 NT436 - NT438 2 NT446 2 NT731 - NT769 2 NT861 - NT862 2 NT901 - NT916 2 NT971 - NT985 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** This service bulletin gives the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and do an inspection and repair of the four critical fastener holes on the horizontal flange. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting.

**Service History Report**  **Strut Cycles**  **Hours Date**  One bolt sheared in horizontal flange. Four bolts loose in vertical flange. - 10,284 29,451 12/93 Four bolts loose in vertical flange of both struts. No. 1 & 2 9,358 25,768 11/96 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. No. 1 & 2

- - 06/98 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. No. 1 & 2 21,749 55,789 11/99

Sixteen bolts loose in horizontal flange. No. 1 & 2 20,161 46,459 01/01 Two bolts loose in vertical flange. No. 1 13,662 49,019 09/01 Two bolt heads cracked.

- 14,633 23,423 01/02 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. No. 1 & 2 12,493 16,601 04/02

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 14 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Service History**  **Report Strut**  **Cycles Hours**  **Date** Migrated shim between bulkhead and vertical flange of fitting. No. 1 & 2 15,522 43,822 05/02 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. No. 2 15,900 46,758 06/02 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. No. 1 20,090 49,807 12/02

Two loose bolts in vertical flange.

- 22,111 50,841 04/03 Three loose bolts in vertical flange. No. 1 9,991 30,072 09/03 Migrated shims between bulkhead and vertical flange of fitting. No. 1 & 2 26,914 60,715 09/03 Three loose bolts in vertical flange. No. 2 15,004 44,985 10/03 Three loose bolts in vertical flange. No. 2 7,922 12,368 01/04 Four loose bolts in vertical flange. No. 1 7,592 12,119 02/04 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. No. 1 13083 44,423 04/06

