### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-57-0066**  Original Issue: April 05, 2011 ATA System: 5740 **SUBJECT:** WINGS - Leading Edge and Leading Edge Devices - Slat Trailing Edge Wedge Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 1 of 33 7.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 2 of 33 **BOEING SERVICE BULLETIN 757-57-0066**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1. Existing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. Data supplied with this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 16 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1. Kits/Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 19 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 19 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 FIGURE 1: INSPECTION OF LEFT WING LEADING EDGE SLAT TRAILING EDGE WEDGES . . . 23 FIGURE 2: INSPECTION OF RIGHT WING LEADING EDGE SLAT TRAILING EDGE WEDGES . . . 26 APPENDIX A: DETERMINATION OF LEADING EDGE SLAT TRAILING EDGE WEDGE TYPE. . . . . 29

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 3 of 33 **BOEING SERVICE BULLETIN 757-57-0066**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 4 of 33 **BOEING SERVICE BULLETIN 757-57-0066**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 757-57-0066** Original Issue: April 05, 2011 ATA System: 5740 **SUBJECT:** WINGS - Leading Edge and Leading Edge Devices - Slat Trailing Edge Wedge Inspection BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** This service bulletin gives instructions for the inspection, monitoring, repair and replacement of disbonded leading edge slat trailing edge wedges. Failure to repair this damage could result in the loss of a trailing edge wedge during flight, with subsequent damage to the fuselage and empennage and reduced controllability of the airplane. The leading edge slat trailing edge wedges may disbond on 757-200 airplanes. This condition was originally addressed for certain airplanes by Service Bulletin 757-57A0038. However, there have been several operators who have reported wedge skin-to-core disbonds after completion of the terminating action specified in Service Bulletin 757-57A0038. Inspection of the submitted damaged wedges indicated that the panels had been contaminated with moisture ingression as there was evidence of aluminum oxide powder on the core and the adhesive had failed at the skin-to-core bondline. It is suspected that there was incomplete removal of moisture and honeycomb core corrosion during the repair of the wedges or that moisture had previously migrated into the panel and was subsequently sealed in during accomplishment of Service Bulletin 757-57A0038. There have also been reports of wedge skin-to-core disbonds on airplanes not in the effectivity of Service Bulletin 757-57A0038. One operator reported major skin-to-core disbonding of a wedge after the airplane had accumulated 42,603 total flight hours and 9,808 total flight cycles. Another operator reported the departure of a wedge during flight after the airplane had accumulated 47,470 total flight hours and 17,579 total flight cycles. This service bulletin supersedes Boeing Service Bulletins 757-57A0038, 757-57A0045 and 757-57A0063 which give instructions to inspect and repair or replace leading edge slat trailing edge wedges on airplanes up to line number 348. Boeing Service Related Problem (SRP) 757-SRP-57-0192 is related to this service bulletin. **ACTION** Do an ultrasonic (preferred) or tap test inspection on all applicable leading edge slat trailing edge wedges to search for areas of skin-to-core disbonding. Monitor, repair or replace all disbonded parts according to the location and size of the disbond. Do the inspections again at the time given in Paragraph 1.E., Compliance

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 5 of 33**EFFECTIVITY** All 757-200,-200CB,-200PF airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** Federal Aviation Administration (FAA) Airworthiness Directives 90-23-06, 91-22-51 and 2005-07-08 are related to this service bulletin. 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 Elapsed Hours**  **Total Task Hours** 10.00 20.00
**MATERIAL INFORMATION** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 6 of 33 **BOEING SERVICE BULLETIN 757-57-0066**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 7 of 33 **BOEING SERVICE BULLETIN 757-57-0066**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 8 of 33 **BOEING SERVICE BULLETIN 757-57-0066**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-57-0066**  Original Issue: April 05, 2011 ATA System: 5740 **SUBJECT:** WINGS - Leading Edge and Leading Edge Devices - Slat Trailing Edge Wedge Inspection BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** All 757-200,-200CB,-200PF series airplanes.

