Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-57A0117

Original Issue: October 01, 2009

Revision 1: March 02, 2011

ATA System: 5700

SUBJECT: WINGS - Skins - Upper Wing Skin Panel at Front Spar Pitch Load Fitting Attachment

- Inspection and Repair

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ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2009 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Unpublished Work - All Rights Reserved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.

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5.0
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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 71

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 75

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 76

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

FIGURE 1: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD

FITTING OF THE LEFT WING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

FIGURE 2: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD

FITTING OF THE RIGHT WING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

FIGURE 3: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR

PITCH LOAD FITTING OF THE LEFT WING . . . . . . . . . . . . . . . . . . . . . . . . . 86

FIGURE 4: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR

PITCH LOAD FITTING OF THE RIGHT WING . . . . . . . . . . . . . . . . . . . . . . . . 88

FIGURE 5: HOLE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

FIGURE 6: FREEZE PLUG REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

FIGURE 7: FASTENER REPLACEMENT, LEFT WING [Group 1-2, 4-5, 8] . . . . . . . . . . . . . . . 95

FIGURE 8: FASTENER REPLACEMENT, RIGHT WING [Group 1-2, 4-5, 8] . . . . . . . . . . . . . 100

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
FIGURE 9: FASTENER REPLACEMENT, LEFT WING [Group 3, 6-7, 9] . . . . . . . . . . . . . . . 105

FIGURE 10: FASTENER REPLACEMENT, RIGHT WING [Group 3, 6-7, 9] . . . . . . . . . . . . . . . 109

APPENDIX A: SUPPLEMENTAL FASTENER REPLACEMENT (EXAMPLE) . . . . . . . . . . . . . . . 113

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 767-57A0117

Original Issue: October 01, 2009

Revision 1: March 02, 2011

ATA System: 5700

SUBJECT: WINGS - Skins - Upper Wing Skin Panel at Front Spar Pitch Load Fitting Attachment

- Inspection and Repair

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on the airplane(s) inspected or changed in accordance with the original issue of this

service bulletin. However, the initial inspection threshold grace period for airplanes that have not accomplished

the inspection in accordance with this service bulletin have been reduced and may require earlier inspections.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-217-AD, is related to

this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2000-19-09 and AD 2004-16-12 are related

to this service bulletin.

REASON FOR REVISION

This revision is sent to revise the Compliance Tables to reduce the inspection grace period times due to inspection

findings in the fleet.

These sections were changed:

1. In Summary, Background, added information about fleet inspection findings.

2. In Summary, Compliance, added NPRM and AD information.

3. In Paragraph 1.C., Reason, added information about fleet inspection findings.

4. In Paragraph 1.E., Compliance, added NPRM and AD information.

5. In Paragraph 1.E., Compliance, revised the compliance information in Table 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,

12, 13 and 14.

6. In Paragraph 1.E., Compliance, revised the description of the conditions in Table 1, 2, 3, 4, 5, 6, 7, 8, 9,

10, 11, 12, 13 and 14.

7. In Paragraph 1.F., Approval, added Alternate Method of Compliance statement.

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8. In Paragraph 2.A., Material - Price and Availability, changed the table to apply effectivity.

9. In Paragraph 3.A., General Information, added notes about access and tool use.

10. In Paragraph 3.B., Accomplishment Instructions, revised the position of the slats.

11. In Paragraph 3.B., Accomplishment Instructions, revised the description of the conditions.

12. In Paragraph 3.B., Accomplishment Instructions, Figure 3, revised the reference for titanium fittings.

13. In Paragraph 3.B., Accomplishment Instructions, Figure 3, added a footnote about fastener removal.

14. In Paragraph 3.B., Accomplishment Instructions, Figure 4, revised the reference for titanium fittings.

15. In Paragraph 3.B., Accomplishment Instructions, Figure 4, added a footnote about fastener removal.

16. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised the 'Inspect' More Data column.

17. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised the 'Ream' More Data column.

18. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised footnote (a).

19. In Paragraph 3.B., Accomplishment Instructions, Figure 5, added a footnote (c) about fastener removal.

20. In Paragraph 3.B., Accomplishment Instructions, Figure 5, revised Table 1 and Table 2.

21. In Paragraph 3.B., Accomplishment Instructions, Figure 6, revised the 'Inspect' More Data column.

The data given in Information Notices 767-57A0117 IN-01, IN-02 and IN-03 is included in this revision.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: October 01, 2009

Revision 1: March 02, 2011

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-57A0117

Original Issue: October 01, 2009

Revision 1: March 02, 2011

ATA System: 5700

SUBJECT: WINGS - Skins - Upper Wing Skin Panel at Front Spar Pitch Load Fitting Attachment

- Inspection and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Accomplishment of this service bulletin will find possible cracks in the upper wing skin at the fastener holes

common to the inboard and outboard front spar pitch load fittings. Undetected upper wing skin cracks at the

fastener holes common to the inboard and outboard front spar pitch load fittings could result in the loss of the

strut-to-wing upper link load path and possible separation of a strut and engine from the airplane during flight.

Multiple operators have reported a total of 36 cracks in the upper wing skin at the fastener holes common to the

inboard and outboard front spar pitch load fittings. The reported airplanes had accumulated between 11,700

and 39,900 total flight-cycles and 28,700 and 83,100 total flight-hours. The reported crack lengths were between

0.016 and 0.140 inch. All cracks were found during accomplishment of the open hole high frequency eddy current

(HFEC) inspections given in strut improvement service bulletins 767-54-0080, 767-54-0081 or 767-54-0082.

Further Boeing analysis has determined the cracks to be a result of fatigue due to higher than predicted fastener

load and skin stress peaking along the aft fastener row.

Subsequent to the original issue of this service bulletin, one operator accomplishing this service bulletin reported

finding a fastener hole with significant crack sizes of 0.53 inches and 0.31 inches on either side of the hole. The

subject airplane had accumulated 18,900 flight cycles and 89,500 flight hours at the time of the inspection.

This service bulletin provides instructions to inspect the upper wing skin at the fastener holes common to the

inboard and outboard front spar pitch load fittings for cracks and repair the holes if cracks are found. Inspection

and repair will prevent undetected upper wing skin cracks at the fastener holes common to the inboard and

outboard front spar pitch load fittings that could result in the loss of the strut-to-wing upper link load path and

possible separation of a strut and engine from the airplane during flight.

Boeing Service Related Problem 767-SRP-57-0206 is related to this service bulletin.

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ACTION

Get access to the upper wing skin at the front spar pitch load fitting. Do a detailed and ultrasonic inspection or

do a HFEC open hole inspection of the fastener holes common to the front spar pitch load fitting and wing skin

for cracks. If any crack is found, repair the hole by oversizing the hole or installing a freeze plug. If no crack is

found, continue to perform repeat inspections. If the crack is too large to repair, contact Boeing for repair

instructions.

EFFECTIVITY

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

airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-217-AD, is related to

this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2000-19-09 and AD 2004-16-12 are related

to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection,and/or repair procedures given in this service

bulletin.

MANPOWER

For detailed Manhour estimates, refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-57A0117

Original Issue: October 01, 2009

Revision 1: March 02, 2011

ATA System: 5700

SUBJECT: WINGS - Skins - Upper Wing Skin Panel at Front Spar Pitch Load Fitting Attachment

- Inspection and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

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

Number, and Serial Number data.

NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below

is complete for airplanes through line number 1009. At least one airplane after line number

1009 is also affected by this service bulletin, and these airplanes are in Group(s) 3,6,7,9.

These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) \"get

effectivity\" result when they are added to the MBF Fleet Profile Page.

GROUP CONFIGURATION DESCRIPTION

767-200, -300 and -300F Airplanes with Pratt and Whitney JT9D

engines with line numbers 1-663.

