## •

({)._ BOEING 

## Commercial Airplanes

Number : Origina l Issue : Revision 4: ATA System : 

## SPECIAL ATTENTION 777-78-0051 October 23. 2003 February 07, 2014 7811 

# 777 Service Bulletin

SUBJECT: EXHAUST (TR ENT 800 Series Engines) - Collector/Nozzle· Turbine Exhaust Plug Assembly - Inspection and Retrofit E xport of this technology Is controlled under the United States Export Administration Regu lations (EAR) (15 CFR 300-774). An export license may be required before i t 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 . ECCN: 9E991 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET C opyrigh t © 2003 Boeing . Unpublished Work . All Rights Reserved . Treatment of this document and Its content is governed by contract with Boeing . Rights to use this document are licensed on 

## a per aircraft basi s and such rights may not 

### be transferable. For more information, contact The Boei ng Company. Boeing , the Boeing signature , the Boeing symbol , 707, 717. 

### 727, 737 . 747 . 757. 767. 777 , 787 . Dreamllner, BBJ. DC-8. DC-9, DC-10. KC -10, KC-46, KDC-10 , MD-10 , MD- 11, MD-80, MD-88, MD·90. P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company: and no trademark license Is granted In connection with this document un less provided i n writing by Boeing .

Origina l Issue: October 23 , 2003 Revision 

### 4 : February 07. 2014 3.0 777-78 -0051 

### 1 

### of 69

# ...

Original Issue : October 23, 2003 Revision 4 : February 07, 2014 BOEING SERVICE BULLETIN 777-78-0051

BLANK PAGE

E)(PQtl COnltOPocf ECCN 9E991 • BOEING PROP~JETARY • Copyrjght O lktpubh.shed 

### w~ . Soo p;1ge 1 for detals. 777-78-0051 

### 2 of 

### 69BOEING SERVICE BULLETIN 777-78-0051 Table of Contents Revision Transmittal Sheet . . . . . . . • • . . • . . . . • • . • . . . . • • . • • . • . . • . , • . . . • . . . 

### 5 Summary ...•.•...... .. . .. .. . • .......... . .. . .. . .. . ............. 

### 7 1 . PLANNING I NFORMATI ON ...••.••..• . •..•• . •..•• .• . . ••.....••.... 

### 13 A. EffectMty .••.••..•.•. ••.•. .•.•...•...•. • .. , .. , • • • • • . • • . . 

### 13 1. Airp lanes . . . . . • • • • • • • • . . . . • • • . • . • . . . . . • . • • • • • • . . • . . . • 

### 13 

### 2. Spa res Affected . . . . . . . • . . . . . . . . . . . . . . • . . • . . . . . . . . . . . . . • 

### 15 B . Concurrent Requirements . . • • . . . . . • . . • . . • . . • . . . • • • • • • • • . • • . • • . • 

### 16 C . Reason . . . . . . . . . . . . . • . • • • • . • • . • • . . • • • • • . • • . . . . . • . . • . . . . 

### 16 D . De scription . • . . • . . . . . . . . . . • . . . . . . . . . . . . . . • . . . . • . . • • . . • • . • 17 

### E. Compli ance • . . . . . . . . . . . • . . • • . • . • • . . • • • • • . • . . • . . . . . . . . . • . • 

### 20 F. Approval . . . . . . . . . . . . . • . . . • . • . . • . . • . . • . . • . . • • . • . • . • . . 

### 25 G . Manpower . • . . . . . . • . . • • . • • . • . . • . . • . . • . . • . • • • • • • . . • . . . . . . 

### 25 H . Weight and Balance Changes . . • . . • . • . • • • . . • . . • . . . . . . . . . • . • . . . . . . 28 I . Electrical Load Data . . . . . . . . . • . . • . . . . . • . . . . . • . . • • • • . • • • . . • • . . 

### 28 

### J . References . • . . . . . • • . • . . . . • • • . • . . • . . • • • • • • • • • • • . . . . . . . . . . 

### 28 1. Existing Data: • . • • . . . . . . • . . . • . . . . . . . . . . . . • • • . . . • . • • . . . . 

### 28 2 . Data Supplied with this Service Bu ll etin : . . . . . . . . . . . . . . . . . . . . • • . • • . • 

### 29 3. Installation Drawings Used In th e Preparation of this Service Bulletin : . . • . . . . • . . . 29 K. Publications Affected . • • . • . . . . . . . . • . . . . . • • . • . . • • • • • . • • . . . . . . . 

### 29 L. Interchangeability and lntermixability of Parts . . . . • . . • . . • . . • • . • . . • . . . . . . . 

### 29 M . Software Accomplishment Summary . • . . . . . . . . • • . • . . • • • . . • . . . . • • • • . . 

### 29 

### 2 . MATER IAL INFORMATION . . . . . . • . . • . • . . • • • • . • • • • • . . . . • . . • . • . . . • . • 

### 31 A . Material· Price and Availability . . . . . . . • . . . . . • . . . . . . . . . . . . • • • • . • • . • 

### 3 1 B . I ndustry Support Information • . . . . . . . • . . . . • . • • . . • . • . . • . . . . . . . . . 

### 31 C . Parts Necessary for Each Alrplane . . . . . . . . • . . . . . • • • • • • . . . • • . . . . • . . • 

### 31 1 . Kits/Parts: •...•..•............•..•..•• . .•.•.... , . . • . . 

### 31 

### 2 . Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . • • . • • • • 

### 32 

### 3. Parts Modified and Reidentified: . . . . . . . . • . . • . . . . • . • • . . . . . . . . • . . 

### 33 4 . Parts Removed and Not Replaced: • • . . • . . • • • • . . . • . • . . . • • . • • . . . . • 33 

### 0 . Parts Necessary to Change Spares . . . . . . . . . . . . . • • • • • • • • . • . . • . . . . . . 

### 34 E . Speci al Tooling - Price and Availability . • . . . . . • . . . • . . • . . . . . . . . • • . . . . . . 

### 35 F. Speclal Tooling Necessary to do th i s Service Bulletin . • . • . . • • . . . . • • • . • • . . . • • 35 3. ACCOMPLISHMENT I NSTRUCTIONS • • . . . . . . . . . . . . . . . . • • . • . . . . • . . . . . . 37 A . GENERAL IN FORMAT I ON • • . • • . . • . • • . . . . . . . . . . . . . 37 B. WORK INSTRUCTIONS • . • • . • . • • . • • . • • . • • . • • . • • . • . • • . . 

### 38 FIGURE 

### 1 : TURB I NE EXHAUST PLUG ASSEMBLY· NUTPLATE REMOVAL ANO HOLE INSPECTION FIGURE 

### 2 : F I GURE 

### 3 : FIGURE 

### 4 : F I GURE 

### 5 : F IGURE 

### 6 : PREPARATION . . . . . . . . . . . . . . . . . . . . . • • . • . . . . . . . 44 TU RBINE EXHAUST PLUG ASSEMBLY HOLES · GENERAL VIS UAL INSPECTION .. 

### 47 IDENTIFICATION TAG · DEEP ETCH MARK ....•.•..•..•.••.•••..•• 48 TURB INE EXHAUST PLUG ASSEMBLY· REPLACEMENT OF ALL 

### 33 3/16 INCH DIAMETER SOL TS WITH 1 /4 INCH DIAMETER BOLTS • • . . • . . • . . . . . • . . . . . . • • . • 49 TURBINE EXHAUS T PLUG ASSEMBLy BOLTS . GENERAL VISUAL INSPECTION [Group 

### 1. Configuration 

### 2-3 ; Group 

### 2] . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . 55 TIJRBINE EXHAUST PLUG ASSEMBLY · REPLACEMENT OF ALL REMA IN ING 

### 3/ 16 INCH DIAMETER BOLTS W ITH 

### 114 INCH DIAMETER BOLTS . . . . . . • . • • . • . . •.• 

### 57 Original Issue: October 

### 23 , 2003 Revision 4 : February 07, 2014 Expon Conll<>8ed E=· 9£991 • BOEING PROPRI ETARY· Cc)pyrlQ:ht C Lh\publiantd Vlo,k • See~ 1 lor d01...._ 777-78-0051 

### 3 of69

### BOEING SERVICE BULLETIN 777-78--0051 FIGURE 7: TURB IN E EXHAUST P LUG ASSEMBLY - FORWARD PLUG , 11 4 IN C H DIAMETER NUTPLATE REPLACEMENT . . • . • . . . • . . • . . • . . . . • . . . . . . . . . . . . . . . . . • • 61 FIGU RE 8: TU RBINE EXHAUST PLUG ASSEMBLY - FO RWARD AND AFT PLUG IDENTIFICATION TAG REPLACEMENT . . • . • • . . . . • • . . • . . • . . • . . • . . . . . • . . . . . . . • • • 63 FIGURE 9: TU RBINE EXHAUST PLUG ASSEMBLY - INSTAL LATION •••.••.••.•.... . . 66 APPENDIX A: 'WEDGELOCK' FASTENER INSTALLATION PROCESS FOR THE REPLACEMENT OF ALL 33 3/16 INCH D IAM ETER BOLTS WITH 1 /4 I NCH D IAMETER BOLTS .....•.... 68 APPENDIX B : WEDGELOCK' AND TEMPORARY FAST E NER INSTALLATION PROCESS FOR THE REPLACEMENT OF ALL REMAINING 3/16 INCH DIAMETER BOLTS WITH 1 /4 INCH D IAMETER BOLTS • . . • . . • . • • . • • . . • . . . . . . . . . . . . . • . . • • . • • . • 69

Original Issue : October 23 . 2003 Revision 4 : February 07, 20 14 Expott ConttOlod ECCN; 9 E991 - BOEING PROPRlETARY - Copynght O Unpublishoct Wot" - See page I fof dtUalfS. 

### 777-78-0051 4 of 

### 69

## Commercial Airplanes 

# 777 Service Bulletin SPEC IAL ATTENTION Numbe r: Original Issue: 777 -78-005 1 October 23. 2003 February 0 7. 2014 78 1 1 

## Revision Transmittal Sheet Revi sion 4 : ATA System : SUBJECT : EXHAUST (TRE NT 800 Series Engines) - Collector/Nozzle - Turbine Exhaust Plug Assembly • Inspection and Retrofit This revis ion lneludes all pages of t he service bulletin . COMPLIANCE INFORMATION RELATED TO THIS REVISION No m ore work is necessary on the airplane(s) inspected and changed in accordance with Revision 3 of th is service bulletin . But. weight and balance data for this service bulle tin has changed in this revision . 

### If an operator cha nged their weight and balance data fo r an airplane to agree with the lower values In accordance with the Original Issue or Revision 1 thru 3, it is reco mmend that the data is cha n ged again lo agree with the higher va lues in accordance with this revision . Airplanes WB176, WB177 , WB193 , WB194, WB215. WB438, WB439. WB510lhruWB512 , WB619thruWB622. WC456 thru WC459. WC486 lhru WC493. WC531 thru WC536. WC566. WC567 and WC571 lhru WC574 are added to new Group 2 of this servi ce bulletin effectivity. REASON FOR REVISION This revis io n I s sen t to add the remai ning d elivered 777 Rolls-Royce (RR) powered airplanes to the effectlvily o f this service bulletin . All variants of turbine exhaus t plug assembly are fully in terchangeable wit h each other and thus maintenance actions could have caused the movemen t o r each turbine ex haust plug assembly between airplanes of the 777 RR powered fl eet. This condition could result In a con figura tiona l difference lo what an airplane had when it was origina lly delive red . These sections are changed : Summary Background Paragraph: Planning data table added . Summary Action Paragraph , Summary Illustration and Paragraph 1 . D.. Description : Wor1< for Group 2 airpl anes added . Paragraph 1 .A.1 .. Alrplanes : Note changed i n rela t ion to the reason for th i s revi sion . Paragraph 1 . E ., Complia n ce : Data for Group 2 airplanes added . Paragraph 1.G ., Manpower: Appllcablllty for Grot• ; J 2 ai rp lanes i s added to the table for 'Part 1' . Paragraph 1 .J . 1 ., Existing Data · Standard Overhaul Practices Manual (SOPM) re ference added . Paragraph 1.K.1 ., Publications: Aircraft Maintenance Manual (AMM) and Power Plant Build-Up (PPBU) Manual reference added . Paragraph 2.C .3 ., Parts Modified and Reidentified: Data deleted for the forward and aft plug assemblies . Paragraph 3 .A .. General Info rmation : Notes cha nged to add new data . Rgure 5 : Applicability changed to add Group 2 a irplanes . Original Issue: October 23, 2003 Revi si on 4 : February 07 , 2014 E.oo<I Con,r- ECCN· 9E991 • BOEI N

G i>AOP:RI ETARY • COpyrlght C Unpubbhod Work · SC. P890 1 tot detlA 777-78-0051 5of69

### BOEING SERVICE BULL ETIN 777-78 -00 51 Figure 

### 9: Step tab l e data changed rela ted to the ldentiftcation for the ins ta ll ation of a turbine exhaust plug assembly. Footnote (b) deleted . Vertica l lines are put on the left edge of each page , e xcept in Paragraph 1 .A ., Effectivity , to show the l ocation of important changes. Pages with no vertical lines have no important changes. REVISION HISTORY Origina l I ssue : Revision 1 : R evision 2 : Revision 3 : Revision 4 :

Original Issue: Oc lo ber 23, 2003 Revision 4. February 07, 2014 October 23, 2003 Deoember 15, 2005 February 18, 2010 August23.2012 February 07. 2014

E)IIOl1 contt0nod ECCN 9E99 t • BOEI NG PROPRIETAAY • Copyrigl'lt O Unpubti'shed Wort .. So& P9Qe 1 fof de1alts 

### 777 -78-0051 6of 69Number: Original Issue : Revision 4 : ATA System: SUBJECT: 

### Commercial Airplanes 

## SPECIAL ATIENTION 777-78-0051 October 23. 2003 February 07 , 2014 

### 7811 

# 777 Service Bullet i n Summary

EXHAUST (TRENT 800 Series Engines) - Co ll ector/Nozzle - Turbine Exhaust Plug Assembl y • I nspection and Retrofit BOEING RECOMMENDS THAT EACH OPERATOR EXAM I NE THIS SERVICE BULLET I N IMM ED IATELY. CONCURRENT REQUIREMENTS None . BACKGROU ND Accomplishment of this service bulletin 

### will make sure the Integrity of the Interface Is kepi between the forward plug and the aft plug of the turbine exhaust plug assembly to prevent separat ion occurrences . The aft plug can come off during a separation occurrence which could result i n a potential hazard to persons on the ground or damage to the ai rplane . Boeing has had three reports of in-night separations of lhe aft plug from the forward plug. which are the two parts of the turbine exhaust plug assembly. Subsequent to the first report where the separation occurred during takeoff, an Investigation showed that some of the interface bolts were found loose or missing . The turbine exhaust plug assembly was sent back to Boeing for ana l ysis and It was found that the remaining bolts had less than the necessary minimum run-on torque value. 

