February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 77 

### Commercial Airplane Group 

# 737 Service Bulletin

Number: 737-78-1069 Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831
SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.BLANK PAGE February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BLANK PAGETable of Contents February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 25 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 25 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 33 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 35 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 1: THRUST REVERSER INSULATION BLANKET REMOVAL . . . . . . . . . . . . . . . . 40 FIGURE 2: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL . . . . 42 FIGURE 3: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT . 46 FIGURE 4: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL . . . . . . . . . . . 50 FIGURE 5: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT . . . . . . . . 54 FIGURE 6: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET FASTENER GROMMET ADDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Table of Contents February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FIGURE 8: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SUPPORT ATTACHMENTS - STUD BOLT AND CLICK-BOND ADDITION . . . . . . . . . . . . . 67 FIGURE 9: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET INSTALLATION . . . 71 FIGURE 10: THRUST REVERSER INSULATION BLANKET FASTENER AND SKIN GROMMET DRILL AND DRILL GUIDE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 APPENDIX A: SKIN GROMMET INSTALLATION - TOOL SET-UP . . . . . . . . . . . . . . . . . . 75 APPENDIX B: ADHESIVE BONDED STUD - CLICK BOND FASTENER INSTALLATION . . . . . . 76February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 77 

### Commercial Airplane Group 

# 737 Service Bulletin

Number: 737-78-1069 

### Revision Transmittal Sheet Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831
SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification

This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed as shown in Revision 3 of this service bulletin.
REASON FOR REVISION Revision 4 is sent to move airplane YA531 from Group 2 to Group 3 and to add three optional parting agents. Airplane YA531 is moved from Group 2 to Group 3 in Paragraph 1.A., Effectivity, and three optional parting agents are added to Paragraph 2.C.2., Parts and Materials Supplied by the Operator and to Figure 9, Step 3. The data given in Information Notice 737-78-1069 IN 03 and 737-78-1069 IN 04 is included in this revision. Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes 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 Release: February 28, 2002 Revision 1: June 13, 2002 Revision 2: February 6, 2003 Revision 3: August 5, 2004 Revision 4: June 16, 2005February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BLANK PAGEFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 77 

### Commercial Airplane Group 

# 737 Service Bulletin

Number: 737-78-1069 

### Summary Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831
SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification

CONCURRENT REQUIREMENTS Operators of Group 1 airplanes cannot make the changes given in this service bulletin unless service bulletin 737-78-1063 has been incorporated. Group 2 and Group 3 airplanes received the equivalent change to that given in 737-78-1063 before delivery.
BACKGROUND Many operators have reported damaged insulation blankets on the engine thrust reverser halves. Some operators have also reported wear damage and pitting on the forward end of the engine thrust links. Boeing found that external air pressure can get under the insulation blankets and expand the blankets toward the engine. This can result in wear damage to the insulation blankets, engine thrust links and other engine components. The change given in this bulletin corrects the chafe condition between the insulation blankets and the engine components. It eliminates worn insulation blankets and worn engine components. As part of a service bulletin validation program, this change was completed on one engine of airplane YD050 by Service Bulletin 737-78-1069 Validation Copy 2 before the initial release of this service bulletin. The change completed on airplane YD050 by Service Bulletin 737-78-1069 Validation Copy 2 is equivalent to the initial release of this service bulletin. Airplane YD050 has the configuration of a Group 3 airplane.
ACTION (PRR 38394) This change installs more supports on the inner wall of the thrust reverser for the attachment of the insulation blankets. New brackets are installed to attach the forward edge of the upper and lower insulation blankets. More attachment grommets are added to the blankets. The blankets are sealed at the forward edge of the fan duct inner walls to prevent the flow of air under the blankets.February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

EFFECTIVITY 737-600, -700, -700C, -800, -900 Airplanes. Refer to service bulletin Paragraph 1.A.1. for effectivity.

COMPLIANCE No compliance time is given.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of October 7, 1999. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER

MATERIAL INFORMATION Boeing Supplied Kits/Parts Refer to Paragraph 2.A., Material - Price and Availability. Airplane Line Positions Group 1 2 thru 20, 22 thru 40 and 172 Group 2 1, 21, 41 thru 171, 173 thru 346 Group 3 347 thru 700

Total Elapsed Time Airplanes Man-Hours (Hours) Remove and Install Thrust Reversers 30.0 8.0 Part I - Changes 54.0 13.5 Part II - Changes 56.0 14.0February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

TO FAN DUCT WALLS ADD MORE BLANKET SUPPORTS INSULATION BLANKETS AND REWORK THE UPPER AND LOWER

LEFT SIDE SHOWN, RIGHT SIDE SIMILAR FWD REVERSER THRUSTV39526February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BLANK PAGEFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 77 

### Commercial Airplane Group 

# 737 Service Bulletin

Number: 737-78-1069 Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831
SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification

1. PLANNING INFORMATION A. Effectivity 1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 38394 for data about this change. Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

Airplane models:
737-600 737-700 737-700C 737-800 737-900 IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AIR ALGERIE (ALG) 3 YD101–YD104 GROUP CONFIGURATION DESCRIPTION 1 - Airplanes use Kit Numbers 012A0020-1, 012A0020-5 and 012A0020-6. Boeing Service Bulletin 737-78-1063 must be done before or at the same time as this service bulletin. 2 - Airplanes use Kit Numbers 012A0020-1, 012A0020-5 and 012A0020-6. No concurrent requirements. 3 - Airplanes use Kit Number 012A0020-2. No concurrent requirements.February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

AIR BERLIN (BER) 1 YC051 2 YC052–YC058 YC701 YC703 3 YC059–YC064 AIR CHINA (BEJ) 3 YA681–YA682 YC944–YC947 YC981–YC983 AIR CHINA CHONGQING BRANCH (CHO) 2 YC941 3 YC942–YC943 AIR EUROPA (ARE) 2 YC761–YC763 3 YC764–YC770 AIR HORIZONS (AHZ) 2 YC704 3 YC707 AIR MAURITANIE (MAR) 1 YA302 AIR NATIONAL GUARD (USK) 3 YG067 YG069 AIR PACIFIC (APC) 2 YA291 YC931–YC932 AIR SAHARA (SAQ) 2 YA253–YA254 YA731 YG001 3 YC901–YC902 AIR SHAMROCK (SHI) 2 YG016 ALASKA AIRLINES (ASA) 2 YA841 3 YA842–YA852 YD501–YD502 ALOHA AIRLINES (ALO) 3 YA608 YA610 YA732–YA733 AMERICAN AIRLINES (AAL) 2 YC801–YC816 3 YC817–YC848 AMIRI FLIGHT (ABD) 2 YG023 3 YG026 ARAMCO ASSOCIATED COMPANY (RAS) 3 YB151–YB152February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

AUSTRIAN (AUL) 2 YC381–YC382 3 YE171–YE172 BABCOCK & BROWN A/C MANAGEMENT (BBB) 1 YA252 BB FIVE, INC (YIP) 3 YG066 BBJ ONE (BBI) 3 YG068 BEL AIR LIMITED (ULL) 2 YG022 BNJ SALES COMPANY (BNJ) 3 YG031 YG033 YG036 YG038 BOEING DEMONSTRATOR JET (BCJ) 3 YG071 BRAATHENS (BRT) 1 YA311 2 YA543 YA545 3 YA547–YA548 BRITANNIA AIRWAYS (BRI) 3 YD001–YD005 BWIA WEST INDIES AIRWAYS (TTA) 3 YC136–YC141 CHARTWELL (CHP) 2 YG017 CHINA AIRLINES (CHI) 2 YC571 YC574–YC580 3 YC581 CHINA EASTERN YUNNAN AIRLINES (YUN) 2 YA811–YA814 COLOMBIAN AIR FORCE (CLB) 2 YG028 COMMONWEALTH OF AUSTRALIA (GAU) 3 YG072 CONTINENTAL AIRLINES (CAL) 1 YA501–YA503 2 YA504–YA530 YC321–YC346 3 YA531–YA536 YC347–YC376February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

COPA AIRLINES (COP) 2 YA755–YA756 3 YA961–YA966 CYPRUS TURKISH AIRLINES (KTHY) (KHT) 3 YD021–YD022 DALLAH AL BARAKA (KAM) 3 YG063 DELTA AIR LINES (DAL) 2 YC601–YC608 3 YC609–YC624 YC681–YC691 DOBRO LIMITED (DOB) 2 YG008 DUBAI AIR WING (DAW) 2 YG007 EASYJET (EZY) 3 YB101 EL AL ISRAEL AIRLINES (ELA) 2 YA881 YC405 YC591–YC593 3 YA882 EXCEL AIRWAYS (SBE) 2 YC111–YC112 3 YC903 YC906 FORD AIR SERVICES (FMC) 2 YA541–YA542 FUNAIR (FUN) 2 YG027 FUTURA (FUA) 2 YC407 3 YC451 YC461–YC466 GAMA AVIATION LTD (GAV) 2 YG010 GE CORPORATE AIR TRANSPORT (GEB) 2 YG003 YG012 GERMANIA (GER) 1 YA231 YA233 YA235–YA240February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

GOL AIRLINES (GOT) 1 YA201–YA202 YA232 YA234 YA251 2 YA241–YA242 YA321 YA602 YA605 3 YA607 YA611–YA612 HAINAN AIRLINES (HNA) 2 YA544 YA546 YA603–YA604 YA606 YC126–YC127 YC401 YC404 YC971 3 YC409 YC452 YC972 YD042–YD045 HAPAG-LLOYD FLUG (HAP) 1 YC001–YC004 2 YC005–YC011 3 YC012–YC020 HI. HAMBURG INTERNATIONAL (HAU) 2 YA574–YA577 3 YA578 ICA BERMUDA (IBL) 3 YG062 JET AIRWAYS (JPL) 2 YA751–YA754 YC402–YC403 YC731–YC734 3 YA609 YA621 YC735–YC736 JET AVIATION (JTA) 2 YG015 YG021 KEVINAIR (KVN) 3 YG037 KLM - ROYAL DUTCH AIRLINES (KLM) 2 YC781–YC783 3 YC784–YC791 KOREAN AIR (KAL) 3 YC441–YC445 YD121–YD123 LAS VEGAS JET (LVJ) 2 YG002 LIMITED BRAND INC. (LII) 2 YG005 LINEAS AEREAS AZTECA (AZX) 2 YA601 MAERSK AIR (MRS) 1 YA203 2 YA204–YA206 YA571–YA573 3 YA207–YA208February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

