### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-57-0065**  Original Issue: May 14, 2009 Revision 1: August 01, 2011 ATA System: 5720 **SUBJECT:** WING - Outerwing - Front Wing Spar Lower Chord At WS 292 Pylon Sidelink Fitting - Inspection 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 1 of 29 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 2 of 29 **BOEING SERVICE BULLETIN 757-57-0065**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 18 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 19 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 19 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FIGURE 1: GAIN ACCESS TO THE FRONT SPAR LOWER CHORD HORIZONTAL FLANGE. . . . 24 FIGURE 2: INSPECT LEFT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE. . . . . 26 FIGURE 3: INSPECT RIGHT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE. . . . 28

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 3 of 29 **BOEING SERVICE BULLETIN 757-57-0065**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 4 of 29 **BOEING SERVICE BULLETIN 757-57-0065**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Revision Transmittal Sheet**  **Number: 757-57-0065** Original Issue: May 14, 2009 Revision 1: August 01, 2011 ATA System: 5720 **SUBJECT:** WING - Outerwing - Front Wing Spar Lower Chord At WS 292 Pylon Sidelink Fitting - Inspection This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-135-AD, is related to this service bulletin. No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.

**REASON FOR REVISION** This revision is sent to reference the (FAA) Notice of Proposed Rule Making and update the view of the support fitting in Figures 2 and 3 to show the 3 possible support fittings that may be installed. These sections were changed: 1. Summary Compliance - Added reference to the (FAA) Notice of Proposed Rule Making. 2. Description Section 1.D. - Added the no more work statement, maintenance zone table. 3. Compliance Section 1.E. - Added reference to the (FAA) Notice of Proposed Rule Making. 4. Reference Section 1.J. - Added reference to the (FAA) Notice of Proposed Rule Making. 5. General Information Section 3.A. - Updated the general note to the current standard. 6. Work Instructions Section 3.B. - Added a clean step prior to the inspection step and added information for the operators to use the view that matches their support fitting, to the inspection step. 7. Figure 1 - Added note (a) to step 1. 8. Figures 2 and 3 - Updated the graphic to show the 3 possible support fittings that may be installed.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 5 of 29Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** May 14, 2009 Original Issue: August 01, 2011 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 6 of 29 **BOEING SERVICE BULLETIN 757-57-0065**

### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 757-57-0065** Original Issue: May 14, 2009 Revision 1: August 01, 2011 ATA System: 5720 **SUBJECT:** WING - Outerwing - Front Wing Spar Lower Chord At WS 292 Pylon Sidelink Fitting - Inspection BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Boeing Service Related Problem (SRP) 757-57-0187 is related to this service bulletin. The purpose of this service bulletin is to provide an inspection to find any crack in the front spar lower chord at the four fastener locations common to the side link support fitting at WS 292. This area is not covered by the normal maintenance activities. Over the past 7 years several operators have reported finding cracks in this area. The cracks were repaired by oversizing the holes and installing freeze plugs. If any crack was to go undetected for a long period of time, it will grow to a critical length which could result in structural failure of the wing. **Service History Report Description**  **Crack Length Flight Cycles**  **Date** Oversized hole and installed freeze plug. 0.030 29,209 2/23/01 Oversized hole and installed freeze plug 0.080 25,336 6/19/01 Oversized hole and installed freeze plug. 0.080 13,100 8/5/04 (LH) 2 outboard holes had cracks c/t the spar chord aft flange. Oversized holes and installed freeze plugs. 0.032 22,027 11/10/04 (RH) outboard hole had a crack c/t the spar chord fwd flange. Oversized hole and installed freeze plug. 0.055 11/13/04 (LH) Damage removed by chamfering. 0.025 33,506 3/27/07 (RH) Oversized hole and installed next size bolt. 0.032