### II was also found tha t the operator of the analyzed turbine exhaust plug assembly had disassemb l ed It a minimum of three limes during maintenance actions. Repeated assembly and disassembly causes the locking property of the nut on the nutplates to wear out and subsequently let the bolls become loose or removed I n-service . This service bulletin gives i nstructi ons to do a general visual I nspection of the forward and aft plug I nterface fasteners and holes of the turbine exhaust plug assembly of each engine and i nstall 1 14 Inch diameter bolts al all 33 locations . Boeing Service Related Problem (SRP) 777-SRP-78-0071 i s related to th i s servi ce bulletin . Boeing Fleet Team Digest 

### (FTO ) 777 

### FTO 78-01002 I s related to th i s servi ce bullet i n. Th i s table Is pro vided l o o perators for planning purposes only. Refer to the applicable sections for more Information . Planning Data Spares Affected Origi nal Issue : October 23. 2003 Revisi on 4 : February 07 , 2014 Affected Reference Yes Paragraph 1.A.2 .. Spares Affected

E .xpc,n. COnttolled ECCN : 9E991 • BOEING PROPRI ET A R

Y· C<>pyrig.. 0 U np..l>llr.hed Wo'1c • See page 1 tor det.ahs 777 -78-0051



### 7 of69BOEING SERVICE BULLETIN 

### m-78-0051 Planning Data Affected Reference AD Related Yes Parag raph 1. E ., Complian ce and Paragraph 1. F ., Approval Weight and Balance Change Yes Paragraph 1 . H ., Wei ght and Balance Changes Electrical Load Changed No Parag raph 1. 1. , Electrical Load Data Publications Affected Yes Paragraph 1 . K .. Publi cations Affected Airplane F l ight Operations Affected (Fli ght C rew Operations Manual and/or FAA Ap p roved AirNo Paragraph 1.K., Publications Affected plane F light M anua l ) Kits/Parts Requi red Yes Paragraph 2.C . 1 ., Kils/Parts Opera to r Supplied Parts/Material Yes Paragraph 2.C.2 ., Parts and Materi als Supplied b y the Operator Specia l Tool fng Required Yes Paragraph 2 . F ., Special Tooling Necessary to do this Service Bullet. in ACTION (PRR 62039) Group 2 : 

## Maintenance Records Check 1 . Check mai ntenance records to find if maintenance actions have caused the movement of a turbine e xhausl plug assembly between airplanes, since delivery . If maintenance reco rds identify t hat an insta lled turbine exhaust plug assembly does not have part number 314W5520-22, o r th e part number of an Insta lled turbine exhaust p l ug assembly is no t known f ro m the maintenance records, do Part 1 . If the two Insta lled turbine exhaust p l ug assembli es have part number 314W5520-22 . no more work Is necessary. Group 1 , Configuration 1: 

## Part 1 • Turbine Exhaust Plug • Airplane work 1 . I nstall a serviceable turbine e xh aust p lug assembly on each engine with 1/4 inch diame ter bolls at all 33 locations ofthe forward and aft plug Interface .**~** A serviceable turbine exhaust plug assembly can be one that Is removed f rom the a i rpl ane and subsequently changed i n accordance with Part 3, or i i can be a spare turbine e xhaust p l ug assembly that Is changed in accordance wi th Part 2 or 3 . Or it can be a new turbine e xhaust plug assembl y , with part number 314W5520-22. 

# I Group 1 , Configuration 2 -3; Group 2: 

## Part 1 • Turbine Exhaust Plug· AJrpJane wo rk 1. Do a general visual Inspecti on of the 33 boll l ocatlons or the forward and aft plug Interface or each turbine exhaust plug assembly or each engine . 2 . If on l y 3/16 inch d iame ter bo l ts are found used , or if a m i x of 3/16 I nch and 1 /4 i nch diameter bolts are round used . Install a serviceable turbine exhaust p l ug assembly on each engine with 1/4 inch diame ter bolls at all 33 l ocations of the forward and aft p l ug interface . Original Issue: October 23. 2003 Revision 4 : February 07 , 2014 Expo,1 Con.... l ed ECC,, 9E991 • BOE ING PROPRt ETARY • COpynght O Unpublllhed \ "IOtk • SN paoo 1 IOl d01'11b 777-78-0051 8of 69

# I BOEING SERVICE BULLETIN 777-78-0051**~** 

### A serviceable turbine exhaust plug assembl y can be one that Is removed from the airplane and subsequently changed In accordance with Part 

### 2 or 3, or it can be a spare turbine exhaust plug assembly that Is changed In accordance with Part 

### 2 o r 

### 3. Or i t can be a turbine exhaust plug assembly, w i th part number 314W5520-22 . 3. For Group 1 Configuration 2 airplanes only. i f on l y 1/4 inch dia m eter bolts are found Installed at all 33 locations. reidentify turbine exhaust plug assembly In accordance with P art 

### 4 . 4 . For G roup 2 airplanes on ly , ifon l y 1/4 I n ch diameter bolts a re found Installed al all 33 locations , inspect to find th e part nu mber of each turbine exhaust plug assembly and If part number 314W5520·1 l s found, reidentify the l u rblne exhaust p lug assembl y In accordance with Part 

### 4 . 

### Part 2 - Replacement Of All Remaining 3/16 (nch Diameter Bolts With 1/4 (nch Diameter Bolts - Component Work : 314wss20-1: 314wss21-1 1 . Remove th e nutplates of 3/16 i nch dia m eter bolts from the forward plug hole s that inte rface with the aft p lug . 

### 2 . Do a general visual Inspection of the 33 holes for damage. 3 . Ream the damaged hole(s ) lo remove damage and/or Increase the diameter of a ll 33 holes to 1/4 Inch o r all remaining 3/16 Inch diameter hol es to 1/4 Inch. Install new nutplates fo r 1/4 inch d i ameter bolls at a ll 33 locations or at all remain ing locations. 4 . For each component Identified with part number 314W5520·1, reidentify the turbi ne exhaust plug assembly in accordance with Part 4. 5. For each componen t Identified with part number 314W5521-1, no turbi ne exhaust plug assembly rei dentificati on is necessary. 

### Part 3 - Replacement Of All 33 3/16 Inch Diameter Bolts With 114 (nch Diameter Bolts - component Wo rk: 314W5520-15. -19 : 314W5520-1: 314W5521-1 1. Remove the nulplate s of th e 

### 33 3/16 i nch diameter bolts from the forward plug holes that in terface w i th the aft plug. 

### 2. Do a general visual inspection of the 33 hates for damage. 

### 3 . Ream the damaged hole(s) to remove damage and in crease the diameter or all 33 holes to 

### 1/4 inch. Install new nutpl ates for 1/4 Inch diame ter bol ts at all 33 locations. 4 . For each componen t identified wi th part number 314W5520-15, -19, part mark and ins tall i dentification tags on the forward and aft plugs to reidentify the turbine eXhaust plug assembly. 5 . For each component Identified with part number 314W5520-1 , reidentily the turbine exhaust plug assembly in accordance with Part 4 . 6. For each component Identified with pan number 314W5521-1, no turbine exhaust plug assembly reidentification is necessary. 

### Part 4
- 

### Reldentmcatjon of the Turbjne Exhaust Plug Assembly - Component work : 314WS52Q-1 1 . Remove the tags that have an Incorrect part number Identification. Original Issue: October 23, 2003 Revision 

### 4 : February 

### 07. 2014 EJ:port.ControlledECCN 9E991-BOEJNG PROPRIE TARY 4 Copyrlgt,1 Cl Unpublished WOtk • See page 1 tor detalls. 

### 1n-1a..0051 9of69BOEING SERVICE BUL L ETIN 777-78-0051 2 . Deep etch mark replacement ldentlficatlon tags and insta ll one on the forward and aft plug. EFFECTIVITY 777-200/300 airplanes powered by Rolls-Royce Trent 800 Series Engines . Refer to Paragraph 1.A. 1 ., Airplanes , for the list of affected airpl anes . Refer to Paragraph 1.A.2 . • Spares Affected for the list or a ffected components . COM PLI AN CE The Federal Aviation Administration (FAA)wi ll possibly release an Airworth iness Directive related to this service bulletin . The Airworthiness Directive will make the compli ance tasks and times given in this service bulletin mandatory. Refer to Parag raph 1 . E .• Compliance . INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the Inspection and/or repair procedures given in this service bulletin. MANPOWER Refer lo Paragraph 1.G . , Manpower. MATERIAL INFORMATION Boei ng and Operator Suppli ed Kits/Parts. Refer to Paragraph 2 .A . • Material - Pri ce and Availability.

Origi nal Issue : Octobe r 23, 2003 Revisi on 4 : February 07 , 2014 Expot1 COnttOllod ECCN· 9E991 • BOEING P R

O PRI ETAA V · Copyrigh1 C Unpubished Work· See page 1 forde!Ms 777-78- 0051 10 of 69B O EING SERVICE BULLETIN 777- 78 -0 05 1

FORWARD PLUG AFT P L UG GROUP 2: DO A MAINTENANCE RECORDS CHECK TO FINO IF EACH TURBINE EXHAUST PLUG ASSEMBLY HAS PART NUMBER 314W5520·22. I F NOT, OR IT IS NOT KNOWN, DO A GENERAL VISUAL INSPECT ION OF EAC H TURBINE EXHAUST PLUG ASSEMBLY TO IDENTI FY ITS CONFIGURAT I ON AND DO THE NECESSARY CORRECTIVE ACTION(S). IF THE TWO TU RBINE EXHA U ST PLUG ASSEMBLIES HAVE PART NUMBER 314W5520·22, NO MORE WORK IS NECESSARY . GROUP 1 CONF I GURATION 1: REMOVE A L L 33 3116 I NCH DIAMETER BOLTS. DO A GENERAL VISUAL INSPECT ION OF EACH HOLE AND INCREASE ITS D I AMETER TO 1 /4 I NCH ANO INSTALL REPLACEMENT 1/4 I NCH D I AMETER BOLTS AND NUTPLATES AT ALL 33 LOCATIONS . RE·IDENTI FY THE PLUG ASSEMBLY.

BEFORE



# [fil

Original Issue: Oclober 23 . 2003 Revision 4 . February 07, 2014 expo'1 conttol!t)d ECCN ; 9E991 • BOEING PROPRIETARY· Copynglil O UnpubkaMd 

### won.· S.O pago 1 ro, de! M TURB I NE EXHA U ST P LUG ASSEMBLY



### 777 -78-0051 11 

## or 69

### Original Issue : October 23. 2003 Revision 4 : February 07 , 2014 BOEING SERVICE BULLETIN 777-78-0051



### BLA NK PAGE

Expon Controlled ECCN: 9E991 • BOEING PROPRIETAAY · Copynght O Unl)t'b!IShed \+/CW\ • See pa;e 1 tor del4ilit 777-78-0051 

### 12 of 

### 69

# I Commercial Airpl anes 

## SPECIAL ATTENTION 

# 777 Service 

# Bulletin Number: 

### 777-78-0051 October 23, 2003 February 07, 2014 7811 Original Issue: Revision 4 : ATA System: SUBJECT: EXHAUST (TRE NT 800 Series Engines). Collecto r /Nozzle. Turbine Exhaust Plug Assembl y • Inspection and Retrofit BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE TH I S SERV I CE BULLETIN I MMED IATELY . 1 . PLANNING INFORMATION A . Effectlvlty Ai rplanes Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number . and Serial Number data . This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes . Refer to PRR 62039 for data about this change . l':I.QIE; Airplanes In Group 

### 1 had the configuration of turbine exhaust plug assemblies Iden tified In this service bulletin Installed at delivery. l nstallatlon of spare turbine exhaust pl ug assemblies could resull In a configurational difference to what an airp l ane had when i t was originally delivered . Check your records to make sure the change In accordance with this service bulletin Is accomplished on applicable !Urbine exhaust plug assemblies. GROUP CONFIGURATION DESCRIPTION



### 1 

# .
1 2 3

Original Issue: October 23, 2003 Revision 

### 4 : February 07 , 2014 

### 777 -2001300 airplanes powered by Trent 800 engines before line number 470, that were delivered with turbine exhaust plug assembly, part number 314W5520-15 or -19. I nstalled . That have not done the Original Issue , Revision 1, Revision 2 or Revision 3 of lhl~ service bulletin That have done the Original Issue, but not Revision 

### 1 or Revision 2 of th is service bulletin Thal have done Revislon 

### 1 or Revision 2 of this service bulletin

£.xpon Con:rOffoct eCCN. 9E991 • BOEING PA:OPRll:TARY • COpynQhl C Unpu~ Wotk • S.. page 1 fo, OttAII"- 777 - 78-0051 

### 13 of 69

### BOEING S E RVICE BUL LETI N 777 -78-0051 GROUP CONFIGURATION DE SC RIPTION 2 

## .
Airpl ane M ode l s: 777-200, 777-300

Original Issue: October 23, 2003 Revision 

### 4 : February 07, 2014 777·200/300 airplanes powered by T rent 800 engines f rom line number 4 70 to 796, tha t we re delivered with t u rbine exhaus t plug assembly, part 

### numbe r 314W5520-22, I nsta ll ed .

Variable N umber Group WA00 1 1 WA086 • WA093 1 WA101 -WA104 1 WA 1 96-WA198 1 W B 031 • WB04 6 1 W B1 01 -WB 1 06 1 WB161 -WB175 1 WB176 -WB 177 2 WB181 - WB192 1 WB193 -WB194 2 WB201 • WB214 1 WB215 2 W B 231 • WB24 7 1 WB416 • WB437 1 WB438 • WB439 2 WB446 • W B453 1 WB501 • WB509 1 WB510-WB512 2 WB601 • WB606 1 WB611 • WB618 1 WB619 - WB622 2 WB631 • WB638 1 WB646 • WB649 1 WC051 • WC073 1 WC101 - WC104 1 WC456 - WC459 

### 2

E,;pew1 ContrOled ECCN· 9E991**~** BOEING PROPRIETARY • Coplfrlghl C Unpubl i$hod \\lode**~** See poge 1 tor deUJllt 

# m-1s-oos1 14 of 69BOEING SERVICE BULLETIN 777-78-0051 Variable Number Group WC486 - WC493 2 WC531 -WC536 2 WC566 - WC567 2 WC571 - WC574 2 2 . Spares Affected Examine your Quick Engine Change (Q EC ) kits fo r parts or components changed as shown in th is service bulletin. I f any parts o r components are found, refer to Paragraph 2.C ., Parts Necessary for Each Airplane, fo r the recomm ended use . Part Number Serial Number or Dash Number 654W0003-62 C0028, C0029, C0030, C0031, C0032 . C0041, C0042 , C0045, C5001, C004 9,COOSO 654W0003-3 C000 1. C0002 654W0003-46 C0052 654W0003·68 C0034. C0035 654W0003-73 C0043 654 W0003-18 C0003, C0004 654W0003-37 C0020 654W0003-8 1 C0051 654W0003-30 C0012 654W0003- 23 C0013, C00 14 , C0015 , C0016, C0017 654W0003-24 C0033 654W0003-12 C0005, C0006 , C0007



# - 654W0003-55 C0027 654W0003-57 C0036, C0039 QECRR777 -3, -4 Examine your spa res suppl y for lhe parts or components Identified below If any parts or components are round , refer to Paragraph 3.B.• Work Instructi ons for the recommended action . Part Number 314W5520-15 314W5520-19 Original Issue : October 23, 2003 Revision 4 : Fe bruary 07 , 2014 E.l(pctt Contr ollea ECCN; 9E991 • BOEING PROPRIETARY• Copy,lghl C UnpubbNd 

### w

....

# s..,,... , ro,..,.... 777-78-0051 15 of 69BOEING SERVICE BULLETIN 777-78-0 051 Part Number 314W5520-1 (a) (a) Existing part number 314W5520-1 could also e xist because or the instructions in the Original Issue or this servioe bulletin. But part number 314W5520· 1 Is incorrect as the post service bu ll etin Identity . B . Concurrent Requirements None. C . Reason Accomplishment of this service bu ll etin will make sure the in tegrity of the interface is kept between the forward plug and the aft plug of the turbine exhaust plug assembly to prevent separation occurrences. The aft p l ug can come off during a sepa ration occurrence which could result in a poten tial hazard to persons on the ground or damage to the airplane. Boeing has had three reports or In-flight separations of the aft plug from the forward plug, which are the two parts or the turbine exhaust p lug assembly . Subsequent to the first report where the separation occurred during takeoff. an investigation showed that some of the in terface bolts were found loose or missing. The lurbine exhaust plug assembly was sent back to Boeing fo r analysis and It was round t hat the remaining bolts had less than the necessary minimum run -on torque value . It was also round tha t the operator or th e analyzed turbine exhaust plug assembly had disassembled It a m i nimum of three limes during maintenance actions. Repeated assembly and disassembly causes the locking property of the nut on the nutptates to wear ou t and subsequently let th e bolts become loose or removed In-service. This service bulletin gives instructions to do a general visual inspection of the forward and aft plug Interface fasteners and holes of the turbine exhaust pl ug assembl y of each engine and Insta ll 1/4 inch diameter bolts a t all 33 locations. Boeing Service Rela ted Problem (SR P) 777-SRP-78-0071 is related to this service bu ll etin . Boeing Fleet Team Digest (FTD) 777 FTD 78-01002 ls related to thi s service bulletin . Revision 1 was sent to tell operators that the assembly number shown on the identification tag was incorrect in Figure 3. This revision changes th e assembly number shown on the Identity tag from 314W5520-1 to 314W5521-1. This revision also corrects the spelling of the word "Sepa rate," on the i dentification tag , and i n the table of Figure 3. Airplane WB510, line 4 70, was deleted from this service bullebn effectivity. 

### It was included in error. Revision 2 

### was sent to change the classificabon or the service bulletin from Standard to Special Attention and to add a compliance recommendation. Revision 2 also corrected a typographical error, adds damage tolerance data and adds maintenance zone data .

