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RT 40-78-03

Revision Transmittal Sheet

RT 40-78-03

Page 1 of 2

Nov 5/12

APPROVED WHITE IN 

This page transmits Revision 1 to Service Bulletin No. 40-78-03, “Installation of the Thrust Reverser and Service Island Mounting Flange Gaskets.”

Rework:

No rework is required for aircraft which have complied with previous issues of this document.

Summary:

This revision adds E-Seal part number 0945 to the 4578330002-801 and -802 kits. A note has been added

to the each of the accomplishment instructions for the -801 and -802 kits explaining the importance of following the Maintenance Manual instructions for removal of the high pressure bleed air manifold to avoid a

complete engine removal.

NOTE: Change bars are placed in the left margin of pages where significant changes are located. This

revision incorporates the latest document format for Learjet service instructions. The general

arrangement of this document may change from the previous issue.

Description of Changes

In the Material Information section:

Changed the 4578330002-801 kit information as follows:

Added part number NAS620C10L washer, quantity 29.

Added part number 0945 E-Seal to the kit parts list.

Changed the 4578330002-802 kit information as follows:

Added part number 0945 E-Seal to the kit parts list.

In the Accomplishment Instructions section:

Changed the Modification Instructions section as follows:

Added a note at two places following the steps to remove the high pressure bleed air manifold to

explain the importance of following the Maintenance Manual procedures for removal of the high

pressure bleed air manifold.

In the Illustrations section:

Changed Figure 1, Sheet 1 as follows:

Changed callout from “AFT INNER FAIRING ASSEMBLY” to “AFT ENGINE MOUNT FAIRING

ASSEMBLY.”

Added callout to the inner fan duct.

Changed Figure 1, Sheet 6 as follows:

Changed verbiage at the end of Flagnote 5 from “...composite duct fan” to “...composite fan duct.”
LEARJET 40

Revision Transmittal Sheet

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RT 40-78-03

Page 2 of 2

Nov 5/12

Filing Instructions:

This is a COMPLETE revision. Remove and discard all pages of the prior issue and replace them with

pages of Revision 1. 

Record of Revisions:

ISSUE DISTRIBUTION DATE

Basic Feb 27/12

Revision 1 Nov 5/12
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Refer to applicable government agency regulations and requirements and make sure that the work described 

in this publication is performed in compliance with manufacturer’s recommendations and/or acceptable industry standards. 

This document is proprietary to Bombardier Inc. and/or its affiliates and may not be reproduced or copied in any form or by any means without the prior written consent of Bombardier Inc. and/or its affiliates. 

© 2012, Bombardier Inc. All rights reserved. Challenger*, Global Express*, Learjet*, are Trademarks of Bombardier Inc.

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Contact Information Distribution Date Rev. No.

Business Aircraft

Learjet Inc.

MS 53

P.O. Box 7707

Wichita, Kansas 67277‐7707

Customer Response Center (CRC)

1‐866‐538‐0247 (Toll Free)

(316) 946‐6100 (Tel)

Push 2 for Parts Services or push 4 then

push 1 for Technical Publications.

November 5, 2012 1

LEARJET 40

If you cannot complete the instructions in this publication because of an STC change to the aircraft, speak to

the STC holder or the regional Federal Aviation Administration (FAA) office for information and disposition.

Service Bulletin

These commodities, technology or software were exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to United States law is prohibited.

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POWERPLANT - INSTALLATION OF THE THRUST REVERSER AND SERVICE ISLAND MOUNTING FLANGE GASKETS

1. Planning Information

A. Effectivity

(1) Learjet 45-2001 thru 45-2132 with composite fan duct installed.

B. Reason

(1) To improve the corrosion resistance of the thrust reverser and service island flanges where they

attach to the engine composite fan duct. 