MID EAST JET (SKL) 2 YG013–YG014 NATIONAL (NJI) 3 YG032 NEWS AMERICA INCORPORATED (NWS) 2 YG020 NOVAIR (NOO) 2 YC705 PEGASUS AIRLINES (PGS) 2 YC391 YC406 YC572–YC573 3 YC410 YC455 PICTON II (UNU) 2 YG006 PRIVATAIR (PTS) 2 YG018 3 YG019 YG064 REPUBLIC OF CHINA AIR FORCE (CAF) 3 YC396 ROYAL AIR MAROC (RAM) 2 YA831–YA832 YC301–YC302 3 YA833–YA834 YC303 ROYAL JET (RJT) 3 YG024–YG025 ROYAL MALAYSIA AIR FORCE (MAF) 3 YG061 RYANAIR (RYR) 2 YC471–YC474 3 YC475–YC480 SAS (SAS) 1 YE002 2 YE001 YE003–YE015 YE101–YE109 3 YB001–YB006 YD041 YD046–YD050 YD081 YE016–YE020 YE051 SAUDI OGER (SAO) 3 YG073 SHANGHAI AIRLINES (SHA) 1 YA312 2 YA272 YA313–YA314 3 YA891–YA892February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

SHARE JET (SJL) 3 YG035 SHENZHEN AIRLINES (SHZ) 2 YA721–YA722 3 YA801–YA803 SIGAIR (SIG) 3 YG034 SOUTH AFRICAN AIRWAYS (SAA) 3 YC708–YC711 YD023–YD024 SOUTHERN AIRCRAFT SERVICES (HUZ) 2 YG009 SOUTHWEST AIRLINES (SWA) 1 YA002–YA011 YA024 YA301 2 YA001 YA012–YA023 YA025–YA043 YA271 3 YA044–YA084 STERLING EUROPEAN AIRLINES (STR) 2 YC101–YC103 YC751–YC752 SUN COUNTRY AIRLINES (SCA) 2 YC121 SUNEXPRESS (SNS) 2 YC702 YC706 3 YC453 TBN AVIATION AVV (TBE) 2 YG029 TRACINDA CORP. (TRD) 2 YG004 TRANSAVIA AIRLINES (TAV) 2 YC071–YC076 3 YC077–YC080 TRAVEL SERVIS (TSF) 2 YC408 3 YC454 TUNISAIR (TUN) 2 YE151–YE153 3 YE154–YE156 YG030 TURKISH AIRLINES (THY) 2 YC501–YC513 3 YC514–YC522February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

TUTOR-SALIBA CORPORATION (TTS) 3 YG070 UNITED STATES NAVY (USN) 3 YG501–YG503 US AIR FORCE (USF) 3 YG074 VARIG AIRLINES (VAR) 3 YA322 VENTURA AVIATION (VTU) 2 YG011 XIAMEN AIRLINES (XIA) 2 YA701–YA704 3 YA705–YA706
IDENTIFICATION BY VARIABLE NUMBER Variable Group YA001 2 YA002–YA011 1 YA012–YA023 2 YA024 1 YA025–YA043 2 YA044–YA084 3 YA201–YA203 1 YA204–YA206 2 YA207–YA208 3 YA231–YA240 1 YA241–YA242 2 YA251–YA252 1 YA253–YA254 2 YA271–YA272 2 YA291 2 YA301–YA302 1 YA311–YA312 1 YA313–YA314 2 YA321 2 YA322 3 YA501–YA503 1 YA504–YA530 2 YA531–YA536 3February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

YA541–YA546 2 YA547–YA548 3 YA571–YA577 2 YA578 3 YA601–YA606 2 YA607–YA612 3 YA621 3 YA681–YA682 3 YA701–YA704 2 YA705–YA706 3 YA721–YA722 2 YA731 2 YA732–YA733 3 YA751–YA756 2 YA801–YA803 3 YA811–YA814 2 YA831–YA832 2 YA833–YA834 3 YA841 2 YA842–YA852 3 YA881 2 YA882 3 YA891–YA892 3 YA961–YA966 3 YB001–YB006 3 YB101 3 YB151–YB152 3 YC001–YC004 1 YC005–YC011 2 YC012–YC020 3 YC051 1 YC052–YC058 2 YC059–YC064 3 YC071–YC076 2 YC077–YC080 3 YC101–YC103 2 YC111–YC112 2 YC121 2 YC126–YC127 2 Variable GroupFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

YC136–YC141 3 YC301–YC302 2 YC303 3 YC321–YC346 2 YC347–YC376 3 YC381–YC382 2 YC391 2 YC396 3 YC401–YC408 2 YC409–YC410 3 YC441–YC445 3 YC451–YC455 3 YC461–YC466 3 YC471–YC474 2 YC475–YC480 3 YC501–YC513 2 YC514–YC522 3 YC571–YC580 2 YC581 3 YC591–YC593 2 YC601–YC608 2 YC609–YC624 3 YC681–YC691 3 YC701–YC706 2 YC707–YC711 3 YC731–YC734 2 YC735–YC736 3 YC751–YC752 2 YC761–YC763 2 YC764–YC770 3 YC781–YC783 2 YC784–YC791 3 YC801–YC816 2 YC817–YC848 3 YC901–YC903 3 YC906 3 YC931–YC932 2 YC941 2 YC942–YC947 3 Variable GroupFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

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. YC971 2 YC972 3 YC981–YC983 3 YD001–YD005 3 YD021–YD024 3 YD041–YD050 3 YD081 3 YD101–YD104 3 YD121–YD123 3 YD501–YD502 3 YE001 2 YE002 1 YE003–YE015 2 YE016–YE020 3 YE051 3 YE101–YE109 2 YE151–YE153 2 YE154–YE156 3 YE171–YE172 3 YG001–YG018 2 YG019 3 YG020–YG023 2 YG024–YG026 3 YG027–YG029 2 YG030–YG038 3 YG061–YG064 3 YG066–YG074 3 YG501–YG503 3 Variable GroupFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

B. Concurrent Requirements Operators of Group 1 airplanes cannot make the changes given in this service bulletin unless service bulletin 737-78-1063 has been incorporated. Group 2 and Group 3 airplanes received the equivalent change to that given in 737-78-1063 before delivery.
C. Reason Many operators have reported damaged insulation blankets on the engine thrust reverser halves. Some operators have also reported wear damage and pitting on the forward end of the engine thrust links. Boeing found that external air pressure can get under the insulation blankets and expand the blankets toward the engine. This can result in wear damage to the insulation blankets, engine thrust links and other engine components. The change given in this bulletin corrects the chafe condition between the insulation blankets and the engine components. It eliminates worn insulation blankets and worn engine components. Revision 1 is sent to delete two items from Paragraph 2.C.2., Parts and Materials Supplied by the Operator and to change some of the information given in the QTY column in Figures 5 and 6. Revision 2 is sent to tell operators that after the release of Revision 1 of this service bulletin it was found that the 012A0020-1 Top Kit does not contain all the necessary brackets. The 012A0020-1 Top Kit is used for Group 1 and Group 2 airplanes. The data given in Information Notice 737-78-1069 IN 01 is included in Revision 2. After the release of Revision 2 of this service bulletin, errors were found in Figures 4, 5, 6 and 10. Revision 3 corrects the errors in Figures 4, 5, 6 and 10. The data given in Information Notice 737-78-1069 IN 02 is included in Revision 3. Revision 4 is sent to move airplane YA531 from Group 2 to Group 3 and to add three optional parting agents. Airplane YA531 is moved from Group 2 to Group 3 in Paragraph 1.A., Effectivity, and three optional parting agents are added to Paragraph 2.C.2., Parts and Materials Supplied by the Operator and to Figure 9, Step 3. The data given in Information Notice 737-78-1069 IN 03 and 737-78-1069 IN 04 is included in this revision. As part of a service bulletin validation program, this change was completed on one engine of airplane YD050 by Service Bulletin 737-78-1069 Validation Copy 2 before the initial release of this service bulletin. The change completed on airplane YD050 by Service Bulletin 737-78-1069 Validation Copy 2 is equivalent to the initial release of this service bulletin. Airplane YD050 has the configuration of a Group 3 airplane. D. Description More supports are installed on the inner wall of the thrust reverser for the attachment of the insulation blankets. New brackets are installed to attach the forward edge of the upper and lower insulation blankets. More attachment grommets are added to the blankets and the blankets are sealed at the forward edge of the fan duct inner walls.February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

Revision 1 - no more work is necessary on airplanes changed as shown in the initial release of this service bulletin. BMS 5-28, Type 6 or Type 7 Potting Compound and BMS 10-103, Type 1 Primer is not necessary and has been deleted from Paragraph 2.C.2., Parts and Materials Supplied by the Operator. Some of the Bolt, Nut and Mylar Template quantities listed in the QTY column of Figures 5 and 6 have been changed. Revision 2 - no more work is necessary on airplanes changed as shown in revision 1 of this service bulletin. Revision 2 adds a new 012A0020-5 Top Kit that contains all the necessary parts for Group 1 and Group 2 airplanes. Supplemental Kit, 012A0020-6 has been added for Group 1 and Group 2 airplane operators that have received the 012A0020-1 Top Kits. The supplemental kit contains brackets, part numbers 315A2134-146 and 315A2134-152. More instructions have been added to Figure 9, Step 3 and Step 10. The instructions are applicable to the fillet seal along the forward edge of the insulation blankets. Revision 3 - no more work is necessary on airplanes changed as shown in revision 2 of this service bulletin. Revision 3 is sent to correct the quantity of bolts and nuts given in Figure 4, Step 3 and to change the reference for the upper bracket assembly, in Figure 5 graphic, from Step 2 to Step 3. The part numbers of the Fastener Grommets given in the Table on the last page of Figure 6 have been corrected. The Table related to Figure 10, second column, the three references to I.D. for the Drill Size have been changed to read O.D. The three references to O.D. for the Drill Guide size have been changed to read I.D. Also, more information has been added to the Table in Paragraph 2.D., Parts Necessary to Change Spares. Revision 4 - no more work is necessary on airplanes changed as given in Revision 3 of this service bulletin. E. Compliance No compliance time is given. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (14 CFR Part 25) and Joint Aviation Requirements (JAR-25) and are FAA/JAA approved. This service bulletin and FAA/JAA approval were based on the airplane in it's original Boeing delivery configuration or as modified by other FAA/JAA 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.
Note: Joint Airworthiness Requirements (JAR) compliance status may be found in the Service Bulletin Index, Part 1.February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

G. Manpower The tables below show an estimate of the man-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 man-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 find the tools.

Note: It is not necessary to remove the thrust reversers to do this change but access is better if the thrust reversers are removed. Add the times given in the table below, to the times given in this table if the thrust reversers are to be removed.