Original Issue: October 23, 2003 Revision 4 : February 07 , 2014 E)ipon Con11oUed ECCN 9E991 • BOEING ""OPR I ETARV · C0oynghl0Unpubll5hed \'IOtk• SN l)IOl 1 

# '°' ct.toils 777-78-0051 

### 16 or 

### 69

# I BOEING SERVICE BULLETIN 

### n7-78-0051 Revision 3 was sent because of misleading Instructions In the Original Issue, Revision 1 and Revision 

### 2 or this service bulletin. As a result , some airplanes could have turbine exhaust plug assemblies with a mix of 

### 114 Inch and 

### 3/16 Inch diameter bolls used to attach the forward and aft plugs together . After accomplishment of the change In this service bulletin only 

### 1/4 Inch diameter bolls are to be Installed at all 33 locations of the forward and aft plug Interface of each turbine exhaust plug assembly, which Is the same as the late st production configuration . Also th is revision corrects a post service bulletin Identification relationship error for the forward and aft plug, where the Instructions ofthe Original Issue, Revision 

### 1 and Revision 

### 2 of this service bulletin gave them the Identification Intended for the next higher assembly part number. Revision 4 Is sent to add the remaining delivered 777 Rolls-Royce (RR) powered airplanes lo the effectivity of this service bulletin . All variants ofturbine exhaust plug assembly are fully interchangeable with each other and thus maintenance actions could have caused the movement ofeach turbine exhaust plug assembly between airplanes or the 777 RR powered fleet . This condition could result in a conngurational difference to what an airplane had when II 

### was originally delivered. D. Descript ion Group 2: 

### Maintenance Records Check 1 . Check maintenance records to find if maintenance actions have caused the movement of a turbine exhaust plug assembly between airplanes. since delivery. If maintenance records identify that an I nstalled turbine exhaust plug assembly does not have part number 

### 314W5520-22 , or the part number or an Installed turbine exhaust plug assembly Is nol known from the maintenance records, do Part 

### 1 . If 

### the two Installed lurbine exhaust plug assemblies have part number 

### 314W5520-22, no mo re work Is necessary . 

### N.QI.I;.; The forward plug and aft plug are a matched set. They must be removed and Installed as a set. Group 1, 

### Configuration 1: 

### Part 1 • Turbine Exhaust Plug • Airplane Work 1 . 

### Insta ll a serviceab le turbine exhaust plug assembly on each engine with 1 /4 

### inch dlameter bolls al all 

### 33 locations of the forward and aft plug interface . ~1 . 

### A serviceable turbine exhaust plug assembly can be one that is removed from the airplane and subsequently changed In accordance with Part 3 , or it can be 

### a spare turbi ne exhaust p lug assembly that is changed in accordance with Part 

### 2 or 

### 3 . Or 

### It can be a new turbine exhaust plug assembly, with part number 

### 314W5520·22. 2. 

### The forward plug and aft 

### plug are a matched set. They must be removed and In stalled as a set. Group 

### 1 , Configuration 

### 2·3 ; Group 

### 2: 

## part 1 • Turbine Exhaust Plug • 

## AJrpJane Work 1. 

### Do a general visual I nspection of the 

### 33 bolt locations of the forward and aft plug in terface ofeach turbine exhaust plug assembly of each engine. Original Issue : October 

### 23, 2003 Revision 

### 4 : February 

### 07 , 2014 Exj,on

# eon,.- ECCN, 9E99 l • BOEING PROAAIETAA:Y, Cot)ytiQh1 Cl Unp,ublithtd work · Sff pttge 1 k>t ~u.lls. 

# 1n-1s.oos1 17 of 69

# I 

# I BOEING SERVICE BULLETIN 777-78-0051 2 . 

### If only 3/16 inch diameter bolts are found used , or If a m i x of 3/16 Inch and 1/4 inch diameter bolts are found used , install a serviceable turbine exhaust plug assembly on each engine with 1/4 inch diameter bolts at all 33 locations or the forward and aft plug in terface. 

### ~1 .



### 2. A serviceable turt>lne exhaust plug assembly can be one that is removed from the airplane and subsequently changed In accordance with Part 

### 2 or 

### 3 , or it can be a spare turt>ine exhaust p lug assembly that Is changed in accordance with Part 

### 2 or 

### 3 . Or it can be a turt>ine exhaust plug assembly, with part number 314W5520-22. The forward plug and aft plug are a matched set They must be removed and i nstalled as a set. 

### 3 . For Group 

### 1 Configuration 

### 2 airplanes on ly . if only 1/4 i nch diameter bolls are found installed at all 

### 33 locations , reldentlfy turt>ine e x haust plug assembly in accordance with Part 

### 4 . 4 . For Group 2 airplanes only, if on ly 1/4 inch diameter bolts are found installed at all 

### 33 locations. Inspect to find the part number of each turbine exhaust plug assembly and if part number 314W5520-1 ls found , reldentlfy the turbine exhaust plug assembly in accordance with Part 4 . 

## Part 2 • Replacement Of AU Remaining 3/16 Inch PJameter Bolts With 1/4 lach Diameter Bolts - Component Work : 314W5520-1: 314Wss21-1 1 . Remove the nutplates of 3/16 i nch diameter bolts from the forward plug holes that interface with the aft plug. 

### 2. Do a general visual Inspection of the 33 holes for damage . 3 . Ream the damaged ho l e(s) to remove damage and/or i ncrease the diameter of all 

### 33 holes to 1/4 Inch or a ll remaining 3/16 inch diameter holes to 1/4 inch. Install new nutplates for 1/4 inch diameter bolts at all 

### 33 locations or at all remaining locations. 

### 4. For each component i dentified with part number 314W5520-1, re ldentlfy the turbine exhaust p lug assembly In accordance with Part 

### 4 . 5 . For each component I dentified with part number 314W5521-1 , no turbine exhaust plug assembly reidentification Is necessary. 

## Part 3 • Replacement Of 

## All 33 3/16 loch Diameter Bolts With 114 (nch Diameter Bolts· Component Work : 314W5520-15. -19 : 

## 314W5520-1 ; 314W5521·1 1 . Remove the nutp l ates or the 33 3/16 Inch diameter bolts from the forward p lug holes !h at in terf ace with the aft plug. 

### 2 . Do a general visual inspection of the 

### 33 holes f or da mage . 

### 3. Ream the damaged hole (s) to remove damage and Increase diameter or all 33 holes to 1 /4 Inch . Install new nutplat es for 

### 1/4 i nch diameter bolts a t all 33 locations. 4 . For each component identified with part number 314W5520-15 . -1 9 , part mar1< and I nstall Identification tags on the forward and 

### aft plugs to reldenlify the turbi ne exhaust p lug assembly. Original Issue: October 23 , 2003 Revision 4 : February 07 , 2014 E.xpo,1 Comrolled ECCN ; 9E991 • BOEING PROPRIETARV · Copynght O lklpvbbhOO Work • See page 1 fo, Cle!ffS. 777-78-0051 18 of69BOEING SERVICE BULLETIN 777-78-0051 5. For each component Identified wit h part number 314W5520-1, reidentify the turbine exhaust plug assembly in accordance with Part 

### 4. 

### 6. For each component Identified with part number 314W5521-1, no turbine exhaust p l ug assembly reidentification is necessary. Part 

## 4 • Reidentjfjcatlon of the Turbine Exhaust Plug Assembl y · Component Work : 

## 314wss20-1 1 . Remove the tags tha t have an incorrect part number Identification . 

### 2. Deep etch mark replacemen t Identificatio n tags and Install one on the forward and aft p l ug. Revision 

### 1 • More work was necessary on airplanes changed as shown in the initia l release of t his service bulletin. I dentification tags with the incorrect assemb l y numbe r shou l d be corrected when manpower and faciliti es are available. Revision 

### 2 • No more work was necessary on airplanes changed In accordance with Revision 

### 1 of this service bulletin . Revision 

### 3 · More work is necessary on the airplane(s) changed In accordance with the Original Issue. Revision 

### 1 or Revision 

### 2 of th is service bulletin . Airplanes identified as Group 

### 1 Configu ration 

### 3. that have done Revision 

### 1 or Revision 

### 2 of this service bulletin. must do a general visual inspection of the fasteners that attach the forward and aft plugs 

### of the turbine exhaust p lug assembly together of each engine, to iden tify if 3116 inch diameter and/or 114 inch diameter bolts are used and, If necessary, insta ll a serviceable turbine exhaust plug assembly with 114 inch diameter bolts at all 33 locations of the forward and aft plug interface . Airplanes i dentified as Group 

### 1 Configuration 

### 2, that have done the Original Issue, but not Revision 

### 1 or Revision 

### 2 of this service bulletin. must do a general visual inspection of the fasteners that attach the forward and aft plugs of the turbine exhaust plug assembly togethe r of each engine, to identify if 3116 mch diameter and/or 1/4 inch diamete r bolts are used and, if necessary, Install a serviceable turbine exhaust plug assembl y with 114 inch diame ter bolts a t all 33 l ocations of the forward and aft plug interface. Additionally, ifonly 

### 1/4 inch diameter bolts are found Installed at all 33 locat ions, it is recommended that the identification tag on each forward and aft plug of each turbine exhaust plug assembly of each engine Is replaced with one that has the correct post service bulletin Identity. Revi sion 

### 4
- No more work i s necessary on the airplane(s) changed In accordance with Revision 

### 3 of th i s service bulletin. But, weight and balance data for this service bulletin has changed in this revision . If an operator changed their weight and balance data for an airplane to agree with the lower values i n accordance with the Origina l Issue or Revision 

### 1 thru 

### 3 , It I s recommend that the data Is changed agai n to agree w i th the higher values In accordance wl1h this revi sion . The work i n this service bulletin is done In the maintenance zone(s) given below. Affected Ma intenance Zon es 

# - Mode l 777 -200. 777-300

Original Issue : October 23 , 2003 Revision 

### 4 · February 07 , 2014 Zon e 419 , 429

f .xport Contr Oled ECCN : 9£991 - BOE.ING PROPRI ETARY · Copyng:t'rl O U n,pu bished WOl'k • See page 1 lo, details. 777-78-0051 19 of 69

# I BOEING SERVICE BULLETIN 777-78-0051 E. Compliance The Federal Avi ation Administration (FAA) will possibly rel ease an Airworthiness D irective related to this service bulletin . The Airworthiness Directive will make the compliance tasks and t imes given In this service bullet in mandatory . Do the required actions In accordance with Paragraph 

### 3. Accomplishment In stru ctions. Group 1 , Configuration 1 : 

## TabJe 1 : Turbine Exhaust Plug Assembly· Replacement Of AH 33 3 /1 § locb Diameter Bolts With 1



## / 4 Inch 

## Dlametor Bolts Condition Action Compliance T i me Repeat Interval (Not to Exceed) All airpl anes Install a serviceable tur- Wilhin 60 months 

# . bine exhaust plug assem- after the Revision bly on each engine with 

### 3 date of this ser

### 1/4 inch diameter bolts at vice bu ll etin . all 

### 33 l ocations of the forward and aft pl ug in terrace in accordance wi th Paragraph 

### 3 . 0 .. Work I nstructions . Part 1 , Step 2.b . (a) (a)



# - A serviceable turbine exhaust plug assembly can be one that Is removed from the airplane and subsequently changed In accordance with Part 3, or it can be a spare turbine exhaust p l ug assembly that is changed In accordance with Part 2 or 

### 3 . Or it can be a new turbine eXhaust p lu g assembl y, w ith part number 314W5520-22.



# - The forward plug and aft plug are a matched set. They must be removed and ins talled as a set.

Ori ginal Issue: October 23, 

### 2003 Revision 4 : February 07 , 2014 E .11 pon Controltd ECCN 9E99 1 OOElNG PRO PRI ETARY• Copyrighl Cl Unpublis.hod

Work , SM pege 1 Sor d"~ilt 777-78-0051 20 of69

# I I BOEING SERVICE BULLETIN 777-78-0051 Group 1 , Configuration 

### 2 : 

## Table 2: Turbine Exhaust Plu g Assembly· General YJsyaJ lospectlon of Bolts Condition Act ion Compliance Time Repeat Interval (N ot to Exceed) 

### All A irplanes Do a general visual In- Within 60 months 

### . spection ofall 33 bolt loca- after the Revision lions of each tu rbine ex- 

### 3 date of this serhaust p lug assembly in vice bulletin . accordance w ith Paragraph 3 . B ., Work lnstruct ions. Part 1 . Step 3 ., to Iden tify if 3/16 inch and/or 1/4 inch diameters are used at the forwa rd and aft plug in terface . On ly 3/16 Inch diameter Insta ll a serviceable tur- Before fu rther 

# . bo lts are found used a t all bine exhaust plug assem- flight. 33 locations of t he forward bly on each engine with and aft plug Interface . 1/4 inch diameter bolts a t all 33 locations of th e forward a n d aft pl ug interla ce in accord ance with Paragraph 3. 8 .. Work Instructions, Part 1 . Step 3.a.(2) . (a) 

### A mix of 3/16 and 1 /4 Inch I nstall a serviceable tur· Before further 

# - diameter bo lts are found b in e exhaust plug assem· flight. used at t he 33 locations of b ly on each engine with the forward and aft plug In· 1/4 Inch diameter bolts a t terface . a ll 33 locations of the forward and aft p lug In terface in accordance with Paragraph 3.8., Work I n· s tructlons. Part 1. S tep 3 . b . (2) . ( b) On l y 1/ 4 inch diameter Reidentify the forward Before further 

## - bolts are found i nsta ll ed at and aft plug in accor- flight. all 33 locations forward and dance with Paragraph aft plug interface . 3.B.. Work tnstruct, ons. Part 4 , Step 

### 1 and 2 . (a)



# - A serviceable turbine e x haust plug assembly can be one that i s removed from the airplane and subsequen tly changed in accordance with Part 3 . or it can be a spare turbine exhaust plug assembl y that is chang ed in accordance with Part 2 or 3 . Or 

### it can be a new turbine ex ha u st p lu g assembl y, wi th part number 314W5520-22 .



### - The forward p lug and aft plug are 

### a matched set. They must be removed and I nstalled as a set.
Original Issue: October 23 , 2003 Revisi on 4 : February 07 , 2014 E.iipon Controlled E CCN. 9£991 • SOEJNG PROPRIETARY • Copyrigh1 0 Unpublished Wont • See page t Sor details 777-78-0051 21 of 69

# I BO E ING S E RVIC E B U L L ETIN 777-7 8-00 51 G roup 

### 1, C onfi guration 

### 2: 

## Table 2: Turbine Exhaust Plu g Assembl y · General YJsual In spe c tio n of Bolts Condition Action Compliance Time Repeat l nt. erva l (N ot to Exceed) (b)



### - A serviceabl e turbine exhaust pl ug assembly can be one that is removed r rom lhe airplane and subsequenlly changed In accordance wi t h Pa rt 2, or it can be a spare turbine exhaust pl ug assembly that Is changed In accordance with Part 2 or 3 . O r It can be a new t u rbine e xhaus t plug assembly, with pa rt number 314W5520- 22 .



### - The forwa rd plug and aft plug are a matched set. They must b e removed a nd installed as a 

### set. Group 

### 1 , Configuration 

### 3 : 

## Ta ble 3: T u rbine Exhau s t Plug Assembly - General V i sual lnspectio n o f Bol ts C o nd i tion All Airp l anes

Only 3/1 6 Inch diame ter bolts are found used at all 33 l ocations of the forward and aft plug Interface .

A mix of 3116 and 

### 1/4 inch diameter bolts are f ound used at the 33 locations of the forward and aft plug Interface .

Original Issue: October 23, 2003 Revision 4 . February 07, 2014 Action Compliance Tlme Do a general visual i n- Within 60 months speclion all 

### 33 bolt loca- afte r the Revision tlons of each turbine ex- 3 date of this se rhaus t plug assembly in v i ce bulletin . accordance wi th Parag raph 3 . B .. Work tnstruo Uons, Part 1, S tep 3 ., to ldenl.ify if3 / 16 i nch and/or 1 /4 i nch d i ameters are used at lhe forward and aft plug Interface. Insta ll a serviceab l e tur- Before further bine ex haust plug assem- flight. bly on each engine with 

### 1/4 Inch diame ter bolts at all 

### 33 l ocations of the fo rward and aft plug Inter

## race in accordance w i th Paragraph 3 . B .. Work Instructions, Part 1, Step 3.a.(2) . (a) Install a serviceable tur- Before further blne exhaust plug assem- Hight. bly on each engine with 1/

4 ,nch diameter bolls at all 33 locatlons of the forward and aft plug interface in accordance with Paragraph 3 . 8 .. Work Instructions, Part 1• Step 3.b.(2). (b)

E,;pon Con!roled ECCN 9E991 - BOE.ING PROPRIET ARY· Copyright O Unpubhhed Wor\ . See page 1 fol' delds Repeat Interval ( N o t t o Exceed)



# .

.



