### 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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9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved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.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 1 of 113 5.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 2 of 113 **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 3 of 113 **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 4 of 113 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 5 of 1138. 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**

October 01, 2009 Original Issue:
March 02, 2011 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 6 of 113 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 7 of 113**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 8 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 9 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 10 of 113 **BOEING SERVICE BULLETIN 767-57A0117 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.

**DESCRIPTION CONFIGURATION**  **GROUP**
767-200, -300 and -300F Airplanes with Pratt and Whitney JT9D engines with line numbers 1-663. - 1

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

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 11 of 113**DESCRIPTION CONFIGURATION**  **GROUP**
767-200, -300 and -300F Airplanes with Pratt and Whitney PW4000 engines with line numbers 1-663. - 2

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

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

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

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

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

767-200, -300 and -300F Airplanes with General Electric CF6-80C2 engines with line numbers 1-663. - 5

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

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

767-200, -300 and -300F Airplanes with General Electric engines with line numbers 664 and on. - 6

767-400ER Airplanes with General Electric engines.

- 7

767-200, -300 and -300F Airplanes with Rolls Royce engines with line numbers 1-663. - 8

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

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

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

**Group Variable Number** 

1 VA001 - VA020

4 VA301 - VA315

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 12 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group**  **Variable Number**

4 VA501 - VA530

1 VA701 - VA719

1 VA801 - VA810

1 VB001 - VB002

4 VB051 - VB055

4 VB101 - VB125

1 VB201 - VB202

4 VB251 - VB253

1 VB281 - VB284

1 VB301 - VB302

4 VB321 - VB330

5 VB331 - VB332

1 VB371 - VB373

4 VB401

5 VB441 - VB444

1 VE001 - VE003

1 VE021 - VE023

1 VE041 - VE043

1 VE061 - VE069

1 VE083 - VE084

2 VE085 - VE086

4 VE101 - VE104

4 VE116 - VE118

5 VE121 - VE126

5 VE141 - VE152

2 VE171 - VE172

5 VF001 - VF002

5 VF041 - VF042

5 VF051

2 VF061 - VF062

2 VF071 - VF072

2 VF091 - VF093

2 VF101 - VF102

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 13 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group**  **Variable Number**

2 VF161 - VF162

5 VF171 - VF172

5 VF180 - VF184

5 VF251

1 VK001 - VK011

5 VK012 - VK015

6 VK016

1 VK021 - VK022

4 VK031 - VK054

2 VK055 - VK056

5 VK081 - VK112

6 VK113

5 VK131 - VK133

5 VK141 - VK147

6 VK148

2 VK161 - VK164

2 VK171

6 VK181

6 VK186

5 VL001 - VL006

2 VL011

5 VL701 - VL703

5 VL751 - VL755

2 VL806 - VL807

8 VL871 - VL873

5 VL891 - VL900

5 VL911 - VL914

2 VL931 - VL932

5 VL941

5 VN001 - VN041

5 VN051 - VN064

5 VN081 - VN098

6 VN099

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 14 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group**  **Variable Number**

8 VN111 - VN127

8 VN130 - VN137

2 VN151 - VN158

2 VN163 - VN168

2 VN171 - VN174

5 VN191 - VN198

2 VN211 - VN212

2 VN221 - VN225

5 VN231 - VN234

2 VN241 - VN243

2 VN251 - VN271

3 VN272 - VN276

5 VN291 - VN293

5 VN301 - VN314

2 VN371 - VN372

2 VN376

2 VN381 - VN388

5 VN421 - VN427

5 VN436

5 VN471 - VN472

2 VN491 - VN513

2 VN531 - VN532

2 VN536 - VN537

2 VN541 - VN542

5 VN546 - VN547

2 VN551

2 VN556 - VN557

2 VN561 - VN562

2 VN631 - VN633

5 VN634 - VN638

5 VN651 - VN657

6 VN658

2 VN671 - VN672

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 15 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group**  **Variable Number**

