November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 56 ALERT ALERT 

### Commercial **Airplane Group**  

# 757

**ALERT ALERT**  

# Service Bulletin

**Number: 757-54A0047** Date: November 13, 2003 Revision 3: June 27, 2007 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.**BLANK PAGE** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

BLANK PAGE**Table of Contents** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT Table of Contents**  Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 26 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 26 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 29 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 30 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 FIGURE 1: ACCESS FOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE . . . . . . . . . . . . . . 37 FIGURE 3: INSPECTION - FASTENERS - HORIZONTAL FLANGE . . . . . . . . . . . . . . . . . . 39 FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE . . . . . . . . . . . . 41 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE . . . . . . . . . . 43 FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE . . . . . . . . 45 FIGURE 7: THIS FIGURE HAS BEEN DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND . . . . . . . . . . . . . . . . . . . . 49 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE. . . . . . . . . . . . . . . . . . . . . 51 FIGURE 10: SEAL COVER PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS . . . . . . 55**Table of Contents** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

BLANK PAGENovember 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 56 ALERT ALERT 

### Commercial **Airplane Group**  

# 757

**ALERT ALERT**  

# Service Bulletin

**Number: 757-54A0047** 

### Revision Transmittal Sheet Date: November 13, 2003 Revision 3: June 27, 2007 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting
This Revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes changed as shown in the Original issue, Revision 1, or Revision 2 of this service bulletin, however the conditions and the compliance time for doing the inspection of the four critical fasteners in the horizontal flange have changed. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-12-04, is related to this service bulletin. **REASON FOR REVISION** Revision 03 is sent to give revised inspection compliance times and replace the phrase "one time inspection" with "inspection" when refering to the Part IV inspection of the critical fastener holes on the horizontal flange . These sections of the service bulletin are changed with revision 03: — Summary - Compliance information is deleted from the Compliance section. — Paragraph 1.E., Compliance - Compliance times are revised and presented in a tabular format. — Summary, Planning Information, Work Instructions: replaced the words "one time inspection" with "inspection". Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes.November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT REVISION HISTORY**  Original Issue: November 13, 2003 Revision 01: March 24, 2005 Revision 02: January 31, 2007 Revision 03: June 27, 2007November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 56 ALERT ALERT 

### Commercial **Airplane Group**  

# 757

**ALERT ALERT**  

# Service Bulletin

**Number: 757-54A0047** 

### Summary Date: November 13, 2003 Revision 3: June 27, 2007 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting

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**This service bulletin gives the instructions to inspect the joint between the aft torque bulkhead and the strut-todiagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and to do an inspection and repair of the four critical fastener holes on the horizontal flange. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. **Service History Date Hours Cycles Strut Report**  12/93 29,451 10,284 - One bolt sheared in horizontal flange. Four bolts loose in vertical flange. 11/96 25,768 9,358 No. 1 & 2 Four bolts loose in vertical flange of both struts. 06/98 - - No. 1 & 2 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. 11/99 55,789 21,749 No. 1 & 2 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. 01/01 46,459 20,161 No. 1 & 2 Sixteen bolts loose in horizontal flange. 09/01 49,019 13,662 No. 1 Two bolts loose in vertical flange.November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 56 Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095 and 757-SRP-54-0118 are related to this service bulletin. **ACTION** Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs. Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A boroscope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection and repair of the four critical fastener holes on the horizontal flange. 01/02 23,423 14,633 - Two bolt heads cracked. 04/02 16,601 12,493 No. 1 & 2 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. 05/02 43,822 15,522 No. 1 & 2 Migrated shim between bulkhead and vertical flange of fitting. 06/02 46,758 15,900 No. 2 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. 12/02 49,807 20,090 No. 1 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. 04/03 50,841 22,111 - Two loose bolts in vertical flange. 09/03 30,072 9,991 No. 1 Three loose bolts in vertical flange. 09/03 60,715 26,914 No. 1 & 2 Migrated shims between bulkhead and vertical flange of fitting. 10/03 44,985 15,004 No. 2 Three loose bolts in vertical flange. 01/04 12,368 7,922 No. 2 Three loose bolts in vertical flange. 02/04 12,119 7,592 No. 1 Four loose bolts in vertical flange. 04/06 44,423 13,083 No. 1 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. **Service History Date Hours Cycles Strut Report** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 56 As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. **EFFECTIVITY** 757-200/-200CB and -200PF airplanes line numbers 1 thru 1048, powered by Rolls Royce engines. **COMPLIANCE** Refer to paragraph 1.E., Compliance for compliance information. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-12-04, is related to this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin.
**MANPOWER**

(a) Inspections only. Does not include time to make repairs if loose fasteners or cracks are found.
**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability. **Airplanes Total Task Hours Elapsed Hours** All 34 (a) 17 (a)November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

HORIZONTAL FLANGE OF FITTING (16 LOCATIONS) INSPECT FASTENERS IN

INSTALLATION INSPECT SHIM INSPECT FASTENERS IN VERTICAL FLANGE (4 LOCATIONS) OF FITTING A

A

FWD FWD



### A-AW38926November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 56 ALERT ALERT 

### Commercial **Airplane Group**  

# 757

**ALERT ALERT**  

# Service Bulletin

**Number: 757-54A0047** Date: November 13, 2003 Revision 3: June 27, 2007 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Inspection for Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting

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 Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.