C. Description

(1) This service bulletin provides instructions to perform Nordam Service Bulletin 5045-78-13 and to

install the thrust reverser and service island mounting flange gaskets to prevent corrosion. A sealant barrier is also applied between the composite fan duct mounting flange and the thrust reverser

and service island mounting flanges to improve corrosion resistance.
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Service Bulletin

D. Compliance

(1) Recommended - Bombardier Learjet Inc. recommends that you complete these instructions within

the next 1200 flight hours or the next C phase inspection, whichever comes first.

E. Approval

(1) The Federal Aviation Administration (FAA) has approved the technical content in this publication

that has an effect on the airplane type design.

(2) The European Aviation Safety Agency (EASA) has accepted the technical content in this publication that has an effect on the airplane type design.

F. Labor Hours - Estimated Accomplishment Time

NOTE: These labor hours are an estimate and are for planning purposes only. Facility and personnel capabilities may cause the labor hours to change.

When planning to complete these instructions, please contact Bombardier Aerospace,

Learjet Inc. Business Aircraft Customer Service, Parts Services for parts availability and

shipping times as necessary. (Refer to the title page of this document for contact information.)

G. Expense Coverage

(1) Labor Coverage - Labor coverage applies to all aircraft affected by this publication.

NOTE: For labor coverage to apply, you must complete these instructions at a Bombardier

Business Aviation Service Facility or at a Bombardier Learjet Authorized Service

Facility. You must complete these instructions within 48 months from the Basic Issue

distribution date of this publication.

(2) Material Coverage - Material coverage applies to all aircraft affected by this publication.

NOTE: For material coverage to apply, you must place an order for these parts from Bombardier Learjet within 48 months from the Basic Issue distribution date of this publication.

(3) Smart Parts Plus Coverage

(a) During or after the above free period, Smart Parts Plus does not pay for the kits.

‐801 KIT ‐802 KIT TASK

3.5 3.5 Labor hours to gain access.

20.0 10.0 Labor hours to do the aircraft modification.

4.0 4.0 Labor hours to do a functional test/operational check.

3.5 3.5 Labor hours to return the aircraft to airworthy status.

31.0 21.0 Total Labor Hours
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Service Bulletin

H. Material Required

NOTE: * One kit must be ordered for each engine.

Refer to Paragraph 2.A. to know which kit is necessary

The above prices can change.

(1) Other materials/parts necessary to complete these instructions.

I. Tools and Equipment

(1) Refer to Nordam Service Bulletin 5045-78-13.

(2) Refer to the Sections in Chapter 24 of the Maintenance Manual as follows:

(a) "Disconnection of Electrical Power from the Aircraft."

(b) "Connection of Electrical Power to the Aircraft."

(3) Refer to the Sections in Chapter 36 of the Maintenance Manual as follows:

(a) "Removal of the High Pressure (HP) Bleed Air Manifold Assembly."

(b) "Installation of the High Pressure (HP) Bleed Air Manifold Assembly."

(4) Refer to the Section in Chapter 78 of the Maintenance Manual as follows:

(a) "Removal of the TR Assembly."

PART NUMBER QTY NOMENCLATURE PRICING

4578330002‐801

(* See Note)

1 Service Bulletin Kit $1,476.85

4578330002‐802

(* See Note)

1 Service Bulletin Kit $1,216.00

PART

NUMBER NOMENCLATURE QTY MANUFACTURER

RTV 159 (Red)

or equivalent

Adhesive As

Req’d

General Electric

Waterford, NY.

S408

or equivalent

Parting Agent

(Dry Film)

As

Req’d

Stoner

Quarryville, PA.

ProSeal 890 B1/2,

Class B

or equivalent

Sealing Compound As

Req’d

PRC‐Desoto

International

Glendale, CA.

ProSeal 890 B2,

Class B

or equivalent

Sealing Compound As

Req’d

PRC‐Desoto

International

Glendale, CA.
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Service Bulletin

J. Weight and Balance

(1) Change in basic weight and balance.

