• 

({)._BOEING 

Commercial 

Airplanes 

Number: 

Original Issue: 

Revision 4: 

ATA System: 

SPECIAL ATTENTION 

777-78-0051 

October 23. 2003 

February 07, 2014 

7811 

777 

Service Bulletin 

SUBJECT: EXHAUST (TRENT 800 Series Engines) - Collector/Nozzle· Turbine Exhaust Plug 

Assembly - Inspection and Retrofit 

Export of this technology Is controlled under the United States Export Administration Regulations (EAR) (15 

CFR 300-774 ). An export license may be required before it Is used for development. production or use by foreign 

persons from specific countries. The controller of this data has the individual responsibility to abide by all export 

laws. 

ECCN: 9E991 

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET 

Copyright © 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Unpublished Work.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 basis and such rights may not be transferable. For more information, contact The 

Boeing 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 unless provided in writing by Boeing. 

Original Issue: October 23, 2003 

Revision 4 : February 07. 2014 

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... 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 

BOEING SERVICE BULLETIN 777-78-0051 

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Table of Contents 

Revision Transmittal Sheet . . . . . . . • • . . • . . . . • • . • . . . . • • . • • . • . . • . , • . . . • . . . 5 

Summary ...•.•...... .. . .. .. . • .......... . .. . .. . .. . ............. 7 

1. PLANNING INFORMATION ...••.••..• . •..•• . •..•• .• . . ••.....••.... 13 

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

1. Airplanes . . . . . • • • • • • • • . . . . • • • . • . • . . . . . • . • • • • • • . . • . . . • 13 

2. Spares Affected . . . . . . . • . . . . . . . . . . . . . . • . . • . . . . . . . . . . . . . • 15 

B. Concurrent Requirements . . • • . . . . . • . . • . . • . . • . . . • • • • • • • • . • • . • • . • 16 

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

D. Description . • . . • . . . . . . . . . . • . . . . . . . . . . . . . . • . . . . • . . • • . . • • . • 17 

E. Compliance • . . . . . . . . . . . • . . • • . • . • • . . • • • • • . • . . • . . . . . . . . . • . • 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 Bulletin: . . . . . . . . . . . . . . . . . . . . • • . • • . • 29 

3. Installation Drawings Used In the Preparation of this Service Bulletin: . . • . . . . • . . . 29 

K. Publications Affected . • • . • . . . . . . . . • . . . . . • • . • . . • • • • • . • • . . . . . . . 29 

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

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

2. MATERIAL INFORMATION . . . . . . • . . • . • . . • • • • . • • • • • . . . . • . . • . • . . . • . • 31 

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

B. Industry 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. Special Tooling - Price and Availability . • . . . . . • . . . • . . • . . . . . . . . • • . . . . . . 35 

F. Speclal Tooling Necessary to do this Service Bulletin . • . • . . • • . . . . • • • . • • . . . • • 35 

3. ACCOMPLISHMENT INSTRUCTIONS • • . . . . . . . . . . . . . . . . • • . • . . . . • . . . . . . 37 

A. GENERAL INFORMATION • • . • • . . • . • • . . . . . . . . . . . . . 37 

B. WORK INSTRUCTIONS • . • • . • . • • . • • . • • . • • . • • . • • . • . • • . . 38 

FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY· NUTPLATE REMOVAL ANO HOLE INSPECTION 

FIGURE 2: 

FIGURE 3: 

FIGURE 4: 

FIGURE 5: 

FIGURE 6: 

PREPARATION . . . . . . . . . . . . . . . . . . . . . • • . • . . . . . . . 44 

TURBINE EXHAUST PLUG ASSEMBLY HOLES · GENERAL VISUAL INSPECTION .. 47 

IDENTIFICATION TAG · DEEP ETCH MARK ....•.•..•..•.••.•••..•• 48 

TURBINE EXHAUST PLUG ASSEMBLY· REPLACEMENT OF ALL 33 3/16 INCH DIAMETER 

SOL TS WITH 1/4 INCH DIAMETER BOLTS • • . . • . . • . . . . . • . . . . . . • • . • 49 

TURBINE EXHAUST PLUG ASSEMBL y BOLTS . GENERAL VISUAL INSPECTION [Group 1. 

Configuration 2-3; Group 2] . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . 55 

TIJRBINE EXHAUST PLUG ASSEMBLY · REPLACEMENT OF ALL REMAINING 3/16 INCH 

DIAMETER BOLTS WITH 114 INCH DIAMETER BOLTS . . . . . . • . • • . • . . •.• 57 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 Expon Conll<>8ed E=· 9£991 • BOEING 

PROPRIETARY· Cc)pyrlQ:ht C Lh\publiantd 

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FIGURE 7: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD PLUG, 114 INCH DIAMETER NUTPLATE 

REPLACEMENT . . • . • . . . • . . • . . • . . . . • . . . . . . . . . . . . . . . . . • • 61 

FIGURE 8: TURBINE EXHAUST PLUG ASSEMBLY - FORWARD AND AFT PLUG IDENTIFICATION TAG 

REPLACEMENT . . • . • • . . . . • • . . • . . • . . • . . • . . . . . • . . . . . . . • • • 63 

FIGURE 9: TURBINE EXHAUST PLUG ASSEMBLY - INSTALLATION •••.••.••.•.... . . 66 

APPENDIX A: 'WEDGELOCK' FASTENER INSTALLATION PROCESS FOR THE REPLACEMENT OF ALL 

33 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH DIAMETER BOLTS .....•.... 68 

APPENDIX B: WEDGELOCK' AND TEMPORARY FASTENER INSTALLATION PROCESS FOR THE 

REPLACEMENT OF ALL REMAINING 3/16 INCH DIAMETER BOLTS WITH 1/4 INCH 

DIAMETER BOLTS • . . • . . • . • • . • • . . • . . . . . . . . . . . . . • . . • • . • • . • 69 

Original Issue: October 23. 2003 

Revision 4: February 07, 2014 Expott ConttOlod ECCN; 9E991 - BOEING 

PROPRlETARY - Copynght O Unpublishoct 

Wot" - See page I fof dtUalfS. 

777-78-0051 

4 of 69 
Commercial 

Airplanes 777 

Service Bulletin 

SPECIAL ATTENTION 

Number: 

Original Issue: 

777 -78-0051 

October 23. 2003 

February 0 7. 2014 

7811 

Revision Transmittal Sheet 

Revision 4: 

ATA System: 

SUBJECT: EXHAUST (TRENT 800 Series Engines) - Collector/Nozzle - Turbine Exhaust Plug 

Assembly • Inspection and Retrofit 

This revision lneludes all pages of the service bulletin. 

COMPLIANCE INFORMATION RELATED TO THIS REVISION 

No more work is necessary on the airplane(s) inspected and changed in accordance with Revision 3 of this 

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 In accordance with the 

Original Issue or Revision 1 thru 3, it is recommend that the data is changed again lo agree with the higher 

values 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 service bulletin effectivity. 

REASON FOR REVISION 

This revision Is sent to add the remaining delivered 777 Rolls-Royce (RR) powered airplanes to the effectlvily 

of this service bulletin. All variants of turbine exhaust plug assembly are fully interchangeable with each other 

and thus maintenance actions could have caused the movement or each turbine exhaust plug assembly between 

airplanes of the 777 RR powered fleet. This condition could result In a configurational difference lo what an 

airplane had when it was originally delivered. 

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 

airplanes added. 

Paragraph 1.A.1 .. Alrplanes: Note changed in relation to the reason for this revision. 

Paragraph 1.E., Compliance: Data for Group 2 airplanes added. 

Paragraph 1.G., Manpower: Appllcablllty for Grot•;J 2 airplanes is added to the table for 'Part 1'. 

Paragraph 1.J.1., Existing Data· Standard Overhaul Practices Manual (SOPM) reference 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 Information: Notes changed to add new data. 

Rgure 5: Applicability changed to add Group 2 airplanes. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 E.oo<I Con,r- ECCN· 9E991 • BOEING 

i>AOP:RIETARY • COpyrlght C Unpubbhod 

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777-78-0051 

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BOEING SERVICE BULLETIN 777-78-0051 

Figure 9: Step table data changed related to the ldentiftcation for the installation of a turbine exhaust plug 

assembly. Footnote (b) deleted. 

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

of important changes. 

Pages with no vertical lines have no important changes. 

REVISION HISTORY 

Original Issue: 

Revision 1: 

Revision 2: 

Revision 3: 

Revision 4: 

Original Issue: Oclober 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 9E99t • BOEING 

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777-78-0051 

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Number: 

Original Issue: 

Revision 4: 

ATA System: 

SUBJECT: 

Commercial 

Airplanes 

SPECIAL A TIENTION 

777 -78-0051 

October 23. 2003 

February 07, 2014 

7811 

777 

Service Bulletin 

Summary 

EXHAUST (TRENT 800 Series Engines) - Collector/Nozzle - Turbine Exhaust Plug 

Assembly • Inspection and Retrofit 

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. 

CONCURRENT REQUIREMENTS 

None. 

BACKGROUND 

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 separation occurrences. The aft plug can 

come off during a separation occurrence which could result in a potential hazard to persons on the ground or 

damage to the airplane. 

