June 25, 2007

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Commercial

Airplane

Group 767

Service Bulletin

Number: 767-27-0186

Date: June 25, 2007

ATA System: 2731

SUBJECT: FLIGHT CONTROLS - Elevator - Elevator Power Control Actuator Bellcrank 

Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2007 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Unpublished Work - All Rights Reserved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, BBJ, DC-8, DC-9, 

DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue 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.
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BOEING SERVICE BULLETIN 767-27-0186

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 Table of Contents

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BOEING SERVICE BULLETIN 767-27-0186

Table of Contents

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 23

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 26

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 27

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FIGURE 1: Left Elevator PCA Bellcrank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

FIGURE 2: Right Elevator PCA Bellcrank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 3: PCA Bellcrank Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
 Table of Contents

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BOEING SERVICE BULLETIN 767-27-0186

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Commercial

Airplane

Group 767

Service Bulletin

Number: 767-27-0186 Summary

Date: June 25, 2007

ATA System: 2731

SUBJECT: FLIGHT CONTROLS - Elevator - Elevator Power Control Actuator Bellcrank 

Replacement

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin gives instructions to replace or rework elevator Power Control Actuator (PCA) bellcranks. 

As an alternative to Boeing Alert Service Bulletin 767-27A0168, the incorporation of this service bulletin 

combined with the repetitive check of the elevator PCA input rod assemblies recommended in Boeing Service 

Bulletin 767-27-0200 and the repetitive check of the elevator PCA rigging recommended in Boeing Service 

Bulletin 767-27-0202 will prevent continued operation with yielded or failed shear rivets in a bellcrank assembly 

for the elevator PCA and will also allow for longer inspection intervals. Operators are currently required by the 

Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2001-04-09 to do the 400 flight-hour 

repetitive check recommended in Boeing Alert Service Bulletin 767-27A0168. 

One operator reported the left elevator drooping during a preflight check. Examination of the elevator control 

system found sheared rivets in the left-inboard and center PCA bellcrank assemblies. The elevator single 

hydraulic system check required by a Certification Maintenance Requirement (CMR) may not detect yielded or 

failed shear rivets in the bellcrank assemblies for the elevator PCA. As a result, the FAA issued AD 2000-17-05 

to mandate the accomplishment of the actions specified in Boeing Alert Service Bulletin 767-27A0166, dated 

August 17, 2000.

Since the issuance of AD 2000-17-05, the FAA has received reports that several 767-200, 767-300, and 767-

300F airplanes failed the one-time functional check of the shear rivets required by the AD. As a result, the FAA 

issued AD 2001-04-09 to mandate the accomplishment of the actions specified in Boeing Alert Service Bulletin 

767-27A0168, dated November 21, 2000.

A detailed design review found that the override device incorporated into the elevator PCA input rod assembly 

provides protection against malfunctions and non-normal PCA operation. This design review also found that the 

shear rivets are not needed. The incorporation of this service bulletin combined with the repetitive check of the 

elevator PCA input rod assemblies recommended in Boeing Service Bulletin 767-27-0200 and the repetitive 

check of the elevator PCA rigging recommended in Boeing Service Bulletin 767-27-0202 is an alternative to the 

400 flight-hour repetitive check recommended in Boeing Alert Service Bulletin 767-27A0168.

Boeing Service Related Problem (SRP) 767-SRP-27-0128 is related to this service bulletin.
 

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BOEING SERVICE BULLETIN 767-27-0186

ACTION (PRR B12901-35S)

Do a general visual inspection for the three PCA bellcranks assemblies on each elevator. If a bellcrank assembly 

has shear rivets, replace it with a solid one-piece bellcrank assembly or rework the bellcrank assembly. Do a 

pogo check for each elevator PCA input rod assembly. Do a mis-rig check for each elevator.

EFFECTIVITY

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

COMPLIANCE

Boeing recommends the instructions in this service bulletin be done within six years after the date on this service 

bulletin.

The FAA will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness 

Directive will make the compliance tasks and times given in this service bulletin mandatory.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

Total Task Hours Elapsed Hours

29.0 18.0
 

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BOEING SERVICE BULLETIN 767-27-0186

PLATE

INDEX

ASSEMBLY

THE BELLCRANK

REPLACE OR REWORK

SHOWN DISASSEMBLED FOR CLARITY

BELLCRANK ASSEMBLY (TYPICAL)

ELEVATOR PCAS

(LEFT SIDE SHOWN)

LEFT SIDE SHOWN

ELEVATOR

EDGE

TRAILING

DO A POGO CHECK

(6 LOCATIONS)

DO A MIS-RIG CHECK

(2 LOCATIONS)

FWD

A

FWD

SEE A

SEE A

SEE A

SEE B

B

W34844
 

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BOEING SERVICE BULLETIN 767-27-0186

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Commercial

Airplane

Group 767

Service Bulletin

Number: 767-27-0186

Date: June 25, 2007

ATA System: 2731

SUBJECT: FLIGHT CONTROLS - Elevator - Elevator Power Control Actuator Bellcrank 

Replacement

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

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

Number, and Serial Number data.