In addition, one operator found a strut torque bulkhead fitting with loose fasteners and cracks at the joint common to the strut diagonal brace fitting on two airplanes with the Strut Improvement Program (SIP) incorporated during production. One airplane had been inspected for loose fasteners in 2006 per service bulletin 75-54A0047 Revision 01 with no findings. Since that inspection, the airplane had accumulated less than 3000 flight cycles. The loose fasteners and cracks were found during an engine change while the area was exposed. Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130 are related to this service bulletin. Revision 01 is sent to give migration limits for the shims in the diagonal brace load path. The inspection given in the initial release of this service bulletin made it necessary to repair a loose shim before an airplane could be put back in service. With these new migration limits, an airplane can be put back in service with a migrated shim if the inspection finds that it is in the permitted limits. The bulkhead crack repair as given in the initial release has been deleted. If cracks are found, they will be reviewed on a case-by-case basis.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 15 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**A new repair is added for the shims in the diagonal brace load path. There are now 4 repairs and 1 repair that has been deleted. For identification, they are referred to as Interim Repairs I, II, III, IV and V. Interim Repair I is almost the same as the one given in the initial release and replaces the two shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Interim Repairs II and III are the same as those given in the initial release. Interim Repair II installs oversize fasteners in the vertical flange of the fitting, and Interim Repair III installs oversize fasteners in the horizontal flange of the fitting. Interim Repair IV is the same bulkhead crack repair given in the initial release and has been deleted. Interim Repair V is new and gives the instructions to cut and remove the exposed plies of the shims as a repair for shim migration of 0.50, or less These sections of the service bulletin were changed with revision 01: — Compliance - Decreased repeat inspection thresholds to address additional in service reports where loose fasteners were found on airplanes with less than 12,000 flight cycles. Also, added compliance information for airplanes line numbers 736 thru 1048 to address additional reports of loose fasteners on airplanes with the latest configuration. — Reason and Description - Add six reports to the service history table. — Effectivity - Added 757-200/-200CB and 200PF airplanes with RB211 engines, Line numbers 736 thru 1048. — Work Instructions, Part I, Step 2 - Add shim migration limits to show the necessary work if shim migration is found during the inspection. — Figure 2 - Add instructions to measure and record the distance a shim has moved from the installed position, if the shim shows signs of movement during the inspection. — Figure 4 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair I. — Make corrections to the illustration and instructions to show the replacement of two shims. One on the left flange of the fitting and one on the right flange of the fitting. — Add a step is to apply sealant around the outer edge of the shim. — Add a step to increase the hole diameter after shim is in place. — Removed repair instructions for cracks.
— Figure 5 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair II. — Removed repair instructions for cracks.
— Figure 6 - Make changes to the figure as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 16 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**— Change the figure title to show that it is Interim Repair III. — Removed repair instructions for cracks.
— Figure 7 - Deleted. — Figure 9 - Add this new figure to give the instructions for Interim Repair V. — Figure 10 - Added this new figure to give instructions for sealing removed parts. Revision 02 is sent to give revised inspection schedule and repair requirements. Instructions are added to inspect for cracking at four critical horizontal flange fasteners holes if one or more loose fasteners is found. Also, do a one-time inspection and repair of the four critical faster holes on the horizontal flange. Figure 11, Interim Repair VI is new and gives location and instruction for the four critical horizontal flange fastener locations. These sections of the service bulletin are changed with revision 02: — Summary - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Action section. Added one report to the Service History in Background section. — Planning - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Description section. Added one report to the Service History in the Reason section. Added Manpower hours for Part IV inspection. — Accomplishment Instructions - Revised access instructions. Added inspections, critical fastener identification, locations, compliance requirement Notes and Part IV inspection. — Figure 6 - Added HFEC inspections to aluminum bulkhead and steel web with NDT references. — Figure 11 - Added, for critical horizontal flange fastener locations, HFEC inspections to aluminum bulkhead and steel web with NDT references. — All references to AD 2004-12-07 are changed to AD 2005-12-04. Revision 03 is sent to give revised inspection compliance times and replace the phrase "one time inspection" with "inspection" when referring to the Part IV inspection of the critical fastener holes on the horizontal flange . These sections of the service bulletin are changed with revision 03: — Summary - Compliance information is deleted from the Compliance section. — Paragraph 1.E., Compliance - Compliance times are revised and presented in a tabular format. — Summary, Planning Information, Work Instructions: replaced the words "one time inspection" with "inspection". Revision 04 is sent to revise the compliance information and to give an alternative method of accessing the critical fasteners at the strut-to-diagonal brace fitting. It is also sent to add more instructions for inspecting the aft torque bulkhead. The following sections were changed:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 17 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**1. More information is added to the Background and Reason sections. 2. Paragraph 1.D., Description - Affected maintenance zones are added. 3. Paragraph 1.E., Compliance - The compliance information is revised. 4. Paragraph 1.F., Approval - An Alternative Method of Compliance (AMOC) statement is added, and the Federal Aviation Administration (FAA) Airworthiness Directives (AD) reference is changed. 5. Paragraph 1.G., Manpower - Added a new manpower table and changed manpower information. 6. Paragraph 1.J.1., Existing Data - Service Related Problem (SRP), Nondestructive Test (NDT) and the FAA (AD) reference is changed. 7. Paragraph 1.K., Publications Affected - A Damage Tolerance Based Structural Inspection statement is added. 8. Paragraph 3.A., General Information - Added new standard Note 1 and Note 7. 9. Paragraph 3.B., Work Instructions - More inspection instructions are added to Part II and Part IV. 10. FIGURE 3 - A new view and more inspection instructions are added. 11. FIGURE 12 and FIGURE 13 are added. **D. Description** Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs. Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A borescope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection of the four critical fastener holes on the horizontal flange. As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. Revision 01 - More work is necessary on airplanes changed as shown in the initial release of this service bulletin. Repeat inspections are required for airplanes that have incorporated Service Bulletin 757-54-0035. Revision 02 - More work is necessary on airplanes changed as shown in the initial release and revision 01 of this service bulletin. Instructions are added to do a one-time inspection and repair of the four critical fastener holes on the horizontal flange.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 18 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**Revision 03 - No more work is necessary on airplanes changed as shown in the Original issue, Revision 1, or Revision 2 of this service bulletin, however the conditions and the compliance time for doing the inspection of the four critical fasteners on the horizontal flange have changed. Revision 04 - More work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2 or Revision 3 of this service bulletin. On airplanes without conclusive records of previous inspections, do a one time open hole High Frequency Eddy Current (HFEC) inspection or ultrasonic inspection of the four critical fastener holes in the horizontal flange as given in this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 433, 443 757-200, 757-200CB, 757- 200PF **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 433, 443 757-200, 757-200PF

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 19 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT E. Compliance**  **Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque Bulkhead** 
**. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition**