5 VN676

2 VN681 - VN691

5 VN731 - VN732

5 VN751 - VN753

5 VN791 - VN792

5 VN811 - VN813

5 VN921 - VN922

2 VN931 - VN936

5 VN951 - VN953

2 VN966 - VN967

5 VN968 - VN969

6 VN970

2 VN971 - VN972

7 VQ001 - VQ021

7 VQ071 - VQ086

7 VQ111

6 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

3 VR421 - VR423

6 VR426

6 VR441

6 VR461

3 VR471 - VR472

6 VS051 - VS056

3 VS061

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 16 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group**  **Variable Number**

3 VS066 - VS070

6 VS073 - VS078

3 VS091 - VS104

6 VS111 - VS113

6 VS131 - VS133

6 VS136 - VS137

6 VS176 - VS177

6 VS186 - VS187

6 VS196 - VS203

3 VS206 - VS208

3 VS211

6 VS216 - VS217

6 VS231

9 VS246 - VS248

6 VS261 - VS263

6 VS266 - VS274

6 VS291 - VS293

3 VS301 - VS303

3 VS306 - VS311

6 VS316

6 VS321 - VS324

6 VS331 - VS333

6 VS336 - VS337

6 VS366 - VS367

6 VS381 - VS382

6 VS391 - VS392

6 VS401

3 VS426 - VS428

6 VS466 - VS472

6 VS486

3 VS496 - VS497

3 VS506 - VS507

6 VS526

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 17 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group**  **Variable Number**

6 VS546 - VS549

6 VS701 - VS736

6 VS751 - VS759

3 VS821 - VS825

3 VS841 - VS844

6 VS861

3 VS881 - VS883

6 VS891

3 VS896

6 VS901 - VS910

3 VS911 - VS912

3 VS916

6 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

5 VW701 - VW716

6 VW717 - VW721

5 VW851

2. Spares Affected

None.

**B. Concurrent Requirements**

None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 18 of 113 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 19 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group 1-2, 4:** 

**Affected Maintenance Zones**

**Zone Model** 
511, 611 767-200, 767-300

**Group 3, 8-9:**

**Affected Maintenance Zones**

**Zone Model** 
511, 611 767-300

**Group 5-6:**

**Affected Maintenance Zones**

**Zone Model** 
511, 611 767-200, 767-300, 767-300F

**Group 7:**

**Affected Maintenance Zones**

**Zone Model** 
511, 611 767-400ER

**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 20 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 18,000Total Flight Cycles or 54,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Remove the crack as given in Paragraph 3.B.4.b.(2) and do theactions 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 inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Contact Boeing for additional instructions and do the repair. Condition 2D: Any crack found in one or more of theaffected 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Within 11,000 Flight Cycles or 33,000 Flight Hours AfterCompleting Service Bulletin 767-54-0080(whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 24 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)**  **Action (d) Condition** 

8,000 Flight Cycles or 24,000 Flight Hours (whichever occurs first) (a) (c) - Within 8,000 Flight Cycles or 24,000 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 theactions 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 767-57A0117 Revision 1: March 02, 2011 25 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 theaffected 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 767-57A0117 Revision 1: March 02, 2011 27 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 12,000Total Flight Cycles or 36,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Remove the crack as given in Paragraph 3.B.4.b.(2) and do theactions 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 inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Contact Boeing for additional instructions and do the repair. Condition 2D: Any crack found in one or more of theaffected 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Within 12,000 Flight Cycles or 36,000 Flight Hours AfterCompleting Service Bulletin 767-54-0080(whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

8,000 Flight Cycles or 24,000 Flight Hours (whichever occurs first) (a) (c) - Within 8,000 Flight Cycles or 24,000 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 theactions 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 theaffected 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 12,000Total Flight Cycles or 36,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Remove the crack as given in Paragraph 3.B.4.b.(2) and do theactions 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 inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Contact Boeing for additional instructions and do the repair. Condition 2D: Any crack found in one or more of theaffected 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 25,000Total Flight Cycles or 75,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