H. Weight and Balance Changes

I. Electrical Load Data Not changed Thrust Reverser Removal and Installation (Optional) Task Number of Persons Man-Hours Elapsed Time (Hours) Remove Thrust Reversers 4 12.0 3.0 Install Thrust Reversers 4 16.0 4.0 Test Thrust Reversers 2 2.0 1.0 TOTAL FOR EACH AIRPLANE 30.0 8.0

PART I - Thrust Reverser Inner Wall Changes Task Number of Persons Man-Hours Elapsed Time (Hours) Remove T/R Insulation Blankets 4 12.0 3.0 Remove Brackets 4 6.0 1.5 Modify T/R Inner Walls 4 12.0 3.0 Install Brackets 4 8.0 2.0 Install Insulation Blankets 4 16.0 4.0 TOTAL FOR EACH AIRPLANE 54.0 13.5
PART II - Thrust Reverser Blanket Changes Task Number of Persons Man-Hours Elapsed Time (Hours) Modify Insulation Blankets 4 56.0 14.0 TOTAL FOR EACH AIRPLANE 56.0 14.0

Change in Weight Change in Moment (Pounds) (Pound-Inches) +2.0 +1,100.0February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

J. References 1. Existing Data: a. Engineering Change Memo PRR 38394 b. 737-600/-700/-800/-900 Maintenance Manual (AMM) Subjects 32-00-01, 78-31-01, 78-31-13 c. 737-600/-700/-800/-900 Structural Repair Manual (SRM) Chapter 51 d. Boeing Component Maintenance Manual 78-31-37 e. Boeing Standard Overhaul Practices Manual (BSOPM) 20-10-06, 20-30-03, 20-41-04, 20-44-04, 20-50-12, 20-50-19 f. Boeing Service Bulletin 737-78-1063 g. Boeing Service Letter 737-SL-78-042-A h. Boeing Document D6-19567, Service Bulletin Index i. Boeing Drawing 65-88700 j. Darchem Engineering LTD, Document No. BOE 2, On Site Repair of Boeing Commercial Airplane Group Cres Insulation Blankets 2. Data supplied with this Service Bulletin:
None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
None
K. Publications Affected

L. Interchangeability and Intermixability of Parts Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information. Publication Chapter-Section 737 Maintenance Manual 78-31 737 Illustrated Parts Catalog 78-31 Component Maintenance Manual 78-31-37February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BLANK PAGEFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, and Paragraph 2.D., Parts Necessary to Change Spares, as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Send purchase orders and letters about the supply data to the Director of Spares and refer to this service bulletin number. B. Industry Support InformationBoeing warranty remedies are available for 737 airplanes in warranty as of October 7, 1999. For manhour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Product Assurance Contracts. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin number and reference the airplane variable number in your purchase order. C. Parts Necessary For Each Airplane
1. Kits/Parts: To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability. ROLT Unit Price Kit Number Name Date QTY (weeks) 012A0020-1 Top Kit - Thrust Reverser Blanket (a)(c)(e) 3/28/02 5 24 No Charge 012A0020-2 Top Kit - Thrust Reverser Blanket (b)(d) 4/11/01 1 24 No Charge 012A0020-5 Top Kit - Thrust Reverser Blanket (a)(f)(h) 6/15/03 20 24 No Charge 012A0020-6 Supplemental Kit - Thrust Reverser Blanket (a)(g)(h) 6/15/03 20 24 No Charge
(a) This kit is used for Group 1 and Group 2 Airplanes. (b) This kit is used for Group 3 Airplanes. (c) 5 Kits available to ship every other week through 5/12/03 (175 kits total). (d) 5 Kits available to ship every other week through 5/19/02 (175 kits total). (e) Supplemental Kit 012A0020-6 is also necessary with this Top Kit. (f) This kit replaces Top Kit 012A0020-1 plus Supplemental Kit 012A0020-6. (g) This Supplemental Kit, is used with Top Kit 012A0020-1. (h) 20 Kits available to ship every week.February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

Note: One Top Kit is necessary for each airplane
012A0020 KIT - THRUST REVERSER BLANKET -8 -7 -6 -5 -4 -3 -2 -1 Quantity Part Number Name . . . . . . . - 012A0020-1 (a)(b) Top Kit - Thrust Reverser Blanket - Group 1 and 2 Airplanes . . . . . . - . 012A0020-2 (a)(b) Top Kit - Thrust Reverser Blanket - Group 3 Airplanes . . . . . - . 2 012A0020-3 Kit - Engine . . . . - . 2 . 012A0020-4 Kit - Engine . . . - . . . . 012A0020-5 (a)(b) Top Kit - Thrust Reverser Blanket - Group 1 and 2 Airplanes . . - . . . . . 012A0020-6 Supplemental Kit - Thrust Reverser Blanket - Group 1 and 2 Airplanes . - . 2 . . . . 012A0020-7 Kit - Engine - . 2 . . . . . 012A0020-8 Kit - Engine - Supplemental . 1 . . 1 1 . . 315A2140-103 Kit - Upper LH Thrust Reverser . 1 . . 1 1 . . 315A2140-104 Kit - Upper RH Thrust Reverser . 1 . . 1 1 . . 315A2140-105 Kit - Lower LH Thrust Reverser . 1 . . 1 1 . . 315A2140-106 Kit - Lower RH Thrust Reverser . . . . . 1 . . 315A2140-107 Kit - LH Thrust Reverser Inner - Wall Bond Assembly . . . . . 1 . . 315A2140-108 Kit - RH Thrust Reverser Inner - Wall Bond Assembly . . . . 1 . . . 315A2140-109 Kit - LH Thrust Reverser Inner - Wall Bond Assembly . . . . 1 . . . 315A2140-110 Kit - RH Thrust Reverser Inner - Wall Bond Assembly . 1 . . 1 1 . . 315A2140-111 Kit - LH Thrust Reverser - Blanket Installation . 1 . . 1 1 . . 315A2140-112 Kit - RH Thrust Reverser - Blanket Installation 1 . . . . . . . 315A2140-113 Kit Supplemental - LH Thrust Reverser - Blanket Installation 1 . . . . . . . 315A2140-114 Kit Supplemental - RH Thrust Reverser - Blanket Installation . 1 . . . . . . 315A2140-115 Kit - LH Thrust Reverser Inner - Wall Bond Assembly . 1 . . . . . . 315A2140-116 Kit - RH Thrust Reverser Inner - Wall Bond Assembly (a) The kit has more parts than are necessary for installation. Discard parts that are not used or keep the parts for spares. (b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicatedFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

315A2140 SUB KIT - THRUST REVERSER BLANKET -112 -111 -110 -109 -108 -107 -106 -105 -104 -103 Quantity Part Number Name . . . . . . . . . - 315A2140-103 Kit - Upper LH TR Blanket . . . . . . . . - . 315A2140-104 Kit - Upper RH TR Blanket . . . . . . . - . . 315A2140-105 Kit - Lower LH TR Blanket . . . . . . - . . . 315A2140-106 Kit - Lower RH TR Blanket . . . . . - . . . . 315A2140-107 Kit - LH TR Inner Wall Bond Assembly (Group 1 and 2 airplanes) . . . . - . . . . . 315A2140-108 Kit - RH TR Inner Wall Bond Assembly Group 1 and 2 airplanes) . . . - . . . . . . 315A2140-109 Kit - LH TR Inner Wall Bond Assembly (Group 3 airplanes) . . - . . . . . . . 315A2140-110 Kit - RH TR Inner Wall Bond Assembly (Group 3 airplanes) . - . . . . . . . . 315A2140-111 Kit - LH TR Blanket Instl - . . . . . . . . . 315A2140-112 Kit - RH TR Blanket Instl . . . 1 . . . . . . 315A2134-146 Bracket Assembly . . . 1 . . . . . . 315A2134-147 Bracket Assembly . . . 1 . . . . . . 315A2134-148 Bracket Assembly . . 1 . . . . . . . 315A2134-152 Bracket Assembly . . 1 . . . . . . . 315A2134-153 Bracket Assembly . . 1 . . . . . . . 315A2134-154 Bracket Assembly . . . . . . 3 3 7 7 315A2141-1 Grommet . . . . . . 3 3 7 7 315A2141-2 Grommet . . . . . . 2 2 3 3 315A2141-3 Grommet . . . . . . 2 2 3 3 315A2141-4 Grommet . . . . . . 2 2 2 2 315A2141-5 Grommet . . . . . . 2 2 2 2 315A2141-6 Grommet . . . . . . 11 11 7 7 315A2141-7 Washer . . . . . . . . . 1 315A2143-1 Mylar Template . . . . . . . . 1 . 315A2143-2 Mylar TemplateFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

. . . . . . . . . 1 315A2143-3 Mylar Template . . . . . . . . 1 . 315A2143-4 Mylar Template . . . . . . . . . 1 315A2143-5 Mylar Template . . . . . . . . 1 . 315A2143-6 Mylar Template . . . . . . . 1 . . 315A2143-7 Mylar Template . . . . . . 1 . . . 315A2143-8 Mylar Template . . . . . . . 1 . . 315A2143-9 Mylar Template . . . . . . 1 . . . 315A2143-10 Mylar Template . . . . . . . 1 . . 315A2143-11 Mylar Template . . . . . . 1 . . . 315A2143-12 Mylar Template . . . . . . . . . 1 315A2143-13 Mylar Template . . . . . . . . 1 . 315A2143-14 Mylar Template . . . . . . . 1 . . 315A2143-15 Mylar Template . . . . . . 1 . . . 315A2143-16 Mylar Template . . . . . . . 1 . . 315A2143-17 Mylar Template . . . . . . 1 . . . 315A2143-18 Mylar Template . . . . . 1 . . . . 315A2144-5 Bracket Assembly . . . . 1 . . . . . 315A2144-6 Bracket Assembly . . . . . 1 . . . . 315A2144-7 Bracket Assembly . . . . 1 . . . . . 315A2144-8 Bracket Assembly . . . 1 . 1 . . . . 315A2176-2 Foam Block . . . 1 . 1 . . . . 315A2176-3 Foam Block . . 1 . 1 . . . . . 315A2176-4 Foam Block . . 1 . 1 . . . . . 315A2176-5 Foam Block . . 3 3 3 3 . . . . 315A2177-3 Bolt . . . . . . 5 5 3 3 315W1652-1 Washer . . . . . . 2 2 2 2 315W1652-13 Washer . . . . . . 2 2 2 2 315W1652-18 Grommet . . . . . . 5 5 3 3 315W1652-24 Grommet . . . . 2 2 . . . . BACB30NY6K19 Bolt . . . . 4 4 . . . . BACB30NY6K20 Bolt . . . . 15 15 . . . . BACB30NY6K21 Bolt . . . . 11 11 . . . . BACB30NY6K22 Bolt . . . . 4 4 . . . . BACB30NY6K23 Bolt . . . . 1 1 . . . . BACB30NY6K24 Bolt . . . . 1 1 . . . . BACB30NY8K17 Bolt . . 1 1 2 2 . . . . BACB30NY8K18 Bolt 315A2140 SUB KIT - THRUST REVERSER BLANKET -112 -111 -110 -109 -108 -107 -106 -105 -104 -103 Quantity Part Number NameFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

