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

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laws.

ECCN: 9E991

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3.0
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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

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BOEING SERVICE BULLETIN 757-57-0065
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BOEING SERVICE BULLETIN 757-57-0065

BLANK PAGE
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.

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

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: May 14, 2009

Revision 1: August 01, 2011

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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

Date Flight Cycles Crack Length Report Description

2/23/01 29,209 0.030 Oversized hole and installed freeze plug.

6/19/01 25,336 0.080 Oversized hole and installed freeze plug

8/5/04 13,100 0.080 Oversized hole and installed freeze plug.

(LH) 2 outboard holes had cracks c/t the spar chord aft

flange. Oversized holes and installed freeze plugs.

11/10/04 22,027 0.032

(RH) outboard hole had a crack c/t the spar chord fwd

flange. Oversized hole and installed freeze plug.

11/13/04 0.055

3/27/07 33,506 0.025 (LH) Damage removed by chamfering.

0.032 (RH) Oversized hole and installed next size bolt.

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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

Airplanes Total Task Hours Elapsed Hours

Open Access 13.00 3.25

Inspect 6.00 3.00

Repair (a) (a)

Close Access 5.00 1.25

Total For Each 24.0 7.50

Airplane

(a) Repair Time is dependent on the extent of corrosion or

number of cracks found

MATERIAL INFORMATION

None.

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BOEING SERVICE BULLETIN 757-57-0065
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BLANK PAGE
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.

GROUP CONFIGURATION DESCRIPTION

1 - All 757-200, -200CB, -200PF & -300 airplanes

Airplane Models:

757-200, 757-200CB, 757-200PF, 757-300

Variable Number Group

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 1

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Variable Number Group

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 1

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BOEING SERVICE BULLETIN 757-57-0065
Variable Number Group

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 1

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BOEING SERVICE BULLETIN 757-57-0065
Variable Number Group

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 1

2. Spares Affected

None.

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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

Date Flight Cycles Crack Length Report Description

2/23/01 29,209 0.030 Oversized hole and installed freeze plug.

6/19/01 25,336 0.080 Oversized hole and installed freeze plug

8/5/04 13,100 0.080 Oversized hole and installed freeze plug.

(LH) 2 outboard holes had cracks c/t the spar chord aft

flange. Oversized holes and installed freeze plugs.

11/10/04 22,027 0.032

(RH) outboard hole had a crack c/t the spar chord fwd

flange. Oversized hole and installed freeze plug.

11/13/04 0.055

3/27/07 33,506 0.025 (LH) Damage removed by chamfering.

0.032 (RH) Oversized hole and installed next size bolt.

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.

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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

Model Zone

757-200, 757-200CB, 757- 532, 541, 632, 641

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)

Condition Action

Prior to 37,500 Total Flight Cycles or 20 12,000 Flight Cycles

years since the date of issuance of the

original standard certificate of airworthiness, whichever occurs first.

Ultrasonic and General visual Inspection as given in

Accomplishment 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

Contact Boeing for addition- Prior to further flight -

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.

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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.

Task Number of Persons Task-Hours Elapsed Hours

Open Access 4 13.00 3.25

Inspect 2 6.00 3.00

Repair (a) (a)

Close Access 4 5.00 1.25

TOTAL FOR EACH AIRPLANE 24.00 7.50

(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

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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:

Drawing Number Title

112N8001 PANEL INSTL - DRY BAY BARRIER, WING

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:

Publication Chapter-Section

757 NDT Manual 757 NDT, Part 4, 57-20-01

2. Damage Tolerance Based Structural Inspections:

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

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

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

L. Interchangeability and Intermixability of Parts

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

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BOEING SERVICE BULLETIN 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.

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BOEING SERVICE BULLETIN 757-57-0065
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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.

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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.

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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.

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FIGURE 1: GAIN ACCESS TO THE FRONT SPAR LOWER CHORD HORIZONTAL FLANGE

(SHEET 1 OF 2)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Refer to 757 AMM 28-11-01

as an accepted procedure.

(a)

1 Remove Access Panels 541CB left side 1

641CB right side 1

Refer to 757 AMM 28-11-07

as an accepted procedure.

2 Remove Drybay Panels 532HZ left side 1

632HZ right side 1

Refer to757 AMM 28-11-07

as an accepted procedure.

3 Install Drybay Panels 532HZ left side 1

632HZ right side 1

Refer to 757 AMM 28-11-01

as an accepted procedure.

4 Install Access Panels 541CB left side 1

641CB right side 1

(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)

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BOEING SERVICE BULLETIN 757-57-0065
FIGURE 2: INSPECT LEFT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE

(SHEET 1 OF 2)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

As given in 757 NDT, Part

4, 57-20-01 (a)

1 Inspect Lower Chord Ultrasonic Inspection 1

The area around the fitting

for corrosion

Side Link Sup- General Visual 1

port Fitting

2 Inspect

(a) If any crack is found contact Boeing for additional repair instructions.

FIGURE 2: INSPECT LEFT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0065
FIGURE 3: INSPECT RIGHT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE

(SHEET 1 OF 2)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

As given in 757 NDT, Part 4,

57-20-01 (a)

1 Inspect Lower Chord Ultrasonic Inspection 1

The area around the fitting for

corrosion

Side Link Sup- General Visual 1

port Fitting

2 Inspect

(a) If any crack is found contact Boeing for additional repair instructions.

FIGURE 3: INSPECT RIGHT WING FRONT SPAR LOWER CHORD HORIZONTAL FLANGE

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-57-0065