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 analysis and It was found that the remaining bolts had less than the 

necessary minimum run-on torque value. II was also found that the operator of the analyzed turbine exhaust 

plug assembly had disassembled 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 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 plug assembly of each engine and install 114 Inch diameter bolts al 

all 33 locations. 

Boeing Service Related Problem (SRP) 777-SRP-78-0071 is related to this service bulletin. 

Boeing Fleet Team Digest (FTO) 777 FTO 78-01002 Is related to this service bulletin. 

This table Is provided lo operators for planning purposes only. Refer to the applicable sections for more 

Information. 

Planning Data 

Spares Affected 

Original Issue: October 23. 2003 

Revision 4: February 07, 2014 

Affected Reference 

Yes Paragraph 1.A.2 .. Spares Affected 

E.xpc,n. COnttolled ECCN: 9E991 • BOEING 

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BOEING SERVICE BULLETIN m-78-0051 

Planning Data Affected Reference 

AD Related Yes Paragraph 1.E., Compliance and Paragraph 

1.F., Approval 

Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes 

Electrical Load Changed No Paragraph 1.1., Electrical Load Data 

Publications Affected Yes Paragraph 1.K .. Publications Affected 

Airplane Flight Operations Affected (Flight Crew 

Operations Manual and/or FAA Approved AirNo Paragraph 1.K., Publications Affected 

plane Flight Manual) 

Kits/Parts Required Yes Paragraph 2.C.1., Kils/Parts 

Operator Supplied Parts/Material Yes Paragraph 2.C.2., Parts and Materials Supplied 

by the Operator 

Special Toolfng Required Yes Paragraph 2.F., Special Tooling Necessary to 

do this Service Bullet.in 

ACTION (PRR 62039) 

Group 2: 

Maintenance Records Check 

1. Check maintenance records to find if maintenance actions have caused the movement of a turbine 

exhausl plug assembly between airplanes, since delivery. If maintenance records identify that an 

installed turbine exhaust plug assembly does not have part number 314W5520-22, or the part number 

of an Installed turbine exhaust plug assembly is not known from the maintenance records, do Part 1. 

If the two Installed turbine exhaust plug assemblies have part number 314W5520-22. no more work Is 

necessary. 

Group 1, Configuration 1: 

Part 1 • Turbine Exhaust Plug • Airplane work 

1. Install a serviceable turbine exhaust plug assembly on each engine with 1/4 inch diameter bolls at all 

33 locations of the forward and aft plug Interface. 

~ A serviceable turbine exhaust plug assembly can be one that Is removed from the airplane 

and subsequently changed in accordance with Part 3, 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 new turbine 

exhaust plug assembly, with part number 314W5520-22. 

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

Part 1 • Turbine Exhaust Plug· AJrpJane work 

1. Do a general visual Inspection of the 33 boll locatlons or the forward and aft plug Interface or each 

turbine exhaust plug assembly or each engine. 

2. If only 3/16 inch diameter bolts are found used, or if a mix of 3/16 Inch and 1/4 inch diameter bolts are 

round used. Install a serviceable turbine exhaust plug assembly on each engine with 1/4 inch diameter 

bolls at all 33 locations of the forward and aft plug interface. 

Original Issue: October 23. 2003 

Revision 4: February 07, 2014 Expo,1 Con .... led ECC,, 9E991 • BOEING 

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BOEING SERVICE BULLETIN 777-78-0051 

~ A serviceable turbine 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 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. 

3. For Group 1 Configuration 2 airplanes only. if only 1/4 inch diameter bolts are found Installed at all 33 

locations. reidentify turbine exhaust plug assembly In accordance with Part 4. 

4. For Group 2 airplanes only, if only 1/4 Inch diameter bolts are found Installed al all 33 locations, inspect 

to find the part number of each turbine exhaust plug assembly and If part number 314W5520·1 ls found, 

reidentify the lurblne exhaust plug assembly 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 the nutplates of 3/16 inch 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 hole(s) lo remove damage and/or Increase the diameter of all 33 holes to 1/4 Inch 

or all remaining 3/16 Inch diameter holes to 1/4 Inch. Install new nutplates for 1/4 inch diameter bolls 

at all 33 locations or at all remaining locations. 

4. For each component Identified with part number 314W5520·1, reidentify the turbine exhaust plug 

assembly in accordance with Part 4. 

5. For each component Identified with part number 314W5521-1, no turbine exhaust plug assembly 

reidentification is necessary. 

Part 3 - Replacement Of All 33 3/16 Inch Diameter Bolts With 114 (nch Diameter Bolts - component 

Work: 314W5520-15. -19: 314W5520-1: 314W5521-1 

1. Remove the nulplates of the 33 3/16 inch diameter bolts from the forward plug holes that interface with 

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 increase the diameter or all 33 holes to 1/4 inch. 

Install new nutplates for 1/4 Inch diameter bolts at all 33 locations. 

4. For each component identified with part number 314W5520-15, -19, part mark and install identification 

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 

PROPRIETARY 4 Copyrlgt,1 Cl Unpublished 

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BOEING SERVICE BULLETIN 777-78-0051 

2. Deep etch mark replacement ldentlficatlon tags and install 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 airplanes. 

Refer to Paragraph 1.A.2 .• Spares Affected for the list or affected components. 

COMPLIANCE 

The Federal Aviation Administration (FAA)will possibly release an Airworthiness Directive related to this service 

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

mandatory. 

Refer to Paragraph 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 

Boeing and Operator Supplied Kits/Parts. 

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

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 Expot1 COnttOllod ECCN· 9E991 • BOEING 

PROPRIETAAV · Copyrigh1 C Unpubished 

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BO EING SERVICE BULLETIN 777-78-0051 

FORWARD 

PLUG 

AFT PLUG 

GROUP 2: 

DO A MAINTENANCE RECORDS CHECK TO FINO IF EACH TURBINE 

EXHAUST PLUG ASSEMBLY HAS PART NUMBER 314W5520·22. IF NOT, OR IT 

IS NOT KNOWN, DO A GENERAL VISUAL INSPECTION OF EACH TURBINE 

EXHAUST PLUG ASSEMBLY TO IDENTIFY ITS CONFIGURATION AND DO THE 

NECESSARY CORRECTIVE ACTION(S). IF THE TWO TURBINE EXHAUST 

PLUG ASSEMBLIES HAVE PART NUMBER 314W5520·22, NO MORE WORK IS 

NECESSARY. 

GROUP 1 CONFIGURATION 1: 

REMOVE ALL 33 3116 INCH DIAMETER BOLTS. DO A GENERAL VISUAL 

INSPECTION OF EACH HOLE AND INCREASE ITS DIAMETER TO 1 /4 INCH 

ANO INSTALL REPLACEMENT 1/4 INCH DIAMETER BOLTS AND NUTPLATES 

AT ALL 33 LOCATIONS. RE·IDENTIFY 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 

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TURBINE EXHAUST 

PLUG ASSEMBLY 

777-78-0051 

11 or 69 
Original Issue: October 23. 2003 

Revision 4: February 07, 2014 

BOEING SERVICE BULLETIN 777-78-0051 

BLANK PAGE 

Expon Controlled ECCN: 9E991 • BOEING 

PROPRIET AAY · Copynght O Unl)t'b!IShed 

\+/CW\ • See pa;e 1 tor del4ilit 

777-78-0051 

12 of 69 
I 

Commercial 

Airplanes 

SPECIAL ATTENTION 

777 

Service Bulletin 

Number: 777 -78-0051 

October 23, 2003 

February 07, 2014 

7811 

Original Issue: 

Revision 4: 

ATA System: 

SUBJECT: EXHAUST (TRENT 800 Series Engines). Collector/Nozzle. Turbine Exhaust Plug 

Assembly • Inspection and Retrofit 

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. 

1. PLANNING INFORMATION 

A. Effectlvlty 

Airplanes 

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 Identified 

In this service bulletin Installed at delivery. lnstallatlon of spare turbine exhaust plug 

assemblies could resull In a configurational difference to what an airplane had when it 

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 4 70, that were delivered with turbine exhaust plug assembly, 

part number 314W5520-15 or -19. Installed. 

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 this 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~ 

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BOEING SERVICE BULLETIN 777-78-0051 

GROUP CONFIGURATION DESCRIPTION 

2 . 

Airplane Models: 

777-200, 777-300 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 

777 ·200/300 airplanes powered by Trent 800 engines from line 

number 4 70 to 796, that were delivered with turbine exhaust plug 

assembly, part number 314W5520-22, Installed. 

Variable Number Group 

WA001 1 

WA086 • WA093 1 

WA101 -WA104 1 

WA196-WA198 1 

WB031 • WB046 1 

WB101 -WB106 1 

WB161 -WB175 1 

WB176 -WB177 2 

WB181 - WB192 1 

WB193 -WB194 2 

WB201 • WB214 1 

WB215 2 

WB231 • WB247 1 

WB416 • WB437 1 

WB438 • WB439 2 

WB446 • WB453 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 Unpubli$hod 

\\lode ~ See poge 1 tor deUJllt 

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BOEING 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 (QEC) kits for parts or components changed as shown in this 

service bulletin. If any parts or components are found, refer to Paragraph 2.C., Parts Necessary 

for Each Airplane, for the recommended use. 