## .

777 - 78-0051 22 of 69

# I I BOEING SERVICE BULLETIN 777-78-0051 Group 

### 1, Configuration 

### 3: 

## T

able 3: Turbine Exhaust Plug Assembly • General Visual Inspection of 

# sons Condition Action Compliance Time Repeat Interval (Not to Exceed) Only 1/4 inch diamete r None. 

## . . bolts are found Installed al a ll 33 location s forward and aft plug Interface . (a)



# - A seivlceable turbine exhaust p l ug assembl y can 

### be one that Is removed from the airplane and subsequently changed In accordance with Part 3, or It can be a spare l urbine e xhaus t plug assembly thal is changed In accordance with Part 2 or 3. Or It can be a new turbine ex haust plug assembly, with part number 314W5520-22.



# - The forward plug and aft plug are a matched set. They must be removed and Installed as 

## a set (b)



# - A seiviceable turbine exhaust plug assembl y can 

### be one that is removed from the airpl ane and subsequently changed In accordance with Part 2. or 

### It can be a spare turbine exhaust plug assembly that is changed In accordance with Part 2 or 3. Or It can be a new turbine ex haust plug assembly, with part number 314W5520-22.



# - The for.vard plug and aft plug are a matched set. They must be removed and Insta lled as a se l. Group 

### 2 : 

### Table 4: Turbine Exhaust Plu g Assembly - Ma intenance 

## Records Check and General Visual 

## Inspection of Bolts Condition A ll Airplanes

Main tenance records Iden

### Ufy that the two i nstalled turbine exhaust plug assemblies have part number 314W5520-22 .

Original I ssue : October 23 , 2003 Revision 4 : Fe bruary 07 , 2014 Action Compliance Time Do a maintenance Within 60 months records check In accor- after the Revision dance with Paragraph 4 date of th is ser3.B.. Work I nstructions to v ice bulletin . find i i maintenance actlons have caused the movemen t of each turb in e exhaust plug assembly between airplanes, since delivery. None. 

### .

l:Jlport Controlled EC(' "I 9E.991 .. SOE~G PROPRIETARY -Copy,.ght C Unpubli&bod Wot\.- See page 1 lo, detah Repeat Interval (Not to Exceed)



## .

.

777-78-0051 23 of 69BOEING SERVICE BULLETIN 777-78-0051 Group 

### 2: 

## Table 4: Turbine Exhaust Plug Assembly - Maintenance Records Check and General 

## v;sual lo· soection of Bolts Condition Maintenance records identify that an installed turbine exhaust plug assembly does not have part number 314W5520-22. or the part number of an Ins talled turbine exhaust plug assembly is not known From the maintenance records. Only 3/16 l nch diameter bolts are found used at all 33 locations or the forward and alt plug In terface .

A mix of 3/16 and 

### 1/4 I nch diameter bolts are found used at the 33 locations or the forward and alt plug I nterface.

Only 1 /4 Inch diameter bolts are found installed at all 33 l ocalions forward and aft pl ug interface and the turbine exhaust plug assemb ly is identified wilh part number 3 14W5520-1 .

Original Issue: October 23, 2003 Revision 4 : February 07 . 2014 Action Compliance Time Do a general visual In- Wilhin 60 months spection of all 33 bolt loca- after the Revision 

### ~ons of each turbine ex- 

### 4 date of this serhaust plug assembly In 

### vice bultelin. accordance with Paragraph 3.8., Work lnstruclions, Part 1, Step 3., lo Identify if 3116 inch and/or 1/4 lnch diameters are used at the forward and aft plug interface. Install a serviceable tur- Before further bine exhaust plug assem- nigh I. bly on each engine with 

### 1/4 Inch diameter bolts at all 33 locations ofthe forward and aft plug interface In accordance with Paragraph 3.8 ., Work Instruclions, Part 1 , Step 3.a.(2) . (a) Install a serviceable tur- Before further bine exhausl plug assem- ftighl. bly on each engine with 1 /4 inch diameter bolts at au 33 localions or the forward and aft plug interface in accordance with Paragraph 3.8., Work Instructions , Part 

### 1 , Step 3.b.(2). (b) Reidenlify ihe forward Before further and aft plug In accor- night dance w i th Paragraph 3.8. , Work I nstructions. Part 4 , Step 

### 1 and 2.

EXPO<l ConltOIIIO 

### ecc,,, 9E991 • aoe1NG PROPRIETARY• Copytighl C> ~ubl'IJhOd wo,k • SOI p;,ge 1 fordotaifs Repeat Interval (N ot to Exceed)



## -



# -

-



# -

1n-1e-oos1 24 of 69BOEING SERVICE BULLETIN 

### 777-78-0051 Group 2: 

## Table 4: Turbine Exhaust Plug Assembly • Maintenance Records Check and General YJsuat lo· specuon of Bolts Condition Action Compliance T ime Repeat Int erval ( N ot t o E x ceed) Only 

### 1/4 inch diameter None. 

### . 

## . bolts are found installed at all 

### 33 locations forward and aft plug interface and the turbine exhaust plug assembly is identified with part number 

### 314W5521-1 or 

### 314W5520-22. (a)



# - A serviceable turbine exhaust plug assembly can be one that rs removed from the airplane and subsequently changed In accordance with Part 

### 3, or rt can be a spare turbine exhaust plug assembly that Is changed In accordance with Part 

### 2 or 

### 3. Or it can be a turbine exhaust plug assemt>ly, with part number 

### 314W5520-22.



### - The forward plug and aft plug are a matched set. They must be removed and Installed as a set. (b)



### - A servioeable turbine exhaust plug assembly can be one that is removed from the airplane and subsequently changed In accordance with Part 

### 2, or ii can be a spare turbine exhaust plug assembly that Is changed In accordance with Part 

### 2 or 

### 3. Or it can be a turbine exhaust plug assembly , with part number 

### 314W5520-22.



# - The forwar d plug and aft plug are a matched se t . They must be removed and Installed as a set. F . Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified In lhls service bulletin comply wilh lhe applicable regu lations and are FAA approved, as well as European Avlatlon Safety Agency (EASA)/Joint Aviatio n Authorities (JAA) approved for all EASA/JAA approved airplanes listed In the service bulletin effectivlty . This service bulletin and Its approval were based on the airplane In its original Boeing delivery configuration o r as modified by other approved Boeing changes. Ifan airplane has a non-Boeing modlficallon or repa i r that affects a component or system also affected by this service bulletin , the operator Is responsible for obtai ning appropriate regulatory agency approval before I ncorporating this serv ice bulletin . G. Manpower The tables bel ow show an estimate of the task-hours necessary to do this service bulletin for each engine. This estimate Is ror direct labor only. done by an experienced crew. Adjust the estimate wilh operator task-hour data If necessary. The estimate does not I nclude lost time . These are some examples or lost time :

- Time to adjus t to the workplace Origi nal Issue: October 

### 23 , 2003 Revisi on 

### 4 : February 

### 07 , 2014 Expo,, 

### eon .. u .. ECCN 9 E99 1 • BOEING PR OPRI ETARY · Copyttgh i C \Jn publ lShocl W ad. • See page 1 f or d etrtllt 

### 777-78-0051 25of 69

# I BOEING SERVICE BULLETIN 777-78.0051 Time to schedule lhe work Time to e x amine the work Time to cure the materials Time to ma ke the parts Time to find t he tools. Group 1, Configuration 1: 

## Part 1 • Ai rplane Work Task Number of Persons De acti vate Th rust 1 Reve rser Remove Turbine Ex- 2 hau st P l ug As se mbl y F I G UR E 9 (a) 2 Activa te Thrust Re- 1 

### verser TOTAL FOR EACH ENGI N E Task Hours 1 .00 1.25 1 .25 1 .00 4 .50 Elapsed Hours 1 . 00 0.63 0 . 63 1.00 3 .25 (a) Th i s estima te does no l Include the time to replace nutp lal es i n accorda nce with F IGU R E 7, If necessary. Group 1 , Configuration 2-3 ; Group 2 : 

## Part 1 • AJrpJane Wo rk Task Number of Persons Task Hours Elapsed Hours Deactivate Thru st 1 1 .00 1 .00 Reverser FIG U RE 5 1 1 .80 1 .80 Remove Turbine Ex- 2 1 .25 0 .63 haust P l ug Assembly FIGURE 9 (a) 2 1 . 25 0.63 Activate Thrust Re- 1 1 . 00 1 .00 verser TOTAL FOR EACH ENG I NE 5 .30 4.05 (a) This estimate does not incl ude the time to replace nutplates In accordance with F I GURE 7, If necessary. 

## fart 

## 2 • Component W ork; 

## 314W ss20 -1 Task FIGURE 1 FIGURE 2 Original Issue: October 23, 2003 Revision 4 : February 07, 2014 N u mber of Persons Task Ho urs 2 8 .00 1 1 .80

Expon Controffed ECCN 9E991 • BOEfNG pqQPRiE TARV 4 Copyrlgtll C Unput:llithed Watte • See page 1 for dOl t:1~ 

### Elapsed Hours 4 .00 1 .80

777-78-0051 260169

### BOEING SERVICE BULLETIN 777-78-0051 

## Part 2 • Component Work ; 314W552Q·1 Task Number of Persons Task Hours Elapsed Hours FIGURE 6 (a) 2 4.70 2 .35 FIGUR E 3 1 0 .25 0 .25 FIGURES 1 0 .60 0 .60 TOTAL FOR EACH ENGINE 15.35 9.00 (a) This estimate is lhe maximum time necessary, which assumes there is a minimum of one 1 /4 inch diameter bolt Installed and the remaining 32 3/16 inch diameter bolts are to be replaced with 1/4 Inch diameter bolts. 

## Part 2 • Component Work ; 314WS521-1 Task Number of Persons Task Hours Elapsed Hours F IGURE 1 

### 2 8.00 4.00 FIGURE2 1 

### 1 .80 1 .80 FIGURE 6 (a) 2 4.70 2.35 TOTAL FOR EACH ENGINE 14 .50 8.15 (a) This estimate is the maximum time necessary, which assumes there Is a min im um of one 1/4 Inch diameter bolt Installed and the remaining 32 3/16 inch diameter bolts are to be replaced with 1/4 Inch diameter bolts . 

## Part 3 • Component Work : 314Wss20.1s, -19 Task Number of Persons Task Hours FIGURE 1 2 8 .00 FIGURE2 

### 1 1 .80 FIGURE3 1 0 .25 FIGURE4 2 6.00 TOTAL FOR EACH ENGINE 16.05 

## Part 3 • Component Work ; 314WS52Q·l: 314wss21.1 Task Number of Persons Task Hours FIGURE 1 

### 2 8 .00 FIGURE2 1 1 .80 FIGURE 4 (a) 

### 2 6 .00 TOTAL FOR EACH ENGINE 15.80

Original Issue : October 23. 2003 Revision 4 : February 07 , 2014 

### e.poo Corur oled ECCN . 9E991**~** SOE.ING PROPRI ETARY · ~ngh l O U,ipubltshed W

ork · See p age 1 for d~alts 

### Elapsed Hours 4.00 1 .80 0 .25 3.00 9 .05 Elapsed Hours 4 .00 1 . 80 3.00 8 .80

777-78-0051 27 of 69

# I

I BOEING SERVICE BULLETIN 777 -78-0051 

## P

art 3 • com ponent Work; 314W ss20 -1: 314w s s

21.1 Task 

# I Number of Persons 

# I Task Hours 

# IElapsed Hours {a) The time t o do this task will be less than the es timate va l ues, as they include identification tag lnst alla l ion work which is not necessary i n th i s task for turbi ne exhaust pl ug assemblies Identified wilh part number 31 4W5520- 1 and 314W5521·1 . 

## Part 4 • Component w ork ; 314wss20 . 1 Task Number of Persons Task Hours Elapsed Hours FIGURE3 

# , 0.25 0.25 FIGUR E S 

### 1 0.60 0 .60 TOTAL FOR EAC H E N GINE 0. 85 0 .85 

## Tu rbine Exhaust Plug Assembly , forward Plug Nutplate Replaceme n t Task Numbe r of Persons Task Hours Elapsed Hours FIGUR E 

### 7 

# , 0.20 0.20 TOTAL FOR EACH NUTPLATE 0 . 20 0.20 H . We ight a nd Balanc e Changes 

## Left And Ri g ht En gine Turbin e Exha ust P l ug Assem blies Changed To Haye All 114 Inch Diamete r Bolts At Their f orward And A ft Pl ug Interface Change I n Weight Change I n Moment Airpla ne ( Pounds ) (Pound-Inches) All + 

### 1 . 2 + 1,379.3 

### I. Electr i ca l Load Data Nol changed. 

### J . Re fe rences 1. Existing Data: a. Engineering Change Memo PRR 62039. b. Boeing Service Letter 777-SL-51-0 13 . c. Boeing Service Related Prob lem {SRP) 777-SRP-78-0071 . d . Service Bulletin Index 0624W001 . e. Boeing S l andard Overhau l Practices Manua l ( SOPM) 20-10 -07, 20-50-01 . 20-50-10 . Original Issue: October 23, 2003 Revision 4 : Fe bruary 07 . 2014 ExPQl1 Conlrollod ECCN 9E991 • BOEING PA:oPR.I E1'AAY • eopyrivl'lt C IJn?ubli.1htd \\10tk • Seo Pt;O 1 ror doloJs 

### 777-78-0051 28 of 69

# I I BOE I N G SERVI CE BULLETIN 777 -78 - 0051 f . 777 Aircraft Mai ntenance Manual (AMM) 78-11 -02, 78-31-00. g . 777 F l ee t Team Digest (FTD) 777 FTD 78-01002 . h . 777-200 Structural Repair Manual (SRM) 51-30-01, 51-40-02 . 54-42-30. I . 777-300 Structural Repai r Manual (SRM) 51-30-01, 51-40-02, 54-42-30 . 

### 2. Data Suppli ed with this Service Bulletin: None. 

### 3. I nstallation Drawings U sed in t he Preparation of this Service Bulleti n :

Draw i ng N umb e r Title 314W5521 RR AFT EXHAUST PLUG ATTAC H MENT I NTERFACE, RE PAIR A N O RETROFIT The table above lists applicable drawings used to prepa re this service bu ll e ti n . The drawings are not necessary to make t he specified changes, and are not supplied with this service bu ll eti n . The drawings may not be appl icable to all airplane confi gurations or ope rators . 

### K . Publi cations Affected 

### 1 . Publications: Pub li ca tion Chapte r-Section 

### 777 Aircraft Maintenance Manual 78-11 777 Illustrated Parts Catalog 78-11 Component M aintenance Manual 78-11 777 Power Plant B uil d-Up Manua l 71-00



### 2 . Damage Tol erance Based Structura l I nspections: Boeing has evaluated the repai rs and/or changes In this service bulletin for effects on Fallgue Critical Structure (FCS) and for changes to Damage Tolerance I nspections (DT I ) required In the Maintenance Program . This service bulletin does not affect FCS, therefore DTls are not necessary. 

### L. In terchangeab i li ty and ln termlxabllity o f Parts Accomplishment of this service bulletin does not affect Interchangeability or in termlxablllty or parts. 