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 7 of 29**ACTION (PRR 54530-274RS)** Gain access as required to the inside of the wing fuel tank. The access panel is located on the lower side of the wing between the ribs at WS 285.65 and WS 313.50. Access the front spar by removing the drybay partition. Perform an ultrasonic inspection of the wing front spar lower chord horizontal flange at WS 294 and look for any crack. Perform a general visual inspection for corrosion in this same area. If any crack or corrosion is found, contact Boeing for repair instruction. Close the access and reinspect at the times indicated in the compliance section of this service bulletin. **EFFECTIVITY** All 757-200, -200CB, -200PF & -300 Airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity. **COMPLIANCE** Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-135-AD, is related to this service bulletin.. See Service Bulletin Paragraph 1.E. for compliance information. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection given in this service bulletin. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  3.25 13.00 Open Access 3.00 6.00 Inspect (a) (a) Repair 1.25 5.00 Close Access 7.50 24.0 Total For Each Airplane (a) Repair Time is dependent on the extent of corrosion or number of cracks found
**MATERIAL INFORMATION** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 8 of 29 **BOEING SERVICE BULLETIN 757-57-0065**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 9 of 29 **BOEING SERVICE BULLETIN 757-57-0065**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 10 of 29 **BOEING SERVICE BULLETIN 757-57-0065**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-57-0065**  Original Issue: May 14, 2009 Revision 1: August 01, 2011 ATA System: 5720 **SUBJECT:** WING - Outerwing - Front Wing Spar Lower Chord At WS 292 Pylon Sidelink Fitting - Inspection BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplanes shown below. Refer to PRR 54530-274RS for data about this change.
**DESCRIPTION CONFIGURATION**  **GROUP** All 757-200, -200CB, -200PF & -300 airplanes

- 1

Airplane Models: 757-200, 757-200CB, 757-200PF, 757-300 **Group Variable Number**  1 NA001 - NA028 1 NA191 - NA199 1 NA201 - NA239 1 NA301 - NA305 1 NA341 - NA352 1 NA391 - NA399 1 NA401 - NA408 1 NA441 - NA447 1 NA501 - NA586

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 11 of 29**Group Variable Number**  1 NB001 - NB004 1 NB021 - NB023 1 NB036 - NB041 1 NB051 - NB053 1 NB061 - NB073 1 NB079 1 NB131 - NB148 1 NB161 - NB162 1 NB166 - NB168 1 NB201 - NB204 1 NB221 - NB228 1 NB230 1 NB236 1 NB239 1 NB261 - NB267 1 NB291 - NB299 1 NB301 - NB302 1 NB311 - NB312 1 NB321 - NB331 1 NB421 - NB438 1 NB446 1 NB451 - NB454 1 NB501 - NB523 1 NB561 1 NB571 1 NB581 - NB583 1 NC001 - NC033 1 NC041 - NC042 1 NC051 - NC052 1 NC056 - NC062 1 NC066 - NC084 1 NC091 - NC094 1 NC151

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 12 of 29 **BOEING SERVICE BULLETIN 757-57-0065 Group**  **Variable Number** 1 NC161 1 NC901 - NC951 1 NC971 - NC974 1 ND001 - ND007 1 ND011 - ND059 1 ND111 - ND113 1 ND161 - ND199 1 ND201 - ND203 1 ND221 - ND225 1 ND241 - ND248 1 ND301 - ND322 1 ND401 1 ND891 1 ND895 1 NE001 - NE008 1 NE011 - NE088 1 NE091 - NE094 1 NE141 - NE150 1 NE161 - NE177 1 NE201 - NE204 1 NE301 - NE302 1 NE311 - NE325 1 NJ001 - NJ004 1 NJ031 - NJ032 1 NJ551 - NJ555 1 NL001 - NL002 1 NL006 - NL017 1 NL101 - NL109 1 NL141 1 NL601 - NL616 1 NN001 - NN002 1 NN051 - NN052 1 NP901 - NP904