- 1

Airplane Models: 757-200, 757-200CB, 757-200PF **Group Variable Number**  1 NA001 - NA028 1 NA191 - NA199 1 NA201 - NA239 1 NA301 - NA305 1 NA341 - NA352 1 NA391 - NA399 1 NA401 - NA408 1 NA441 - NA447 1 NA501 - NA586 1 NB001 - NB004 1 NB021 - NB023

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 9 of 33**Group Variable Number**  1 NB036 - NB041 1 NB051 - NB053 1 NB061 - NB073 1 NB079 1 NB131 - NB148 1 NB161 - NB162 1 NB166 - NB168 1 NB201 - NB204 1 NB221 - NB228 1 NB230 1 NB236 1 NB239 1 NB261 - NB267 1 NB291 - NB299 1 NB301 - NB302 1 NB311 - NB312 1 NB321 - NB331 1 NB421 - NB438 1 NB446 1 NB451 - NB454 1 NB501 - NB523 1 NB561 1 NB571 1 NB581 - NB583 1 NC001 - NC033 1 NC041 - NC042 1 NC051 - NC052 1 NC056 - NC062 1 NC066 - NC084 1 NC091 - NC094 1 NC151 1 NC161 1 NC901 - NC951

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 10 of 33 **BOEING SERVICE BULLETIN 757-57-0066 Group**  **Variable Number** 1 NC971 - NC974 1 ND001 - ND007 1 ND011 - ND059 1 ND111 - ND113 1 ND161 - ND199 1 ND201 - ND203 1 ND221 - ND225 1 ND241 - ND248 1 ND301 - ND322 1 ND401 1 ND891 1 ND895 1 NE001 - NE008 1 NE011 - NE088 1 NE091 - NE094 1 NE141 - NE150 1 NE161 - NE177 1 NE201 - NE204 1 NE301 - NE302 1 NE311 - NE325 1 NJ001 - NJ004 1 NJ031 - NJ032 1 NJ551 - NJ555 1 NN001 - NN002 1 NN051 - NN052 1 NP901 - NP904 1 NS601 - NS616 1 NT001 - NT009 1 NT201 - NT202 1 NT231 - NT234 1 NT237 - NT240 1 NT242 1 NT245 - NT248

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 11 of 33 **BOEING SERVICE BULLETIN 757-57-0066 Group**  **Variable Number** 1 NT281 - NT289 1 NT341 - NT347 1 NT351 - NT360 1 NT371 - NT373 1 NT375 - NT379 1 NT381 - NT386 1 NT401 - NT409 1 NT411 - NT412 1 NT426 - NT427 1 NT431 - NT432 1 NT436 - NT438 1 NT441 - NT442 1 NT446 1 NT701 - NT769 1 NT791 - NT796 1 NT861 - NT862 1 NT881 - NT885 1 NT901 - NT916 1 NT971 - NT985 1 NU031 - NU038 2. Spares Affected Examine your spares supply for the parts identified in APPENDIX A. If any part is found, the work given in this service bulletin will become necessary if the part is installed on an airplane. **B. Concurrent Requirements** None. **C. Reason** This service bulletin gives instructions for the inspection, monitoring, repair and replacement of disbonded leading edge slat trailing edge wedges. Failure to repair this damage could result in the loss of a trailing edge wedge during flight, with subsequent damage to the fuselage and empennage and reduced controllability of the airplane.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 12 of 33 **BOEING SERVICE BULLETIN 757-57-0066**The leading edge slat trailing edge wedges may disbond on 757-200 airplanes. This condition was originally addressed for certain airplanes by Service Bulletin 757-57A0038. However, there have been several operators who have reported wedge skin-to-core disbonds after completion of the terminating action specified in Service Bulletin 757-57A0038. Inspection of the submitted damaged wedges indicated that the panels had been contaminated with moisture ingression as there was evidence of aluminum oxide powder on the core and the adhesive had failed at the skin-to-core bondline. It is suspected that there was incomplete removal of moisture and honeycomb core corrosion during the repair of the wedges or that moisture had previously migrated into the panel and was subsequently sealed in during accomplishment of Service Bulletin 757-57A0038. There have also been reports of wedge skin-to-core disbonds on airplanes not in the effectivity of Service Bulletin 757-57A0038. One operator reported major skin-to-core disbonding of a wedge after the airplane had accumulated 42,603 total flight hours and 9,808 total flight cycles. Another operator reported the departure of a wedge during flight after the airplane had accumulated 47,470 total flight hours and 17,579 total flight cycles. This service bulletin supersedes Boeing Service Bulletins 757-57A0038, 757-57A0045 and 757-57A0063 which give instructions to inspect and repair or replace leading edge slat trailing edge wedges on airplanes up to line number 348. Boeing Service Related Problem (SRP) 757-SRP-57-0192 is related to this service bulletin. **D. Description** Do an ultrasonic (preferred) or tap test inspection on all applicable leading edge slat trailing edge wedges to search for areas of skin-to-core disbonding. Monitor, repair or replace all disbonded parts according to the location and size of the disbond. Do the inspections again at the time given in Paragraph 1.E., Compliance. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 512, 522, 523, 524, 525, 612, 622, 623, 624, 625 757-200, 757-200CB, 757- 200PF **E. Compliance** Federal Aviation Administration (FAA) Airworthiness Directives 90-23-06, 91-22-51 and 2005-07-08 are related to this service bulletin. 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. Boeing recommends that the inspections given in this Service Bulletin are done according to Table 1.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 13 of 33 **BOEING SERVICE BULLETIN 757-57-0066 Table 1: Inspection and repair/replacement of leading edge slat trailing edge wedges**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs First)**  **Action Condition** 