1 -

1 Airplanes that have not accomplished SB 767-54-0080.

2 Airplanes that have accomplished SB 767-54-0080.

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GROUP CONFIGURATION DESCRIPTION

767-200, -300 and -300F Airplanes with Pratt and Whitney PW4000

engines with line numbers 1-663.

2 -

1 Airplanes that have not accomplished SB 767-54-0080.

2 Airplanes that have accomplished SB 767-54-0080.

767-200, -300 and -300F Airplanes with Pratt and Whitney engines

with line numbers 664 and on.

3 -

767 Airplanes with General Electric CF6-80A engines with line

numbers 1-663.

4 -

1 Airplanes that have not accomplished SB 767-54-0081.

2 Airplanes that have accomplished SB 767-54-0081.

767-200, -300 and -300F Airplanes with General Electric CF6-80C2

engines with line numbers 1-663.

5 -

1 Airplanes that have not accomplished SB 767-54-0081.

2 Airplanes that have accomplished SB 767-54-0081.

767-200, -300 and -300F Airplanes with General Electric engines

with line numbers 664 and on.

6 -

7 - 767-400ER Airplanes with General Electric engines.

767-200, -300 and -300F Airplanes with Rolls Royce engines with

line numbers 1-663.

8 -

1 Airplanes that have not accomplished SB 767-54-0082.

2 Airplanes that have accomplished SB 767-54-0082.

767-200, -300 and -300F Airplanes with Rolls Royce engines with

line numbers 664 and on.

9 -

Airplane Models:

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

Variable Number Group

VA001 - VA020 1

VA301 - VA315 4

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Variable Number Group

VA501 - VA530 4

VA701 - VA719 1

VA801 - VA810 1

VB001 - VB002 1

VB051 - VB055 4

VB101 - VB125 4

VB201 - VB202 1

VB251 - VB253 4

VB281 - VB284 1

VB301 - VB302 1

VB321 - VB330 4

VB331 - VB332 5

VB371 - VB373 1

VB401 4

VB441 - VB444 5

VE001 - VE003 1

VE021 - VE023 1

VE041 - VE043 1

VE061 - VE069 1

VE083 - VE084 1

VE085 - VE086 2

VE101 - VE104 4

VE116 - VE118 4

VE121 - VE126 5

VE141 - VE152 5

VE171 - VE172 2

VF001 - VF002 5

VF041 - VF042 5

VF051 5

VF061 - VF062 2

VF071 - VF072 2

VF091 - VF093 2

VF101 - VF102 2

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Variable Number Group

VF161 - VF162 2

VF171 - VF172 5

VF180 - VF184 5

VF251 5

VK001 - VK011 1

VK012 - VK015 5

VK016 6

VK021 - VK022 1

VK031 - VK054 4

VK055 - VK056 2

VK081 - VK112 5

VK113 6

VK131 - VK133 5

VK141 - VK147 5

VK148 6

VK161 - VK164 2

VK171 2

VK181 6

VK186 6

VL001 - VL006 5

VL011 2

VL701 - VL703 5

VL751 - VL755 5

VL806 - VL807 2

VL871 - VL873 8

VL891 - VL900 5

VL911 - VL914 5

VL931 - VL932 2

VL941 5

VN001 - VN041 5

VN051 - VN064 5

VN081 - VN098 5

VN099 6

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Variable Number Group

VN111 - VN127 8

VN130 - VN137 8

VN151 - VN158 2

VN163 - VN168 2

VN171 - VN174 2

VN191 - VN198 5

VN211 - VN212 2

VN221 - VN225 2

VN231 - VN234 5

VN241 - VN243 2

VN251 - VN271 2

VN272 - VN276 3

VN291 - VN293 5

VN301 - VN314 5

VN371 - VN372 2

VN376 2

VN381 - VN388 2

VN421 - VN427 5

VN436 5

VN471 - VN472 5

VN491 - VN513 2

VN531 - VN532 2

VN536 - VN537 2

VN541 - VN542 2

VN546 - VN547 5

VN551 2

VN556 - VN557 2

VN561 - VN562 2

VN631 - VN633 2

VN634 - VN638 5

VN651 - VN657 5

VN658 6

VN671 - VN672 2

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BOEING SERVICE BULLETIN 767-57A0117

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Variable Number Group

VN676 5

VN681 - VN691 2

VN731 - VN732 5

VN751 - VN753 5

VN791 - VN792 5

VN811 - VN813 5

VN921 - VN922 5

VN931 - VN936 2

VN951 - VN953 5

VN966 - VN967 2

VN968 - VN969 5

VN970 6

VN971 - VN972 2

VQ001 - VQ021 7

VQ071 - VQ086 7

VQ111 7

VR051 - VR060 6

VR081 6

VR084 6

VR086 - VR089 6

VR106 - VR109 6

VR201 - VR211 6

VR251 6

VR256 - VR260 6

VR266 - VR277 6

VR401 6

VR421 - VR423 3

VR426 6

VR441 6

VR461 6

VR471 - VR472 3

VS051 - VS056 6

VS061 3

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Variable Number Group

VS066 - VS070 3

VS073 - VS078 6

VS091 - VS104 3

VS111 - VS113 6

VS131 - VS133 6

VS136 - VS137 6

VS176 - VS177 6

VS186 - VS187 6

VS196 - VS203 6

VS206 - VS208 3

VS211 3

VS216 - VS217 6

VS231 6

VS246 - VS248 9

VS261 - VS263 6

VS266 - VS274 6

VS291 - VS293 6

VS301 - VS303 3

VS306 - VS311 3

VS316 6

VS321 - VS324 6

VS331 - VS333 6

VS336 - VS337 6

VS366 - VS367 6

VS381 - VS382 6

VS391 - VS392 6

VS401 6

VS426 - VS428 3

VS466 - VS472 6

VS486 6

VS496 - VS497 3

VS506 - VS507 3

VS526 6

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Variable Number Group

VS546 - VS549 6

VS701 - VS736 6

VS751 - VS759 6

VS821 - VS825 3

VS841 - VS844 3

VS861 6

VS881 - VS883 3

VS891 6

VS896 3

VS901 - VS910 6

VS911 - VS912 3

VS916 3

VS921 - VS925 6

VS931 - VS933 6

VS941 6

VS951 - VS954 6

VS961 - VS965 6

VS971 - VS972 6

VS976 6

VT501 6

VT511 - VT513 6

VT521 - VT523 6

VT531 - VT533 6

VT541 - VT543 6

VW701 - VW716 5

VW717 - VW721 6

VW851 5

2. Spares Affected

None.

B. Concurrent Requirements

None.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
C. Reason

Accomplishment of this service bulletin will find possible cracks in the upper wing skin at the fastener

holes common to the inboard and outboard front spar pitch load fittings. Undetected upper wing skin

cracks at the fastener holes common to the inboard and outboard front spar pitch load fittings could

result in the loss of the strut-to-wing upper link load path and possible separation of a strut and engine

from the airplane during flight.

Multiple operators have reported a total of 36 cracks in the upper wing skin at the fastener holes common

to the inboard and outboard front spar pitch load fittings. The reported airplanes had accumulated

between 11,700 and 39,900 total flight-cycles and 28,700 and 83,100 total flight-hours. The reported

crack lengths were between 0.016 and 0.140 inch. All cracks were found during accomplishment of

the open hole high frequency eddy current (HFEC) inspections given in strut improvement service

bulletins 767-54-0080, 767-54-0081 or 767-54-0082. Further Boeing analysis has determined the cracks

to be a result of fatigue due to higher than predicted fastener load and skin stress peaking along the

aft fastener row.