### M . S o ftwar e A ccomplishment Summa ry Not affected .

Original Issue: October 23, 2003 Revision 4: February 07, 2014 E><Pon Co<lt,olled ECCN 9E991 , SOEINO PROPRlE'TARY - Copynghl O UnpubOs.hod Work
- See pa~ t lor dellil• 

### 777-78-0051 29 of 69Ori gina l Issue: October 23 , 2003 Revi si on 4 : F ebruary 07 , 2014 BOEING SERVICE BULLETIN 777-78-0051



### BLANK PAGE

£..,.an Conttoled ECCN. 9E99 1 · BOEJNG PAOAAIE1'ARY• CowlQhl C UopubliShed Wof'lt. Seo pogo 1 fordOUtila 777- 78-0051 30 of 69

### BO E ING SERVICE BULLE TIN 777 -78- 005 1 2 . MATERIA L INFORMATION A . Material • Price and Availability Boeing can supply the kits shown In Paragraph 2.C . , Parts Necessary fo r Each Airp l ane an d Paragra ph 

### 2 . D., Parts Necessary to Change Spares . Operators a re encouraged to s ha re sched ule requi rements with Boeing ro r i ncorporation oft he service bu ll eti n . The ki ts a re s u b j e c t to t he term s a nd co ndition s of the Boeing standard pu rchase order acknowl edgme nt. P rices are I n U nited States D ollars. Term s: Net 30 days. Reference th is service bu ll etin and s u bmit your purchase o rder by o n e of these m e thods: 1. Orde r on-line via ATA Spec 2000 o r The Boeing PART Page 2 . Fax to (206) 662-7145 

## RE FER T O THE BOEING PART PAGE ON M Y

BQEING F LEE T, COM OR CONTACT FIRST RESPONDER AT FR@BO EING .COM F OR THE LATEST REORDER LEAP T IME (ROLD ANP PRICE INFORMATION Kit Number Name ROL T as or the Unit Price as of Revision 03 date the Revision 02

of this Service date of this SerBulletin (Calendar vice Bulletin ( US Days) Dollars) 005W3246-1 Top Kil· 777 Ai rplanes , T rent -800 Powered 567 $7, 1 98 005W3246-2 Subk il, Engi ne 553 $3,599 B . Industry Support Information Boei ng warranty remedies are no t available for t he Inspection and/or repair procedures given In this service bu ll etin . C . Parts Necessary for Each Airplane 1 . Ki ts/Parts: To get the kits/parts shown below, refer to Parag raph 2 .A .. Material - Price and Availability.**~** 

### One top ki t and the i tems shown I n Paragraph 2.C. 2 . • Parts and Materials Supplied by the Operator, as applicable , are necessary ror each airplane . 

## Part 3 • Com ponent W ork: 314wss20-1s. -1 9 K i t 005W3 246 N ew Pa rt N umber QTY

-2 005W3246-1 005W3246-2 . Original Issue: October 23, 2003 Revision 4 : February 07, 2014 N ame ·1



## . Top Kit . Airpl ane 2 Subklt. Engine

Expon Conltelod ECCN 91:99 1 • BOEI NG PROPRIETARY • Cowlgl\lC Unj)uWork• Sff p,oe, t tor Cl«alls 

### Ex i sti ng P art Number Notes

777-78-0051 31 of 69

### BOEING SERVICE BULLETIN n7-78-0051 

## Part 3 • Component work : 314W5520-15. -19 Kit 005W324 6 New Part N umber QTY Name Ex i sting Part Notes 

### -2 -1 N umber 314W5520·23 2 Identification Tag BACB30UU4·1 33 Bolt (a) BACN11G4DE1F 33 Nutplate , Self-Locking BACN11G3AE1F MS20427M3-4 66 Rivet (a) MS20615-4M3 6 Rivet (a) (a) 

### Ifgrip length shown Is not available at Boeing , rasteners supplied in kits may be one grip length longer than indicated . Also, If any fasteners part numbers listed are not available or have been superseded . substitute fasteners may be supplied in kits. 2. Parts and Materials Suppl i ed by the Operator: The following parts or materials are necessary to do the change i n this service bulletin . Parts and materials In the manuals g iven In Paragraph 1.J ., References , can also be necessary . Examine operator part and material supply to make sure all necessary parts and materials are available. 

## Part 2 • 

## component Work : 

## 314WSS2Q-1: 314WS521·l Part N umber I QTY N ame Notes Specification BACN11G4DE1F 64 Nulplate. Self-Locki ng Maximum quantity . Adjust as necessary . MS20427M3-4 128 Ri vet Maximum quantity for two for each nutplate. Adjust as necessary. (a) BACB30UU4· 1 

### 64 Bolt Max i mum quantity. Adjust as necessary . (a ) Refer to 777 Structural Repair Manual Chapter 51 for alternate fasteners. 

## Part 3 • Component Work : 314WSs20-1 Part Number 

### I QTY j Name Specification 005W3246-2 1**~**



### Ong l nal I ssue: October 23 , 2003 Revision 4 ; Februa ry 07, 2014 

# I Subkit, Engine

E.x;port Cooltollod ECCN 9E991 • BOEING PROPRIETAAY - Copyright O Unpubli&hed Work - See JM198 1 to, detaifs 

### Notes

777-78-005 1 32 of 69BOEING SERVICE BULLETIN 777-78-0051 

## Part 3 • Component Work : 314W5521-1 Part N umber 

### I QTY N ame Notes Specification BACN11G4DE1 F 

### 66 Nutplate , Self-Locking MS20427M3-4 132 Rivet (a) BACB30UU4-1 

### 66 Bolt (a) Refer to 777 Structural Repair Manual Chapter 51 for altemate fasteners . 

## Part 4 • Component Work : 314W552Q-l Part N umber 

### I QTY N ame Notes Specif ication 31 4W552 0·23 4 Identification Tag MS20615-4M3 12 Rivet (a) (a) Refer to 777 Structural Repai r Manual Chapter 51 for altemate fasteners . 3. Parts Modified and Reidentified : The parts shown below are changed as shown In th i s service bulletin . The quantity (QTY) is the number of parts changed on each airplane . Existing Part QTY Name N ew Part N umber Notes Number 314W5520-15 or 2 Primary Plug 

### Assy 314W5521-1 Referred to as 'Tur314W5520-19 b i ne Exhaust Plug 314W5520·1 Assembly' . (a) (b) (c) (d) (e) (a) Make the change in accordance with lhls service bulletin. (b) This Is the part number after the change Is done in accordance with this service bulletin . (c) This part Is not used In production (d ) The equivalent production part number Is 314W5520-22. (e) Existing part number 314W5520-1 could also exist because of the Instructions In the Original Issue of this service bullet in. Bui part number 314W5520·1 Is Incorrect as the post service bulletin identity. 

### 4 . Parts Removed and Not Replaced . None .

Original Issue: October 23 , 2003 Revision 4: February 07 , 2014 Expoc, Conttolted ECCN• 9E991 • BOEING PROPRlETAAY**~** Copv,9ht C UnpobliShed Work· See page 1 (o, details. 777 -78-005 1

33 of 

### 69BOEING SERVICE BULLETIN 777-78-0051 D . Parts Necessary to Change Spares II is recommended thal primary plug assemblies (or 'turbine exhaust plug' assemblies) held as spares are Inspected in accordance with FIGURE 5 and. If necessary. change them in accordance with Parag raph 3 . 6 .• Work Instructions . Part 2. 3 or 4, as applicable. To get the k its shown below. for each turbine exhaust plug assembly, refer to Paragraph 2.A.. Material

- P rice and Availability . 

## Part 2 - component w ork: 314w ss20-1 Part N umber N ame QTY 314W5520-23 Identification Tag 2 BACN11G4DE1 F Nutplale. Sell-Lock- 32 ( maximum) Ing MS20427M3-4 Rivet 64 ( maximum ) MS20615-4M3 Rivet 

### 6 BACB30UU4-1 Bott 32 (maximum) 

## Part 2 • component Work : 314Wss21.1 Part Number N ame QTY BACN11G4DE1F Nulplate , Self-Lock- 32 ( maximum) Ing MS204 27 M3-4 Rivet 64 ( maximum) BACB30UU4-1 Bolt 32 ( maximum) 

## Part 3 • component Work : 314wss20-1s. -19: 314wss20-1 Kit N umber Name 005W3246-2 Subkit , Engine 

## Part 3 • Component Work· 314wss21.1 Part Number Name BACN11G4DE1F Nutplate , Self-Locki ng MS20427M3-4 Rivel BACB30UU4-1 Bott

Original Issue: October 23, 2003 Revision 4 . February 07, 2014 Expo,, ConllOiled ECCN . 9E991 , BOEING PROPRIETAAY • Copyrlgl'l1 0 Unpubkhocl \ 0JOC\ • Sot page 1 tor dtlnfl QTY 1

QTY 33 

### 66 33

777-78-0051 34 of 69

### BOEI N G SERVICE BULLETI N n7-78-0051 

## P

art 4 • component work: 314wss20-1 Pa rt Nu m b e r Na m e QTY 314W5520- 23 Identification Tag 2 MS20615-4M3 Rivet 6 E. Spe ci al Tooling • Pr ice a nd Ava ila bility The operator can supply the tools shown In Paragraph 2 . F ., Special Tooling Necessary to do this Service Bul l etin . Tool p rice and suppl y data are not given . F. S pe cia l T oo li ng Necessary to do this Service Bulletin To get the tools shown be l ow. refer to Paragraph 2 . E .. Special Tooling· Price and Availabi l ity . Main tenance and overhaul tools in the manuals shown i n Paragraph 1 . J ., Refe rences . can a l so be necessary. Examine operator tool suppl y to make sure ail necessary tools are available . Pa rt N um ber Nam e ST1664R·2620-2550· Step Reamer 4-221-4-64-2-4 , or equivalent (a) ST30-7216A-200- 3116 inch diameter temporary 216-1 .0, or equiva lent fastener (b) ST30-7216A-200- 1/4 inch diameter temporary 279-1 .0, or equivalent fastener (b) (a) Can be purchased rrom : Boeing, Spares Customer Support - MC 36- 65, Boeing Spares Departmen t , P .0 . Box 3707, Seattle , WA 96124-2207 , USA. (b) A quantity of 32 are necessary .

Original Issue : October 23, 2003 Revi si on 4: February 07, 2014 E...pon Controlled ECCN 9 E991 4 BOEING PROPRI ETARY· Cos)ynoht C Uni,ubbhed WOfk • Soe paoe 1 to, CMUIU 

### 777- 76-0051 35 of 69Original Issue: October 23, 2003 Revision 4 : February 07 , 2014 BOEING SERVICE BULLETIN 777-78-0051

BLAN K PAGE

Expon ConlrolledECCN &E:991-SOEING PROPRIETARY - Copynght O Unpublished Wont
- See page 1 lo, dota~s 777-78-0051 

### 36 of 

### 69BOEING SERVICE BULLETIN 

### 777-78-0051 3. ACCOMPLISHMENT I N STRUCTIONS A . GE N ERAL INFORMATION 

## CAUTION : KEEP THE WORK AREA. WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTI CLES OR CONTAMINATION CAUG HT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES . DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTH ER ELECTRICAL DAMAGE .**~** 1 . Manual lilies are referred lo by aCfonyms . Refer lo Paragraph 

### 1 . J . , References, for definition or t he aCfonyms . 

### 2 . Obey all of lhe warnings and caullons given in lhe specified manua l sections . 

### 3 . The work instructions are divided Into wor1< packages . Task Hours and Elapsed Hours for each package are given In Paragraph 1 . G ., Manpower. You can do Part 

### 1 . 2 . 3 and 

### 4 independently . 

### 4 . Unless shown d ifferently, these dimensions and tolerances are used : Linear dimensions are in inches Tolerance on linear dimensions , olher than rivet and bo l t edge margi ns , is p lu s or minus 

### 0 .03 i nch Tolerance on rivet and bol t edge margin is pl us or minus 

### 0 .05 inch Angular tolerance Is plus or minus 

### 2 degrees Hole dimensions for standard solid rive ts and fasteners are in Structural Repair Manual (SRM) Chapter 

### 51 Torque Va l ues : Values for struclural fasteners are given In 

### 777 Slructura l Repair Manual , Chapter 

### 51. Values for airframe maintenance tasks are I ncluded In Chapter 

### 20 of 

### 777 Ai rplane Mai ntenance Manual (AMM) . Values for engine maintenance tasks are included in Chapter 

### 70 of 

### 777 Ai rplane Mai ntenance Manual (AMM) . Non-standard torque va l ues for mai n tenance tasks are Incl uded in the applicable Installation step. 

### 5 . Use the approved fastener and process material substitutions in accordance w i th SRM C hapter 

### 51 . 

### 6 . Ifthe l ength of 

### any fastener spec ified I n th i s service bulletin does not meet i nstallation standards g i ven i n SRM Chapter 

### 51 . then a fastener of the same specification . or an approved substi tute , with a l ength which meets lhe i nstallation standards g i ven I n SRM Chapter 

### 51 may be used . In add ition , washers 

### may be i nstalled for fastener grip length i n accordance with SRM Chapter 

### 5 1 . Refer to SOPM 

### 20-50-01 for alternate full threaded Fasteners ( screws ) needed for lnstallallon i n this service bullelin .

O ri g i nal I s sue: October 

### 23, 2003 Re v ision 

### 4 : Febru a ry 

### 07 . 201 4 ExportControled ECCN 9E991 ·BOEING PROPRIE TARY· Copyright O Unp ubli&hed Work - See page_ I to1 de!a11s, 

### 777
-78-0051 37 of 69

### BOEING SERVICE BULLETIN 777-78-0051 7. A General Visual Inspection is defined as: A visual examination of an lnlerior or exterior area , i nstallation o r assembly lo detect obvious damage. !allure or irregularity. This level of Inspection Is made from within touching distance un l ess otherwise specified . A mirror may be necessary lo enhance visual access lo all e xposed surfaces in the In spection area. Th is l evel or i nspection Is made under normally available lighting condilions such as dayli ght, hangar light ing, nashllght or drop-light and may requ ire removal or opening of access panels or doers . Stands , ladders or platforms may be required lo gain proximity lo lhe area being checked . 8 . These work instructions refer to procedures incl uded in other Boeing documents . When lhe words "refer to• are used and the operator has an accepted a l ternative procedure, lhe accepted alternative procedure can be used. When the words "I n accordance wilh" are included In lhe i nstruction, lhe procedure in the Boeing document must be used . 

### 9 . Boeing Service Letter 777-SL-51-013 , Damage Reporting and Repair Plan/Design Guidelines, Is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letler describes whal Information must be provided l o Boeing before a structural repair can be provided . 10. The Instructions in Paragraph 3.B ., Work lnslructlons and lhe figures can Include operation oftools or test equipment. Boeing Engineering Tool Drawings, lhe llluslrated Tool and Equipment Manual , and lhe Special Tool and Ground Handling Drawi ng Index contain data on versions of lhe tools or tesl equipment that you can use . 

### It Is permitted to use replaced tools . 

### It is not permitted to use superseded tools . 11. 

### If it is necessary to remove more parts for access, you can remove those parts. 

### If you can get access without removing Identified parts, II is nol necessary to remove all of the Identified parts. Jacking and shoring limitations must be observed. 12 . Where the work 

### lnslrucllons Include Insta ll ation or a kept part , a new or serviceabl e part wflh lhe same part number can be Installed as an alternative to the kepi part. 13 . If shading is used, shaded areas In Figures are to separate the non-critical and non-aulhorltallve lnformallon lrom the critical and authoritative Information. 14. The forward plug ancl all plug are a matched sel. They must be removed and In stalled as a set. 1 5. ' Run-on torque' is used In t his SB i n place or 'self-locking torque'. 'Self-locl<ing torque' i s defined as the torque necessary lo turn 

## a fastener with a self-locking feature on i ts mating threaded part when 100 percent or lhe locking fea ture is engaged, and the fastener is nol down against th e mating surface . ( Reference SOPM 20·50·01) 

### B. WORK INSTRUCTIONS Group 

### 2: 

## Majntenance Records Check 1 . Check maintenance records lo find if maintenance actions have caused lhe movement of a turbine exhaust plug assembly between airplanes , since delivery: a . An installed turbine exhaust plug assembly , does not have part number 314W5520-22. Original Issue: October 23, 2003 Revisio n 4: February 07, 2014 Expon Controlled ECCN :9 E991 • BOEJNG PROPRlETAAV · Copyright O Unpublished Wo,k • Soe page 1 for cfe1ffl 

### 717-78-0051 38 of69

# I BOE I N G SERVICE BULLE TIN 77 7-78 --0051 b . The two inslalled lurb in e exhausl plug assemblies, have part number 314W5520- 22 . c . The part number o f an installed tu rb i ne exhausl p l ug assembl y is no t known . 2 . I f lhe condllion of S l ep 1 .a. or Slep 1 .c. is found, do "Part 1 - Turbine E xhaus l Plug - Airpl ane Work' . 3 . If lhe condilion of Slep 1 . b . is found, no more wo rk is necessary.**~** 

### The forward plug and aft plug are a ma l ched sel. They must be remove d a nd Install ed as a set. 

## P

art l
- T urbi ne Exhaust Plug - Airplane 

## Work 1 . Oeactiva l e l he Thrust Reve rsers (T/R's) for g round m ai ntenance . Refer l o 777 AM M 7 8-31-00 as an accep ted procedure . 2 . G r oup 1 , Conf iguration 1 : 

## a. Remove l he turb i ne exhaust p l ug assembly from each engine. R efer l o 777 AMM 78-11-02 as an ac,;epted procedure. b . Insta l l a serviceable tu rbine exhaust pl ug assembly. w ith 1/4 i n ch d i ameler bolts at a ll 33 locations of lhe forward and aft plug in terface. back on each engine in accordance with F I GURE 

### 9 . ~1 .



### 2. A serviceabl e turbine exhaust p l ug assembl y can be one that is removed from lhe ai rpl ane and subsequenUy changed in acco rdance with Part 3 , or i t can be a spare tu rbine e xhaust plug assemb l y that Is changed in accordance wilh Part 2 or 3. O r it can be a new turbi ne e xhausl pl ug assembl y. wi th part number 314W5520- 22. The forward plug and aft plug ar e a matched set. They mus t be removed and i nstalled as a set. (1) 

### If one or more of the 1/4 Inch diameter bolts has a run-on torque val ue of l ess lhan 5 .0 Inch-pounds, replace the nu tp l ate on the forwa rd plug for each of the rela l ed bolt(s) I n accordance with F I GURE 7 . 