- Within 24 months afterthe original issue date of this service bulletin Within 3000flight cycles after the original issue date of this service bulletin For each leading edge slat trailing edge wedge, check maintenance records or do an inspection of the slatwedge to determine the assembly number in accordance with Work Instructions, Paragraph 3.B.1. All airplanes

- - No action is required For each Type B leading edge slat trailing edge wedge (a) 3000 flight cycles or 24 months, whichever occurs first (b) Within 24 months afterthe original issue date of this service bulletin Within 3000flight cycles after the original issue date of this service bulletin Do an ultrasonic (preferred) or tap test inspection of thewedge for disbonds in accordance with Work Instructions, Paragraph 3.B.2. For each Type A leading edge slat trailing edge wedge (a)

- Within 3000 flight cycles after this condition was foundRepair the disbond or replace the wedge in accordance with Work Instructions, Paragraph 3.B.2.a.(1) For each disbond that is less than or equal to 1.50 inches in maximum dimension AND is located more than or equal to 1.0 inch from the edge of the panel AND is located more than or equal to 4 times the disbond maximum dimension, measured edgeto edge, from adjacent damage. 600 flight cycles (c) Within 600 flight cycles after this condition was found (c)Repeat the ultrasonic (preferred) or tap test inspectionof the disbond area or repaired area in accordance with Work Instructions, Paragraph 3.B.2.