Airplane models: 757-200 757-200CB 757-200PF IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AEROTURBINE (AUB) 1 NA023 NA395 **GROUP CONFIGURATION DESCRIPTION** 1 - All 757-200 airplanes line number 1 thru 735, powered by Rolls Royce engines. 1 Airplanes without SB 757-54-0035 incorporation 2 Airplanes with SB 757-54-0035 incorporation 2 - All 757-200 airplanes line number 736 thru 1048, powered by Rolls Royce engines.November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** AIR ASTANA (AKZ) 1 NB561 2 NT231 NT411–NT412 AIR CHINA SOUTHWEST BRANCH (XIN) 1 NB291–NB295 NB297–NB299 NB301–NB302 NB327 2 NT201–NT202 AIR FINLAND (FNL) 1 NB221 NB239 NB454 AIR GREENLAND AS (GRL) 1 NA350 AMERICA WEST AIRLINES (AMW) 1 NA018–NA020 NB021–NB023 NB036–NB041 AMERICAN AIRLINES (AAL) 1 ND011–ND044 ND046–ND059 ND111–ND113 ND161–ND166 ND168–ND199 2 NT731–NT750 NT971–NT985 ASTRAEUS, LTD. (AUA) 1 NA442 NB131 NB134 NB142 2 ND401 ATA AIRLINES, INC. (AAT) 1 NC058 NC061 2 NC062 NT281–NT283 ATLASJET AIRLINES (ABE) 1 NA025–NA026 NA196 2 NT910–NT911 AVIANCA (AVI) 1 NA341 NA347 NA351 NA406 NA444 NB324 NB326 AZERBAIJAN AIRLINES (AHY) 1 ND248 2 NT437–NT438 BABCOCK & BROWN A/C MANAGEMENT (BBB) 1 NA447 BELAIR AIRLINES (BLB) 2 NT426–NT427 BRITISH AIRWAYS (BAB) 1 NA237–NA239 NA303–NA305 NA398 2 NB581–NB583 NT401–NT403November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** CAMEROON AIRLINES (CAM) 1 NB135 CEBU PACIFIC AIR (CEB) 1 NA301–NA302 CHINA SOUTHERN AIRLINES (GUN) 1 NA349 NB064–NB068 NB070 NB261–NB267 NB296 CHINA XINJIANG AIRLINES (XIJ) 1 NB325 NB328 2 NT381–NT386 NT408–NT409 CONTINENTAL AIRLINES (CAL) 1 ND301–ND317 2 ND318–ND322 NT751–NT769 CORPORACION YGNUS AIR (REI) 1 ND241 DHL INTERNATIONAL (DHI) 1 NA201–NA204 NA206–NA213 NA215–NA236 EL AL ISRAEL AIRLINES (ELA) 1 NB073 ND002 ND004–ND007 ESTADO NACIONAL ARGENTINO ENA (ESA) 1 NB144 EUROATLANTIC AIRWAYS (MAE) 1 NA197 EUROPEAN AIR TRANSPORT (EPT) 1 NC974 FAR EASTERN AIR TRANSPORT (FAT) 1 NC973 FEDEX (FED) 1 NA394 NB501 NB503 NB508 FIRST CHOICE AIRWAYS (ATZ) 1 NA346 NA352 NA443 NB322 NB329 NB506–NB507 2 NJ001–NJ004 NT245–NT246 NT404–NT407 FLYGLOBESPAN.COM (FGS) 1 NB224 FLYJET LIMITED (FJE) 1 NB132 NB140November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** FUNAIR (FUN) 2 NT909 GIRJET (GRJ) 1 NA348 HARMONY AIRWAYS INC. (MYA) 1 ND001 ND003 2 NT248 HOLA AIRLINES (HLB) 1 NA399 HONEYWELL AEROSPACE (SGC) 1 NA005 IBERIA AIRLINES (IBE) 2 NT905–NT908 NT915–NT916 ICELANDAIR (ICE) 1 NA028 NB079 NB138–NB139 NB421 NC971 ND201–ND203 ND244–ND247 2 NN001–NN002 NT861–NT862 NT913 JET2.COM LTD (CEX) 1 NA396–NA397 NB061–NB063 NB071–NB072 NB145 KRASAIR (ZXD) 2 NT901–NT904 L-3 C.I.S. (CIJ) 1 NB146–NB148 2 NT436 L.T.E. INTERNATIONAL AIRWAYS (LTE) 1 NA191 LEGATUM (LGM) 1 NC060 MACQUARIE AIR FINANCE (ZGT) 1 NA194 MAP (MGP) 1 NA214 MEXICO'S PRESIDENTIAL AIRCRAFT (MXG) 1 NA027 MONARCH AIRLINES (MON) 1 NA401–NA405 NA407–NA408November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** MYTRAVEL AIRWAYS (GUE) 1 NA006 NA008 2 NB571 NASA (NAS) 1 NA002 NORTH AMERICAN AIRLINES (NNA) 1 NB236 2 NT239–NT240 NT242 NT247 OCEANAIR AIRLINES (OAL) 1 NB453 OMNI AIR INTERNATIONAL (OAE) 1 NA446 NB137 NB204 NB225 ORIENT THAI AIRLINES (OTH) 1 NA193 PACE AIRLINES (PIE) 1 NA205 ND242 PAI AVIATION, INC. (PSS) 1 NA391 PLUNA (PLU) 1 NB133 PRIMARIS AIRLINES INC. (PIM) 1 NA199 PRIVATAIR (PTS) 1 NB136 PRIVILEGE STYLE (PVG) 1 ND243 RAK AIRWAYS (RKW) 2 NT914 ROYAL BRUNEI AIRLINES (RBA) 1 NB052 ROYAL NEPAL AIRLINES (RNA) 1 ND891 ND895 ROYAL NEW ZEALAND AIR FORCE (RNZ) 1 NB451–NB452 RYAN INTERNATIONAL AIRLINES (RYN) 1 NA195 NA198 NA342 NB203November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 56 SANTA BARBARA AIRLINES C.A. (YDJ) 1 NA392–NA393 SKYSERVICE AIRLINES (SKB) 1 NA345 STATE AIR COMPANY "BERKUT" (ORE) 1 NB053 THE YUCAIPA COMPANIES (YUC) 1 NB312 THOMAS COOK AIRLINES UK (JMA) 1 NA445 NB201 NB222–NB223 NB330–NB331 NB446 2 NB226–NB228 NB230 NT232–NT234 NT237–NT238 THOMSONFLY (BRI) 1 NA343–NA344 NB422–NB424 NB426–NB438 2 NT431–NT432 TITAN AIRWAYS (TIU) 1 NB323 2 NT912 TURKMENISTAN AIRLINES (TUE) 1 NB143 NB161–NB162 2 NT446 UPS (UPS) 1 NC936–NC950 NS601–NS610 2 NS611–NS616 NT001–NT009 US AIRWAYS (USA) 1 NA003–NA004 NA007 NA009–NA010 NA012–NA016 NB502 NB504–NB505 NB509–NB523 2 NT286 NT288–NT289 VARIG LOGISTICA S.A. (VRG) 1 NA021–NA022 NA441 VIM AVIA (VIM) 1 NC059 2 NT284–NT285 NT287 VULCAN INC. (VUL) 1 NB141 NB311 XIAMEN AIRLINES (XIA) 1 ND221–ND225 2 NJ031–NJ032 NN051–NN052November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** XL AIRWAYS (SBE) 1 NA024 NB321 ZOOM AIRLINES (YFM) 1 NB202 IDENTIFICATION BY VARIABLE NUMBER **Variable Group** NA002–NA028 1 NA191–NA199 1 NA201–NA239 1 NA301–NA305 1 NA341–NA352 1 NA391–NA399 1 NA401–NA408 1 NA441–NA447 1 NB021–NB023 1 NB036–NB041 1 NB051–NB053 1 NB061–NB073 1 NB079 1 NB131–NB148 1 NB161–NB162 1 NB201–NB204 1 NB221–NB225 1 NB226–NB228 2 NB230 2 NB236 1 NB239 1 NB261–NB267 1 NB291–NB299 1 NB301–NB302 1 NB311–NB312 1 NB321–NB331 1 NB421–NB438 1 NB446 1 NB451–NB454 1 NB501–NB523 1 NB561 1 NB571 2 NB581–NB583 2November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

