Commercial 

Airplanes 767

Service Bulletin

Number: 767-57A0100

Original Issue: August 21, 2006

Revision 3: July 28, 2011

ATA System: 5720 2811

SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2006 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more

information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the

Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in

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2.0
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BOEING SERVICE BULLETIN 767-57A0100

BLANK PAGE
Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 22

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 24

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FIGURE 1: SEAL OF THE FASTENERS [Group 1-2; Group 3, Configuration 1] . . . . . . . . . . . . 29

FIGURE 2: UPPER WING SKIN - LEFT MAIN TANK - LOCATION OF THE FASTENERS [Group 1-2; Group

3, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 3: UPPER WING SKIN - RIGHT MAIN TANK - LOCATION OF THE FASTENERS [Group 1-2;

Group 3, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS

[Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE

FASTENERS [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FIGURE 6: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - LEFT WING [Group

3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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BOEING SERVICE BULLETIN 767-57A0100
FIGURE 7: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - RIGHT WING [Group

3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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BOEING SERVICE BULLETIN 767-57A0100
Commercial 

Airplanes 767

Service Bulletin

Revision Transmittal Sheet Number: 767-57A0100

Original Issue: August 21, 2006

Revision 3: July 28, 2011

ATA System: 5720 2811

SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

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

2 of this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service bulletin.

REASON FOR REVISION

This revision is sent to correct the quantity of the fasteners specified in Figure 5. The figure incorrectly shows

15 fasteners that must be sealed at Rear Spar Station (RSS) 468.06. The correct fastener quantity for RSS

468.06 is 14. Also clarification was added to show that Figure 1 is a typical view of a fastener that was intended

to apply to rivets or bolts with collars.

These sections were changed:

1. In Figure 1, added the text rivet or bolt with a collar to the illustration and to footnotes (a), (c), (e), and (f).

2. In Figure 5, updated the illustration text to specify 14 locations at RSS 468.06 and update the total fastener

quantity in the table.

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

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: August 21, 2006

Revision 1: June 19, 2008

Revision 2: May 20, 2010

Revision 3: July 28, 2011

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BOEING SERVICE BULLETIN 767-57A0100

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

Summary Number: 767-57A0100

Original Issue: August 21, 2006

Revision 3: July 28, 2011

ATA System: 5720 2811

SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Accomplishment of the modifications within this service bulletin will help prevent possible ignition sources in the

main fuel tanks, and the surge tanks caused by a lightning strike on certain wing surfaces. An ignition source

in a fuel tank could result in a fire or an explosion.

A review by Boeing identified a certain fastener type in the fuel tank walls that have an insufficient bond to the

structure. If energy from lightning strike goes through these fasteners, arcing can occur at the ends of the

fasteners in the fuel tank. The ends of the fasteners in the fuel tank do not have sufficient electrical insulation

to contain the energy from the arcs.

This Service Bulletin gives the instructions to seal the end of certain fasteners in the fuel tank walls. These

changes make sure that the risk of an ignition source in the fuel tank from a lightning strike on the wing is kept

to a minimum.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel Tank

System Fault Tolerance Evaluation Requirements".

ACTION (PRR B13421-10)

Group 1:

Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the fasteners on the

brackets that hold the vortex generators. Get access to the right main tank. Seal the ends of the fasteners on

the brackets that hold the vortex generators. Close access to the main fuel tanks.

Group 2:

Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the fasteners on the

brackets that hold the vortex generators. Seal the ends of fasteners on certain stiffeners on the rear spar. Get

access to the right main tank. Seal the ends of the fasteners on the brackets that hold the vortex generators.

Seal the ends of fasteners on certain stiffeners on the rear spar. Close access to the main fuel tanks.

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Group 3:

Get access to the outer surface of the upper wing panel on the left wing. Do a General Visual Inspection of the

specified vortex generators on the upper wing panel of the left wing. Get access to the outer surface of the upper

wing panel on the right wing. Do a General Visual Inspection of the specified vortex generators on the upper

wing panel on the right wing. If the vortex generators are attached with adhesive alone, no more work is necessary.

If the vortex generators are attached with fasteners, do the following steps: Prepare the main fuel tanks for entry.

Get access to the left main tank. Seal the ends of the fasteners on the brackets that hold the vortex generators.

