### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-57A0076**  Original Issue: October 26, 2000 Revision 3: April 04, 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2000 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 1 of 46 2.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 2 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 9 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 22 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 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:. . . . . . . . . . . . . . . . . . . . . . . . 25 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 28 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 FIGURE 1: LOGIC DIAGRAM OF INSPECTION AND MAINTENANCE ALTERNATIVES. . . . . . . 33 FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION. . . . . . . . . . . . . . . . . 34 FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION. . . . 38 FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . 43

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 3 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 4 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 767-57A0076** Original Issue: October 26, 2000 Revision 3: April 04, 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** Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin. No more work is necessary on airplanes which previously accomplished Part 3 - Terminating Action of this service bulletin. No more work is necessary on airplanes that have been previously inspected in accordance with the original issue, Revision 1, or Revision 2 that have hinge fittings with the tool runout. No more work is necessary on airplanes that have been previously inspected in accordance with the original issue, Revision 1, or Revision 2 that have hinge fittings without the tool runout but continued inspections are required at reduced intervals as follows: 1. Airplanes that were last inspected in accordance with Part 1 - Detailed Inspection: Repeat Part 1 - Detailed Inspection or Do Part 2 - Detailed and Eddy Current Inspection within 300 flight-cycles of the last Part 1 - Detailed Inspection. 2. Airplanes that were last inspected in accordance with Part 2 - Detailed and Eddy Current Inspection: Repeat Part 2 - Detailed and Eddy Current Inspection or Do Part 1 - Detailed Inspection within 750 flight-cycles, from the last Part 2 - Detailed and Eddy Current Inspection or before 300 flight-cycles after the Revision 3 date of this service bulletin, whichever is later, but not to exceed 1,500 flight cycles. Do continued inspections and actions in accordance with Paragraph 1.E., Compliance. **REASON FOR REVISION** This revision is sent to reduce the compliance time for the repeat inspection interval of the inboard trailing edge main flap outboard hinge fittings and change the area and limit to the outboard half only. Subsequent to the release of Revision 2 of this service bulletin, one operator reported finding a fractured hinge fitting assembly. The fracture occurred on a hinge fitting assembly, that did not have the runout option, at approximately 780 flight-cycles after its last inspection, which was a significant number of flight-cycles before the next scheduled repeat Part 2 inspection. As a result, the repeat inspection interval for Part 2 Inspection is reduced from 1500 flight-cycles to 750 flight-cycles. An examination of the fractured hinge fitting assembly showed that the crack