- - Within 90 days of the date of Revision 4 of this service bulletin. Inspect the four criticalfasteners in the horizontal flange in accordancewith Part IV unless already accomplished inaccordance with Revision 2 or Revision 3 of this service bulletin. All airplane struts that had findings on the horizontal orvertical fasteners or the shims whichlead to a rejection while doing Revision 1 or the original release of thisservice bulletin, and all airplanes that had equivalent findings prior tothe original release of thisservice bulletin. (a)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 20 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque**  **Bulkhead**
**. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition** 1800 flight cycles. 1800 flight cyclesfrom the last inspection for loose fasteners and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, Step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection ofthe bulkhead in accordance with Part II, Step 3.Group 1 Configuration 1

OR 3000 flight cycles. 1800 flight cyclesfrom the last inspection for loose fasteners and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, Step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspectionand an ultrasonic inspection of the bulkhead in accordance with Part II, Step 3. 3000 flight cycles. 3,000 flight cyclesfrom the last inspection for loose fasteners and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, Step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection ofthe bulkhead in accordance with Part II, Step 3.Group 1 Configuration 2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 21 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque**  **Bulkhead**
**. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition** 3000 flight cycles. 3,000 flight cyclesfrom the last inspection for loose fasteners and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection ofthe bulkhead in accordance with Part II, Step 3. Group 2

- - Within 90 days of the date of Revision 04 of this service bulletin. Do an open hole HighFrequency Eddy Current (HFEC) inspection at the critical fastener location in accordance with Work Instructions Part IV, Step 2.a.Airplanes without conclusiverecords of previous inspection.

OR

- - Within 90 days of the date of Revision 04 of this service bulletin.Do an ultrasonic inspection of the critical fastener holes in the horizontal flange in accordance with Work Instructions Part IV, Step 2.b.

- - Before further flight after completing all inspections. Repair in accordance with Part I, Step 4.a.Total cumulative shim movement equal to or less than 0.50 inch.

- - Before further flight after completing all inspections. Repair in accordance with Part I, Step.4.b.Total cumulative shim movement more than 0.50 inch.

- - Before further flight after completing all inspections. Repair in accordance with Part I, Step 5.a.(2) AND Inspect and repair in accordance with Part I, Step 5.a.(3)Rejected fastener in the vertical flange.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 22 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque**  **Bulkhead**
**. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition**

- - Before further flight after completing all inspections. Repair in accordance with Part II, Step 2.a.(2) AND Inspect and repair in accordance with Part II, Step 2.a.(3)Rejected fastener in the horizontal flange.

- - Before further flight. Contact Boeing for re- pair instructions and do the repair. Any crack found in the bulkhead flange or thevertical stiffeners or the access door cutout edge.

- - Before further flight. Contact Boeing for re- pair instructions and do the repair. Any crack found in any critical fastener hole. (a) Findings on Group 1, Configuration 2 airplane struts prior to service bulletin 757-54-0035 incorporation are excluded from this condition.

Federal Aviation Administration (FAA) Airworthiness Directives (AD) 2004-12-07 and 2008-05-10 are related to this service bulletin. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. The Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the inspection methods and fastener replacements specified in Table 1 under paragraph 1.E., "Compliance," of Service Bulletin 757-54A0047, Revision 4, as an AMOC to the inspection methods and modifications specified in SB 757-54-0035, Revision 1, dated April 15, 1999; or Revision 2, dated June 13, 2002, as required by paragraphs (b) and (d) of AD 2004-12-07. All provisions of AD 2004-12-07, including the compliance times, that are not specifically referenced in the preceding sentence remain fully applicable and must be complied with. In addition, the manager of the SACO approves the inspection methods, and modifications specified in Table 1 under paragraph 1.E., "Compliance," of Service Bulletin 757-54A0047, Revision 4, including Part IV, Option 2 - Ultrasonic Inspection, as an AMOC to the inspections and modifications in accordance with SB 757-54A0047 Revision 3, dated June 27, 2007 specified by paragraphs (g) and (l) of AD 2008-05-10. All provisions of AD 2008-05-10, including the compliance times, that are not specifically referenced in the preceding sentence remain fully applicable and must be complied with.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 23 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 and repair for each strut. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace. — Time to schedule the work. — Time to examine the work. — Time to cure the materials. — Time to make the parts. — Time to find the tools. **Part I - Inspection - Fasteners and Shim - Vertical Flange Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