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

production airplanes. Refer to PRR B12901-35S for data about this change.

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AA 767 LLC (SVX)

1 VE067

ABX AIR (ABX)

1 VA301 VA304–VA305 VA309–VA313 VA315

VA803 VA807–VA809 VB101–VB123 VB125

VB302

AEROFLOT (ARO)

1 VL896–VL897 VN471–VN472 VS216–VS217 VS321–VS324

VS392

AEROMEXICO (AMX)

1 VF071 VF093 VF162 VS211

GROUP CONFIGURATION DESCRIPTION

1 - 767 -200, -300 and -300F airplanes line 

numbers 1-901.
 

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BOEING SERVICE BULLETIN 767-27-0186

AEROSVIT (UKA)

1 VN155 VN157

AEROTURBINE (AUB)

1 VB051 VB054–VB055 VB321–VB322

AIR ALGERIE (ALG)

1 VK131–VK133

AIR ASTANA (AKZ)

1 VL899

AIR CANADA (ACN)

1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202

VN051–VN054 VN056–VN062 VN531 VN536

VN541–VN542 VN546–VN547 VN751–VN752 VN811–VN812

VN931–VN936 VS381–VS382 VS546–VS549

AIR CHINA (BEJ)

1 VE064 VE083–VE086 VK161–VK164 VN388

VS206 VS208 VS274 VS307

AIR DO (HIA)

1 VS176–VS177

AIR EUROPA (ARE)

1 VN638 VS291–VS293

AIR ITALY (RIT)

1 VL913

AIR MADAGASCAR (MAD)

1 VN167 VN731

AIR NEW ZEALAND (ANZ)

1 VN653 VN655–VN658 VS113

AIR NIUGINI (NIU)

1 VN651

AIR PACIFIC (APC)

1 VN676

AIR SAHARA (SAQ)

1 VN495

AIR SEYCHELLES (ASY)

1 VL941 VS526

AIR TRANSPORT INTERNATIONAL (TIN)

1 VA509–VA513
 

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AIR ZIMBABWE (ZMB)

1 VF061–VF062

ALITALIA (ALI)

1 VL701–VL702 VN422–VN427 VN732 VN813

VS366–VS367 VS401

ALL NIPPON AIRWAYS (ANA)

1 VK081–VK113 VN191–VN198 VR401 VS721–VS728

VT501

AMERICAN AIRLINES (AAL)

1 VA501–VA508 VA514–VA525 VA527–VA530 VN001–VN041

VS196–VS203 VS751–VS753

ARKEFLY (HXL)

1 VN156 VN164–VN165 VN225

ASIANA AIRLINES (AAR)

1 VK143–VK148 VR426 VW851

AUSTRALIAN AIRLINES (AUF)

1 VN089–VN092 VS486

AUSTRIAN (AUL)

1 VN242–VN243 VN671 VS301–VS303

AVIANCA (AVI)

1 VE171–VE172 VF072 VF092 VF161

VN152 VN532

AWAS (AWW)

1 VB325

BELAIR AIRLINES (BLB)

1 VL932

BELLVIEW AIRLINES (BEB)

1 VE125–VE126

BLUE CITY HOLDING (BCY)

1 VE069

BLUE PANORAMA AIRLINES (BPA)

1 VL911 VN174 VN681 VS061

BOEING (TBC)

1 VA001

BRA TRANSPORTES AEREOS (BRW)

1 VA806 VN376
 

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BOEING SERVICE BULLETIN 767-27-0186

BRAVO AIRLINES (BVA)

1 VE104

BRITISH AIRWAYS (BAB)

1 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137

VS246–VS248

CAMEROON AIRLINES (CAM)

1 VA801 VS308

CHINA EASTERN YUNNAN AIRLINES (YUN)

1 VL871–VL873

CONDOR (CDF)

1 VN683–VN691

CONTINENTAL AIRLINES (CAL)

1 VR051–VR060

DELTA AIR LINES (DAL)

