Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0263

Original Issue: January 12, 2015

ATA System: 5300

SUBJECT: FUSELAGE - Section 43 - Inspection of Skin and Splice Fittings at Stringer 29, Body

Station 786 Ring Chord

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

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

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2015 Boeing.

Unpublished Work. All Rights Reserved.

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are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

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BOEING SERVICE BULLETIN 767-53A0263

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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 18

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 21

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FIGURE 1: LEFT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE

FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

FIGURE 2: RIGHT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER

SPLICE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-53A0263

Original Issue: January 12, 2015

ATA System: 5300

SUBJECT: FUSELAGE - Section 43 - Inspection of Skin and Splice Fittings at Stringer 29, Body

Station 786 Ring Chord

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

While replacing a cracked underwing longeron fitting per service bulletin 767-57A0126, a crack indication was

found in the STA 786 ring chord at the tension bolt hole common to the wing front spar lower chord and the

internal bathtub fittings. There were two similar reports of these findings from two separate operators. The

airplanes in these reports had 14,367 and 18,354 flight cycles and had 90,389 and 96,826 flight hours, respectively.

The current Maintenance Planning Document (MPD) inspections are not sufficient to detect any possible fuselage

skin crack in the area adjacent to the ring chord at STA 786 before the crack extends to a critical length. The

fuselage skin in this area is hidden between the splice fittings on the external side of the fuselage and the bathtub

fittings on the internal side. This service bulletin specifies an external ultrasonic inspection of the skin hidden

by the upper and lower splice fittings on both sides of the fuselage to detect any fatigue crack in the fuselage

skin. It also specifies an external detailed inspection of the splice fittings and the adjacent visible fuselage skin

and structure for any crack, corrosion or other damage. If the service bulletin action is not accomplished, then

cracks in the fuselage skin in this hidden area could go undetected, potentially leading to a loss of a primary

load path between the fuselage and the wing box. The loss of the primary load path could adversely affect the

structural integrity of the airplane.

To date, there have been no reports of any fuselage skin cracks in the area that is inspected by this service

bulletin.

Boeing Service Related Problem (SRP) 767-53-0461 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 53-14001 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

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Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected No Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required No Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Remove the wing-to-body access panels on the left and right sides of the airplane to open access to the splice

fittings on the fuselage adjacent and forward of the STA 786 ring chord. Do an initial external ultrasonic and

detailed inspection of the area on both sides of the fuselage. Do repeat inspections if no damage is found. If

damage is found, contact Boeing to get instructions for the repair for this service bulletin and do the work

instructed by Boeing, before further flight. Do the inspections in accordance with paragraph 1.E., Compliance.

EFFECTIVITY

767-200/-300/-300F/-400ER airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection given in this service bulletin.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

All Airplanes 8.60 4.60

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ALERT ALERT
MATERIAL INFORMATION

None.

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0263

Original Issue: January 12, 2015

ATA System: 5300

SUBJECT: FUSELAGE - Section 43 - Inspection of Skin and Splice Fittings at Stringer 29, Body

Station 786 Ring Chord

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

This service bulletin is applicable to all 767-200/-300/-300F/-400ER airplanes, line numbers 1-9999

in one (1) Group. The Variable Numbers and Group Information for the applicable airplanes is

given below.

Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1093.

Affected airplanes after Line Number 1093 will be added to the service bulletin's

MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet

Profile Page.

GROUP CONFIGURATION DESCRIPTION

1 - All 767 Airplanes, line numbers 1-9999

Airplane Models:

