### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-57A0079**  Original Issue: June 20, 2002 Revision 2: March 23, 2012 ATA System: 5750 **SUBJECT:** WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Assembly Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 1 of 38 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 2 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 16 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 18 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 19 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES. . . . . . . 25 FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION . . . . . . . . . . . . . . . . . 26 FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION . . . . 29 FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 33

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 3 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 4 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 767-57A0079** Original Issue: June 20, 2002 Revision 2: March 23, 2012 ATA System: 5750 **SUBJECT:** WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Assembly Inspection and Replacement This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on the airplanes changed in accordance with the original issue or Revision 1 of this service bulletin. However, operators must continue to do the repetitive inspections of the hinge fittings, at the times in accordance with Paragraph 1.E., Compliance until new hinge fitting assemblies 113T2271-419 (Left) and 113T2271-420 (Right) are installed. **REASON FOR REVISION** This revision is sent to change the inspection requirements in Figure 2 and Figure 3 of this service bulletin. The inspection area on the trailing edge main flap hinge fitting is changed and limited to the outboard half only. Subsequent to the release of Revision 1 of this service bulletin, one operator reported finding a fractured hinge fitting assembly. The fracture occurred on a hinge fitting assembly at approximately 780 flight-cycles after its last inspection on a 767-300 airplane. An examination of the fractured hinge fitting assembly showed that the crack started at the edge of the current inspection area. The service bulletin illustrations have been updated to clearly show the expected crack location and direction. The latest service bulletin format standards have also been updated where applicable. These sections are changed: 1. Service Bulletin Title updated. 2. Summary - Illustration - Illustration updated to show the expected crack location and direction. 3. Paragraph 1.F., Approval - AMOC statement updated. 4. Paragraph 1.G., Manpower - Table updated. 5. Paragraph 1.K.1., Publications - CMM reference added. 6. Paragraph 1.K.2., Damage Tolerance Based Structural Inspections - Damage Tolerance Inspections (DTI) statement added. 7. Paragraph 3.A., General Information - General notes updated.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 5 of 388. Paragraph 3.B., Work Instructions - Titles updated and Part 3, Steps 3 and 5 updated to correct the access panel numbers. Also the latest service bulletin format standards have also been updated where applicable. 9. Figure 1 - Illustration updated to revise the data in compliance Logic Diagram. 10. Figure 2 - Illustration updated to incorporate the new inspection requirements. 11. Figure 3 - Illustration updated to incorporate the new inspection requirements. 12. Figure 4 - Step table updated to remove the QTY for shims. The data given in Alternative Method of Compliance Notice 767-57A0079-AMOC-01 is included in this revision. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** June 20, 2002 Original Issue: May 06, 2010 Revision 1: March 23, 2012 Revision 2:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 6 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Summary**  **Number: 767-57A0079** Original Issue: June 20, 2002 Revision 2: March 23, 2012 ATA System: 5750 **SUBJECT:** WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Assembly Inspection and Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Accomplishment of this service bulletin will detect cracks, prevent fractures and ensure the structural integrity of the inboard trailing edge main flap outboard hinge fittings. Fracture of the hinge fitting assemblies could result in the inboard aft flap becoming unrestrained potentially striking the aircraft upon departure, resulting in significant damage to the surrounding structure and could cause potential personal injury. One operator of a 767-300 reported lug fractures on both the inboard and outboard hinge fittings of the outboard hinge assembly mounted to the main flap. The hinge assembly provides one of two primary attachment points of the inboard trailing edge aft flap assembly. The outboard hinge fitting was fractured just above the lug hole. The fractured hinge fittings were found during a routine maintenance inspection. The airplane had accumulated 9,598 flight-hours and 5,393 flight cycles. During root cause analysis of the fractured hinge fitting it was discovered that an optional tool runout was not present on the damaged fitting assemblies. The tool runout option allows the part to be machined thicker within the area reported to be fractured. Boeing has received no reports of cracks or fractures on fitting that have the additional material area of the optional tool runout. Service bulletin 767-57A0076 was released to inspect and replace the suspect hinge fittings if and as required on all 767-200, 767-300 and 767-300F airplanes line numbers 1 through 825. The inboard trailing edge main flap outboard hinge fittings on the 767-400ER are similar in design to the 767-200, 767-300 and 767-300F fittings. The 767-400ER fittings are wider and thicker; however, higher fatigue loads are associated with the 767-400ER in this area. Analysis indicates the 767-400ER fittings could be susceptible to early fatigue cracking and/or fractures as a result of these higher loads. Subsequent to the original issue of this service bulletin, 3 reports of hinge fitting assembly fracture have been received. The fractures all occurred at approximately 9,100 flight-cycles and in 1 case fracture at approximately 1,400 flight-cycles after the last detailed - eddy current inspection. Based on the reports of the fractured hinge fitting assemblies prior to the initial threshold and the repeat interval, revision 1 reduced the initial threshold and repeat interval. Revision 2 changed the inspection area to show clearly the expected crack location and direction.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 7 of 38Replacement of the hinge fitting assembly with a more robust designed fitting will ensure the structural integrity of the aft flap, prevent damage to the surrounding structure and stop the potential for personal injury. Boeing Service Related Problem (SRP) 767-SRP-57-0119 is related to this service bulletin. Boeing Service Related Problem (SRP) 767-SRP-57-0233 is related to this service bulletin. **ACTION** Inspect the inboard trailing edge main flap outboard hinge fittings on the left and right wing for cracks or fractures. If any cracks or fractures are found, complete terminating action. If cracks or fractures are not found, repeat the inspections at the intervals in accordance with FIGURE 1 until terminating action is completed. **EFFECTIVITY** 767-400ER Airplanes. Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes. **COMPLIANCE** Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin. Refer to FIGURE 1 Logic Diagram for Inspection and Maintenance Alternatives. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 8 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 9 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 10 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-57A0079**  Original Issue: June 20, 2002 Revision 2: March 23, 2012 ATA System: 5750 **SUBJECT:** WINGS - Trailing Edge and Trailing Edge Devices - Inboard Main Flap - Hinge Fitting Assembly Inspection and Replacement 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 D6-24T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR12901-9S for data about this change.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-400ER airplanes line numbers 758 through 877.

