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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 56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Unpublished Work - All Rights Reserved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

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

BLANK PAGE
 Table of Contents

November 13, 2003

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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

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

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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.
 

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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, 2007
November 13, 2003

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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.
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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
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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)
 

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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-A

W38926
November 13, 2003

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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.
 

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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–NT403
 

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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 NB140
 

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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–NA408
 

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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 NB203
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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–NN052
 

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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 2
 

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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
 

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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
 

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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
 

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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".
 

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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.
 

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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

- --
 

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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)
 

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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 3.0
 

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(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 Strut
 

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ALERT ALERT

L. Interchangeability and Intermixability of Parts

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

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ALERT ALERT

BLANK PAGE
 

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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)
 

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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.
 

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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 not 
 

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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.
 

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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 FASTENER 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

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

FIGURE 1: ACCESS FOR INSPECTION

RIGHT ALMOST THE SAME

LEFT SHOWN

FWD

FWD

LEFT

SEE A

A

RIGHT WING/STRUT THE SAME

WING/STRUT SHOWN

SEE B

6

5

4

3

2

1

W39396

(SHEET 1 OF 3)
 FIGURE 1: ACCESS FOR INSPECTION

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

LEFT SHOWN

RIGHT OPPOSITE

FWD

A-A

A

A

EXISTING

COMPOUND

INBD

B

7

W39439

(SHEET 2 OF 3)
 FIGURE 1: ACCESS FOR INSPECTION

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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

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ALERT ALERT

FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE

A

A

SHIM

FASTENER

(4 LOCATIONS)

1

5

SHIM

2 3 4

A-A

FITTING

2

VERTICAL

MEASUREMENT

HORIZONTAL

MEASUREMENT

2

4

VERTICAL

MEASUREMENT

HORIZONTAL

MEASUREMENT

4

SHIM SHOWN

IN MIGRATED

POSITION

FWD

W39458

(SHEET 1 OF 2)
 FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE

November 13, 2003

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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

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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 LOCATIONS

W40119

(SHEET 1 OF 2)
 FIGURE 3: INSPECTION - FASTENERS - HORIZONTAL FLANGE

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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

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE

F

A

A FWD 2 4

A-A

4 LOCATIONS

A

10

FITTING

1 3 5 6

W40524

(SHEET 1 OF 2)
 FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE

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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 A1 and A2.

(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

A1 Bolt BACB30NX14K10X 0.4526 - 0.4536 Install wet with Sealant BMS 5-63 or 

Dow Corning 93-006. Collar BACC30BH14S -

A2 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

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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

1 2 3

W40549

(SHEET 1 OF 2)
 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE

November 13, 2003

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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 A1 and A2.

(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

A1 Bolt BACB30NX14K10X 0.4526 - 0.4536 Install wet with Sealant BMS 5-63 or 

Dow Corning 93-006. Collar BACC30BH14S -

A2 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

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE

RADIUS FILLER

0.063

1.00 1.00

0.35 RADIUS OR LARGER

A

A

FWD

FWD

A

SEE A

A-A

FITTING

3

2

1

6 LOCATIONS

8 LOCATIONS N

11

B

N

6

C

N

11

D

W40801

(SHEET 1 OF 3)
 FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE

November 13, 2003

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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 B1 and B2

2 Remove Fastener - - -

Inspect Fastener Hole - - (a)

Install Fastener - - See Codes C1 and C2

3 Remove Fastener - - -

Inspect Fastener Hole - - (a)

Make/Install Radius Filler - - (b)

Install Fastener - - See Codes D1 and D2

(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

B1 Bolt BACB30YK12K11X 0.3901 - 0.3911 Install wet with Sealant BMS 5-63 or Dow 

Corning 93-006. Collar BACC30CP12C -

B2 Bolt BACB30YK12K11Y 0.4057 - 0.4067 Install wet with Sealant BMS 5-63 or Dow 

Corning 93-006. Collar BACC30CP12CY -

C1 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

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

C2 Bolt BACB30MD12A6U 0.4057 - 0.4067 Install wet with Sealant BMS 5-63 or Dow 

Corning 93-006. Collar BACC30AC12S -

D1 Bolt BACB30FP12A11U 0.3901 - 0.3911 (a) Install wet with Sealant BMS 5-63 or 

Dow Corning 93-006. Collar BACC30AB12SY -

D2 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

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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 - SEALANT AND LEVELING COMPOUND

November 13, 2003

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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

SEE A

A

W42540

(SHEET 1 OF 2)
 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND

November 13, 2003

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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

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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

2 3 4 5 6 7 8

386720

(SHEET 1 OF 2)
 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE

November 13, 2003

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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

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BOEING SERVICE BULLETIN 757-54A0047

ALERT ALERT

FIGURE 10: SEAL COVER PLATES

RIGHT ALMOST THE SAME

LEFT SHOWN

FWD

FWD

SEE A

A

RIGHT WING/STRUT THE SAME

LEFT WING/STRUT SHOWN

3

2

4

5

1

D34431

(SHEET 1 OF 2)
 FIGURE 10: SEAL COVER PLATES

November 13, 2003

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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 HORIZONTAL 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

3

1335626

(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 -

B1 Bolt BACB30YK12K11X 0.3901 - 0.3911 Install wet with Sealant BMS 5-63 or Dow 

Corning 93-006. Collar BACC30CP12C -

B2 Bolt BACB30YK12K11Y 0.4057 - 0.4067 Install wet with Sealant BMS 5-63 or Dow 

Corning 93-006. Collar BACC30CP12CY -

(SHEET 2 OF 2)