January 09, 2003

Revision 2: May 24, 2007 757-57-0060

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 68

Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0060

Date: January 09, 2003

Revision 2 May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2003 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Unpublished Work - All Rights Reserved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, BBJ, DC-8, DC-9, 

DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue 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.
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BLANK PAGE
 Table of Contents

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BOEING SERVICE BULLETIN 757-57-0060

Table of Contents

Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 25

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 27

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 28

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 3 AND

GROUP 4 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

FIGURE 2: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 2 AIRPLANES . . . 41

FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND

GROUP 4, CONFIGURATION 1 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . 42

FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND

GROUP 4, CONFIGURATION 1 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . 47

FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND

GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND

GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
 Table of Contents

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FIGURE 7: INSPECTION AND APPLICATION OF SECONDARY FUEL BARRIER - GROUP 3

AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

FIGURE 8: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 1, GROUP 3 AND

GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

FIGURE 9: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 2 AIRPLANES 65

APPENDIX A: RECORD OF THICKNESS MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . 66
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Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0060 Revision Transmittal Sheet

Date: January 09, 2003

Revision 2: May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes changed as shown in the initial release of this service bulletin.

REASON FOR REVISION

Revision 2 is sent to add a group of airplanes that may have been delivered with improperly mixed secondary 

fuel vapor barrier sealant and to provide new thickness measurement inspection limits. This revision also 

corrects and clarifies inspection points on the front spar and top surface of the Center Wing Box.

Paragraph 1.E, Compliance, was changed to 5 years to better align with heavy maintenance check intervals.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity 

paragraph for changes.

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.

The data given in Information Notice 757-57-0060 R01 IN02 is included in this revision. The Information Notice 

advised operators about the errors in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.

REVISION HISTORY

Original Issue: January 9, 2003

Revision 1: April 10, 2003

Revision 2: May 24, 2007
 

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Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0060 Summary

Date: January 09, 2003

Revision 2: May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Initial inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied to the 

outboard corners of the front spar. As a result, Boeing Service Bulletin 757-57-0053 "WINGS - Wing Center 

Section - Application of Secondary Fuel Barrier to Areas on the Front Spar" was issued with a related 

Airworthiness Directive (AD). More inspections found defective examples of the Secondary Fuel Barrier applied 

along the front spar and the upper panel.

The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure. When 

the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from fuel leaks or 

fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener holes or cracks in the 

structure and pass into the passenger compartment. There are no reports from operators of fuel leaks or fumes 

in the passenger compartment.

This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front spar and 

upper panel. The inspections will identify locations where the secondary fuel barrier is not satisfactory. A new 

layer of secondary fuel barrier will be applied if it is necessary. A satisfactory secondary fuel barrier will keep 

fuel leaks or fumes out of the pressurized cabin.

Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin.

ACTION

Get access to the front spar and the top of the Wing Center Section by removal of the seats, floor covers, floor 

panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If necessary, remove the bulkhead 

lining for more access.

Examine the specified locations where the Secondary Fuel Barrier is applied. Look for examples of missing, 

peeled, non-continuous or non-transparent secondary fuel barrier. Make sure the applied thickness of the 

secondary fuel barrier is between the specified limits. Remove the corrosion inhibitor compound if it is 

necessary, then clean the area where the new layer of secondary fuel barrier will be applied. Install all the 

components that were removed for access. Do system tests as necessary.
 

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BOEING SERVICE BULLETIN 757-57-0060

EFFECTIVITY

Airplane Models 757-200, 757-200CB and 757-200PF; Line numbers 1 thru 964; divided into four groups. 

COMPLIANCE

Boeing recommends the inspection of the Secondary Fuel Barrier at the next regularly scheduled heavy 

maintenance check. Apply the secondary fuel barrier, if it is necessary, no later than five years after the release 

of this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of September 22, 2000. Please refer to 

Paragraph 2.B., Industry Support Information.

MANPOWER

See Paragraph 1.G Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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900

STA

1040

STA

BARRIER.

A NEW LAYER OF SECONDARY FUEL

IF DEFECTIVE, REMOVE AND APPLY

OF SECONDARY FUEL BARRIER.

SPAR FOR DEFECTIVE APPLICATION

EXAMINE THE UPPER PANEL AND FRONT

V83767
 

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Revision 2: May 24, 2007 757-57-0060

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Commercial

Airplane

Group 757

Service Bulletin

Number: 757-57-0060

Date: January 09, 2003

Revision 2: May 24, 2007

ATA System: 5710 2810

SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier 

on the Front Spar and Upper Panel

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-24N001 Part 3 for Airplane Variable Number, Line 

Number, and Serial Number data.

