Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-25-0507

Original Issue: June 30, 2011

ATA System: 2566

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Door-Mounted Escape Slide Pack - Change

to Escape Slide/Raft to Prevent Corrosion of Packboard Release Mechanism

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

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

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

laws.

ECCN: 9E991

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Copyright © 2011 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more

information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

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5.0
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BOEING SERVICE BULLETIN 777-25-0507

BLANK PAGE
Table of Contents

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 17

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 19

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Summary Number: 777-25-0507

Original Issue: June 30, 2011

ATA System: 2566

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Door-Mounted Escape Slide Pack - Change

to Escape Slide/Raft to Prevent Corrosion of Packboard Release Mechanism

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

The service bulletin(s) listed below must be done before or at the same time as this service bulletin:

Company Service Bulletin Description

Inspect the housing assembly to determine

if it is unsealed and replace the assembly

with a new assembly if necessary.

Air Cruisers Company SB 777-107-25-30,

Original Issue

Air Cruisers Company

BACKGROUND

This service bulletin describes modification to door mounted escape slide/rafts. Modification is done in accordance

with Air Cruisers Company SB 777-107-25-30 to packboard release mechanism to prevent corrosion. If you do

not do this service bulletin, escape slide/rafts may not deploy when required and may prohibit doors from opening

in the armed mode.

Three 777 operators have reported the detection of corrosion at first overhaul of main deck door mounted escape

slide/raft packboard release mechanisms. Two of the operators have reported incidents at the time of first

deployment where the escape slide/raft did not release from the door and prevented door opening in the armed

mode. The third operator reported evidence of corrosion on 25 out of 270 escape slide/rafts overhauled during

the last 3 years.

Investigation revealed several packboard release mechanism components exhibited in-service galvanic corrosion.

The cause was due to non-isolation of dissimilar metals, use of galvanic corrosion susceptible metals, and

finishes that are not effective in protecting from galvanic corrosion.

Boeing Service Related Problem (SRP) 777-SRP-25-0293 is related to this service bulletin. This SRP is described

in Fleet Team Digest Article 777 FTD 25-10002.

ACTION (PRR 62777-75S)

Airplanes are divided into groups because of difference in number of entry doors or difference in entry door

numbers.

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Group 1:

Remove escape slide/rafts at passenger/crew entry doors 1, 2, 3, and 4, left and right. Modify escape slide/rafts

in accordance with Air Cruisers Company SB 777-107-25-30. Reinstall escape slide/rafts.

Group 2:

Remove escape slide/rafts at passenger/crew entry doors 1, 2, 4, and 5, left and right. Modify escape slide/rafts

in accordance with Air Cruisers Company SB 777-107-25-30. Reinstall escape slide/rafts.

Group 3:

Remove escape slide/rafts at crew entry doors 1 left and right. Modify escape slide/rafts in accordance with Air

Cruisers Company SB 777-107-25-30. Reinstall escape slide/rafts.

EFFECTIVITY

Model 777-200, 777-200LR, 777-300, 777-300ER, and 777F airplanes. Refer to Paragraph 1.A., Effectivity 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.

Boeing recommends that the changes given in this service bulletin be done within 42 months after the original

issue date of this service bulletin.

INDUSTRY SUPPORT INFORMATION

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

MANPOWER

Elapsed

Hours

Total Task

Hours

Airplanes

Group 1 and 2 (8 escape slide/rafts) 16.00 (a) 8.00 (a)

Group 3 (2 escape slide/rafts) 4.00 (a) 2.00 (a)

(a) Does not include time required to modify escape slide/rafts in accordance with Air Cruisers

Company SB 777-107-25-30.

MATERIAL INFORMATION

Refer to Air Cruisers Company SB 777-107-25-30.

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-25-0507

Original Issue: June 30, 2011

ATA System: 2566

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Door-Mounted Escape Slide Pack - Change

to Escape Slide/Raft to Prevent Corrosion of Packboard Release Mechanism

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplane(s) shown below. An equivalent change is on subsequent

production airplanes. Refer to PRR 62777-75S for data about this change.