Get access to the right main tank. Seal the ends of the fasteners on the brackets that hold the vortex generators.

Close access to the main fuel tanks.

Service Bulletin 767-57A0102 has similar access requirements as this bulletin and can be incorporated at the

same time or separately. Service Bulletin 767-57A0102 is separate from this bulletin because it makes

improvements to existing design and does not have warranty remedies.

EFFECTIVITY

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

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service bulletin.

Boeing recommends that this service bulletin be incorporated within 60 months from the effective date of FAA

AD 2009-18-02.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of July 16, 2004. Please refer to Paragraph

2.B., Industry Support Information.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

Group 1 29.25 10.00

Group 2 143.24 38.81

Group 3, Config- 29.75 10.05

uration 1

Group 3, Config- 0.50 0.50

uration 2

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 767-57A0100

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

Number: 767-57A0100

Original Issue: August 21, 2006

Revision 3: July 28, 2011

ATA System: 5720 2811

SUBJECT: WINGS - Outer Wing - Change to Fasteners in Fuel Tank Walls - Application of Sealant

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent

production airplanes. Refer to PRRB13421-10 for data about this change.

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

Number, and Serial Number data.

GROUP CONFIGURATION DESCRIPTION

1 - 767-200/300/300F airplanes

2 - 767-400ER airplanes

767-200/300 airplanes that have vortex fasteners installed with or

without fasteners

3 -

1 Airplanes that have vortex generators installed with fasteners

2 Airplanes that have vortex generators installed with adhesive alone

Airplane Models:

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

Variable Number Group

VA001 - VA020 1

VA301 - VA315 1

VA501 - VA515 1

VA516 - VA519 3

VA520 - VA530 1

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Variable Number Group

VA701 - VA719 1

VA801 - VA810 1

VB001 - VB002 1

VB051 - VB055 1

VB101 - VB121 1

VB122 - VB123 3

VB124 - VB125 1

VB201 - VB202 1

VB251 - VB253 1

VB281 - VB284 1

VB301 - VB302 1

VB321 - VB332 1

VB371 - VB373 1

VB401 1

VB441 - VB444 1

VE001 - VE003 1

VE021 - VE023 1

VE041 3

VE042 - VE043 1

VE061 - VE066 1

VE067 - VE068 3

VE069 1

VE083 - VE086 1

VE101 1

VE102 - VE103 3

VE104 1

VE116 - VE117 3

VE118 1

VE121 - VE126 1

VE141 - VE152 1

VE171 - VE172 1

VF001 - VF002 1

VF041 - VF042 1

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BOEING SERVICE BULLETIN 767-57A0100
Variable Number Group

VF051 1

VF061 - VF062 1

VF071 - VF072 1

VF091 - VF093 1

VF101 - VF102 1

VF161 - VF162 1

VF171 - VF172 1

VF180 - VF184 1

VF251 1

VK001 - VK003 3

VK004 - VK016 1

VK021 - VK022 1

VK031 3

VK032 - VK056 1

VK081 - VK113 1

VK131 - VK133 1

VK141 - VK148 1

VK161 - VK164 1

VK171 1

VK181 1

VK186 1

VL001 - VL006 1

VL011 1

VL701 - VL703 1

VL751 - VL755 1

VL806 - VL807 1

VL871 - VL873 1

VL891 - VL900 1

VL911 - VL914 1

VL931 - VL932 1

VL941 1

VN001 - VN041 1

VN051 - VN064 1

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BOEING SERVICE BULLETIN 767-57A0100
Variable Number Group

VN081 - VN099 1

VN111 - VN127 1

VN130 - VN137 1

VN151 - VN158 1

VN163 - VN168 1

VN171 - VN174 1

VN191 - VN198 1

VN211 - VN212 1

VN221 - VN225 1

VN231 - VN234 1

VN241 - VN243 1

VN251 - VN276 1

VN291 - VN293 1

VN301 - VN314 1

VN371 - VN372 1

VN376 1

VN381 - VN388 1

VN421 - VN427 1

VN436 1

VN471 - VN472 1

VN491 - VN513 1

VN531 - VN532 1

VN536 - VN537 1

VN541 - VN542 1

VN546 - VN547 1

VN551 1

VN556 - VN557 1

VN561 - VN562 1

VN631 - VN638 1

VN651 - VN658 1

VN671 - VN672 1

VN676 1

VN681 - VN691 1

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BOEING SERVICE BULLETIN 767-57A0100
Variable Number Group