. . 2 2 9 9 . . . . BACB30NY8K19 Bolt . . 10 10 3 3 . . . . BACB30NY8K20 Bolt . . 6 6 3 3 . . . . BACB30NY8K21 Bolt . . 12 12 9 9 . . . . BACB30NY8K22 Bolt . . 1 1 . . . . . . BACB30NY8K22X Bolt . . 17 17 2 2 . . . . BACB30NY8K23 Bolt . . 2 2 . . . . . . BACB30NY8K23X Bolt . . 3 3 1 1 . . . . BACB30NY8K24 Bolt . . 1 1 . . . . . . BACB30NY8K24X Bolt . . 2 2 . . . . . . BACB30NY8K25 Bolt 16 16 . . . . . . . . BACN10YR3C Nut . . . . 20 20 . . . . BACN10YT3CD Nut . . 33 33 18 18 . . . . BACN10YT4CD Nut 10 10 . . . . . . . . BACS12GU3K10 Screw 5 5 . . . . . . . . BACS12GU3K12 Screw 16 16 . . . . . . . . BACS12GU3K16 Screw . . 3 3 3 3 . . . . BACW10EC3C Washer 39 39 . . . . . . . . BACW10P399CD Washer 47 47 3 3 3 3 . . . . BACW10P458CD Washer . . 9 9 9 9 . . . . CB4017C3CRA12R Click Bond Stud Fastener . . 3 3 3 3 . . . . RH30C3NL Nut . . . . . . 2 2 2 2 NAS1398C6A10 Rivet . . . . . . 5 5 3 3 NAS1398C6A12 Rivet 39 39 . . . . . . . . 0090-13365 Nut, Self Locking

315A2140 SUB KIT - THRUST REVERSER BLANKET -116 -115 -114 -113 Quantity Part Number Name . . . - 315A2140-113 Kit - Supplemental - LH TR Blanket Instl . . - . 315A2140-114 Kit - Supplemental - RH TR Blanket Instl . - . . 315A2140-115 Kit - LH TR Blanket Instl - . . . 315A2140-116 Kit - RH TR Blanket Instl 315A2140 SUB KIT - THRUST REVERSER BLANKET -112 -111 -110 -109 -108 -107 -106 -105 -104 -103 Quantity Part Number NameFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

. 1 . 1 315A2134-146 Bracket Assembly 1 . 1 . 315A2134-152 Bracket Assembly . 1 . . 315A2144-5 Bracket Assembly 1 . . . 315A2144-6 Bracket Assembly . 1 . . 315A2144-7 Bracket Assembly 1 . . . 315A2144-8 Bracket Assembly . 1 . . 315A2176-2 Foam Block . 1 . . 315A2176-3 Foam Block 1 . . . 315A2176-4 Foam Block 1 . . . 315A2176-5 Foam Block 3 3 . . 315A2177-3 Bolt 2 2 . . BACB30NY6K19 Bolt 4 4 . . BACB30NY6K20 Bolt 15 15 . . BACB30NY6K21 Bolt 11 11 . . BACB30NY6K22 Bolt 4 4 . . BACB30NY6K23 Bolt 1 1 . . BACB30NY6K24 Bolt 1 1 . . BACB30NY8K17 Bolt 2 2 . . BACB30NY8K18 Bolt 9 9 . . BACB30NY8K19 Bolt 3 3 . . BACB30NY8K20 Bolt 3 3 . . BACB30NY8K21 Bolt 9 9 . . BACB30NY8K22 Bolt 2 2 . . BACB30NY8K23 Bolt 1 1 . . BACB30NY8K24 Bolt 20 20 . . BACN10YT3CD Nut 18 18 . . BACN10YT4CD Nut 3 3 . . BACW10EC3C Washer 3 3 . . BACW10P458CD Washer 9 9 . . CB4017C3CRA12R Click Bond Stud Fastener 3 3 . . RH30C3NL Nut 315A2140 SUB KIT - THRUST REVERSER BLANKET -116 -115 -114 -113 Quantity Part Number NameFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

2. Parts and Materials Supplied by the Operator: QTY Part Number/Specification Name Kit 16 BMS 5-63, Type II, Class B1/2 or B4 (a) Sealant (2.5 Ounce Kit) Quart 1 BMS 5-141 (a) (b) Adhesive Tube 4 RTV 106 (BAC 5010, Type 74 Adhesive) (a) (c) Adhesive (6 Ounce tube) Quart 1 598-5002 or AZ-534-2B (optional) or AZ-634-2 (optional) or Partall Coverall Film (optional) (a) (d) (a) (f) (a) (f) (a) (g) Parting Agent

Kit 1 463-6-4 (a) (e) Aluminized Epoxy Primer (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Dexter Hysol Aerospace Inc. (V33564) 2850 Willow Pass Road PO Box 312 Pittsburg, California 94565-3237 (c) General Electric Company (V01139) Silicon Products Business Department Hudson River Road Waterford, New York 12188 (d) Lilly Industries, Inc. (V17359) 13535 Monster Road South Seattle, Washington 98178 (e) AKZO Nobel Aerospace Coatings (VOKXA5) 1 East Water Street Waukegan, Illinois 60085 (f) Aztec Chemical Inc. (0A3C8) 10770 Lower Azusa Road El Monte, California 91731 (g) Rexco Chemical Company (17629) 879 Davis Drive SE Conyers, Georgia 30094February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

3. Parts Modified and Reidentified: The parts shown below are changed as shown in this service bulletin. Quantity (QTY) is the number of parts changed on each airplane.

4. Parts Removed and Not Replaced:
None.

D. Parts Necessary to Change Spares To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.

E. Special Tooling - Price and Availability The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. The tools are available from the supplier as shown in Paragraph 2.F. Tool price and supply data are not given. Existing Part Number QTY Name New Part Number Notes S315A213-43 2 Insulation Blanket, Upper LH S315A213-49 (a) (b) (e) S315A213-44 2 Insulation Blanket, Upper RH S315A213-50 (a) (b) (e) S315A213-45 2 Insulation Blanket, Lower LH S315A213-51 (a) (b) (e) S315A213-46 2 Insulation Blanket, Lower RH S315A213-52 (a) (b) (e) (a) Make the change given in this service bulletin. (b) The function, fit, and dimensions of the changed part and the new part are equivalent but not fully the same. (c) This is the part number after the change given in this service bulletin. (d) The operator can use the new part number to identify the changed part. (e) Do not use the existing part to replace the new or changed part..

QTY Part Number Name 1 012A0020-7 Kit - Engine 1 315A2140-103 Kit - Upper LH Thrust Reverser Blanket 1 315A2140-104 Kit - Upper RH Thrust Reverser Blanket 1 315A2140-105 Kit - Lower LH Thrust Reverser Blanket 1 315A2140-106 Kit - Lower RH Thrust Reverser BlanketFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

F. Special Tooling Necessary to do this Service Bulletin To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available.

Tool Number Name Notes T-29057-301 Grommet Setting Tool, Full Diameter 0.340 Inch Inside Diameter T-29057-305 (optional to -301) Grommet Setting Tool, 1/4 Diameter 0.340 Inch Inside Diameter T-29058-301 Grommet Setting Tool, Full Diameter 0.460 Inch Inside Diameter T-29058-305 (optional to -301) Grommet Setting Tool, 1/4 Diameter 0.460 Inch Inside Diameter Hi Temp Insulation Inc. (V25167) 4700 Calle Alto Camarillo, Ca 93012February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BLANK PAGEFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

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 two parts. Part I gives instructions to remove the insulation blankets, make a modification to the inner walls of each thrust reverser half and install changed insulation blankets on each thrust reverser half. Part II gives instructions for the rework of the insulation blankets for the thrust reverser halves. It is not necessary to rework the existing insulation blankets if operators get the new type insulation blankets (with more grommets). 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. — Torque limits to tighten nuts and bolts are given in 737 Structural Repair Manual, Chapter 51. 5. For approved fastener and process material substitutions, refer to 737 Structural Repair Manual, Chapter 51, Alternate fasteners are given in 737 Structural Repair Manual 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.
B. WORK INSTRUCTIONS Part I - All Airplane Groups - Remove the insulation blankets from the thrust reverser halves, make a modification to the inner wall of each thrust reverser half. Install the insulation blankets on each thrust reverser half. 1. Make sure the landing gear ground lock pins are installed. Refer to 737-600/700/800/900 AMM 32-00-01.February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

2. Make sure that the wheel chocks for the main landing gear are in place.
WARNING: DO THESE SPECIFIED TASKS IN THE CORRECT SEQUENCE BEFORE YOU OPEN THE THRUST REVERSER: RETRACT THE LEADING EDGE, DO THE DEACTIVATION PROCEDURES FOR THE LEADING EDGE AND THE THRUST REVERSER (FOR GROUND MAINTENANCE), AND OPEN THE FAN COWL PANELS. IF YOU DO NOT OBEY THE ABOVE SEQUENCE, INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR. 3. Open the number 1 and number 2 engine thrust reversers. Refer to 737-600/700/800/900 AMM 78-31-00. 4. Make a decision to remove or not to remove the number 1 and number 2 engine thrust reversers.
Note: It is not necessary to remove the thrust reversers but access will be better if the thrust reversers are removed. 5. Remove the upper and lower insulation blankets from each thrust reverser half. Refer to 737-600/700/800/900 AMM 78-31-13 and Figure 1.
Note: Remove the upper insulation blanket then remove the lower insulation blanket on each thrust reverser half. Be careful not to damage the insulation blankets because the same blankets will be installed after they are modified. 6. Remove and discard the attachment brackets for the blankets from the forward edge of each bonded panel assembly. Group 1 and 2 airplanes refer to Figure 2. Group 3 airplanes refer to Figure 4. 7. Install 2 new brackets and 1 foam block on the forward edge of the upper blanket on each thrust reverser half. Install 1 new bracket and 1 foam block on the forward edge of the lower blanket on each thrust reverser half. Group 1 and 2 airplanes refer to Figure 3. Group 3 airplanes refer to Figure 5. 8. Change the insulation blankets. Add more fastener grommets and new skin grommets. Refer to Part II Work Instructions.
Note: Operators can make the changes to the insulation blankets given in Part II, or as an option, new type insulation blankets (with more grommets) can be installed. 9. Use the added fastener grommet holes in the changed or new insulation blankets as a template and transfer (mark) each new grommet hole location on the inner wall of each thrust reverser half. Install 2 stud bolts and 8 new click bond stud fasteners on the inner wall of each half of each thrust reverser. Refer to Figure 8 and Appendix B. 10. Install the changed insulation blankets on the inner wall of the thrust reversers. Seal the leading edge of each blanket on each thrust reverser half with BMS 5-63 sealant. Refer to Figure 9 and 737-600/700/800/900 AMM 78-31-13.
Note: Install the lower insulation blanket then install the upper insulation blanket on each thrust reverser half.
WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO CLOSE THE THRUST REVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TOFebruary 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR. 11. If the thrust reversers for the number 1 and number 2 engines were removed, install the thrust reversers. Refer to 737-600/700/800/900 AMM 78-31-01. 12. Close the number 1 and number 2 engine thrust reversers. Refer to 737-600/700/800/900 AMM 78-31-00. 13. If the thrust reversers for the number 1 and number 2 engines were removed, do the Thrust Reverser Normal Operation Test. Refer to 737-600/700/800/900 AMM 78-31-01. 14. Put the airplane back to a serviceable condition.