Subsequent to the original issue of this service bulletin, one operator accomplishing this service bulletin

reported finding a fastener hole with significant crack sizes of 0.53 inches and 0.31 inches on either

side of the hole. The subject airplane had accumulated 18,900 flight cycles and 89,500 flight hours at

the time of the inspection.

This service bulletin provides instructions to inspect the upper wing skin at the fastener holes common

to the inboard and outboard front spar pitch load fittings for cracks and repair the holes if cracks are

found. Inspection and repair will prevent undetected upper wing skin cracks at the fastener holes

common to the inboard and outboard front spar pitch load fittings that could result in the loss of the

strut-to-wing upper link load path and possible separation of a strut and engine from the airplane during

flight.

Boeing Service Related Problem 767-SRP-57-0206 is related to this service bulletin.

Revision 1 is sent to revise the Compliance Tables to reduce the inspection grace period times due to

inspection findings in the fleet.

D. Description

Get access to the upper wing skin at the front spar pitch load fitting. Do a detailed and ultrasonic

inspection or do a HFEC open hole inspection of the fastener holes common to the front spar pitch

load fitting and wing skin for cracks. If any crack is found, repair the hole by oversizing the hole or

installing a freeze plug. If no crack is found, continue to perform repeat inspections. If the crack is too

large to repair, contact Boeing for repair instructions.

Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of

this service bulletin. However, the initial inspection threshold grace period for airplanes that have not

accomplished the inspection in accordance with this service bulletin have been reduced and may

require earlier inspections.

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

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1-2, 4:

Affected Maintenance Zones

Model Zone

767-200, 767-300 511, 611

Group 3, 8-9:

Affected Maintenance Zones

Model Zone

767-300 511, 611

Group 5-6:

Affected Maintenance Zones

Model Zone

767-200, 767-300, 767-300F 511, 611

Group 7:

Affected Maintenance Zones

Model Zone

767-400ER 511, 611

E. Compliance

Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-217-AD, is

related to this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2000-19-09 and AD 2004-16-12

are related to this service bulletin.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1, Configuration 1:

Table 1: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 18,000

Total Flight Cycles or 54,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

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21 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1, Configuration 1:

Table 1: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

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22 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1, Configuration 1:

Table 1: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

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23 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1, Configuration 1:

Table 1: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

Group 1, Configuration 2:

Table 2: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Within 11,000

Flight Cycles or

33,000 Flight

Hours After

Completing Service Bulletin

767-54-0080

(whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1, Configuration 2:

Table 2: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1, Configuration 2:

Table 2: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

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26 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1, Configuration 2:

Table 2: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 2, Configuration 1:

Table 3: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 12,000

Total Flight Cycles or 36,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

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28 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 2, Configuration 1:

Table 3: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

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29 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 2, Configuration 1:

Table 3: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

30 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 2, Configuration 1:

Table 3: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

Group 2, Configuration 2:

Table 4: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Within 12,000

Flight Cycles or

36,000 Flight

Hours After

Completing Service Bulletin

767-54-0080

(whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

31 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 2, Configuration 2:

Table 4: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

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Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

32 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 2, Configuration 2:

Table 4: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

33 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 2, Configuration 2:

Table 4: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

34 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 3:

Table 5: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 12,000

Total Flight Cycles or 36,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 7,000 -

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 10,000

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 7,000 -

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 10,000

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

35 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 3:

Table 5: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to 0.469

inches.

-AND7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 7,000 -

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 10,000

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

36 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 3:

Table 5: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.469 inches

and less than or equal to

0.477 inches. -AND7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 7,000 -

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 10,000

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.477 inches

and less than or equal to

0.540 inches.

-AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

37 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 3:

Table 5: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

Group 4, Configuration 1:

Table 6: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 25,000

Total Flight Cycles or 75,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

38 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 4, Configuration 1:

Table 6: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

39 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 4, Configuration 1:

Table 6: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

40 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 4, Configuration 1:

Table 6: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

41 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 4, Configuration 2:

Table 7: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Within 17,000

Flight Cycles or

51,000 Flight

Hours After

Completing Service Bulletin

767-54-0081

(whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

42 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 4, Configuration 2:

Table 7: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

43 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 4, Configuration 2:

Table 7: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 12,000 -

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 17,000 Flight Cy- -ORcles or 51,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 17,000

Flight Cycles or

51,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

44 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 4, Configuration 2:

Table 7: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

Group 5, Configuration 1:

Table 8: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 18,000

Total Flight Cycles or 54,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

45 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 5, Configuration 1:

Table 8: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

46 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 5, Configuration 1:

Table 8: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

47 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 5, Configuration 1:

Table 8: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

48 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 5, Configuration 2:

Table 9: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Within 15,000

Flight Cycles or

45,000 Flight

Hours After

Completing Service Bulletin

767-54-0081

(whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

49 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 5, Configuration 2:

Table 9: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

50 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 5, Configuration 2:

Table 9: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND10,000 Flight Cycles or 30,000

Flight Hours

(whichever occurs

first) (a) (c)

Within 10,000 -

Flight Cycles or

30,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR-

-OR- 15,000 Flight Cy- -ORcles or 45,000

Flight Hours

(whichever occurs

first) (b) (c)

Within 15,000

Flight Cycles or

45,000 Flight

Hours (whichever occurs first)

(b) (c)

Do Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

51 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 5, Configuration 2:

Table 9: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

Group 6:

Table 10: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 18,000

Total Flight Cycles or 54,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

52 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 6:

Table 10: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 9,000 -

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 9,000 -

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

53 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 6:

Table 10: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to 0.469

inches.

-AND9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 9,000 -

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.469 inches

and less than or equal to

0.477 inches. -AND9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 9,000 -

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR12,000 Flight Cycles or 36,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 12,000

Flight Cycles or

36,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

54 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 6:

Table 10: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.477 inches

and less than or equal to

0.540 inches.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

55 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 7:

Table 11: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 18,000

Total Flight Cycles or 54,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

56 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 7:

Table 11: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to 0.469

inches.

-AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

57 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 7:

Table 11: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.469 inches

and less than or equal to

0.477 inches. -AND8,000 Flight Cycles

or 24,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 8,000 -

Flight Cycles or

24,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR11,000 Flight Cycles or 33,000

Flight Hours

(whichever occurs

first) (b) (c)

-ORWithin 11,000

Flight Cycles or

33,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.477 inches

and less than or equal to

0.540 inches.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

58 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 7:

Table 11: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

Group 8, Configuration 1:

Table 12: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 12,000

Total Flight Cycles or 36,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

59 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 8, Configuration 1:

Table 12: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

60 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 8, Configuration 1:

Table 12: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

61 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 8, Configuration 1:

Table 12: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND4,000 Flight Cycles

or 12,000 Flight

Hours (whichever

occurs first)

Within 4,000 -

Flight Cycles or

12,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

62 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 8, Configuration 2:

Table 13: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Within 9,000

Flight Cycles or

27,000 Flight

Hours After

Completing Service Bulletin

767-54-0082

(whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

63 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 8, Configuration 2:

Table 13: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to

0.4042 inches.

-AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 01, 2009

Revision 1: March 02, 2011 767-57A0117

64 of 113

BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 8, Configuration 2:

Table 13: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.4042 inches

and less than or equal to

0.453 inches. -AND6,000 Flight Cycles

or 18,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 6,000 -

Flight Cycles or

18,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR9,000 Flight Cycles

or 27,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 9,000

Flight Cycles or

27,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.453 inches

and less than or equal to

0.540 inches.

-AND4,000 Flight Cycles

or 12,000 Flight

Hours (whichever

occurs first)

Within 4,000 -

Flight Cycles or

12,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 8, Configuration 2:

Table 13: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Actions is on a per hole basis.

Group 9:

Table 14: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Within 2,000 -

Flight Cycles or

6,000 Flight

Hours After the

Original Issue

Date of this Service Bulletin

(whichever occurs first).