# I 3 . G r oup 

### 1, Confi gura tion 

### 2-3 ; Group 

### 2 : At each engine, do a general visua l i nspecllon of the all of the 33 bolt locations at the forward and aft plug Interface In accordance with F I GURE 5 . 

## a. Only 

### 3/16 Inch diameter bolls are found used at all 33 locations: ( 1 ) 

### Remove lhe l urblne exhausl plug assembly from each engi ne. Refer to 777 AMM 78-11-02 as an accepted procedure. (2) I nstall a serviceable turbine exhaus1 pl ug assembly , w i th 

### 1/4 i nch diameter bolts at all 33 locations of the forward and aft plug Interface , back on each engine I n accordance wllh F I G U RE 

### 9.

Original Issue: October 23 , 2003 Revision 

### 4 : February 07 , 2014 Eirpon Conuolled ECCN. 9£991**~** BOEING PROPRIEiARY • ~'tiQhl C U!'lp,ublit htd WOft • See pog• I for dotolls 

### 777-78-0051 

### 39 of 

### 69

# I

I BOEING SERVICE BULLETIN 

# 1n-1a-oos1 ~1 .



## 2. A serviceable turbine exhaust plug assembly can 

### be ooe lhal is removed from lhe airplane and subsequently changed In accordance with Part 

### 3, or 

### II can be a spare tu rbine exhaust plug assembly that Is changed in acco rdance with Part 

### 2 or 

### 3 . Or 

### II can be a turbine exhaust plug assembly, wilh part number 

### 314W5520·22 . The forward plug and aft p l ug are a matched sel. They must be removed and installed as a set. (a) II one or more of lhe 

### 1/4 inch dlameter bolts has a run-on torque value of less lhan 

### 5.0 Inch-pounds. replace lhe nutplate on the forward p l ug for each of the related bolt(s) in accordance wilh FIGU RE 

### 7 . b. 

### A mix or 

### 3/16 Inch diameter and 

### 1/4 inch diameter bolts are found used a l the 

### 33 locations . 

### (1) Remove the turbine exhaust plug assembly from each eng ine . Refer to 

### 777 AMM 

### 78-11-02 as an accepted procedure. 

### (2) Install a serviceable lurbine exhaust plug assembl y, wilh 

### 114 inch diameter bol ts at all 

### 33 l oca tions or lhe forward and aft plug I nterface. back on each engine In accordance wi th FIGURE 

### 9 .



### ~ 1 .



## 2. Aserviceabl e turbine exhaust plug assembly can 

### be one I hat Is removed from the airp l ane and subsequently changed In accordance wllh Part 2, or 

### it can be a spare turbine exhaust p l ug assembly lhat Is changed In accordance with Part 

### 2 or 

### 3. Or 

### II can be a turbine exhaust plug assembly. wilh part number 

### 314W5520-22. The forward plug and aft plug are a mat ched set. They must be re moved and Installed as a set. (a) II one or more of the 

### 1/4 inch diameter bolts has a run-on torque va l ue of less than 

### 5 .0 Inch-pounds. replace the nulplate on the forward plug for each of the related bolt(s) In accordance with FIGURE 

### 7 . c. Only 

### 1/4 Inch diameter bolls are found Installed at all 

### 33 locations: 

### (1) Group 

### 1 , Configuration 

### 2 : Reldentify lhe turbine exhaust plug assembly: (a) Remove the turbine exhaust plug assembly from each eng i ne . Refer to 

### 777 AMM 

### 78-11-02 as an accepted procedure. (b) Do Part 4 . (c) Install the turbine exhaust plug assembly wtlh the reidentlfied forward and aft plugs back on each engine In accordance wilh FIGURE 

### 9 . 1) 

### Ifone or more or lhe 1/4 Inch diameter bolts has a run-on torque value of less than 

### 5 .0 Inch - pounds. replace the nutplale on the forward plug for each of the related boll(s) In accordance w i lh FIGURE 

### 7 . Original Issue: October 

### 23, 2003 Revision 

### 4: February 

### 07 . 2014 Expon Controlleo ECCN 9£991 • BOE.INC PROPRIETARY · Copytig:h10 Unput>bnOd Wotk • See pege 1 for oo!All. 

### 777-78-00 61 40of 69BOEING SERVICE BULLETIN 777-78-0051 (2) Group 1, Configuration 3: No more worl< Is necessary. 

### (3) Group 

### 2 : Inspect the part number of each turbine exhaust plug assembly: (a) Remove the turbine exhaust p lug assembl y from each engine. Refer lo 777 AMM 78-11·02 as an accepted procedure. 

### MQre II is not necessary to remove the forwa rd plug from the engine at this time . (b) Inspect the ID lags of the forward aft plugs to find the part number of the turbine exhaust plug assembly. tiQIJ;,;. Refer to FIGURE 

### 8 for lhe location of lhe ID tag on the forward and aft plugs. 1) If part number 314W5520- 1 is found: a) Remove the remaining forward plug from each engine . Refer to m AMM 78· 11 ·02 as an accepted procedure. b} Do Part 

### 4. c} Install the turbine exhaust p lug assembly with the reldentified forward and aft plugs back on each engine In accordance with FIGURE 

### 9 . {1) 

### If one or more of the 

### 1f4 Inch diameter bolts has a run-on torque value of less than 5.0 I nch-pounds , rep lace the nutplate on the forward plug for each of the rela ted bolt(s} In accordance with FIGURE 

### 7. 2) If part number 314W5521·1 or 314W5520-22 is found: a) Install the turbine exhaust plug assembly 

### back on each engine I n accordance with FIGURE 

### 9 . tiQIJ;,;. 

### II is only necessary to Install the aft plug . {1 

## J If one or more of the 1/4 In ch diameter bolts has a run-on torque value of less than 5.0 inch-pounds, replace the nutplate on the forward plug for each of the related bo l t(s} in accordance with FIGURE 

### 7 . 4 If not done . activate the T/R's after ground maintenance. Refer to 777 AMM 78-31-00 as an accepted procedure. 

### 5 Put the airplane back to a serviceable condition. 

## Pao 2 • Reo(acement 01 All RemalnJng 

## 3116 Inch 

## Diameter Bo(ts With 

## 114 locb Diameter Bolts· Component Work : 

## 314W5520·1· 314WSS21·1 1 . 

### As applicable: Original Issue: October 23, 2003 Revision 4 : February 07, 2014 Expon Con1tolled ECCN : 9E991 • BOEING PROPRIETARY · Copyright O Un,pubbhed WOfk ·Seepage 1 to, d618ft 777-78-0051 

### 41 of69

### BOEING SERVICE BULLETIN 777-78-0051 Get each spare turbi ne exhaust plug assembly for wh i ch the description of Part 2 is necessary to be accomplished . Get each removed turbine exhaust plug assembly for which the description of Part 2 l s necessary to be accomplished. 2 . Put and hold lhe forward plug vertically and remove all o f the remaining 3/16 Inch diamete r nutplates from the holes that interface with the aft plug In accordance wlth FIGURE 1 . 3 . Do a general visua l inspection of the ho l es. rela te d to the removed 3/16 inch diameter nutplates, at lhe forward and aft p l ug Interface In accordance wllh FIGURE 2 . a . If a hol e has damage that is more than the 0.2910 Inch limit, contact Boeing for repair instructions. Refer to Boeing Service Letter 777-S L-51-013. 4 . I nstall 1/4 Inch diameter nutplales at a ll remai ning hole l ocations where 3/16 Inch diameter nutplates were removed In accordance with FIGURE 6 . 5 . For each component Identified with part number 314W5520- 1: a . Reidenlify the lurbine exhaust plug assembly in accordance with Part 4 . 6 . For each component Identified with part number 314W5521 - 1 : a . No lurbine exhaust plug assembly reidentificat ion is necessary . 

## Part 3 - Replacement OfAU 33 3/16 Inch Diameter Bolts Wjth 1(4 Inch Diameter Bolts -Component Work: 314W5520-15, -19: 314WSS20-1: 314WS521-1 1 . As applicabl e : Get each spare turbine exhaus t plug assembly for which the description of Part 3 is necessary lo be accomplished . Get each removed turbine exhaus t plug assembl y for which the description of Part 3 Is necessary to be accomplished . 2 Pul and hold the forward plug vertically and remove all ofthe 33 3/16 inch diameter nutplates from lhe holes that I nterface with lhe aft plug in accordance with FIGURE 1 . 3 . Do a genera l vi sual l nspecllon of lhe holes . related lo lhe removed 3/16 inch diameter nutplates, at the forward and aft plug I nterface I n accordance with FIGURE 2 . a . Ifa hole has damage that i s more than the 0 .2910 i nch limit , contact Boeing for repai r I nstructions . Refer to Boeing Service Letter 777-SL-51-013. 4 . For each component Identified wilh part number 314W5520 - 15 , - 19 : a . Deep etch mark the new Identification tags for the forward and aft plugs l n accordance with FIGURE 3. b . Install 1/4 Inch diameter nutplates at all 33 hole locations and reidentlfy the turbine exhaust plug assembly i n accordance with FIGURE 4 . 

### 5. For each component identified with part number 314W5520-1 : Origi nal Issue : October 23, 2003 Revisi on 

### 4 : February 07 , 2014 Expon Controlled E CCN: 9E 99 1 · BOEJN G PR

OPRIETARY· Coi,yngN O Uni:,wliShed Wotk**~** See page 1 tor detail~. 

### 777-78-0051 42 of 69BOEING SERVICE BULLETIN 777-78-0051

a . In stall 1/4 i nch diameter nutplates at all 33 hole locations in accordance with FIGURE 4 . b. Reidentify the t urbine exhaust p l ug assembly i n accord ance with Part 

### 4 . 6 . For each component lden l ified with part number 314W552 1·1 : a. Install 1 /4 Inch diameter nulplates al all 33 hole localions in accordance with F I GURE 4. b . No lurbine exhaust plug assembly reidentificalion is necessary . 

## Pact 4 · Rejdentjficatlon ofthe Turbine Exhaust Plu gAssembly· Component W ork; 314W5520-1 1 . Deep etch mark the replacement identi fication tags for the forward and aft plugs in accordance with F IGU RE 

### 3 . 

### 2 . Remove the lncorreclly Identi fied Identification tag s and install the replacemenl identification tag s for the forward and aft plugs in accordance with F IGURE 

### 8 .

O ri gina l Issue: October 23, 2003 Revi sion 

### 4 : February 

### 07 , 2014 &po,1 Conlrolled ECCN 9 E99t · BOEI NG PROPRI ET ARY - Copyog:ht C Unpubkt!ed WM - See page 1 l o, de!a!IS 777-78-0051 

### 43 of 69

### BOEING SERVICE BULLETIN 777-78-0051

F O RW ARD P LUG

TYPICAL AT 33 LOCATIONS ( MAX I MUM)

# ~

FIGURE 1 : TURBINE EXHAUST PLUG ASSEMBLY· NUTPLATE REMOVAL AND HOLE INSPECTION PREPARATION Origi nal Issue: Octobe r 23, 2003 Revision 4 February 07 . 201 4 

### ( SHEET 1 OF 3) El(J)O<t Conln>llod ECCN · 9E991 - BOE ING P

ROPRIET A

R

Y· Copyrioh10 Unpijbhshfx:I Work • See pa,oe 1tor delah. 

### 777-78- 0051 44 of 69

### BOEING SERVICE BULLETIN 

### 777-78-0051

2 AFTP LU G

FORWARD AND AFT PLUG ( AFT PLUG P UT ON FORWARD P LUG WITHOUT BOLTS A ND NUTPLATES) 

### l FORWARD PLUG



### The step numbers shown below agree with the numbers shown I n the circl e symbol s I n the figure . The QTY numbers shown below are the number of parts necessary for each turbine exhaus t plug assembly.

Step Task Name Identification Qty 

### More Data

1 Remove RIVET 

## . . (a) (c) Remove NUTPLATE BACN11 G3 A E1 

### F 

## . (b)

FIGURE 

### 1 : TURBINE EXHAUST PLUG ASSEMBLY· NUTPLATE REMOVAL AND HOLE INSPECTION PREPARATION (SHEET 

### 2 OF 

### 3) 

# ;

.... 

# i

Origina l Issue: October 23, 

### 2003 Revi sion 

### 4 February 

### 07 , 2014 Expoct eo.i1,ot1ec1 ECCN · 9 E991 - BOEING PROPRJETARY - Copyrigh t O Unpubh hed W

ork · See page 1 f o, detds. 

### 777-78-0051 

### 45 of 69BOEING SERVICE BULLETIN 777-78-0051 Step Task Name Identification Qty M ore Data

2 Pul 

### I Hold FORWARD PLUG 314W5520-16 OR 1 on lhe aft p l ug. 314W5520-21 Put/ Hold AFT PLUG 314W5520-3 OR 1 on lhe forward plug. 314W5520-20 3 Align HOLE 

# - 33 of each plug. (a) Quantity 66. if each turbi ne exhaust plug assembly is lo have all 33 3/16 inch diameter bolts replaced with 1 /4 i ndl diameter bolts . Or, quantity as necessary, for each turbi ne exhaust plug assembly that i s to have all remain ing locations thal have 3/16 i nch diameter bolts replaced with 1 /4 in ch diameter bolts . Refer 10 777-200 SRM 51 -4 0-02 or 777 -300 SRM 51-40-02 an accepted procedure . (b ) Quantity 33 , if each turbine exhaust plug assembly is to have all 33 3/16 inch diameter bolts replaced w ith 1/4 inch diameter bolts. Or, quantity as necessary, for each turbi ne exhaust p lug assembly that is to have all remaining l ocations that have 3/16 i nch diameter bo lts replaced w i th 1/4 i nch diameter bolts . (c) Be careful during the removal of ri vets to minimize damage to the holes .

FIGURE 1 : TURBI NE EXHAUST PLUG ASSEMBLY - NUTPLATE REMOVAL AND HOLE INSPECTION PREPARATION Origina l I ssue: October 23, 2003 Revision 4 February 07. 2014 (SHEET 3 OF 3) E"POI\

# Coo,,_ ECCN 9E991 • BOElNG PROPRIETARY· ~hlC Unpublrsh ed Wo,k. • See page 1 for de1a1:s 777-78-0051 46of 690.2238 EXISTING 3116 BOEING SERVICE BULLETIN 777-78-0051

INCH DIAMETER NOM I NAL CLASS Il l HOLE

0 . 3050 EXIST I NG COUNTERSINK HOLE

FORWARD PLUG SKIN EXAMPLE OF DAMAGED HOLE

TYPICAL HOLE AT 33 LOCATIONS (MAXIMUM) LIM IT OF DAMAGE FOR HOLE REPA I R 0.2910 0.2790

AFT PLUG SK I N

The step numbers shown below agree wilh the numbers shown in the circle symbols In lhe figure . The QTY numbers shown below are lhe number of parts necessary for each t urbine exhaust p l ug assembly.

Step Task Name Identification Qty More Data



### 1 (a) Inspeel HOLE 

# - - (a) by general visual lnspecUon. at lhe 33 locallons of lhe forward plug and aft plug Interface , for wear damage and/or hole elongation . for each turbine exhaust plug assembly that is lo have all 33 3/16 inch diameter bolls replaced . Or. by general visual inspection . at each 3/16 inch diameter bolt location, at lhe forward plug and aft plug lnlerface, for wear damage and/or hole elongatlon, for each turbine exhaust plug assembly that is to have all remaining locations that have 3/16 Inch diameter bolts replaced with 1 /4 inch diameter bolts.