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 5 of 46started at the edge of the current inspection area. The service bulletin illustrations have been updated to clearly show the expected crack location and direction. A new Boeing Service Related Problem (SRP) 767-SRP-57-0251 was initiated as a result of this in service report. This service bulletin also corrects the existing warranty date to show remedies are available for airplanes in warranty as of March 8, 2000 instead of August 3, 2000. The latest service bulletin format standards have also been updated where applicable. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. These sections are changed: 1. Service Bulletin Title updated. 2. Summary - Background - Reference to Boeing Service Related Problem (SRP) 767-SRP-57-0251 added. 3. Summary - Industry Support Information - Warranty date updated. 4. Summary - Illustration - Illustration updated to show the expected crack location and direction. 5. Paragraph 1.C., Reason - Reference to Boeing Service Related Problem (SRP) 767-SRP-57-0251 added. 6. Paragraph 1.D., Description - Affected Maintenance Zone Table added. 7. Paragraph 1.G., Manpower - Table updated. 8. Paragraph 1.J.1., Existing Data - Reference to Boeing Service Related Problem (SRP) 767-SRP-57-0251 added. 9. Paragraph 1.K.1, Publications - Table updated. 10. Paragraph 1.K.2., Damage Tolerance Based Structural Inspections - Damage Tolerance Inspections (DTI) statement added. 11. Paragraph 2.B., Industry Support Information - Warranty date updated. 12. Paragraph 3.A., General Information - General notes updated. 13. Paragraph 3.B., Work Instructions - Titles updated and the latest service bulletin format standards have also been updated where applicable. 14. Figure 1 - Compliance information in the logic table updated. 15. Figure 2 - Illustrations and step table updated to incorporate the new inspection requirements. 16. Figure 3 - Illustrations and step table updated to incorporate the new inspection requirements. The data given in Information Notice 767-57A0076 IN 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 6 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT REVISION HISTORY**  October 26, 2000 Original Issue: March 29, 2001 Revision 1: November 22, 2006 Revision 2: April 04, 2012 Revision 3:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 7 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 8 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Summary**  **Number: 767-57A0076** Original Issue: October 26, 2000 Revision 3: April 04, 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 cause potential personal injury. One operator 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. 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 assembly. 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 fittings that have the optional tool runout. Replacement of the hinge fittings without the tool runout option will ensure the structural integrity of the aft flap, prevent damage to the surrounding structure and the potential for personal injury. Subsequent to the release of Revision 2 of this service bulletin, one operator reported finding a fractured hinge fitting assembly. The fracture occurred on a hinge fitting assembly, that did not have the runout option, at approximately 780 flight-cycles after its last inspection, which was a significant number of flight-cycles before the next scheduled repeat Part 2 inspection. The service bulletin illustrations have been updated to clearly show the expected crack location and direction. A new Boeing Service Related Problem (SRP) 767-SRP-57-0251 was initiated as a result of this in service report.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 9 of 46Boeing Service Related Problem (SRP) 767-SRP-57-0119 and 767-SRP-57-0251 are related to this service bulletin. **ACTION** Inspect the inboard trailing edge main flap outboard hinge fittings of the left and right wing for cracks, fractures and tool runout option. If any cracks or fractures are found, complete terminating action. If fittings have the tool runout option and no cracks or fractures are found, no further action is required. If fittings do not have the tool runout option and no cracks or fractures are found, repeat inspections until terminating action is completed. **EFFECTIVITY** 767-200/300/300F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. **COMPLIANCE** Refer to FIGURE 1 Logic Diagram for Inspection and Maintenance Alternatives. Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of March 8, 2000. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 10 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 11 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 12 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-57A0076**  Original Issue: October 26, 2000 Revision 3: April 04, 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 D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-200/-300/-300F airplanes line numbers 1 - 825.

- 1

Airplane Models: 767-200, 767-300, 767-300F **Group Variable Number**  1 VA001 - VA020 1 VA301 - VA315 1 VA501 - VA530 1 VA701 - VA719 1 VA801 - VA810 1 VB001 - VB002

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 13 of 46**Group Variable Number**  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 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 14 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT Group**  **Variable Number** 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 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 15 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT Group**  **Variable Number** 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 VN931 - VN936 1 VN951 - VN953 1 VN966 - VN972 1 VR051 - VR055 1 VR201 - VR209 1 VR251 1 VR256 - VR257 1 VR401

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 16 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT Group**  **Variable Number** 1 VR421 - VR422 1 VR426 1 VR441 1 VR461 1 VR471 - VR472 1 VS051 - VS056 1 VS061 1 VS066 - VS070 1 VS073 - VS078 1 VS091 - VS102 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 VS246 - VS248 1 VS261 - VS262 1 VS266 - VS274 1 VS291 1 VS301 - VS303 1 VS306 - VS308 1 VS316 1 VS321 - VS324 1 VS366 - VS367 1 VS381 - VS382 1 VS391 - VS392 1 VS401 1 VS466 - VS470 1 VS486