1 VA302–VA303 VA306 VA314 VK035–VK056

VL753 VN251–VN276 VN301–VN306 VR471–VR472

VS066–VS070 VS073–VS078 VS266–VS273 VS466–VS472

EDREES AVIATION (SME)

1 VA804

EL AL ISRAEL AIRLINES (ELA)

1 VB281–VB284 VF101–VF102 VN537 VN682

VN972

ERITREAN AIR LINES (ERJ)

1 VE066

ETHIOPIAN AIRLINES (ETH)

1 VE002 VL898 VS306 VS506–VS507

ETIHAD AIRWAYS (ETI)

1 VS391

EUROATLANTIC AIRWAYS (MAE)

1 VN151 VN551 VN561–VN562

EVERGREEN AIR CENTER (EAC)

1 VE061

EXCEL AIRWAYS (SBE)

1 VB326–VB327 VL011 VN153 VN557

FIRST CHOICE AIRWAYS (ATZ)

1 VL751–VL752 VL754 VN791–VN792 VN921
 

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BOEING SERVICE BULLETIN 767-27-0186

FLYGLOBESPAN.COM (FGS)

1 VN654 VS112

FLYJET LIMITED (FJE)

1 VE117

GABON AIRLINES (GBO)

1 VA017–VA018

GE CAPITAL CORPORATION (GEF)

1 VE123

GULF AIR (GUL)

1 VL004–VL006 VN307–VN310 VN313–VN314

HAINAN AIRLINES (HNA)

1 VS426–VS428 VS496–VS497

HAWAIIAN AIRLINES (HWI)

1 VK031–VK034 VN171–VN173 VN381 VS309–VS311

VS821–VS824 VS841–VS843

HEWA BORA AIRWAYS (EXD)

1 VE021

ICELANDAIR (ICE)

1 VN158 VN163 VN211

ITOCHU CORPORATION (CIT)

1 VF181–VF184

JAL INTERNATIONAL (JAL)

1 VB371–VB373 VK001–VK016 VK021–VK022 VK181

VK186 VR441 VR461 VS701–VS703

KALAIR (BERMUDA) (KLB)

1 VN311

KENYA AIRWAYS (KEN)

1 VK141 VL003 VN421 VS331–VS333

KLM - ROYAL DUTCH AIRLINES (KLM)

1 VL900 VS136

KRASAIR (ZXD)

1 VE001 VE022–VE023 VF051

LAN AIRLINES (LAN)

1 VL703 VN063–VN064 VN166 VN168

VN753 VN966–VN971 VR251 VR256–VR260

VS111 VS131–VS133
 

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BOEING SERVICE BULLETIN 767-27-0186

LOT POLISH AIRLINES (LOT)

1 VF041–VF042 VN233 VN291–VN293 VN652

MALEV HUNGARIAN AIRLINES (HGA)

1 VF171–VF172

MARTINAIR HOLLAND (MTH)

1 VN221–VN224 VN385 VN672

MAXJET AIRWAYS (SLQ)

1 VB301 VE041 VE063 VF001–VF002

MEXICANA (CMA)

1 VL001–VL002 VN154

MID EAST JET (SKL)

1 VF251

MYTRAVEL AIRWAYS (GUE)

1 VN951–VN953

NATIONWIDE AIRLINES (NWR)

1 VN556

NEOS (NEO)

1 VL892 VL894

NORTH AMERICAN AIRLINES (NNA)

1 VL755 VL895 VN922 VS316

OCEANAIR AIRLINES (OAL)

1 VN500

PACE AIRLINES (PIE)

1 VB053

PHOENIX AIRCRAFT LEASING, INC. (PLB)

1 VA810

PLUNA (PLU)

1 VN436

PRIVATAIR (PTS)

1 VS137

QANTAS (QAN)

1 VN081–VN088 VN093–VN099 VN115–VN117 VN123

VN130–VN132 VS186–VS187

ROYAL AIR MAROC (RAM)

1 VN636 VS336–VS337
 

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BOEING SERVICE BULLETIN 767-27-0186

ROYAL BRUNEI AIRLINES (RBA)

1 VN372 VN382–VN384 VN386–VN387

SALAMIS AVIATION (LMV)

1 VE068

SHANGHAI AIRLINES (SHA)

1 VK171 VR421–VR423 VS207

SKYMARK AIRLINES (SKM)

1 VN637 VS231 VS261–VS263

SKYSTAR (SYW)

1 VA012

STAR AIR (SBJ)

1 VA307–VA308 VB323 VB328 VB441–VB444

VE101–VE103

STATE AIR COMPANY "BERKUT" (ORE)

1 VR081

TAA (TNL)