767-200, 767-300, 767-300F, 767-400ER

Variable Number Group

VA001 - VA020 1

VA301 - VA315 1

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Variable Number Group

VA501 - VA530 1

VA701 - VA719 1

VA801 - VA810 1

VB001 - VB002 1

VB051 - VB055 1

VB101 - VB125 1

VB201 - VB202 1

VB251 - VB253 1

VB281 - VB284 1

VB301 - VB302 1

VB321 - VB332 1

VB371 - VB373 1

VB401 1

VB441 - VB444 1

VE001 - VE003 1

VE021 - VE023 1

VE041 - VE043 1

VE061 - VE069 1

VE083 - VE086 1

VE101 - VE104 1

VE116 - VE118 1

VE121 - VE126 1

VE141 - VE152 1

VE171 - VE172 1

VF001 - VF002 1

VF041 - VF042 1

VF051 1

VF061 - VF062 1

VF071 - VF072 1

VF091 - VF093 1

VF101 - VF102 1

VF161 - VF162 1

VF171 - VF172 1

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Variable Number Group

VF180 - VF184 1

VF251 1

VK001 - VK016 1

VK021 - VK022 1

VK031 - VK056 1

VK081 - VK113 1

VK131 - VK133 1

VK141 - VK148 1

VK161 - VK164 1

VK171 1

VK181 1

VK186 1

VL001 - VL006 1

VL011 1

VL701 - VL703 1

VL751 - VL755 1

VL806 - VL807 1

VL871 - VL873 1

VL891 - VL900 1

VL911 - VL914 1

VL931 - VL932 1

VL941 1

VN001 - VN041 1

VN051 - VN064 1

VN081 - VN099 1

VN111 - VN127 1

VN130 - VN137 1

VN151 - VN158 1

VN163 - VN168 1

VN171 - VN174 1

VN191 - VN198 1

VN211 - VN212 1

VN221 - VN225 1

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Variable Number Group

VN231 - VN234 1

VN241 - VN243 1

VN251 - VN276 1

VN291 - VN293 1

VN301 - VN314 1

VN371 - VN372 1

VN376 1

VN381 - VN388 1

VN421 - VN427 1

VN436 1

VN471 - VN472 1

VN491 - VN513 1

VN531 - VN532 1

VN536 - VN537 1

VN541 - VN542 1

VN546 - VN547 1

VN551 1

VN556 - VN557 1

VN561 - VN562 1

VN631 - VN638 1

VN651 - VN658 1

VN671 - VN672 1

VN676 1

VN681 - VN691 1

VN731 - VN732 1

VN751 - VN753 1

VN791 - VN792 1

VN811 - VN813 1

VN921 - VN922 1

VN931 - VN936 1

VN951 - VN953 1

VN966 - VN972 1

VQ001 - VQ021 1

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ALERT ALERT
Variable Number Group

VQ071 - VQ086 1

VQ111 1

VR051 - VR060 1

VR081 1

VR084 1

VR086 - VR089 1

VR106 - VR109 1

VR201 - VR211 1

VR251 1

VR256 - VR260 1

VR266 - VR292 1

VR401 1

VR421 - VR423 1

VR426 1

VR441 1

VR461 1

VR471 - VR472 1

VS051 - VS056 1

VS061 1

VS066 - VS070 1

VS073 - VS078 1

VS091 - VS104 1

VS111 - VS113 1

VS131 - VS133 1

VS136 - VS137 1

VS176 - VS177 1

VS186 - VS187 1

VS196 - VS203 1

VS206 - VS208 1

VS211 1

VS216 - VS217 1

VS231 1

VS246 - VS248 1

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Variable Number Group

VS261 - VS263 1

VS266 - VS274 1

VS291 - VS293 1

VS301 - VS303 1

VS306 - VS311 1

VS316 1

VS321 - VS324 1

VS331 - VS333 1

VS336 - VS337 1

VS366 - VS367 1

VS381 - VS382 1

VS391 - VS392 1

VS401 1

VS426 - VS428 1

VS466 - VS472 1

VS486 1

VS496 - VS497 1

VS506 - VS507 1

VS526 1

VS546 - VS549 1

VS701 - VS736 1

VS751 - VS759 1

VS821 - VS825 1

VS841 - VS844 1

VS861 1

VS881 - VS883 1

VS891 1

VS896 1

VS901 - VS912 1

VS916 1

VS921 - VS928 1

VS931 - VS933 1

VS941 1

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ALERT ALERT
Variable Number Group

VS951 - VS954 1

VS961 - VS969 1

VS971 - VS977 1

VS981 - VS984 1

VT001 - VT013 1

VT021 1

VT031 - VT033 1

VT501 1

VT511 - VT513 1

VT521 - VT523 1

VT531 - VT533 1

VT541 - VT546 1

VT551 - VT552 1

VT556 - VT581 1

VV001 1

VW701 - VW721 1

VW851 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

While replacing a cracked underwing longeron fitting per service bulletin 767-57A0126, a crack indication

was found in the STA 786 ring chord at the tension bolt hole common to the wing front spar lower chord

and the internal bathtub fittings. There were two similar reports of these findings from two separate

operators. The airplanes in these reports had 14,367 and 18,354 flight cycles and had 90,389 and

96,826 flight hours, respectively. The current Maintenance Planning Document (MPD) inspections are

not sufficient to detect any possible fuselage skin crack in the area adjacent to the ring chord at STA

786 before the crack extends to a critical length. The fuselage skin in this area is hidden between the

splice fittings on the external side of the fuselage and the bathtub fittings on the internal side. This

service bulletin specifies an external ultrasonic inspection of the skin hidden by the upper and lower

splice fittings on both sides of the fuselage to detect any fatigue crack in the fuselage skin. It also

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BOEING SERVICE BULLETIN 767-53A0263

ALERT ALERT
specifies an external detailed inspection of the splice fittings and the adjacent visible fuselage skin and

structure for any crack, corrosion or other damage. If the service bulletin action is not accomplished,

then cracks in the fuselage skin in this hidden area could go undetected, potentially leading to a loss

of a primary load path between the fuselage and the wing box. The loss of the primary load path could

adversely affect the structural integrity of the airplane.