VN731 - VN732 1

VN751 - VN753 1

VN791 - VN792 1

VN811 - VN813 1

VN921 - VN922 1

VN931 - VN936 1

VN951 - VN953 1

VN966 - VN972 1

VQ001 - VQ021 2

VQ071 - VQ086 2

VR051 - VR060 1

VR081 1

VR084 1

VR086 - VR087 1

VR106 1

VR201 - VR211 1

VR251 1

VR256 - VR260 1

VR401 1

VR421 - VR423 1

VR426 1

VR441 1

VR461 1

VR471 - VR472 1

VS051 - VS056 1

VS061 1

VS066 - VS070 1

VS073 - VS078 1

VS091 - VS104 1

VS111 - VS113 1

VS131 - VS133 1

VS136 - VS137 1

VS176 - VS177 1

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BOEING SERVICE BULLETIN 767-57A0100
Variable Number Group

VS186 - VS187 1

VS196 - VS203 1

VS206 - VS208 1

VS211 1

VS216 - VS217 1

VS231 1

VS246 - VS248 1

VS261 - VS263 1

VS266 - VS274 1

VS291 - VS293 1

VS301 - VS303 1

VS306 - VS311 1

VS316 1

VS321 - VS324 1

VS331 - VS333 1

VS336 - VS337 1

VS366 - VS367 1

VS381 - VS382 1

VS391 - VS392 1

VS401 1

VS426 - VS428 1

VS466 - VS472 1

VS486 1

VS496 - VS497 1

VS506 - VS507 1

VS526 1

VS546 - VS549 1

VS701 - VS712 1

VS721 - VS732 1

VS751 - VS759 1

VS821 - VS825 1

VS841 - VS844 1

VS861 1

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BOEING SERVICE BULLETIN 767-57A0100
Variable Number Group

VS881 - VS883 1

VS891 1

VS896 1

VT501 1

VT511 1

VV001 1

VW701 - VW721 1

VW851 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Accomplishment of the modifications within this service bulletin will help prevent possible ignition

sources in the main fuel tanks, and the surge tanks caused by a lightning strike on certain wing surfaces.

An ignition source in a fuel tank could result in a consequent fire or explosion.

A review by Boeing identified a certain fastener type in the fuel tank walls that have an insufficient bond

to the structure. If energy from lightning strike goes through these fasteners, arcing can occur at the

ends of the fasteners in the fuel tank. The ends of the fasteners in the fuel tank do not have sufficient

electrical insulation to contain the energy from the arcs.

This Service Bulletin gives the instructions to seal the end of certain fasteners in the fuel tank walls.

These changes make sure that the risk of an ignition source in the fuel tank from a lightning strike on

the wing is kept to a minimum.

This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88, "Fuel

Tank System Fault Tolerance Evaluation Requirements".

Revision 1 is sent to to give instructions to do a General Visual Inspection of the vortex generators on

certain airplanes. Before work is done, the vortex generators on certain airplanes must be inspected

to determine if the vortex generators are installed with fasteners or adhesive alone. An operator reported

that the vortex generators on some 767 airplanes are attached with adhesive alone. If fasteners are

not used to install the vortex generators it is not necessary to apply sealant at these locations. A review

of the engineering drawing for the upper wing inspar panel installation confirms that some airplanes in

a certain line number range were delivered with vortex generators that are attached by adhesive alone.

The data given in Information Notice 767-57A0100 IN 01 is included in this revision.

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BOEING SERVICE BULLETIN 767-57A0100
Revision 2 is sent to correct a typographical error in the quantity of fasteners specified in certain figures.

Figure 4 and Figure 5 correctly shows 10 fasteners that must be sealed at Rear Spar Station (RSS)

916.70 and the text after the circle note specifies a quantity of 9 locations. Also this revision corrects

discrepancies in references and specifies alternative fuel tank sealants.

The data given in Information Notice 767-57A0100 IN 02 is included in this revision.