GROUP CONFIGURATION DESCRIPTION

1 - 777-200, 777-200LR Airplanes

2 - 777-300, 777-300ER Airplanes

3 - 777F Airplanes

Airplane Models:

777-200, 777-200LR, 777-300, 777-300ER, 777F

Variable Number Group

WA001 - WA017 1

WA076 - WA079 1

WA086 - WA093 1

WA101 - WA104 1

WA116 - WA119 1

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Variable Number Group

WA131 - WA137 1

WA171 - WA175 1

WA196 - WA198 1

WA206 - WA212 1

WA221 - WA223 1

WA231 - WA232 1

WA241 - WA250 1

WA261 - WA266 1

WA281 - WA283 1

WA301 - WA304 1

WB001 - WB021 1

WB031 - WB046 1

WB051 - WB088 1

WB101 - WB106 1

WB121 - WB125 1

WB131 - WB148 1

WB151 - WB155 1

WB161 - WB177 1

WB181 - WB194 1

WB201 - WB215 1

WB231 - WB247 1

WB271 - WB273 1

WB276 - WB286 1

WB291 - WB302 1

WB306 - WB307 1

WB311 - WB337 1

WB341 - WB342 1

WB366 - WB368 1

WB371 - WB388 1

WB406 1

WB411 - WB413 1

WB416 - WB439 1

WB446 - WB453 1

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BOEING SERVICE BULLETIN 777-25-0507
Variable Number Group

WB476 1

WB481 - WB484 1

WB501 - WB512 2

WB531 - WB537 2

WB551 - WB554 2

WB591 - WB597 2

WB601 - WB606 2

WB611 - WB622 2

WB631 - WB638 2

WB646 - WB649 2

WC051 - WC073 1

WC101 - WC104 1

WC111 - WC120 1

WC221 - WC224 1

WC241 - WC243 1

WC281 - WC290 1

WC301 - WC308 1

WC361 - WC364 1

WC371 - WC374 1

WC381 - WC395 1

WC441 1

WC446 - WC449 1

WC456 - WC459 1

WC486 - WC493 1

WC506 - WC508 1

WC521 - WC522 1

WC531 - WC536 1

WC546 - WC548 1

WC556 1

WC566 - WC567 1

WC571 - WC574 1

WC581 1

WD001 - WD002 1

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BOEING SERVICE BULLETIN 777-25-0507
Variable Number Group

WD011 - WD018 1

WD031 - WD036 1

WD046 - WD055 1

WD066 - WD075 1

WD081 - WD088 1

WD091 1

WD096 1

WD101 - WD103 1

WD501 - WD513 2

WD521 - WD541 2

WD546 - WD554 2

WD561 - WD573 2

WD581 - WD599 2

WD606 - WD609 2

WD621 - WD632 2

WD651 - WD665 2

WD671 - WD676 2

WD691 - WD709 2

WD741 - WD752 2

WD761 - WD771 2

WD786 - WD788 2

WD796 - WD813 2

WD826 - WD837 2

WD846 - WD861 2

WD871 - WD883 2

WD911 - WD915 2

WD921 - WD922 2

WD936 - WD939 2

WD946 - WD951 2

WD966 - WD970 2

WD981 - WD982 2

WD986 - WD987 2

WD996 2

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BOEING SERVICE BULLETIN 777-25-0507
Variable Number Group

WE001 - WE004 2

WE011 - WE012 2

WE021 - WE024 2

WE031 2

WE051 - WE052 2

WE071 2

WE081 - WE082 2

WE126 - WE132 2

WF001 - WF004 3

WF016 - WF020 3

WF031 - WF032 3

WF046 - WF054 3

WF076 - WF077 3

WF081 - WF088 3

WF096 - WF099 3

WF106 - WF107 3

WF111 - WF112 3

WF121 3

2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for

the recommended use.