Before 12,000

Total Flight Cycles or 36,000

Total Flight

Hours (whichever occurs first).

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

All Airplanes

NOTE: The following conditions, times and intervals are on a per wing basis.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 9:

Table 14: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Condition 1 for airplanes

on which Part 1 Inspections

were done: No crack(s)

found at any hole location.

-OR7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 7,000

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Oversize the hole as given in Paragraph

3.B.4.a.(1) and install a

new fastener as given in

Paragraph 3.B.4.a.(2) .

Condition 1 for airplanes

on which Part 2 Inspection

was done: No crack(s)

found at any hole location.

-AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 7,000

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Remove the crack as given in Paragraph

3.B.4.b.(2) and do the

actions given in Conditions 2A, 2B, 2C or 2D

based on repaired hole

diameter. (f)

Condition 2: Any crack

found

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 9:

Table 14: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions. (f)

Condition 2A: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

less than or equal to 0.469

inches.

-AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 7,000

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

Before further - -

flight.

Do Part 4 - Fastener Installation as given in

Paragraph 3.B., Work Instructions and replace

adjacent fasteners as

given in APPENDIX A. (f)

Condition 2B: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.469 inches

and less than or equal to

0.477 inches. -AND5,000 Flight Cycles

or 15,000 Flight

Hours (whichever

occurs first) (a) (c)

Within 5,000 -

Flight Cycles or

15,000 Flight

Hours (whichever occurs first)

(a) (c)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

-OR7,000 Flight Cycles

or 21,000 Flight

Hours (whichever

occurs first) (b) (c)

-ORWithin 7,000

Flight Cycles or

21,000 Flight

Hours (whichever occurs first)

(b) (c)

-ORDo Part 2 - Open Hole

HFEC Inspection as given in Paragraph 3.B.,

Work Instructions. (e)

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 9:

Table 14: Upper Wing Skin at the Front Spar Pitch Load Fitting Attachment Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action (d)

Before further - -

flight.

Do Part 3 - Freeze Plug

Repair as given in Paragraph 3.B., Work Instructions and Do Part 4 -

Fastener Installation as

given in Paragraph 3.B.,

Work Instructions and replace adjacent fasteners

as given in APPENDIX A.

(f)

Condition 2C: Any crack

found in one or more of the

affected fastener locations

that can be removed with

a repaired hole diameter

greater than 0.477 inches

and less than or equal to

0.540 inches.

-AND4,000 Flight Cycles

or 12,000 Flight

Hours (whichever

occurs first)

Within 4,000 -

Flight Cycles or

12,000 Flight

Hours (whichever occurs first)

Do Part 1 - Upper Wing

Skin Surface Detailed

and Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)

Before further - -

flight.

Contact Boeing for additional instructions and do

the repair.

Condition 2D: Any crack

found in one or more of the

affected fastener hole locations that can not be removed with a repaired hole

diameter of less than or

equal to 0.540 inches.

(a) If Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections was previously done.

(b) If Part 2 - Open Hole HFEC Inspection was previously done.

(c) If freeze plug repairs are installed at one or more of the affected fastener locations, refer to Condition 2C

for Compliance and Repeat Interval times.

(d) If a freeze plug is installed in any one of the wing skin holes common to the pitch load fitting, only Part

1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspections can be accomplished for that side of

the airplane.

(e) Action is on a per wing basis.

(f) Action is on a per hole basis.

F. Approval

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

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

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

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

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

changes.

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BOEING SERVICE BULLETIN 767-57A0117

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

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

before incorporating this service bulletin.

The Manager of the FAA Seattle Aircraft Certification Office (SACO) approves the repairs and required

post repair inspections of the upper wing skin at front spar pitch load fitting, defined in SB 767-57A0117,

Revision 1, as a method of compliance (MOC) to the fastener hole repair and fastener replacement

only to the holes common to the upper wing skin and front spar pitch load fitting, defined in SBs

767-54-0080, 767-54-0081 and 767-54-0082, as applicable, required by paragraphs (c) and (f) of AD

2004-16-12 and paragraph (c) of AD 2000-19-09. When this SB specifies contacting Boeing for repair

instructions, the repair instructions must be approved by the FAA in accordance with paragraph (n) of

AD 2004-16-12 and paragraph (d) of AD 2000-19-09. All provisions of AD 2004-16-12 and AD

2000-19-09 that are not specifically referenced in this paragraph remain fully applicable and must be

complied with.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection and repair for

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

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

examples of lost time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Number of Per- Task Hours Elapsed Hours

sons

Task

Access 2 8.50 4.25

Part 1: Figure 1 1 1.50 1.50

Part 1: Figure 2 1 1.50 1.50

Part 2: Figure 3 1 3.20 3.20

Part 2: Figure 4 1 3.20 3.20

Figure 5 (a) 1 0.20 0.20

Figure 6 (a) 1 0.20 0.20

Figure 7 (a) 1 0.20 0.20

Figure 8 (a) 1 0.20 0.20

Figure 9 (a) 1 0.20 0.20

Figure 10 (a) 1 0.20 0.20

Close Access 2 8.50 4.25

TOTAL FOR EACH AIRPLANE (b) (b)

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Number of Per- Task Hours Elapsed Hours

sons

Task

(a) Repairs are per hole with 48 holes per airplane. Not every hole will require

repair.

(b) Hours per airplane is dependent on amount of repair. Every airplane will be

different and hours needed will only be known after inspections are complete.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Boeing Service Related Problem (SRP) 767-SRP-57-0206

b. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2000-19-09, 2004-16-12

c. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM)

2009-NM-217-AD

d. Standard Overhaul Practices Manual (SOPM) 20-30-03

e. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 27-81-00, 51-21-00, 54-51-03, 78-31-00

f. 767 Non-Destructive Testing (NDT) Manual Part 4, 57-20-04, Part 6, 51-00-14, Part 6, 51-00-16

g. 767-200 Structural Repair Manual (SRM) 51-20-07, 51-40-09

h. 767-300 Structural Repair Manual (SRM) 51-20-07, 51-40-09

i. 767-300F Structural Repair Manual (SRM) 51-20-07, 51-40-09

j. 767-400 Structural Repair Manual (SRM) 51-20-07, 51-40-09

2. Data supplied with this Service Bulletin

None.

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

Drawing Number Title

112T7102 Support Instl - Engine Strut, Front Spar, Wing

112T7001 Support Instl - Engine Strut, Wing

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

None.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane 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.

Group 1-2, 4-5, 8:

Unit Price as of

the Revision 1

date of this Service Bulletin

(US Dollars)

ROLT as

of the Revision 1

date of

this Service Bulletin (Calendar

Days)

Kit Number Name Date QTY

015T1829-1 Wing Skin Inspection Kit 03/24/08 10 529 $3,555.00

Group 3, 6-7, 9:

Unit Price as of

the Revision 1

date of this Service Bulletin

(US Dollars)

ROLT as

of the Revision 1

date of

this Service Bulletin (Calendar

Days)

Kit Number Name Date QTY

015T1829-2 Wing Skin Inspection Kit 03/24/08 10 564 $28,836.00

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.

Reference this service bulletin and submit your purchase order by one of the methods that

follow:

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes inspection, and/or repair

procedures given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by

the Operator, are necessary for each airplane.

Kit 015T1829

New Part Number QTY Name Notes

-1 -2

Top Kit - Front (a)

Spar Pitch Load

Fitting Attachment

Fasteners - Replacement

015T1829-1 - .

Top Kit - Front (a)

Spar Pitch Load

Fitting Attachment

Fasteners - Replacement

015T1829-2 . -

112T7001-77 4 . RADIUS FILLER

BOLT, 100 DEG

HEX DR

BACB30YM12K15X 44 .