Part II - All Airplane Groups - Make a modification to the LH and RH upper and lower insulation blankets for each thrust reverser half.
CAUTION: USE BREATHING AND EYE PROTECTION WHEN HOLES ARE MADE AND GROMMETS ARE INSTALLED IN INSULATION BLANKETS. WEAR APPROVED DUST MASK TO AVOID BREATHING DUST AND FIBER PARTICLES AND WEAR SAFETY GLASSES. 1. Use mylar templates contained in kits to locate, mark, make holes for and install 9 more fastener grommets in each upper insulation blanket and 4 more fastener grommets in each lower insulation blanket. Refer to Figure 6 and Figure 10.
Note: Replace insulation blankets that are damaged more than the repair limits. Refer to 737-600/700/800/900 AMM 78-31-13. 2. Use mylar templates contained in kits to locate, mark, make holes for and install 3 skin grommets in each upper insulation blanket and 5 skin grommets in each lower insulation blanket. Refer to Figure 7, Figure 10 and Appendix A.FIGURE 1: THRUST REVERSER INSULATION BLANKET REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 1: THRUST REVERSER INSULATION BLANKET REMOVAL



### LEFT SIDE SHOWN, RIGHT SIDE SIMILAR 27 PLACES

FWD THRUST REVERSER

8

3

6 6

6

5

5 5

4 4 4 1 1

1 7 4 3 1 1 2V39529

(SHEET 1 OF 2)FIGURE 1: THRUST REVERSER INSULATION BLANKET REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.
STEP TASK NAME PART NUMBER QTY NOTES 1 Cut / Remove Adhesive (Silicone) RTV106 - From the gap between the compression pad and blanket cutout, 6 places. 2 Remove / Discard Nut 0090-13365 27 Washer 315W1163-54 27 3 Remove / Discard Screw BACS12GU3K10 6 Washer 315W1163-26 6 4 Remove / Discard Screw BACS12GU3K12 4 Washer 315W1163-26 4 5 Remove / Discard Nut BACN10YR3C 14 Washer 315W1163-26 14 6 Remove / Discard Screw BACS12GU3K16 14 Washer 315W1163-26 14 7 Remove / Keep Upper Insulation Blanket (Left Side) S315A213-43 1 Refer to 737-600/700/800/900 AMM 78-31-13. Upper Insulation Blanket (Right Side) S315A213-44 1

Note: Remove the upper insulation blanket then remove the lower insulation blanket. Take care not to damage blanket. 8 Remove / Keep Lower Insulation Blanket (Left Side) S315A213-45 1 Refer to 737-600/700/800/900 AMM 78-31-13. Lower Insulation Blanket (Right Side) S315A213-46 1

Note: Remove the upper insulation blanket then remove the lower insulation blanket. Take care not to damage blanket.

(SHEET 2 OF 2)FIGURE 2: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 2: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL



### LEFT SIDE SHOWN, RIGHT SIDE SIMILAR BRACKET SUPPORT

FWD THRUST REVERSER

SEE AV39530

(SHEET 1 OF 4)FIGURE 2: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BOLT, NUT BOLT, NUT BOLT, NUT

BOLT, NUT NAC STA 204.5650

BOLT, NUT

BOLT, NUT (2 PLACES) BOLT, NUT (2 PLACES)

ASSEMBLY BRACKET

ASSEMBLY BRACKET

BOLT, NUT BOLT, NUT BOLT, NUT BOLT, NUT ASSEMBLY BRACKET

V-BLADE SEAL ASSEMBLY BRACKET

10 15 7 14

9 8 7 5 13 1 12



### A 11 10 2

5
4

6 1

3V39586

(SHEET 2 OF 4)FIGURE 2: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.
STEP TASK NAME PART NUMBER QTY NOTES 1 Remove / Discard Bolt BACB30NY8K20 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 2 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 3 Remove / Discard Bolt BACB30NY6K21 3 Nut BACN10YT3CD 3 4 Remove / Discard Bolt BACB30NY6K21 2 Nut BACN10YT3CD 2 5 Remove / Discard Bolt BACB30NY8K20 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 6 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 7 Remove / Discard Bolt BACB30NY8K20 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 8 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 9 Remove / Discard Bolt BACB30NY6K21 2 Nut BACN10YT3CD 2 10 Remove / Discard Bolt BACB30NY8K20 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 11 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 12 Install Bolt BACB30NY8K19 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 13 Install Bolt BACB30NY8K19 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds.

(SHEET 3 OF 4)FIGURE 2: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

a. If necessary, use bolts with grip lengths one or two sizes longer or shorter to make allowance for different thickness of the inner wall material. 14 Install Bolt BACB30NY8K19 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 15 Install Bolt BACB30NY8K19 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds.

(SHEET 4 OF 4)FIGURE 3: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 3: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT



### LEFT SIDE SHOWN, RIGHT SIDE SIMILAR BRACKET SUPPORT

FWD SEE AV39621 THRUST REVERSER

(SHEET 1 OF 4)FIGURE 3: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

(3 PLACES)

BOLT, NUT (2 PLACES) BOLT, NUT (2 PLACES) BOLT, NUT (2 PLACES) BOLT, NUT

(2 PLACES)

BOLT, NUT (2 PLACES) BOLT, NUT (2 PLACES) BOLT, NUT FOAM BLOCK

FOAM BLOCK

ASSEMBLY BRACKET ASSEMBLY BRACKET

V-BLADE SEAL ASSEMBLY BRACKET NAC STA 204.5650

FWD 7 6 5 4 3 2

5 2

8

9 1

1



### AV39627

(SHEET 2 OF 4)FIGURE 3: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.

STEP TASK NAME PART NUMBER QTY NOTES 1 Install Bracket Assembly 315A2134-146 1 Left thrust reverser half Bracket Assembly 315A2134-152 1 Right thrust reverser half Bolt, Upper BACB30NY8K21(a)(b) 1 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Bolt, Lower BACB30NY8K22 (a) 1 Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. Note: 1. Install bracket flush with V-Blade. 2. Apply BMS 5-63 fay surface seal between bracket and inner V-Blade. Refer to SOPM 20-50-19. 2 Install Bracket Assembly 315A2144-7 1 Left thrust reverser half 315A2144-8 1 Right thrust reverser half Bolt BACB30NY6K22 (a) 3 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT3CD 3 Torque to 25-35 Inch Pounds. Note: 1. Install bracket flush with V-Blade. 2. Apply BMS 5-63 fay surface seal between bracket and inner V-Blade. Refer to SOPM 20-50-19. 3 Install Bolt BACB30NY6K22 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT3CD 2 Torque to 25-35 Inch Pounds. 4 Install Bolt BACB30NY8K22 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 5 Install Bracket Assembly 315A2144-5 1 Left thrust reverser half 315A2144-6 1 Right thrust reverser half Bolt BACB30NY8K22 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. Note: 1. Install bracket flush with V-Blade. 2. Apply BMS 5-63 fay surface seal between bracket and inner V-Blade. Refer to SOPM 20-50-19. 6 Install Bolt BACB30NY6K22 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT3CD 2 Torque to 25-35 Inch Pounds.

(SHEET 3 OF 4)FIGURE 3: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

a. If necessary, use bolts with grip lengths one or two sizes longer or shorter to make allowance for different thickness of the inner wall material. b. Make sure that the complete chamfer of the bolt extends past the surface of the nut. If the chamfer does not extend past the surface of the nut, use a bolt one size longer. It is permitted for the bracket tab to contact bolt threads up to .010 inch interference.

7 Install Bolt, Upper BACB30NY8K22 (a) 1 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Bolt, Lower BACB30NY8K21(a)(b) 1 Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 8 Bond Foam Block 315A2176-2 1 Left thrust reverser half. 315A2176-4 1 Right thrust reverser half. Note: Bond foam block to inner wall and mating edge of V-Blade and bracket. Use RTV 106 (BAC 5010, Type 74 adhesive, refer to SOPM 20-50-12) or BAC 5010, Type 68 adhesive. BMS 5-63 sealant can be used as an alternative. Refer to SOPM 20-50-19. 9 Bond Foam Block 315A2176-3 1 Left thrust reverser half. 315A2176-5 1 Right thrust reverser half. Note: Bond foam block to inner wall and mating edge of V-Blade and bracket. Use RTV 106 (BAC 5010, Type 74 adhesive, refer to SOPM 20-50-12) or BAC 5010, Type 68 adhesive. BMS 5-63 sealant can be used as an alternative. Refer to SOPM 20-50-19.

(SHEET 4 OF 4)FIGURE 4: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 4: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL



### LEFT SIDE SHOWN, RIGHT SIDE SIMILAR BRACKET SUPPORT

FWD SEE AV39587 THRUST REVERSER

(SHEET 1 OF 4)FIGURE 4: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

ASSEMBLY BRACKET BOLT, NUT BOLT, NUT

BOLT, NUT BOLT, NUT BOLT, NUT

BOLT, NUT BOLT, NUT PIN, SLEEVE, COLLAR

BOLT, NUT BOLT, NUT NAC STA 204.5650

BOLT, NUT (2 PLACES) BOLT, NUT (2 PLACES)

ASSEMBLY BRACKET ASSEMBLY BRACKET

V-BLADE SEAL ASSEMBLY BRACKET

10 10 17 9 8 7 16 5 15 13 12 1 14



### A 11 7 2

5
4

6 1

3V39590

(SHEET 2 OF 4)FIGURE 4: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.
STEP TASK NAME PART NUMBER QTY NOTES 1 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 2 Remove / Discard Bolt BACB30NY8K22 2 Nut BACN10YT4CD 2 3 Remove / Discard Bolt BACB30NY8K22 1 Nut BACN10YT4CD 1 4 Remove / Discard Bolt BACB30NY8K22 2 Nut BACN10YT4CD 2 5 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 6 Remove / Discard Bolt BACB30NY8K22 2 Nut BACN10YT4CD 2 7 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 8 Remove / Discard Bolt BACB30NY8K22 2 Nut BACN10YT4CD 2 9 Remove / Discard Bolt BACB30NY8K22 2 Nut BACN10YT4CD 2 10 Remove / Discard Bolt BACB30NY8K21 2 Nut BACN10YT4CD 2 Bracket Assembly 315A2134-13 1 11 Remove / Discard Bolt BACB30NY8K22 2 Nut BACN10YT4CD 2 12 Remove / Drill Pin ASPFF-V08-21AC 1 Remove the flush head positive lock fastener. Sleeve ASPF-S-V08AC 1 Lock Collar ASP-LC-MV08 1 Note: Use a 0.1875 inch diameter drill with a drill bushing (HUCK part number 103618) or equivalent. Drill 1/16 (0.0625) inch deep into the sleeve to get to the lock collar. Pick out the lock collar from the sleeve lock pocket then unthread the sleeve from the pin for removal. 13 Drill / Ream Hole - 1 Use a 0.266 - 0.270 inch diameter drill to make the hole larger.