- Before further flight Contact Boeing for instruc-tions and do the work instructed by Boeing or replace the wedge in accordance with Work Instructions, Paragraph 3.B.2.b.(1) For each disbond that is more than 1.50 inches in maximum dimension or is located less than 1.0 inch from the edge of the panel or is located less than 4 times the disbond maximum dimension, measured edgeto edge, from adjacent damage. (a) Refer to APPENDIX A for determination of wedge type. (b) Inspection of a Type A wedge is terminated when the wedge is replaced with a Type B wedge. (c) Repair of a disbond on a Type A wedge does not terminate inspections of the repaired area. Inspections of the disbond area or the repaired area are terminated when the Type A wedge is replaced with a Type B wedge.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 14 of 33 **BOEING SERVICE BULLETIN 757-57-0066 F. Approval**  This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. In addition, the Manager of the Seattle ACO approves the accomplishment of the applicable inspections, and investigative and corrective actions, at the times specified Table 1, of SB 757-57-0066, at each applicable slat location, as an AMOC to the inspections, and investigative and corrective actions required by paragraphs (a), (b), (c), and (d) of AD 90-23-06. All provisions of AD 90-23-06 that are not specifically referenced above remain fully applicable and must be complied with accordingly. In addition, the Manager of the Seattle ACO approves the accomplishment of the applicable inspections, and investigative and corrective actions, at the times specified in Table 1, of SB 757-57-0066, at each applicable slat location, as an AMOC to the inspections, and investigative and corrective actions required by paragraphs (a), (b), and (c) of AD 91-22-51. All provisions of AD AD 91-22-51 that are not specifically referenced above remain fully applicable and must be complied with accordingly. In addition, the Manager of the Seattle ACO approves the accomplishment of the applicable inspections, and investigative and corrective actions, at the times specified in Table 1 of SB 757-57-0066, at each applicable slat location, as an AMOC to the inspections, and investigative and corrective actions required by paragraphs (f) and (g) of AD 2005-07-08. All provisions of AD 2005-07-08 that are not specifically referenced above remain fully applicable and must be complied with accordingly. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. **G. Manpower** The table below shows an estimate of the task hours necessary to do this inspection and repair/replacement for each leading edge slat trailing edge wedge. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **Elapsed Hours Task Hours (a)**  **Number of Per- sons**  **Task**
5.00 10.00 (b) 2 FIGURE 1 5.00 10.00 (b) 2 FIGURE 2 10.00 20.00 TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 15 of 33 **BOEING SERVICE BULLETIN 757-57-0066 Elapsed Hours**  **Task Hours (a) Number of Per-**  **sons Task**  (a) The task hours given assume that all trailing edge wedges are Type A and require inspection. (b) The task hours given assume that the ultrasonic inspection method is used. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data a. Boeing Service Bulletin 757-57A0038, 757-57A0045, 757-57A0063 b. Boeing Service Related Problem (SRP) 757-SRP-57-0192 c. Federal Aviation Administration (FAA) Airworthiness Directive 2005-07-08, 90-23-06, 91-22-51 d. 757 Non-Destructive Testing (NDT) Manual PART 1, 51-05-01, PART 4, 57-40-01 e. 757-200 Structural Repair Manual (SRM) 51-70-10 f. 757-200CB Structural Repair Manual (SRM) 51-70-10 g. 757-200PF Structural Repair Manual (SRM) 51-70-10 2. Data supplied with this Service Bulletin None. 3. Installation Drawings Used in the Preparation of this Service Bulletin None. **K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 16 of 33 **BOEING SERVICE BULLETIN 757-57-0066 L. Interchangeability and Intermixability of Parts**  Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 17 of 33 **BOEING SERVICE BULLETIN 757-57-0066**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 18 of 33 **BOEING SERVICE BULLETIN 757-57-0066**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  None. **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 None. 2. Parts and Materials Supplied by the Operator None. 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 19 of 33 **BOEING SERVICE BULLETIN 757-57-0066**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 20 of 33 **BOEING SERVICE BULLETIN 757-57-0066**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch 5. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS** 1. For each leading edge slat trailing edge wedge, check maintenance records or do an inspection of the slat wedge to determine the assembly number and refer to APPENDIX A to determine whether it is a Type A or a Type B wedge. 2. For each Type A wedge, do an ultrasonic (preferred) or tap test inspection of the wedge for disbonds in accordance with FIGURE 1 and FIGURE 2. a. For each disbond that is less than or equal to 1.50 inches in maximum dimension AND is located more than or equal to 1.0 inch from the edge of the panel AND is located more than or equal to 4 times the disbond maximum dimension, measured edge to edge, from adjacent damage:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 21 of 33 **BOEING SERVICE BULLETIN 757-57-0066**(1) Repair the disbond in accordance with 757-200 SRM 51-70-10, Rev 97, 20 May 2009 or later, 757-200CB SRM 51-70-10, Rev 71, 20 May 2009 or later, or 757-200PF SRM 51-70-10, Rev 75, 20 May 2009 or later, or replace the wedge at the time given in Paragraph 1.E., Compliance. (2) Repeat the ultrasonic (preferred) or tap test inspection of the disbond area or repaired area in accordance with Work Instructions, Paragraph 3.B.2. at the time given in Paragraph 1.E., Compliance. b. For each disbond that is more than 1.50 inches in maximum dimension or is located less than 1.0 inch from the edge of the panel or is located less than 4 times the disbond maximum dimension, measured edge to edge, from adjacent damage: (1) Contact Boeing for instruction and do the work instructed by Boeing or replace the wedge at the time given in Paragraph 1.E., Compliance. 3. For each Type A wedge, repeat the ultrasonic (preferred) or tap test inspection of the wedge for disbonds in accordance with Work Instructions, Paragraph 3.B.2. at the time given in Paragraph 1.E., Compliance. 4. For each Type B wedge, no work is required. 5. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 22 of 33 **BOEING SERVICE BULLETIN 757-57-0066 FIGURE 1: INSPECTION OF LEFT WING LEADING EDGE SLAT TRAILING EDGE WEDGES**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 23 of 33 **BOEING SERVICE BULLETIN 757-57-0066 FIGURE 1: INSPECTION OF LEFT WING LEADING EDGE SLAT TRAILING EDGE WEDGES**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 24 of 33 **BOEING SERVICE BULLETIN 757-57-0066**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY shown below are the number of leading edge slat trailing edge wedges on the left wing that require inspection.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Inspect for skin-tocore disbonds. (b) (c) (a)