Revision 3 is sent to correct the quantity of the fasteners specified in Figure 5. The figure incorrectly

shows 15 fasteners that must be sealed at Rear Spar Station (RSS) 468.06. The correct fastener

quantity for RSS 468.06 is 14. Also clarification was added to show that Figure 1 is a typical view of a

fastener that was intended to apply to rivets or bolts with collars.

D. Description

Group 1:

Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the fasteners

on the brackets that hold the vortex generators. Get access to the right main tank. Seal the ends of

the fasteners on the brackets that hold the vortex generators. Close access to the main fuel tanks.

Group 2:

Prepare the main fuel tanks and surge tanks for entry. Get access to the left main tank. Seal the ends

of the fasteners on the brackets that hold the vortex generators. Seal the ends of fasteners on certain

stiffeners on the rear spar. Get access to the right main tank. Seal the ends of the fasteners on the

brackets that hold the vortex generators. Seal the ends of fasteners on certain stiffeners on the rear

spar. Close access to the main fuel tanks.

Group 3:

Get access to the outer surface of the upper wing panel on the left wing. Do a General Visual Inspection

of the specified vortex generators on the upper wing panel of the left wing. Get access to the outer

surface of the upper wing panel on the right wing. Do a General Visual Inspection of the specified vortex

generators on the upper wing panel on the right wing. If the vortex generators are attached with adhesive

alone, no more work is necessary. If the vortex generators are attached with fasteners, do the following

steps: Prepare the main fuel tanks for entry. Get access to the left main tank. Seal the ends of the

fasteners on the brackets that hold the vortex generators. Get access to the right main tank. Seal the

ends of the fasteners on the brackets that hold the vortex generators. Close access to the main fuel

tanks.

Service Bulletin 767-57A0102 has similar access requirements as this bulletin and can be incorporated

at the same time or separately. Service Bulletin 767-57A0102 is separate from this bulletin because it

makes improvements to existing design and does not have warranty remedies.

Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this

service bulletin.

Revision 2 - No more work is necessary on airplanes changed in accordance with the original issue

and Revision 1 of this service bulletin.

Revision 3 - No more work is necessary on airplanes changed in accordance with the original issue,

Revision1, and Revision 2 of this service bulletin.

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

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BOEING SERVICE BULLETIN 767-57A0100
Group 1:

Affected Maintenance Zones

Model Zone

767-200, 767-300, 767-300F 541, 641

Group 2:

Affected Maintenance Zones

Model Zone

767-400ER 541, 542, 641, 642

Group 3:

Affected Maintenance Zones

Model Zone

767-200, 767-300 541, 641

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-18-02 is related to this service

bulletin.

Boeing recommends that this service bulletin be incorporated within 60 months from the effective date

of FAA AD 2009-18-02.

F. Approval

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

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

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

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

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

changes.

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

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

before incorporating this service bulletin.

In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection

or modification) defined in this service bulletin as an alternative method of compliance to the requirements

of paragraph (f) of AD 2009-18-02. All provisions of AD 2009-18-02 that are not specifically referenced

in the above statement remain fully applicable and must be complied with.

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BOEING SERVICE BULLETIN 767-57A0100
G. Manpower

The table below shows an estimate of the task-hours necessary to do this change for each airplane.

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

task-hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Group 1:

Number of Per- Task-Hours Elapsed Hours

sons

Task

Prepare 4 13.00 3.25

Open Access 2 3.00 1.50

Figure 1 and Figure 2 6.00 3.00

2

Close Access 4 7.25 1.80

TOTAL FOR EACH AIRPLANE 29.25 8.75

Group 2:

Number of Per- Task-Hours Elapsed Hours

sons

Task

Prepare 4 13.00 3.25

Open Access 2 6.00 3.00

Figure 1 and Figure 2 6.00 3.00

3

Figure 1 and Figure 4 54.00 13.50

4

Figure 1 and Figure 4 54.00 13.50

5

Close Access 4 10.25 2.56

TOTAL FOR EACH AIRPLANE 143.25 38.81

Group 3, Configuration 1:

Number of Per- Task Hours Elapsed Hours

sons

Task

Inspect - Figure 6 1 0.50 0.50

and Figure 7

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BOEING SERVICE BULLETIN 767-57A0100
Group 3, Configuration 1:

Number of Per- Task Hours Elapsed Hours

sons

Task

Prepare 4 13.00 3.25

Open Access 2 3.00 1.50

Figure 1 and Figure 2 6.00 3.00

2

Close Access 4 7.25 1.80

TOTAL FOR EACH AIRPLANE 29.75 10.05

Group 3, Configuration 2:

Number of Per- Task Hours Elapsed Hours

sons

Task

Inspect - Figure 6 1 0.50 0.50

and Figure 7

TOTAL FOR EACH AIRPLANE 0.50 0.50

H. Weight and Balance Changes

Group 1; Group 3, Configuration 1:

Change in Moment

(Pound-Inches)

Change in Weight

(Pounds)

Airplane

Group 1 +0.14 +152.6

Group 2:

Change in Moment

(Pound-Inches)

Change in Weight

(Pounds)

Airplane

Group 2 +1.4 +1526

Group 3, Configuration 2:

None.

I. Electrical Load Data

Not changed.

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BOEING SERVICE BULLETIN 767-57A0100
J. References

1. Existing Data:

a. Engineering Change Memo PRR B13421-10

b. 767 Aircraft Maintenance Manual (AMM) 28-11-00, 28-11-01, 28-11-02, 28-11-03, 28-26-00

c. Boeing Service Bulletin 767-57A0102

d. Boeing Standard Overhaul Practices Manual SOPM 20-30-93

e. Federal Aviation Administration (FAA) Airworthiness Directive 2009-18-02

2. Data supplied with this Service Bulletin:

None.

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

Drawing Number Title

112T1901 Rear Spar Inst - Wing

112T3000 Panel Installation, Inspar Wing, Upper

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

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

L. Interchangeability and Intermixability of Parts

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

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BOEING SERVICE BULLETIN 767-57A0100
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary For Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

B. Industry Support Information

Boeing warranty remedies are available for 767 airplanes in warranty as of July 16, 2004. For man-hour

and material reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Commercial Airplanes Group - Warranties.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

Group 1-2; Group 3, Configuration 1:

Part Number / QTY Name Notes

Specification

BMS 11-7 (SOL- 10 fl. oz. SOLVENT (a) (b)

VENTS IN SOPM

20-30-93optional)

BMS 5-45, CLASS 7 fl. oz. SEALANT (a) (b)

A-2, GRADE

1(PERMITTED ALTERNATIVE FUEL

TANK SEALANTS

IN 767 AMM 28-

11-01 optional)

BMS 5-45, CLASS 28 fl. oz. SEALANT (a) (b)

B-2 (PERMITTED

ALTERNATIVE

FUEL TANK

SEALANTS IN 767

AMM 28-11-01 optional)

BMS 15-5 - WIPER, ABSORBENT (a)

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

supplier data.

(b) Quantity is approximate.

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BOEING SERVICE BULLETIN 767-57A0100
Group 3, Configuration 2:

None.

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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BOEING SERVICE BULLETIN 767-57A0100
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. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to ensure visual access to all surfaces in the

inspection area. This level of inspection is made under normal available lighting

conditions such as daylight, hangar lighting, flashlight or drop-light and may require

removal or opening of access panels or doors. Stands, ladders or platforms may be

required to gain proximity to the area being checked.

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

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

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

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

be used.

B. WORK INSTRUCTIONS

WARNING: KEEP PERSONS AND EQUIPMENT AWAY FROM ALL CONTROL SURFACES WHEN

HYDRAULIC POWER IS SUPPLIED. AILERONS, ELEVATORS, RUDDER, FLAPS,

SLATS, SPOILERS, AND STABILIZER ARE FULLY POWERED SURFACES. INJURY

TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC

POWER IS SUPPLIED.

1. Group 3:

Get access to the outer surface of the upper wing panel on the left wing.

2. Group 3:

Do a General Visual Inspection of the specified vortex generators on the upper wing panel on the

left wing as given in FIGURE 6.

WARNING: KEEP PERSONS AND EQUIPMENT AWAY FROM ALL CONTROL SURFACES WHEN

HYDRAULIC POWER IS SUPPLIED. AILERONS, ELEVATORS, RUDDER, FLAPS,

SLATS, SPOILERS, AND STABILIZER ARE FULLY POWERED SURFACES. INJURY

TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC

POWER IS SUPPLIED.

3. Group 3:

Get access to the outer surface of the upper wing panel on the right wing.