BACB30YM12K15Y 44 . BOLT

BACB30YM12K16X 44 . BOLT, HEX DRIVE

BACB30YM12K16Y 44 . BOLT, HEX DRIVE

BOLT, 100 DEG

HEX DR

BACB30YM12K17X 4 .

BACB30YM12K17Y 4 . BOLT

BACB30YM12K18X 4 . BOLT, HEX DRIVE

BACB30YM12K18Y 4 . BOLT

BOLT, 100 DEG

HEX DR

BACB30YM14K15 . 48

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Kit 015T1829

New Part Number QTY Name Notes

-1 -2

BACB30YM14K15X . 48 BOLT, HEX DRIVE

BACB30YM14K15Y . 48 BOLT, HEX DRIVE

BACB30YM14K16 . 48 BOLT

BACB30YM14K16X . 48 BOLT, HEX DRIVE

BACB30YM14K16Y . 48 BOLT, HEX DRIVE

BACN11Z6CD 48 . NUT

BACN11Z7CD . 48 NUT

BACW10BP61APU 48 . WASHER, PLAIN

BACW10BP62APU 48 . WASHER, PLAIN

BACW10BP71APU . 48 WASHER, PLAIN

BACW10BP72APU . 48 WASHER, PLAIN

BACW10BP7APU . 48 WASHER

(a) If grip length shown is not available at Boeing, fasteners

supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not

available or have been superseded, substitute fasteners

may be supplied in kits. Boeing Document D-590 and

Boeing Drawing 012W6100 are used to determine the part

numbers used as substitutes.

2. Parts and Materials Supplied by the Operator

Group 1-2, 4-5, 8:

Part Number / QTY Name Notes

Specification

BMS5-95 1 pint Sealant (a)

BACB30YM14K* 24 Bolt (b)

BACB30YM14K*X 24 Bolt (b)

BACB30YM14K*Y 24 Bolt (b)

BACW10BP7APU 24 Washer (b)

BACW10BP71APU 24 Washer, Plain (b)

BACW10BP72APU 24 Washer, Plain (b)

BACN11Z7CD 24 Nut (b)

(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for

supplier data.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
Group 1-2, 4-5, 8:

Part Number / QTY Name Notes

Specification

(b) Refer to 767 Structural Repair Manual Chapter 51 for alternate fasteners.

Group 3, 6-7, 9:

Part Number / QTY Name Notes

Specification

BMS5-95 1 pint Sealant (a)

BACB30YM16K* 24 Bolt (b)

BACW10BP8APU 24 Washer (b)

BACN11Z8CD 24 Nut (b)

(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for

supplier data.

(b) Refer to 767 Structural Repair Manual Chapter 51 for alternate fasteners.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

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

definition of the acronyms.

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

4. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets are given in 767 SRM, Chapter 51

– Torque limits to tighten nuts and bolts are given in 767 SRM, Chapter 51

5. For approved fastener and process material substitutions, refer to 767 SRM, Chapter

51. Alternate fasteners are given in 767 SRM Chapter 51 and Boeing Drawing

012W6100.

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

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

specification, or an approved substitute, with a length which meets the installation

standards given in SRM Chapter 51 may be used.

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

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

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

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

necessary. Surface cleaning and elaborate procedures may be required.

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BOEING SERVICE BULLETIN 767-57A0117

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

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

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

given in" are included in the instruction, the procedure in the Boeing document must

be used.

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

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

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

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

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

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

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

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

B. WORK INSTRUCTIONS

1. Do the deactivation procedure for the leading edge slats on both wings. Refer to 767 AMM 27-81-00

as an accepted procedure.

2. Do the deactivation procedure for the thrust reverser isolation valve for ground maintenance on

both sides of the airplane. Refer to 767 AMM 78-31-00 as an accepted procedure.

3. Remove and keep the following access panels. Refer to 767 AMM 06-44-00 as an accepted

procedure.

— Left Wing: 511PT, 511ST

— Right Wing: 611PT, 611ST

4. Do Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspection or do Part 2 - Open Hole

High Frequency Eddy Current Inspection.

NOTE: The following conditions and actions are on a per hole basis.

a. Condition 1: No crack(s) found.

(1) If Part 2 was done, oversize the hole to the next available fastener size as given in FIGURE

5.

(2) If Part 2 was done, install new fastener as given in Part 4 - Fastener Installation.

(3) Repeat Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspection or repeat

Part 2 - Open Hole High Frequency Eddy Current Inspection at the time given in Paragraph

1.E., Compliance.

b. Condition 2: Any crack found.

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
(1) Remove and keep the Upper Link with the engine installed, if not already removed. Refer

to 767 AMM 54-51-03 as an accepted procedure.

(2) Remove the crack as given in FIGURE 5.

(3) Measure the diameter of the hole.

(a) Condition 2A: Any crack found in one or more of the affected fastener locations that

can be removed with a repaired hole diameter less than or equal to:

Group 1-2, 4-5, 8:

0.4042 inches.

Group 3, 6-7, 9:

0.469 inches.

1) Install new fastener as given in Part 4 - Fastener Installation.

2) Repeat Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspection or

repeat Part 2 - Open Hole High Frequency Eddy Current Inspection at the time

given in Paragraph 1.E., Compliance.

(b) Condition 2B: Any crack found in one or more of the affected fastener locations that

can be removed with a repaired hole diameter greater than:

Group 1-2, 4-5, 8:

0.4042 inches and less than or equal to 0.453 inches.

Group 3, 6-7, 9:

0.469 inches and less than or equal to 0.477 inches.

1) Install new fastener as given in Part 4 - Fastener Installation.

2) If the repaired hole is in the forward three rows of the fitting, replace all fasteners

linearly aft of the repaired hole with the next nominal size fastener as given in

FIGURE 5 and Part 4 - Fastener Installation. Refer to APPENDIX A as a guide.

3) If the repaired hole is in the aft three rows of the fitting, replace the remaining

two linear fasteners with the next nominal size fastener as given in FIGURE 5

and Part 4 - Fastener Installation. Refer to APPENDIX A as a guide.

4) Repeat Part 1 - Upper Wing Skin Surface Detailed and Ultrasonic Inspection or

repeat Part 2 - Open Hole High Frequency Eddy Current Inspection at the time

given in Paragraph 1.E., Compliance.

(c) Condition 2C: Any crack found in one or more of the affected fastener locations that

can be removed with a repaired hole diameter greater than:

Group 1-2, 4-5, 8:

0.453 inches and less than or equal to 0.540 inches.

Group 3, 6-7, 9:

0.477 inches and less than or equal to 0.540 inches.

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ALERT ALERT
1) Do Part 3 - Freeze Plug Repair.

2) Install new fastener as given in Part 4 - Fastener Installation.

3) If the repaired hole is in the forward three rows of the fitting, replace all fasteners

linearly aft of the repaired hole with the next nominal size fastener as given in

FIGURE 5 and Part 4 - Fastener Installation. Refer to APPENDIX A as a guide.

4) If the repaired hole is in the aft three rows of the fitting, replace the remaining

two linear fasteners with the next nominal size fastener as given in FIGURE 5

and Part 4 - Fastener Installation. Refer to APPENDIX A as a guide.

5) Repeat Part 1 - Upper Wing Skin Surface Ultrasonic Inspection at the time given

in Paragraph 1.E., Compliance.

(d) Condition 2D: Crack not removed with a repaired hole diameter less than or equal

to 0.540 inches.

1) Contact Boeing for additional instructions and do the repair at the time given in

Paragraph 1.E., Compliance.

5. Restore the finish on the Upper Wing surface, if removed. Refer to 767 AMM 51-21-00 as an

accepted procedure.

6. Reinstall the Upper Link with the engine installed, if removed. Refer to 767 AMM 54-51-03 as an

accepted procedure.