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 17 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT Group**  **Variable Number** 1 VS496 - VS497 1 VS506 - VS507 1 VW701 - VW721 1 VW851 2. Spares Affected Examine your inboard trailing edge main flap spares supply for the outboard hinge fitting assemblies without the tool runout as identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts are found, refer to Paragraph 2.C. 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 cause potential personal injury. One operator 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. 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 assembly. 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 fittings that have the optional tool runout. Replacement of the hinge fittings without the tool runout option will ensure the structural integrity of the aft flap, prevent damage to the surrounding structure and the potential for personal injury. Subsequent to the release of Revision 2 of this service bulletin, one operator reported finding a fractured hinge fitting assembly. The fracture occurred on a hinge fitting assembly, that did not have the runout option, at approximately 780 flight-cycles after its last inspection, which was a significant number of flight-cycles before the next scheduled repeat Part 2 inspection. The service bulletin illustrations have been updated to clearly show the expected crack location and direction. A new Boeing Service Related Problem (SRP) 767-SRP-57-0251 was initiated as a result of this in service report. Revision 1 was sent to inform operators of the following changes: 1. Revise Figure 2 and 3 to add an isometric view to further clarify the tool runout inspections. 2. Revise Figure 2 and 3 to add allowable surface mismatch tolerances for the inboard and outboard hinge fitting assemblies.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 18 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**3. Revise industry support information to add warranty remedies. 4. Revise effectivity to limit airplanes to all 767-200, 767-300 and 767-300F line numbers 1 through 825. Revision 2 was sent to add optional parts for the replacement outboard hinge fitting assemblies. The optional parts are the same as the existing replacement parts except the production handling holes are omitted. Revision 2 makes the following changes to the service bulletin: — Revised the warranty date in the Summary and Material Information section. — Add optional parts for the replacement outboard hinge fittings in the Material Information section and in Figure 4. — Added note to the Material Information section and Figure 4 that the replacement hinge fitting may require different length installation bolts due to variations in the thickness of the installation stack-up. — Revise the Accomplishment Instructions, Part 3, Step 3 and 5 to show the correct access panels 555JT and 655JT. — Revise the Accomplishment Instructions to clarify that the work is accomplished on both the left and right wing. — Add reference to the related FAA Airworthiness Directive (AD). Revision 3 is sent to reduce the compliance time for the repeat inspection interval of the inboard trailing edge main flap outboard hinge fittings and change the area and limit to the outboard half only. Subsequent to the release of Revision 2 of this service bulletin, one operator reported finding a fractured hinge fitting assembly. The fracture occurred on a hinge fitting assembly, that did not have the runout option, at approximately 780 flight-cycles after its last inspection, which was a significant number of flight-cycles before the next scheduled repeat Part 2 inspection. As a result, the repeat inspection interval for Part 2 Inspection is reduced from 1500 flight-cycles to 750 flight-cycles. 