NC058–NC061 1 NC062 2 NC936–NC950 1 NC971–NC974 1 ND001–ND007 1 ND011–ND059 1 ND111–ND113 1 ND161–ND199 1 ND201–ND203 1 ND221–ND225 1 ND241–ND248 1 ND301–ND317 1 ND318–ND322 2 ND401 2 ND891 1 ND895 1 NJ001–NJ004 2 NJ031–NJ032 2 NN001–NN002 2 NN051–NN052 2 NS601–NS610 1 NS611–NS616 2 NT001–NT009 2 NT201–NT202 2 NT231–NT234 2 NT237–NT240 2 NT242 2 NT245–NT248 2 NT281–NT289 2 NT381–NT386 2 NT401–NT409 2 NT411–NT412 2 NT426–NT427 2 NT431–NT432 2 NT436–NT438 2 NT446 2 NT731–NT769 2 **Variable Group**November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

2. Spares Affected
None. **B. Concurrent Requirements**
None. **C. Reason** This service bulletin gives the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and do an inspection and repair of the four critical fastener holes on the horizontal flange. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. NT861–NT862 2 NT901–NT916 2 NT971–NT985 2

**Service History Date Hours Cycles Strut Report**  12/93 29,451 10,284 - One bolt sheared in horizontal flange. Four bolts loose in vertical flange. 11/96 25,768 9,358 No. 1 & 2 Four bolts loose in vertical flange of both struts. 06/98 - - No. 1 & 2 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. 11/99 55,789 21,749 No. 1 & 2 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. 01/01 46,459 20,161 No. 1 & 2 Sixteen bolts loose in horizontal flange. 09/01 49,019 13,662 No. 1 Two bolts loose in vertical flange. 01/02 23,423 14,633 - Two bolt heads cracked. 04/02 16,601 12,493 No. 1 & 2 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. 05/02 43,822 15,522 No. 1 & 2 Migrated shim between bulkhead and vertical flange of fitting. 06/02 46,758 15,900 No. 2 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. 12/02 49,807 20,090 No. 1 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. 04/03 50,841 22,111 - Two loose bolts in vertical flange. **Variable Group**November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095 and 757-SRP-54-0118 are related to this service bulletin. Revision 01 is sent to give migration limits for the shims in the diagonal brace load path. The inspection given in the initial release of this service bulletin made it necessary to repair a loose shim before an airplane could be put back in service. With these new migration limits, an airplane can be put back in service with a migrated shim if the inspection finds that it is in the permitted limits. The bulkhead crack repair as given in the initial release has been deleted. If cracks are found, they will be reviewed on a case-by-case basis. A new repair is added for the shims in the diagonal brace load path. There are now 4 repairs and 1 repair that has been deleted. For identification, they are referred to as Interim Repairs I, II, III, IV and V. Interim Repair I is almost the same as the one given in the initial release and replaces the two shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Interim Repairs II and III are the same as those given in the initial release. Interim Repair II installs oversize fasteners in the vertical flange of the fitting, and Interim Repair III installs oversize fasteners in the horizontal flange of the fitting. Interim Repair IV is the same bulkhead crack repair given in the initial release and has been deleted. Interim Repair V is new and gives the instructions to cut and remove the exposed plies of the shims as a repair for shim migration of 0.50, or less These sections of the service bulletin were changed with revision 01: — Compliance - Decreased repeat inspection thresholds to address additional in service reports where loose fasteners were found on airplanes with less than 12,000 flight cycles. Also, added compliance information for airplanes line numbers 736 thru 1048 to address additional reports of loose fasteners on airplanes with the latest configuration. — Reason and Description - Add six reports to the service history table. — Effectivity - Added 757-200/-200CB and 200PF airplanes with RB211 engines, Line numbers 736 thru 1048. 09/03 30,072 9,991 No. 1 Three loose bolts in vertical flange. 09/03 60,715 26,914 No. 1 & 2 Migrated shims between bulkhead and vertical flange of fitting. 10/03 44,985 15,004 No. 2 Three loose bolts in vertical flange. 01/04 12,368 7,922 No. 2 Three loose bolts in vertical flange. 02/04 12,119 7,592 No. 1 Four loose bolts in vertical flange. 04/06 44,423 13083 No. 1 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. **Service History Date Hours Cycles Strut Report** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