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4. Group 3:

Do a General Visual Inspection of the specified vortex generators on the upper wing panel on the

right wing as given in FIGURE 7.

5. Group 3:

If the vortex generators are attached with adhesive alone, no more work is necessary. If the vortex

generators are attached with fasteners, go to the next step.

NOTE: Airplanes with vortex generators that are attached with fasteners are in Group 3,

Configuration 1.

NOTE: Airplanes with vortex generators that are attached with adhesive alone are in Group 3,

Configuration 2.

6. Group 1-2; Group 3, Configuration 1:

Defuel the left and right main fuel tank. Refer to 767 AMM 28-26-00, Page Block 201 as an accepted

procedure.

7. Group 1; Group 3, Configuration 1:

Prepare the left and right main fuel tanks for entry. Refer to 767 AMM 28-11-00 Page Block 201

as an accepted procedure.

8. Group 2:

Prepare the left and right main fuel tanks and surge tanks for entry. Refer to 767 AMM 28-11-00

Page Block 201 as an accepted procedure.

9. Group 1; Group 3, Configuration 1:

Get access to the left main fuel tank. Remove and keep the access doors as shown in the table

below. Refer to 767 AMM 28-11-01 as an accepted procedure.

Gives Access to Rear or Front Spar

Area between Rib Number

Access Door

541AB Ribs 10 and 11

541BB Ribs 11 and 12

541CB Ribs 12 and 13

10. Group 1; Group 3, Configuration 1:

Get access to the right main fuel tank. Remove and keep the access doors as shown in the table

below. Refer to 767 AMM 28-11-01 as an accepted procedure.

Gives Access to Rear or Front Spar

Area between Rib Number

Access Door

641AB Ribs 10 and 11

641BB Ribs 11 and 12

641CB Ribs 12 and 13

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BOEING SERVICE BULLETIN 767-57A0100
11. Group 2:

Get access to the left main fuel tank and the surge tank. Remove and keep the access doors as

shown in the table below. Refer to 767 AMM 28-11-01 and 767 AMM 28-11-03 as an accepted

procedure.

Gives Access to Rear or Front Spar

Area between Rib Number

Access Door

541BB Ribs 11 and 12

541CB Ribs 12 and 13

541VB Ribs 28 and 29

541XB Ribs 30 and 31

542BB Ribs 32 and 33

12. Group 2:

Get access to the right main fuel tank and the surge tank. Remove and keep the access doors as

shown in the table below. Refer to 767 AMM 28-11-01 and 767 AMM 28-11-03 as an accepted

procedure.

Gives Access to Rear or Front Spar

Area between Rib Number

Access Door

641BB Ribs 11 and 12

641CB Ribs 12 and 13

641VB Ribs 28 and 29

641XB Ribs 30 and 31

642BB Ribs 32 and 33

13. Group 1-2; Group 3, Configuration 1:

Find and seal the fasteners for the brackets that hold the vortex generators on the upper wing skin

in the main tank in as given in:

— FIGURE 1 for the seal of the fastener

— FIGURE 2 for the location of the fasteners in the left main tank

— FIGURE 3 for the location of the fasteners in the right main tank.

14. Group 2:

Find and seal the fasteners for the stiffeners on the rear spar in the main tank and the surge tank

as given in:

— FIGURE 1 for the seal of the fastener

— FIGURE 4 for the location of the fasteners in the left main tank and surge tank

— FIGURE 5 for the location of the fasteners in the right main tank and surge tank.

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BOEING SERVICE BULLETIN 767-57A0100
15. Group 1; Group 3, Configuration 1:

Close access to the fuel tanks. Install the access doors that were removed. Refer to 767 AMM

28-11-01 as an accepted procedure.

16. Group 2:

Close access to the fuel tanks. Install the access doors that were removed. Refer to 767 AMM

28-11-01 and 767 AMM 28-11-03 as an accepted procedure.

17. Group 1-2; Group 3, Configuration 1:

Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 1-2; Group 3, Configuration 1.

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 this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Make sure that the

debris around the

areas to be sealed

is removed.

1 Remove DEBRIS - -

Use a BMS 15-5

wiper wet with solvent. (a)

BMS 11-7 (SOL- -

VENTS IN BSOPM 20-

30-93 optional)

2 Apply SOLVENT

Use a non-metallic

brush.