Airplane models:

757-200 757-200CB 757-200PF

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AEROMEXICO (AMX)

1 NC068 NC070–NC071 NE301

GROUP CONFIGURATION DESCRIPTION

1 - 757-200 Airplanes

2 - 757-200CB and 757-200PF Airplanes

3 - 757-200 Airplanes that only require inspection 

of the front spar center section.

4 - 757-200 Airplanes previously in Group 1 that 

could have fuel vapor barrier material applied 

that was thinned with lacquer thinner.

1 Group 4 Airplanes that have not incorporated 

previous releases of Service Bulletin 757-57-

0060.

2 Group 4 Airplanes that have incorporated 

previous releases of Service Bulletin 757-57-

0060.
 

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AEROMEXPRESS (MEX)

1 NA447

AIR ASTANA (AKZ)

1 NB561 NT411–NT412

AIR ATLANTA ICELANDIC (AID)

1 NA022 NA024 NB321

AIR CHINA SOUTHWEST BRANCH (XIN)

1 NB291–NB295 NB297–NB299 NB301–NB302 NB327

NT201–NT202

AIR FINLAND (FNL)

1 NB221 NB239 NB454

AIR GREENLAND AS (GRL)

1 NA350

AIR ITALY (RIT)

1 NE162–NE164

AIR SLOVAKIA (SLO)

1 NB071

AMERICA WEST AIRLINES (AMW)

1 NA018–NA020 NA028 NB021–NB023 NB036–NB041

AMERICAN AIRLINES (AAL)

1 NC075–NC084 NC091 NC093 ND011–ND044

ND046–ND059 ND111–ND113 ND161–ND166 ND168–ND199

NT352 NT731–NT736

3 NT743–NT744

4 NT353–NT354 NT360 NT371–NT373 NT737–NT742

ARKIA ISRAELI AIRLINES (ARK)

1 NA395

ASTRAEUS, LTD. (AUA)

1 NA442 NB131 NB142 NC052

NC067

ATA AIRLINES, INC. (AAT)

1 NC058 NC061–NC062 NT281–NT282

4 NT283

ATLASJET INT'L AIRWAYS (ABE)

1 NA025–NA026 NA196–NA197 NT910–NT911

AVIANCA (AVI)

1 NA341 NA347 NA351 NA406

NA441 NA444 NB324 NB326
 

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AXIS AIRWAYS (AXY)

1 NB453

AZERBAIJAN AIRLINES (AHY)

1 ND248

3 NT438

4 NT437

BELAIR AIRLINES (BLB)

1 NT426–NT427

BLUE PANORAMA AIRLINES (BPA)

1 NC094 NT351

BOEING (TBC)

1 NA001

BRITISH AIRWAYS (BAB)

1 NA237–NA239 NA303–NA305 NA398 NB581–NB583

NT401–NT403

CAMEROON AIRLINES (CAM)

1 NB135

CEBU PACIFIC AIR (CEB)

1 NA301–NA302 NA348

CHANNEL EXPRESS (AIR SERVICES) (CEX)

1 NA396 NB072

CHINA SOUTHERN AIRLINES (GUN)

1 NA349 NB061–NB068 NB070 NB261–NB267

NB296

CHINA XINJIANG AIRLINES (XIJ)

1 NB325 NB328 NT231 NT381–NT382

3 NT384

4 NT383 NT408–NT409

CONDOR (CDF)

1 NE166

CONTINENTAL AIRLINES (CAL)

1 ND301–ND322 NT751–NT760 NT769

4 NT761–NT768

DELTA AIR LINES (DAL)

1 NA501–NA586 NB001–NB004 NE008 NT701–NT708

NT717–NT723

3 NT724–NT730

4 NT709–NT716
 

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DHL INTERNATIONAL (DHI)

1 NA201–NA204 NA206–NA213 NA215–NA236

EL AL ISRAEL AIRLINES (ELA)

1 NA394 NB073 ND002 ND004–ND007

ND401

EOS AIRLINES, INC. (EPX)

1 NC056 NC072–NC073

ESTADO NACIONAL ARGENTINO ENA (ESA)

1 NB144

ETHIOPIAN AIRLINES (ETH)

1 NC092 NE201–NE204

2 NC951

4 NT356

EUROPEAN AIR TRANSPORT (EPT)

2 NC974

EXCEL AIRWAYS (SBE)

1 NA023

FAR EASTERN AIR TRANSPORT (FAT)