Part Number Serial Number or 

Dash Number 

654W0003-62 C0028, C0029, C0030, 

C0031, C0032. C0041, 

C0042, C0045, C5001, 

C0049,COOSO 

654W0003-3 C0001. C0002 

654W0003-46 C0052 

654W0003·68 C0034. C0035 

654W0003-73 C0043 

654 W0003-18 C0003, C0004 

654W0003-37 C0020 

654W0003-81 C0051 

654W0003-30 C0012 

654W0003-23 C0013, C0014, C0015, 

C0016, C0017 

654W0003-24 C0033 

654W0003-12 C0005, C0006, C0007 

-

654W0003-55 C0027 

654W0003-57 C0036, C0039 

QECRR777 -3, -4 

Examine your spares supply for lhe parts or components Identified below If any parts or components 

are round, refer to Paragraph 3.B .• Work Instructions for the recommended action. 

Part Number 

314W5520-15 

314W5520-19 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 E.l(pctt Controllea ECCN; 9E991 • BOEING 

PROPRIETARY• Copy,lghl C UnpubbNd 

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BOEING SERVICE BULLETIN 777-78-0051 

Part Number 

314W5520-1 (a) 

(a) Existing part number 314W5520-1 could also exist 

because or the instructions in the Original Issue 

or this servioe bulletin. But part number 314W5520· 

1 Is incorrect as the post service bulletin Identity. 

B. Concurrent Requirements 

None. 

C. Reason 

Accomplishment of this service bulletin will make sure the integrity 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 plug can come off during a separation occurrence which could result in a potential 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 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 lurbine exhaust plug assembly was sent back to Boeing for analysis and It was round that 

the remaining bolts had less than the necessary minimum run-on torque value. It was also round that 

the operator or the analyzed turbine exhaust plug assembly had disassembled It a minimum of three 

limes during maintenance actions. Repeated assembly and disassembly causes the locking property 

of the nut on the nutptates to wear out and subsequently let the 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 plug assembly of each engine and Install 1/4 inch 

diameter bolts at all 33 locations. 

Boeing Service Related Problem (SRP) 777-SRP-78-0071 is related to this service bulletin. 

Boeing Fleet Team Digest (FTD) 777 FTD 78-01002 ls related to this 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 the assembly number shown on the Identity tag from 

314W5520-1 to 314W5521-1. This revision also corrects the spelling of the word "Separate," on the 

identification tag, and in 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 

""OPRIETARV · C0oynghl0Unpubll5hed 

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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 latest production configuration. Also this revision corrects a post service bulletin 

Identification relationship error for the forward and aft plug, where the Instructions of the 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 of turbine exhaust plug assembly are fully interchangeable 

with each other and thus maintenance actions could have caused the movement of each 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. Description 

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 

Installed 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 more 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. Install a serviceable 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 turbine exhaust plug 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 

Installed as a set. 

Group 1, Configuration 2·3; Group 2: 

part 1 • Turbine Exhaust Plug • AJrpJane Work 

1. Do a general visual Inspection of the 33 bolt locations of the forward and aft plug interface of each 

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 

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2. If only 3/16 inch diameter bolts are found used, or If a mix 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 interface. 

~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 plug 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 

installed as a set. 

3. For Group 1 Configuration 2 airplanes only. if only 1/4 inch diameter bolls are found installed at 

all 33 locations, reldentlfy turt>ine exhaust plug assembly in accordance with Part 4. 

4. For Group 2 airplanes only, if only 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 inch 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 hole(s) to remove damage and/or increase the diameter of all 33 holes to 1/4 

Inch or all 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 identified with part number 314W5520-1, reldentlfy the turbine exhaust plug 

assembly In accordance with Part 4. 

5. For each component Identified 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 nutplates or the 33 3/16 Inch diameter bolts from the forward plug holes !hat interface 

with the aft plug. 

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

3. Ream the damaged hole(s) to remove damage and Increase diameter or all 33 holes to 1/4 Inch. 

Install new nutplates for 1 /4 inch diameter bolts at all 33 locations. 

4. For each component identified with part number 314W5520-15. -1 9, part mar1< and Install 

Identification tags on the forward and aft plugs to reldenlify the turbine exhaust plug assembly. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 E.xpo,1 Comrolled ECCN; 9E991 • BOEING 

PROPRIET ARV · Copynght O lklpvbbhOO 

Work • See page 1 fo, Cle!ffS. 

777-78-0051 

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BOEING SERVICE BULLETIN 777-78-0051 

5. For each component Identified with 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 plug assembly 

reidentification is necessary. 

Part 4 • Reidentjfjcatlon of the Turbine Exhaust Plug Assembly · Component Work: 314wss20-1 

1. Remove the tags that have an incorrect part number Identification. 

2. Deep etch mark replacement Identification tags and Install one on the forward and aft plug. 

Revision 1 • More work was necessary on airplanes changed as shown in the initial release of this 

service bulletin. Identification tags with the incorrect assembly number should be corrected when 

manpower and facilities 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 this service bulletin. 

Airplanes identified as Group 1 Configuration 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 plug assembly together of each engine, to identify if 3116 inch 

diameter and/or 114 inch diameter bolts are used and, If necessary, install a serviceable turbine 

exhaust plug assembly with 114 inch diameter bolts at all 33 locations of the forward and aft plug 

interface. 

Airplanes identified 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 together of each engine, to 

identify if 3116 mch diameter and/or 1/4 inch diameter bolts are used and, if necessary, Install a 

serviceable turbine exhaust plug assembly with 114 inch diameter bolts at all 33 locations of the 

forward and aft plug interface. Additionally, if only 1/4 inch diameter bolts are found Installed at all 

33 locations, 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. 

Revision 4 - No more work is necessary on the airplane(s) changed In accordance with Revision 3 of 

this 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 in 

accordance with the Original Issue or Revision 1 thru 3, It Is recommend that the data Is changed again 

to agree with the higher values In accordance wl1h this revision. 

The work in this service bulletin is done In the maintenance zone(s) given below. 

Affected Maintenance Zones 

-

Model 

777 -200. 777-300 

Original Issue: October 23, 2003 

Revision 4· February 07, 2014 

Zone 

419, 429 

f .xport ContrOled ECCN: 9£991 - BOE.ING 

PROPRIETARY · Copyng:t'rl O Un,pubished 

WOl'k • See page 1 lo, details. 

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BOEING SERVICE BULLETIN 777-78-0051 

E. Compliance 

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to 

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given In this 

service bulletin mandatory. 

Do the required actions In accordance with Paragraph 3. Accomplishment Instructions. 

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 Time Repeat Interval 

(Not to Exceed) 

All airplanes Install a serviceable tur- Wilhin 60 months . bine exhaust plug assem- after the Revision 

bly on each engine with 3 date of this ser1/4 inch diameter bolts at vice bulletin. 

all 33 locations of the forward and aft plug interrace in accordance with 

Paragraph 3.0 .. Work Instructions. 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 plug 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. 

- The forward plug and aft plug are a matched set. They must be removed and installed 

as a set. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 E.11pon Controltd ECCN 9E991 OOElNG 

PROPRIETARY• Copyrighl Cl Unpublis.hod 

Work , SM pege 1 Sor d"~ilt 

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Group 1, Configuration 2: 

Table 2: Turbine Exhaust Plug Assembly· General YJsyaJ lospectlon of Bolts 

Condition Action Compliance Time Repeat Interval 

(Not to Exceed) 

All Airplanes Do a general visual In- Within 60 months . 

spection of all 33 bolt loca- after the Revision 

lions of each turbine ex- 3 date of this serhaust plug assembly in vice bulletin. 

accordance with Paragraph 3.B., Work lnstructions. Part 1. Step 3., to 

Identify if 3/16 inch and/or 

1/4 inch diameters are 

used at the forward and 

aft plug interface. 

Only 3/16 Inch diameter Install a serviceable tur- Before further . bolts are found used at all bine exhaust plug assem- flight. 

33 locations of the forward bly on each engine with 

and aft plug Interface. 1/4 inch diameter bolts at 

all 33 locations of the forward and aft plug interlace in accordance with 

Paragraph 3.8 .. Work Instructions, Part 1. Step 

3.a.(2). (a) 

A mix of 3/16 and 1/4 Inch Install a serviceable tur· Before further - diameter bolts are found bine exhaust plug assem· flight. 

used at the 33 locations of bly on each engine with 

the forward and aft plug In· 1/4 Inch diameter bolts at 

terface. all 33 locations of the forward and aft plug Interface in accordance with 

Paragraph 3.8., Work In· 

structlons. Part 1. Step 

3.b.(2). (b) 

Only 1/4 inch diameter Reidentify the forward Before further - bolts are found installed 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 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 plug 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. 