- 1

Airplane Models: 767-400ER **Group Variable Number**  1 VQ001 - VQ021 1 VQ071 - VQ085

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 11 of 382. Spares Affected Examine your 767-400ER inboard trailing edge main flap spares supply for the 113T2271-401 and 113T2271-402 outboard hinge fitting assemblies. If any parts are found, refer to Paragraph 2.C., Parts Necessary for Each Airplane and Paragraph 2.D., Parts Necessary to Change Spares for the recommended use. **B. Concurrent Requirements** None. **C. Reason** Accomplishment of this service bulletin will detect cracks, prevent fractures and ensure the structural integrity of the inboard trailing edge main flap outboard hinge fittings. Fracture of the hinge fittings could result in the inboard aft flap becoming unrestrained potentially striking the aircraft upon departure, resulting in significant damage to the surrounding structure and could cause potential personal injury. One operator of a 767-300 reported lug fractures on both the inboard and outboard hinge fittings of the outboard hinge assembly mounted to the main flap. The hinge assembly provides one of two primary attachment points of the inboard trailing edge aft flap assembly. The outboard fitting was fractured just above the lug hole. The fractured fittings were found during a routine maintenance inspection. The airplane had accumulated 9,598 flight-hours and 5,393 flight cycles. During root cause analysis of the fractured hinge fitting it was discovered that an optional tool runout was not present on the damaged fitting assemblies. The tool runout option allows the part to be machined thicker within the area reported to be fractured. Boeing has received no reports of cracks or fractures on fitting that have the additional material area of the optional tool runout. Service bulletin 767-57A0076 was released to inspect and replace the suspect hinge fittings if and as required on all 767-200, 767-300 and 767-300F airplanes line numbers 1 through 825. The inboard trailing edge main flap outboard hinge fittings on the 767-400ER are similar in design to the 767-200, 767-300 and 767-300F fittings. The 767-400ER fittings are wider and thicker; however, higher fatigue loads are associated with the 767-400ER in this area. Analysis indicates the 767-400ER fittings could be susceptible to early fatigue cracking and/or fractures as a result of these higher loads. Subsequent to the original issue of this service bulletin, 3 reports of hinge assembly fracture have been received. The fractures all occurred at approximately 9,100 flight-cycles and in 1 case fracture at approximately 1,400 flight-cycles after the last detailed - eddy current inspection. Based on the reports of the fractured hinge fitting assemblies prior to the initial threshold and the repeat interval, revision 1 reduced the initial threshold and repeat interval. Revision 2 changed the inspection area to show clearly the expected crack location and direction. Replacement of the outboard hinge fitting with a more robust designed fitting will ensure the structural integrity of the aft flap, prevent damage to the surrounding structure and stop the potential for personal injury. Boeing Service Related Problem (SRP) 767-SRP-57-0119 is related to this service bulletin. Boeing Service Related Problem (SRP) 767-SRP-57-0233 is related to this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 12 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**Revision 1 was sent to 1. To reduce the initial compliance time and repeat interval based on service reports. Subsequent to the original issue of this service bulletin, operators have reported finding 3 fractured hinge fitting assemblies. The fractured hinge fitting assemblies had accumulated less flight-cycles than the initial compliance threshold and in 1 case, the hinge fitting assembly fractured after the original inspection and prior to the next repeat inspection. Boeing Service Related Problem (SRP) 767-SRP-57-0233 was issued to address this issue. 