— Work Instructions, Part I, Step 2 - Add shim migration limits to show the necessary work if shim migration is found during the inspection. — Figure 2 - Add instructions to measure and record the distance a shim has moved from the installed position, if the shim shows signs of movement during the inspection. — Figure 4 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair I. — Make corrections to the illustration and instructions to show the replacement of two shims. One on the left flange of the fitting and one on the right flange of the fitting. — Add a step is to apply sealant around the outer edge of the shim. — Add a step to increase the hole diameter after shim is in place. — Removed repair instructions for cracks. — Figure 5 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair II. — Removed repair instructions for cracks. — Figure 6 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair III. — Removed repair instructions for cracks. — Figure 7 - Deleted. — Figure 9 - Add this new figure to give the instructions for Interim Repair V. — Figure 10 - Added this new figure to give instructions for sealing removed parts. Revision 02 is sent to give revised inspection schedule and repair requirements. Instructions are added to inspect for cracking at four critical horizontal flange fasteners holes if one or more loose fasteners is found. Also, do a one-time inspection and repair of the four critical faster holes on the horizontal flange. Figure 11, Interim Repair VI is new and gives location and instruction for the four critical horizontal flange fastener locations. These sections of the service bulletin are changed with revision 02: — Summary - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Action section. Added one report to the Service History in Background section. — Planning - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Description section. Added one report to the Service History in the Reason section. Added Manpower hours for Part IV inspection. — Accomplishment Instructions - Revised access instructions. Added inspections, critical fastener identification, locations, compliance requirement Notes and Part IV inspection. — Figure 6 - Added HFEC inspections to aluminum bulkhead and steel web with NDT references. — Figure 11 - Added, for critical horizontal flange fastener locations, HFEC inspections to aluminum bulkhead and steel web with NDT references. — All references to AD 2004-12-07 are changed to AD 2005-12-04. Revision 03 is sent to give revised inspection compliance times and replace the phrase "one time inspection" with "inspection" when refering to the Part IV inspection of the critical fastener holes on the horizontal flange . These sections of the service bulletin are changed with revision 03: — Summary - Compliance information is deleted from the Compliance section. — Paragraph 1.E., Compliance - Compliance times are revised and presented in a tabular format. — Summary, Planning Information, Work Instructions: replaced the words "one time inspection" with "inspection".November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT D. Description**  Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs. Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A boroscope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection of the four critical fastener holes on the horizontal flange. As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. Revision 01 - More work is necessary on airplanes changed as shown in the initial release of this service bulletin. Repeat inspections are required for airplanes that have incorporated Service Bulletin 757-54-0035. Revision 02 - More work is necessary on airplanes changed as shown in the initial release and revision 01 of this service bulletin. Instructions are added to do a one-time inspection and repair of the four critical fastener holes on the horizontal flange. Revision 03 - No more work is necessary on airplanes changed as shown in the Original issue, Revision 1, or Revision 2 of this service bulletin, however the conditions and the compliance time for doing the inspection of the four critical fasteners on the horizontal flange have changed.November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT E. Compliance**  Table 1: Compliance

**Condition Action Compliance Time**  **(Whichever Occurs later) Repeat Interval**  **(Whichever Occurs first)**  All airplane struts that had findings on the horizontal or vertical fasteners or the shims which lead to a rejection while doing Revision 1 or the original release of this service bulletin, and all airplanes that had equivalent findings prior to the original release of this service bulletin (a) Inspect the four critical fasteners in the horizontal flange as given in Part IV unless already accomplished as given in Revision 2 of this service bulletin. 90 days after the date on this service bulletin - --

Group 1 Configuration 1 Inspect the shim installation as given in Part I, Step 3. AND Inspect all four fasteners in the vertical flange as given in Part I, Step 5 AND Inspect the fasteners in the horizontal flange as given in Part II, Step 2 90 days after the date on this service bulletin (b) - 6,000 Flight Cycles 36 months

Group 1 Configuration 2 Inspect the shim installation as given in Part I, Step 3 AND Inspect all four fasteners in the vertical flange as given in Part I, Step 5 AND Inspect the fasteners in the horizontal flange as given in Part II, Step 2 6,000 flight cycles or 36 months, whichever occurs first, after incorporation of service bulletin 757- 54-0035. (b) 90 days after the date on this service bulletin (b) 9,000 Flight Cycles 54 months

Group 2 Inspect the shim installation as given in Part I, step 3 AND Inspect all four fasteners in the vertical flange as given in Part I, Step 5 AND Inspect the fasteners in the horizontal flange as given in Part II, Step 2 6,000 flight cycles or 36 months, whichever occurs first, after date of issuance of airworthiness certificate. (b) 90 days after the date on this service bulletin (b) 9,000 Flight Cycles 54 months

Total cumulative shim movement equal to or less than 0.50 inch Repair as given in Part I, Step 4.a. Before further flight after completing all inspections - --November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-12-04, is related to this service bulletin. AD worksheet 06-AD-42 is also related to 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. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the modification defined in this service bulletin as an alternative method of compliance (AMOC) to the modification required by paragraphs (b) and (d) of AD 2004-12- 07. Also, the Manager of the FAA Seattle Aircraft Certification Office approves the inspection defined in this service bulletin as an AMOC to the inspection required by paragraph (g) of AD 2005-12-04. All provisions of AD 2004-12-07 and 2005-12-04 that are not specifically referenced in the above statements remain fully applicable and must be complied with. 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. Total cumulative shim movement more than 0.50 inch Repair as given in Part I, Step.4.b. Before further flight after completing all inspections - --

Rejected fastener in the vertical flange Repair as given in Part I, Step 5.a.(2) AND Inspect and repair as given in Part I, Step 5.a.(3) Before further flight after completing all inspections - --

Rejected fastener in the horizontal flange Repair as given in Part II, Step 2.a.(2) AND Inspect and repair as given in Part II, Step 2.a.(3) Before further flight after completing all inspections - --

(a) Findings on Group 1, Configuration 2 airplane struts prior to SB 757-54-0035 incorporation are excluded from this condition. (b) If you have done this inspection as given in an earlier release of this service bulletin, then the compliance time to initiate this inspection does not apply. You must still do repeat inspections at the intervals shown. Table 1: Compliance

**Condition Action Compliance Time**  **(Whichever Occurs later) Repeat Interval**  **(Whichever Occurs first)** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT G. Manpower**  The table below shows an estimate of the task-hours necessary to do this inspection and repair for each strut. 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 examine the work. — Time to cure the materials. — Time to make the parts. — Time to find the tools.