NOTE: The above weight and moment change is for one thrust reverser kit. If this modification is done to both thrust reversers, the weight and moment must be doubled. 

K. References

(1) Learjet Maintenance Manual, Chapters 20, 24, 36, 71 and 78. 

(2) Nordam Service Bulletin 5045-78-13.

(3) Garrett TFE-731 Engine Maintenance Manual.

2. Material Information

A. Parts Required

(1) The 4578330002-801 kit is for aircraft 45-2001 thru 45-2129 equipped with composite fan ducts

and contains the parts that follow:

NOTE: The kit that follows is for one thrust reverser. Two kits are required to do both thrust

reversers.

CHANGE IN BASIC WEIGHT CHANGE IN BASIC MOMENT

Plus (+) 0.24 lbs

(See Note)

Plus (+) 106.2 in/lbs

(See Note)

PART

NUMBER QTY NOMENCLATURE ALTERNATEPART NUMBER

B0201076D3‐7 37 Bolt

VN936NP3C 37 Washer AS4987NP3C

NAS620C10L 29 Washer

4578300009‐001 1 Gasket, Lower

4578300008‐001 1 Gasket, Outboard

4578300007‐001 1 Gasket, Upper

4578300006‐001 1 Gasket, Service Island

NAS1802‐3‐7 1 Screw

NAS1149C0316R 1 Washer

MS9592‐010 1 Bracket

MS21042‐3 1 Nut

MS21919WH4 1 Clamp

MS21919WH5 1 Clamp

0945 1 E‐Seal
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Service Bulletin

NOTE: Some hardware comes in pre-packaged quantities. When that occurs, the quantity in the

kit will be more that the quantity in the parts list.

(2) The 4578330002-802 kit is for aircraft 45-2130 thru 45-2132 and contains the parts that follow:

NOTE: The kit that follows is for one thrust reverser. Two kits are required to do both thrust

reversers.

NOTE: Some hardware comes in pre-packaged quantities. When that occurs, the quantity in the

kit will be more that the quantity in the parts list.

3. Accomplishment Instructions

A. Gain Access

(1) Disconnect external electrical power and the main and emergency batteries from the aircraft.

(Refer to Chapter 24 of the Maintenance Manual.)

(2) Remove the upper and lower engine cowling from the engine that is being modified (LH, 450AL

and 450CL; RH, 460AR and 460CR). (Refer to Chapter 71 of the Maintenance Manual.)

(3) Remove the lower pylon access panels (LH, 340DL, 340EL, 340FL; RH, 340DR, 340ER, 340CR)

as required.

PART

NUMBER QTY NOMENCLATURE

4578300009‐001 1 Gasket, Lower

4578300008‐001 1 Gasket, Outboard

4578300007‐001 1 Gasket, Upper

4578300006‐001 1 Gasket, Service Island

NAS1802‐3‐7 1 Screw

NAS1149C0316R 1 Washer

MS9592‐010 1 Bracket

MS21042‐3 1 Nut

MS21919WH4 1 Clamp

MS21919WH5 1 Clamp

0945 1 E‐Seal
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B. Inspection/Modification of Aircraft

NOTE: The instructions that follow are for the left engine. Instructions for the right engine are the

same.

(1) On aircraft 45-2001 thru 45-2129 (-801 kit) with composite fan ducts installed, do the steps that follow:

(a) Remove the thrust reverser from the engine and discard the attaching hardware. Retain the

nutplate mounting rings for later installation. (Refer to Chapter 78 of the Maintenance Manual.)

(b) Remove the high pressure bleed air manifold. (Refer to Chapter 36 of the Maintenance Manual.)

NOTE: It is important to follow the procedure steps for removal of the high pressure bleed

air manifold as outlined in Chapter 36 of the Maintenance Manual to avoid a complete engine removal. These procedures also include instructions for removal of

the service island, the aft engine mount assembly, and the aft engine mount fairing assembly. 