- Leading edge slat trail- ing edge wedge Inspect 1

(a) Inspect all Type A wedges. Refer to APPENDIX A for determination of wedge type.(b) Do an ultrasonic inspection in accordance with 757 NDT PART 4, 57-40-01 or a tap test inspection in accordance with 757 NDT PART 1, 51-05-01. Ultrasonic inspection is the preferred method. (c) If the tap test inspection in accordance with 757 NDT PART 1, 51-05-01 is used, use a scan increment of 1/3 inch.

**FIGURE 1: INSPECTION OF LEFT WING LEADING EDGE SLAT TRAILING EDGE WEDGES (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 25 of 33 **BOEING SERVICE BULLETIN 757-57-0066 FIGURE 2: INSPECTION OF RIGHT WING LEADING EDGE SLAT TRAILING EDGE WEDGES**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 26 of 33 **BOEING SERVICE BULLETIN 757-57-0066 FIGURE 2: INSPECTION OF RIGHT WING LEADING EDGE SLAT TRAILING EDGE WEDGES**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 27 of 33 **BOEING SERVICE BULLETIN 757-57-0066**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY shown below are the number of leading edge slat trailing edge wedges on the right wing that require inspection.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Inspect for skin-tocore disbonds. (b) (c) (a)

- Leading edge slat trail- ing edge wedge Inspect 1

(a) Inspect all Type A wedges. Refer to APPENDIX A for determination of wedge type.(b) Do an ultrasonic inspection in accordance with 757 NDT PART 4, 57-40-01 or a tap test inspection in accordance with 757 NDT PART 1, 51-05-01. Ultrasonic inspection is the preferred method. (c) If the tap test inspection in accordance with 757 NDT PART 1, 51-05-01 is used, use a scan increment of 1/3 inch.

**FIGURE 2: INSPECTION OF RIGHT WING LEADING EDGE SLAT TRAILING EDGE WEDGES (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 28 of 33 **BOEING SERVICE BULLETIN 757-57-0066**It is necessary to determine the type of each leading edge slat trailing edge wedge that is installed on the airplane or owned as a spare. Find the assembly number of each trailing edge wedge and use the figure and Table A1 on the following pages to determine whether the wedge is Type A or Type B. **NOTE:** Table A1 lists slat-wedge configurations from production. If either the wedge or the slat has been changed since production, use only the wedge assembly number to determine the wedge type. 1.

2. If there is insufficient evidence to determine a wedge as Type B, it should be assumed that it is Type A.

**APPENDIX A: DETERMINATION OF LEADING EDGE SLAT TRAILING EDGE WEDGE TYPE (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 29 of 33 **BOEING SERVICE BULLETIN 757-57-0066 APPENDIX A: DETERMINATION OF LEADING EDGE SLAT TRAILING EDGE WEDGE TYPE**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 30 of 33 **BOEING SERVICE BULLETIN 757-57-0066 TABLE A1: WEDGE TYPE DETERMINATION FROM ASSEMBLY NUMBERS**  **Wedge Type Wedge Assembly Number**  **Slat Assembly Number Slat Number** 

A 114N4057-1 or 114N4002-1 thru

1 114N4057-45 or 114N4002-159, or 114N4057-57 or 114N4002-165 or 114N4057-81 or

114N4002-171 114N4057-97 or 114N4057-105

B 114N4057-137 114N4002-163 or

114N4002-169 114N4057-181 114N4002-187

A 114N4057-3 or 114N4003-1 thru

2 114N4057-47 or 114N4003-191, or 114N4057-59 or 114N4003-195 or 114N4057-83 or

114N4003-203 114N4057-99 or 114N4057-107

B 114N4057-139 114N4003-193 or

114N4003-201 114N4057-183 114N4003-221

A 114N4057-5 or 114N4004-1 thru

3 114N4057-49 or 114N4004-177, or 114N4057-61 or 114N4004-181 or 114N4057-85 or 114N4004-185 or 114N4057-101 or