Clean FASTENERS - -

The remaining solvent must be removed while wet

with a clean, dry

BMS 15-5 wiper. (b)

Remove SOLVENT - -

Use a BMS 15-5

wiper wet with solvent. (a)(c)

BMS 11-7 (SOL- -

VENTS IN BSOPM 20-

30-93 optional)

3 Apply SOLVENT

Use a non-metallic

brush.

Clean FASTENERS - -

The remaining solvent must be removed while wet

with a clean, dry

BMS 15-5 wiper.(b)

Remove SOLVENT - -

FIGURE 1: SEAL OF THE FASTENERS

(SHEET 1 OF 2)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

Precoat sealant.

(d)(e)

BMS 5-45, CLASS A-2, -

GRADE 1 (PERMITTED ALTERNATIVE

FUEL TANK

SEALANTS IN 767

AMM 28-11-00 optional)

4 Apply SEALANT

BMS 5-45, CLASS B-2, - Fillet sealant. (d)(f)

GRADE 1 (PERMITTED ALTERNATIVE

FUEL TANK

SEALANTS IN 767

AMM 28-11-00 optional)

5 Apply SEALANT

(a) Make sure that an area approximately 0.5 inch from the base of the fastener (rivet or bolt with a collar) is

clean. The cleaned area must be larger than the area that has sealant.

(b) Make sure that the wiper has no visible soil remaining after the area is cleaned.

(c) It is not necessary to apply solvent, clean the fasteners (rivets or bolts with collars) and remove the solvent

again if Step 2 is done immediately before the precoat sealant is applied.

(d) Make sure to use the sealants specified in this table or specified alternatives.

(e) Make sure to apply the precoat sealant on the fastener (rivet or bolt with a collar). Refer to 767 AMM 28-

11-00 as an accepted procedure.

(f) Make sure to apply the fillet sealant on the fastener (rivet or bolt with a collar). Refer to 767 AMM 28-11-

00 as an accepted procedure.

FIGURE 1: SEAL OF THE FASTENERS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 1-2; Group 3, Configuration 1.

FIGURE 2: UPPER WING SKIN - LEFT MAIN TANK - LOCATION OF THE FASTENERS

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
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 this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Get access. Find the location of

the fasteners that must be

sealed.

1 Locate FASTENERS - 8

FIGURE 2: UPPER WING SKIN - LEFT MAIN TANK - LOCATION OF THE FASTENERS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 1-2; Group 3, Configuration 1.

FIGURE 3: UPPER WING SKIN - RIGHT MAIN TANK - LOCATION OF THE FASTENERS

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
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 this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Get access. Find the location of

the fasteners that must be

sealed.

1 Locate FASTENERS - 8

FIGURE 3: UPPER WING SKIN - RIGHT MAIN TANK - LOCATION OF THE FASTENERS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 2.

FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
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 this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Get access. Find the location of

the fasteners that must be

sealed.

1 Locate FASTENERS - 72

FIGURE 4: REAR SPAR - LEFT MAIN TANK AND SURGE TANK - LOCATION OF THE FASTENERS

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 2.

FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE

FASTENERS

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE

FASTENERS

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE

FASTENERS

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
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 this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Get access. Find the location of

the fasteners that must be

sealed.

1 Locate FASTENERS - 71

FIGURE 5: GROUP 2 - REAR SPAR - RIGHT MAIN TANK AND SURGE TANK - LOCATION OF THE

FASTENERS

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 3.

FIGURE 6: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - LEFT WING

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
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 this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

VORTEX GENERA- - 4

TOR

1 Locate

VORTEX GENERA- - 4 (a)

TOR

Inspect

(a) Do a General Visual Inspection to find if the vortex generator is installed with fasteners or adhesive alone.

FIGURE 6: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - LEFT WING

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
This Figure applies only to: Group 3.

FIGURE 7: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - RIGHT WING

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100
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 this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

VORTEX GENERA- - 4

TOR

1 Locate

VORTEX GENERA- - 4 (a)

TOR

Inspect

(a) Do a General Visual Inspection to find if the vortex generator is installed with fasteners or adhesive alone.

FIGURE 7: INSPECTION OF THE VORTEX GENERATORS - UPPER WING SKIN - RIGHT WING

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-57A0100