6.0 12.0 2 Open Access 1.0 2.0 2 Inspect

- - - Repair (a) 7.0 14.0 2 Close Access 14.0 28.0 TOTAL FOR EACH STRUT (a) An estimate for the task-hours necessary to do the repair is not given. **Part II - Inspection - Fasteners - Horizontal Flange Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

1.0 2.0 2 Open Access 6.0 12.0 2 Inspect

- - - Repair (a) 1.0 2.0 2 Close Access 8.0 16.0 TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) More time can be necessary for the removal of the engine, diagonal brace, and precooler.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 24 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Engine Removed)**  **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

2.5 10.0 4 Open Access (En- gine Removed) 1.0 2.0 2.0 Inspect Option 1 2.0 4.0 2.0 Inspect Option 2

- - - Repair (a) 3.0 12.0 4 Close Access (En- gine Removed) 3.0 6.0 3 Trim and Check En- gine 8.5 (b) 28.0 (b) TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) Total does not include inspection estimate. Add inspection estimate for option used to total shown to arrive at revised total. **Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Common Nozzle Exhaust Removed)**  **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

3.5 7.0 2 Open Access (Common Nozzle Exhaust Removed) 1.0 2.0 2.0 Inspect Option 1 2.0 4.0 2.0 Inspect Option 2

- - - Repair (a) 3.5 7.0 2 Close Access (Common Nozzle Exhaust Removed) 7.0 (b) 14.0 (b) TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) Total does not include inspection estimate. Add inspection estimate for option used to total shown to arrive at revised total. **H. Weight and Balance Changes** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 25 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT I. Electrical Load Data**  Not changed. **J. References** 1. Existing Data: a. Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130. b. 757 Aircraft Maintenance Manual (AMM) 54-51-02, 54-53-01, 54-53-02, 71-00-02, 71- 00-02, 71-11-07, 78-11-04 and 78-31-00. c. 757 Structural Repair Manual (SRM) Chapter 51. d. 757 Non-Destructive Testing (NDT) Manual Part 4, 54-50-02, Part 6, 51-00-14, Part 6, 51-00-16 and Part 6, 51-00-17. e. Standard Overhaul Practices Manual (SOPM) 20-43-03, 20-50-19 f. Boeing Service Bulletin 757-54-0035, 'NACELLES/PYLONS Rolls Royce RB211 Powered Airplanes - Nacelle Strut and Wing Structure Improvement'. g. FAA Airworthiness Directives AD 2004-12-07 and 2008-05-10. h. Boeing Parts Standards Document D-590. i. Boeing Drawing 65-88700. 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  Spar Installation - Lower Nacelle Strut 311N5042 Torque Bulkhead Installation 311N5045 Seal Application - Nacelle Strut 311N5062 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 26 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**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. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 27 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 28 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  None. **B. Industry Support Information** Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Speci-**  **fication** (a) Chemical Conversion Treatment 4 oz. Type 2, Class A (c) Primer 8 oz. BMS 10-11, Type 1 (c) Sealant 1 pt. BMS 5-63 (d) Primer 8 oz. DAPCO 1-400 (e) Primer 8 oz. DC 1200

- Sealant 1 pt. DC 93-006

- Leveling Compound 1 qt. DC 3110 (f)

- - RTV 560 (f)

- - RTV 3 (f)