B. Concurrent Requirements

The service bulletin(s) listed below must be done before or at the same time as this service bulletin:

Company Service Bulletin Description

Inspect the housing assembly to determine

if it is unsealed and replace the assembly

with a new assembly if necessary.

Air Cruisers Company SB 777-107-25-30,

Original Issue

Air Cruisers Company

C. Reason

This service bulletin describes modification to door mounted escape slide/rafts. Modification is done

in accordance with Air Cruisers Company SB 777-107-25-30 to packboard release mechanism to

prevent corrosion. If you do not do this service bulletin, escape slide/rafts may not deploy when required

and may prohibit doors from opening in the armed mode.

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BOEING SERVICE BULLETIN 777-25-0507
Three 777 operators have reported the detection of corrosion at first overhaul of main deck door mounted

escape slide/raft packboard release mechanisms. Two of the operators have reported incidents at the

time of first deployment where the escape slide/raft did not release from the door and prevented door

opening in the armed mode. The third operator reported evidence of corrosion on 25 out of 270 escape

slide/rafts overhauled during the last 3 years.

Investigation revealed several packboard release mechanism components exhibited in-service galvanic

corrosion. The cause was due to non-isolation of dissimilar metals, use of galvanic corrosion susceptible

metals, and finishes that are not effective in protecting from galvanic corrosion.

Boeing Service Related Problem (SRP) 777-SRP-25-0293 is related to this service bulletin. This SRP

is described in Fleet Team Digest Article 777 FTD 25-10002.

D. Description

Airplanes are divided into groups because of difference in number of entry doors or difference in entry

door numbers.

Group 1:

Remove escape slide/rafts at passenger/crew entry doors 1, 2, 3, and 4, left and right. Modify escape

slide/rafts in accordance with Air Cruisers Company SB 777-107-25-30. Reinstall escape slide/rafts.

Group 2:

Remove escape slide/rafts at passenger/crew entry doors 1, 2, 4, and 5, left and right. Modify escape

slide/rafts in accordance with Air Cruisers Company SB 777-107-25-30. Reinstall escape slide/rafts.

Group 3:

Remove escape slide/rafts at crew entry doors 1 left and right. Modify escape slide/rafts in accordance

with Air Cruisers Company SB 777-107-25-30. Reinstall escape slide/rafts.

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

Group 1:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR 831, 832, 834, 835, 841, 842, 844, 845

Group 2:

Affected Maintenance Zones

Model Zone

777-300, 777-300ER 831, 832, 834, 835, 841, 842, 844, 845

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BOEING SERVICE BULLETIN 777-25-0507
Group 3:

Affected Maintenance Zones

Model Zone

777F 831, 841

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.

Boeing recommends that the changes given in this service bulletin be done within 42 months after the

original issue date of 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.

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 change 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.

Group 1-2:

Number of Per- Task Hours Elapsed Hours

sons

Task

Remove 8 escape 2 8.00 4.00

slide/rafts

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Group 1-2:

Number of Per- Task Hours Elapsed Hours

sons

Task

Reinstall 8 escape 2 8.00 4.00

slide/rafts

TOTAL FOR EACH AIRPLANE (a) 16.00 8.00

(a) Time to modify escape slide/rafts in accordance with Air Cruisers Company

SB 777-107-25-30 is not included.

Group 3:

Number of Per- Task Hours Elapsed Hours

sons

Task

Remove 2 escape 2 2.00 1.00

slide/rafts

Reinstall 2 escape 2 2.00 1.00

slide/rafts

TOTAL FOR EACH AIRPLANE (a) 4.00 2.00

(a) Time to modify escape slide/rafts in accordance with Air Cruisers Company

SB 777-107-25-30 is not included.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Engineering Change Memo PRR 62777-75S

b. 777 Aircraft Maintenance Manual (AMM) 25-66-01

c. 777 Fleet Team Digest (FTD) 25-10002

d. Air Cruisers Company Service Bulletin 777-107-25-30

e. Service Related Problem (SRP) 777-SRP-25-0293

2. Data supplied with this Service Bulletin

None.