114N4004-195 114N4057-109

B 114N4057-141 114N4004-179 or 114N4004-183 or

114N4004-191 114N4057-185 114N4004-215

A 114N4057-7 or 114N4005-1 thru

4 114N4057-51 or 114N4005-191, or 114N4057-63 or 114N4005-195 or 114N4057-87 or 114N4005-199 or 114N4057-103 or

114N4005-205 114N4057-111

B 114N4057-143 114N4005-193 or 114N4005-203 or

114N4005-213 114N4057-187 114N4005-229

**APPENDIX A: DETERMINATION OF LEADING EDGE SLAT TRAILING EDGE WEDGE TYPE (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 31 of 33 **BOEING SERVICE BULLETIN 757-57-0066 TABLE A1: WEDGE TYPE DETERMINATION FROM ASSEMBLY NUMBERS**  **Wedge Type Wedge Assembly Number**  **Slat Assembly Number Slat Number** 

A 114N3003-1 or 114N3002-1 thru

5 114N3003-19 or 114N3002-141, or 114N3003-23 or 114N3002-147 or 114N3003-25 or

114N3002-149 114N3003-27 or 114N3003-31 or

114N3003-33

B 114N3003-35 114N3002-135 or 114N3002-137 or 114N3002-143 or

114N3002-153
114N3003-57 114N3002-145 or 114N3002-155 or

114N3002-163 114N3056-1 114N3002-151
114N3056-13 114N3002-161 or 114N3002-165 or

114N3002-167

A 114N3003-2 or 114N3002-2 thru

6 114N3003-20 or 114N3002-142, or 114N3003-24 or 114N3002-148 or 114N3003-26 or

114N3002-150 114N3003-28 or 114N3003-32 or

114N3003-34

B 114N3003-36 114N3002-136 or 114N3002-138 or 114N3002-144 or

114N3002-154
114N3003-58 114N3002-146 or 114N3002-156 or

114N3002-164 114N3056-2 114N3002-152
114N3056-14 114N3002-162 or 114N3002-166 or

114N3002-168

A 114N4057-8 or 114N4005-2 thru 7 114N4057-52 or 114N4005-192, or 114N4057-64 or 114N4005-196 or 114N4057-88 or 114N4005-200 or

**APPENDIX A: DETERMINATION OF LEADING EDGE SLAT TRAILING EDGE WEDGE TYPE (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 32 of 33 **BOEING SERVICE BULLETIN 757-57-0066 TABLE A1: WEDGE TYPE DETERMINATION FROM ASSEMBLY NUMBERS**  **Wedge Type Wedge Assembly Number**  **Slat Assembly Number Slat Number**  114N4005-206 114N4057-104 or 114N4057-112

B 114N4057-144 114N4005-194 or 114N4005-204 or

114N4005-214 114N4057-188 114N4005-230

A 114N4057-6 or 114N4004-2 thru

8 114N4057-50 or 114N4004-178, or 114N4057-62 or 114N4004-182 or 114N4057-86 or 114N4004-186 or 114N4057-102 or

114N4004-196 114N4057-110

B 114N4057-142 114N4004-180 or 114N4004-184 or

114N4004-192 114N4057-186 114N4004-216

A 114N4057-4 or 114N4003-2 thru

9 114N4057-48 or 114N4003-192, or 114N4057-60 or 114N4003-196 or 114N4057-84 or

114N4003-204 114N4057-100 or 114N4057-108

B 114N4057-140 114N4003-194 or

114N4003-202 114N4057-184 114N4003-222

A 114N4057-2 or 114N4002-2 thru

10 114N4057-46 or 114N4002-160, or 114N4057-58 or 114N4002-166 or 114N4057-82 or

114N4002-172 114N4057-98 or 114N4057-106

B 114N4057-138 114N4002-164 or

114N4002-170 114N4057-182 114N4002-188

**APPENDIX A: DETERMINATION OF LEADING EDGE SLAT TRAILING EDGE WEDGE TYPE (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 05, 2011 757-57-0066 33 of 33 **BOEING SERVICE BULLETIN 757-57-0066**