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. A new Boeing Service Related Problem (SRP) 767-SRP-57-0251 was initiated as a result of this in service report. This service bulletin also corrects the existing warranty date to show remedies are available for airplanes in warranty as of March 8, 2000 instead of August 3, 2000. The latest service bulletin format standards have also been updated where applicable. Boeing Service Related Problem (SRP) 767-SRP-57-0119 and 767-SRP-57-0251 are related to this service bulletin. **D. Description** Inspect the inboard trailing edge main flap outboard hinge fittings of the left and right wing for cracks, fractures and tool runout option. If any cracks or fractures are found, complete terminating action. If fittings have the tool runout option and no cracks or fractures are found, no further action is required. If fittings do not have the tool runout option and no cracks or fractures are found, repeat inspections until terminating action is completed. Revision 1 - No more work was necessary on airplanes changed as shown in the original issue of this service bulletin. Revision 2 - No more work was necessary on airplanes changed as shown in the original issue or Revision 1 of this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 19 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**Revision 3 - No more work is necessary on airplanes which previously accomplished Part 3 - Terminating Action of this service bulletin. No more work is necessary on airplanes that have been previously inspected in accordance with the original issue, Revision 1, or Revision 2 that have hinge fittings with the tool runout. No more work is necessary on airplanes that have been previously inspected in accordance with the original issue, Revision 1, or Revision 2 that have hinge fittings without the tool runout but continued inspections are required at reduced intervals as follows: 1. Airplanes that were last inspected in accordance with Part 1 - Detailed Inspection: Repeat Part 1 - Detailed Inspection or Do Part 2 - Detailed and Eddy Current Inspection within 300 flight-cycles of the last Part 1 - Detailed Inspection. 2. Airplanes that were last inspected in accordance with Part 2 - Detailed and Eddy Current Inspection: Repeat Part 2 - Detailed and Eddy Current Inspection or Do Part 1 - Detailed Inspection within 750 flight-cycles, from the last Part 2 - Detailed and Eddy Current Inspection or before 300 flight-cycles after the Revision 3 date of this service bulletin, whichever is later, but not to exceed 1,500 flight cycles. Do continued inspections and actions in accordance with Paragraph 1.E., Compliance. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 571, 671 767-200, 767-300, 767-300F **E. Compliance** Refer to FIGURE 1 Logic Diagram for Inspection and Maintenance Alternatives. Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-13-01 is related to this service bulletin. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 20 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the Inspections and Terminating Action defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (a), (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. **G. Manpower** The table below shows an estimate of the man-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 man-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 Time (Hours) Man-Hours**  **Number of Persons Task**  1.0 2.0 2 Open Access 1.0 1.0 1 Detailed Inspec- tion 1.0 2.0 2 Close Access 3.0 5.0 TOTAL FOR EACH WING 6.0 10.0 TOTAL FOR EACH AIRPLANE
**Part 2 - Detailed and Eddy Current Inspection**  **Elapsed Time (Hours) Man-Hours**  **Number of Persons Task**  1.0 2.0 2 Open Access 1.0 1.0 1 Detailed Inspec- tion 1.5 1.5 1 Eddy Current In- spection 1.0 2.0 2 Close Access (a) (a) TOTAL FOR EACH WING (a) (a) TOTAL FOR EACH AIRPLANE (a) The total task hours and elapsed hours are not given as the work necessary for each wing and airplane is variable.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 21 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT Part 3 - Terminating Action**  **Elapsed Time (Hours) Man-Hours**  **Number of Persons 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 Related Problem (SRP) 767-SRP-57-0119, 767-SRP-57-0251 b. Component Maintenance Manual (CMM) 57-53-27 c. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-13-01 d. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-50-10, 20-50-19 e. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 27-51-00 f. 767 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-19 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 113T2101 FLAP INSTL - INBD T.E. FLAP 113T2000 MAIN FLAP INSTL - INBD T.E. FLAP 113T2201 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 22 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT 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: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 23 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 24 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**