1 VA002–VA003 VA006 VA009–VA011 VA014–VA015

VA019–VA020

TAMPA CARGO (TMP)

1 VE121–VE122 VE124

TEEBAH AIRLINES (EBH)

1 VA710

THE SULTAN'S FLIGHT (BWN)

1 VF180

THOMSONFLY (BRI)

1 VB329–VB332 VL912 VL914 VS051–VS056

TRANSAERO AIRLINES (TRX)

1 VE116 VE118 VE143 VN371

VN631–VN633

TUI AIRLINES BELGIUM (TLB)

1 VN234

UK INTERNATIONAL AIRLINES (UKI)

1 VA004–VA005

UNITED AIRLINES (UAL)

1 VA007–VA008 VA016 VN491–VN494 VN496–VN499

VN501–VN513 VS091–VS104
 

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BOEING SERVICE BULLETIN 767-27-0186

UPS (UPS)

1 VR201–VR211 VW701–VW721

US AIRWAYS (USA)

1 VE141–VE142 VE144–VE149 VE151–VE152

UZBEKISTAN AIRWAYS (UZB)

1 VL806–VL807

VARIG AIRLINES (VAR)

1 VN055 VN231–VN232

VIVA MACAU (VMC)

1 VF091 VK142

VOLARE S.P.A (VLR)

1 VL931

YONA (IOP)

1 VN312

ZOOM AIRLINES (YFM)

1 VL891 VL893 VN634–VN635

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

VA001–VA020 1

VA301–VA315 1

VA501–VA530 1

VA701–VA719 1

VA801–VA810 1

VB001–VB002 1

VB051–VB055 1

VB101–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–VE043 1
 

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BOEING SERVICE BULLETIN 767-27-0186

VE061–VE069 1

VE083–VE086 1

VE101–VE104 1

VE116–VE118 1

VE121–VE126 1

VE141–VE152 1

VE171–VE172 1

VF001–VF002 1

VF041–VF042 1

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–VK016 1

VK021–VK022 1

VK031–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

Variable Group
 

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BOEING SERVICE BULLETIN 767-27-0186

VN051–VN064 1

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

VN731–VN732 1

VN751–VN753 1

VN791–VN792 1

VN811–VN813 1

VN921–VN922 1

Variable Group
 

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BOEING SERVICE BULLETIN 767-27-0186

VN931–VN936 1

VN951–VN953 1

VN966–VN972 1

VR051–VR060 1

VR081 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

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

Variable Group
 

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BOEING SERVICE BULLETIN 767-27-0186

2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts 

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for 

the recommended use.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions to replace or rework elevator Power Control Actuator (PCA) 

bellcranks. As an alternative to Boeing Alert Service Bulletin 767-27A0168, the incorporation of this 

service bulletin combined with the repetitive check of the elevator PCA input rod assemblies 

recommended in Boeing Service Bulletin 767-27-0200 and the repetitive check of the elevator PCA 

rigging recommended in Boeing Service Bulletin 767-27-0202 will prevent continued operation with 

yielded or failed shear rivets in a bellcrank assembly for the elevator PCA and will also allow for longer 

inspection intervals. Operators are currently required by the Federal Aviation Administration (FAA) 

Airworthiness Directive (AD) 2001-04-09 to do the 400 flight-hour repetitive check recommended in 

Boeing Alert Service Bulletin 767-27A0168. 

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–VS703 1

VS721–VS728 1

VS751–VS753 1

VS821–VS824 1

VS841–VS843 1

VT501 1

VW701–VW721 1

VW851 1

Variable Group
 

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BOEING SERVICE BULLETIN 767-27-0186

One operator reported the left elevator drooping during a preflight check. Examination of the elevator 

control system found sheared rivets in the left-inboard and center PCA bellcrank assemblies. The 

elevator single hydraulic system check required by a Certification Maintenance Requirement (CMR) 

may not detect yielded or failed shear rivets in the bellcrank assemblies for the elevator PCA. As a 

result, the FAA issued AD 2000-17-05 to mandate the accomplishment of the actions specified in 

Boeing Alert Service Bulletin 767-27A0166, dated August 17, 2000.

Since the issuance of AD 2000-17-05, the FAA has received reports that several 767-200, 767-300, 

and 767-300F airplanes failed the one-time functional check of the shear rivets required by the AD. 

As a result, the FAA issued AD 2001-04-09 to mandate the accomplishment of the actions specified 

in Boeing Alert Service Bulletin 767-27A0168, dated November 21, 2000.