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 13 of 29 **BOEING SERVICE BULLETIN 757-57-0065 Group**  **Variable Number** 1 NS601 - NS616 1 NT001 - NT009 1 NT201 - NT202 1 NT231 - NT234 1 NT237 - NT240 1 NT242 1 NT245 - NT248 1 NT281 - NT289 1 NT341 - NT347 1 NT351 - NT360 1 NT371 - NT373 1 NT375 - NT379 1 NT381 - NT386 1 NT401 - NT409 1 NT411 - NT412 1 NT426 - NT427 1 NT431 - NT432 1 NT436 - NT438 1 NT441 - NT442 1 NT446 1 NT701 - NT769 1 NT791 - NT796 1 NT861 - NT862 1 NT881 - NT885 1 NT901 - NT916 1 NT971 - NT985 1 NU031 - NU038 1 NU701 - NU705 1 NU721 - NU728 1 NU731 - NU732 2. Spares Affected None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 14 of 29 **BOEING SERVICE BULLETIN 757-57-0065 B. Concurrent Requirements**  None. **C. Reason** Boeing Service Related Problem (SRP) 757-SRP-57-0187 is related to this service bulletin. The purpose of this service bulletin is to provide an inspection to find any crack in the front spar lower chord at the four fastener locations common to the side link support fitting at WS 292. This area is not covered by the normal maintenance activities. Over the past 7 years several operators have reported finding cracks in this area. The cracks were repaired by oversizing the holes and installing freeze plugs. If any crack was to go undetected for a long period of time, it will grow to a critical length which could result in structural failure of the wing. Revision 1 is sent to add the reference to the (FAA) Notice of Proposed Rule Making and update the view of the support fitting in Figures 2 and 3 to show the 3 possible support fittings that may be installed. **Service History Report Description**  **Crack Length Flight Cycles**  **Date** Oversized hole and installed freeze plug. 0.030 29,209 2/23/01 Oversized hole and installed freeze plug 0.080 25,336 6/19/01 Oversized hole and installed freeze plug. 0.080 13,100 8/5/04 (LH) 2 outboard holes had cracks c/t the spar chord aft flange. Oversized holes and installed freeze plugs. 0.032 22,027 11/10/04 (RH) outboard hole had a crack c/t the spar chord fwd flange. Oversized hole and installed freeze plug. 0.055 11/13/04 (LH) Damage removed by chamfering. 0.025 33,506 3/27/07 (RH) Oversized hole and installed next size bolt. 0.032 **D. Description** Gain access as required to the inside of the wing fuel tank. The access panel is located on the lower side of the wing between the ribs at WS 285.65 and WS 313.50. Access the front spar by removing the drybay partition. Perform an ultrasonic inspection of the wing front spar lower chord horizontal flange at WS 294 and look for any crack. Perform a general visual inspection for corrosion in this same area. If any crack or corrosion is found, contact Boeing for repair instructions. Close the access and reinspect at the times indicated in the compliance section of this service bulletin. **NOTE:** Due to common access requirements, the operator should consider working Service Bulletin 757-54-0034 and 757-54-0035 at the same time as this service bulletin on the applicable airplanes. 1.

2. If the damaged area is more than the specified limits, write to Boeing for repair instructions. Give the size and location of the damage. When possible, send sketches and photographs. If the damage includes corrosion, send data on the length, width, and largest depth of clean up.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 15 of 29 **BOEING SERVICE BULLETIN 757-57-0065**Send to: BOEING COMMERCIAL AIRPLANES GROUP ATTENTION: MANAGER, AIRLINE SUPPORT Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 532, 541, 632, 641 757-200, 757-200CB, 757- 200PF, 757-300 **E. Compliance** Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-135-AD, is related to this service bulletin. **Table 1: Required Times for Ultrasonic and General Visual Inspection and Repair of the Wing Front Spar Lower Chord Horizontal Flange..**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Which ever occurs later)**  **Action Condition**  12,000 Flight Cycles Prior to 37,500 Total Flight Cycles or 20 years since the date of issuance of theoriginal standard certificate of airworthiness, whichever occurs first.Ultrasonic and General visual Inspection as given inAccomplishment instruction 3.B.5 All airplanes

Within 3,000 flight cycles after the date on this service bulletin.Within 12,000 flight cycles after incorporation of the modification requirements of AD 2003-18-05 or AD 2004-12-07

- Prior to further flight Contact Boeing for addition- al repair instructions and perform the repair.Any crack or Corrosion found during Accomplishment instruction 3.B.5 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 16 of 29 **BOEING SERVICE BULLETIN 757-57-0065**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. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this Service Bulletin 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. **Elapsed Hours Task-Hours**  **Number of Persons Task**  3.25 13.00 4 Open Access 3.00 6.00 2 Inspect (a) (a) Repair 1.25 5.00 4 Close Access 7.50 24.00 TOTAL FOR EACH AIRPLANE (a) Repair Time is dependent on the extent of corrosion or number of cracks found **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Engineering Change Memo PRR 54530-274RS b. Service Related Problem (SRP) 757-57-0187 c. 757 Maintenance Manual (AMM) Subject 757 AMM 28-11-00,757 AMM 28-11-01, 757 AMM 28-11-07, 757 AMM 28-26-00 d. 757 Structural Repair Manual (SRM) Subject 757 SRM 51-10-02 , 757-200CB SRM 51-10-02, 757-200PF SRM 51-10-02 , 757-300 SRM 51-10-02