BLANK PAGE**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, and Paragraph 2.D., Parts Necessary to Change Spares. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin does not show the Boeing price and supply data. **B. Industry Support Information** Boeing warranty remedies are available for 767 airplanes in warranty as of March 08, 2000. For inspection task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours and parts are required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Specifica-**  **tion** (a) Outboard Hinge Fitting Assy - Left Wing 1 113T2271-43 113T2271Y43 (Optional) (a) Outboard Hinge Fitting Assy - Right Wing 1 113T2271-44 113T2271Y44 (Optional) (b) (e) Bolt 4 BACB30LE5K19 (b) (e) Bolt (Optional 1/64 Oversize) 4 BACB30LE5K19X (b) (e) Bolt 4 BACB30LE5K20 (b) (e) Bolt (Optional 1/64 Oversize) 4 BACB30LE5K20X (d) Shim 4 BACS40R015D015F (d) Shim 4 BACS40R015D017F (d) Washer 8 BACW10BP5CD (d) Washer (Optional 1/64 Oversize) 8 BACW10BP51CD (d) Washer 8 BACW10BP5DP (d) Washer (Optional 1/64 Oversize) 8 BACW10BP51DP (d) Nut 8 NAS1805-5L (c) Sealant 8 Ounces BMS 5-95

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 25 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT Notes**  **Name QTY**  **Part Number / Specifica- tion**  (c) Primer 4 Ounces BMS 10-11 Type I (c) Grease 4 Ounces MIL-G-23827 (a) The 113T2271Y( ) optional part is identical to the 113T2271-( ) part except the optional part omits the handling holes used in production. (b) Refer to 767 Structural Repair Manual Chapter 51 for alternative fasteners. (c) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (d) Use original shims located between the fitting assembly and the flap skin to maintain the original hinge line geometry of the fittings. However if original shims are damaged, replace shims. Maintain the thickness and location of the original shims.(e) Due to variations in the hinge fitting installation stack-up thickness, it is possible that different fastener lengths may be required. It is acceptable to install a different fastener length of the same bolt type if required.
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.
**Notes New Part Number**  **Name QTY**  **Existing Part Number**  (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-13 (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-14 (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-23 (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-24 (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-29 (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-30 (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-33 (a) (b) (c) (d)

- Hinge Fitting Assembly 1 113T2271-34(a) Hinge Fitting Assemblies with tool runout found to have no cracks or fractures during inspections in accordance with this service bulletin. (b) Make the change in accordance with this service bulletin. (c) There is no equivalent Boeing part number for the changed part. Identify on the part that the change in accordance with this service bulletin was made. (d) You can use the existing part to replace the new or changed part. If you use the existing part, you cancel the effect of the change given in this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 26 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
**Notes Name**  **QTY Part Number**  (d) Outboard Hinge Fitting Assy - Left Wing 1 113T2271-43113T2271Y43 (Optional) (d) Outboard Hinge Fitting Assy - Right Wing 1 113T2271-44113T2271Y44 (Optional) (a) (e) Bolt 4 BACB30LE5K19 (a) (e) Bolt (Optional 1/64 Oversize) 4 BACB30LE5K19X (a) (e) Bolt 4 BACB30LE5K20 (a) (e) Bolt (Optional 1/64 Oversize) 4 BACB30LE5K20X (c) Shim 4 BACS40R015D015F (c) Shim 4 BACS40R015D017F (c) Washer 8 BACW10BP5CD (c) Washer (Optional 1/64 Oversize) 8 BACW10BP51CD (c) Washer 8 BACW10BP5DP (c) Washer (Optional 1/64 Oversize) 8 BACW10BP51DP (c) Nut 8 NAS1805-5L (b) Sealant 8 ounces BMS 5-95 (b) Primer 4 ounces BMS 10-11 Type I (b) 4 ounces MIL-G-23827 (a) Refer to 767 Structural Repair Manual Chapter 51 for alternative fasteners. (b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) Use original shims located between the fitting assembly and the flap skin to maintain the original hinge line geometry of the fittings. However if original shims are damaged, replace shims. Maintain the thickness and location of the original shims. (d) The 113T2271Y( ) optional part is identical to the 113T2271-( ) part except the optional part omits the handling holes used in production. (e) Due to variations in the hinge fitting installation stack-up thickness, it is possible that different fastener lengths may be required. It is acceptable to install a different fastener length of the same bolt type if required.