1 NC051 NE302 NT881–NT882

2 NC973

4 NT883–NT885

FINNAIR (FIN)

1 NT341–NT344

4 NT345

FINOVA (GRB)

1 NC060

FIRST CHOICE AIRWAYS (ATZ)

1 NA346 NA352 NA443 NB134

NB322 NB329 NB506–NB507 NT232

3 NT245–NT246

4 NT404–NT407

FISCHER AIR POLAND (FSP)

1 NB167 NC057

FLYJET LIMITED (FJE)

1 NB132 NB140

FUNAIR (FUN)

1 NT909

GREECE AIRWAYS (GRX)

1 NA397
 

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HARMONY AIRWAYS INC. (MYA)

1 NB202 ND001 ND003

HOLA AIRLINES (HLB)

1 NA399 ND243

HONEYWELL AEROSPACE (SGC)

1 NA005

IBERIA AIRLINES (IBE)

1 ND241 NT912–NT913

3 NT914–NT916

4 NT905–NT908

ICELANDAIR (ICE)

1 NB079 NB138–NB139 NB224 NB421

ND201–ND203 ND244–ND247 NN001 NT861

2 NC971

3 NN002

4 NT862

L-3 C.I.S. (CIJ)

1 NB146–NB148

4 NT436

L.T.E. INTERNATIONAL AIRWAYS (LTE)

1 NA191

MEXICANA (CMA)

1 NE161 NT376–NT378

3 NT375

MEXICO'S PRESIDENTIAL AIRCRAFT (MXG)

1 NA027

MID EAST JET (SKL)

1 NC161

MONARCH AIRLINES (MON)

1 NA401–NA405 NA407–NA408

MYTRAVEL AIRWAYS (GUE)

1 NA006 NA008 NB145 NB571

NASA (NAS)

1 NA002

NORTH AMERICAN AIRLINES (NNA)

1 NB236 NT242

3 NT240

4 NT239
 

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NORTHWEST AIRLINES (NWA)

1 NC001–NC033 NE311–NE325

OMNI AIR INTERNATIONAL (OAE)

1 NB137 NB204 NB225

ORIENT THAI AIRLINES (OTH)

1 NA193

PACE AIRLINES (PIE)

1 NA194 NA205 ND242

PEGASUS AVIATION, INC. (PSS)

1 NA214 NA391–NA393

PLUNA (PLU)

1 NB133

PRIMARIS AIRLINES INC. (PIM)

1 NA199

PRIVATAIR (PTS)

1 NB136

ROYAL AIR MAROC (RAM)

1 NC041–NC042

ROYAL BRUNEI AIRLINES (RBA)

1 NB052

ROYAL NEPAL AIRLINES (RNA)

1 ND891

2 ND895

ROYAL NEW ZEALAND AIR FORCE (RNZ)

1 NB451–NB452

RYAN INTERNATIONAL AIRLINES (RYN)

1 NA021 NA195 NA198 NA342

NB203

SAUDI ROYAL FLIGHT (SRF)

1 NB168

SHANGHAI AIRLINES (SHA)

1 NE001–NE007

4 NT358

SKYSERVICE AIRLINES (SKB)

1 NA345

STATE AIR COMPANY "BERKUT" (ORE)

1 NB053
 

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SUNEXPRESS (SNS)

1 NC066 NC069

TACV-CABO VERDE AIRLINES (TCV)

1 NC074

3 NT379

THE YUCAIPA COMPANIES (YUC)

1 NB312

THOMAS COOK AIRLINES UK (JMA)

1 NA445 NB201 NB222–NB223 NB226–NB228

NB230 NB330–NB331 NB446 NT233

NT237–NT238

4 NT234

THOMSONFLY (BRI)

1 NA343–NA344 NB422–NB424 NB426–NB438

4 NT431–NT432

TITAN AIRWAYS (TIU)

1 NB323

TURKMENISTAN AIRLINES (TUE)

1 NB143 NB161–NB162

3 NT446

UNITED AIRLINES (UAL)

1 NE011–NE088 NE092–NE094 NE141–NE150 NT791–NT794

4 NT795–NT796

UPS (UPS)

1 NT005–NT007

2 NC901–NC950 NS601–NS616 NT001–NT004

4 NT008–NT009

US AIR FORCE (USF)

1 NP901–NP904

US AIRWAYS (USA)

1 NA003–NA004 NA007 NA009–NA010 NA012–NA016

NB501–NB505 NB508–NB523 NT286

3 NT288–NT289

UZBEKISTAN AIRWAYS (UZB)

