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

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

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2003 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Unpublished Work - All Rights Reserved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.

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3.0
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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

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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

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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.

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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.

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

Original Issue: November 13, 2003

Revision 1: March 24, 2005

Revision 2: January 31, 2007

Revision 3: June 27, 2007

Revision 4: June 24, 2010

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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

Date Hours Cycles Strut Report

One bolt sheared in horizontal flange. Four bolts

loose in vertical flange.

12/93 29,451 10,284 -

11/96 25,768 9,358 No. 1 & 2 Four bolts loose in vertical flange of both struts.

One bolt loose in vertical flange of Strut No. 1. Four

bolts loose in vertical flange of Strut No. 2.

06/98 - - No. 1 & 2

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.

11/99 55,789 21,749 No. 1 & 2

01/01 46,459 20,161 No. 1 & 2 Sixteen bolts loose in horizontal flange.

09/01 49,019 13,662 No. 1 Two bolts loose in vertical flange.

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Service History

Date Hours Cycles Strut Report

01/02 23,423 14,633 - Two bolt heads cracked.

Two bolts loose in horizontal flange of Strut No. 1.

Three bolts loose in horizontal flange of Strut No. 2.

04/02 16,601 12,493 No. 1 & 2

Migrated shim between bulkhead and vertical flange

of fitting.

05/02 43,822 15,522 No. 1 & 2

Four bolts loose in vertical flange. Five bolts loose in

horizontal flange.

06/02 46,758 15,900 No. 2

One bolt missing and one bolt loose in horizontal

flange. Cracks in the aluminum bulkhead at three

hole locations.

12/02 49,807 20,090 No. 1

04/03 50,841 22,111 - Two loose bolts in vertical flange.

09/03 30,072 9,991 No. 1 Three loose bolts in vertical flange.

Migrated shims between bulkhead and vertical flange

of fitting.

09/03 60,715 26,914 No. 1 & 2

10/03 44,985 15,004 No. 2 Three loose bolts in vertical flange.

01/04 12,368 7,922 No. 2 Three loose bolts in vertical flange.

02/04 12,119 7,592 No. 1 Four loose bolts in vertical flange.

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.

04/06 44,423 13,083 No. 1

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.

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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

Airplanes Total Task Hours Elapsed Hours

All 44.0 (a) 22.0 (a)

(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.

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT
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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.

GROUP CONFIGURATION DESCRIPTION

757-200/-200CB/-200PF airplanes line number 1 thru 735, powered

by Rolls Royce engines.

1 -

1 Airplanes without SB 757-54-0035 incorporation.

2 Airplanes with SB 757-54-0035 incorporation.

757-200/-200PF airplanes line number 736 thru 1048, powered by

Rolls Royce engines.

2 -

Airplane Models:

757-200, 757-200CB, 757-200PF

Variable Number Group

NA002 - NA028 1

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Variable Number Group

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 1

NB226 - NB228 2

NB230 2

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 1

NB571 2

NB581 - NB583 2

NC058 - NC061 1

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT
Variable Number Group

NC062 2

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 1

ND318 - ND322 2

ND401 2

ND891 1

ND895 1

NJ001 - NJ004 2

NJ031 - NJ032 2

NN001 - NN002 2

NN051 - NN052 2

NS601 - NS610 1

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 2

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT
Variable Number Group

NT436 - NT438 2

NT446 2

NT731 - NT769 2

NT861 - NT862 2

NT901 - NT916 2

NT971 - NT985 2

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

Date Hours Cycles Strut Report

One bolt sheared in horizontal flange. Four bolts

loose in vertical flange.

12/93 29,451 10,284 -

11/96 25,768 9,358 No. 1 & 2 Four bolts loose in vertical flange of both struts.

One bolt loose in vertical flange of Strut No. 1. Four

bolts loose in vertical flange of Strut No. 2.

06/98 - - No. 1 & 2

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.

11/99 55,789 21,749 No. 1 & 2

01/01 46,459 20,161 No. 1 & 2 Sixteen bolts loose in horizontal flange.

09/01 49,019 13,662 No. 1 Two bolts loose in vertical flange.

01/02 23,423 14,633 - Two bolt heads cracked.

Two bolts loose in horizontal flange of Strut No. 1.

Three bolts loose in horizontal flange of Strut No. 2.

04/02 16,601 12,493 No. 1 & 2

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14 of 62

BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT
Service History

Date Hours Cycles Strut Report

Migrated shim between bulkhead and vertical flange

of fitting.

05/02 43,822 15,522 No. 1 & 2

Four bolts loose in vertical flange. Five bolts loose in

horizontal flange.