FIGURE 2: TURBINE EXHAUST PLUG ASSEMBLY HOLES - GENERAL VISUAL INSPECTION (SHEET 1 OF 1) Original Issue: October 23, 2003 Revision 

### 4 February 07, 2014 EXPM ContrOlled ECCN : 9E991 - BOEING PROPRIETAR Y · Copyngh1 Cl Unpubllshed W(Mi( - See page l k)r detallS 777-78- 0051 47 of69BOEIN G SERVIC E BULLETIN 777-78.0051

As sy 314W 5521- 1 

## O MATCHED SET. 00 NOT SEPARATE 

## 0 

# SI N XXX-XXXX 0
The step numbers shown below agree with the numbers shown in the ci rc l e symbols In the fig ure . The QTY numbers shown below a re the number of parts necessary for each turbine exhaust pl ug assembly.

Step Task Name Identification Qty More Data

1

(a) 

### (bl I dentify I DENT I FICATION TAG 314W5520-23 2 w ith the text as fo llows, for the forward and a ft plug: Assy 314W5521-1; MA TC H ED SET . 00 NOT SEPARATE : SIN: 

### XXX -XXXX. Refer l o SO PM 20- 50-1 

### O as an acce pted procedure . (a) (b) The serial number code Is to be operator defined . A uni que serial number Is necessary for each matched se t of forward and aft plugs (a turbine exhaust plug assembl y) l o help the ope rator keep the hardware as a matched seL EXAMPLE : SIN TBC-0001 . The serial number I s recommended to be on one half of the identification tag and one-quarter inch (24 point) In height. The remaining text is reco m mended to be on the other hal f of the identification tag and 1 2 poin t In height. The text is recom mended to be cen tered to keep a minimum 20 dista n ce from each of the rivets after Installation.

FIGURE 

### 3: IDENTIF IC ATION TAG - DEEP ETCH MARK (SHEET 1 O F 1) Original Issue: October 23, 2003 Revision 4 February 07, 2014 Expon Conltolled ECCN: 9E991 - BOEING PROPRIETARY· Coll)'tighl Cl Unr,wli"""' WQtfc • Seo Pillg41 1tor d0lail$ 777-78-0051 48 of 69

### BOEING SERVICE BULLETIN 777-78-0051

FORWARD AND AFT PLUG



### TYP I CAL FORWARD 

## A PLUG

FORWARD PLUG 1 /4 INCH DIAM ETER HOLE (33 LOCAT IONS)



### FIGURE 4 : TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER BOLTS WITH 1 /4 INCH DIAMETER BOLTS Original Issue: October 23, 2003 Revision 4 February 07, 2014 (SHEET 1 OF 6) Expon Controled ECCN . 9£991 - BOEING PROPRJETARY • Copyflgh10 Unpublishea WOl"k • See page 1 for deta,ls 

### 777 -78-0051 

### 49 

## o r 69BOEING SERVICE BULLETIN 777-78-0051

FORWARD PLUG 0 .40 (2 LOCATIONS) 0 . 125 

# I

4 .500

BOTIOM DEA D CENTER - · 

# _ _

l

_ _ _

____ +-

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY· REPLACEMENT OF ALL 33 3 / 16 INCH DIAMETER BOLTS WITH 1 /4 INCH DIAMETER BOLTS Origina l I ssue: October 23 , 2003 Revision 4 February 07 , 2014 (SHEET 2 OF 6 ) E, pon ContlOlod ECCN , 9€99 1 • 80El'1G PROPRI ETARY • CopyrightO Unpublished Work . SOo pogo 1fof d e(affs 777-78-0051 50 of69BOEING SERVICE BULLETIN 777-78-0051



# c AFT PLUG 

### 0.40 (2 LOCATIONS)

O 

# l**~** 4.50 BOTTOM DEAD CENTER -- 0 

# - l _____

0 0.39

-- o-1 0

FIGURE 4 : TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS Origina l Issue: October 23, 2003 Revision 4 February 07. 2014 (SHEET 3 OF 6) Expon Conlrolled ECCN 9E991 • BOEING PROPRIETARY • Copynght C Uni,ubbhed 

### w~· 

### soo paoo 1 to, d01$JI• 777-78-0051 51 

### of 69BOEING SERVICE BULLETIN 777-78-0051 The step numbers shown below agree with the numbers shown in the circle symbols In the figure . The QTY numbers shown below are the number of parts necessary for each turbine exhaust plug assembly.**~** If this Figure is used for a turbine exhaust plug assembly Identified with part number 314W5520-1 or 314W5521 - 1, Steps 8 thru 11 are not necessary. Step Task Name Identification Qty More Data

1 Install (Temporary) 3/16 I NCH D IA FAS- ST30-7216A-200-216- 5 i n the In terface holes TENER 1 . 0 ('WEDGELOCK') of the aft plug and OR EQUIVALENT the forward p l ug . (a) WABt:llt:lG ; USE CARE W H EN DRILLING IN TITANI UM . SMALL PARTICLES AND FINE SHAVINGS OF T IT ANIUM ARE H I GHLY FLAMMABLE . WATER W ITH HOT TITAN I UM CAN CAUSE A STEAM EXPLOSION . EXTINGUISH ALL F I RES OF TITAN I UM W ITH FULLY DRY TALC. CALC I UM CARBONATE , SAND, OR GRAPHITE . APPLY T HE POWDER TO A DEPTH OF ONE-HALF INCH OR MORE OVER THE BURN I NG METAL. DO NOT USE FOAM, WATER, CARBON TETRACHLORIDE . OR CARBON DIOXIDE . I F YOU DO NOT OBEY, INJURY TO PERSONS CAN BE CAUSED. 2 Ream HOLE 

# - 1 to 1 /4 inch diameter. Class 

### Ill hole . Use Step Reamer part number ST1864R2820-2550-4-221-4- 64-2-4, or equlvalen t, between the first and 

### fifth 'wedgelocks' to remove damage up to the repair limit , or to increase Its diameter to 1/4 inch . (c) 3 Inspect HOLE 

# - 1 that was reamed, by general visual inspection, to make sure there Is no damage. 4 I ns tall (Temporary) 1/4 INCH D IA FASTEN- ST30-7216A-200-279- 1 i nto the repaired or ER 1 . 0 ('WEDGELOCK') i ncreased diameter OR EQUIVALENT hole. (a) 5 Remove 

### I Keep 3 / 16 INCH DIA FAS- ST30-7216A-200- 216- 

### 5 that were temporariTENER 1.0 ('WEDGELOCK') ly Installed . (a) OR EQUIVALENT

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL 33 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS Origi nal Issue : October 23, 2003 Revisi on 4 February 07. 2014 (SHEET 4 OF 6) Expon Con110H e<1 ECCN 9E991 • B OEING PAOPRI ET AA Y • Copyrll)tl 1C l.h\ pubhhed Wort. • SN pago 1 ( Of" Otlail 777-78-0051 52 of 69BOEING SERVICE BULLETIN 777-78-005 1 Step Task Name Identification Qty More Data

6 Remove 1/4 INC H DIA FASTEN- ST30·7216A-200-279· 32 that were temporariER 1 .0 ('WEDGELOCK') ly installed. OR EQU IVALENT Remove I Keep AFT PLUG 314W5520-3 OR 1 314W5520- 20 7 Install (New) N UTP LATE BACN11G4DE1F 33 on t he Inn er circumfer ence of the forward pl ug using the existing rivet holes. In stall (New) RIVET MS20427M3-4 66 (d) 

### QA!..!IIQt!!; ADJUST THE IDENTIFICATION TAG POS I TI ONS TO AVOID DRILLING HOLES WITHIN 0.31 INCHES OF A WELD CENTERLINE 8 Pull Hol d I DENTIFICATION TAG 314W5520-23 1 identified for the forward p l ug . (b) Drill / Ream HOLE 

## . 3 0 . 124 • 0 . 128 inch diameter. (c) 9 Install (New) IDENTIFICATI ON TAG 314W552()..23 1 i dentified for the forward plug. I nstall (New) RIVET MS206 15-4 M3 3 (d) 10 Put I Hold IDENTIFICATI ON TAG 314W5520-23 1 Identified for the aft p lug. (b) Drill/ Ream HOLE 

## . 3 0 . 124 • 0 . 128 lnch diameter. (c) 1 1 Install (New) IDENTI FI CATION TAG 314W5520·23 1 I dentified for the aft p l ug. Install (New) RIVET MS20615-4M 

### 3 3 (d) (a) Do not install the 'wedgelocks' (or equivalent 3116 inch diameter temporary fasteners) In a continuous sequence. I nstall the first 'wedgelock' In the hole located sequentially nex t to the hol e that is found to have the largest damage . Install the second 'wedgelock' in the hol e nearest to the circumferential opposite of the first 'wedgelock' Installed . Install the third 'wedgelock' in the hole nearest to the circumferential midpolnl between the first and second 'wedgelocks' . Install the fourth 'wedgelock' In the hole nearest to the circumrerentlal opposite as the third Installed \vedgelock' . I nstall the fifth 'wedgelock' In the hole located sequenUally next to the hole lhat to has the largest damage . After the hole Is reamed and no damage Is found , Install a 114 Inch 'wedgelock' In the repaired or Increased diameter hole . Move the first thru 

### fifth 'wedgelocl<s' clockwise or counter-clockwise to repair the hole with the next largest damage , until five 3116 Inch diameter 'wedgel ocks' cannot be insta ll ed because 1/4 Inch diameter 'wedge l ocks' are Installed . Do steps 1 thru 

### 5 again to repeat this process until 32 holes are filled wilh 1 /4 Inch 'wedgelocks' and all of the 

### 33 holes are repaired and/or increased to 114 Inch diameter . Refer to APPENDIX A for a graphical example of the 'wedgelock' i nstallation process.

FIGURE 4 : TURBI N E EXHAUST PLUG ASSEMBLY · REPLACEMENT OF ALL 33 3116 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS Original I ssue: October 23. 2003 Revision 4 February 07. 2014 (SHEET 5 OF 6) Expect Controled ECCN 9£991 • 80EJNG PROPRIETARY· CopyrlgN C Vnpubll$hod Work: • See page I tor detalla 777-78-0051 53 of 69BOE I NG SERVICE BULLETIN 777-78 -0051 Step ! Tas k 

# I Na me 

# I lde n tlflcatlon 

# I Qty 

# I More Da ta (b) The Identification tag I s to 

### be posi tioned on the side of the stringer where the d i stance between the stri n ger and the s k in chem-m illed area Is maxi mum . but with the mini mum conditi ons that the re i s a 20 ed ge margin between the rivets and the edges of the ident i fication tag and that t here l s a 20 ed ge margin between the rivets and the chem i ca ll y milled area . Refer to 777-200 SRM 54-42 -30 or 777-300 S R M 54-42- 30 for turbine exhaus t pl ug assemb l y details. (c) Refer to SOPM 20-10-07 and 777 -200 SRM 51-30-01 o r 777-300 SRM 5 1 -30-01 Section 5 , as an accepted procedu re . to drill or ream ti tanium . (d) Refer to 777- 200 SRM 51-40-02 or 777..:JOO SRM 51-40-02 as an accepted procedu re .

F IGUR E 4 : TU RB I NE EXHAUST PL U G ASSEMBLY - REPLACEMENT OF A LL 3 3 3/16 I NCH D IAMET ER BO LT S WITH 1/ 4 INCH DIAMETER BOLTS Ori g inal Issu e: Octobe r 23 . 200 3 Re vi si o n 4 February 07, 20 14 (SHEET 

### 6 O F 

### 6) E

JtpOrt Con1rolled E CCN· 9 E 991 - BOE ING PROPRIETARY • Coc,yngh t O Uftpublished Wortc · See PBOe 1 fOf details. 777-78-0051 54 of 69

### BOEING SERVICE BULLETIN n7-78-0051 

# I Th i s Figure applies only to : Group 1 , Configuration 2-3 ; Group 2 .



### A

FORWARD P LUG

ALIGNMENT RIVET 114 I NCH DIAMETER BOLT FORWARD PLUG AFT P LUG TURBI NE E XHAUST

PLUG ASS EMBL Y

FORWARD PLUG AFT PLUG



### FIGURE 5 : TURBINE EXHAUST PLUG ASSEMBLY BOLTS - GENERAL VISUAL INSPECTION (SHEET 1 OF 2) Original Issue: October 

### 23. 2003 Revision 4 February 07, 2014 Expon Controlled ECCN 9E991 , 90£1 NG PROPRIETAAY • CclpytightOLklpubhhed Work • Soo Pl9• 1 for dol.llils 

### 777-78 -0051 

### SS of 

### 69

### BOEING SERVICE BULLETIN 777-78-0051 The step numbers shown below agree wilh the numbers shown In the ci rcle symbols in the figure. The QTY numbers shown below are the nu m ber of parts necessary for each engine.

Step Task Name Identification Qty 

### M ore Data

1 Inspect BOLT 123423·3· 1 OR 33 by general visual I nBACB30UU4-1 spection. at the rorward and aft plug inlerface , to find 1r 3/16 Inch diameter bolts and/or 1 /4 inch diameter bolts are used .

FtGURE 5 : TURBINE EXHAUST PLUG ASSEMBLY BOLTS· GENERAL VISUAL INSPECTION (SHEET 

### 2 OF 

### 2 ) Original Issue : October 23 , 2003 Revision 4 February 07 , 2014 Expon Con1rotled E CCN· 9E991 - SOE ING PROPRIETARY • Cooyrlg.ht O Unpublished Work , .$oe page 1 to, dOU111S 

### 777-78-0051 56of69

### BOEING SERVICE BULLETIN 777-78-0051

FORWARD AND AFT PLUG

TYPICAL FORWARD 

## A PLUG

FORWARD PLUG 1/4 INCH DIAMETER HOLE (33 LOCATIONS. MAXIMUM)



### FIGURE 6 : TURBINE EXHAUST PLUG ASSEMBLY· REPLACEMENT OF ALL REMAINING 3/ 16 INCH DIAMETER BOLTS WITH 1 /4 INCH DIAMETER BOLTS Original Issue: October 23. 2003 Revision 4 February 07. 2014 (SHEET 1 OF 4 ) &Don Coot'°'9d ECCN :9E991 • BOEING PROPRIETARY • Copynghl O Unpubbthed Work • SM OG90 1

### tot dOt.HS. 

### 777 -78-0051 57 of 69BOEING SERVICE BULLETIN 777-78-0051 The step numbers shown bel ow agree with the numbers shown i n the ci rcle symbol s I n the figure . T he Q TY numbers shown be low are the numbe r o f parts necessary for each turbi ne exhaust plug assembly.

Step Task Name Identification Qty More Data

1 Install (Temporary) FASTENER 

# . 5 Use 3116 Inch diameter fastener, ST30- 7216A-200-216- 1 .0 (Wedgelock' ) or equivalent , in the In· terface holes of the aft p l ug and the forward p lug , that do not have a nutplate . Or, use 1 /4 Inch di· ameter fasteners i n the Interface holes of the aft pl ug and the forward plug that have a nutplate . (a) WABl:llt!~ ; USE CARE WHEN DR I LLING IN TITAN I UM . SMALL PARTICLES ANO FINE S HAVINGS OF T ITANIUM ARE HIGHLY FLAMMABLE . WATER WITH HOT TITAN I UM CAN CAUSE A STEAM EXPLOSION . EXT INGUISH ALL F I RES OF TITAN I UM W IT H FULL Y ORY TALC , CALCIUM CARBONATE , SAND, OR GRAP H ITE . APPLY THE POWDER TO A DEPTH OF ONE-HALF INCH OR MORE OVER THE BURN IN G METAL. DO NOT USE FOAM , WATER , CARBON TETRACHLORIDE, OR CARBON DIOXIDE . I F YOU DO NOT OBEY , INJURY TO PERSONS CAN BE CAUSED . 