(c) Remove and discard the service island mating flange hardware.

(d) Do Nordam Service Bulletin 5045-78-13.

(e) Solvent clean the composite fan duct flange. (Refer to Chapter 20 of the Maintenance Manual.)

(f) Attach the thrust reverser and service island to the composite fan bypass duct as follows:

1) Apply a coat of parting agent to the composite bypass duct flange and both sides of the

gasket and allow to dry to the touch before attaching the thrust reverser and service

island. (Refer to Chapter 20 of the Maintenance Manual.)

CAUTION: DO NOT ABRADE THE GREEN EPOXY PRIMED SURFACES.

2) To improve sealant adhesion, lightly abrade the gloss painted surfaces of the thrust

reverser and service island where the sealant is to be applied. DO NOT abrade green

epoxy primer. (See Figure 1, View E-E.) 

3) Solvent clean abraded area. (Refer to Chapter 20 of the Maintenance Manual.)

4) Apply Class B (890 B2) sealant to the thrust reverser and service island flanges.

NOTE: When applying sealant, completely cover the mating flange surfaces, outer

flange edge and a 1.0 (± 0.25) in [2.54 cm (± 6.35 mm)] band on inner surfaces around the entire circumference. (See Figure 1, View E-E.) Sealant

must reach a minimum of work life before mating the thrust reverser and service island to the composite fan duct.

5) Install the service island and gasket on the engine composite fan duct mounting flange

using new attaching hardware. Install the fasteners wet with Class B (890 B1/2) sealant.

Do not torque the attaching hardware at this time. (Refer to Chapter 20 of the Maintenance Manual.)

NOTE: Apply sealant to the shank of the bolt only. Do not apply sealant to the bolt

threads.

6) Install the high pressure bleed air manifold. (Refer to Chapter 36 of the Maintenance Manual.)
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7) Install the thrust reverser and gaskets to the composite bypass fan duct as follows:

a) Apply a coat of parting agent to the composite fan duct flange and both sides of the

gasket and allow to dry to the touch before attaching the thrust reverser and service

island. (Refer to Chapter 20 of the Maintenance Manual.)

b) Locate the thrust reverser gaskets in their correct positions.

c) Locate the thrust reverser in its correct position.

d) Wet install the thrust reverser with the attaching hardware with Class B (890 B1/2)

sealant. DO NOT perform the functional test at this time as instructed in Chapter 78 of

the Maintenance Manual.

NOTE: Apply sealant to the shank of the bolt only. Do not apply sealant to the bolt

threads.

8) Torque the service island and thrust reverser attaching hardware to 50 to 70 in/lbs [5.64 to

7.90 Nm] above rundown torque. (Refer to Chapter 20 of the Maintenance Manual.)

9) Install the wiring and throttle clamps. (See Figure 1, Detail F.)

(2) On aircraft 45-2130 thru 45-2132 (-802 kit) with composite fan ducts installed, do the steps that follow:

(a) Remove the thrust reverser from the engine and retain the attaching hardware. (Refer to

Chapter 78 of the Maintenance Manual.)

(b) Remove the high pressure bleed air manifold and retain the hardware. (Refer to Chapter 36 of

the Maintenance Manual.)

NOTE: It is important to follow the procedure steps for removal of the high pressure bleed

air manifold as outlined in Chapter 36 of the Maintenance Manual to avoid a complete engine removal. These procedures also include instructions for removal of

the service island, the aft engine mount assembly, and the aft engine mount fairing assembly. 

(c) Inspect the thrust reverser flange for damage to the sealant.

(d) Apply Class B sealant (890 B2) to the thrust reverser flange and service island flange where

necessary. Sealant must reach a minimum of work life before mating the thrust reverser and

service island to the composite fan duct. (See Figure 1.)

(e) Install the service island to the composite bypass fan duct as follows:

1) Apply a coat of parting agent to the composite bypass fan duct flange and both sides of

the gasket and allow to dry to the touch before attaching the thrust reverser and service

island. (Refer to Chapter 20 of the Maintenance Manual.)