(SHEET 3 OF 4)FIGURE 4: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

a. If necessary, use bolts with grip lengths one or two sizes longer or shorter to make allowance for different thickness of the inner wall material. 14 Install Bolt BACB30NY8K20 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 15 Install Bolt BACB30NY8K20 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 16 Install Bolt BACB30NY8K20 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 17 Install Bolt BACB30NY8K20 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds.

(SHEET 4 OF 4)FIGURE 5: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 5: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT



### LEFT SIDE SHOWN, RIGHT SIDE SIMILAR BRACKET SUPPORT

FWD SEE AV39629 THRUST REVERSER

(SHEET 1 OF 4)FIGURE 5: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BOLT, NUT (2 PLACES) (2 PLACES) BOLT, NUT

BOLT, NUT (2 PLACES) REPAIR WASHER (2 PLACES) BOLT, NUT

(2 PLACES) BOLT, NUT

BOLT, NUT (2 PLACES) BOLT, NUT (2 PLACES)

FOAM BLOCK

FOAM BLOCK

ASSEMBLY BRACKET ASSEMBLY BRACKET

V-BLADE SEAL ASSEMBLY BRACKET NAC STA 204.5650

3

FWD 7 6

8 2 1

3

5 4

10

6 9 1



### AV39630

(SHEET 2 OF 4)FIGURE 5: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.
STEP TASK NAME PART NUMBER QTY NOTES 1 Install Bracket Assembly 315A2134-146 1 Left thrust reverser half. Bracket Assembly 315A2134-152 1 Right thrust reverser half. Bolt, Upper BACB30NY8K22 (a)(b) 1 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Bolt, Lower BACB30NY8K23 (a) 1 Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. Note: 1. Install bracket flush with V-Blade. 2. Apply BMS 5-63 fay surface seal between bracket and inner V-Blade. Refer to SOPM 20-50-19. 2 Make / Install Repair Washer - 1 Used to fill upper bolt countersink on inside surface of inner wall, install before bracket is installed. Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Refer to 737-600/-700/-800/-900 SRM 51-40-08 to make repair washer. 3 Install Bracket Assembly 315A2134-147 1 Left thrust reverser half. 315A2134-153 1 Right thrust reverser half. Bolt, Upper BACB30NY8K23X (a) 1 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Bolt, Lower BACB30NY8K23 (a) 1 Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. Note: 1. Install bracket flush with V-Blade. 2. Apply BMS 5-63 fay surface seal between bracket and inner V-Blade. Refer to SOPM 20-50-19. 4 Install Bolt BACB30NY8K23 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 5 Install Bolt BACB30NY8K23 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 6 Install Bracket Assembly 315A2134-148 1 Left thrust reverser half 315A2134-154 1 Right thrust reverser half Bolt BACB30NY8K23 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. Note: 1. Install bracket flush with V-Blade. 2. Apply BMS 5-63 fay surface seal between bracket and inner V-Blade. Refer to SOPM 20-50-19

(SHEET 3 OF 4)FIGURE 5: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

a. If necessary, use bolts with grip lengths one or two sizes longer or shorter to make allowance for different thickness of the inner wall material. b. Make sure that the complete chamfer of the bolt extends past the surface of the nut. If the chamfer does not extend past the surface of the nut, use a bolt one size longer. It is permitted for the bracket tab to contact bolt threads up to .010 inch interference. 7 Install Bolt BACB30NY8K23 (a) 2 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 8 Install Bolt, Upper BACB30NY8K23 (a) 1 Install wet with BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Bolt, Lower BACB30NY8K22 (a)(b) 1 Nut BACN10YT4CD 2 Torque to 50-70 Inch Pounds. 9 Bond Foam Block 315A2176-2 1 Left thrust reverser half. 315A2176-4 1 Right thrust reverser half. Note: Bond foam block to inner wall and mating edge of V-Blade and bracket. Use RTV 106 (BAC 5010, Type 74 adhesive, refer to SOPM 20-50-12) or BAC 5010, Type 68 adhesive. BMS 5-63 sealant can be used as an alternative. Refer to SOPM 20-50-19. 10 Bond Foam Block 315A2176-3 1 Left thrust reverser half. 315A2176-5 1 Right thrust reverser half. Note: Bond foam block to inner wall and mating edge of V-Blade and bracket. Use RTV 106 (BAC 5010, Type 74 adhesive, refer to SOPM 20-50-12) or BAC 5010, Type 68 adhesive. BMS 5-63 sealant can be used as an alternative. Refer to SOPM 20-50-19.

(SHEET 4 OF 4)FIGURE 6: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET FASTENER GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 6: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET FASTENER GROMMET ADDITION

TYPICAL GROMMET INSTALLATION 

### A-A

(BLANKET COLD SIDE) LEFT SIDE SHOWN, RIGHT SIDE SIMILAR MYLAR

MYLAR MYLAR MYLAR

MYLAR MYLAR

A A THRUST REVERSER

FWD 13 12 9

8 10 11 3

2

5 1 7 6

4 HOT SIDE COLD SIDE

GROMMET

0.50

BLANKET INSULATIONV39597

(SHEET 1 OF 4)FIGURE 6: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET FASTENER GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.

STEP TASK NAME PART NUMBER QTY NOTES 1 Position / Mark Mylar Template 315A2143-1 1 Put template on COLD side of S315A213-43, left upper insulation blanket. 315A2143-2 1 Put template on COLD side of S315A213-44, right upper insulation blanket. 2 Make Hole - 2 See a. Install Grommet 315A2141-3 2 Install on HOT side of blanket. 315A2141-4 2 Install on COLD side of blanket. Note: Maximum height of grommets not more than 0.205 inch. 3 Position / Mark Mylar Template 315A2143-3 1 Put template on COLD side of S315A213-43, left upper insulation blanket. 315A2143-4 1 Put template on COLD side of S315A213-44 right, upper insulation blanket. 4 Make Hole - 2 See a. Install Grommet 315A2141-1 2 Install on HOT side of blanket. 315A2141-2 2 Install on COLD side of blanket. Note: Maximum height of grommets not more than 0.455 inch. 5 Make Hole - 1 See a. Install Grommet 315A2141-5 1 Install on HOT side of blanket. 315A2141-6 1 Install on COLD side of blanket. Note: Maximum height of grommets not more than 0.330 inch. 6 Position / Mark Mylar Template 315A2143-5 1 Put template on COLD side of S315A213-43, left upper insulation blanket. 315A2143-6 1 Put template on COLD side of S315A213-44, right upper insulation blanket. 7 Make Hole - 4 See a. Install Grommet 315A2141-1 4 Install on HOT side of blanket. 315A2141-2 4 Install on COLD side of blanket. Note: Maximum height of grommets not more than 0.455 inch. 8 Position / Mark Mylar Template 315A2143-7 1 Put template on COLD side of S315A213-45, left lower insulation blanket. 315A2143-8 1 Put template on COLD side of S315A213-46, right lower insulation blanket.

(SHEET 2 OF 4)FIGURE 6: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET FASTENER GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

a. Fastener Grommet Installation Instructions: 1. Use a piece of 5/8 inch (0.625) diameter (size 10) thin wall tubing (or equivalent), chamfer the inside wall of tube 45 degrees and use a plastic or a wood drill guide to make the holes for the grommets. Refer to Figure 10. 2. Use the tubing and the drill guide and carefully drill a 5/8 (0.625-0.875) inch diameter hole for each grommet through the S315A213-43/-44 left and right upper blanket or S315A213-45/-46 left and right lower blanket. 3. If Rulon-J bondable tape is installed in the location for the grommets, carefully cut and remove sufficient Rulon-J to let the flange of the grommet touch the skin surface of the blanket. Apply BMS 5-63 sealant to edge of Rulon-J where cutout is made for grommet installation. 4. Make sure there are no cuts, tears or cracks in the metal skin of the blanket that extend beyond the flange of the grommet. Refer to Permanent Repair Procedure in Vendor CMM (Darchem Engineering, Document No. BOE 2) to repair tears or cracks in the metal skin of the blanket. 5. Apply a layer of BMS 5-63 sealant to grommets, shank and face of flange that will be in contact with blanket. Refer to SOPM 20-50-19.

9 Make Hole - 1 See a. Install Grommet 315A2141-3 1 Install on HOT side of blanket. 315A2141-4 1 Install on COLD side of blanket. Note: Maximum height of grommets not more than 0.205 inch. 10 Position / Mark Mylar Template 315A2143-9 1 Put template on COLD side of S315A213-45, left lower insulation blanket. 315A2143-10 1 Put template on COLD side of S315A213-46, right lower insulation blanket. 11 Make Hole - 1 See a. Install Grommet 315A2141-5 1 Install on HOT side of blanket. 315A2141-6 1 Install on COLD side of blanket. Note: Maximum height of grommets not more than 0.330 inch. 12 Position / Mark Mylar Template 315A2143-11 1 Put template on COLD side of S315A213-45, left lower insulation blanket. 315A2143-12 1 Put template on COLD side of S315A213-46, right lower insulation blanket. 13 Make Hole - 2 See a. Install Grommet 315A2141-1 2 Install on HOT side of blanket. 315A2141-2 2 Install on COLD side of blanket. Note: Maximum height of grommets not more than 0.455 inch.

(SHEET 3 OF 4)FIGURE 6: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET FASTENER GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

6. Insert grommet parts as shown. Make sure that grommet height is not more than the maximum grommet height given below. Make sure to keep the correct grommet height while the sealant cures.

7. Make sure BMS 5-63 sealant is visible fully around the grommet after installation. 8. Make sure the grommet does not puncture or cut the metal skin of the blanket. NAME PART NUMBER POSITION MAXIMUM GROMMET HEIGHT Fastener Grommet 315A2141-1 Hot Side 0.455 Inch 315A2141-2 Cold Side Fastener Grommet 315A2141-3 Hot Side 0.205 Inch 315A2141-4 Cold Side Fastener Grommet 315A2141-5 Hot Side 0.330 Inch 315A2141-6 Cold Side

(SHEET 4 OF 4)FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 62 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION



### (BLANKET COLD SIDE) LEFT SIDE SHOWN, RIGHT SIDE SIMILAR MYLAR 

### A-A TYPICAL SKIN GROMMET INSTALLATION BLANKET INSULATION WASHER COLD SIDE SEALANT GROMMET

HOT SIDE RIVET

A A REVERSER THRUST

FWD 10 9 6 8 7

11
13 12 1 5 4 3 2

15 14 13 11 8 3 5

3 13 11 8 5V39619

(SHEET 1 OF 5)FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.