(a) An estimate for the task-hours necessary to do the repair is not given.

(a) An estimate for the task-hours necessary to do the repair is not given. (b) More time can be necessary for the removal of the engine, diagonal brace, and precooler.

(a) An estimate for the task-hours necessary to do the repair is not given. Part I - Inspection - Fasteners and Shim - Vertical Flange

**Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 12.0 6.0 Inspect 2 2.0 1.0 Repair (a) - - - Close Access 2 14.0 7.0 TOTAL FOR EACH STRUT 28.0 14.0

Part II - Inspection - Fasteners - Horizontal Flange

**Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 2.0 1.0 Inspect 2 2.0 1.0 Repair (a) - - - Close Access 2 2.0 1.0 TOTAL FOR EACH STRUT (b) 6.0 3.0

Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange

**Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 2.0 1.0 Inspect 2 2.0 1.0 Repair (a) - - - Close Access 2 2.0 1.0 TOTAL FOR EACH STRUT (b) 6.0 3.0November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

(b) More time can be necessary for the removal of the engine, diagonal brace, and precooler. **H. Weight and Balance Changes**
None.
**I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Service Related Problems (SRP) 757-SRP-54-0095 and 757-SRP-54-0118. b. 757 Maintenance Manual (AMM) 54-53-01, 54-53-02, 71-00-02, 71-11-07, 78-31-00. c. 757 Structural Repair Manual (SRM) Subject 51-00-06. d. 757 Nondestructive Test (NDT) Manual Part 6, 51-00-14, Part 6, 51-00-16, Part 6, 51-00-17. e. Standard Overhaul Practices Manual (SOPM) 20-43-03, 20-50-19. f. Boeing Service Bulletin 757-54-0035,’NACELLES/PYLONS Rolls Royce RB211 Powered Airplanes - Nacelle Strut and Wing Structure Improvement’. g. FAA Airworthiness Directive AD 2005-12-04. h. Boeing Parts Standards Document D-590. i. Boeing Drawing 65-88700. 2. Data supplied with this Service Bulletin:
None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:

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. **Drawing Number Title** 311N5042 Spar Installation - Lower Nacelle Strut 311N5045 Torque Bulkhead Installation 311N5062 Seal Application - Nacelle StrutNovember 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT L. Interchangeability and Intermixability of Parts**  Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

BLANK PAGENovember 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability**
None. **B. Industry Support Information** Boeing warranty remedies are not available for the 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:

(a) Can be necessary if you make the radius filler shown in Figure 6. Refer to SOPM 20- 43-03 for data about the Chemical Conversion Treatment. (b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) Alternative to DC 93-006. (d) Primer is necessary if BMS 5-63 is applied over rubber/silicon substrates. (e) Use with DC 93-006 and DC 3110. (f) Alternative to DC 3110. **Part Number / Specification QTY Name Notes**  Type 2, Class A 4 oz. Chemical Conversion Treatment (a) BMS 10-11, Type 1 8 oz. Primer (b) BMS 5-63 1 pt. Sealant (c) DAPCO 1-400 8 oz. Primer (d) DC 1200 8 oz. Primer (e) DC 93-006 1 pt. Sealant - DC 3110 1 qt. Leveling Compound - RTV 560 - - (f) RTV 3 - - (f) RTV 60 - - (f) 301 SS 1/2 Hard - CRES Plate 2.50 x 2.50 x 0.080 (g) BACB30* - Bolt (h) BACC30* - Collar - BACS40R015B027F 2 Shim, Laminated (i) BACS40R015C027F optional BACF3H10JT010HG 2 Filler, Radius (j)November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