7. Reinstall the following access panels. Refer to 767 AMM 06-44-00 as an accepted procedure.

— Left Wing: 511PT, 511ST

— Right Wing: 611PT, 611ST

8. Do the activation procedure for the thrust reverser isolation valves for ground maintenance on

both sides of the airplane. Refer to 767 AMM 78-31-00 as an accepted procedure.

9. Do the activation procedure for the leading edge slats on both wings in the retracted position. Refer

to 767 AMM 27-81-00 as an accepted procedure.

Part 1 - Upper Wing Skin Surface Ultrasonic Inspection

1. Do a detailed and Ultrasonic Inspection of the fastener holes of the front pitch load fitting on the

top surface of the left wing as given in FIGURE 1.

2. Do a detailed and Ultrasonic Inspection of the fastener holes of the front pitch load fitting on the

top surface of the right wing as given in FIGURE 2.

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ALERT ALERT
Part 2 - Open Hole HFEC Inspection

1. Remove and keep the Upper Link with the engine installed. Refer to 767 AMM 54-51-03 as an

accepted procedure.

2. Do a HFEC inspection of the wing skin fastener holes in the left wing as given in FIGURE 3.

3. Do a HFEC inspection of the wing skin fastener holes in the right wing as given in FIGURE 4.

Part 3 - Freeze Plug Repair

1. Install a freeze plug as given in FIGURE 6.

Part 4 - Fastener Installation

1. Group 1-2, 4-5, 8:

a. Install new fastener(s) at all hole locations that were removed in the left wing as given in

FIGURE 7.

b. Install new fastener(s) at all hole locations that were removed in the right wing as given in

FIGURE 8.

2. Group 3, 6-7, 9:

a. Install new fastener(s) at all hole locations that were removed in the left wing as given in

FIGURE 9.

b. Install new fastener(s) at all hole locations that were removed in the right wing as given in

FIGURE 10.

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ALERT ALERT
FIGURE 1: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD

FITTING OF THE LEFT WING

(SHEET 1 OF 2)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

around the fasteners. Refer to SOPM

20-30-03 as an accepted procedure.

1 Clean Upper Wing Skin - -

for cracks around

the aft twenty four

fasteners by a detailed inspection.

2 Inspect Upper Wing Skin - -

for cracks around

the aft twenty four

fasteners as given in

767 NDT Part 4, 57-

20-04.

3 Inspect Upper Wing Skin - -

FIGURE 1: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD

FITTING OF THE LEFT WING

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 2: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD

FITTING OF THE RIGHT WING

(SHEET 1 OF 2)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

around the fasteners. Refer to SOPM

20-30-03 as an accepted procedure.

1 Clean Upper Wing Skin - -

for cracks around

the aft twenty four

fasteners by a detailed inspection.

2 Inspect Upper Wing Skin - -

for cracks around

the aft twenty four

fasteners as given in

767 NDT Part 4, 57-

20-04.

3 Inspect Upper Wing Skin - -

FIGURE 2: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD

FITTING OF THE RIGHT WING

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 3: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR

PITCH LOAD FITTING OF THE LEFT WING

(SHEET 1 OF 2)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Bolt - 24 (b)

Remove Washer - 24 (b)

Remove Nut - 24 (b)

Do a High Frequency Eddy Current inspection for cracks

in the wing skin as

given in 767 NDT

Part 6, 51-00-16.

2 Inspect Wing Skin Hole - 24

Do a High Frequency Eddy Current inspection for cracks

in the fitting as given

in 767 NDT Part 6,

51-00-16 for aluminum fittings and

as given in 767 NDT

Part 6, 51-00-14 for

titanium fittings. (a)

3 Inspect Fitting Hole - 24

(a) Groups 1, 2, 4, 5 and 8 have aluminum fittings. Groups 3, 6, 7 and 9 have titanium fittings.

(b) If the pylon is still attached to the wing, only remove every other fastener, and no more than 12 at the

same time while doing this inspection. If the pylon is removed from the wing, any number of fasteners,

up to 24, can be removed at the same time during this inspection.

FIGURE 3: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR

PITCH LOAD FITTING OF THE LEFT WING

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 4: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR

PITCH LOAD FITTING OF THE RIGHT WING

(SHEET 1 OF 2)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove Bolt - 24 (b)

Remove Washer - 24 (b)

Remove Nut - 24 (b)

Do a High Frequency Eddy Current inspection for cracks

in the wing skin as

given in 767 NDT

Part 6, 51-00-16.

2 Inspect Wing Skin Hole - 24

Do a High Frequency Eddy Current inspection for cracks

in the fitting as given

in 767 NDT Part 6,

51-00-16 for aluminum fittings and

as given in 767 NDT

Part 6, 51-00-14 for

titanium fittings. (a)

3 Inspect Fitting Hole - 24

(a) Groups 1, 2, 4, 5 and 8 have aluminum fittings. Groups 3, 6, 7 and 9 have titanium fittings.

(b) If the pylon is still attached to the wing, only remove every other fastener, and no more than 12 at the

same time while doing this inspection. If the pylon is removed from the wing, any number of fasteners,

up to 24, can be removed at the same time during this inspection.

FIGURE 4: HFEC INSPECTION OF THE UPPER WING SKIN FASTENER HOLES AT THE FRONT SPAR

PITCH LOAD FITTING OF THE RIGHT WING

(SHEET 2 OF 2)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

if not already removed. (c)1 Remove Bolt - 1

if not already removed. (c)Remove Nut - 1

if not already removed. (c)Remove Washer - 1

to next larger hole

diameter. Refer to

Table 1 or Table 2

below, as applicable.

(a)

2 Ream Hole - 1

Do a High Frequency Eddy Current inspection for cracks

in the wing skin and

the fitting as given in

767 NDT Part 6, 51-

00-16 for aluminum

fittings and as given

in 767 NDT Part 6,

51-00-14 for titanium

fittings. (b)

3 Inspect Hole - 1

FIGURE 5: HOLE REPAIR

(SHEET 1 OF 3)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

as required for the

hole sizes indicated

in Table 1 or Table

2 below with high interference as given

in 767-200 SRM 51-

40-09, 767-300 SRM

51-40-09, 767-300F

SRM 51-40-09 or

767-400 SRM 51-

40-09.

4 ColdWork Hole - 1

to the diameter given in the After ColdWork Hole Diameter

column of Table 1 or

Table 2, as applicable.

Ream Hole - 1

(a) Ream hole to Repaired Hole Diameter size in Table 1 or Table 2, as applicable.

(b) Repeat steps 2 and 3 until no crack indication is found or hole diameter is equal to 0.540 inches. If crack

can not be removed with a final hole diameter less than or equal to 0.540 inches, follow the instructions

of Condition 2D as given in Paragraph 3.B.4.b.(3)(d).

(c) If the pylon is still attached to the wing, only remove every other fastener, and no more than 12 at the

same time while doing the hole repairs. If the pylon is removed from the wing, any number of fasteners

can be removed at the same time while doing hole repairs. But at any hole being repaired, there must be

a tooling pin, temporary fastener or the actual permanent fastener located in the hole on either side of

the hole being repaired.

GROUPS 1-2, 4-5, 8: TABLE 1 - HOLE SIZE INCREMENTS

Bolt Part Number (Reference Only)After ColdWork Hole DiameterSize Repaired Hole Diameter

First Oversize 0.3866-0.3886 (a) - BACB30YM12K*X

Second Oversize 0.4022-0.4042 (a) - BACB30YM12K*Y

Nominal (d) 0.421-0.424 (b) 0.4335-0.4355 BACB30YM14K*

First Oversize (d) 0.437-0.440 (b) 0.4491-0.4511 BACB30YM14K*X

Second Oversize (d) 0.450-0.453 (b) 0.4647-0.4667 BACB30YM14K*Y

Special Repair 0.453-0.540 (c) - Freeze Plug

(a) This hole diameter corresponds to Condition 2A.