1 NC151

4 NT355 NT357 NT359 NT441–NT442

VARIG AIRLINES (VAR)

4 NT901–NT904
 

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VIM AIRLINES (VIM)

1 NC059 NE165 NE167–NE177 NT287

4 NT284–NT285

VULCAN INC. (VUL)

1 NB141 NB311

XIAMEN AIRLINES (XIA)

1 ND221–ND225

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

NA001–NA028 1

NA191–NA199 1

NA201–NA239 1

NA301–NA305 1

NA341–NA352 1

NA391–NA399 1

NA401–NA408 1

NA441–NA447 1

NA501–NA586 1

NB001–NB004 1

NB021–NB023 1

NB036–NB041 1

NB051–NB053 1

NB061–NB073 1

NB079 1

NB131–NB148 1

NB161–NB162 1

NB166–NB168 1

NB201–NB204 1

NB221–NB228 1

NB230 1

NB236 1

NB239 1

NB261–NB267 1

NB291–NB299 1

NB301–NB302 1

NB311–NB312 1

NB321–NB331 1

NB421–NB438 1

NB446 1
 

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BOEING SERVICE BULLETIN 757-57-0060

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 2

NC971–NC974 2

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 2

NE001–NE008 1

NE011–NE088 1

NE091–NE094 1

NE141–NE150 1

NE161–NE177 1

NE201–NE204 1

NE301–NE302 1

NE311–NE325 1

NN001 1

NN002 3

NP901–NP904 1

NS601–NS616 2

NT001–NT004 2

Variable Group
 

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NT005–NT007 1

NT008–NT009 4

NT201–NT202 1

NT231–NT233 1

NT234 4

NT237–NT238 1

NT239 4

NT240 3

NT242 1

NT245–NT246 3

NT281–NT282 1

NT283–NT285 4

NT286–NT287 1

NT288–NT289 3

NT341–NT344 1

NT345 4

NT351–NT352 1

NT353–NT360 4

NT371–NT373 4

NT375 3

NT376–NT378 1

NT379 3

NT381–NT382 1

NT383 4

NT384 3

NT401–NT403 1

NT404–NT409 4

NT411–NT412 1

NT426–NT427 1

NT431–NT432 4

NT436–NT437 4

NT438 3

NT441–NT442 4

NT446 3

NT701–NT708 1

NT709–NT716 4

NT717–NT723 1

NT724–NT730 3

NT731–NT736 1

Variable Group
 

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2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Initial inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied 

to the outboard corners of the front spar. As a result, Boeing Service Bulletin 757-57-0053 "WINGS - 

Wing Center Section - Application of Secondary Fuel Barrier to Areas on the Front Spar" was issued 

with a related Airworthiness Directive (AD). More inspections found defective examples of the 

Secondary Fuel Barrier applied along the front spar and the upper panel.

The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure. 

When the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from 

fuel leaks or fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener 

holes or cracks in the structure and pass into the passenger compartment. There are no reports from 

operators of fuel leaks or fumes in the passenger compartment.

This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front 

spar and upper panel. The inspections will identify locations where the secondary fuel barrier is not 

satisfactory. A new layer of secondary fuel barrier will be applied if it is necessary. A satisfactory 

secondary fuel barrier will keep fuel leaks or fumes out of the pressurized cabin.

NOTE: A satisfactory secondary fuel barrier is described in the Accomplishment Instructions,

Part IV - Inspection of the Secondary Fuel Barrier - Group 1 and Group 2.

Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin.

NT737–NT742 4

NT743–NT744 3

NT751–NT760 1

NT761–NT768 4

NT769 1

NT791–NT794 1

NT795–NT796 4

NT861 1

NT862 4

NT881–NT882 1

NT883–NT885 4

NT901–NT908 4

NT909–NT913 1

NT914–NT916 3

Variable Group
 

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Revision 1 was sent to add airplanes NT373, NT716, NT717, NT767, NT768, NT884, NT885 and 

NT908 to Group 1 of the service bulletin effectivity. This revision also includes new Weight and 

Balance Changes in Paragraph 2.H.

Revision 2 is sent to add a group of airplanes that may have been delivered with improperly mixed 

secondary fuel vapor barrier sealant and to provide new thickness measurement inspection limits. 

This revision includes the correct special tooling part numbers for the accomplishment of the service 

bulletin, and provides clarifications and corrections to inspection points on the Front Spar and Upper 

Panel. 