2) Position the gasket between the service island and fan duct assembly.

3) Wet install the attaching hardware that was previously removed with Class B (890 B1/2)

sealant. Do not torque attaching hardware at this time.

NOTE: Apply sealant to the shank of the bolt only. Do not apply sealant to the bolt

threads.

(f) Install the high pressure bleed air manifold. (Refer to Chapter 36 of the Maintenance Manual.)

NOTE: Do not install the thrust reverser as instructed in Chapter 78 of the Maintenance

Manual. Refer to the steps that follow to install the thrust reverser.

(g) Install the thrust reverser and gaskets to the composite bypass fan duct as follows: 

1) Apply a coat of parting agent to both sides of the gasket and allow to dry to the touch

before attaching the thrust reverser. (Refer to Chapter 20 of the Maintenance Manual.)
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2) Locate the gaskets between the thrust reverser and the composite bypass fan duct in their

correct positions. (See Figure 1, Detail D.)

3) Install the thrust reverser to the composite bypass fan duct with previously removed

attaching hardware. Install fasteners wet with Class B (890 B1/2) sealant. (Refer to Chapter 20 of the Maintenance Manual.)

NOTE: Apply sealant to the shank of the bolt only. Do not apply sealant to the bolt

threads.

(h) Torque the service island and thrust reverser attaching hardware to 50 to 70 in/lbs [5.64 to

7.90 Nm] above rundown torque. (Refer to Chapter 20 of the Maintenance Manual.)

(i) Install the wiring and throttle clamps. (See Figure 1, Detail F.)

C. Functional Test/Operational Check.

(1) Connect the main and emergency batteries and external electrical power to the aircraft. (Refer to

Chapter 24 of the Maintenance Manual.)

(2) Do the Engine Operation Check and examine for leaks. (Refer to Garrett TFE-731 Engine Maintenance Manual.)

(3) Do the Operational Check of Thrust Reverser System and examine for leaks. (Refer to Chapter 78

of the Maintenance Manual.) 

(4) Do the Operational Check of the Bleed Air System and examine for leaks. (Refer to Chapter 36 of

the Maintenance Manual.)

NOTE: Make sure no leaks exist around the couplings of the high pressure bleed air manifold.

D. Return Aircraft to Airworthy Status

(1) Install the lower pylon access panels (LH, 340DL, 340EL, 340FL; RH, 340DR, 340ER, 340CR) as

required.

(2) Install the upper and lower engine cowling (LH, 450AL and 450CL; RH, 460AR and 460CR).

(Refer to Chapter 71 of the Maintenance Manual.)

(3) If not already done, connect the main and emergency batteries to the aircraft. (Refer to Chapter 24

of the Maintenance Manual.)

E. Compliance Response Form

(1) Complete the compliance response form.

(2) Send the compliance response form to Learjet Inc. as soon as possible.

F. Aircraft Maintenance Records

(1) Complete the Aircraft Maintenance Records in accordance with the regulatory requirements of

your aircraft certification authority.
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Installation of the Thrust Reverser and Service Island Mounting Flange Gaskets

Figure 1 (Sheet 1 of 6)
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Installation of the Thrust Reverser and Service Island Mounting Flange Gaskets

Figure 1 (Sheet 2 of 6)
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Installation of the Thrust Reverser and Service Island Mounting Flange Gaskets

Figure 1 (Sheet 3 of 6)
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Installation of the Thrust Reverser and Service Island Mounting Flange Gaskets

Figure 1 (Sheet 4 of 6)
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Installation of the Thrust Reverser and Service Island Mounting Flange Gaskets

Figure 1 (Sheet 5 of 6)
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Installation of the Thrust Reverser and Service Island Mounting Flange Gaskets

Figure 1 (Sheet 6 of 6)