(b) This hole diameter corresponds to Condition 2B.

(c) This hole diameter corresponds to Condition 2C.

FIGURE 5: HOLE REPAIR

(SHEET 2 OF 3)

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ALERT ALERT
GROUPS 1-2, 4-5, 8: TABLE 1 - HOLE SIZE INCREMENTS

Bolt Part Number (Reference Only)After ColdWork Hole DiameterSize Repaired Hole Diameter

(d) Cold working required.

GROUPS 3, 6-7, 9: TABLE 2 - HOLE SIZE INCREMENTS

Bolt Part Number (Reference Only)After ColdWork Hole DiameterSize Repaired Hole Diameter

Nominal 0.434-0.438 (a) - BACB30YM14K*

First Oversize 0.450-0.453 (a) - BACB30YM14K*X

Second Oversize 0.466-0.469 (a) - BACB30YM14K*Y

Nominal (d) 0.474-0.477 (b) 0.496-0.500 BACB30YM16K*

Special Repair 0.477-0.540 (c) - Freeze Plug

(a) This hole diameter corresponds to Condition 2A.

(b) This hole diameter corresponds to Condition 2B.

(c) This hole diameter corresponds to Condition 2C.

(d) Cold working required.

FIGURE 5: HOLE REPAIR

(SHEET 3 OF 3)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

to remove any

cracks, if not previously done. Maximum hole diameter

is 0.540 inches. (a)

1 Ream Hole - 1

Do a High Frequency Eddy Current inspection for cracks

in the skin and the

fitting as given in

767 NDT Part 6, 51-

00-16 for aluminum

fittings and as given

in 767 NDT Part 6,

51-00-14 for titanium

fittings.

2 Inspect Hole - 1

after all cracks have

been removed to increase diameter by

0.060 inches. Maximum hole diameter

is 0.600 inches.

3 Ream Hole - 1

FIGURE 6: FREEZE PLUG REPAIR

(SHEET 1 OF 2)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

with countersink as

given in 767-200

SRM 51-20-07, 767-

300 SRM 51-20-07,

767-300F SRM 51-

20-07 and 767-400

SRM 51-20-07.

4 Install (New) Freeze Plug - 1

(a) If crack can not be removed with a final hole diameter less than or equal to 0.540 inches, follow the instructions of Condition 2D as given in Paragraph 3.B.4.b.(3)(d).

FIGURE 6: FREEZE PLUG REPAIR

(SHEET 2 OF 2)

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ALERT ALERT
This Figure applies only to: Group 1-2, 4-5, 8.

FIGURE 7: FASTENER REPLACEMENT, LEFT WING

(SHEET 1 OF 5)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

wet with BMS 5-95

sealant

1 Install (New) Bolt - -

Install (New) Washer - -

Install (New) Nut - -

FIGURE 7: FASTENER REPLACEMENT, LEFT WING

(SHEET 2 OF 5)

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ALERT ALERT
FIGURE 7: FASTENER REPLACEMENT, LEFT WING

(SHEET 3 OF 5)

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ALERT ALERT
CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

BOLT, 100 DEG HEX BACB30YM12K15X 22 0.3866-0.3886 Optional. (a)

DR

A

BOLT BACB30YM12K15Y 22 0.4022-0.4042 Optional. (a)

BOLT, HEX DRIVE BACB30YM12K16X 22 0.3866-0.3886 Optional. (a)

BOLT, HEX DRIVE BACB30YM12K16Y 22 0.4022-0.4042 Optional. (a)

BOLT BACB30YM14K* 22 0.4335-0.4355 Optional. (b)

BOLT BACB30YM14K*X 22 0.4491-0.4511 Optional. (b)

BOLT BACB30YM14K*Y 22 0.4647-0.4667 Optional. (b)

Use with

BACB30YM12K*X. Install

under nut. (a)

WASHER, PLAIN BACW10BP61APU 22 -

Use with

BACB30YM12K*Y. Install

under nut. (a)

WASHER, PLAIN BACW10BP62APU 22 -

Use with

BACB30YM14K*. Install

under nut. (b)

WASHER BACW10BP7APU 22 -

Use with

BACB30YM14K*X. Install

under nut. (b)

WASHER, PLAIN BACW10BP71APU 22 -

Use with

BACB30YM14K*Y. Install

under nut. (b)

WASHER, PLAIN BACW10BP72APU 22 -

Use with any

BACB30YM12K bolt.

Torque to 300-320 in-lbs.

(a)

NUT BACN11Z6CD 22 -

Use with any

BACB30YM14K bolt.

Torque to 420-450 in-lbs.

(b)

NUT BACN11Z7CD 22 -

FIGURE 7: FASTENER REPLACEMENT, LEFT WING

(SHEET 4 OF 5)

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ALERT ALERT
CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

BOLT, 100 DEG HEX BACB30YM12K17X 2 0.3866-0.3886 Optional. (a)

DR

B

BOLT BACB30YM12K17Y 2 0.4022-0.4042 Optional. (a)

BOLT, HEX DRIVE BACB30YM12K18X 2 0.3866-0.3886 Optional. (a)

BOLT BACB30YM12K18Y 2 0.4022-0.4042 Optional. (a)

BOLT BACB30YM14K* 2 0.4335-0.4355 Optional. (b)

BOLT BACB30YM14K*X 2 0.4491-0.4511 Optional. (b)

BOLT BACB30YM14K*Y 2 0.4647-0.4667 Optional. (b)

Use with

BACB30YM12K*X. Install

under nut. (a)

WASHER, PLAIN BACW10BP61APU 2 -

Use with

BACB30YM12K*Y. Install

under nut. (a)

WASHER, PLAIN BACW10BP62APU 2 -

Use with

BACB30YM14K*. Install

under nut. (b)

WASHER BACW10BP7APU 2 -

Use with

BACB30YM14K*X. Install

under nut. (b)

WASHER, PLAIN BACW10BP71APU 2 -

Use with

BACB30YM14K*Y. Install

under nut. (b)

WASHER, PLAIN BACW10BP72APU 2 -

RADIUS FILLER 112T7001-77 2 -

Use with any

BACB30YM12K bolt.

Torque to 300-320 in-lbs.

(a)

NUT BACN11Z6CD 2 -

Use with any

BACB30YM14K bolt.

Torque to 420-450 in-lbs.

(b)

NUT BACN11Z7CD 2 -

(a) Quantity indicated may be in excess of parts required. Quantity indicated is quantity in kit.

(b) Quantity indicated may be in excess of parts required. Operator supplied.

FIGURE 7: FASTENER REPLACEMENT, LEFT WING

(SHEET 5 OF 5)

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ALERT ALERT
This Figure applies only to: Group 1-2, 4-5, 8.