D. Description

Get access to the front spar and the Wing Center Section by removal of the seats, floor covers, floor 

panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If necessary, remove the 

bulkhead lining for more access.

Examine the specified locations where the Secondary Fuel Barrier is applied. Look for examples of 

missing, peeled, non-continuous or non-transparent secondary fuel barrier. Make sure the applied 

thickness of the secondary fuel barrier is between the specified limits. Remove the corrosion inhibitor 

compound if it is necessary, then clean the areas where the new layer of secondary fuel barrier will 

be applied. Install all the components that were removed for access. Do system tests if it is 

necessary. 

The airplane effectivity is divided into four groups. The airplanes in Group 1, Group 2 and Group 4 

must complete all of the service bulletin. Group 1 and Group 4 contain the 757-200 Airplanes and 

Group 2 contains the 757-200CB and 757-200PF Airplanes. As a result, there are differences in the 

instructions to get access to the Front Spar and Upper Panel for the two groups. The airplanes in 

Group 3 do not have to complete all of the service bulletin. Group 3 will only do work on the Front 

Spar.

Revision 2 - More work is necessary on airplanes changed as shown in the previous releases of this 

service bulletin. The airplanes in Group 4, Configuration 2 must be checked to determine if the 

Secondary Fuel Barrier meets the thickness requirements.

PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION 

RESULTS WHEN EACH INSPECTION IS COMPLETE.

Send your report to:

BOEING COMMERCIAL AIRPLANES GROUP

ATENTION: MANAGER, AIRLINE SUPPORT

E. Compliance

Boeing recommends the inspection of the Secondary Fuel Barrier at the next regularly scheduled 

heavy maintenance check. Apply the secondary fuel barrier, if it is necessary, no later than five years 

after the release of this service bulletin.
 

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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.

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 bulletin for each airplane. 

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator 

task-hour data if necessary. The estimate does not include lost time. These are some examples of 

lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Group 1 and Group 4, Configuration 1 ONLY

Group 2 ONLY

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 13.0 6.5

Inspection 2 8.0 4.0

Thickness Measurement 1 6.0 6.0

Secondary Fuel Barrier 

Application

1 6.5 6.5

Close Access 2 15.0 7.5

TOTAL FOR EACH AIRPLANE 48.5 30.5

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 8.0 4.0

Examine 2 8.0 4.0

Thickness Measurement 1 6.0 6.0
 

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Group 3 ONLY

Group 4, Configuration 2 ONLY

H. Weight and Balance Changes

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Miscellaneous Retrofit Requirement (MRR) MRR 5574-1067

b. Service Related Problem (SRP) 757-SRP-28-0067

Secondary Fuel Barrier 

Application

1 6.5 6.5

Close Access 2 10.0 5.0

TOTAL FOR EACH AIRPLANE 38.5 25.5

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 4.0 2.0

Inspection 2 8.0 4.0

Secondary Fuel Barrier 

Application

1 6.5 6.5

Close Access 2 6.0 3.0 

TOTAL FOR EACH AIRPLANE 24.5 15.5

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 13.0 6.5

Thickness Measurement 1 6.0 6.0

Secondary Fuel Barrier 

Application

1 6.5 6.5

Close Access 2 15.0 7.5

TOTAL FOR EACH AIRPLANE 40.5 26.5

Airplane

Change in Weight 

(Pounds)

Change in Moment 

(Pound-Inches)

Passenger 757-200 + 2 + 2,000

Cargo 757-200CB / 757-200PF + 2 + 2,000

Task

Number of 

Persons Task-Hours Elapsed Hours
 

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c. Boeing Document D6-56722, Customer Cost Benefit Methodology Guide

d. 757 Maintenance Manual (AMM) Subjects 20-10-11, 20-10-12, 21-00-00, 21-00-01,

21-21-00, 21-23-06, 24-22-00, 25-21-02, 25-25-01, 25-27-01, 25-50-03, 25-50-04,

28-11-00, 36-00-00 and 53-01-01.

e. 757 Structural Repair Manual (SRM) Subject 57-10-10

f. Boeing Standard Overhaul Practices Manual (BSOPM) 20-41-05, 20-50-19 and 20-60-01

g. 757 Maintenance Planning Document (MPD) Item Number CP53-124-01I

h. Boeing Service Bulletin 757-57-0053, "WINGS - Wing Center Section - Application of 

Secondary Fuel Barrier to Areas on the Front Spar"

i. FAA Airworthiness Directive 98-19-05, Amendment 39-10747

j. Boeing Parts Standards Document D-590

k. Boeing Drawing 65-88700

l. Boeing specification BAC 5527 - Application of Secondary Fuel Barrier

2. Data supplied with this Service Bulletin:

None.