- - RTV 60 2.50 x 2.50 x 0.080 (g) CRES Plate

- 301 SS 1/2 Hard (h) Bolt

- BACB30*

- Collar

- BACC30* (i) BACS40R015C027F optional Shim, Laminated 2 BACS40R015B027F (j) Filler, Radius 2 BACF3H10JT010HG (a) Can be necessary if you make the radius filler shown in Figure 6. Refer to SOPM 20- 43-03 for data about the Chemical Conversion Treatment. (b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) Alternative to DC 93-006.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 29 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Notes**  **Name QTY**  **Part Number / Speci- fication**  (d) Primer is necessary if BMS 5-63 is applied over rubber/silicon substrates. (e) Use with DC 93-006 and DC 3110. (f) Alternative to DC 3110. (g) Can be necessary if a crack is found in the aft bulkhead that cannot be repaired with the installation of an oversize fastener. (h) See the Paragraph 3.B., Work Instructions, Figures 4, 5, 6, and 7, for the oversize bolt/collars that can be necessary if the inspections find a loose shim and/or damaged fasteners. (i) Can be necessary if loose shims are found during the inspection. (j) Can be necessary if oversize fasteners are installed as shown in Figure 6. Instructions are also given to make the filler from 0.063 thick 2024-T3, T4, T42, or 7075-T6 Bare Aluminum Sheet.
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** A borescope, or other inspection aids, can be necessary to do the inspection of the fasteners in the horizontal flange of the strut-to-diagonal brace fitting. Also, 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 30 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. The instructions in Paragraph 3.B., Work Instructions, and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches. — Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. — Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch. — Angular tolerance is plus or minus 2 degrees. — Hole dimensions for standard solid rivets are in 757 SRM, Chapter 51. — Torque limits to tighten nuts and bolts are in 757 SRM, Chapter 51. 5. For approved fastener and process material substitutions, refer to 757 SRM, Chapter 51, Alternate fasteners are in 757 SRM Chapter 51 and Boeing Drawing 65-88700. 6. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 7. Inspections, used in the service bulletin, are defined as follows: Detailed Inspection: An intensive visual examination of a specific structural area, system, 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 by the inspector. Inspection aids such as mirrors, magnifying lenses, etc. may be used. Surface cleaning and elaborate access procedures may be required.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 31 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**Non-Destructive Testing (NDT) inspections are used to examine all subsurface damage and most small cracks. NDT is also used in areas where a visual inspection is not sufficient to find the dimensions of damage. 8. These work instructions refer to procedures included on other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS PART I - INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE - ALL AIRPLANES**  1. Refer to 757 AMM 78-31-00 and do the Thrust Reverser Deactivation for Ground Maintenance. **WARNING:** DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENT THE OPERATION OF THE THRUST REVERSER. THE ACCIDENTAL OPERATION OF THE THRUST REVERSER CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 2. Get access for the inspection of the fasteners and shim in the vertical flange in accordance with FIGURE 1. 3. Do the inspection of the shim installation between the vertical flange and bulkhead in accordance with FIGURE 2: a. For Group 1 and Group 2 airplanes: If the shim installation shows signs of movement and is rejected: Continue with Step 4, below. **NOTE:** All Part I and Part II inspections can be accomplished before repairs are done. b. If the shim installation is satisfactory: Continue with the inspection of the four fasteners in the vertical flange in accordance with step 5, below. 4. Do repairs to the shim installation between the vertical flange and the bulkhead as given below: a. If the shim(s) Total cumulative movement is 0.50 or less: Do Interim Repair V in accordance with FIGURE 9. Record the amount of total shim movement and save for future inspections. b. If the shim(s) Total cumulative movement is more than 0.50: Remove the engine. Refer to 757 AMM 71-00-02 as an accepted procedure and do Interim Repair I in accordance with FIGURE 4. Also, do the inspection and repair of the four critical fastener holes on the horizontal flange in accordance with Part IV. 5. Do the inspection of the four fasteners in the vertical flange in accordance with FIGURE 2: a. If one or more of the four fasteners are rejected: (1) Remove the engine. Refer to 757 AMM 71-00-02 as an accepted procedure.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 32 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT NOTE:**  All Part I and Part II inspections can be accomplished before repairs are done. (2) At the locations where fasteners are rejected in the vertical flange: Remove the fastener, increase the hole diameter and install oversize fasteners as shown for Interim Repair II in accordance with FIGURE 5. (3) Do the inspection and repair of the four critical fastener holes on the horizontal flange in accordance with Part IV. **PART II - INSPECTION - FASTENERS - HORIZONTAL FLANGE - ALL AIRPLANES** 1. Get more access, and removal of the leveling compound, for the inspection of the fasteners in the horizontal flange in accordance with FIGURE 1. 2. Do the inspection of the sixteen fasteners that hold the strut to the horizontal flange of the strut-to-diagonal brace fitting in accordance with FIGURE 3: a. If one or more of the sixteen fasteners are rejected: (1) Remove the engine. Refer to 757 AMM 71-00-02 as an accepted procedure. **NOTE:** All Part I and Part II inspections can be accomplished before repairs are done. (2) Remove the rejected fastener, inspect the fastener hole for cracking, increase the hole diameters and install oversize fasteners as shown for Interim Repair III in accordance with FIGURE 6. (3) Do the inspection and repair of the four critical horizontal flange fastener holes on the horizontal flange in accordance with Part IV. 3. Inspect the bulkhead in the area around the access door cutout and around the critical fasteners in the horizontal flange in accordance with FIGURE 3, and do an optional ultrasonic inspection of the bulkhead around the fasteners in the horizontal flange in accordance with FIGURE 13. a. If any crack is found in the bulkhead or the access door cutout edge, contact Boeing for repair instructions and do the repair. b. If no crack is found in the bulkhead or the access door cutout edge, do repeat inspections in accordance with Paragraph 1.E., Compliance. **PART III - CLOSE ACCESS - ALL AIRPLANES** 1. Apply new sealant in accordance with FIGURE 8. 2. Apply the leveling compound in accordance with FIGURE 8. 3. Install and seal the covers in accordance with FIGURE 10. 4. Install the remaining components that were removed to get access for the inspection.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 33 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**5. If necessary, install the engine. Refer to 757 AMM 71-00-02 as an accepted procedure. 6. Put the airplane back to a serviceable condition. 7. Schedule the airplane for the repeat inspection at the time in accordance with Paragraph 1.E., Compliance. **PART IV - INSPECTION - CRITICAL FASTENER HOLES ON THE HORIZONTAL FLANGE** 1. If not already done get access in accordance with FIGURE 1. 2. Inspect the critical fastener holes in the horizontal flange using one of the options that follow: a. Option 1 - High Frequency Eddy Current (HFEC) inspection. (1) Get additional access by removing the engine, if not already done. Refer to 757 AMM 71- 00-02 as an accepted procedure, or remove the common exhaust in accordance with FIGURE 12. (2) Remove the fasteners and do an HFEC inspection in accordance with FIGURE 11. (a) If any crack is found, contact Boeing for repair instructions and do the repair. (3) At locations where the critical fastener hole was rejected, increase the hole size and install an oversize fastener in accordance with FIGURE 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener in accordance with FIGURE 11. (4) At locations where the fastener hole was not rejected, install the same size fastener as was removed in accordance with FIGURE 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener in accordance with FIGURE 11. b. Option 2 - Ultrasonic Inspection: (1) Do an ultrasonic inspection in accordance with FIGURE 13. (a) If any crack is found, contact Boeing for repair instructions and repair. (b) If no crack is found, do the repeat inspections in accordance with Paragraph 1.E., Compliance.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4: June 24, 2010 34 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 1: ACCESS FOR INSPECTION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 35 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 1: ACCESS FOR INSPECTION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 36 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut.
**NOTES QTY**  **REFERENCES NAME**  **TASK STEP** 