2. Add instructions to transfer the stainless steel filler and the shims for the mid fairing roller from the old hinge fitting assembly to the new hinge fitting assembly. 3. Revise inspection area to show inspection from the center of the lug forward, not the end of the lug forward. This moves the inspection forward to inspect additional area where cracking has been found, not the lug bore where cracking has not been found. 4. Add reference to the existing AD, add an AMOC to the existing AD, and reference the possible new AD which would make the compliance tasks and times in Revision 1 of this service bulletin mandatory. 5. Update the format of the service bulletin to meet current service bulletin standards. Revision 2 is sent to change the inspection requirements in Figure 2 and Figure 3 of this service bulletin. The inspection area on the trailing edge main flap hinge fitting is changed and limited to the outboard half only. Subsequent to the release of Revision 1 of this service bulletin, one operator reported finding a fractured hinge fitting. The fracture occurred on a hinge fitting at approximately 780 flight-cycles after its last inspection on a 767-300 airplane. An examination of the fractured hinge fitting assembly showed that the crack started at the edge of the current inspection area. The service bulletin illustrations have been updated to clearly show the expected crack location and direction. The latest service bulletin format standards have also been updated where applicable. **D. Description** Inspect the inboard trailing edge main flap outboard hinge fittings on the left and right wing for cracks or fractures. If any cracks or fractures are found, complete terminating action. If cracks or fractures are not found, repeat the inspections at the intervals in accordance with FIGURE 1 until terminating action is completed. Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Revision 2 - No more work is necessary on the airplanes changed in accordance with the original issue or Revision 1 of this service bulletin. However, operators must continue to do the repetitive inspections of the hinge fittings, at the times in accordance with Paragraph 1.E., Compliance until new hinge fitting assemblies 113T2271-419 (Left) and 113T2271-420 (Right) are installed. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 555, 655 767-400ER

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 13 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT E. Compliance**  Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin. Refer to FIGURE 1 Logic Diagram for Inspection and Maintenance Alternatives. **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. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspections, follow-on and corrective actions, and terminating action in this service bulletin as an alternative method of compliance to the requirements of paragraph (a)(2), (b), and (f) of AD 2003-13-01. All provisions of AD 2003-13-01 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. **G. Manpower** The table below shows an estimate of the task-hours necessary to do the fitting inspections and replacement 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. Part 1 - Detailed Inspection **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

1.0 2.0 2 Open Access 1.0 1.0 1 Detailed Inspection 1.0 2.0 2 Close Access 3.0 5.0 TOTAL FOR EACH WING 6.0 10.0 TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 14 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**Part 2 - Detailed and Eddy Current Inspection **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

1.0 2.0 2 Open Access 1.0 1.0 1 Detailed Inspection 1.5 1.5 1 Eddy Current In- spection 1.0 2.0 2 Close Access 4.5 6.5 TOTAL FOR EACH WING 9.0 13.0 TOTAL FOR EACH AIRPLANE (a) The total task hours and elapsed hours are not given as the work necessary for each airplane is variable. Part 3 - Terminating Action **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