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

These drawings were used to prepare this service bulletin. These drawings are not necessary 

to make the specified changes, and are not supplied with this service bulletin. These drawings 

may not be applicable to all airplane configurations or operators.

K. Publications Affected

None.

L. Interchangeability and Intermixability of Parts

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

Drawing Number Title

110N0004 Seal Application - Secondary Fuel Barrier Coating, Wing Center 

Section

112N2010 Terminal Fitting Installation - Wing / Body Joint, Front Spar

144N2101 Bulkhead Installation, Front Spar Body Station 900
 

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BLANK PAGE
 

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2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are available for 757 airplanes in warranty as of September 22, 2000. For 

inspection man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim 

to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin 

is found during the inspection for airplanes in warranty as of that date and additional man-hours and 

kits, parts, and/or special tools are required, send a warranty claim to Boeing Commercial Airplanes 

Group - Warranties. Please refer to this service bulletin number and reference the airplane variable 

numbers in your purchase order.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

Part Number / Specification QTY Name Notes

180 to 400 grit 20 Sheets Abrasive Paper, Aluminum Oxide

BMS 5-81, Type II 40 oz. Sealant, Secondary Fuel Barrier (a)

BMS 3-23, Type II, Class 2 1 Pint Organic Corrosion Inhibiting Compound (a)

BMS 3-29 1 Pint Advanced Organic Corrosion Inhibiting 

Compounds (CIC)

(a)

BMS 3-35 1 Pint Heavy Duty Corrosion Inhibiting Compound (a)

BMS 10-11, Type I 1 Pint Chemical and Solvent Resistant Finish (a)

BMS 5-95, Type 1, Class B-1/2, 

B -2 or B-4

1 Pint Pressure and Environmental Sealant - 

Chromate Type

(a) (b)

(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier 

data.

(b) Refer to BSOPM 20-50-19
 

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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 Non-Conductive Coating Thickness Gage 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 all necessary 

tools are available.

Tool Number Name

602-816 Dualscope MP20 (a) (b)

602-128 ETA 3.3H Probe (a) (b)

(a) The Dualscope with probe is an example of a Non-Conductive Coating 

Thickness Gage (NCCTG). The use of any NCCTG is permitted, but it must 

have a thickness range from 0.001 - 0.045 inches.

(b) Fisher Technology (9U437)

750 Marshall Phelps Rd.

Windsor, CT 06095-2199
 

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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

NOTE:

1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for 

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. The work instructions are divided into work packages. Task-Hours and Elapsed-Hours 

for each package are given in Paragraph 1.G., Manpower. You can do each work 

package independently.

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.

— 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 are given in 757 Structural Repair 

Manual, Chapter 51

— Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, 

Chapter 51.

5. For approved fastener and process material substitutions, refer to 757 Structural Repair 

Manual, Chapter 51, Alternate fasteners are given in 757 Structural Repair Manual 

Chapter 51 and Boeing Drawing 65-88700

6. Refer to the Boeing Standard Wiring Practices Manuals 20-10-11 and 20-10-12 for the 

wire installation procedures.

7. If the length of fasteners specified in this service bulletin do not meet the installation 

standards, fasteners of the same specification, or an approved substitute, one grip 

length longer or shorter may be used.

8. Detailed Visual Inspection - An intensive examination of a specific item, installation or 

assembly to detect damage, failure or irregularity. Available lighting is normally 

supplemented with a direct source of good lighting at an intensity deemed appropriate. 

Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface 

cleaning and elaborate access procedures may be required.

B. WORK INSTRUCTIONS

1. For Group 1, Group 2, Group 3 and Group 4, Configuration 1 airplanes, do Part I through Part X 

as applicable.

2. For Group 4, Configuration 2 airplanes, do Part XI.

PART I - Open Access - Group 1 and Group 4, Configuration 1 

1. Supply external power to the airplane, as given in 757 AMM 24-22-00.
 

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2. Release the pressure from the pneumatic system; refer to 757 AMM 36-00-00.

3. Set the L and R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to 

757 AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

b. Put a DO-NOT-OPERATE tag on the selectors.

4. Set the L and R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel P5. 

Refer to 757 AMM 21-00-01.

a. Make sure the INOP lights go on, and the ON lights go off.

b. Put a DO-NOT-OPERATE tag on the switch-lights.

5. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section.

a. Between BS 900 and 1040, remove:

(1) The passenger seats, as referenced in 757 AMM 25-25-01.