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 27 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT 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: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 28 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets 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: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 29 of 46 **BOEING SERVICE BULLETIN 767-57A0076 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. 12. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data. **B. WORK INSTRUCTIONS Part 1 -** **Detailed Inspection WARNING:**  TRAILING EDGE FLAPS ARE FAST ACTING. MAKE SURE THAT PERSONS AND EQUIPMENT ARE CLEAR OF TRAILING EDGE FLAPS AND THE FLAP DRIVE MECHANISMS BEFORE YOU MOVE THE FLAP CONTROL LEVER. ONCE THE TRAILING FLAPS ARE DEPLOYED LOCKS MUST BE INSTALLED TO PREVENT POSSIBLE INJURY DUE TO INADVERTENT OPERATION OF THE FLAPS. 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, fractures and tool runout option in accordance with FIGURE 2. 4. If cracked or fractured fittings are found, do Part 3 - Terminating Action. 5. If fittings have the tool runout option and no cracks or fractures are found, mark the incorporation of this service bulletin on each hinge fitting assembly by rubber stamp or stencil method. No further action is required. Refer to SOPM 20-50-10 as an accepted procedure. 6. If fittings do not have the tool runout option and no cracks or fractures are found, repeat the inspections at the intervals shown in accordance with FIGURE 1 until terminating action is completed. 7. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 30 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT Right Wing**  **Left Wing** 671GL 571GL 671GR 571GR 8. Activate and retract the trailing edge flaps. Refer to 767 AMM 27-51-00 as an accepted procedure. 9. Put the airplane back to a serviceable condition. **Part 2 - Detailed and Eddy Current Inspection**  **WARNING:** TRAILING EDGE FLAPS ARE FAST ACTING. MAKE SURE THAT PERSONS AND EQUIPMENT ARE CLEAR OF TRAILING EDGE FLAPS AND THE FLAP DRIVE MECHANISMS BEFORE YOU MOVE THE FLAP CONTROL LEVER. ONCE THE TRAILING FLAPS ARE DEPLOYED LOCKS MUST BE INSTALLED TO PREVENT POSSIBLE INJURY DUE TO INADVERTENT OPERATION OF THE FLAPS. 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 and eddy current inspection of the inboard trailing edge main flap outboard hinge fittings for cracks, fractures and tool runout option in accordance with FIGURE 3. 4. If cracked or fractured fittings are found, do Part 3 - Terminating Action. 5. If fittings have the tool runout option and no cracks or fractures are found, mark the incorporation of this service bulletin on each hinge fitting assembly by rubber stamp or stencil method. No further action is required. Refer to SOPM 20-50-10 as an accepted procedure. 6. If fittings do not have the tool runout option and no cracks or fractures are found, repeat the inspections at the intervals in accordance with FIGURE 1 until terminating action is completed. 7. 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 8. Activate and retract 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: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 31 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**9. Put the airplane back to a serviceable condition. **Part 3 - Terminating Action WARNING:**  TRAILING EDGE FLAPS ARE FAST ACTING. MAKE SURE THAT PERSONS AND EQUIPMENT ARE CLEAR OF TRAILING EDGE FLAPS AND THE FLAP DRIVE MECHANISMS BEFORE YOU MOVE THE FLAP CONTROL LEVER. ONCE THE TRAILING FLAPS ARE DEPLOYED LOCKS MUST BE INSTALLED TO PREVENT POSSIBLE INJURY DUE TO INADVERTENT OPERATION OF THE FLAPS. 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 fairing sections. **Right Wing Left Wing**  671DB 571DB 3. Remove the number 3 and 6 trailing edge main flap 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. **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 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 fairing sections. **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: October 26, 2000 767-57A0076 Revision 3: April 04, 2012 32 of 46 **BOEING SERVICE BULLETIN 767-57A0076 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: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 33 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 34 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 35 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 36 of 46 **BOEING SERVICE BULLETIN 767-57A0076 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 20-30-03 as an accepted procedure. 1 113T2271-( ) OutboardHinge Fitting Clean 1