FIGURE 8: FASTENER REPLACEMENT, RIGHT WING

(SHEET 1 OF 5)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

wet with BMS 5-95

sealant

1 Install (New) Bolt - -

Install (New) Washer - -

Install (New) Nut - -

FIGURE 8: FASTENER REPLACEMENT, RIGHT WING

(SHEET 2 OF 5)

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ALERT ALERT
FIGURE 8: FASTENER REPLACEMENT, RIGHT WING

(SHEET 3 OF 5)

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ALERT ALERT
CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

BOLT, 100 DEG HEX BACB30YM12K15X 22 0.3866-0.3886 Optional. (a)

DR

A

BOLT BACB30YM12K15Y 22 0.4022-0.4042 Optional. (a)

BOLT, HEX DRIVE BACB30YM12K16X 22 0.3866-0.3886 Optional. (a)

BOLT, HEX DRIVE BACB30YM12K16Y 22 0.4022-0.4042 Optional. (a)

BOLT BACB30YM14K* 22 0.4335-0.4355 Optional. (b)

BOLT BACB30YM14K*X 22 0.4491-0.4511 Optional. (b)

BOLT BACB30YM14K*Y 22 0.4647-0.4667 Optional. (b)

Use with

BACB30YM12K*X. Install

under nut. (a)

WASHER, PLAIN BACW10BP61APU 22 -

Use with

BACB30YM12K*Y. Install

under nut. (a)

WASHER, PLAIN BACW10BP62APU 22 -

Use with

BACB30YM14K*. Install

under nut. (b)

WASHER BACW10BP7APU 22 -

Use with

BACB30YM14K*X. Install

under nut. (b)

WASHER, PLAIN BACW10BP71APU 22 -

Use with

BACB30YM14K*Y. Install

under nut. (b)

WASHER, PLAIN BACW10BP72APU 22 -

Use with any

BACB30YM12K bolt.

Torque to 300-320 in-lbs.

(a)

NUT BACN11Z6CD 22 -

Use with any

BACB30YM14K bolt.

Torque to 420-450 in-lbs.

(b)

NUT BACN11Z7CD 22 -

FIGURE 8: FASTENER REPLACEMENT, RIGHT WING

(SHEET 4 OF 5)

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CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

BOLT, 100 DEG HEX BACB30YM12K17X 2 0.3866-0.3886 Optional. (a)

DR

B

BOLT BACB30YM12K17Y 2 0.4022-0.4042 Optional. (a)

BOLT, HEX DRIVE BACB30YM12K18X 2 0.3866-0.3886 Optional. (a)

BOLT BACB30YM12K18Y 2 0.4022-0.4042 Optional. (a)

BOLT BACB30YM14K* 2 0.4335-0.4355 Optional. (b)

BOLT BACB30YM14K*X 2 0.4491-0.4511 Optional. (b)

BOLT BACB30YM14K*Y 2 0.4647-0.4667 Optional. (b)

Use with

BACB30YM12K*X. Install

under nut. (a)

WASHER, PLAIN BACW10BP61APU 2 -

Use with

BACB30YM12K*Y. Install

under nut. (a)

WASHER, PLAIN BACW10BP62APU 2 -

Use with

BACB30YM14K*. Install

under nut. (b)

WASHER BACW10BP7APU 2 -

Use with

BACB30YM14K*X. Install

under nut. (b)

WASHER, PLAIN BACW10BP71APU 2 -

Use with

BACB30YM14K*Y. Install

under nut. (b)

WASHER, PLAIN BACW10BP72APU 2 -

RADIUS FILLER 112T7001-77 2 -

Use with any

BACB30YM12K bolt.

Torque to 300-320 in-lbs.

(a)

NUT BACN11Z6CD 2 -

Use with any

BACB30YM14K bolt.

Torque to 420-450 in-lbs.

(b)

NUT BACN11Z7CD 2 -

(a) Quantity indicated may be in excess of parts required. Quantity indicated is quantity in kit.

(b) Quantity indicated may be in excess of parts required. Operator supplied.

FIGURE 8: FASTENER REPLACEMENT, RIGHT WING

(SHEET 5 OF 5)

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This Figure applies only to: Group 3, 6-7, 9.

FIGURE 9: FASTENER REPLACEMENT, LEFT WING

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

wet with BMS 5-95

sealant

1 Install (New) Bolt - -

Install (New) Washer - -

Install (New) Nut - -

FIGURE 9: FASTENER REPLACEMENT, LEFT WING

(SHEET 2 OF 4)

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FIGURE 9: FASTENER REPLACEMENT, LEFT WING

(SHEET 3 OF 4)

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ALERT ALERT
CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

BOLT, 100 DEG HEX BACB30YM14K15 24 0.434-0.438 Optional. (a)

DR

A

BOLT, HEX DRIVE BACB30YM14K15X 24 0.450-0.453 Optional. (a)

BOLT, HEX DRIVE BACB30YM14K15Y 24 0.466-0.469 Optional. (a)

BOLT BACB30YM14K16 24 0.434-0.438 Optional. (a)

BOLT, HEX DRIVE BACB30YM14K16X 24 0.450-0.453 Optional. (a)

BOLT, HEX DRIVE BACB30YM14K16Y 24 0.466-0.469 Optional. (a)

BOLT BACB30YM16K* 24 0.496-0.500 Optional. (b)

Use with

BACB30YM14K*. Install

under nut. (a)

WASHER BACW10BP7APU 24 -

Use with

BACB30YM14K*X. Install

under nut. (a)

WASHER, PLAIN BACW10BP71APU 24 -

Use with

BACB30YM14K*Y. Install

under nut. (a)

WASHER, PLAIN BACW10BP72APU 24 -

Use with

BACB30YM16K*. Install

under nut. (b)

WASHER BACW10BP8APU 24 -

Use with any

BACB30YM14K bolt.

Torque to 420-450 in-lbs.

(a)

NUT BACN11Z7CD 24 -

Use with BACB30YM16K*

bolt. Torque to 700-740 inlbs. (b)

NUT BACN11Z8CD 24 -

(a) Quantity indicated may be in excess of parts required. Quantity indicated is quantity in kit.

(b) Quantity indicated may be in excess of parts required. Operator supplied.

FIGURE 9: FASTENER REPLACEMENT, LEFT WING

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
This Figure applies only to: Group 3, 6-7, 9.

FIGURE 10: FASTENER REPLACEMENT, RIGHT WING

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

wet with BMS 5-95

sealant

1 Install (New) Bolt - -

Install (New) Washer - -

Install (New) Nut - -

FIGURE 10: FASTENER REPLACEMENT, RIGHT WING

(SHEET 2 OF 4)

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FIGURE 10: FASTENER REPLACEMENT, RIGHT WING

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 767-57A0117

ALERT ALERT
CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

BOLT, 100 DEG HEX BACB30YM14K15 24 0.434-0.438 Optional. (a)

DR

A

BOLT, HEX DRIVE BACB30YM14K15X 24 0.450-0.453 Optional. (a)

BOLT, HEX DRIVE BACB30YM14K15Y 24 0.466-0.469 Optional. (a)

BOLT BACB30YM14K16 24 0.434-0.438 Optional. (a)

BOLT, HEX DRIVE BACB30YM14K16X 24 0.450-0.453 Optional. (a)

BOLT, HEX DRIVE BACB30YM14K16Y 24 0.466-0.469 Optional. (a)

BOLT BACB30YM16K* 24 0.496-0.500 Optional. (b)

Use with

BACB30YM14K*. Install

under nut. (a)

WASHER BACW10BP7APU 24 -

Use with

BACB30YM14K*X. Install

under nut. (a)

WASHER, PLAIN BACW10BP71APU 24 -

Use with

BACB30YM14K*Y. Install

under nut. (a)

WASHER, PLAIN BACW10BP72APU 24 -

Use with

BACB30YM16K*. Install

under nut. (b)

WASHER BACW10BP8APU 24 -

Use with any

BACB30YM14K bolt.

Torque to 420-450 in-lbs.

(a)

NUT BACN11Z7CD 24 -

Use with BACB30YM16K*

bolt. Torque to 700-740 inlbs. (b)

NUT BACN11Z8CD 24 -

(a) Quantity indicated may be in excess of parts required. Quantity indicated is quantity in kit.

(b) Quantity indicated may be in excess of parts required. Operator supplied.

FIGURE 10: FASTENER REPLACEMENT, RIGHT WING

(SHEET 4 OF 4)

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APPENDIX A: SUPPLEMENTAL FASTENER REPLACEMENT (EXAMPLE)

(SHEET 1 OF 1)

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ALERT ALERT