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

as a set. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 E.iipon Controlled ECCN. 9£991 • SOEJNG 

PROPRIETARY • Copyrigh1 0 Unpublished 

Wont • See page t Sor details 

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BOEING SERVICE BULLETIN 777-78-0051 

Group 1, Configuration 2: 

Table 2: Turbine Exhaust Plug Assembly · General YJsual Inspection of Bolts 

Condition Action Compliance Time Repeat lnt.erval 

(Not to Exceed) 

(b) 

- A serviceable turbine exhaust plug assembly can be one that is removed rrom lhe 

airplane and subsequenlly 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 exhaust 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. 

Group 1, Configuration 3: 

Table 3: Turbine Exhaust Plug Assembly -General Visual lnspection of Bolts 

Condition 

All Airplanes 

Only 3/1 6 Inch diameter 

bolts are found used at all 

33 locations of the forward 

and aft plug Interface. 

A mix of 3116 and 1 /4 inch 

diameter bolts are found 

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 in- Within 60 months 

speclion all 33 bolt loca- after the Revision 

tlons of each turbine ex- 3 date of this serhaust plug assembly in vice bulletin. 

accordance with Paragraph 3.B .. Work tnstruoUons, Part 1, Step 3., to 

ldenl.ify if3/16 inch and/or 

1 /4 inch diameters are 

used at lhe forward and 

aft plug Interface. 

Install a serviceable tur- Before further 

bine exhaust plug assem- flight. 

bly on each engine with 

1 /4 Inch diameter bolts at 

all 33 locations of the forward and aft plug Interrace in accordance with 

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 

PROPRIETARY· Copyright O Unpubhhed 

Wor\ . See page 1 fol' delds 

Repeat Interval 

(Not to Exceed) 

. 

. 

. 

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BOEING SERVICE BULLETIN 777-78-0051 

Group 1, Configuration 3: 

Table 3: Turbine Exhaust Plug Assembly • General Visual Inspection of sons 

Condition Action Compliance Time Repeat Interval 

(Not to Exceed) 

Only 1/4 inch diameter None. . . 

bolts are found Installed al 

all 33 locations forward and 

aft plug Interface. 

(a) 

- A seivlceable 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 

lurbine exhaust plug assembly thal is changed In accordance with Part 2 or 3. Or It 

can be a new turbine exhaust 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 assembly can be one that is removed from the 

airplane 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 exhaust plug assembly, with part number 314W5520-22. 

- The for.vard plug and aft plug are a matched set. They must be removed and Installed 

as a sel. 

Group 2: 

Table 4: Turbine Exhaust Plug Assembly - Maintenance Records Check and General Visual Inspection of Bolts 

Condition 

All Airplanes 

Maintenance records IdenUfy that the two installed 

turbine exhaust plug assemblies have part number 

314W5520-22. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 

Action Compliance Time 

Do a maintenance Within 60 months 

records check In accor- after the Revision 

dance with Paragraph 4 date of this ser3.B .. Work Instructions to vice bulletin. 

find ii maintenance actlons have caused the 

movement of each turbine 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) 

. 

. 

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BOEING 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 Installed turbine exhaust plug assembly is not known From the 

maintenance records. 

Only 3/16 lnch diameter 

bolts are found used at all 

33 locations or the forward 

and alt plug Interface. 

A mix of 3/16 and 1/4 Inch 

diameter bolts are found 

used at the 33 locations or 

the forward and alt plug Interface. 

Only 1/4 Inch diameter 

bolts are found installed at 

all 33 localions forward and 

aft plug interface and the 

turbine exhaust plug assembly is identified wilh part 

number 314W5520-1 . 

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 of the 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 with Paragraph 

3.8., Work Instructions. 

Part 4, Step 1 and 2. 

EXPO<l ConltOIIIO ecc,,, 9E991 • aoe1NG 

PROPRIETARY• Copytighl C> ~ubl'IJhOd 

wo,k • SOI p;,ge 1 for dotaifs 

Repeat Interval 

(Not to Exceed) 

-

-

-

-

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BOEING 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 Time Repeat Interval 

(Not to Exceed) 

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 forward plug and aft plug are a matched set. 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 regulations and are FAA approved, as well as European 

Avlatlon Safety Agency (EASA)/Joint Aviation 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 or as modified by other approved Boeing 

changes. 

If an airplane has a non-Boeing modlficallon or repair that affects a component or system also affected 

by this service bulletin, the operator Is responsible for obtaining appropriate regulatory agency approval 

before Incorporating this service bulletin. 

G. Manpower 

The tables below 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 Include lost time. These are some examples 

or lost time: 

- Time to adjust to the workplace 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 Expo,, eon .. u .. ECCN 9E991 • BOEING 

PROPRIETARY · Copyttghi C \JnpubllShocl 

Wad. • See page 1 for detrtllt 

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BOEING SERVICE BULLETIN 777-78.0051 

Time to schedule lhe work 

Time to examine the work 

Time to cure the materials 

Time to make the parts 

Time to find the tools. 

Group 1, Configuration 1: 

Part 1 • Airplane Work 

Task Number of Persons 

Deactivate Thrust 1 

Reverser 

Remove Turbine Ex- 2 

haust Plug Assembly 

FIGURE 9 (a) 2 

Activate Thrust Re- 1 

verser 

TOTAL FOR EACH ENGINE 

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) This estimate does nol Include the time to replace nutplales in accordance 

with FIGURE 7, If necessary. 

Group 1, Configuration 2-3; Group 2: 

Part 1 • AJrpJane Work 

Task Number of Persons Task Hours Elapsed Hours 

Deactivate Thrust 1 1.00 1.00 

Reverser 

FIGURE 5 1 1.80 1.80 

Remove Turbine Ex- 2 1.25 0.63 

haust Plug Assembly 

FIGURE 9 (a) 2 1.25 0.63 

Activate Thrust Re- 1 1.00 1.00 

verser 

TOTAL FOR EACH ENGINE 5.30 4.05 

(a) This estimate does not include the time to replace nutplates In accordance 

with FIGURE 7, If necessary. 

fart 2 • Component Work; 314Wss20-1 

Task 

FIGURE 1 

FIGURE 2 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 

Number of Persons Task Hours 

2 8.00 

1 1.80 

Expon Controffed ECCN 9E991 • BOEfNG 

pqQPRiETARV 4 Copyrlgtll C Unput:llithed 

Watte • See page 1 for dOlt:1~ 

Elapsed Hours 

4.00 

1.80 

777-78-0051 

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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 

FIGURE 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 

FIGURE 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 

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 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 Coruroled ECCN. 9E991 ~ SOE.ING 

PROPRIETARY · ~nghl O U,ipubltshed 

Work · See page 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 

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Part 3 • component Work; 314Wss20-1: 314wss21.1 

Task I Number of Persons I Task Hours I Elapsed Hours 

{a) The time to do this task will be less than the estimate values, as they include 

identification tag lnstallalion work which is not necessary in this task for turbine 

exhaust plug assemblies Identified wilh part number 314W5520-1 and 

314W5521·1. 

Part 4 • Component work; 314wss20.1 

Task Number of Persons Task Hours Elapsed Hours 

FIGURE3 , 0.25 0.25 

FIGURE S 1 0.60 0.60 

TOTAL FOR EACH ENGINE 0.85 0.85 

Turbine Exhaust Plug Assembly, forward Plug Nutplate Replacement 

Task Number of Persons Task Hours Elapsed Hours 

FIGURE 7 , 0.20 0.20 

TOTAL FOR EACH NUTPLATE 0.20 0.20 

H. Weight and Balance Changes 

Left And Right Engine Turbine Exhaust Plug Assemblies Changed To Haye All 114 

Inch Diameter Bolts At Their f orward And Aft Plug Interface 

Change In Weight Change In Moment 

Airplane (Pounds) (Pound-Inches) 

All + 1.2 + 1,379.3 

I. Electrical Load Data 

Nol changed. 

J. References 

1. Existing Data: 

a. Engineering Change Memo PRR 62039. 

b. Boeing Service Letter 777-SL-51-013. 

c. Boeing Service Related Problem {SRP) 777-SRP-78-0071. 

d. Service Bulletin Index 0624W001. 

e. Boeing Slandard Overhaul Practices Manual (SOPM) 20-10-07, 20-50-01. 20-50-10. 

Original Issue: October 23, 2003 

Revision 4: February 07. 2014 ExPQl1 Conlrollod ECCN 9E991 • BOEING 

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\\10tk • Seo Pt;O 1 ror doloJs 

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f. 777 Aircraft Maintenance Manual (AMM) 78-11-02, 78-31-00. 

g. 777 Fleet 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 Repair Manual (SRM) 51-30-01, 51-40-02, 54-42-30. 

2. Data Supplied with this Service Bulletin: 

None. 

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

Drawing Number Title 

314W5521 RR AFT EXHAUST PLUG ATTACHMENT INTERFACE, REPAIR 

ANO RETROFIT 

The table above lists applicable drawings used to prepare this service bulletin. The drawings are 

not necessary to make the specified changes, and are not supplied with this service bulletin. The 

drawings may not be applicable to all airplane configurations or operators. 