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 17 of 29 **BOEING SERVICE BULLETIN 757-57-0065**e. Boeing Standard Wiring Practices Manual (SWPM) SWPM 20-10-11, SWPM 20-10-12 , SWPM 20-10-19 f. 757 Nondestructive Test (NDT) Manual D634N301, 757 NDT, Part 4, 57-20-01 g. Boeing Service Bulletins 757-54-0034 and 757-54-0035 h. FAA Airworthiness Directive AD 2003-18-05 , AD 2004-12-07 i. Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-135-AD j. Boeing Parts Standards Document D590 k. Boeing Drawing 65-88700 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  PANEL INSTL - DRY BAY BARRIER, WING 112N8001 This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: **Chapter-Section Publication**  757 NDT, Part 4, 57-20-01 757 NDT 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** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 18 of 29 **BOEING SERVICE BULLETIN 757-57-0065 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** None. **B. Industry Support Information** Boeing warranty remedies are not available for the inspection procedures given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: None. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 19 of 29 **BOEING SERVICE BULLETIN 757-57-0065**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 20 of 29 **BOEING SERVICE BULLETIN 757-57-0065**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in SRM Chapter 51 4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. 6. The necessary conditions for selection of clamp type and size are included in SWPM 20-10-12. If any wire bundle support clamp specified in this service bulletin does not make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted procedure to select a clamp that fits correctly. 7. 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. 8. A Special Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. The examination is likely to make extensive use of specialized Inspection techniques and/or equipment. Intricate cleaning and substantial access or disassembly procedure may be required.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 21 of 29 **BOEING SERVICE BULLETIN 757-57-0065**9. 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 enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally 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. 10. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "as given in" are included in the instruction, the procedure in the Boeing document must be used. 11. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 12. 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. 13. 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. 14. 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. The removed part can be discarded if a new or serviceable part is installed. 15. 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. 16. 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** 1. Gain access to the lower side of the wing main fuel tanks between WS 285.65 and WS 313.50 on both the left and right sides of the plane. 2. De-fuel the wing main fuel tanks. Refer to 757 AMM 28-26-00 as an accepted procedure. 3. Drain / Purge the tanks. Refer to 757 AMM 28-11-00 as an accepted procedure.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 22 of 29 **BOEING SERVICE BULLETIN 757-57-0065**4. Remove the access panels, as necessary, as given in Figure 1 to gain access to the front spar lower chord. a. Clean the inspection area. Refer to 757 NDT Part 4, 57-20-01 section 3., as an acceptable procedure. 5. Perform the inspection as given in Figure 2 and Figure 3 and Section 1.E. Compliance of this service bulletin. Use the view that matches your support fitting. a. If corrosion or any crack is found contact Boeing for additional repair instructions. b. If you do not find corrosion or any crack you may restore the airplane. 6. Touch-up the sealant and finish on the transducer inspection surfaces if/as required 7. Install the access panels as given in Figure 1. 8. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1: August 01, 2011 23 of 29 **BOEING SERVICE BULLETIN 757-57-0065 FIGURE 1: GAIN ACCESS TO THE FRONT SPAR LOWER CHORD HORIZONTAL FLANGE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1 August 01, 2011 24 of 29 **BOEING SERVICE BULLETIN 757-57-0065**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Refer to 757 AMM 28-11-01 as an accepted procedure. (a) 1 541CB left side Access Panels Remove 1 1 641CB right side Refer to 757 AMM 28-11-07 as an accepted procedure. 1 532HZ left side Drybay Panels Remove 2 1 632HZ right side Refer to757 AMM 28-11-07 as an accepted procedure. 1 532HZ left side Drybay Panels Install 3 1 632HZ right side Refer to 757 AMM 28-11-01 as an accepted procedure. 1 541CB left side Access Panels Install 4 1 641CB right side (a) This AMM procedure may contain additional removals within it, including the removal of panels 434BL and 444BL.

**FIGURE 1: GAIN ACCESS TO THE FRONT SPAR LOWER CHORD HORIZONTAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1 August 01, 2011 25 of 29 **BOEING SERVICE BULLETIN 757-57-0065 FIGURE 2: INSPECT LEFT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1 August 01, 2011 26 of 29 **BOEING SERVICE BULLETIN 757-57-0065**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  As given in 757 NDT, Part 4, 57-20-01 (a) 1 Ultrasonic Inspection Lower Chord Inspect 1 The area around the fitting for corrosion 1 General Visual Side Link Sup- port Fitting Inspect 2 If any crack is found contact Boeing for additional repair instructions. (a)

**FIGURE 2: INSPECT LEFT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1 August 01, 2011 27 of 29 **BOEING SERVICE BULLETIN 757-57-0065 FIGURE 3: INSPECT RIGHT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1 August 01, 2011 28 of 29 **BOEING SERVICE BULLETIN 757-57-0065**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  As given in 757 NDT, Part 4, 57-20-01 (a) 1 Ultrasonic Inspection Lower Chord Inspect 1 The area around the fitting for corrosion 1 General Visual Side Link Sup- port Fitting Inspect 2 If any crack is found contact Boeing for additional repair instructions. (a)

**FIGURE 3: INSPECT RIGHT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 14, 2009 757-57-0065 Revision 1 August 01, 2011 29 of 29 **BOEING SERVICE BULLETIN 757-57-0065**