To date, there have been no reports of any fuselage skin cracks in the area that is inspected by this

service bulletin.

Boeing Service Related Problem (SRP) 767-53-0461 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 767 FTD 53-14001 is related to this service bulletin.

D. Description

Remove the wing-to-body access panels on the left and right sides of the airplane to open access to

the splice fittings on the fuselage adjacent and forward of the STA 786 ring chord. Do an initial external

ultrasonic and detailed inspection of the area on both sides of the fuselage. Do repeat inspections if

no damage is found. If damage is found, contact Boeing to get instructions for the repair for this service

bulletin and do the work instructed by Boeing, before further flight. Do the inspections in accordance

with paragraph 1.E., Compliance.

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones

Model Zone

767-200, 767-300, 767-300F, 193, 194

767-400ER

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

Table 1: Inspection For Damage At The Splice Fitting Locations

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3000 -

flight cycles or

24 months, after

the original issue date of this

service bulletin

(whichever occurs first)

Before 37,500

total flight cycles

or 87,500 total

flight hours

(whichever occurs first)

Do PART 1: EXTERNAL

ULTRASONIC AND DETAILED INSPECTION AT

THE SPLICE FITTINGS

All airplanes

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Table 1: Inspection For Damage At The Splice Fitting Locations

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

6,000 flight cycles

or 18,000 flight

hours(whichever

occurs first)

Repeat PART 1: EXTER- - -

NAL ULTRASONIC AND

DETAILED INSPECTION

AT THE SPLICE FITTINGS

CONDITION 1: No crack,

corrosion or other damage

found

Before further - -

flight

Contact Boeing to get instructions for the repair

for this service bulletin

and do the work instructed by Boeing.

CONDITION 2: Any crack,

corrosion or other damage

found

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.30 0.30

Inspect

...Left - FIGURE 1 2 4.00 2.00

...Right - FIGURE 2 2 4.00 2.00

Close Access 1 0.30 0.30

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Task Number of Persons Task Hours Elapsed Hours

TOTAL FOR EACH AIRPLANE 8.60 4.60

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Boeing Service Letter 767-SL-51-036

b. Boeing Service Related Problem (SRP) 767-53-0461

c. Service Bulletin Index D624T001

d. Standard Overhaul Practices Manual (SOPM) 20-50-01

e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19

f. 767 Aircraft Maintenance Manual (AMM) 53-52-01

g. 767 Fleet Team Digest (FTD) 53-14001

h. 767 Non-Destructive Testing (NDT) Manual [Part 4, 53-30-02]

2. Data Supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

140T0120 MONOCOQUE INTEGRATION - SECTION 43 TO 45

140T0720 INTEGRATION INSTL - FWD OF FRONT SPAR FAIRING

The table above lists applicable drawings used to prepare this service bulletin. The drawings are

not necessary to make the specified changes, and are not supplied with this service bulletin. The

drawings may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

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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.

M. Software Accomplishment Summary

Not affected.

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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

None.

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

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. The work instructions are divided into work packages. Task Hours and Elapsed Hours

for each package are given in Paragraph 1.G., Manpower. You can do each work

package independently.

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 and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 767 Structural Repair Manual,

Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 767

Aircraft Maintenance Manual (AMM).

— Values for electrical maintenance tasks are included in Chapter 20 of

Standard Wiring Practices Manual (SWPM).

— Values for engine maintenance tasks are included in Chapter 70 of 767

Aircraft Maintenance Manual (AMM).

— Non-standard torque values for maintenance tasks are included in the

applicable installation step.

5. Use the approved fastener, process and material substitutions in accordance with

SRM Chapter 51.

6. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

7. The necessary conditions for selection of clamp type and size are included in SWPM

20-10-12. If any wire bundle support clamp specified in this service bulletin does not

make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted

procedure to select a clamp that fits correctly.

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8. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate

full threaded fasteners (screws) needed for installation in this service bulletin.

9. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

10. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

11. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

12. Boeing Service Letter 767-SL-51-036 , Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

13. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

14. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

15. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

16. If shading is used, shaded areas in Figures are to separate the non-critical and

non-authoritative information from the critical and authoritative information.