K. Publications Affected 

1. Publications: 

Publication Chapter-Section 

777 Aircraft Maintenance Manual 78-11 

777 Illustrated Parts Catalog 78-11 

Component Maintenance Manual 78-11 

777 Power Plant Build-Up Manual 71-00 

2. Damage Tolerance Based Structural Inspections: 

Boeing has evaluated the repairs and/or changes In this service bulletin for effects on Fallgue 

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

Maintenance Program. This service bulletin does not affect FCS, therefore DTls are not necessary. 

L. Interchangeability and lntermlxabllity of Parts 

Accomplishment of this service bulletin does not affect Interchangeability or intermlxablllty or parts. 

M. Software Accomplishment Summary 

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 69 
Original Issue: October 23, 2003 

Revision 4: February 07, 2014 

BOEING SERVICE BULLETIN 777-78-0051 

BLANK PAGE 

£..,.an Conttoled ECCN. 9E991 · BOEJNG 

PAOAAIE1' ARY• CowlQhl C UopubliShed 

Wof'lt. Seo pogo 1 fordOUtila 

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BOEING SERVICE BULLETIN 777-78-0051 

2. MATERIAL INFORMATION 

A. Material • Price and Availability 

Boeing can supply the kits shown In Paragraph 2.C., Parts Necessary for Each Airplane and Paragraph 

2.D., Parts Necessary to Change Spares. Operators are encouraged to share schedule requirements 

with Boeing ror incorporation of the service bulletin. The kits are subject to the terms and conditions of 

the Boeing standard purchase order acknowledgment. Prices are In United States Dollars. Terms: Net 

30 days. 

Reference this service bulletin and submit your purchase order by one of these methods: 

1. Order on-line via ATA Spec 2000 or The Boeing PART Page 

2. Fax to (206) 662-7145 

REFER TO THE BOEING PART PAGE ON MYBQEINGFLEET,COM OR CONTACT FIRST RESPONDER 

AT FR@BOEING.COM FOR THE LATEST REORDER LEAP TIME (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 Airplanes, Trent -800 Powered 567 $7, 198 

005W3246-2 Subkil, Engine 553 $3,599 

B. Industry Support Information 

Boeing warranty remedies are not available for the Inspection and/or repair procedures given In this 

service bulletin. 

C. Parts Necessary for Each Airplane 

1. Kits/Parts: 

To get the kits/parts shown below, refer to Paragraph 2.A .. Material - Price and Availability. 

~ One top kit and the items shown In Paragraph 2.C.2 .• Parts and Materials Supplied by 

the Operator, as applicable, are necessary ror each airplane. 

Part 3 • Component Work: 314wss20-1s. -19 

Kit 005W3246 

New Part Number QTY 

-2 

005W3246-1 

005W3246-2 . 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 

Name 

·1 

. Top Kit. Airplane 

2 Subklt. Engine 

Expon Conltelod ECCN 91:991 • BOEING 

PROPRIETARY • Cowlgl\l C Unj)uWork • Sff p,oe, t tor Cl«alls 

Existing Part 

Number 

Notes 

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BOEING SERVICE BULLETIN n7-78-0051 

Part 3 • Component work: 314W5520-15. -19 

Kit 005W3246 

New Part Number QTY Name Existing Part Notes 

-2 -1 Number 

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) If grip 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 Supplied by the Operator: 

The following parts or materials are necessary to do the change in this service bulletin. Parts and 

materials In the manuals given 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 Number I QTY Name Notes 

Specification 

BACN11G4DE1F 64 Nulplate. Self-Locking Maximum quantity. Adjust 

as necessary. 

MS20427M3-4 128 Rivet Maximum quantity for two 

for each nutplate. Adjust as 

necessary. (a) 

BACB30UU4· 1 64 Bolt Maximum 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 

Onglnal Issue: October 23, 2003 

Revision 4; February 07, 2014 

I Subkit, Engine 

E.x;port Cooltollod ECCN 9E991 • BOEING 

PROPRIET AAY - Copyright O Unpubli&hed 

Work - See JM198 1 to, detaifs 

Notes 

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Part 3 • Component Work: 314W5521-1 

Part Number I QTY Name 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 Number I QTY Name Notes 

Specification 

314W5520·23 4 Identification Tag 

MS20615-4M3 12 Rivet (a) 

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

3. Parts Modified and Reidentified: 

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

number of parts changed on each airplane. 

Existing Part QTY Name New Part Number Notes 

Number 

314W5520-15 or 2 Primary Plug Assy 314W5521-1 Referred to as 'Tur314W5520-19 bine 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 bulletin. 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. 

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BOEING 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 

Paragraph 3.6 .• Work Instructions. Part 2. 3 or 4, as applicable. 

To get the kits shown below. for each turbine exhaust plug assembly, refer to Paragraph 2.A.. Material 

- Price and Availability. 

Part 2 -component work: 314wss20-1 

Part Number Name 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 Name QTY 

BACN11G4DE1F Nulplate, Self-Lock- 32 (maximum) 

Ing 

MS20427M3-4 Rivet 64 (maximum) 

BACB30UU4-1 Bolt 32 (maximum) 

Part 3 • component Work: 314wss20-1s. -19: 314wss20-1 

Kit Number Name 

005W3246-2 Subkit, Engine 

Part 3 • Component Work· 314wss21.1 

Part Number Name 

BACN11G4DE1F Nutplate, Self-Locking 

MS20427M3-4 Rivel 

BACB30UU4-1 Bott 

Original Issue: October 23, 2003 

Revision 4. February 07, 2014 Expo,, ConllOiled ECCN. 9E991 , BOEING 

PROPRIET AAY • Copyrlgl'l1 0 Unpubkhocl 

\

0

JOC\ • Sot page 1 tor dtlnfl 

QTY 

1 

QTY 

33 

66 

33 

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BOEING SERVICE BULLETIN n7-78-0051 

Part 4 • component work: 314wss20-1 

Part Number Name QTY 

314W5520-23 Identification Tag 2 

MS20615-4M3 Rivet 6 

E. Special Tooling • Price and Availability 

The operator can supply the tools shown In Paragraph 2.F., Special Tooling Necessary to do this 

Service Bulletin. Tool price and supply data are not given. 

F. Special Tooling Necessary to do this Service Bulletin 

To get the tools shown below. refer to Paragraph 2.E .. Special Tooling· Price and Availability. 

Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References. can also be 

necessary. Examine operator tool supply to make sure ail necessary tools are available. 

Part Number Name 

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 equivalent 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 Department, 

P.0 .Box 3707, Seattle, WA 96124-2207, USA. 

(b) A quantity of 32 are necessary. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 E...pon Controlled ECCN 9E991 4 BOEING 

PROPRIETARY· Cos)ynoht C Uni,ubbhed 

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BOEING SERVICE BULLETIN 777-78-0051 

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PROPRIETARY - Copynght O Unpublished 

Wont - See page 1 lo, dota~s 

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BOEING SERVICE BULLETIN 777 -78-0051 

3. ACCOMPLISHMENT INSTRUCTIONS 

A. GENERAL INFORMATION 

CAUTION: KEEP THE WORK AREA. WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL 

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, 

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE 

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR 

OTHER ELECTRICAL DAMAGE. 

~ 1. Manual lilies are referred lo by aCfonyms. Refer lo Paragraph 1.J., References, for 

definition or the aCfonyms. 

2. Obey all of lhe warnings and caullons given in lhe specified manual 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 differently, these dimensions and tolerances are used: 

Linear dimensions are in inches 

Tolerance on linear dimensions, olher than rivet and bolt edge margins, is plus 

or minus 0.03 inch 

Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch 

Angular tolerance Is plus or minus 2 degrees 

Hole dimensions for standard solid rivets and fasteners are in Structural Repair 

Manual (SRM) Chapter 51 

Torque Values: 

Values for struclural fasteners are given In 777 Slructural Repair Manual, 

Chapter 51. 

Values for airframe maintenance tasks are Included In Chapter 20 of 777 

Airplane Maintenance Manual (AMM). 

Values for engine maintenance tasks are included in Chapter 70 of 777 

Airplane Maintenance Manual (AMM). 

Non-standard torque values for maintenance tasks are Included in the 

applicable Installation step. 

5. Use the approved fastener and process material substitutions in accordance with 

SRM Chapter 51. 

6. If the length of any fastener specified In this service bulletin does not meet installation 

standards given in SRM Chapter 51. then a fastener of the same specification. or 

an approved substitute, with a length which meets lhe installation standards given 

In SRM Chapter 51 may be used. In addition, washers may be installed for fastener 

grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate 

full threaded Fasteners (screws) needed for lnstallallon in this service bullelin. 

Original Issue: October 23, 2003 

Revision 4: February 07. 201 4 ExportControledECCN 9E991 ·BOEING 

PROPRIETARY· Copyright O Unpubli&hed 

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BOEING SERVICE BULLETIN 777-78-0051 

7. A General Visual Inspection is defined as: A visual examination of an lnlerior or 

exterior area, installation or assembly lo detect obvious damage. !allure or irregularity. 

This level of Inspection Is made from within touching distance unless otherwise 

specified. A mirror may be necessary lo enhance visual access lo all exposed surfaces 

in the Inspection area. This level or inspection Is made under normally available 

lighting condilions such as daylight, hangar lighting, nashllght or drop-light and may 

require 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 included in other Boeing documents. 