(g) Can be necessary if a crack is found in the aft bulkhead that cannot be repaired with the installation of an oversize fastener. (h) See the Paragraph 3.B., Work Instructions, Figures 4, 5, 6, and 7, for the oversize bolt/collars that can be necessary if the inspections find a loose shim and/or damaged fasteners. (i) Can be necessary if loose shims are found during the inspection. (j) Can be necessary if oversize fasteners are installed as shown in Figure 6. Instructions are also given to make the filler from 0.063 thick 2024-T3, T4, T42, or 7075-T6 Bare Aluminum Sheet. 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** A boroscope, or other inspection aids, can be necessary to do the inspection of the fasteners in the horizontal flange of the strut-to-diagonal brace fitting. Also, 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.November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **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. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. 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 757 Structural Repair Manual, Chapter 51. — Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, Chapter 51. 4. For approved fastener and process material substitutions, refer to 757 Structural Repair Manual, Chapter 51, Alternate fasteners are given in 757 Structural Repair Manual Chapter 51 and Boeing Drawing 65-88700. 5. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 6. Inspections, used in the service bulletin, are defined as follows: Detailed Inspection: An intensive visual examination of a specific structural area, system, 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 by the inspector. Inspection aids such as mirrors, magnifying lenses, etc. may be used. Surface cleaning and elaborate access procedures may be required. Special Detailed (non-Destructive Testing) Inspection: An intensive examination of a specific item(s), installation, or an assembly to detect damage, failure or irregularity. The examination is likely to make extensive use of specialized inspection techniques and/or equipment. Intricate cleaning and substantial access or disassembly procedure may be required. Non-Destructive Testing (NDT) inspections are used to examine all subsurface damage and most small cracks. NDT is also used in areas where a visual inspection is notNovember 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** sufficient to find the dimensions of damage. **B. WORK INSTRUCTIONS PART I - INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE - ALL AIRPLANES**  1. Refer to 757 AMM 78-31-00 and do the Thrust Reverser Deactivation for Ground Maintenance.
**WARNING:** DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENT THE OPERATION OF THE THRUST REVERSER. THE ACCIDENTAL OPERATION OF THE THRUST REVERSER CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 2. Refer to Figure 1 and do the steps necessary to get access for the inspection of the fasteners and shim in the vertical flange. 3. Refer to Figure 2 and do the inspection of the shim installation between the vertical flange and bulkhead: a. For Group 1 and Group 2 airplanes: If the shim installation shows signs of movement and is rejected: Continue with Step 4, below.
**NOTE:** All Part I and Part II inspections can be accomplished before repairs are done. b. If the shim installation is satisfactory: Continue with the inspection of the four fasteners in the vertical flange as given in step 5, below. 4. Do repairs to the shim installation between the vertical flange and the bulkhead as given below: a. If the shim(s) Total cumulative movement is 0.50 or less: Do Interim Repair V as shown in Figure 9. Record the amount of total shim movement and save for future inspections. b. If the shim(s) Total cumulative movement is more than 0.50: Remove the engine as given in 757 AMM 71-00-02 and do Interim Repair I as shown in Figure 4. Also, do the inspection and repair of the four critical fastener holes on the horizontal flange as given in Part IV. 5. Refer to Figure 2 and do the inspection of the four fasteners in the vertical flange: a. If one or more of the four fasteners are rejected: (1) Remove the engine 757 AMM 71-00-02
**NOTE:** All Part I and Part II inspections can be accomplished before repairs are done. (2) At the locations where fasteners are rejected in the vertical flange: Remove the fastener, increase the hole diameter and install oversize fasteners as shown for Interim Repair II in Figure 5. (3) Do the inspection and repair of the four critical fastener holes on the horizontal flange as given in Part IV.November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

**PART II - INSPECTION - FASTENERS - HORIZONTAL FLANGE - ALL AIRPLANES** 1. Refer to Figure 1 and do the steps necessary to get more access, and removal of the leveling compound, for the inspection of the fasteners in the horizontal flange. 2. Refer to Figure 3 and do the inspection of the sixteen fasteners that hold the strut to the horizontal flange of the strut-to-diagonal brace fitting: a. If one or more of the sixteen fasteners are rejected: (1) Remove the engine as given in 757 AMM 71-00-02.
**NOTE:** All Part I and Part II inspections can be accomplished before repairs are done. (2) Remove the rejected fastener, inspect the fastener hole for cracking, increase the hole diameters and install oversize fasteners as shown for Interim Repair III in Figure 6. (3) Do the inspection and repair of the four critical horizontal flange fastener holes on the horizontal flange as given in Part IV. **PART III - CLOSE ACCESS - ALL AIRPLANES** 1. Apply new sealant as shown in Figure 8. 2. Apply the leveling compound shown in Figure 8. 3. Install and seal the covers as shown in Figure 10. 4. Install the remaining components that were removed to get access for the inspection. 5. If necessary, install the engine as given in 757 AMM 71-00-02. 6. Put the airplane back to a serviceable condition. 7. Schedule the airplane for the repeat inspection at the time given in Paragraph 1.E., Compliance. **PART IV - INSPECTION - CRITICAL FAST ENER HOLES ON THE HORIZONTAL FLANGE**  1. Remove engine to gain access if not already done, as given in 757 AMM 71-00-02. 2. Remove the four critical horizontal flange fasteners and do a HFEC inspection of the fastener holes for cracking as given in Figure 11. a. If any crack or crack indication is found contact Boeing for repair instructions and repair before further flight. 3. At locations where the critical fastener hole was rejected, increase the hole size and install an oversize fastener as given in Figure 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener as given in Figure 11. 4. At locations where the fastener hole was not rejected, install the same size fastener as was removed as given in Figure 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener as given in Figure 11.**FIGURE 1: ACCESS FOR INSPECTION** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 1: ACCESS FOR INSPECTION** 

RIGHT ALMOST THE SAME LEFT SHOWN

FWD

FWD

LEFT A SEE



### A

RIGHT WING/STRUT THE SAME WING/STRUT SHOWN B SEE 6

5

4 3

2 1W39396

**(SHEET 1 OF 3) FIGURE 1: ACCESS FOR INSPECTION**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

LEFT SHOWN RIGHT OPPOSITE

FWD



### A-A A

A

EXISTING COMPOUND INBD



### B

7W39439

**(SHEET 2 OF 3) FIGURE 1: ACCESS FOR INSPECTION**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut.

**STEP TASK NAME REFERENCES QTY NOTES** 1 Open or Remove Access Door 757 AMM 54-53-02 1 - 2 Loosen Clamp - 1 - 3 Move Boot Seal - 1 - 4 Remove Cover - 1 - 5 Remove Coverplate 757 AMM 54-53-01 1 - 6 Remove Seal 757 AMM 71-11-07 1 Remove the seal between the strut and the common nozzle fairing. 7 Remove Leveling Compound - - As necessary, remove the leveling compound from the area around the fasteners.