(2) The floor covering, as referenced in 757 AMM 25-27-01.

(3) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(4) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.

b. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1.

c. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in

757 AMM 25-50-03.

PART II - Open Access - Group 2

1. Supply external power to the airplane, as given in 757 AMM 24-22-00.

2. Release the pressure from the pneumatic system; refer to 757 AMM 36-00-00.

3. Set the L and R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to 

757 AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

b. Put a DO-NOT-OPERATE tag on the selectors.

4. Set the L and R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel P5. 

Refer to 757 AMM 21-00-01.

a. Make sure the INOP lights go on, and the ON lights go off.

b. Put a DO-NOT-OPERATE tag on the switch-lights.
 

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5. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section.

a. Between BS 900 and 1040, remove:

(1) The floor covering, as referenced in 757 AMM 25-27-01.

(2) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(3) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.

b. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 2.

c. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in

757 AMM 25-50-03.

Part III - Open Access - Group 3 

1. Supply external power to the airplane, as given in 757 AMM 24-22-00.

2. Release the pressure from the pneumatic system; refer to 757 AMM 36-00-00.

3. Set the L and R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to 

757 AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

b. Put a DO-NOT-OPERATE tag on the selectors.

4. Set the L and R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel P5. 

Refer to 757 AMM 21-00-01.

a. Make sure the INOP lights go on, and the ON lights go off.

b. Put a DO-NOT-OPERATE tag on the switch-lights.

5. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section.

a. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1.

b. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in

757 AMM 25-50-03.

Part IV - Inspection of the Secondary Fuel Barrier - Group 1, Group 2 and Group 4, 

Configuration 1

1. Do a Detailed Visual Inspection of the Front Spar and the Upper Panel. Refer to Figure 3 and 

Figure 4 for the specified location of the application.

a. Look for signs of missing, peeled, non-continuous or non-transparent secondary fuel barrier. 

(1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to 

examine in Paragraph 1.b.
 

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(2) If defective surfaces are found, the secondary fuel barrier is NOT permitted. Record 

the location. Repair as given in Part VI - Repair of Secondary Fuel Barrier - Group 1, 

Group 2 and Group 4. Continue to examine in Paragraph 1.b.

b. Look for small air bubbles, air pockets or blister-like areas, or solid particles in the secondary 

fuel barrier or between the secondary fuel barrier and the structure.

(1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to 

examine the surface as directed in Paragraph 1.c.

(2) If some small air bubbles or non-metallic solid particles are found, they must NOT break 

the continuity of the application of the secondary fuel barrier. If there are no more than 

2 (two) occurrences in a 12 inch by 12 inch area the application is permitted. Continue 

to examine the surface as directed in Paragraph 1.c if this statement is correct.

(3) Air pockets or blister-like areas between the secondary fuel barrier and the structure 

are NOT permitted. Record the location and repair as given in Part VI – Repair of the 

Secondary Fuel Barrier – Group 1, Group 2 and Group 4.

NOTE: Solid metallic particles are not acceptable. Record the location and repair as

given in Part VI – Repair of the Secondary Fuel Barrier – Group 1, Group 2

and Group 4.

(4) If small air bubbles, air pockets or non-metallic solid particles break the continuity of the 

application of the secondary fuel barrier, the application is NOT permitted. Record the 

location. Repair as given in Part VI - Repair of the Secondary Fuel Barrier - Group 1, 

Group 2 and Group 4. Continue to examine in the surface as directed in Paragraph 1.c.

c. Look for fillet sealant, primer, corrosion inhibiting compound or other finishes that are 

applied on top of the Secondary Fuel Barrier.

(1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to 

examine in Paragraph 1.d.

(2) If defective surfaces are found, and the structure below can be seen, it is a permitted 

secondary fuel barrier. Continue to examine in Paragraph 1.d.

(3) If defective surfaces are found, but the structure below cannot be seen, it is NOT a 

permitted secondary fuel barrier. Record the location. Repair as given in Part VI - 

Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 4. Continue to 

examine in Paragraph 1.d.

d. Look for missing fillet (cap) seals common to the fastener locations shown in Figure 3,

View J-J.

(1) If all the locations are cap sealed, no work is necessary. Continue to do the 

Accomplishment Instructions.

(2) If there are locations that are not cap sealed, record the location. Repair as given in 

Part VI - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 4. 

Continue to do the Accomplishment Instructions.
 

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Part V - Thickness Measurement Inspection - Group 1 and Group 2

1. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figure 5 

and Figure 6.