STEP TASK NAME PART NUMBER QTY NOTES 1 Position / Mark Mylar Template 315A2143-13 1 Put template on COLD side of S315A213-43, left upper insulation blanket. 315A2143-14 1 Put template on COLD side of S315A213-44, right upper insulation blanket. 2 Make Hole - 2 See a. Install Washer 315W1652-1 2 Install on COLD side of blanket. Grommet 315W1652-24 2 Install on HOT side of blanket. Note: Maximum grommet height not more than 0.580 inch. 3 Install Washer 315A2141-7 4 See c. Rivet NAS1398C6A12 2 Put rivet head on HOT side of blanket. 4 Make Hole - 1 See b. Install Washer 315W1652-13 1 Install on COLD side of blanket. Grommet 315W1652-18 1 Install on HOT side of blanket. Note: 1. If necessary move skin grommet location forward or aft approximately 3 inches to miss blanket identification plate or blanket stiffener. 2. Maximum grommet height not more than 0.455 inch. 5 Install Washer 315A2141-7 2 See c. Rivet NAS1398C6A10 1 Put rivet head on HOT side of blanket. 6 Position / Mark Mylar Template 315A2143-15 1 Put template on COLD side of S315A213-45, left lower insulation blanket. 315A2143-16 1 Put template on COLD side of S315A213-46, right lower insulation blanket. 7 Make Hole - 2 See a. Install Washer 315W1652-1 2 Install on COLD side of blanket. Grommet 315W1652-24 2 Install on HOT side of blanket. Note: Maximum grommet height not more than 0.580 inch. 8 Install Washer 315A2141-7 4 See c. Rivet NAS1398C6A12 2 Put rivet head on HOT side of blanket.

(SHEET 2 OF 5)FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

a. Skin Grommet Installation Instructions: 1. Use a piece of 1/2 inch (0.500) diameter (size 8) thin wall tubing (or equivalent), chamfer the inside wall of tube 45 degrees and use a plastic or a wood drill guide to make the holes for the grommets. Refer to Figure 10. 2. Use the tubing and the drill guide and carefully drill a 1/2 inch (0.50-0.610) inch diameter hole for grommet through the S315A213-43/-44 left and right upper blanket or S315A213-45/-46 left and right lower blanket. 3. Make sure there are no cuts, tears or cracks in the metal skin of the blanket that extend beyond the flange of the grommet. Refer to Permanent Repair Procedure in Vendor CMM (Darchem Engineering, Document No. BOE 2) to repair tears or cracks in the metal skin of the blanket. 4. Apply a layer of BMS 5-63 sealant to underside of grommet flange, shank and the face of the washer that will be against the blanket. Refer to SOPM 20-50-19.
Note: Refer to Appendix A for Skin Grommet Installation Tool Set-up.

9 Make Hole - 1 See b. Install Washer 315W1652-13 1 Install on COLD side of blanket. Grommet 315W1652-18 1 Install on HOT side of blanket. Note: 1. If necessary move skin grommet location forward or aft approximately 3 inches to miss blanket identification plate or blanket stiffener. 2. Maximum grommet height not more than 0.455 inch. 10 Install Washer 315A2141-7 2 See c. Rivet NAS1398C6A10 1 Put rivet head on HOT side of blanket. 11 Position / Mark Mylar Template 315A2143-17 1 Put template on COLD side of S315A213-45, left lower insulation blanket. 315A2143-18 1 Put template on COLD side of S315A213-46, right lower insulation blanket. 12 Make Hole - 2 See a. Install Washer 315W1652-1 2 Install on COLD side of blanket. Grommet 315W1652-24 2 Install on HOT side of blanket. Note: Maximum grommet height not more than 0.580 inch. 13 Install Washer 315A2141-7 4 See c. Rivet NAS1398C6A12 2 Put rivet head on HOT side of blanket. 14 Part Mark Blanket, Upper S315A213-49 1 After left blanket is reworked. S315A213-50 1 After right blanket is reworked. 15 Part Mark Blanket, Lower S315A213-51 1 After left blanket is reworked. S315A213-52 1 After right blanket is reworked.

(SHEET 3 OF 5)FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

5. Insert grommet from hot side, put washer over shank (make sure the grooved face of washer is up). Use setting tool (T-29058-301or equivalent) strike tool with hammer. 6. Make sure grommet shank is rolled over the washer all the way. 7. Make sure there are no visual cracks in the grommet shank. 8. Make sure BMS 5-63 sealant is visible fully around the grommet and washer. 9. Make sure that 315W1652-24 grommet and 315W1652-1 washer height is not more than the maximum blanket thickness of 0.580 inch. 10. Make sure the grommet does not puncture or cut the metal skin of the blanket.

b. Skin Grommet Installation Instructions: 1. Use a piece of 3/8 inch (0.375) diameter (size 6) thin wall tubing (or equivalent), chamfer the inside wall of tube 45 degrees and use a plastic or a wood drill guide to make the holes for the grommets. Refer to Figure 10. 2. Use the tubing and the drill guide and carefully drill a 3/8 (0.375-0.500) inch diameter hole for grommet through the S315A213-43/-44 left and right upper blanket or S315A213-45/-46 left and right lower blanket. 3. Make sure there are no cuts, tears or cracks in the metal skin of the blanket that extend beyond the flange of the grommet. Refer to Permanent Repair Procedure in Vendor CMM (Darchem Engineering, Document No. BOE 2) to repair tears or cracks in the metal skin of the blanket. 4. Apply a layer of BMS 5-63 sealant to underside of grommet flange, shank and the face of the washer that will be against the blanket. Refer to SOPM 20-50-19.
Note: Refer to Appendix A for Skin Grommet Installation Tool Set-up.

5. Insert grommet from hot side, put washer over shank (make sure the grooved face of washer is up). Use setting tool (T-29057-301or equivalent) strike tool with hammer. 6. Make sure grommet shank is rolled over the washer all the way. 7. Make sure there are no visual cracks in the grommet shank. 8. Make sure BMS 5-63 sealant is visible fully around the grommet and washer. 9. Make sure that 315W1652-18 grommet and 315W1652-13 washer height is not more than the maximum blanket thickness of 0.455 inch. 10. Make sure the grommet does not puncture or cut the metal skin of the blanket.

(SHEET 4 OF 5)FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

c. Skin Grommet Washer and Rivet Installation Instructions: 1. Fill grommet holes and under washers with BMS 5-63 sealant. Refer to SOPM 20-50-19. 2. After BMS 5-63 sealant is cured, drill a 0.192-0.196 inch hole through center of sealant. 3. Install a washer on each side of the grommet and install the rivet. Make sure rivet head is correctly formed. 4. Apply a layer of RTV 106 adhesive (BAC 5010, Type 74 adhesive) (BMS 5-63 sealant optional) to the cold side of rivet head and washer. Minimum thickness of RTV 106 or BMS 5-63 layer over cold side of rivet is 0.05 inch. Refer to SOPM 20-50-12 (RTV 106) or SOPM 20-50-19 (BMS 5-63).

(SHEET 5 OF 5)FIGURE 8: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SUPPORT ATTACHMENTS - STUD BOLT AND CLICK-BOND ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 67 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 8: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SUPPORT ATTACHMENTS - STUD BOLT AND CLICK-BOND ADDITION



### LEFT SIDE SHOWN, RIGHT SIDE SIMILAR FWD SEE A 10 7 8 9 3 5 2

6 1 12 11 4 SEE B

12 11 4 SEE BV39632 THRUST REVERSER

(SHEET 1 OF 4)FIGURE 8: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SUPPORT ATTACHMENTS - STUD BOLT AND CLICK-BOND ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 68 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

BOLT
NUT
WASHER

INNER WALL BONDED PANEL ASSEMBLY, 8

10 9 (NON-PERFORATED SURFACE)

(PERFORATED SURFACE)

BONDED PANEL ASSEMBLY,

OUTER WALL

INNER WALL



### A

B 12

11V39634

(SHEET 2 OF 4)FIGURE 8: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SUPPORT ATTACHMENTS - STUD BOLT AND CLICK-BOND ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 69 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.

STEP TASK NAME PART NUMBER QTY NOTES 1 Position Insulation Blanket, Lower S315A213-51 1 Temporarily install reworked blanket on left bonded panel assembly. S315A213-52 1 Temporarily install reworked blanket on right bonded panel assembly. Note: 1. Install the lower insulation blanket before upper blanket is installed. 2. Use reworked insulation blanket or a new blanket as a template and transfer (mark) the location of added blanket attachment grommets onto bonded panel assembly, fan duct inner wall. 2 Position Insulation Blanket, Upper S315A213-49 1 Temporarily install reworked blanket on left bonded panel assembly. S315A213-50 1 Temporarily install reworked blanket on right bonded panel assembly. Note: 1. Make sure that the lower edge of the upper blanket overlaps the upper edge of the lower blanket. 2. Use reworked insulation blanket or a new blanket as a template and transfer (mark) the location of added blanket attachment grommets onto bonded panel assembly, fan duct inner wall. 3 Mark Hole Location - 2 On left bonded panel 315A2101-41 (inner wall) for stud bolt installation. - 2 On right bonded panel 315A2102-41 (inner wall) for stud bolt installation. 4 Mark Hole Location - 8 On left bonded panel 315A2101-41 (inner wall) for bonded stud (Click Bond) installation. - 8 On right bonded panel 315A2102-41for bonded stud (Click Bond) installation. 5 Remove / Keep Insulation Blanket, Upper S315A213-49 1 From left bonded panel assembly. S315A213-50 1 From right bonded panel assembly. 6 Remove / Keep Insulation Blanket, Lower S315A213-51 1 From left bonded panel assembly. S315A213-52 1 From right bonded panel assembly. 7 Drill / Countersink Hole (full size) - 2 Through left bonded panel 315A2101-41 (inner wall) for upper and lower stud bolts. - 2 Through right bonded panel 315A2102-41 (inner wall) for upper and lower stud bolts. Note: Make hole 0.190-0.194 inch diameter, counter sink 100 degrees, 0.35-0.36 inch deep.