A detailed design review found that the override device incorporated into the elevator PCA input rod 

assembly provides protection against malfunctions and non-normal PCA operation. This design 

review also found that the shear rivets are not needed. The incorporation of this service bulletin 

combined with the repetitive check of the elevator PCA input rod assemblies recommended in Boeing 

Service Bulletin 767-27-0200 and the repetitive check of the elevator PCA rigging recommended in 

Boeing Service Bulletin 767-27-0202 is an alternative to the 400 flight-hour repetitive check 

recommended in Boeing Alert Service Bulletin 767-27A0168.

Boeing Service Related Problem (SRP) 767-SRP-27-0128 is related to this service bulletin.

D. Description

Do a general visual inspection for the three PCA bellcranks assemblies on each elevator. If a bellcrank 

assembly has shear rivets, replace it with a solid one-piece bellcrank assembly or rework the bellcrank 

assembly. Do a pogo check for each elevator PCA input rod assembly. Do a mis-rig check for each 

elevator.

E. Compliance

Boeing recommends the instructions in this service bulletin be done within six years after the date on 

this service bulletin.

The FAA will possibly release an Airworthiness Directive related to this service bulletin. The 

Airworthiness Directive will make the compliance tasks and times given in this service bulletin 

mandatory.

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.
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This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle 

Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service 

bulletin combined with the actions defined in Boeing Service Bulletins 767-27-0200 and 767-27-0202 

as an alternative method of compliance to the requirements of paragraph (a) of AD 2001-04-09. All 

provisions of AD 2001-04-09 that are not specifically referenced in the above statement remain fully 

applicable and must be complied with.

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.

Work Package 1 can be done at the same time as Work Package 2.

H. Weight and Balance Changes

None.

Work Package 

Number Task

Number of 

Persons Task-Hours Elapsed Hours

1 Remove PCA Input Linkage 2 3.0 1.5

Figure 1 1 0.5 0.5

Figure 3 1 3.0 3.0

Test Input Rod Assemblies 

(Pogo Check)

2 4.0 2.0

Install PCA Input Linkage 2.0 3.0 1.5

Mis-Rig Test 2 1.0 0.5

TOTAL FOR WORK PACKAGE 1 14.5 9.0

2 Remove PCA Input Linkage 2 3.0 1.5

Figure 2 1 0.5 0.5

Figure 3 1 3.0 3.0

Test Input Rod Assemblies 

(Pogo Check)

2 4.0 2.0

Install PCA Input Linkage 2.0 3.0 1.5

Mis-Rig Test 2 1.0 0.5

TOTAL FOR WORK PACKAGE 2 14.5 9.0

TOTAL FOR EACH AIRPLANE 29.0 18.0
 

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BOEING SERVICE BULLETIN 767-27-0186

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR B12901-35S

b. Service Related Problem (SRP) 767-SRP-27-0128

c. 767 Aircraft Maintenance Manual (AMM) 27-31-00, 27-31-06

d. Engineering Change Memo PRR B12901-35S

e. 767 Structural Repair Manual (SRM) Chapter 51

f. Boeing Standard Overhaul Practices Manual (BSOPM) 20-43-03, 20-50-10

g. Component Maintenance Manual (CMM) 27-31-64, 27-31-66

h. Boeing Service Bulletin 767-27A0166

i. Boeing Service Bulletin 767-27A0168

j. Boeing Service Bulletin 767-27-0200

k. Boeing Service Bulletin 767-27-0202

l. FAA Airworthiness Directive 2000-17-05

m. FAA Airworthiness Directive 2001-04-09

n. Boeing Drawing 012W6100.

2. Data supplied with this Service Bulletin:

None.

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

None.
 

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BOEING SERVICE BULLETIN 767-27-0186

K. Publications Affected

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability 

information.

Publication Chapter-Section

767 Illustrated Parts Catalog 27-31

Component Maintenance Manual 27-31
 

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BOEING SERVICE BULLETIN 767-27-0186

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 not available for the configuration changes given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.
 

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BOEING SERVICE BULLETIN 767-27-0186

2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the 

number of parts changed on each airplane.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

Part Number / 

Specification QTY Name Existing Part Number Notes

252T2118-6 (a) 6 PCA Bellcrank 

Assembly

252T2118-1 or 

252T2118-2 or 

256T2118-3

BACR15FT6KE9C 

(b)

12 Rivet 252T3139-3 or 

BACR15BB5AD9C

BMS 3-24 1 pint Grease - (c)

BMS 10-11, Type 1 8 

ounces

Primer - (c)

Alodine 600 or 

1200

8 

ounces

Chemical 

Conversion 

Coating

- (d)

(a) This part is required if bellcranks are being replaced.