12,000 Flight Cycles or 36,000 Flight Hours (whichever occurs first) (a) (c) - Within 12,000 Flight Cycles or 36,000 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 theactions 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 theaffected 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Within 17,000 Flight Cycles or 51,000 Flight Hours AfterCompleting Service Bulletin 767-54-0081(whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Remove the crack as given in Paragraph 3.B.4.b.(2) and do theactions 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 inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 17,000 Flight Cy- cles or 51,000 Flight Hours (whichever occurs first) (b) (c) Within 17,000 Flight Cycles or 51,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Contact Boeing for additional instructions and do the repair. Condition 2D: Any crack found in one or more of theaffected 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 18,000Total Flight Cycles or 54,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

10,000 Flight Cycles or 30,000 Flight Hours (whichever occurs first) (a) (c) - Within 10,000 Flight Cycles or 30,000 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 theactions 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 theaffected 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Within 15,000 Flight Cycles or 45,000 Flight Hours AfterCompleting Service Bulletin 767-54-0081(whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Remove the crack as given in Paragraph 3.B.4.b.(2) and do theactions 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 inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e) -OR--OR-OR- 15,000 Flight Cy- cles or 45,000 Flight Hours (whichever occurs first) (b) (c) Within 15,000 Flight Cycles or 45,000 FlightHours (whichever occurs first) (b) (c) Do Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Contact Boeing for additional instructions and do the repair. Condition 2D: Any crack found in one or more of theaffected 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 18,000Total Flight Cycles or 54,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

9,000 Flight Cycles or 27,000 Flight Hours (whichever occurs first) (a) (c) - Within 9,000 Flight Cycles or 27,000 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 theactions 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 theaffected 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 18,000Total Flight Cycles or 54,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Remove the crack as given in Paragraph 3.B.4.b.(2) and do theactions 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 inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Contact Boeing for additional instructions and do the repair. Condition 2D: Any crack found in one or more of theaffected 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 12,000Total Flight Cycles or 36,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

6,000 Flight Cycles or 18,000 Flight Hours (whichever occurs first) (a) (c) - Within 6,000 Flight Cycles or 18,000 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 theactions 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 theaffected 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Within 9,000 Flight Cycles or 27,000 Flight Hours AfterCompleting Service Bulletin 767-54-0082(whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Remove the crack as given in Paragraph 3.B.4.b.(2) and do theactions 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 inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 767-57A0117 Revision 1: March 02, 2011 65 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)**  **Action (d) Condition** 

- - Before further flight.Contact Boeing for additional instructions and do the repair. Condition 2D: Any crack found in one or more of theaffected 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)**  **Action (d) Condition** 

- Within 2,000 Flight Cycles or 6,000 Flight Hours After the Original IssueDate of this Service Bulletin(whichever occurs first). Before 12,000Total Flight Cycles or 36,000 Total FlightHours (whichever occurs first). Do Part 1 - Upper Wing Skin Surface Detailedand Ultrasonic Inspections as given in Paragraph 3.B., Work Instructions. (e)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 66 of 113 **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)**  **Action (d) Condition** 

5,000 Flight Cycles or 15,000 Flight Hours (whichever occurs first) (a) (c) - Within 5,000 Flight Cycles or 15,000 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 theactions 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 767-57A0117 Revision 1: March 02, 2011 67 of 113 **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)**  **Action (d) Condition** 

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC Inspection as given in Paragraph 3.B., Work Instructions. (e)

- - Before further flight.Do Part 4 - Fastener Installation as given inParagraph 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 FlightHours (whichever occurs first) (a) (c) Do Part 1 - Upper Wing Skin Surface Detailedand 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 FlightHours (whichever occurs first) (b) (c)-ORDo Part 2 - Open HoleHFEC 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 767-57A0117 Revision 1: March 02, 2011 68 of 113 **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)**  **Action (d) Condition** 

- - Before further flight. Do Part 3 - Freeze PlugRepair 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 FlightHours (whichever occurs first) Do Part 1 - Upper Wing Skin Surface Detailedand 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 theaffected 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 69 of 113 **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.