**(SHEET 3 OF 3) FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE** 



### A

A SHIM FASTENER (4 LOCATIONS)

1 5

SHIM 3 2 4



### A-A FITTING 2 VERTICAL MEASUREMENT

HORIZONTAL MEASUREMENT 2 4 VERTICAL MEASUREMENT

HORIZONTAL MEASUREMENT 4 SHIM SHOWN IN MIGRATED POSITION FWDW39458

**(SHEET 1 OF 2) FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Shim Installation (left shim) Detailed Inspection 757 SRM 51-00-06 (a)
2 Measure/ Record Shim Migration (left shim) - - (b) 3 Inspect Shim Installation (right shim) Detailed Inspection 757 SRM 51-00-06 (a)
4 Measure/ Record Shim Migration (right shim) - - (b) 5 Inspect Fastener Detailed Inspection 757 SRM 51-00-06, (c) Four locations (a) Look for signs of damaged sealant around the outer edge of the shim. Look for signs that show movement of the shim. Reject a shim that shows signs of movement. (b) Measure and record the horizontal movement and the vertical movement of the shim from the installed position. Add the movement in each direction together to obtain the total movement of the shim at this inspection. This movement must be added to all previous measurements to obtain total cumulative movement of the shim(s). This data is used during the repeat inspection and to make decisions about repairs. Data necessary for the repeat inspection and to make decisions about repairs are: - The shims have not moved from the installed position. - The shim total cumulative movement is 0.50, or less.
-The shim total cumulative movement is more than 0.50. (c) Look at the two sides of the fastener installation for signs of damaged sealant. Remove the sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar.

**(SHEET 2 OF 2) FIGURE 3: INSPECTION - FASTENERS - HORIZONTAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 3: INSPECTION - FASTENERS - HORIZONTAL FLANGE** 

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Fastener Detailed Inspection 757 SRM 51-00-06, (a) (b) Eight locations. 2 Inspect Fastener Detailed Inspection 757-SRM 51-00-06, (a) (b) Eight locations. A

A FWD

FWD 

### A-A 2 1 8 LOCATIONS

8 LOCATIONSW40119

**(SHEET 1 OF 2) FIGURE 3: INSPECTION - FASTENERS - HORIZONTAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** (a) Use a boroscope, or other inspection aids if necessary, to view the lower surface of the fasteners installation. (b) Look at the two sides of the fastener installation for signs of damaged paint and/or sealant. Remove the paint and/or sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar.

**(SHEET 2 OF 2) FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE** 

F A A FWD 4 2



### A-A 4 LOCATIONS A 10 FITTING

3 1 5 6W40524

**(SHEET 1 OF 2) FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for the replacement of one shim.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.

**STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove Fastener - 2 (left bolts and/or right bolts). 2 Remove Shim - 1 (left shim and/or right shim). 3 Inspect Fastener Hole - 2 (a) 4 Measure Clearance - - Adjust Shim BACS40R015B027F 1 (b) BACS40R015C027F is optional. (c) Drill Holes - 2 Drill holes in shim to agree with hole diameters in fitting. Clean/Deburr Shim - - Apply Sealant DC93-006 - To mating surfaces. Install Shim - - 5 Ream Holes - 2 Increase diameter by 0.0156 6 Install Fastener - 2 See Code A 1 and A 2 . (a) Do an eddy current inspection of the holes through the titanium fitting as given in 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead as given in 757 NDT Part 6, 51-00-16. If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. (b) Remove laminations to adjust the shim thickness. Remove all sharp edges. The maximum clearance permitted with the shim in position is 0.005. (c) Alternative: Make a solid shim from 2024-T3, or 2024-T4, -T81, T861, or 7075-T6. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 for data about the chemical conversion treatment.

**CODE NAME PART NUMBER HOLE DIA NOTES**

A 1 Bolt BACB30NX14K10X 0.4526 - 0.4536 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30BH14S - A 2 Bolt BACB30NX14K10Y 0.4682 - 0.4692 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30AC14S -

**(SHEET 2 OF 2) FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE** 

F A A FWD



### A-A 4 LOCATIONS A 10 FITTING

2 1 3W40549

**(SHEET 1 OF 2) FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for strut.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.

**STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove Fastener - - - 2 Inspect Fastener Hole - - (a) 3 Install Fastener - - See Codes A 1 and A 2 . (a) Do an eddy current inspection of the hole(s) through the titanium fitting as given in 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead as given in 757 NDT Part 6, 51-00-16. If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions.

**CODE NAME PART NUMBER HOLE DIA NOTES**

A 1 Bolt BACB30NX14K10X 0.4526 - 0.4536 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30BH14S - A 2 Bolt BACB30NX14K10Y 0.4682 - 0.4692 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30AC14S -

**(SHEET 2 OF 2) FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 6: INTERIM REPAIR III - OV**  **ERSIZE FASTENERS - HORIZONTAL FLANGE**

RADIUS FILLER 0.063 1.00 1.00

0.35 RADIUS OR LARGER A

A FWD

FWD 

### A

A SEE



### A-A FITTING

3 2 1

6 LOCATIONS 8 LOCATIONS N 11 B

N 6 C N 11 DW40801

**(SHEET 1 OF 3) FIGURE 6: INTERIM REPAIR III - OV**  **ERSIZE FASTENERS - HORIZONTAL FLANGE** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.

**STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove Fastener - - - Inspect Fastener Hole - - (a) Install Fastener - - See Codes B 1 and B 2 2 Remove Fastener - - - Inspect Fastener Hole - - (a) Install Fastener - - See Codes C 1 and C 2 3 Remove Fastener - - - Inspect Fastener Hole - - (a) Make/Install Radius Filler - - (b) Install Fastener - - See Codes D 1 and D 2 (a) Do an eddy current inspection of the hole(s) through the titanium fitting as given in 757 NDT, Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead as given in 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, as given in 757 NDT, Part 6, 51-00-17: If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions. (b) If necessary, make and install a radius filler below the seal retainer at these fastener locations. Install Radius Filler BACF3H10JT010HG, or make the filler from 0.063 thick 2024-T3, -T4, -T42, or 7075-T6 Bare Aluminum Sheet as shown. Apply a Chemical Conversion Treatment, Type 2, Class A, and one layer of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 for data about the chemical conversion treatment. Install the filler with Sealant BMS 5-63 or Dow Corning 93-006.

**CODE NAME PART NUMBER HOLE DIA NOTES**

B 1 Bolt BACB30YK12K11X 0.3901 - 0.3911 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30CP12C - B 2 Bolt BACB30YK12K11Y 0.4057 - 0.4067 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30CP12CY - C 1 Bolt BACB30MC12A6U 0.3901 - 0.3911 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30BH12S -

**(SHEET 2 OF 3) FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT**

C 2 Bolt BACB30MD12A6U 0.4057 - 0.4067 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30AC12S - D 1 Bolt BACB30FP12A11U 0.3901 - 0.3911 (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30AB12SY - D 2 Bolt BACB30KK12A11U 0.4057 - 0.4067 (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30AC12S - (a) If the installation of the radius filler is necessary, fasteners with longer grip lengths will also be necessary. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 3 OF 3) FIGURE 7: THIS FIGURE HAS BEEN DELETED**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 7: THIS FIGURE HAS BEEN DELETED** 

THIS FIGURE IS DELETED.1328539

**(SHEET 1 OF 1) FIGURE 8: REPAIR - SEA**  **LANT AND LEVELING COMPOUND** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND** 

COMPOUND EXISTING A

A
FWD

3 2 1

EXAMPLE-FASTENER LOCATIONS



### A-A A SEE 

### AW42540

**(SHEET 1 OF 2) FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut.

**STEP TASK NAME PART NUMBER QTY NOTES**

1 Apply Primer Dow Corning 1200 -

- (a) (b) If the shim was replaced during the repair procedures, apply primer and a fillet seal around the outer edge of the shim/fitting flange. Sealant Dow Corning 93-006

2 Apply Primer Dow Corning 1200 - (a) (b) Apply to all locations where sealant was removed for the inspections and/or fastener replacement. Sealant Dow Corning 93-006 -
3 Apply Primer Dow Corning 1200 - (c) (d) Leveling Compound Dow Corning 3110 - Optional compound is RTV560, RTV3 or RTV60. (a) Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Primer DAPCO 1-400 and Sealant BMS 5-63, Type II is optional. Before Sealant BMS 5-63 is applied let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours. (c) Before the Dow Corning 3110 compound is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (d) You can mix solvent BMS 3-2, Type II, with the leveling compound to make it more liquid. The maximum quantity of solvent permitted in the mixture is 20 percent when measured by weight.

**(SHEET 2 OF 2) FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE** 

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut. **STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION:**  DO NOT INSTALL A NEW COLLAR OR TRY TO TIGHTEN EXISTING COLLAR IN AN ATTEMPT TO TIGHTEN THE JOINT BETWEEN THE FITTING AND BULKHEAD AS STRUCTURAL DAMAGE MAY OCCUR. 1 Cut Exposed plies (left shim) - -- 2 Apply Primer BMS 10-11, Type 1 - - 3 Apply Primer DAPCO 1-400 - (a) 4 Apply Sealant BMS 5-63 - (b) Seal edges 5 Cut Exposed plies (right shim) - -- 6 Apply Primer BMS 10-11, Type 1 - - 7 Apply Primer DAPCO 1-400 (a) 8 Apply Sealant BMS 5-63, Type II - (b) Seal edges 

### FWD SHIM 1 SHIM 5 2 6 3 7 4 8386720

**(SHEET 1 OF 2) FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** (a) Dow Corning 93-006 sealant and Dow Corning 1200 primer are optional for this application. Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Before Sealant BMS 5-63 is applied let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours.

**(SHEET 2 OF 2) FIGURE 10: SEAL COVER PLATES**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 10: SEAL COVER PLATES** 

RIGHT ALMOST THE SAME LEFT SHOWN FWD

FWD A SEE



### A

RIGHT WING/STRUT THE SAME

LEFT WING/STRUT SHOWN 3

2 4

5 1D34431

**(SHEET 1 OF 2) FIGURE 10: SEAL COVER PLATES**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut

**STEP TASK NAME QTY REFERENCE NOTES** 1 Install Cover 1 - - 2 Apply Primer DC 1200 Sealant DC93-006 -

- SOPM 20-50-19 (a)

3 Install Cover Plate 1 AMM 54-53-01 - 4 Move Boot Seal 1 - (b) 5 Adjust Clamp 1 - Tighten Clamp (a) Apply Intermediate liquid control fillet seal around entire periphery of the cover. Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Move the Boot Seal back to the original position as necessary.

**(SHEET 2 OF 2) FIGURE 11: INSPECTION - CRITICAL HO**  **RIZONTAL FLANGE FASTENER LOCATIONS** November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT FIGURE 11: INSPECTION - CRITICAL**  **HORIZONTAL FLANGE FASTENER LOCATIONS** 

A

A FWD

FWD 

### A-A FITTING 1 4 LOCATIONS N 11 B 2 31335626

**(SHEET 1 OF 2) FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS**  November 13, 2003 Revision 3: June 27, 2007 757-54A0047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 56 

### BOEING SERVICE BULLETIN 757-54A0047 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one strut.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.

**STEP TASK NAME PART NUMBER QTY MORE DATA** 1 Remove Fastener - - - 2 Inspect Fastener Hole - - (a) (b) 3 Install Fastener - - See Codes B0, B1 and B2 (a) Do an eddy current inspection of the hole(s) through the titanium fitting as given in 757 NDT, Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead as given in 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, as given in 757 NDT, Part 6, 51-00-17. (b) Measure the hole diameter. If the hole is true and round, and the diameter is within the limits allowed for installation of the same size fastener, do not increase the hole size. Otherwise, increase the hole size to remove damage.

**CODE NAME PART NUMBER HOLE DIA NOTES**

Bo Bolt BACB30YK12K11 0.3745 - 0.3755 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30CP12C - B 1 Bolt BACB30YK12K11X 0.3901 - 0.3911 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30CP12C - B 2 Bolt BACB30YK12K11Y 0.4057 - 0.4067 Install wet with Sealant BMS 5-63 or Dow Corning 93-006. Collar BACC30CP12CY -

**(SHEET 2 OF 2)**