### 2 Ream HOLE 

### . 1 to 1/4 inch diameter, Class Ill hol e . Use S tep Reamer part number ST1864R2820-2550-4 · 221-4- 64- 2-4, or equlval ent. between the first and fifth ' wedgel ocks' , or first and fifth 1 /4 Inch diameter temporary fasten ers, to remove d a mage up to the r epair limit , or to I ncrease Its diam eter to 1 / 4 Inch . ( b) 3 Inspect H OL E 

# - 1 by general v i sual Inspec U on. to make sure there Is no damage . FIGURE 6: TURBI NE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL REMAINING 

### 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER SOL TS O rig i nal Is sue: O cto ber 2 3. 2003 R evi sion 4 Fe bruary 07, 2 0 14 (SHEET 2 OF 4) E.xpon Con1t016d ECCN 9E99 l • BOE ING PROPRIETARY • Copyright O Unpobbhed W0tk • Soe P11V8 1 fot detail& 777-78-005 1 5 8 of 69

### BOEING SERVICE BULLETIN 777-78-0051 Step Task Name Identification 

### Qty More Data

4 

### Install (Temporary) 1/4 INCH DIA FASTEN · ST30-7216A-200-279· 1 l nlo the repaired or ER 1 .0 ('WEDGELOCK ') Increased diameter OR EQUIVALENT hole . (a) 5 Remove 

### I Keep FASTENER 

### . 5 3/16 Inch diameter fasteners. ST30· 7216A-200-216·1 .0 (Wedgelock·) or equivalent, Uial were temporarily i nstalled. Or , 1 /4 inch diameter fasteners lhat were temporarily Installed. (a) 6 Remove FASTENER 

## . 32 1/4 Inch diameter fasteners , ST30· 7216A-200-279-1 . 0 ('Wedgelock') or equivalent, that were temporarily Installed . Or, 1/4 Inch dlameter fasteners that were temporarily In · stalled . Remove 

### I Keep AFT PLUG 31 4W5520-3 OR 1 314W5520-20 

### 7 Install (New) NUTPLATE BACN11G4DE1 F 

### . as necessary, al all remaining locations that do not have nutplates for 1/4 Inch diameter bolts, on the inner circumference or the forward plug, using the existIng rivet holes. Install (New) RIVET MS20427M3-4 

### . as necessary, two lor each nulplale . (c)

FIGURE 6 : TURBINE EXHAUST PLUG ASSEMBLY· REPLACEMENT OF ALL REMAINING 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS O ri ginal Issue. October 23, 2003 Revision 

### 4 February 07, 2014 (SHEET 3 OF 4) E.l:por1 Controlled ECCN· 9£99 1 - 80ElNG PROPRIETAAY • Copyngh1 C UnpublltMCI Work - See page 1 f or detail~ 

### 777-78-0051 59 of 69BOEING SERVICE BULLETIN 

### 777-78-0051 Stop ! Task 

# IName 

# IIdentification 

# I Qty 

# I More Data (a) Do nol Install the 'wedgelocks' (or equivalenl 

### 3/16 inch diameter temporary fasteners) or temporary 

### 1/4 inch diameter fasteners In a continuous sequence. I ns tall the first •wedgelock·.1n lhe hole localed sequenHally next to lhe hole l hal is found to have lhe l argesl damage or that is remaining at 

### 3/16 inch diame ter. or install the firs t temporary fastener In the equivalently located 

### 1/4 inch diameter hole . I nstall the second 'wedgelock· in the hole nearest to the circumferenti al opposite of lhe firsl 'wedgelock' In stalled, or insta ll l he second temporary fa stener in the equiva l ently locat ed 

### 1/4 inch diameter hole . Install the third 'wedgelock· In the hole nearest to the circumferential midpoint between the flrs t and second 'wedgelocks·. or install the third temporary fastener In the equlval enlly l ocated 

### 1/4 I nch diameter hole. Install the fourth 'wedgelock· in the hole nea re st to lhe circumferential opposite as the third installed ·wedge l ock·. or inslall the fourth temporary faslene r In the equivalently located 

### 1/4 Inch diamet er hole. Install the fifth 'wedge l ock· in the hole l oca ted sequentia ll y next to lhe hol e that to has t he largest damage. or Ins tall the fifth temporary fastener in the equiva l ently l ocated 

### 1/4 i nch diameter hol e. After l he hole Is reamed and no damage Is found. Install a 

### 1/4 i nch 'wedgelock' In the repaired or Increased diamete r hole . Move the first thru fifth 'wedgelocks' , or the first thru fifth 

### 1/4 Inch diameter temporary fast ene rs clockwise or counter-cl ockwise to repair the hole with the next l argest damage and/or increase i ts diamet er to 1/4 Inch, until 5 'wedgelocks' cannot be Installed because 

### 1 /4 inch d i ameter wedge l ocks or 

### 1/4 inch diamete r temporary fast eners are Installed . Do steps 

### 1 lhru 

### 5 again to repeat this process unti l 

### 32 fastene r holes are filled with 

### 1/4 inch di· a meter 'wedgelocks' or 

### 1/4 Inch diameter temporary fasteners and all of the 

### 33 fastener hol es are repaired and/or Increased to 

### 1/4 Inch diameter. Refer to APPENDIX B for a graphical example of the 'wedgelock' and/or temporary fastener Insta llation process. (b) Refer to SOPM 

### 20-10-07 and 

### 777-200 SRM 

### 51-30-01 or 

### 777-300 SRM 

### 51-30
- 01 Section 

### 5, as an accepted procedure, to drill or ream titanium . (c) Refer to 

### 777-200 SRM 

### 51-40-02 o r 

### 777-300 SRM 

### 51-40-02 as an accepted procedure.

FIGURE 

### 6: TURBINE EXHAUST PLUG ASSEMBLY. REPLACEMENT OF ALL REMAINING 

### 3/16 INCH DIAMETER BOLTS WITH 

### 1/4 INCH DIAMETER BOLTS Original Issue: October 

### 23 , 2003 Revision 

### 4 February 

### 07, 2014 (SHEET 4 OF 4) EJlpon COI\IIOllod ECCN 9E991 · BOEING PROPRIETARY - Copyng:hl C Unpu~ WO,,. - See c,age t fof delais 

### 777-78-0051 60of 69BOEING SERVICE BULLETIN 777 -78-0051 

### A

FORWARD PLUG

1/4 INCH DIAMETER HOLE

TYP ICAL

FIGURE 7 : TURBINE EXHAUST PLUG ASSEMBLY· FORWARD PLUG , 1/4 INCH DIAMETER NUTPLATE REPLACEMENT Original I ssue : October 23. 2003 Revision 4 February 07 , 2014 (SHEET 1 OF 2) E~CoMrolled ECCN 9E991 - 80EIN0 PROPRIETARY· Cov,nght O Unpubbned Wol'k - See page l for deialll. 777-78-0051 

### 61 of 

### 69

### BOEING SERVICE BULLETIN 777-78-0051 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 

### fo r each nut plate locaUon ol a turbine exhaust plug assembly .

Step Task Name Identification Qty More Data

1 Remove RIVET MS20427M3-4 2 Refer to 777 -200 SRM 51-40-02 or 777-300 SRM 51- 40-02 as an accepted procedure. Remove NUTPLATE BACN11G4DE1F 1 

### 2 Install (New) NUTPLATE BACN11G40E1F 1 Install (New) RIVET MS20427M3-4 2 Reier to 777 -200 SRM 51-40-02 or 777-300 SRM 51- 40-02 as an accepted procedure.

FIGURE 7: TURBINE EXHAUST PLUG ASSEMBLY. FORWARD PLUG , 1/4 INCH DIAMETER NUTPLATE REPLACEMENT Original Issue: October 23. 2003 Revision 4 February 07, 2014 (SHEET 2 

### OF 2) E~Conlrolld ECCN · 9E991 - BOEING PROPRIETARY - Copyrigh1 C Unpubl!Shed Work· See pagec 1 lor det.aJIJ.. 

### 777-78-0051 

### 62 of 

### 69BOEING SERVICE BULLETIN 777-78-0051

AFT PLUG

0

BOTIOM DEAD CENTER -- 

## o------

0

0

FIGURE 8 : TURBINE EXHAUST PLUG ASSEMBLY • FORWARD AND AFT PLUG IDENTIFICATION TAG REPLACEMENT Original I ssue: October 23, 2003 Revision 4 February 07, 2014 (SHEET 1 OF 3) Expon Consroled ECCN 9€99t• SOEJNG PROPAIEiARY • Copyright O Unpublished Work • See page I 

# '°' 00111ds 777-78-005 1 

### 63o F 69BOEING SERVICE BULLETIN 777 -78-0051

FORWARD PLUG



### 1 2
BOTIOM OEA O CENTE R -· 

# -------------- +--

FIGURE 8 : TURBINE EXHAUST PLUG ASSEMBLY· FORWARD AND AFT PLUG IDENTIFICATION TAG REPLACEMENT Origina l I ssue: October 23, 2003 Revision 4 February 07, 2014 (SHEET 2 OF 3) Expon Controlled ECCN 9E991**~** BOE ING PROPRIETAAY · Copyngl\10Unpubli$h0d Work**~** 500 P$QO 1 IOt CI01t1ils 777-78- 0051 64 

### of 69

### BOEING SERVICE BULLETIN 777-78-0051 The step numbers shown below agree with the numbers shown i n the circle symbols I n the figure . The QTY numbers shown below are the number o f parts necessary for each turbine exhaust pl ug assembly.

Step Task Name Identification 

### Qty More Data

1 Remove RIVET MS20615-4M3 6 Refer to 777·200 SRM 51-40·02 or 777 · 300 SRM 51 · 40-02 an accepted procedure. Remove IDENTIFICATION TAG 314W5520-23 2 that were i ncorrectly Identified with 'Assy 314W5520·1' . 

### 2 I nstall ( New) IDENTI F I CATION TAG 314W5520-23 2 o ne on the forward plug and one on the aft plug . (a) Install ( New) RIVET MS20615-4M 3 6 lhree for each identificallon 

### tag . Refer to 777-200 SRM 5 1- 40-02 or 777 ·300 SRM 51 ·40-02 an accepled procedure . (a) (a) Make sure lhe idenlification tag Is located on lhe s ide of the stringer where lhe distance between the Slringer and the skin che m-milled area Is maximum . bul with the minimum conditions that there Is 

### a 20 edge margin between the rive ts and the edges 

### of lhe Identification lag and lhat there Is a 2D edge margin between the rivets a nd the chemica lly milled area .

FIGURE 8: TURBINE EXHAUST PLUG ASSEMBL 

### V • FORWARD AND AFT PLUG IDENTIFICATION TAG REPLACEMENT Original Issue: October 23 , 2003 Revision 4 

### February 07. 2014 (SHEET 3 OF 3) E,:pcw, COmtoUod ECCN 9E991 • BOEING PROPRIETARY · Covfnvht C ltopubhhed \York • See page 1fOf dm&Js 

### 777-78- 0051 

### 65 o f 

### 69

## A BOEING SERVICE BULLETIN 777-78-0051

<..) 

# ---~

FORWARD PLUG 

# 0 1 AFT PLUG
TURBINE EXHAUST

PLUG ASSEMBLY



### FIGURE 9 : TURBINE EXHAUST PLUG ASSEMBLY -INSTALLATION (SHEET 1 OF 2) O rigina l Issue: October 23, 2003 Revision 4 February 07, 2014 £,pon COnttoilO<I ECCN 9E991 , BOEING PROPRIETARY· Col>yrighl C Uo-oned Wo,',. • See page 1 tor details 

## 1n-1a.oos1 6 6 o(69

# I 

# I I BOEING SERVICE BULLETIN 777-78-0051

The step numbers shown below agree with the numbers shown i n the circle symbols in the figure . The QTY numbers shown bel ow are the number of parts necessary for each engi ne .

Step Task Name Identification 

### Qty More Data



### 1

( a) Install (Changed) TURBINE EXHAUST 314W5521 - 1 

### 1 If applicable. (a) PLUG ASSEMBLY I nstall (New) TURBINE EXHAUST 314W5520-22 1 If applicable. (a) PLUG ASSEMBLY Install (Kept) TURBINE E XHAUS T 314W5520-22 1 If applicable. (a) PLUG ASSEMBLY Install (New) BOLT BACB30UU4-1 33 If applicable. (a) Install ( Kept) BOLT BACB30UU4-1 33 If applicable. (a) Torque BOLT BACB30UU4-1 33 73 - 83 inch-pounds. Refer to 777 AMM 78-11--02 as an accepted procedure . During lnslallation , make sure there 

### ls 5 . 0 Inchpounds or 

## more of run-on torque for each of the bolts related lo nutplates of the forward plug . at the forward and aft plug I nterface.

FIGURE 

### 9: TURBINE EXHAUST PLUG ASSEMBLY - INSTALLATION (SHEET 2 OF 2) O rig i na l I s sue: Ociobe r 23, 200 3 Revis ion 4 February 07 , 201 4 Expon CM1rolod ECCN . 9E 99t • BOEI NG PROPAIETARY • Cc)p)'tlvhl O lMPU~ Worle • SOo l)8VO 1 ICH' dotllb 777-78-0051 

### 67 of 69BOEING SERVICE BULLETIN 777-78·0051 F I RST3116 INCH DIAMETER WEDGELOCK POSITION AFT PLU G THIRD 3/16 INCH DIAMETER WEDGE LOCK POSITION O O C 0

FORWARD ANO AFT PLUG FORWARD PLUG 

### 0 

### 0

0 0 

### 0

SECOND 3/16 INCH 

### I DIAMETER WEOGELOCK POS ITION 0 

# A-A F IRST HOLE REPA I R · EXAMPLE 

# • • 

# • LAST HOLE TO BE REPAIRED ANO /OR INCREASED TO 114 INCH D IAMETER FIRST HOLE WITH LARGEST DAMAGE FIFTH 3/16 I NCH DIAMETER WEDGELOCK POSITION 

## 0 0

FOURTH 3/16 I NCH DIAMETER WEOGELOCK POS ITION

32 114 INCH DIAMETER WEDGELOCKS INSTALLED - ._--- 1 14 INC H DIAMETER 

# • •

A-A WEDGE LOCK IN F IRST •· REPAIRED FASTENER • HOLE



# •



# • • 

# •

LAST HOLE REPAIR OR DIAMETER IN CREASE·EXAMPLE

APPENDIX A: 'WEDGELOCK' FASTENER INSTALLATION PROCESS FOR THE REPLACEMENT OF ALL 33 3/16 INCH DIAMETER BOLTS WITH 

### 1/4 INCH DIAMETER BOLTS Original Issue: October 

### 2 3, 2003 Revision 

### 4 February 07 , 

### 2014 (SHEET 1 OF 1) E.x.pon Controlled ECCN 9E001 • SOEtNG PAOPAIETARV · Copvrlght O Unpublished Work • See p.19& \ tor details 777-78-0051 68 oreg

### BOEING SERVICE BULLETIN 777-78-0051

FORWARD ANO AFT PLUG THIRD 3116 INCH WEDGELOCKOR 114 I NCH DIAMETER TEMPORARY FASTENER POSITION

FORWARD PLUG 

### 0 

## 0

0 0

SECOND 3116 INCH WEDGELOCKOR 1 /4 INCH - - _,.,~ DIAMETER TEMPORARY FASTENER POSITION 

### I FIRST 31 16 INCH WEOGELOCKOR 114 INCH DIAMETER TEMPORARY FASTENER POSITION

0 FIRST HOLE WITH LARGEST DAMAGE ORTO BE I NCREASED TO 1/4 I NCH DIAMETER FIFTH 3116 INCH WEOGELOCKOR 1/4 I NCH DIAMETER TEMPORARY O FASTENER

O POSITION 

### 0 0

0 

# A-A FOURTH 3116 INCH WEOGELOCKOR 114 I NCH D IAM ETER TEMPORARY FASTENER POSITION FIRST HOLE REPAIR OR DIAMETER 32 1/4 INCH DIAMETER WEDGE LOCKS OR TEMPORARY FASTENERS INSTALLED



### I 

# • INCREASE · EXAMPLE 

### • e • LAST HOLE TO BE REPAIRED AND/OR I NCREASEDTO 1/ 4 I NCH DIAMETER



# A-A 1 / 4 INCH DIAMETER WEOGELOCK IN F IRST REPAIRED OR • INCREASED DIAMETER FASTENER HOLE 

# • I

LAST HOLE REPAIR OR DIAMETER INCREASE ·EXAMPLE



### APPENDIX B: 'WEDGELOCK' AND TEMPORARY FASTENER INSTALLATION PROCESS FOR THE REPLACEMENT OF ALL REMAINING 3116 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS (SHEET 1 OF 1) 

### Original Issue: October 23, 2003 Rev1s1on 4 

### February 07. 2014 E¥00tt Controlfed ECCN 9€991 • BOEING PROPRIETARY • COOynghl O Unpubli1h0d Work • Soo p;e,g41 t for clotolls 

### 777-78-0051 

### 69 of 

### 69