1.0 2.0 2 Open Access 6.0 12.0 2 Replace Fitting 1.0 2.0 2 Close Access 8.0 16.0 TOTAL FOR EACH WING 16.0 32.0 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Boeing Service Bulletin 767-57A0076 b. Boeing Service Related Problem (SRP) 767-SRP-57-0119, 767-SRP-57-0233 c. Component Maintenance Manual (CMM) 57-53-27 d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-13-01 e. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-50-10, 20-50-19

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 15 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**f. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 27-51-00 g. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-19 h. Engineering Change Memo PRR 12901-9S 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  Flap Instl - Inbd T.E. Flap 113T2000 This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: **Chapter-Section Publication**  27-51 767 Illustrated Parts Catalog 57-53 Component Maintenance Manual 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** Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 16 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane, and Paragraph 2.D., Parts Necessary to Change Spares. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 **REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION** 
**Unit Price as of the Revision 02** **date of this Ser vice Bulletin (US**  **Dollars) ROLT as of the**  **Revision 02 date**

**of this Service Bulletin (Calendar**  **Days) QTY**  **Date Name**  **Kit Number**

$46,390.00 367 1 May 06/02 Top Kit 015T1689-1 2 Jun 27/02 8 Nov 15/02 **B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts:
**Kit 015T1689 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -1**  **-2 -3**  Subkit, Top Kit

- . . 015T1689-1 Subkit, Hinge Fitting 1

- . 015T1689-2 Subkit, Hinge Fitting 1

. - 015T1689-3 (a) (b) (c) (f) 113T2271-401 Hinge Fitting Assembly - Left

. . 1 113T2271-419 (a) (b) (c) (g) 113T2271-402 Hinge Fitting Assembly - Right

. 1

. 113T2271-420

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 17 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT Kit 015T1689**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-1 -2**  **-3** (d) Bolt

. 2 2 BACB30LE5K19 (d) Bolt (optional 1/64 oversize)

. 2 2 BACB30LE5K19X (d) Bolt

. 2 2 BACB30LE5K20 (d) Bolt (optional 1/64 oversize)

. 2 2 BACB30LE5K20X (e) Shim

. 2 2 BACS40R015D015F (e) Shim

. 2 2 BACS40R015D017F Washer

. 4 4 BACW10BP5CD Washer (optional 1/64 oversize)

. 4 4 BACW10BP51CD Washer

. 4 4 BACW10BP5DP Washer (optional 1/64 oversize)

. 4 4 BACW10BP51DP Nut

. 4 4 NAS1805-5L (a) Discard the existing part. (b) This part is used in production. (c) You cannot use the existing part to replace the new or changed part. (d) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. (e) Use original shims located between the fitting assembly and the flap skin to maintain the original hinge line geometry of the fittings. However, if the original shims are damaged, replace shims. Maintain the thickness and location of the original shims. (f) The 113T2271-419 hinge fitting assembly is composed of a matched set of hinge fittings. The 113T2271-415 and the 113T2271-417. (g) The 113T2271-420 hinge fitting assembly is composed of a matched set of hinge fittings. The 113T2271-416 and the 113T2271-418.