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

procedure, lhe accepted alternative procedure can be used. When the words "In 

accordance wilh" are included In lhe instruction, 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 lo Boeing before a structural repair can be provided. 

10. The Instructions in Paragraph 3.B., Work lnslructlons and lhe figures can Include 

operation of tools or test equipment. Boeing Engineering Tool Drawings, lhe llluslrated 

Tool and Equipment Manual, and lhe Special Tool and Ground Handling Drawing 

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 Installation or a kept part, a new or serviceable 

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 Installed 

as a set. 

15. 'Run-on torque' is used In this SB in place or 'self-locking torque'. 'Self-locl<ing torque' 

is defined as the torque necessary lo turn a fastener with a self-locking feature on 

its mating threaded part when 100 percent or lhe locking feature is engaged, and 

the fastener is nol down against the 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 

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PROPRlET AAV · Copyright O Unpublished 

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b. The two inslalled lurbine exhausl plug assemblies, have part number 314W5520-22. 

c. The part number of an installed turbine exhausl plug assembly is not known. 

2. If lhe condllion of Slep 1.a. or Slep 1.c. is found, do "Part 1 - Turbine Exhausl Plug - Airplane Work'. 

3. If lhe condilion of Slep 1.b. is found, no more work is necessary. 

~ The forward plug and aft plug are a malched sel. They must be removed and Installed 

as a set. 

Part l -Turbine Exhaust Plug - Airplane Work 

1. Oeactivale lhe Thrust Reversers (T/R's) for ground maintenance. Refer lo 777 AMM 78-31-00 as 

an accepted procedure. 

2. Group 1, Configuration 1: 

a. Remove lhe turbine exhaust plug assembly from each engine. Refer lo 777 AMM 78-11-02 

as an ac,;epted procedure. 

b. Install a serviceable turbine exhaust plug assembly. with 1/4 inch diameler bolts at all 33 

locations of lhe forward and aft plug interface. back on each engine in accordance with FIGURE 

9. 

~1. 

2. 

A serviceable turbine exhaust plug assembly can be one that is removed 

from lhe airplane and subsequenUy changed in accordance with Part 3, or 

it can be a spare turbine exhaust plug assembly that Is changed in 

accordance wilh Part 2 or 3. Or it can be a new turbine exhausl 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. 

(1) If one or more of the 1 /4 Inch diameter bolts has a run-on torque value of less lhan 5.0 

Inch-pounds, replace the nutplate on the forward plug for each of the relaled bolt(s) In 

accordance with FIGURE 7. 

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

At each engine, do a general visual inspecllon of the all of the 33 bolt locations at the forward and 

aft plug Interface In accordance with FIGURE 5. 

a. Only 3/16 Inch diameter bolls are found used at all 33 locations: 

( 1) Remove lhe lurblne exhausl plug assembly from each engine. Refer to 777 AMM 78-11-02 

as an accepted procedure. 

(2) Install a serviceable turbine exhaus1 plug assembly, with 1/4 inch diameter bolts at all 33 

locations of the forward and aft plug Interface, back on each engine In accordance wllh 

FIGURE 9. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 Eirpon Conuolled ECCN. 9£991 ~ BOEING 

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~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 turbine exhaust plug assembly that 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 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 plug for each of the related 

bolt(s) in accordance wilh FIGURE 7. 

b. A mix or 3/16 Inch diameter and 1 /4 inch diameter bolts are found used al the 33 locations. 

(1) Remove the turbine exhaust plug assembly from each engine. Refer to 777 AMM 78-11-02 

as an accepted procedure. 

(2) Install a serviceable lurbine exhaust plug assembly, wilh 114 inch diameter bolts at all 33 

locations or lhe forward and aft plug Interface. back on each engine In accordance with 

FIGURE 9. 

~ 1. 

2. 

A serviceable turbine exhaust plug assembly can be one I hat Is removed 

from the airplane and subsequently changed In accordance wllh Part 

2, or it can be a spare turbine exhaust plug 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 matched set. They must be removed 

and Installed as a set. 

(a) II one or more of the 1/4 inch diameter bolts has a run-on torque value 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 engine. 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) If one 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 wilh FIGURE 7. 

Original Issue: October 23, 2003 

Revision 4: February 07. 2014 Expon Controlleo ECCN 9£991 • BOE.INC 

PROPRIETARY · Copytig:h10 Unput>bnOd 

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(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 plug assembly from each engine. Refer lo 777 AMM 

78-11·02 as an accepted procedure. 

MQre II is not necessary to remove the forward 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 plug 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 Inch-pounds, replace the nutplate on the forward plug 

for each of the related 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 In accordance 

with FIGURE 9. 

tiQIJ;,;. II is only necessary to Install the aft plug. 

{1 J If one or more of the 1/4 Inch 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 bolt(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 

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Get each spare turbine exhaust plug assembly for which the description of Part 2 is necessary 

to be accomplished. 

Get each removed turbine exhaust plug assembly for which the description of Part 2 ls 

necessary to be accomplished. 

2. Put and hold lhe forward plug vertically and remove all of the remaining 3/16 Inch diameter nutplates 

from the holes that interface with the aft plug In accordance wlth FIGURE 1. 

3. Do a general visual inspection of the holes. related to the removed 3/16 inch diameter nutplates, 

at lhe forward and aft plug Interface In accordance wllh FIGURE 2. 

a. If a hole has damage that is more than the 0.2910 Inch limit, contact Boeing for repair 

instructions. Refer to Boeing Service Letter 777 -SL-51-013. 

4. Install 1/4 Inch diameter nutplales at all remaining hole locations 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 reidentification 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 applicable: 

Get each spare turbine exhaust plug assembly for which the description of Part 3 is necessary 

lo be accomplished. 

Get each removed turbine exhaust plug assembly for which the description of Part 3 Is 

necessary to be accomplished. 

2 Pul and hold the forward plug vertically and remove all of the 33 3/16 inch diameter nutplates from 

lhe holes that Interface with lhe aft plug in accordance with FIGURE 1. 

3. Do a general visual lnspecllon of lhe holes. related lo lhe removed 3/16 inch diameter nutplates, 

at the forward and aft plug Interface In accordance with FIGURE 2. 

a. If a hole has damage that is more than the 0.2910 inch limit, contact Boeing for repair 

Instructions. 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 ln accordance with 

FIGURE 3. 

b. Install 1/4 Inch diameter nutplates at all 33 hole locations and reidentlfy the turbine exhaust 

plug assembly in accordance with FIGURE 4 . 

5. For each component identified with part number 314W5520-1: 

Original Issue: October 23, 2003 

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PROPRIETARY· Coi,yngN O Uni:,wliShed 

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a. Install 1/4 inch diameter nutplates at all 33 hole locations in accordance with FIGURE 4. 

b. Reidentify the turbine exhaust plug assembly in accordance with Part 4. 

6. For each component ldenlified with part number 314W5521· 1: 

a. Install 1/4 Inch diameter nulplates al all 33 hole localions in accordance with FIGURE 4. 

b. No lurbine exhaust plug assembly reidentificalion is necessary. 

Pact 4 · Rejdentjficatlon of the Turbine Exhaust Plug Assembly· Component Work; 314W5520-1 

1. Deep etch mark the replacement identification tags for the forward and aft plugs in accordance 

with FIGURE 3. 

2. Remove the lncorreclly Identified Identification tags and install the replacemenl identification tags 

for the forward and aft plugs in accordance with FIGURE 8. 

Original Issue: October 23, 2003 

Revision 4: February 07, 2014 &po,1 Conlrolled ECCN 9E99t · BOEING 

PROPRIETARY - Copyog:ht C Unpubkt!ed 

WM - See page 1 lo, de!a!IS 

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BOEING SERVICE BULLETIN 777-78-0051 

FORWARD PLUG 

TYPICAL AT 33 LOCATIONS (MAXIMUM) 

~ 

FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY· NUTPLATE REMOVAL AND HOLE INSPECTION 

PREPARATION 

Original Issue: October 23, 2003 

Revision 4 February 07. 2014 

(SHEET 1 OF 3) 

El(J)O<t Conln>llod ECCN· 9E991 - BOEING 

PROPRIETARY· Copyrioh10 Unpijbhshfx:I 

Work • See pa,oe 1 tor delah. 

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2 AFTPLUG 

FORWARD AND AFT PLUG 

(AFT PLUG PUT ON FORWARD PLUG WITHOUT 

BOLTS AND NUTPLATES) 

l FORWARD 

PLUG 

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. 

Step Task Name Identification Qty More Data 

1 Remove RIVET . . (a) (c) 

Remove NUTPLATE BACN11 G3AE1 F . (b) 

FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY· NUTPLATE REMOVAL AND HOLE INSPECTION 

PREPARATION 

(SHEET 2 OF 3) 

; 

.... 

i 

Original Issue: October 23, 2003 

Revision 4 February 07, 2014 Expoct eo.i1,ot1ec1 ECCN· 9E991 - BOEING 

PROPRJET ARY - Copyright O Unpubhhed 

Work · See page 1 fo, detds. 