17. Use of colors in Figures is based on guidance from the ATA e-Business Program

(ATA) iSpec 2200.

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18. When more than one OPTION is given for a CONDITION, do only one of the OPTION

numbers. When more than one ACTION is given for a CONDITION number or an

OPTION number, do all of the ACTION numbers for that CONDITION number or

OPTION number.

19. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

20. The CONDITIONS, ACTIONS and OPTIONS shown apply to each area on the

fuselage (left and right sides) where the splice fittings are located independently.

21. Some steps in the Work Instructions are identified as Required for Compliance (RC).

If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps

identified as RC must be done to comply with the AD. Alternative procedures for

steps not identified with RC can be used if the RC steps can still be done as specified,

and the airplane can be put back in a serviceable condition. An Alternative Method

of Compliance (AMOC) is not necessary for deviations to steps that are not identified

as RC.

B. WORK INSTRUCTIONS

1. Do the PART 1: EXTERNAL ULTRASONIC AND DETAILED INSPECTION AT THE SPLICE

FITTINGS within the compliance time in Paragraph 1.E., Compliance.

a. CONDITION 1: NO CRACK, CORROSION, OR OTHER DAMAGE FOUND

(1) Repeat PART 1: EXTERNAL ULTRASONIC AND DETAILED INSPECTION AT THE

SPLICE FITTINGS within the compliance time in Paragraph 1.E., Compliance.

b. CONDITION 2: ANY CRACK, CORROSION, OR OTHER DAMAGE FOUND

(1) Contact Boeing to get instructions for the repair for this service bulletin and do the work

instructed by Boeing, before further flight.

PART 1: EXTERNAL ULTRASONIC AND DETAILED INSPECTION AT THE SPLICE FITTINGS

1. Remove the wing-to-body access panel to open access to the splice fittings. Refer to 767 AMM

53-52-01 as an accepted procedure.

Left Right

193CL 194CR

2. RC - Do an external ultrasonic and detailed inspection at the upper and lower splice fittings area

adjacent to the ring chord in accordance with the figures below:

Left Right

FIGURE 1 FIGURE 2

3. Install the wing-to-body access panel to close access to the splice fittings. Refer to 767 AMM

53-52-01 as an accepted procedure.

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Left Right

193CL 194CR

4. Return the airplane to a serviceable condition.

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FIGURE 1: LEFT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE

FITTINGS

(SHEET 1 OF 2)

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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 this figure.

Step Task Name Identification Qty More Data

Do an ultrasonic inspection of the skin

hidden by the upper

and lower splice fittings for any

crack.(a) (c)

1 Inspect Splice Fittings - -

Do a detailed inspection of the upper and

lower splice fittings

for any crack, corrosion, or other damage, including displaced fasteners.(b)

(c)

2 Inspect Splice Fittings - -

Do a detailed inspection of the skin surface for any crack,

corrosion, or other

damage, including

displaced fasteners.(b) (c)

3 Inspect Skin - -

(a) Do the inspection in accordance with 767 NDT Manual [Part 4, 53-30-02].

(b) It is only necessary to do the detailed inspection of the exposed skin and exposed surfaces of splice fittings

not covered by permanently attached structure. The fitting assemblies that are depicted on the illustration

exist only on some airplanes and are shown as examples of structure that does not need to be removed.

(c) It is not necessary to remove any fasteners to do the inspection.

FIGURE 1: LEFT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE

FITTINGS

(SHEET 2 OF 2)

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FIGURE 2: RIGHT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE

FITTINGS

(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 this figure

Step Task Name Identification Qty More Data

Do an ultrasonic inspection of the skin

hidden by the upper

and lower splice fittings for any

crack.(a) (c)

1 Inspect Splice Fittings - -

Do a detailed inspection of the upper and

lower splice fittings

for any crack, corrosion, or other damage, including displaced fasteners.(b)

(c)

2 Inspect Splice Fittings - -

Do a detailed inspection of the skin surface for any crack,

corrosion, or other

damage, including

displaced fasteners.(b) (c)

3 Inspect Skin - -

(a) Do the inspection in accordance with 767 NDT Manual [Part 4, 53-30-02].

(b) It is only necessary to do the detailed inspection of the exposed skin and exposed surfaces of splice fittings

not covered by permanently attached structure. The fitting and bracket assemblies that are depicted on

the illustration exist only on some airplanes and are shown as examples of structure that does not need

to be removed.

(c) It is not necessary to remove any fasteners to do the inspection.

FIGURE 2: RIGHT SIDE OF FUSELAGE – EXTERNAL INSPECTION AT THE UPPER AND LOWER SPLICE

FITTINGS

(SHEET 2 OF 2)

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