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BOEING SERVICE BULLETIN 777-25-0507
3. Installation Drawings Used in the Preparation of this Service Bulletin

Drawing Number Title

462W1000 ESCAPE SLIDE/RAFT INSTL

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:

Publication Chapter-Section

777 Illustrated Parts Catalog 25-66

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability

information.

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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Refer to Air Cruisers Company SB 777-107-25-30.

B. Industry Support Information

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

C. Parts Necessary For Each Airplane

1. Kits/Parts

Refer to Air Cruisers Company SB 777-107-25-30.

2. Parts and Materials Supplied by the Operator

Refer to Air Cruisers Company SB 777-107-25-30.

3. Parts Modified and Reidentified

Existing Part Number QTY Name New Part Number Notes

S462W001-( ) - Escape Slide/Raft - (a), (b), (c)

(a) Make the change in accordance with Air Cruisers Company SB 777-107-25-30.

(b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change

done in accordance with this service bulletin was made.

(c) You can use the existing part to replace the new or changed part. If you use the existing part, you

cancel the effect of the change given in this service bulletin.

4. Parts Removed and Not Replaced

Refer to Air Cruisers Company SB 777-107-25-30.

D. Parts Necessary to Change Spares

Refer to Air Cruisers Company SB 777-107-25-30.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

None.

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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. The instructions identified in Paragraph 3.B., Work Instructions, 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 given in the specified manual sections.

4. 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.

5. Replacement of all slide/rafts at the same time is not required.

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BOEING SERVICE BULLETIN 777-25-0507
B. WORK INSTRUCTIONS

1. Group 1:

a. Remove escape slide/rafts at Doors 1, 2, 3, and 4, left and right. Refer to 777 AMM 25-66-01

as an accepted procedure.

b. Modify each escape slide/raft by doing a visual inspection of the housing assembly to determine

if it is unsealed, and if necessary, replace the housing assembly with a new housing assembly,

in accordance with Air Cruisers Company SB 777-107-25-30.

c. Install escape slide/rafts modified in accordance with Air Cruisers Company SB 777-107-25-30

at Doors 1, 2, 3, and 4, left and right. Refer to 777 AMM 25-66-01 as an accepted procedure.

d. Put the airplane back in a serviceable condition.

2. Group 2:

a. Remove escape slide/rafts at Doors 1, 2, 4, and 5, left and right. Refer to 777 AMM 25-66-01

as an accepted procedure.

b. Modify each escape slide/raft by doing a visual inspection of the housing assembly to determine

if it is unsealed, and if necessary, replace the housing assembly with a new housing assembly,

in accordance with Air Cruisers Company SB 777-107-25-30.

c. Install escape slide/rafts modified in accordance with Air Cruisers Company SB 777-107-25-30

at Doors 1, 2, 4, and 5, left and right. Refer to 777 AMM 25-66-01 as an accepted procedure.

d. Put the airplane back in a serviceable condition.

3. Group 3:

a. Remove escape slide/rafts at Doors 1 Left and Right. Refer to 777 AMM 25-66-01 as an

accepted procedure.

b. Modify each escape slide/raft by doing a visual inspection of the housing assembly to determine

if it is unsealed, and if necessary, replace the housing assembly with a new housing assembly,

in accordance with Air Cruisers Company SB 777-107-25-30.

c. Install escape slide/rafts modified in accordance with Air Cruisers Company SB 777-107-25-30

at Doors 1 Left and Right. Refer to 777 AMM 25-66-01 as an accepted procedure.

d. Put the airplane back in a serviceable condition.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: June 30, 2011

777-25-0507

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BOEING SERVICE BULLETIN 777-25-0507