(b) This part is required if existing bellcranks are being reworked.

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

for supplier data.

(d) Refer to BSOPM 20-43-03 for applicable suppliers.

Existing Part 

Number QTY Name New Part Number Notes

252T2118-1 6 Bellcrank Assembly 252T2118-4 (a), (b), (c)

252T2118-2 or 

252T2118-3

6 Bellcrank Assembly 252T2118-5 (a), (b), (c)

(a) This is the part number after the change given in this service bulletin, if the existing 

bellcranks are being reworked.

(b) Do not use the existing part to replace the new or changed part.

(c) This part is not used in production. The equivalent production part number is 

252T2118-6.
 

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BOEING SERVICE BULLETIN 767-27-0186

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 767-27-0186

BLANK PAGE
 

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BOEING SERVICE BULLETIN 767-27-0186

3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

WARNING: DO NOT SUPPLY HYDRAULIC POWER DURING THE REMOVAL /INSTALLATION

OF THE PCA BELLCRANK ASSEMBLY. INJURY TO PERSONS OR DAMAGE TO

EQUIPMENT CAN OCCUR.

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. The work instructions are divided into work packages. Task-Hours and Elapsed-Hours 

for each package are given in Paragraph 1.G., Manpower. The work instructions for the 

left and right elevators are the same and both work packages need to be completed 

before the plane is returned to service.

4. 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

— Hole dimensions for standard solid rivets are given in 767 Structural Repair 

Manual, Chapter 51

5. For approved fastener and process material substitutions, refer to 767 Structural Repair 

Manual, Chapter 51, Alternate fasteners are given in 767 Structural Repair Manual 

Chapter 51 and Boeing Drawing 012W6100.

6. If the length of fasteners specified in this service bulletin do not meet the installation 

standards, fasteners of the same specification, or an approved substitute, one grip 

length longer or shorter may be used.

7. 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.

8. These work instructions refer to procedures included on other Boeing documents. 

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

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BOEING SERVICE BULLETIN 767-27-0186

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

WORK PACKAGE 1 - LEFT ELEVATOR

1. Remove elevator Power Control Actuator (PCA) input linkage. Refer to 767 AMM 27-31-06 as an 

accepted procedure. 

2. Do a general visual inspection of the three PCA bellcrank assemblies as given in Figure 1.

a. If the bellcrank assembly has solid rivets and part number 252T2118-4 or 252T2118-5, no 

more action is required for the bellcrank.

b. If the bellcrank is a solid one-piece bellcrank (no rivets), no more action is required for the 

bellcrank.

c. If the bellcrank assembly has shear rivets and part number 252T2118-1, 252T2118-2, or 

252T2118-3, do one of the two following steps:

(1) At operator’s discretion, rework the existing bellcrank to replace the shear rivets with 

solid rivets as given in Figure 3. After rework, the 252T2118-2 or 252T2118-3 bellcrank 

assembly is changed to 252T2118-5 and the 252T2118-1 bellcrank assembly is 

changed to 252T2118-4. 

(2) Obtain new solid one-piece (no rivets) bellcrank assembly 252T2118-6. Use this new 

bellcrank assembly in step 4.

3. Do the following functional test (pogo check) on each of the three elevator PCA input rod 

assemblies. 

a. Make sure that the load is 42-62 lbs for initial breakout in the extending and collapsing 

directions.

b. Make sure that the load is 67-97 lbs for travel 0.005 to 0.020 inches from the fully 

compressed or extended position.

c. Make sure that the deflection is 1.15-1.35 inches in both the fully compressed or extended 

position at full travel of the elevator PCA input rod assembly.

d. Make sure that all operations are smooth and free from binding.

e. Replace or overhaul the elevator PCA input rod assembly if it fails to meet any requirement 

above. Refer to CMM 27-31-64 as an accepted procedure.

4. Install elevator PCA input linkage. Refer to 767 AMM 27-31-06 as an accepted procedure.

5. Do the elevator PCA Mis-Rig test. Refer to 767 AMM 27-31-00 as an accepted procedure.

6. Put the airplane back to a serviceable condition.
 

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BOEING SERVICE BULLETIN 767-27-0186

WORK PACKAGE 2 - RIGHT ELEVATOR

1. Remove elevator PCA input linkage. Refer to 767 AMM 27-31-06 as an accepted procedure. 

2. Do a general visual inspection of the three PCA bellcrank assemblies as given in Figure 2.

a. If the bellcrank assembly has solid rivets and part number 252T2118-4 or 252T2118-5, no 

more action is required for the bellcrank.

b. If the bellcrank is a solid one-piece bellcrank (no rivets), no more action is required for the 

bellcrank.

c. If the bellcrank assembly has shear rivets and part number 252T2118-1, 252T2118-2, or 

252T2118-3, do one of the two following steps:

(1) At operator’s discretion, the existing bellcrank can be reworked to replace the shear 

rivets with solid rivets as given in Figure 3. After rework, the 252T2118-2 or 252T2118-

3 bellcrank assembly is changed to 252T2118-5 and the 252T2118-1 bellcrank 

assembly is changed to 252T2118-4. 