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Step Task Name Identification Qty More Data 

2 Pul I Hold FORWARD PLUG 314W5520-16 OR 1 on lhe aft plug. 

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 turbine exhaust plug assembly is lo have all 33 3/16 inch diameter bolts replaced 

with 1/4 indl diameter bolts. Or, quantity as necessary, for each turbine exhaust plug assembly that is to 

have all remaining locations thal have 3/16 inch diameter bolts replaced with 1 /4 inch diameter bolts. 

Refer 10 777-200 SRM 51 -40-02 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 

with 1/4 inch diameter bolts. Or, quantity as necessary, 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. 

(c) Be careful during the removal of rivets to minimize damage to the holes. 

FIGURE 1: TURBINE EXHAUST PLUG ASSEMBLY - NUTPLATE REMOVAL AND HOLE INSPECTION 

PREPARATION 

Original Issue: October 23, 2003 

Revision 4 February 07. 2014 

(SHEET 3 OF 3) 

E"POI\ Coo,,_ ECCN 9E991 • BOElNG 

PROPRIETARY· ~hl C Unpublrshed 

Wo,k. • See page 1 for de1a1:s 

777-78-0051 

46of 69 
0.2238 

EXISTING 3116 

BOEING SERVICE BULLETIN 777-78-0051 

INCH DIAMETER 

NOMINAL CLASS 

Ill HOLE 

0.3050 

EXISTING 

COUNTERSINK 

HOLE 

FORWARD 

PLUG SKIN 

EXAMPLE OF 

DAMAGED 

HOLE 

TYPICAL HOLE AT 33 LOCATIONS (MAXIMUM) 

LIMIT OF DAMAGE 

FOR HOLE REPAIR 

0.2910 

0.2790 

AFT PLUG SKIN 

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 turbine exhaust plug assembly. 

Step Task Name Identification Qty More Data 

1 

(a) 

Ins peel 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 

PROPRIETARY · Copyngh1 Cl Unpubllshed 

W(Mi( - See page l k)r detallS 

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BOEING SERVICE BULLETIN 777-78.0051 

Assy 314W5521-1 

O MATCHED SET. 

00 NOT SEPARATE 

0 SIN XXX-XXXX 0 

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. 

Step Task Name Identification Qty More Data 

1 

(a) 

(bl 

Identify IDENTIFICATION TAG 314W5520-23 2 with the text as follows, for the forward 

and aft plug: Assy 

314W5521-1; 

MATCHED SET. 00 

NOT SEPARATE: 

SIN: XXX-XXXX. 

Refer lo SOPM 20-

50-1 O as an accepted procedure. (a) (b) 

The serial number code Is to be operator defined. A unique serial number Is necessary for each matched 

set of forward and aft plugs (a turbine exhaust plug assembly) lo help the operator keep the hardware as 

a matched seL EXAMPLE: SIN TBC-0001. 

The serial number Is recommended to be on one half of the identification tag and one-quarter inch (24 

point) In height. The remaining text is recommended to be on the other half of the identification tag and 

12 point In height. The text is recommended to be centered to keep a minimum 20 distance from each 

of the rivets after Installation. 

FIGURE 3: IDENTIFICATION TAG - DEEP ETCH MARK 

(SHEET 1 OF 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 1 tor d0lail$ 

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BOEING SERVICE BULLETIN 777-78-0051 

FORWARD AND AFT PLUG 

TYPICAL 

FORWARD A 

PLUG 

FORWARD PLUG 

1/4 INCH DIAMETER HOLE 

(33 LOCATIONS) 

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 • Copyflgh1 0 Unpublishea 

WOl"k • See page 1 for deta,ls 

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BOEING SERVICE BULLETIN 777-78-0051 

FORWARD PLUG 0 .40 

(2 LOCATIONS) 

0.125 I 

4.500 

BOTIOM 

DEAD CENTER - · __ 

l _______ +-

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 2 OF 6) 

E, pon ContlOlod ECCN, 9€991 • 80El'1G 

PROPRIETARY • Copyright O Unpublished 

Work . SOo pogo 1 fof de(affs 

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BOEING 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 

Original 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• 

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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 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 INCH DIA FAS- ST30-7216A-200-216- 5 in the Interface holes 

TENER 1.0 ('WEDGELOCK') of the aft plug and 

OR EQUIVALENT the forward plug. (a) 

WABt:llt:lG; USE CARE WHEN DRILLING IN TITANIUM. SMALL PARTICLES AND FINE SHAVINGS OF 

TITANIUM ARE HIGHLY FLAMMABLE. WATER WITH HOT TITANIUM CAN CAUSE A STEAM 

EXPLOSION. EXTINGUISH ALL FIRES OF TITANIUM WITH FULLY DRY TALC. CALCIUM 

CARBONATE, SAND, OR GRAPHITE. APPLY THE POWDER TO A DEPTH OF ONE-HALF 

INCH OR MORE OVER THE BURNING METAL. DO NOT USE FOAM, WATER, CARBON 

TETRACHLORIDE. OR CARBON DIOXIDE. IF 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 equlvalent, 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 Install (Temporary) 1/4 INCH DIA FASTEN- ST30-7216A-200-279- 1 into the repaired or 

ER 1.0 ('WEDGELOCK') increased 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 

Original Issue: October 23, 2003 

Revision 4 February 07. 2014 

(SHEET 4 OF 6) 

Expon Con110He<1 ECCN 9E991 • BOEING 

PAOPRIETAAY • Copyrll)tl1 C l.h\pubhhed 

Wort. • SN pago 1 (Of" Otlail 

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Step Task Name Identification Qty More Data 

6 Remove 1/4 INCH DIA FASTEN- ST30·7216A-200-279· 32 that were temporariER 1.0 ('WEDGELOCK') ly installed. 

OR EQUIVALENT 

Remove I Keep AFT PLUG 314W5520-3 OR 1 

314W5520-20 

7 Install (New) NUTPLATE BACN11G4DE1F 33 on the Inner circumference of the forward plug using the 

existing rivet holes. 

Install (New) RIVET MS20427M3-4 66 (d) 

QA!..!IIQt!!; ADJUST THE IDENTIFICATION TAG POSITIONS TO AVOID DRILLING HOLES WITHIN 0.31 

INCHES OF A WELD CENTERLINE 

8 Pull Hold IDENTIFICATION TAG 314W5520-23 1 identified for the forward plug. (b) 

Drill / Ream HOLE . 3 0.124 • 0.128 inch 

diameter. (c) 

9 Install (New) IDENTIFICATION TAG 314W552()..23 1 identified for the forward plug. 

Install (New) RIVET MS20615-4M3 3 (d) 

10 Put I Hold IDENTIFICATION TAG 314W5520-23 1 Identified for the aft 

plug. (b) 

Drill/ Ream HOLE . 3 0.124 • 0.128 lnch 

diameter. (c) 

11 Install (New) IDENTIFICATION TAG 314W5520·23 1 Identified for the aft 

plug. 

Install (New) RIVET MS20615-4 M 3 3 (d) 

(a) Do not install the 'wedgelocks' (or equivalent 3116 inch diameter temporary fasteners) In a continuous 

sequence. Install the first 'wedgelock' In the hole located sequentially next to the hole that is found to have 

the largest damage. Install the second 'wedgelock' in the hole 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'. Install 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 'wedgelocks' cannot be installed because 1/4 Inch diameter 'wedgelocks' 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' installation process. 

FIGURE 4: TURBINE EXHAUST PLUG ASSEMBLY · REPLACEMENT OF ALL 33 3116 INCH DIAMETER 

BOLTS WITH 1/4 INCH DIAMETER BOLTS 

Original Issue: 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 

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BOEING SERVICE BULLETIN 777-78-0051 

Step ! Task I Name I ldentlflcatlon I Qty I More Data 

(b) The Identification tag Is to be positioned on the side of the stringer where the distance between the stringer 

and the skin chem-milled area Is maximum. but with the minimum conditions that there is a 20 edge 

margin between the rivets and the edges of the identification tag and that there ls a 20 edge margin between the rivets and the chemically milled area. Refer to 777-200 SRM 54-42-30 or 777-300 SRM 54-42-

30 for turbine exhaust plug assembly details. 

(c) 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. 

(d) Refer to 777-200 SRM 51-40-02 or 777..:JOO SRM 51-40-02 as an accepted procedure. 

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 6 OF 6) 

EJtpOrt Con1rolled ECCN· 9E991 - BOEING 

PROP RI ET ARY • Coc,ynght O Uftpublished 

Wortc · See PBOe 1 fOf details. 

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BOEING SERVICE BULLETIN n7-78-0051 

I This Figure applies only to: Group 1, Configuration 2-3; Group 2. 

A 

FORWARD 

PLUG 

ALIGNMENT 

RIVET 

114 INCH 

DIAMETER 

BOLT 

FORWARD 

PLUG 

AFT PLUG 

TURBINE EXHAUST 

PLUG ASSEMBLY 

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£1NG 

PROPRIETAAY • CclpytightOLklpubhhed 

Work • Soo Pl9• 1 for dol.llils 

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The step numbers shown below agree wilh the numbers shown In the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for each engine. 