06/02 46,758 15,900 No. 2

One bolt missing and one bolt loose in horizontal

flange. Cracks in the aluminum bulkhead at three

hole locations.

12/02 49,807 20,090 No. 1

04/03 50,841 22,111 - Two loose bolts in vertical flange.

09/03 30,072 9,991 No. 1 Three loose bolts in vertical flange.

Migrated shims between bulkhead and vertical flange

of fitting.

09/03 60,715 26,914 No. 1 & 2

10/03 44,985 15,004 No. 2 Three loose bolts in vertical flange.

01/04 12,368 7,922 No. 2 Three loose bolts in vertical flange.

02/04 12,119 7,592 No. 1 Four loose bolts in vertical flange.

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.

04/06 44,423 13083 No. 1

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.

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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:

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— 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:

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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.

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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

Model Zone

757-200, 757-200CB, 757- 433, 443

200PF

Group 2:

Affected Maintenance Zones

Model Zone

757-200, 757-200PF 433, 443

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ALERT ALERT
E. Compliance

Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque

Bulkhead .

Condition Action Compliance Time (Whichever Occurs later) Repeat Interval

Within 90 days of the - -

date of Revision 4 of

this service bulletin.

Inspect the four critical

fasteners in the horizontal flange in accordance

with Part IV unless already accomplished in

accordance with Revision 2 or Revision 3 of

this service bulletin.

All airplane

struts that had

findings on the

horizontal or

vertical fasteners or the

shims which

lead to a rejection while doing Revision 1

or the original

release of this

service bulletin, and all

airplanes that

had equivalent

findings prior to

the original release of this

service bulletin. (a)

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Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque

Bulkhead .

Condition Action Compliance Time (Whichever Occurs later) Repeat Interval

1800 flight cycles 1800 flight cycles.

from 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 accordance

with 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 of

the bulkhead in accordance with Part II, Step

3.

Group 1 Configuration 1

OR

1800 flight cycles 3000 flight cycles.

from 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 accordance

with 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

and an ultrasonic inspection of the bulkhead in accordance

with Part II, Step 3.

3,000 flight cycles 3000 flight cycles.

from 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 accordance

with 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 of

the bulkhead in accordance with Part II, Step

3.

Group 1 Configuration 2

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ALERT ALERT
Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque

Bulkhead .

Condition Action Compliance Time (Whichever Occurs later) Repeat Interval

3,000 flight cycles 3000 flight cycles.

from 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 accordance

with 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 of

the 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 High

Frequency Eddy Current (HFEC) inspection

at the critical fastener

location in accordance

with Work Instructions

Part IV, Step 2.a.

Airplanes without conclusive

records 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.

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ALERT ALERT
Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque

Bulkhead .

Condition Action Compliance Time (Whichever Occurs later) Repeat Interval

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.

Contact Boeing for re- Before further flight. - -

pair instructions and do

the repair.

Any crack

found in the

bulkhead

flange or the

vertical stiffeners or the access door

cutout edge.

Contact Boeing for re- Before further flight. - -

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.

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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

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 12.0 6.0

Inspect 2 2.0 1.0

Repair (a) - - -

Close Access 2 14.0 7.0

TOTAL FOR EACH STRUT 28.0 14.0

(a) An estimate for the task-hours necessary to do the repair is not given.

Part II - Inspection - Fasteners - Horizontal Flange

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 2.0 1.0

Inspect 2 12.0 6.0

Repair (a) - - -

Close Access 2 2.0 1.0

TOTAL FOR EACH STRUT (b) 16.0 8.0

(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.

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Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Engine Removed)

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access (En- 4 10.0 2.5

gine Removed)

Inspect Option 1 2.0 2.0 1.0

Inspect Option 2 2.0 4.0 2.0

Repair (a) - - -

Close Access (En- 4 12.0 3.0

gine Removed)

Trim and Check En- 3 6.0 3.0

gine

TOTAL FOR EACH STRUT (b) 28.0 (b) 8.5 (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)

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 7.0 3.5

(Common Nozzle

Exhaust Removed)

Inspect Option 1 2.0 2.0 1.0

Inspect Option 2 2.0 4.0 2.0

Repair (a) - - -

Close Access 2 7.0 3.5

(Common Nozzle

Exhaust Removed)

TOTAL FOR EACH STRUT (b) 14.0 (b) 7.0 (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.

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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:

Drawing Number Title

311N5042 Spar Installation - Lower Nacelle Strut

311N5045 Torque Bulkhead Installation

311N5062 Seal Application - Nacelle Strut

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:

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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.

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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:

Part Number / Speci- QTY Name Notes

fication

Chemical Conversion (a)

Treatment

Type 2, Class A 4 oz.