**Elapsed Hours Task Hours**  **Number of Per-**

**sons Task** 

4.25 8.50 2 Access

1.50 1.50 1 Part 1: Figure 1

1.50 1.50 1 Part 1: Figure 2

3.20 3.20 1 Part 2: Figure 3

3.20 3.20 1 Part 2: Figure 4

0.20 0.20 1 Figure 5 (a)

0.20 0.20 1 Figure 6 (a)

0.20 0.20 1 Figure 7 (a)

0.20 0.20 1 Figure 8 (a)

0.20 0.20 1 Figure 9 (a)

0.20 0.20 1 Figure 10 (a)

4.25 8.50 2 Close Access (b) (b) TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 70 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Elapsed Hours**  **Task Hours Number of Per-** 

**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

**Title Drawing Number** Support Instl - Engine Strut, Front Spar, Wing 112T7102 Support Instl - Engine Strut, Wing 112T7001

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 71 of 113 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 72 of 113 **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 Ser vice Bulletin**  **(US Dollars) ROLT as** **of the Re vision 1**  **date of this Ser** **vice Bul letin (Cal**  **endar Days)**  **QTY Date**  **Name Kit Number** 

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

**Group 3, 6-7, 9:**

**Unit Price as of the Revision 1** **date of this Ser vice Bulletin**  **(US Dollars) ROLT as** **of the Re vision 1**  **date of this Ser** **vice Bul letin (Cal**  **endar Days)**  **QTY Date**  **Name Kit Number** 

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

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 73 of 113 **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**

**Notes Name**  **QTY New Part Number** 

**-2 -1**  (a) Top Kit - Front Spar Pitch Load Fitting AttachmentFasteners - Replacement . - 015T1829-1

(a) Top Kit - Front Spar Pitch Load Fitting AttachmentFasteners - Replacement - . 015T1829-2

RADIUS FILLER

. 4 112T7001-77
BOLT, 100 DEG HEX DR . 44 BACB30YM12K15X

BOLT

. 44 BACB30YM12K15Y
BOLT, HEX DRIVE

. 44 BACB30YM12K16X
BOLT, HEX DRIVE

. 44 BACB30YM12K16Y
BOLT, 100 DEG HEX DR . 4 BACB30YM12K17X

BOLT

. 4 BACB30YM12K17Y
BOLT, HEX DRIVE

. 4 BACB30YM12K18X

BOLT

. 4 BACB30YM12K18Y
BOLT, 100 DEG HEX DR 48

. BACB30YM14K15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 74 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Kit 015T1829** 

**Notes Name**  **QTY New Part Number** 

**-2 -1** 
BOLT, HEX DRIVE 48

. BACB30YM14K15X
BOLT, HEX DRIVE 48

. BACB30YM14K15Y

BOLT 48

. BACB30YM14K16
BOLT, HEX DRIVE 48

. BACB30YM14K16X
BOLT, HEX DRIVE 48

. BACB30YM14K16Y

NUT

. 48 BACN11Z6CD

NUT 48

. BACN11Z7CD
WASHER, PLAIN

. 48 BACW10BP61APU
WASHER, PLAIN

. 48 BACW10BP62APU
WASHER, PLAIN 48

. BACW10BP71APU
WASHER, PLAIN 48

. BACW10BP72APU

WASHER 48

. BACW10BP7APU (a) If grip length shown is not available at Boeing, fastenerssupplied 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:**

**Notes Name**  **QTY Part Number /**  **Specification** (a) Sealant 1 pint BMS5-95 (b) Bolt 24 BACB30YM14K* (b) Bolt 24 BACB30YM14K*X (b) Bolt 24 BACB30YM14K*Y (b) Washer 24 BACW10BP7APU (b) Washer, Plain 24 BACW10BP71APU (b) Washer, Plain 24 BACW10BP72APU (b) Nut 24 BACN11Z7CD (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 75 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT Group 1-2, 4-5, 8:** 

**Notes Name**  **QTY Part Number /**  **Specification** (b) Refer to 767 Structural Repair Manual Chapter 51 for alternate fasteners.

**Group 3, 6-7, 9:**

**Notes Name**  **QTY Part Number /**  **Specification** (a) Sealant 1 pint BMS5-95 (b) Bolt 24 BACB30YM16K* (b) Washer 24 BACW10BP8APU (b) Nut 24 BACN11Z8CD (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 76 of 113 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 77 of 113 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 78 of 113 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 79 of 113 **BOEING SERVICE BULLETIN 767-57A0117 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 80 of 113 **BOEING SERVICE BULLETIN 767-57A0117 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1: March 02, 2011 81 of 113 **BOEING SERVICE BULLETIN 767-57A0117 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 82 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**

around the fasteners. Refer to SOPM20-30-03 as an accepted procedure. - - Upper Wing Skin Clean 1

for cracks around the aft twenty fourfasteners by a detailed inspection. - - Upper Wing Skin Inspect 2

for cracks around the aft twenty four fasteners as given in 767 NDT Part 4, 57- 20-04. - - Upper Wing Skin Inspect 3

**FIGURE 1: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD FITTING OF THE LEFT WING**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 83 of 113 **BOEING SERVICE BULLETIN 767-57A0117 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 84 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**

around the fasteners. Refer to SOPM20-30-03 as an accepted procedure. - - Upper Wing Skin Clean 1

for cracks around the aft twenty fourfasteners by a detailed inspection. - - Upper Wing Skin Inspect 2

for cracks around the aft twenty four fasteners as given in 767 NDT Part 4, 57- 20-04. - - Upper Wing Skin Inspect 3

**FIGURE 2: ULTRASONIC INSPECTION OF THE UPPER WING SKIN AT THE FRONT SPAR PITCH LOAD FITTING OF THE RIGHT WING**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 85 of 113 **BOEING SERVICE BULLETIN 767-57A0117 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 86 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) 24

- Bolt Remove 1 (b) 24

- Washer Remove (b) 24

- Nut Remove Do a High Frequency Eddy Current inspection for cracks in the wing skin as given in 767 NDT Part 6, 51-00-16. 24

- Wing Skin Hole Inspect 2

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) 24

- Fitting Hole Inspect 3

(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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 87 of 113 **BOEING SERVICE BULLETIN 767-57A0117 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 88 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) 24

- Bolt Remove 1 (b) 24

- Washer Remove (b) 24

- Nut Remove Do a High Frequency Eddy Current inspection for cracks in the wing skin as given in 767 NDT Part 6, 51-00-16. 24

- Wing Skin Hole Inspect 2

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) 24

- Fitting Hole Inspect 3

(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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 89 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** if not already removed. (c) 1

- Bolt Remove 1

if not already removed. (c) 1

- Nut Remove

if not already removed. (c) 1

- Washer Remove

to next larger hole diameter. Refer to Table 1 or Table 2 below, as applicable. (a) 1

- Hole Ream 2

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) 1

- Hole Inspect 3

**FIGURE 5: HOLE REPAIR (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 90 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** as required for the hole sizes indicated in Table 1 or Table2 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. 1

- Hole ColdWork 4

to the diameter given in the After ColdWork Hole Diameter column of Table 1 orTable 2, as applicable. 1

- Hole Ream

(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 (Refer ence Only)** **After ColdWork Hole Di ameter**  **Repaired Hole Diameter Size** 

BACB30YM12K*X

- 0.3866-0.3886 (a) First Oversize

BACB30YM12K*Y

- 0.4022-0.4042 (a) Second Oversize

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

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

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

- 0.453-0.540 (c) Special Repair (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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 91 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT GROUPS 1-2, 4-5, 8: TABLE 1 - HOLE SIZE INCREMENTS** 

**Bolt Part Number (Refer ence Only)** **After ColdWork Hole Di ameter**  **Repaired Hole Diameter Size** 

(d) Cold working required.

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

**Bolt Part Number (Refer ence Only)** **After ColdWork Hole Di ameter**  **Repaired Hole Diameter Size** 

BACB30YM14K*

- 0.434-0.438 (a) Nominal

BACB30YM14K*X

- 0.450-0.453 (a) First Oversize

BACB30YM14K*Y

- 0.466-0.469 (a) Second Oversize

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

- 0.477-0.540 (c) Special Repair (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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 92 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**
to remove anycracks, if not previously done. Maximum hole diameter is 0.540 inches. (a) 1

- Hole Ream 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. 1

- Hole Inspect 2

after all cracks havebeen removed to increase diameter by0.060 inches. Maximum hole diameter is 0.600 inches. 1

- Hole Ream 3

**FIGURE 6: FREEZE PLUG REPAIR (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 93 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**

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. 1

- Freeze Plug Install (New) 4

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 94 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT This Figure applies only to: Group 1-2, 4-5, 8.** 

**FIGURE 7: FASTENER REPLACEMENT, LEFT WING (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 95 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**

wet with BMS 5-95 sealant - - Bolt Install (New) 1

- - Washer Install (New)

- - Nut Install (New)

**FIGURE 7: FASTENER REPLACEMENT, LEFT WING (SHEET 2 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 96 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT FIGURE 7: FASTENER REPLACEMENT, LEFT WING**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 97 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** Optional. (a) 0.3866-0.3886 22 BACB30YM12K15X BOLT, 100 DEG HEX DR A

Optional. (a) 0.4022-0.4042 22 BACB30YM12K15Y BOLT Optional. (a) 0.3866-0.3886 22 BACB30YM12K16X BOLT, HEX DRIVE Optional. (a) 0.4022-0.4042 22 BACB30YM12K16Y BOLT, HEX DRIVE Optional. (b) 0.4335-0.4355 22 BACB30YM14K* BOLT Optional. (b) 0.4491-0.4511 22 BACB30YM14K*X BOLT Optional. (b) 0.4647-0.4667 22 BACB30YM14K*Y BOLT

Use with BACB30YM12K*X. Install under nut. (a) - 22 BACW10BP61APU WASHER, PLAIN

Use with BACB30YM12K*Y. Install under nut. (a) - 22 BACW10BP62APU WASHER, PLAIN

Use with BACB30YM14K*. Install under nut. (b) - 22 BACW10BP7APU WASHER

Use with BACB30YM14K*X. Install under nut. (b) - 22 BACW10BP71APU WASHER, PLAIN

Use with BACB30YM14K*Y. Install under nut. (b) - 22 BACW10BP72APU WASHER, PLAIN

Use with any BACB30YM12K bolt. Torque to 300-320 in-lbs. (a) - 22 BACN11Z6CD NUT

Use with any BACB30YM14K bolt. Torque to 420-450 in-lbs. (b) - 22 BACN11Z7CD NUT

**FIGURE 7: FASTENER REPLACEMENT, LEFT WING (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 98 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** Optional. (a) 0.3866-0.3886 2 BACB30YM12K17X BOLT, 100 DEG HEX DR B

Optional. (a) 0.4022-0.4042 2 BACB30YM12K17Y BOLT Optional. (a) 0.3866-0.3886 2 BACB30YM12K18X BOLT, HEX DRIVE Optional. (a) 0.4022-0.4042 2 BACB30YM12K18Y BOLT Optional. (b) 0.4335-0.4355 2 BACB30YM14K* BOLT Optional. (b) 0.4491-0.4511 2 BACB30YM14K*X BOLT Optional. (b) 0.4647-0.4667 2 BACB30YM14K*Y BOLT

Use with BACB30YM12K*X. Install under nut. (a) - 2 BACW10BP61APU WASHER, PLAIN

Use with BACB30YM12K*Y. Install under nut. (a) - 2 BACW10BP62APU WASHER, PLAIN

Use with BACB30YM14K*. Install under nut. (b) - 2 BACW10BP7APU WASHER

Use with BACB30YM14K*X. Install under nut. (b) - 2 BACW10BP71APU WASHER, PLAIN

Use with BACB30YM14K*Y. Install under nut. (b) - 2 BACW10BP72APU WASHER, PLAIN

- 2 112T7001-77 RADIUS FILLER Use with any BACB30YM12K bolt. Torque to 300-320 in-lbs. (a) - 2 BACN11Z6CD NUT

Use with any BACB30YM14K bolt. Torque to 420-450 in-lbs. (b) - 2 BACN11Z7CD NUT

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 99 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT This Figure applies only to: Group 1-2, 4-5, 8.** 

**FIGURE 8: FASTENER REPLACEMENT, RIGHT WING (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 100 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**

wet with BMS 5-95 sealant - - Bolt Install (New) 1

- - Washer Install (New)

- - Nut Install (New)

**FIGURE 8: FASTENER REPLACEMENT, RIGHT WING (SHEET 2 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 101 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT FIGURE 8: FASTENER REPLACEMENT, RIGHT WING**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 102 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** Optional. (a) 0.3866-0.3886 22 BACB30YM12K15X BOLT, 100 DEG HEX DR A

Optional. (a) 0.4022-0.4042 22 BACB30YM12K15Y BOLT Optional. (a) 0.3866-0.3886 22 BACB30YM12K16X BOLT, HEX DRIVE Optional. (a) 0.4022-0.4042 22 BACB30YM12K16Y BOLT, HEX DRIVE Optional. (b) 0.4335-0.4355 22 BACB30YM14K* BOLT Optional. (b) 0.4491-0.4511 22 BACB30YM14K*X BOLT Optional. (b) 0.4647-0.4667 22 BACB30YM14K*Y BOLT

Use with BACB30YM12K*X. Install under nut. (a) - 22 BACW10BP61APU WASHER, PLAIN

Use with BACB30YM12K*Y. Install under nut. (a) - 22 BACW10BP62APU WASHER, PLAIN

Use with BACB30YM14K*. Install under nut. (b) - 22 BACW10BP7APU WASHER

Use with BACB30YM14K*X. Install under nut. (b) - 22 BACW10BP71APU WASHER, PLAIN

Use with BACB30YM14K*Y. Install under nut. (b) - 22 BACW10BP72APU WASHER, PLAIN

Use with any BACB30YM12K bolt. Torque to 300-320 in-lbs. (a) - 22 BACN11Z6CD NUT

Use with any BACB30YM14K bolt. Torque to 420-450 in-lbs. (b) - 22 BACN11Z7CD NUT

**FIGURE 8: FASTENER REPLACEMENT, RIGHT WING (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 103 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** Optional. (a) 0.3866-0.3886 2 BACB30YM12K17X BOLT, 100 DEG HEX DR B

Optional. (a) 0.4022-0.4042 2 BACB30YM12K17Y BOLT Optional. (a) 0.3866-0.3886 2 BACB30YM12K18X BOLT, HEX DRIVE Optional. (a) 0.4022-0.4042 2 BACB30YM12K18Y BOLT Optional. (b) 0.4335-0.4355 2 BACB30YM14K* BOLT Optional. (b) 0.4491-0.4511 2 BACB30YM14K*X BOLT Optional. (b) 0.4647-0.4667 2 BACB30YM14K*Y BOLT

Use with BACB30YM12K*X. Install under nut. (a) - 2 BACW10BP61APU WASHER, PLAIN

Use with BACB30YM12K*Y. Install under nut. (a) - 2 BACW10BP62APU WASHER, PLAIN

Use with BACB30YM14K*. Install under nut. (b) - 2 BACW10BP7APU WASHER

Use with BACB30YM14K*X. Install under nut. (b) - 2 BACW10BP71APU WASHER, PLAIN

Use with BACB30YM14K*Y. Install under nut. (b) - 2 BACW10BP72APU WASHER, PLAIN

- 2 112T7001-77 RADIUS FILLER Use with any BACB30YM12K bolt. Torque to 300-320 in-lbs. (a) - 2 BACN11Z6CD NUT

Use with any BACB30YM14K bolt. Torque to 420-450 in-lbs. (b) - 2 BACN11Z7CD NUT

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 104 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT This Figure applies only to: Group 3, 6-7, 9.** 

**FIGURE 9: FASTENER REPLACEMENT, LEFT WING (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 105 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**

wet with BMS 5-95 sealant - - Bolt Install (New) 1

- - Washer Install (New)

- - Nut Install (New)

**FIGURE 9: FASTENER REPLACEMENT, LEFT WING (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 106 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT FIGURE 9: FASTENER REPLACEMENT, LEFT WING**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 107 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** Optional. (a) 0.434-0.438 24 BACB30YM14K15 BOLT, 100 DEG HEX DR A

Optional. (a) 0.450-0.453 24 BACB30YM14K15X BOLT, HEX DRIVE Optional. (a) 0.466-0.469 24 BACB30YM14K15Y BOLT, HEX DRIVE Optional. (a) 0.434-0.438 24 BACB30YM14K16 BOLT Optional. (a) 0.450-0.453 24 BACB30YM14K16X BOLT, HEX DRIVE Optional. (a) 0.466-0.469 24 BACB30YM14K16Y BOLT, HEX DRIVE Optional. (b) 0.496-0.500 24 BACB30YM16K* BOLT

Use with BACB30YM14K*. Install under nut. (a) - 24 BACW10BP7APU WASHER

Use with BACB30YM14K*X. Install under nut. (a) - 24 BACW10BP71APU WASHER, PLAIN

Use with BACB30YM14K*Y. Install under nut. (a) - 24 BACW10BP72APU WASHER, PLAIN

Use with BACB30YM16K*. Install under nut. (b) - 24 BACW10BP8APU WASHER

Use with any BACB30YM14K bolt. Torque to 420-450 in-lbs. (a) - 24 BACN11Z7CD NUT

Use with BACB30YM16K*bolt. Torque to 700-740 inlbs. (b) - 24 BACN11Z8CD NUT

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 108 of 113 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 109 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP**

wet with BMS 5-95 sealant - - Bolt Install (New) 1

- - Washer Install (New)

- - Nut Install (New)

**FIGURE 10: FASTENER REPLACEMENT, RIGHT WING (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 110 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT FIGURE 10: FASTENER REPLACEMENT, RIGHT WING**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 111 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** Optional. (a) 0.434-0.438 24 BACB30YM14K15 BOLT, 100 DEG HEX DR A

Optional. (a) 0.450-0.453 24 BACB30YM14K15X BOLT, HEX DRIVE Optional. (a) 0.466-0.469 24 BACB30YM14K15Y BOLT, HEX DRIVE Optional. (a) 0.434-0.438 24 BACB30YM14K16 BOLT Optional. (a) 0.450-0.453 24 BACB30YM14K16X BOLT, HEX DRIVE Optional. (a) 0.466-0.469 24 BACB30YM14K16Y BOLT, HEX DRIVE Optional. (b) 0.496-0.500 24 BACB30YM16K* BOLT

Use with BACB30YM14K*. Install under nut. (a) - 24 BACW10BP7APU WASHER

Use with BACB30YM14K*X. Install under nut. (a) - 24 BACW10BP71APU WASHER, PLAIN

Use with BACB30YM14K*Y. Install under nut. (a) - 24 BACW10BP72APU WASHER, PLAIN

Use with BACB30YM16K*. Install under nut. (b) - 24 BACW10BP8APU WASHER

Use with any BACB30YM14K bolt. Torque to 420-450 in-lbs. (a) - 24 BACN11Z7CD NUT

Use with BACB30YM16K*bolt. Torque to 700-740 inlbs. (b) - 24 BACN11Z8CD NUT

(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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 112 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT APPENDIX A: SUPPLEMENTAL FASTENER REPLACEMENT (EXAMPLE)**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 01, 2009 767-57A0117 Revision 1 March 02, 2011 113 of 113 **BOEING SERVICE BULLETIN 767-57A0117 ALERT**  **ALERT**