(2) Obtain new solid one-piece (no rivets) bellcrank assembly 252T2118-6. Use this new 

bellcrank assembly in step 4.

3. Do the following functional test (pogo check) on each of the three elevator PCA input rod 

assemblies. 

a. Make sure that the load is 42-62 lbs for initial breakout in the extending and collapsing 

directions.

b. Make sure that the load is 67-97 lbs for travel 0.005 to 0.020 inches from the fully 

compressed or extended position.

c. Make sure that the deflection is 1.15-1.35 inches in both the fully compressed or extended 

position at full travel of the elevator PCA input rod assembly.

d. Make sure that all operations are smooth and free from binding.

e. Replace or overhaul the elevator PCA input rod assembly if it fails to meet any requirement 

above. Refer to CMM 27-31-64 as an accepted procedure.

4. Install elevator PCA input linkage. Refer to 767 AMM 27-31-06 as an accepted procedure.

5. Do the elevator PCA Mis-Rig test. Refer to 767 AMM 27-31-00 as an accepted procedure.

6. Put the airplane back to a serviceable condition.
 FIGURE 1: Left Elevator PCA Bellcrank Inspection

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BOEING SERVICE BULLETIN 767-27-0186

FIGURE 1: Left Elevator PCA Bellcrank Inspection

ELEVATOR PCAs

BELLCRANK ASSEMBLY

(TYPICAL)

FOR CLARITY)

(SHOWN DISASSEMBLED

(SOLID ONE-PIECE)

BELLCRANK ASSEMBLY BELLCRANK ASSEMBLY

(SOLID RIVETS)

BELLCRANK ASSEMBLY

(SHEAR RIVETS)

REQUIRED

NO INSPECTION

NO RIVETS

IN THE MIDDLE

NO INSPECTION HOLE

SOLID RIVETS WITH

THE MIDDLE

INSPECTION HOLE IN

0.070 INCH (1.77 mm)

SHEAR RIVETS WITH

CENTER

OUTBOARD

INBOARD

E

1

2

C D E

B

A

FWD

SEE B

SEE B

SEE A

SEE B

SEE C D

W34846

(SHEET 1 OF 2)
 FIGURE 1: Left Elevator PCA Bellcrank Inspection

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BOEING SERVICE BULLETIN 767-27-0186

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

STEP TASK NAME PART NUMBER QTY MORE DATA

1 Inspect Bellcrank Assembly - 3 Do a general visual inspection of 

rivets at locations shown. Note type 

of rivets.

2 Inspect Bellcrank Assembly - 3 Do a general visual inspection for 

part number

(SHEET 2 OF 2)
 FIGURE 2: Right Elevator PCA Bellcrank Inspection

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BOEING SERVICE BULLETIN 767-27-0186

FIGURE 2: Right Elevator PCA Bellcrank Inspection

ELEVATOR PCAs

SOLID RIVETS WITH

NO INSPECTION HOLE

IN THE MIDDLE

NO RIVETS

NO INSPECTION

REQUIRED

BELLCRANK ASSEMBLY

(SOLID RIVETS) (SOLID ONE-PIECE)

BELLCRANK ASSEMBLY

(SHOWN DISASSEMBLED

FOR CLARITY)

(TYPICAL)

BELLCRANK ASSEMBLY

INBOARD

OUTBOARD

CENTER

THE MIDDLE

SHEAR RIVETS WITH

0.070 INCH (1.77 mm)

INSPECTION HOLE IN

(SHEAR RIVETS)

BELLCRANK ASSEMBLY

FWD

A

1

SEE B

SEE B

SEE B

D E

2

SEE C E D

B

SEE A

C

W34845

(SHEET 1 OF 2)
 FIGURE 2: Right Elevator PCA Bellcrank Inspection

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BOEING SERVICE BULLETIN 767-27-0186

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

STEP TASK NAME PART NUMBER QTY MORE DATA

1 Inspect Bellcrank Assembly - 3 Do a general visual inspection of 

rivets at locations shown. Note type 

of rivets.