- 1 Refer to 757 AMM 54-53-02. Access Door Open or Remove 1

- 1

- Clamp Loosen 2

- 1

- Boot Seal Move 3

- 1

- Cover Remove 4

- 1 Refer to 757 AMM 54-53-01. Cover Plate Remove 5
Remove the seal between the strut and the common nozzle fairing. 1 Refer to 757 AMM 71-11-07. Seal Remove 6

As necessary, remove the leveling compound from the area around the fasteners. - - Leveling Com- pound Remove 7

**FIGURE 1: ACCESS FOR INSPECTION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 37 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 38 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**NOTES PROCEDURE**  **NAME TASK**  **STEP** (a) Detailed Inspection Shim Installation (left shim) Inspect 1 (b)

- Shim Migration (left shim) Measure/Record 2 (a) Detailed Inspection Shim Installation (right shim) Inspect 3 (b)

- Shim Migration (right shim) Measure/Record 4 (c) Four locations Detailed Inspection Fastener Inspect 5 (a) Look for signs of damaged sealant around the outer edge of the shim. Look for signs that show movement of the shim. Reject a shim that shows signs of movement. (b) Measure and record the horizontal movement and the vertical movement of the shim from the installed position. Add the movement in each direction together to obtain the total movement of the shim at this inspection. This movement must be added to all previous measurements to obtain total cumulative movement of the shim(s). This data is used during the repeat inspection and to make decisions about repairs. Data necessary for the repeat inspection and to make decisions about repairs are: (i) The shims have not moved from the installed position. (ii) The shim total cumulative movement is 0.50, or less. (iii)The shim total cumulative movement is more than 0.50. (c) Look at the two sides of the fastener installation for signs of damaged sealant. Remove the sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar.

**FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 39 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 40 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 41 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**NOTES PROCEDURE**  **NAME TASK**  **STEP** (a)(b) Detailed Inspection Fastener Inspect 1 Eight locations. (a)(b) Detailed Inspection Fastener Inspect 2 Eight locations. (c) Detailed Inspection Access Door Cutout Inspect 3 (d) Detailed Inspection Bulkhead Inspect 4(a) Use a borescope, or other inspection aids if necessary, to view the lower surface of the fasteners installation. (b) Look at the two sides of the fastener installation for signs of damaged paint and/or sealant. Remove the paint and/or sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar. (c) Do a detailed inspection of the edge of the access door cutout for cracking at the forward and aft side of the cutout. (d) Do a detailed inspection of the bulkhead for cracking in the area shown.

**FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 42 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 43 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 the replacement of one shim.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  (left bolts and/or right bolts). 2

- Fastener Remove 1 (left shim and/or right shim). 1

- Shim Remove 2 (a) 2

- Fastener Hole Inspect 3

- - Clearance Measure 4 (b) BACS40R015C027F is optional. (c) 1 BACS40R015B027F Shim Adjust Drill holes in shim to agree with hole diameters in fitting. 2

- Holes Drill

- - Shim Clean/Deburr To mating surfaces.

- DC93-006 Sealant Apply

- - Shim Install Increase diameter by 0.0156 2

- Holes Ream 5 See Code A1 and A2. 2

- Fastener Install 6 Do an eddy current inspection of the holes through the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT Part 6, 51-00-16. (a)
If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. Remove laminations to adjust the shim thickness. Remove all sharp edges. The maximum clearance permitted with the shim in position is 0.005. (b) Alternative: Make a solid shim from 2024-T3, or 2024-T4, -T81, T861, or 7075-T6. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 for data about the chemical conversion treatment. (c)

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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4526 - 0.4536 BACB30NX14K10X Bolt A1

- BACC30BH14S Collar

**FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 44 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT NOTES**  **HOLE DIA PART NUMBER**  **NAME CODE**  Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4682 - 0.4692 BACB30NX14K10Y Bolt A2

- BACC30AC14S Collar

**FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 45 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 46 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP** 

- - - Fastener Remove 1 (a)

- - Fastener Hole Inspect 2 See Codes A1 and A2.

- - Fastener Install 3 Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT Part 6, 51-00-16. (a)
If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions. 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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4526 - 0.4536 BACB30NX14K10X Bolt A1

- BACC30BH14S Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4682 - 0.4692 BACB30NX14K10Y Bolt A2

- BACC30AC14S Collar

**FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 47 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 48 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP** 

- - - Fastener Remove 1 (a)

- - Fastener Hole Inspect See Codes B1 and B2

- - Fastener Install

- - - Fastener Remove 2 (a)

- - Fastener Hole Inspect See Codes C1 and C2

- - Fastener Install

- - - Fastener Remove 3 (a)

- - Fastener Hole Inspect (b)

- - Radius Filler Make/Install See Codes D1 and D2

- - Fastener Install Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT, Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, in accordance with 757 NDT, Part 6, 51-00-17: (a)

If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions. If necessary, make and install a radius filler below the seal retainer at these fastener locations. Install Radius Filler BACF3H10JT010HG, or make the filler from 0.063 thick 2024-T3, -T4, -T42, or 7075-T6 Bare Aluminum Sheet as shown. Apply a Chemical Conversion Treatment, Type 2, Class A, and one layer of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 for data about the chemical conversion treatment. Install the filler with Sealant BMS 5-63 or Dow Corning 93-006. (b)

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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30YK12K11X Bolt B1

- BACC30CP12C Collar

**FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 49 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT NOTES**  **HOLE DIA PART NUMBER**  **NAME CODE**  Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30YK12K11Y Bolt B2

- BACC30CP12CY Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30MC12A6U Bolt C1

- BACC30BH12S Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30MD12A6U Bolt C2

- BACC30AC12S Collar (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30FP12A11U Bolt D1

- BACC30AB12SY Collar (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30KK12A11U Bolt D2

- BACC30AC12S Collar (a) If the installation of the radius filler is necessary, fasteners with longer grip lengths will also be necessary.

**FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 50 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 7: THIS FIGURE HAS BEEN DELETED**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 51 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 52 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  (a) (b) If the shim was replaced during the repair procedures, apply primer and a fillet seal around the outer edge of the shim/fitting flange. - Dow Corning 1200 Primer Apply 1 Dow Corning 93-006 Sealant

(a) (b) Apply to all locations where sealant was removed for the inspections and/or fastener replacement. - Dow Corning 1200 Primer Apply 2

- Dow Corning 93-006 Sealant
(c) (d)

- Dow Corning 1200 Primer Apply 3 Optional compound is RTV560, RTV3 or RTV60. - Dow Corning 3110 Leveling Compound (a) Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Primer DAPCO 1-400 and Sealant BMS 5-63, Type II is optional. Before Sealant BMS 5-63 is applied let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours. (c) Before the Dow Corning 3110 compound is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (d) You can mix solvent BMS 3-2, Type II, with the leveling compound to make it more liquid. The maximum quantity of solvent permitted in the mixture is 20 percent when measured by weight.

**FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 53 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP** CAUTION: DO NOT INSTALL A NEW COLLAR OR TRY TO TIGHTEN EXISTING COLLAR IN AN ATTEMPT TO TIGHTEN THE JOINT BETWEEN THE FITTING AND BULKHEAD AS STRUCTURAL DAMAGE MAY OCCUR.

- - - Exposed plies (left shim) Cut 1

- - BMS 10-11, Type 1 Primer Apply 2 (a)

- DAPCO 1-400 Primer Apply 3 (b) Seal edges

- BMS 5-63 Sealant Apply 4

- - - Exposed plies (right shim) Cut 5

- - BMS 10-11, Type 1 Primer Apply 6 (a) DAPCO 1-400 Primer Apply 7 (b) Seal edges

- BMS 5-63, Type II Sealant Apply 8

**FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 54 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) Dow Corning 93-006 sealant and Dow Corning 1200 primer are optional for this application. Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Before Sealant BMS 5-63 is applied let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours.

**FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 55 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 10: SEAL COVER PLATES**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 56 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut
**NOTES REFERENCE**  **QTY NAME**  **TASK STEP** 

- - 1 Cover Install 1 (a) Refer to SOPM 20-50-19.

-- Primer DC 1200 Sealant DC93-006 Apply 2

- Refer to 757 AMM 54-53- 01. 1 Cover Plate Install 3 (b)

- 1 Boot Seal Move 4 Tighten Clamp

- 1 Clamp Adjust 5 (a) Apply Intermediate liquid control fillet seal around entire periphery of the cover. Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Move the Boot Seal back to the original position as necessary.

**FIGURE 10: SEAL COVER PLATES (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 57 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 58 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut.
**MORE DATA QTY**  **PART NUMBER NAME**  **TASK STEP** 

- - - Fastener Remove 1 (a) (b) 4

- Fastener Hole Inspect 2 Refer to Codes B0, B1 and B2

- - Fastener Install 3 (a) Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT,Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, in accordance with 757 NDT, Part 6, 51-00-17. (b) Measure the hole diameter. If the hole is true and round, and the diameter is within the limits allowed for installation of the same size fastener, do not increase the hole size. Otherwise, increase the hole size to remove damage 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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3745 - 0.3755 BACB30YK12K11 Bolt B0

- BACC30CP12C Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30YK12K11X Bolt B1

- BACC30CP12C Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30YK12K11Y Bolt B2

- BACC30CP12CY Collar

**FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 59 of 62 **BOEING SERVICE BULLETIN 757-54A0047 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 strut.
**MORE DATA QTY**  **PART NUMBER NAME**  **TASK STEP**  Refer to 757 AMM 78-11-04 as an accepted procedure. 1

- Common Nozzle Exhaust Remove 1

(a) 1

- (Diagonal Brace) Load Release 2 (a) Remove the load from the diagonal brace. Refer to 757 AMM 54-51-02 as an accepted procedure.

**FIGURE 12: NACELLE/PYLONS - ALTERNATIVE ACCESS TO THE CRITICAL HORIZONTAL FLANGE FASTENERS**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 60 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 61 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**NOTES REFERENCES**  **PROCEDURE NAME**  **TASK STEP** 

- In accordance with 757 NDT Part 4, 54- 50-02 Ultrasonic Inspection Fasteners Inspect 1

**FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 4 June 24, 2010 62 of 62 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**