BMS 10-11, Type 1 8 oz. Primer (c)

BMS 5-63 1 pt. Sealant (c)

DAPCO 1-400 8 oz. Primer (d)

DC 1200 8 oz. Primer (e)

DC 93-006 1 pt. Sealant -

DC 3110 1 qt. Leveling Compound -

RTV 560 - - (f)

RTV 3 - - (f)

RTV 60 - - (f)

301 SS 1/2 Hard - CRES Plate 2.50 x 2.50 x 0.080 (g)

BACB30* - Bolt (h)

BACC30* - Collar -

BACS40R015B027F 2 Shim, Laminated (i) BACS40R015C027F optional

BACF3H10JT010HG 2 Filler, Radius (j)

(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.

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Part Number / Speci- QTY Name Notes

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.

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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.

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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.

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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.

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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.

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ALERT ALERT
FIGURE 1: ACCESS FOR INSPECTION

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 1: ACCESS FOR INSPECTION

(SHEET 2 OF 3)

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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.

STEP TASK NAME REFERENCES QTY NOTES

Refer to 757 AMM 1 -

54-53-02.

1 Open or Remove Access Door

2 Loosen Clamp - 1 -

3 Move Boot Seal - 1 -

4 Remove Cover - 1 -

Refer to 757 AMM 1 -

54-53-01.

5 Remove Cover Plate

Remove the seal between the

strut and the common nozzle

fairing.

Refer to 757 AMM 1

71-11-07.

6 Remove Seal

As necessary, remove the leveling compound from the area

around the fasteners.

Leveling Com- - -

pound

7 Remove

FIGURE 1: ACCESS FOR INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PROCEDURE NOTES

1 Inspect Shim Installation (left shim) Detailed Inspection (a)

2 Measure/Record Shim Migration (left shim) - (b)

3 Inspect Shim Installation (right shim) Detailed Inspection (a)

4 Measure/Record Shim Migration (right shim) - (b)

5 Inspect Fastener Detailed Inspection (c) Four locations

(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)

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ALERT ALERT
FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PROCEDURE NOTES

1 Inspect Fastener Detailed Inspection (a)(b)

Eight locations.

2 Inspect Fastener Detailed Inspection (a)(b)

Eight locations.

Access Door Detailed Inspection (c)

Cutout

3 Inspect

4 Inspect Bulkhead Detailed Inspection (d)

(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)

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ALERT ALERT
FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE

(SHEET 1 OF 3)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Fastener - 2 (left bolts and/or right bolts).

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

3 Inspect Fastener Hole - 2 (a)

4 Measure Clearance - -

(b) BACS40R015C027F is optional. (c)Adjust Shim BACS40R015B027F 1

Drill holes in shim to agree with

hole diameters in fitting.

Drill Holes - 2

Clean/Deburr Shim - -

Apply Sealant DC93-006 - To mating surfaces.

Install Shim - -

5 Ream Holes - 2 Increase diameter by 0.0156

6 Install Fastener - 2 See Code A1 and A2.

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.

CODE NAME PART NUMBER HOLE DIA NOTES

Install wet with Sealant BMS 5-63 or

Dow Corning 93-006.

A1 Bolt BACB30NX14K10X 0.4526 - 0.4536

Collar BACC30BH14S -

FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE

(SHEET 2 OF 3)

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ALERT ALERT
CODE NAME PART NUMBER HOLE DIA NOTES

Install wet with Sealant BMS 5-63 or

Dow Corning 93-006.

A2 Bolt BACB30NX14K10Y 0.4682 - 0.4692

Collar BACC30AC14S -

FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE

(SHEET 1 OF 2)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Fastener - - -

2 Inspect Fastener Hole - - (a)

3 Install Fastener - - See Codes A1 and A2.

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.

CODE NAME PART NUMBER HOLE DIA NOTES

Install wet with Sealant BMS 5-63 or

Dow Corning 93-006.

A1 Bolt BACB30NX14K10X 0.4526 - 0.4536

Collar BACC30BH14S -

Install wet with Sealant BMS 5-63 or

Dow Corning 93-006.

A2 Bolt BACB30NX14K10Y 0.4682 - 0.4692

Collar BACC30AC14S -

FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE

(SHEET 1 OF 3)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Fastener - - -

Inspect Fastener Hole - - (a)

Install Fastener - - See Codes B1 and B2

2 Remove Fastener - - -

Inspect Fastener Hole - - (a)

Install Fastener - - See Codes C1 and C2

3 Remove Fastener - - -

Inspect Fastener Hole - - (a)

Make/Install Radius Filler - - (b)

Install Fastener - - See Codes D1 and D2

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.