2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number /**  **Specification** (a) Sealant 8 ounces BMS 5-95 (a) Primer 4 ounces BMS 10-11, Type I (a) Grease 4 ounces MIL-G-23827(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 18 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** To get the kit shown below, refer to Paragraph 2.A., Material - Price and Availability.
**Notes QTY**  **Name Part Number**  (a) 1 Top Kit 015T1689-1 (a) The 015T1689-1 top kit consists of two 015T1689 hinge fitting sub kits. The 015T1689-2 subkit contains the parts required to rework a right inboard trailing edge main flap assembly. The 015T1689-3 subkit contains the parts required to rework a left inboard trailing edge main flap assembly. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 19 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 20 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. 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 and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in SRM Chapter 51 4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 6. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 7. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 8. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 21 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**9. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 10. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 11. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. **B. WORK INSTRUCTIONS PART 1 - DETAILED INSPECTION**  1. Extend and deactivate the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure. 2. Remove the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer to 767 AMM 06-44-00 for location of these panels. **Right Wing Left Wing**  671GL 571GL 671GR 571GR 3. On the left and right wing, do a Detailed Inspection of the inboard trailing edge main flap outboard hinge fittings for cracks and or fractures in accordance with FIGURE 2. 4. If cracked or fractured fittings are found, do Part 3 - Terminating action. 5. If no cracks or fractures are found, repeat the inspections at the intervals in accordance with FIGURE 1 until terminating action is completed. 6. Install the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer to 767 AMM 06-44-00 for location of these panels. **Right Wing Left Wing**  671GL 571GL 671GR 571GR 7. Activate and retract the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure. 8. Put the airplane back to a serviceable condition. **PART 2 - DETAILED AND EDDY CURRENT INSPECTION**  1. Extend and deactivate the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 22 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**2. Remove the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer to 767 AMM 06-44-00 for location of these panels. **Right Wing Left Wing**  671GL 571GL 671GR 571GR 3. On the left and right wing, do a Detailed Inspection and an eddy current inspection of the inboard trailing edge main flap outboard hinge fittings for cracks and or fractures in accordance with FIGURE 3. 4. If cracked or fractured fittings are found, do Part 3 - Terminating action. 5. If no cracks or fractures are found, repeat the inspections at the intervals in accordance with FIGURE 1 until terminating action is completed. 6. Install the number 3 and 6 trailing edge aft flap adjustment access panels listed below. Refer to 767 AMM 06-44-00 for location of these panels. **Right Wing Left Wing**  671GL 571GL 671GR 571GR 7. Activate and retract the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure. 8. Put the airplane back to a serviceable condition. **PART 3 - TERMINATING ACTION** 1. Extend and deactivate the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure. 2. Remove the number 3 and 6 trailing edge main flap fairing mid sections listed below. Refer to 767 AMM 06-44-00 for location of these fairings. **Right Wing Left Wing**  671DB 571DB 3. Remove the number 3 and 6 trailing edge main flap fairing upper skin access panels listed below. Refer to 767 AMM 06-44-00 for location of these panels. **Right Wing Left Wing**  655JT 555JT 4. On the left and right wing, replace the inboard trailing edge main flap outboard hinge fittings in accordance with FIGURE 4.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 23 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT NOTE:**  The outboard hinge fitting and the inboard hinge fitting are attached together to make the hinge fitting assembly. If cracks or fractures are found on the outboard hinge fitting, it is necessary to change both (inboard and outboard) hinge fittings. 5. Install the number 3 and 6 trailing edge main flap fairing upper skin access panels listed below. Refer to 767 AMM 06-44-00 for location of these panels. **Right Wing Left Wing**  655JT 555JT 6. Install the number 3 and 6 trailing edge main flap fairing mid sections listed below. Refer to 767 AMM 06-44-00 for location of these fairings. **Right Wing Left Wing**  671DB 571DB 7. Activate and retract the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure. 8. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2: March 23, 2012 24 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 25 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 26 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 27 of 38 **BOEING SERVICE BULLETIN 767-57A0079 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 side of the airplane.
**More Data Qty**  **Identification Name**  **Task Step**  to remove loose dirt, grease and oil. Refer to SOPM 20-30-03as an accepted procedure. 1

- Outboard Hinge Fittings Clean 1

Do a Detailed Inspection for cracks or fractures within the indicated area. (a) 1

- Outboard Hinge Fittings Inspect 2

(a) On outboard hinge fitting only. Both faces on the outboard hinge fitting require inspection in the area shown.

**FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 28 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 29 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 30 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 31 of 38 **BOEING SERVICE BULLETIN 767-57A0079 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 side of the airplane.
**More Data Qty**  **Identification Name**  **Task Step**  to remove loose dirt, grease and oil. Refer to SOPM 20-30-03as an accepted procedure. 1

- Outboard Hinge Fittings Clean 1

Do a Detailed Inspection for cracks or fractures within the indicated area. (a) 1

- Outboard Hinge Fittings Inspect 2

Do an Eddy Current inspection for cracks within the indicated area in accordance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00- 19. Use a right angle pencil probe with a maximum drop of 0.1 inch. (a) 1

- Outboard Hinge Fittings Inspect 3

(a) On outboard hinge fitting only. Both faces on the outboard hinge fitting require inspection in the area shown.

**FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 32 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT**  **(SHEET 1 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 33 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT**  **(SHEET 2 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 34 of 38 **BOEING SERVICE BULLETIN 767-57A0079 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 of the airplane.
**More Data Qty**  **Identification Name**  **Task Step**  Maintain fasteners location and stackup for later installation. Refer to CMM 57-53-27 as an accepted procedure. 4

- Fasteners Remove / Keep 1

4

- Fasteners Remove 2 1 113T2271-() Hinge Fitting Assembly Remove 3 (a)

- BACS40R015D015F Shims "A" Remove / Keep 4 (a)

- BACS40R015D017F Shims "B" Remove / Keep

**FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT (SHEET 3 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 35 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** (b) 1 113T2271-419 (LEFT) Hinge Fitting Assembly Install (New) 5 (b) 1 113T2271-420 (RIGHT) Hinge Fitting Assembly Install (New)

- BACS40R015D015F Shims "A" Install (Kept)

- BACS40R015D017F Shims "B" Install (Kept) 4

- Fasteners Install (New) 4

- Fasteners Install (Kept) the incorporation of this service bulletin on each hinge fitting assembly. Refer to SOPM 20-50-10 asan accepted procedure. - - Rubber Stamp or Sten- cil Identify 6

1 BACB30LU3-20 OR BACB30LH3-20 Bolt "A" Remove / Keep 7

1 BACB30LU3-13 OR BACB30LH3-13 Bolt "B" Remove / Keep

2 BACW10BP3AP OR BACW10BP3DP Washer Remove / Keep

2 BACN10JC3 OR BACN10JC3CD Nut Remove / Keep

- BACS40R008A026F Shim "C" Remove / Keep

- BACS40R008E026F Shim "D" Remove / Keep 1 113T1700-9 Filler Remove / Keep

**FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT (SHEET 4 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 36 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** 1 113T1700-9 Filler Install (Kept) 8

- BACS40R008E026F Shim "D" Install (Kept)

- BACS40R008A026F Shim "C" Install (Kept) 1 BACB30LU3-13 OR BACB30LH3-13 Bolt "B" Install (Kept)

1 BACB30LU3-20 OR BACB30LH3-20 Bolt "A" Install (Kept)
BACW10BP3AP is used withBACB30LU3-() fasteners. BACW10BP3DP is used withBACB30LH3-() fasteners. 2 BACW10BP3AP OR BACW10BP3DP Washer Install (Kept)

Tighten to 19-21inch-pounds (20 target). BACN10JC3 is used withBACB30LU3-() fasteners. BACN10JC3CD is used withBACB30LH3-() fasteners. 2 BACN10JC3 OR BACN10JC3CD Nut Install (Kept)

(a) Maintain original location of shims. If shims are damaged, replace shims maintaining the original thickness. Apply BMS 10-11 Type I primer to the replacement shims and any bare surfaces of the original shims. Refer to SOPM 20-41-02 as an accepted procedure. (b) Locate and install hinge fitting with kept or identical replacement shims in the same location to maintain the original hinge line geometry of the fitting. Refer to CMM 57-53-27 as an accepted procedure. Fay seal shims and install fasteners wet with BMS 5-95 common to the fitting assembly and the main flap. Refer to SOPM 20-50-19 as an accepted procedure. Install kept fasteners common to the flap linkage and hinge fittings with MIL-G-23827 grease. Refer to CMM 57-53-27 as an accepted procedure.

**FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT (SHEET 5 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 37 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**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. The QTY numbers shown below are the number of fasteners necessary for this figure.
**MORE DATA HOLE DIA**  **QTY IDENTIFICA-**  **TION NAME**  **CODE** (a)

- - BACB30LE5K * Bolt A (a)

- - BACB30LE5K * XOpt 1/64 Oversize (a)

- - BACW10BP5CD Washer (a)

- - BACW10BP51CD Opt 1/64 Over- size (a)

- - BACW10BP5DP Washer (a)

- - BACW10BP51DP Opt 1/64 Over- size (a)

- - NAS1805-5L Nut (a) Install bolts wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 as an accepted procedure.

**FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT (SHEET 6 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 20, 2002 767-57A0079 Revision 2 March 23, 2012 38 of 38 **BOEING SERVICE BULLETIN 767-57A0079 ALERT**  **ALERT**