(SHEET 3 OF 4)FIGURE 8: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SUPPORT ATTACHMENTS - STUD BOLT AND CLICK-BOND ADDITION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 70 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

8 Install Bolt, Stud 315A2177-3 2 Install bolt wet, use BMS 5-63 sealant. Refer to SOPM 20-50-19, Method 3. Washer BACW10P458CD 2 Washer BACW10EC3C 2 Nut RH30C3NL 2 Torque to 25-35 Inch Pounds. 9 Clean Surface - 2 Left bonded panel 315A2101-41 (outer wall) at hole location for stud bolt. - 2 In right bonded panel 315A2102-41 (outer wall) at hole location for stud bolt. Note: Solvent clean perforated side surface (outer side of thrust reverser bonded panel). Scuff sand to remove surface gloss, double solvent wipe. Refer to SOPM 20-30-03. 10 Apply Primer - 2 Left bonded panel 315A2101-41 (outer wall) at hole location for stud bolt. - 2 In right bonded panel 315A2102-41 (outer wall) at hole location for stud bolt. Note: Apply one layer of 463-6-4 aluminized epoxy primer (BAC 5755, Type 10) to the perforated side surface and stud bolt head (outer side of thrust reverser bonded panel). Refer to SOPM 20-41-04. 11 Drill Hole - 8 In left bonded panel 315A2101-41 (inner wall) for bonded stud (Click Bond) installation. Refer to Appendix B. - 8 In right bonded panel assembly 315A2102-41 for bonded stud (Click Bond) installation. Refer to Appendix B. Note: Make hole 0.088-0.093 inch diameter, 0.35-0.40 inch deep. 12 Install Bonded Stud (Click-Bond) CB4017C3CRA12R 8 On left bonded panel assembly. Refer to Appendix B. CB4017C3CRA12R 8 On right bonded panel assembly. Refer to Appendix B. Note: 1. Solvent clean the faying surface for Click Bond installation. 2. Apply a coat of BMS 5-141 adhesive to the base of the stud. Make sure that locating pin of stud is coated with BMS 5-141 adhesive. Refer to SOPM 20-50-12, Type 111 and Appendix B for Click Bond installation. STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 4 OF 4)FIGURE 9: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET INSTALLATION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 71 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

FIGURE 9: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET INSTALLATION



### LEFT SIDE SHOWN, RIGHT SIDE SIMILAR 35 PLACES

FWD 11 2

9

9

1 7 11 7 11 8 7 9 8 8 10 6

5

11 5 7 11 3 4V39635 THRUST REVERSER

(SHEET 1 OF 3)FIGURE 9: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET INSTALLATION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 72 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each thrust reverser half.
STEP TASK NAME PART NUMBER QTY NOTES 1 Install Lower Insulation Blanket (Left Side) S315A213-51 1 Refer to 737-600/700/800/900 AMM 78-31-13. Lower Insulation Blanket (Right Side) S315A213-52 1

Note: Install lower insulation blanket before the upper blanket is installed. 2 Install Upper Insulation Blanket (Left Side) S315A213-49 1 Refer to 737-600/700/800/900 AMM 78-31-13. Upper Insulation Blanket (Right Side) S315A213-50 1

Note: Make sure that the lower edge of the upper insulation blanket overlaps the upper edge of the lower blanket. 3 Apply Parting Agent 598-5002 or AZ-534-2B or AZ-634-2 or Partall Coverall Film - Refer to SOPM 20-50-19. Boeing recommends that the parting agent be applied by brush.

Sealant BMS 5-63 - Note: 1. Apply parting agent to the insulation blankets forward edge before sealant is applied. 2. Seal the upper insulation blanket to the inner wall. 3. Apply the sealant from the top edge of the upper blanket to the top edge of the upper V-Blade seal. 4. Make sure sealant extends 0.75 to 1 inch aft of the forward edge of insulation blanket. 5. Make sure that the blanket edge is no more than 0.82 inches above the inner wall surface. Blanket must not hang over the outer edges of the inner wall. 4 Install Nut 0090-13365 35 Torque to 25-35 Inch Pounds. Washer BACW10P399CD 35 Note: 1. Make sure that the end of stud is not recessed more than 0.160 inch below top surface of the nut. 2. Add more washers if necessary so that nut does not bottom out on threads. 3. The end of stud can be above the top surface of the nut. 5 Install Screw BACS12GU3K10 9 On the 3 new fwd edge brackets. Torque to 25-35 Inch Pounds. Washer BACW10P458CD 9 6 Install Nut BACN10YR3C 2 Torque to 25-35 Inch Pounds. Washer BACW10P458CD 2 7 Install Screw BACS12GU3K12 4 Torque to 25-35 Inch Pounds. Washer BACW10P458CD 4 8 Install Nut BACN10YR3C 14 Torque to 25-35 Inch Pounds. Washer BACW10P458CD 14 9 Install Screw BACS12GU3K16 14 Torque to 25-35 Inch Pounds. Washer BACW10P458CD 14

(SHEET 2 OF 3)FIGURE 9: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET INSTALLATION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 73 of 77 

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10 Apply Parting Agent 598-5002 or AZ-534-2B or AZ-634-2 or Partall Coverall Film - Refer to SOPM 20-50-19.

Sealant BMS 5-63 - Note: 1. Apply parting agent to the insulation blankets forward edge before sealant is applied. 2. Fillet seal between the insulation blankets and the inner wall structure. Apply sealant along the full forward edge of the blankets, from the top edge of the upper blanket to the bottom edge of the lower blanket. 3. Make sure that the blanket edge is no more than 0.82 inches above the inner wall surface. Blanket must not hang over the outer edges of the inner wall. 11 Apply Parting Agent 598-5002 or AZ-534-2B or AZ-634-2 or Partall Coverall Film - Refer to SOPM 20-50-19.

Sealant BMS 5-63 - Note: 1. Apply parting agent to the edge of the insulation blanket cutout for the compression pad spacer (6 places) before sealant is applied. 2. Fillet seal the gap between the blanket cutout and the compression pad spacer (6 places). STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 3 OF 3)FIGURE 10: THRUST REVERSER INSULATION BLANKET FASTENER AND SKIN GROMMET DRILL AND DRILL GUIDE TOOLS February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 74 of 77 

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FIGURE 10: THRUST REVERSER INSULATION BLANKET FASTENER AND SKIN GROMMET DRILL AND DRILL GUIDE TOOLS

NAME "A" DIAMETER NOTES Drill 3/8 Inch (0.375) O.D. (a) Make from thin wall MIL-T-8504 CRES tubing or equivalent material. Insert drill into drill guide to drill grommet holes in blankets. 1/2 Inch (0.500) O.D. (a)(b) 5/8 Inch (0.625) O.D. (b)
Note: Keep chamfered edge of tube sharp and free from nicks and cracks to prevent tear damage to the blanket. Drill Guide 3/8 Inch (0.375) I.D. (c) Make from plastic, wood or other equivalent material. 1/2 Inch (0.500) I.D. (c) 5/8 Inch (0.625) I.D. (c) (a) Both ends of tubing can be chamfered and used to drill the blankets. (b) It could be necessary to reduce the diameter of one end of tubing to fit the chuck of the drill motor. (c) Make three separate drill guides, each one with one of the hole diameters shown. CHAMFER 45 DEGREE 1.00 DRILL CHUCK DIAMETER TO FIT IF NECESSARY REDUCE



### 5/8 INCH GROMMET DRILL SHOWN 4.00

A



### TYPICAL DRILL GUIDE A 6.00 2.50

0.50V73501

(SHEET 1 OF 1)APPENDIX A: SKIN GROMMET INSTALLATION - TOOL SET-UP February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 75 of 77 

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APPENDIX A: SKIN GROMMET INSTALLATION - TOOL SET-UP 1. Apply a layer of BMS 5-63 sealant to grommet shank and face of washer that will be in contact with blanket. 2. Insert grommet from hot side of the blanket. 3. Install washer over shank of grommet. Make sure that the grooved face of washer is up. 4. Use setting tool T-29057-( ) or equivalent for 315W1652-18 grommet and 315W1652-13 washer. Use setting tool T-29058-( ) or equivalent for 315W1652-24 grommet and 315W1652-1 washer. Strike tool with hammer to set grommet. 5. Make sure grommet shank is rolled over the washer all the way. 6. Make sure there are no visual cracks in the grommet shank. 7. Make sure BMS 5-63 sealant is visible around the grommet and washer. 8. Make sure grommet height does not exceed the maximum blanket thickness (0.455 inch forward of NAC STA 240.75 and 0.580 aft of NAC STA 240.75). Refer to Figure 7. 9. Make sure the grommet does not puncture or cut the polymide skin of the blanket.

(COLD SIDE) TOOL HAMMER

(HOT SIDE) TOOL BASE GROMMET (GROOVED FACE UP) WASHER MATERIAL BLANKET



### TOOL AND GROMMET SET-UP (HOT SIDE) TOOL BASE GROMMET WASHER MATERIAL BLANKET (COLD SIDE) TOOL HAMMER



### INSTALLED GROMMETV48896APPENDIX B: ADHESIVE BONDED STUD - CLICK BOND FASTENER INSTALLATION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 76 of 77 

### BOEING SERVICE BULLETIN 737-78-1069

APPENDIX B: ADHESIVE BONDED STUD - CLICK BOND FASTENER INSTALLATION 1. Each Adhesive Bonded Stud "Click Bond" fastener has a pressure application fixture (PAF) to aid in location and installation. Refer to Steps 1 thru 5 for installation. 2. Clean and prepare the base of the click bond stud and the surface of the structure where the click bond is to be installed. Refer to Boeing Standard Operating Procedures Manual SOPM 20-50-12, Type 111. A. Apply a thin, equal coat of BMS 5-141 adhesive approximately 40 mils thick to the click bond stud base. B. Coat the pilot pin on the bottom of the base of the click bond stud with BMS 5-141 adhesive.
Note: Make sure base of click bond stud is above the bottom of the PAF. Refer to Step 1. C. Remove the release liner ring to expose the pressure sensitive adhesive on the bottom of the PAF. Refer to Step 2. D. Position the PAF so that pilot pin on the bottom of the stud base is centered over the drilled hole in the inner wall of the bonded panel assembly, where the click bond stud is to be installed. Refer to Figure 8. E. Press down (P) around the outer edge of the PAF to bond the fixture to the structure. DO NOT apply pressure to the center the fixture. Refer to Step 3.
Note: Make sure that the base of the click bond stud is above the bottom of the PAF. Refer to Step 1. F. Operate the PAF, press down (P) near the center of the fixture until a click is felt or heard. Refer to Step 4.
Note: The above step will cause the base of the click bond stud to come in contact with the structure and apply pressure to the click bond stud and will cause the adhesive to come out. No other clamp pressure is necessary. G. Allow adhesive to cure as specified in SOPM 20-50-12, Type 111. H. After adhesive cures, peel off and discard the PAF. Refer to Step 5. 3. After Installation Inspection of Click Bond Stud Fasteners. A. Make sure there is a continuous bead of adhesive all the way around the base of the click bond.
B. Make sure that no cured adhesive is on the stud threads of the click bond. Remove cured adhesive from threads with Scotch-Brite or equivalent.
4. Removal of Click Bond Stud Fasteners. A. Use a flat based tool and work it under and around the edge of the base of the click bond stud. Peel and pry the base off the structure.
Note: Take care not to damage the structure during removal.APPENDIX B: ADHESIVE BONDED STUD - CLICK BOND FASTENER INSTALLATION February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 77 of 77 

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CLICK BOND FIXTURE

(UNACTIVATED

RELEASE LINER OF PAF BOTTOM STEP 1 STUD BASE PILOT PIN STEP 2 POSITION) PAF

STUD (P) (P) (ACTIVATED

INSTALLED CLICK BOND DISCARD

STEP 4 PAF POSITION) (P) (P) STEP 3

STRUCTURE STEP 5 FIXTURE (PAF) PRESSURE APPLICATION CROSS HAIRS



### INSTALLATION SEQUENCEV39636