CODE NAME PART NUMBER HOLE DIA NOTES

Install wet with Sealant BMS 5-63 or Dow

Corning 93-006.

B1 Bolt BACB30YK12K11X 0.3901 - 0.3911

Collar BACC30CP12C -

FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE

(SHEET 2 OF 3)

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ALERT ALERT
CODE NAME PART NUMBER HOLE DIA NOTES

Install wet with Sealant BMS 5-63 or Dow

Corning 93-006.

B2 Bolt BACB30YK12K11Y 0.4057 - 0.4067

Collar BACC30CP12CY -

Install wet with Sealant BMS 5-63 or Dow

Corning 93-006.

C1 Bolt BACB30MC12A6U 0.3901 - 0.3911

Collar BACC30BH12S -

Install wet with Sealant BMS 5-63 or Dow

Corning 93-006.

C2 Bolt BACB30MD12A6U 0.4057 - 0.4067

Collar BACC30AC12S -

(a) Install wet with Sealant BMS 5-63 or

Dow Corning 93-006.

D1 Bolt BACB30FP12A11U 0.3901 - 0.3911

Collar BACC30AB12SY -

(a) Install wet with Sealant BMS 5-63 or

Dow Corning 93-006.

D2 Bolt BACB30KK12A11U 0.4057 - 0.4067

Collar BACC30AC12S -

(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)

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ALERT ALERT
FIGURE 7: THIS FIGURE HAS BEEN DELETED

(SHEET 1 OF 1)

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ALERT ALERT
FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND

(SHEET 1 OF 2)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

(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.

1 Apply Primer Dow Corning 1200 -

Sealant Dow Corning 93-006

(a) (b) Apply to all locations

where sealant was removed for

the inspections and/or fastener

replacement.

2 Apply Primer Dow Corning 1200 -

Sealant Dow Corning 93-006 -

3 Apply Primer Dow Corning 1200 - (c) (d)

Optional compound is RTV560,

RTV3 or RTV60.

Leveling Compound Dow Corning 3110 -

(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)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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.

1 Cut Exposed plies (left shim) - - -

2 Apply Primer BMS 10-11, Type 1 - -

3 Apply Primer DAPCO 1-400 - (a)

4 Apply Sealant BMS 5-63 - (b) Seal edges

5 Cut Exposed plies (right shim) - - -

6 Apply Primer BMS 10-11, Type 1 - -

7 Apply Primer DAPCO 1-400 (a)

8 Apply Sealant BMS 5-63, Type II - (b) Seal edges

FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE

(SHEET 1 OF 2)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

(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)

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ALERT ALERT
FIGURE 10: SEAL COVER PLATES

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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

STEP TASK NAME QTY REFERENCE NOTES

1 Install Cover 1 - -

Primer DC 1200 -- Refer to SOPM 20-50-19. (a)

Sealant DC93-006

2 Apply

Refer to 757 AMM 54-53- -

01.

3 Install Cover Plate 1

4 Move Boot Seal 1 - (b)

5 Adjust Clamp 1 - Tighten Clamp

(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)

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ALERT ALERT
FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS

(SHEET 1 OF 2)

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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.

STEP TASK NAME PART NUMBER QTY MORE DATA

1 Remove Fastener - - -

2 Inspect Fastener Hole - 4 (a) (b)

3 Install Fastener - - Refer to Codes B0, B1 and B2

(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.

CODE NAME PART NUMBER HOLE DIA NOTES

Install wet with Sealant BMS 5-63 or Dow

Corning 93-006.

B0 Bolt BACB30YK12K11 0.3745 - 0.3755

Collar BACC30CP12C -

Install wet with Sealant BMS 5-63 or Dow

Corning 93-006.

B1 Bolt BACB30YK12K11X 0.3901 - 0.3911

Collar BACC30CP12C -

Install wet with Sealant BMS 5-63 or Dow

Corning 93-006.

B2 Bolt BACB30YK12K11Y 0.4057 - 0.4067

Collar BACC30CP12CY -

FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS

(SHEET 2 OF 2)

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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.

STEP TASK NAME PART NUMBER QTY MORE DATA

Refer to 757

AMM 78-11-04

as an accepted

procedure.

Common Nozzle - 1

Exhaust

1 Remove

(Diagonal Brace) - 1 (a)

Load

2 Release

(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)

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ALERT ALERT
FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PROCEDURE REFERENCES NOTES

In accordance with -

757 NDT Part 4, 54-

50-02

1 Inspect Fasteners Ultrasonic Inspection

FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT