### Commercial **Airplanes** 

# 767 Service Bulletin **SPECIAL ATTENTION Number: 767-53-0207**  Original Issue: December 17, 2009 ATA System: 5365 2312 **SUBJECT:** FUSELAGE - Section 46 Skin - Fuselage Skin and Backup Structure Inspection and Repair at the Lower VHF Antenna Cutout at Station 1197 + 99, Between Stringers 39L and 39R Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 1 of 27 4.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 2 of 27 **BOEING SERVICE BULLETIN 767-53-0207**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Data supplied with this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 15 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 17 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 17 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FIGURE 1: FUSELAGE SKIN WITH THE ANTENNA REMOVED - INSPECTION . . . . . . . . . . . 22 FIGURE 2: BACKUP STRUCTURE - INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FIGURE 3: FUSELAGE SKIN WITHOUT ANTENNA REMOVED - INSPECTION . . . . . . . . . . . . 26

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 3 of 27 **BOEING SERVICE BULLETIN 767-53-0207**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 4 of 27 **BOEING SERVICE BULLETIN 767-53-0207**

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### Commercial **Airplanes** 

# 767 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 767-53-0207** Original Issue: December 17, 2009 ATA System: 5365 2312 **SUBJECT:** FUSELAGE - Section 46 Skin - Fuselage Skin and Backup Structure Inspection and Repair at the Lower VHF Antenna Cutout at Station 1197 + 99, Between Stringers 39L and 39R BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Accomplishment of the inspections in this service bulletin will make sure that cracks in fuselage skin around the VHF antenna and internal backup structure at station 1197+ 99 are found and repaired. If not repaired, cracks in the fuselage skin and/or internal backup structure could result in unscheduled repairs. Two operators have reported cracks in the section 46 fuselage lower skin around the periphery of the VHF antenna baseplate at station 1197+99. One operator reported 5 cracks with a maximum length of 11 inches, found on an airplane with 38,804 total flight-hours/34,929 total flight-cycles. Another operator reported a maximum crack length of 9.5 inches, found on an airplane with 60,467 total flight-hours/29,185 total fight-cycles. Boeing investigation has revealed that the fuselage skin and/or internal backup structure cracks are attributed to fatigue. This fatigue is the result of bending loads in the skin, which are caused by vibration of the antenna in flight. No operator reported crack findings for the backup structure. This service bulletin gives instructions to do detail inspections for cracks, and repair if necessary, of the fuselage skin and internal backup structure at the VHF antenna at station 1197+ 99. Boeing Service Related Problem (SRP) 767-SRP-53-0323 is related to this service bulletin. **ACTION** Part 1 - Fuselage Skin and Backup Structure Inspection ( Initial Inspection ) Do an external Detail Inspection ( DI ) of the fuselage skin at the lower aft VHF antenna cutout and internal DI of the backup structure for crack at station 1197+99 and do as follows: Condition 1 ( No fuselage skin and backup structure crack found ) Do an external DI of the fuselage skin in accordance with Part 2 at the times given in Paragraph 1.E.Table 2 Compliance.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 5 of 27Condition 2 ( Fuselage skin crack found ) Repair fuselage skin crack in accordance with 767-300 SRM. Condition 3 ( Backup structure crack found ) Repair or replace cracked part(s). Part 2 - Fuselage Skin Inspection ( Repeat Inspection ) Do an external DI of the fuselage skin for crack at the periphery of the antenna baseplate and do as follows: Condition 4 ( No fuselage skin crack found ) Repeat Part 2 Paragraph 1 inspection at the times given in Paragraph 1.E. Table 2 Compliance. Condition 5 ( Fuselage skin crack found ) Repair fuselage skin crack in accordance with 767-300 SRM. Airplanes after line number 350 incorporate an improved VHF antenna backup structure that makes skin cracks around the antenna cutout less likely. **EFFECTIVITY** 767-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 6 of 27 **BOEING SERVICE BULLETIN 767-53-0207**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 7 of 27 **BOEING SERVICE BULLETIN 767-53-0207**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 8 of 27 **BOEING SERVICE BULLETIN 767-53-0207**

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### Commercial **Airplanes** 

# 767 Service Bulletin **SPECIAL ATTENTION Number: 767-53-0207**  Original Issue: December 17, 2009 ATA System: 5365 2312 **SUBJECT:** FUSELAGE - Section 46 Skin - Fuselage Skin and Backup Structure Inspection and Repair at the Lower VHF Antenna Cutout at Station 1197 + 99, Between Stringers 39L and 39R BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-300 airplanes. Line numbers 132-350 except 310, 323, 328, 331,and 332. - 1

Airplane Models: 767-300 **Group Variable Number**  1 VK001 - VK011 1 VK021 - VK022 1 VK031 - VK048 1 VK081 - VK097 1 VL001 - VL006 1 VL011 1 VN001 - VN015

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 9 of 27**Group Variable Number**  1 VN051 - VN060 1 VN081 - VN088 1 VN111 - VN119 1 VN151 - VN156 1 VN163 - VN166 1 VN171 - VN173 1 VN191 - VN192 1 VN211 - VN212 1 VN221 - VN222 1 VN231 - VN234 1 VN241 1 VN251 - VN259 1 VN291 1 VN301 - VN303 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** Accomplishment of the inspections in this service bulletin will make sure that cracks in fuselage skin around the VHF antenna and internal backup structure at station 1197+ 99 are found and repaired. If not repaired, cracks in the fuselage skin and/or internal backup structure could result in unscheduled repairs. Two operators have reported cracks in the section 46 fuselage lower skin around the periphery of the VHF antenna baseplate at station 1197+99. One operator reported 5 cracks with a maximum length of 11 inches, found on an airplane with 38,804 total flight-hours/34,929 total flight-cycles. Another operator reported a maximum crack length of 9.5 inches, found on an airplane with 60,467 total flight-hours/29,185 total fight-cycles. Boeing investigation has revealed that the fuselage skin and/or internal backup structure cracks are attributed to fatigue. This fatigue is the result of bending loads in the skin, which are caused by vibration of the antenna in flight. No operator reported crack findings for the backup structure. This service bulletin gives instructions to do detail inspections for cracks, and repair if necessary, of the fuselage skin and internal backup structure at the VHF antenna at station 1197+ 99. Boeing Service Related Problem (SRP) 767-SRP-53-0323 is related to this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 10 of 27 **BOEING SERVICE BULLETIN 767-53-0207 D. Description**  Part 1 - Fuselage Skin and Backup Structure Inspection. ( Initial Inspection ) Do an external Detail Inspection ( DI ) of the fuselage skin at the lower aft VHF antenna cutout and internal DI of the backup structure for crack at station 1197+ 99 and do as follows: Condition 1 ( No fuselage skin and backup structure crack found ) Do an external DI of the fuselage skin in accordance with Part 2 at the times given in Paragraph 1.E. Table 2 Compliance. Condition 2 ( Fuselage skin crack found ) Repair fuselage skin crack in accordance with 767-300 SRM. Condition 3 ( Backup structure crack found ) Repair or replace cracked part(s). Part 2 - Fuselage Skin Inspection ( Repeat Inspection ) Do an external DI of the fuselage skin for crack at the periphery of the antenna baseplate and do as follows: Condition 4 ( No fuselage skin crack found ) Repeat Part 2 Paragraph 1 inspection at the times given in Paragraph 1.E. Table 2 Compliance Condition 5 ( Fuselage skin crack found ) Repair fuselage skin crack in accordance with 767-300 SRM Airplanes after line number 350 incorporate an improved VHF antenna backup structure that makes skin cracks around the antenna cutout less likely. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 155, 156 767-300 **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 11 of 27 **BOEING SERVICE BULLETIN 767-53-0207 Table 1 - Initial Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later )**  **Action Condition** 

- Within 3000flight cycles after the date onthis service bulletin. Within 25,000total flight cycles. ( 1 ) Do an external Detail Inspection ( DI ) of thefuselage skin with the antenna removed, in accordance with Accomplishment Instructions Paragraph 3.B. Part 1. All airplanes (a)

- Within 3,000flight cycles after the date onthis service bulletin Within 25,000total flight cycles. ( 2 ) Do an internal DI of the antenna backup structure in accordancewith Accomplishment Instructions Paragraph 3.B. Part 1. or Within 6,000 flight cycles if no fuselage skin cracks arefound per external detailed inspection. ( 1 )

- - - Go to Accomplishment Instructions Paragraph 3.B. Part 2. Condition 1 - No fuselage skin and backup structure crack found. (b)

- Before further flight. Repair fuselage skin crack in accordance withAccomplishment Instructions Paragraph 3.B. Part 1. Condition 2 - Fuselage skin crack found.

- - Before further flight. Repair or replace cracked part(s) in accordance withAccomplishment Instructions Paragraph 3.B. Part 1. Condition 3 - Backup structure crack found.

(a) Airplanes with FAA approved repairs for skin cracking at this subject location prior to the release of this service bulletin, do not require this service bulletin action. (b) Do the repair in accordance with Accomplishment Instructions 3.B. Part 1 to terminate the inspections in this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 12 of 27 **BOEING SERVICE BULLETIN 767-53-0207 Table 2 - Repeat Inspection**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition**  3,000 flight cycles.

- Within 3,000 flight cyclesfrom last external detailed inspection. Do an external DI of thefuselage skin without antenna removal, in accordance with Accomplishment Instructions Paragraph 3.B., Part 2. Condition 4 - No fuselage skin crack found.

(a)

- Before further flight. Repair fuselage skin crack in accordance withAccomplishment Instructions Paragraph 3.B. Part 2. Condition 5 - Fuselage skin crack found.

(a) Do the repair in accordance with Accomplishment Instructions 3.B. Part 2 to terminate the inspections in this service bulletin.
DAMAGE TOLERANCE BASED STRUCTURAL INSPECTIONS: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the maintenance program. No new DTI are required by this service bulletin. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. **G. Manpower** The table below shows an estimate of the task hours necessary to do this 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 13 of 27 **BOEING SERVICE BULLETIN 767-53-0207**• Time to cure the materials • Time to make the parts • Time to find the tools. Part 1 - Fuselage Skin and Backup Structure Inspection. ( Initial Inspection ) **Condition 1 - No fuselage skin and backup structure crack found Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 
2.50 2.50 1 Open Access 0.15 0.15 1 Figure 1 2.00 2.00 1 Figure 2 2.50 2.50 1 Close Access 7.15 7.15 TOTAL FOR EACH AIRPLANE **Condition 2 - Fuselage skin crack found Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 
2.50 2.50 1 Open Access 0.15 0.15 1 Figure 1 15.50(a) 31.00(a) 2 Repair 2.50 2.50 1 Close Access 20.65 36.15 TOTAL FOR EACH AIRPLANE (a) Does not include time to make parts. **Condition 3 - Backup structure crack found Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 
2.50 2.50 1 Open Access 2.00 2.00 1 Figure 2 2.50 2.50 1 Close Access 7.00(a) 7.00(a) TOTAL FOR EACH AIRPLANE (a) More time will be necessary for repair or replace cracked part(s). Part 2 - Fuselage Skin Inspection. ( Repeat Inspection )

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 14 of 27 **BOEING SERVICE BULLETIN 767-53-0207 Condition 4 - No fuselage skin crack found**  **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task**
0.15 0.15 1 Figure 3 0.15 0.15 TOTAL FOR EACH AIRPLANE **Condition 5 - Fuselage skin crack found Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 
2.50 2.50 1 Open Access 15.50(a) 31.00(a) 2 Repair 2.50 2.50 1 Close Access 20.50 36.00 TOTAL FOR EACH AIRPLANE (a) Does not include time to make parts. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data a. 767 Aircraft Maintenance Manual (AMM) 23-12-03, 25-52-03, and 53-01-05. b. 767-300 Structural Repair Manual (SRM) 53-60-01. c. Service Related Problem (SRP) 767-SRP-53-0323. 2. Data supplied with this Service Bulletin None. 3. Installation Drawings Used in the Preparation of this Service Bulletin
**Title Drawing Number**  Panel Integration - Antenna Provisions 146T0012 This drawing is used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 15 of 27 **BOEING SERVICE BULLETIN 767-53-0207 K. Publications Affected**  **Chapter-Section Publication**  53-60 767 Structural Repair Manual **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: December 17, 2009 767-53-0207 16 of 27 **BOEING SERVICE BULLETIN 767-53-0207 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** None. **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 None. 2. Parts and Materials Supplied by the Operator None. **NOTE:** No parts or materials are required for inspection. However, if repairs are necessary, the materials shown in the applicable Structural Repair Manual sections will be necessary. 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: December 17, 2009 767-53-0207 17 of 27 **BOEING SERVICE BULLETIN 767-53-0207**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 18 of 27 **BOEING SERVICE BULLETIN 767-53-0207**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. The instructions identified in Paragraph 3.B., Work Instructions 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. A Detailed Inspection ( DI ) 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. 5. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS Part 1 - Fuselage Skin and Backup Structure Inspection ( Initial Inspection )**  1. Remove/keep lower VHF antenna at station 1197 + 99. Refer to 767 AMM 23-12-03 as an acceptable procedure. 2. Do an external Detailed Inspection ( DI ) of the fuselage skin with the antenna removed at the lower aft VHF antenna cutout in accordance with Figure 1 and at the time given in Paragraph 1.E. Table 1 Compliance. **NOTE:** If no fuselage skin cracks are found, the following internal DI of the backup structure for crack inspection can be deferred in accordance with Paragraph 1.E. Table 1 Compliance. 3. Remove/keep cargo floor panel at station 1197+ 99, S-39L to S-39R approximately. Refer to 767 AMM 53-01-05 as an acceptable procedure. 4. Remove/keep insulation blankets at station 1197+ 99, S-39L to S-39R approximately. Refer to 767 AMM 25-52-03 as an acceptable procedure. 5. Do an internal DI of the backup structure for crack in accordance with Figure 2 and at the times given in Paragraph 1.E. Table 1 Compliance and do as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 19 of 27 **BOEING SERVICE BULLETIN 767-53-0207**Condition 1 - ( No fuselage skin and backup structure crack found ) a. Install/kept insulation blankets. Refer to 767 AMM 25-52-03 as an acceptable procedure. b. Install/kept cargo floor panel. Refer to 767 AMM 53-01-05 as an acceptable procedure. c. Install/kept lower VHF antenna at station 1197+ 99. Refer to 767 AMM 23-12-03 as an acceptable procedure. d. Go to Part 2. Condition 2 - ( Fuselage skin crack found ) a. Repair fuselage skin crack in accordance with 767-300 SRM 53-60-01, Repair 2 before further flight. **NOTE:** Accomplishment of this repair terminates the Part 2 repeat inspection in this service bulletin. b. Install/kept insulation blankets. Refer to 767 AMM 25-52-03 as an acceptable procedure. c. Install/kept cargo floor panel. Refer to 767 AMM 53-01-05 as an acceptable procedure. d. Install/kept lower VHF antenna at station 1197+ 99. Refer to 767 AMM 23-12-03 as an acceptable procedure. Condition 3 - ( Backup structure crack found ) a. Repair or replace cracked part(s) before further flight. b. Install/kept insulation blankets. Refer to 767 AMM 25-52-03 as an acceptable procedure. c. Install/kept cargo floor panel. Refer to 767 AMM 53-01-05 as an acceptable procedure. d. Install/kept lower VHF antenna at station 1197+ 99. Refer to 767 AMM 23-12-03 as an acceptable procedure. 6. Put the airplane back to a serviceable condition. **Part 2 - Fuselage Skin Inspection ( Repeat Inspection )** 1. Do an external DI of the fuselage skin without antenna removal for crack at the periphery of the antenna baseplate in accordance with Figure 3 and at the times given in Paragraph 1.E. Table 2 Compliance and do as follows: Condition 4 - ( No fuselage skin crack found ) a. Repeat Part 2 Paragraph 1 inspection at the times given in Paragraph 1.E. Table 2 Compliance. Condition 5 - ( Fuselage skin crack found ) a. Repair fuselage skin crack in accordance with 767-300 SRM 53-60-01, Repair 2 before further flight.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 20 of 27 **BOEING SERVICE BULLETIN 767-53-0207 NOTE:**  Accomplishment of this repair terminates the Part 2 repeat inspection in this service bulletin. 2. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 21 of 27 **BOEING SERVICE BULLETIN 767-53-0207 FIGURE 1: FUSELAGE SKIN WITH THE ANTENNA REMOVED - INSPECTION**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 22 of 27 **BOEING SERVICE BULLETIN 767-53-0207**The step number shown below agree with the number shown in the circle symbol in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a)

- - Fuselage Skin Inspect 1 (a) Detail inspection for cracks in the fuselage skin under the VHF antenna and a 2 inch periphery around the antenna footprint.

**FIGURE 1: FUSELAGE SKIN WITH THE ANTENNA REMOVED - INSPECTION (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 23 of 27 **BOEING SERVICE BULLETIN 767-53-0207 FIGURE 2: BACKUP STRUCTURE - INSPECTION**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 24 of 27 **BOEING SERVICE BULLETIN 767-53-0207**The step number shown below agree with the number shown in the circle symbol in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b)

- - Backup Structure Inspect 1 (a) Detail inspection for cracks of the backup structure between stringer 39L and 39R including stringers and between station 1197+ 88 and 1197+110. (b) Backup structure consist of nut plate assemblies, channels, clips, and support bracket.

**FIGURE 2: BACKUP STRUCTURE - INSPECTION (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 25 of 27 **BOEING SERVICE BULLETIN 767-53-0207 FIGURE 3: FUSELAGE SKIN WITHOUT ANTENNA REMOVED - INSPECTION**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 26 of 27 **BOEING SERVICE BULLETIN 767-53-0207**The step number shown below agree with the number shown in the circle symbol in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a)

- - Fuselage Skin Inspect 1 (a) Detail inspection for cracks in the fuselage skin around 2 inch periphery around the antenna baseplate.

**FIGURE 3: FUSELAGE SKIN WITHOUT ANTENNA REMOVED - INSPECTION (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 17, 2009 767-53-0207 27 of 27 **BOEING SERVICE BULLETIN 767-53-0207**