2 Inspect Bellcrank Assembly - 3 Do a general visual inspection for 

part number

(SHEET 2 OF 2)
 FIGURE 3: PCA Bellcrank Rework

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BOEING SERVICE BULLETIN 767-27-0186

FIGURE 3: PCA Bellcrank Rework

66.30°

66.80°

LOWER ARM

RIVET

SHOWN DISASSEMBLED FOR CLARITY

BELLCRANK ASSEMBLY (TYPICAL)

ARM ASSEMBLY

LOWER ARM

B-B

0.35

0.33

ASSEMBLY

ARM

DIA THRU

0.202

0.191

C/L

SYMM

A-A

B

B

A

A

1 9

8

14

14

4

12

6 10

13

2 5 11

3

7

8

9

W34847

(SHEET 1 OF 3)
 FIGURE 3: PCA Bellcrank Rework

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BOEING SERVICE BULLETIN 767-27-0186

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 each bellcrank.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove /

Discard

Shear Rivet 252T3139-3 or 

BACR15BB5AD9C

2 If rivets are damaged, position 

bellcrank arms as required so rivet 

pieces are in alignment.

2 Remove /Keep Lower Arm 252T2174-( ) (a) 1 Remove lower arm from arm 

assembly. 

3 Remove /DiscardMarker BAC27TCT0114 1

4 Clean Lower Arm and 

Arm Assembly

252T2174-( ) and 

252T2173-( ) 

(a)(b)

2 Clean the mating surfaces of each 

part. If damage is found refer to CMM 

27-31-66 to repair parts. 

5 Install Lower Arm 252T2174-( ) (a) 1 Attach to arm assembly. 

6 Inspect Lower Arm and 

Arm Assembly

252T2174-( ) and 

252T2173-( ) 

(a)(b)

- Make sure that the lower arm turns 

freely on the shaft of the arm 

assembly. Hold lower arm in vertical 

position and place arm assembly in 

horizontal position. Release arm 

assembly and make sure it rotates 

freely to vertical position. 

7 Ream Lower Arm 

Hole

- 1 If necessary, to increase diameter of 

hole to the minimum dimension 

(1.1255-1.1260 inch) that lets the part 

turn freely. Repeat with inspection until 

part turns freely with no binding.

8 Rotate Lower Arm and 

Arm Assembly

252T2174-( ) and 

252T2173-( ) 

(a)(b)

1 To put bellcrank arms in the position 

shown. Use clamps to hold the 

bellcrank arms in position shown. 

9 Drill / Ream Rivet holes - 2 Increase the diameter of the rivet holes 

to dimension shown (0.191-0.202 inch) 

while keeping bellcrank arms in 

position. Make sure to put a temporary 

cover on the bearing in the arm 

assembly. Metal particles can cause 

damage to the bearing.

10 Disassemble / 

Clean

Lower Arm and 

Arm Assembly

252T2174-( ) and 

252T2173-( ) 

(a)(b)

- Make sure to remove all particles and 

burrs from the mating surfaces of each 

part. Remove the cover from the 

bearing. 

11 Install Lower Arm 252T2174-( ) (a) - Apply grease to the mating surfaces of 

the lower arm and the arm assembly. 

Use a temporary clamp to hold the 

bellcrank arms in the position shown. 

Use Grease BMS 3-24 -

12 Install Rivets BACR15FT6KE9C 2 Apply grease to all surfaces of each 

rivet. Use Grease BMS 3-24 -

(SHEET 2 OF 3)
 FIGURE 3: PCA Bellcrank Rework

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BOEING SERVICE BULLETIN 767-27-0186

13 Part Mark Bellcrank 

Assembly

- 1 Rubber stamp new bellcrank assembly 

part number 252T2118-5 on arm 

assembly for reworked bellcrank 

252T2118-2 and 252T2118-3. Rubber 

stamp new bellcrank assembly part 

number 252T2118-4 on arm assembly 

for reworked bellcrank 252T2118-1. 

Refer to BSOPM 20-50-10.

14 Apply Chemical 

Conversion 

Coating

Alodine 600 or 

1200 

- To any bare surfaces on lower arm and 

arm assembly. Refer to CMM 27-31-

66.

Primer BMS 10-11, Type 1 -

(a) Lower arm 252T2174 -( ) part numbers are 252T2174-1, 252T2174-3, 252T2174-5 and 252T2174-6

(b) Arm assembly 252T2173-( ) part numbers are 252T2173 -1 and 252T2173 -5

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 3 OF 3)