Step Task Name Identification Qty More Data 

1 Inspect BOLT 123423·3·1 OR 33 by general visual InBACB30UU4-1 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 ECCN· 9E991 -SOE ING 

PROPRIETARY • Cooyrlg.ht O Unpublished 

Work , .$oe page 1 to, dOU111S 

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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 

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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. 

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 plug and the forward plug, that do 

not have a nutplate. 

Or, use 1/4 Inch di· 

ameter fasteners in 

the Interface holes 

of the aft plug and 

the forward plug that 

have a nutplate. (a) 

WABl:llt!~; USE CARE WHEN DRILLING IN TITANIUM. SMALL PARTICLES ANO FINE SHAVINGS OF 

TITANIUM ARE HIGHLY FLAMMABLE. WATER WITH HOT TITANIUM CAN CAUSE A STEAM 

EXPLOSION. EXTINGUISH ALL FIRES OF TITANIUM WITH FULLY ORY TALC, CALCIUM 

CARBONATE, SAND, OR GRAPHITE. APPLY THE POWDER TO A DEPTH OF ONE-HALF 

INCH OR MORE OVER THE BURNING METAL. DO NOT USE FOAM, WATER, CARBON 

TETRACHLORIDE, OR CARBON DIOXIDE. IF 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 equlvalent. between the 

first and fifth 'wedgelocks', or first and 

fifth 1/4 Inch diameter temporary fasteners, to remove damage up to the repair 

limit, or to Increase 

Its diameter to 1/4 

Inch. (b) 

3 Inspect HOLE - 1 by general visual InspecUon. to make 

sure there Is no 

damage. 

FIGURE 6: TURBINE EXHAUST PLUG ASSEMBLY - REPLACEMENT OF ALL REMAINING 3/16 INCH 

DIAMETER BOLTS WITH 1/4 INCH DIAMETER SOL TS 

Original Issue: October 23. 2003 

Revision 4 February 07, 2014 

(SHEET 2 OF 4) 

E.xpon Con1t016d ECCN 9E99l • BOEING 

PROPRIETARY • Copyright O Unpobbhed 

W0tk • Soe P11V8 1 fot detail& 

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Step Task Name Identification Qty More Data 

4 Install (Temporary) 1/4 INCH DIA FASTEN· ST30-7216A-200-279· 1 lnlo 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 installed. 

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 

Original Issue. October 23, 2003 

Revision 4 February 07, 2014 

(SHEET 3 OF 4) 

E.l:por1 Controlled ECCN· 9£991 - 80ElNG 

PROPRIET AAY • Copyngh1 C UnpublltMCI 

Work - See page 1 for detail~ 

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Stop !Task I Name I Identification 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. Install the first •wedgelock·.1n lhe hole localed sequenHally next to lhe hole lhal is found to have lhe largesl damage or that is remaining at 3/16 inch diameter. 

or install the first temporary fastener In the equivalently located 1/4 inch diameter hole. Install the second 

'wedgelock· in the hole nearest to the circumferential opposite of lhe firsl 'wedgelock' Installed, or install 

lhe second temporary fastener in the equivalently located 1/4 inch diameter hole. Install the third 

'wedgelock· In the hole nearest to the circumferential midpoint between the flrst and second 'wedgelocks·. 

or install the third temporary fastener In the equlvalenlly located 1/4 Inch diameter hole. Install the fourth 

'wedgelock· in the hole nearest to lhe circumferential opposite as the third installed ·wedgelock·. or inslall 

the fourth temporary faslener In the equivalently located 1/4 Inch diameter hole. Install the fifth 'wedgelock· 

in the hole located sequentially next to lhe hole that to has the largest damage. or Install the fifth temporary 

fastener in the equivalently located 1/4 inch diameter hole. After lhe hole Is reamed and no damage Is 

found. Install a 1/4 inch 'wedgelock' In the repaired or Increased diameter hole. Move the first thru fifth 

'wedgelocks', or the first thru fifth 1/4 Inch diameter temporary fasteners clockwise or counter-clockwise 

to repair the hole with the next largest damage and/or increase its diameter to 1/4 Inch, until 5 'wedgelocks' 

cannot be Installed because 1 /4 inch diameter wedgelocks or 1/4 inch diameter temporary fasteners are 

Installed. Do steps 1 lhru 5 again to repeat this process until 32 fastener holes are filled with 1/4 inch di· 

a meter 'wedge locks' or 1/4 Inch diameter temporary fasteners and all of the 33 fastener holes 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 Installation 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 or 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 69 
BOEING SERVICE BULLETIN 777-78-0051 

A 

FORWARD PLUG 

1/4 INCH DIAMETER HOLE 

TYPICAL 

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 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 for 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 69 
BOEING 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 Issue: 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 

777-78-0051 

63oF69 
BOEING SERVICE BULLETIN 777-78-0051 

FORWARD PLUG 

1 2 

BOTIOM 

OEAO CENTER -· -------------- +--

FIGURE 8: TURBINE EXHAUST PLUG ASSEMBLY· FORWARD AND AFT PLUG IDENTIFICATION TAG 

REPLACEMENT 

Original Issue: October 23, 2003 

Revision 4 February 07, 2014 

(SHEET 2 OF 3) 

Expon Controlled ECCN 9E991 ~ BOEING 

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 in the circle symbols In the figure. The QTY 

numbers shown below are the number of parts necessary for each turbine exhaust plug 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 incorrectly 

Identified with 'Assy 

314W5520·1'. 

2 Install (New) IDENTIFICATION TAG 314W5520-23 2 one on the forward 

plug and one on the 

aft plug. (a) 

Install (New) RIVET MS20615-4M3 6 lhree for each identificallon tag. Refer to 

777-200 SRM 51-

40-02 or 777 ·300 

SRM 51 ·40-02 an 

accepled procedure. 

(a) 

(a) Make sure lhe idenlification tag Is located on lhe side of the stringer where lhe distance between the 

Slringer and the skin chem-milled area Is maximum. bul with the minimum conditions that there Is a 20 

edge margin between the rivets and the edges of lhe Identification lag and lhat there Is a 2D edge margin 

between the rivets and the chemically 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 1 fOf dm&Js 

777-78-0051 

65 of 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) 

Original 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 

66 o(69 
I 

I 

I 

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 for each engine. 

Step Task Name Identification Qty More Data 

1 

(a) 

Install (Changed) TURBINE EXHAUST 314W5521-1 1 If applicable. (a) 

PLUG ASSEMBLY 

Install (New) TURBINE EXHAUST 314W5520-22 1 If applicable. (a) 

PLUG ASSEMBLY 

Install (Kept) TURBINE EXHAUST 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 Interface. 

FIGURE 9: TURBINE EXHAUST PLUG ASSEMBLY - INSTALLATION 

(SHEET 2 OF 2) 

Original Issue: Ociober 23, 2003 

Revision 4 February 07, 201 4 Expon CM1rolod ECCN. 9E99t • BOEING 

PROPAIET ARY • Cc)p)'tlvhl O lMPU~ 

Worle • SOo l)8VO 1 ICH' dotllb 

777-78-0051 

67 of 69 
BOEING SERVICE BULLETIN 777-78·0051 

FIRST3116 INCH 

DIAMETER WEDGE LOCK 

POSITION 

AFT PLUG 

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 

POSITION 

0 

A-A 

FIRST HOLE REPAIR·EXAMPLE 

• • • 

LAST HOLE TO BE 

REPAIRED ANO/OR 

INCREASED TO 114 

INCH DIAMETER 

FIRST HOLE 

WITH LARGEST 

DAMAGE 

FIFTH 3/16 INCH 

DIAMETER 

WEDGELOCK 

POSITION 

0 

0 

FOURTH 3/16 INCH 

DIAMETER 

WEOGELOCK 

POSITION 

32 114 INCH DIAMETER 

WEDGELOCKS 

INSTALLED - ._--- 114 INCH DIAMETER 

• 

• 

A-A 

WEDGELOCK IN FIRST 

•· REPAIRED FASTENER 

• HOLE 

• 

• 

• 

• 

LAST HOLE REPAIR OR DIAMETER INCREASE·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 23, 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 INCH 

DIAMETER TEMPORARY 

FASTENER POSITION 

FORWARD 

PLUG 

0 

0 

0 

0 

SECOND 3116 INCH 

WEDGELOCKOR 1/4 INCH- - _,.,~ 

DIAMETER TEMPORARY 

FASTENER POSITION I 

FIRST 3116 INCH 

WEOGELOCKOR 114 INCH 

DIAMETER TEMPORARY 

FASTENER POSITION 

0 

FIRST HOLE WITH 

LARGEST DAMAGE 

ORTO BE 

INCREASED TO 1/4 

INCH DIAMETER 

FIFTH 3116 INCH 

WEOGELOCKOR 

1/4 INCH 

DIAMETER 

TEMPORARY 

O FASTENER 

O POSITION 

0 

0 

0 

A-A 

FOURTH 3116 INCH 

WEOGELOCKOR 114 INCH 

DIAMETER 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 

INCREASEDTO 1/4 

INCH DIAMETER 

A-A 

1/4 INCH DIAMETER 

WEOGELOCK IN FIRST 

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