Do a Detailed Inspection for cracks or fractures as indicated. (a) 1 113T2271-( ) OutboardHinge Fitting Inspect 2

Do a Detailed Inspection to find out if the hinge fitting configuration is machined with or without a tool runout. Hinge fittings with the tool runout option will be thicker in the lug area as indicated. (b) 1 113T2271-( ) OutboardHinge Fitting Inspect 3

(a) On outboard hinge fitting only. Both faces on the outboard hinge fitting require inspection in the area shown.(b) This step is not required for the repeat inspections if the tool runout condition has previously been determined. The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA FLAG**  **NOTE**A (0.000 - 0.030) of an inch surface mismatch is allowable on the outboard fitting as indicated. 1

**FIGURE 2: OUTBOARD HINGE FITTING - DETAILED INSPECTION (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 37 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION**  **(SHEET 1 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 38 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 39 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 40 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION**  **(SHEET 4 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 41 of 46 **BOEING SERVICE BULLETIN 767-57A0076 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 20-30-03 as an accepted procedure. 1 113T2271-( ) Out- board Hinge Fitting Clean 1

Do a Detailed Inspection for cracks or fractures as indicated. (a) 1 113T2271-( ) Out- board Hinge Fitting Inspect 2

Do a Detailed Inspection to find out if the hinge fitting configuration is machined with or without the tool runout. Hinge fittings with the tool runout option will be thicker in the lug area as indicated. (b) 113T2271-( ) Out- board Hinge Fitting Inspect 3

Do an Eddy Current inspection. Use a right anglepencil probe with a maximum drop of 0.1 inch to inspect the area for cracks in accordance with 767 NDT Part 6, 51-00-01 or 767 NDT Part 6, 51-00-19. (a) (c) 1 113T2271-( ) Out- board Hinge Fitting Inspect 4

(a) On outboard hinge fitting only. Both faces on the outboard hinge fitting require inspection in the area shown.(b) This step is not required for the repeat inspections if the tool runout condition has previously been determined. (c) This step is not necessary if the outboard hinge fitting has the tool runout option. The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA FLAG**  **NOTE**A (0.000 - 0.030) of an inch surface mismatch is allowable on the outboard fitting as indicated. 1

**FIGURE 3: OUTBOARD HINGE FITTING - DETAILED AND EDDY CURRENT INSPECTION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 42 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 43 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT FIGURE 4: HINGE FITTING ASSEMBLY - REPLACEMENT**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 44 of 46 **BOEING SERVICE BULLETIN 767-57A0076 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**  Maintain fasteners location and stack-up 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 Maintain original location of shims. If shims are damaged, replace shims maintaining the original thickness. Apply BMS 10-11 Type I primer to replacement shims and any bare surfaces of the original shims. Refer to SOPM 20-41-02 as an accepted procedure. 2 BACS40R015D015F Shims "A" Remove / Keep 4 2 BACS40R015D017F Shims "B"

(a) 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 fitting assembly and the main flap. Refer to SOPM 20-50-19 as an accepted procedure. Install kept fastenerscommon to the flap linkage and hinge fittings with MIL-G-23827 grease. Refer to CMM 57-53-27 as an accepted procedure. 1 113T2271-43 or 113T2271Y43 (Optional) Hinge Fitting Assembly (Left) Install (New) 5

1 113T2271-44 or 113T2271Y44 (Optional) Hinge Fitting Assembly (Right) 2 BACS40R015D015F Shims "A" (Kept) 2 BACS40R015D017F Shims "B" (Kept) 4

- Fasteners (New) 4

- Fasteners (Kept) the incorporation of this service bulletin on each hinge fitting assembly. Refer toSOPM 20-50-10 as an accepted procedure. - - Rubber Stamp or Stencil Identify 6

(a) The 113T2271Y( ) optional part is identical to the 113T2271-( ) part except the optional part omits the handling holes used in production.

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 45 of 46 **BOEING SERVICE BULLETIN 767-57A0076 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.
**MORE DATA IDENTIFICATION**  **NAME CODE**  (a) Install bolts wet with BMS 5-95 Sealant. Refer to SOPM 20-50-19 as an accepted procedure. BACB30LE5K19 Nominal Bolt A BACB30LE5K19X Optional 1/64 Oversize BACW10BP5CD Nominal Washer BACW10BP51CD Optional 1/64 Oversize BACW10BP5DP Nominal Washer BACW10BP51DP Optional 1/64 Oversize NAS1805-5L Nut (a) Install bolts wet with BMS 5-95 Sealant. Refer to SOPM 20-50-19 as an accepted procedure. BACB30LE5K20 Nominal Bolt B BACB30LE5K20X Optional 1/64 Oversize BACW10BP5CD Nominal Washer BACW10BP51CD Optional 1/64 Oversize BACW10BP5DP Nominal Washer BACW10BP51DP Optional 1/64 Oversize NAS1805-5L Nut (a) Due to variations in the hinge fitting installation stack-up thickness, it is possible that different fastenerlengths may be required. It is acceptable to install a different fastener length of the same bolt type if required.

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 26, 2000 767-57A0076 Revision 3 April 04, 2012 46 of 46 **BOEING SERVICE BULLETIN 767-57A0076 ALERT**  **ALERT**