2. Make sure the thickness is 0.007 - 0.022 inch. (This includes a 0.002 inch layer of primer.)

a. If the thickness is less than 0.007 inch, apply more Secondary Fuel Barrier as given in Part 

XII - Application of More Secondary Fuel Barrier.

b. If the thickness is more than 0.022 inch, it must have a transparent quality. A transparent 

quality makes it easy to see a crack in the structure. An applied secondary fuel barrier that 

is not transparent must be removed. Repair as given in Part VI - Repair of Secondary Fuel 

Barrier - Group 1, Group 2 and Group 4. 

c. If the thickness is more than 0.042 inch, the secondary fuel barrier is NOT permitted. Repair 

as given in Part VI - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 4.

NOTE: Do NOT measure on top of the other sealants. There is no limit to the thickness of

secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental

Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant).

3. Record the thickness data in the Inspection Worksheets given in Appendix A. 

Part V(a) - Thickness Measurement Inspection - Group 4, Configuration 1

1. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figure 5 

and Figure 6.

NOTE: The thickness measurements below includes a 0.002 inch layer of primer.

a. If the thickness is less than 0.007 inch, apply a minimum of 0.005 inch new Secondary Fuel 

Barrier as given in Part XII - Application of More Secondary Fuel Barrier. 

b. If the thickness is greater than 0.012 inch, but less than or equal to 0.017 inch, apply a 

minimum of 0.005 inch new Secondary Fuel Barrier as given in Part XII - Application of More 

Secondary Fuel Barrier.

NOTE: Thicknesses between 0.007 inch and 0.012 inch do not require the application of

the additional 0.005 inch secondary fuel barrier. Overcoating is allowed in this

thickness range to make the repair of adjacent areas more efficient.

c. If the thickness is greater than 0.017 inch, but less than or equal to 0.037 inch it must have 

a transparent quality and it must be overcoated with a minimum of 0.005 inch of new 

Secondary Fuel Barrier as givein in Part XII - Application of More Secondary Fuel Barrier. 

NOTE: A transparent quality makes it easy to see a crack in the structure. An applied

secondary fuel barrier that is not transparent must be removed. Repair as given in

Part VI - Repair of Secondary Fuel Barrier - Group 1, Group 2 and Group 4.

d. If the thickness is more than 0.037 inch, the secondary fuel barrier is NOT permitted. Repair 

as given in Part VI - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 4.
 

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NOTE: Do NOT measure on top of the other sealants. There is no limit to the thickness of

secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental

Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant).

2. Record the thickness data in the Inspection Worksheets given in Appendix A and keep the 

worksheet with the airplane maintenance records for future reference. 

Part VI - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 4

1. Repair the Secondary Fuel Barrier at the locations noted in Part IV - Inspection of the Secondary 

Fuel Barrier - Group 1, Group 2 and Group 4, Configuration 1; and in Part V - Thickness 

Measurement Inspection - Group 1 and Group 2, or Part V(a) for Group 4, Configuration 1.

a. Remove the secondary fuel barrier as given in 757 AMM 28-11-00.

NOTE: 757 AMM 28-11-00 does not directly address removal of large areas of BMS 5-81

sealant. It is permissible to remove the bulk of the sealant with the use of plastic or

wooden scrapers. Boeing production typically uses plastic scrapers.

b. If not already applied, apply a cap seal to the top side of the fasteners as specified in 

BSOPM 20-50-19. Refer to Figure 3, View J-J.

c. Apply the secondary fuel barrier as given in 757 AMM 28-11-00.

Part VII - Inspection and Application of the Secondary Fuel Barrier - Group 3

1. Do a Detailed Visual Inspection of the Front Spar and the Upper Panel to ensure that the 

application covers the minimum area specified in Figure 7.

a. Make sure the Secondary Fuel Barrier is applied a minimum of 1.50 inches below the lowest 

fastener that passes through the front spar web and the lower chord.

b. If the Secondary Fuel Barrier does not cover the minimum specified area, apply more 

secondary fuel barrier 757 AMM 28-11-00.

Part VIII - Close Access - Group 1 and Group 4, Configuration 1

1. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center 

Section.

a. Install the air conditioning ducts on the mix manifold as shown in Figure 8.

b. Do a leak test of the air conditioning ducts as given in 757 AMM 21-23-06 "Do the Riser Duct 

Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser 

duct.

c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in

AMM 25-50-03.

d. Between BS 900 and 1040, install:

(1) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.
 

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(2) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(3) The floor covering, as referenced in 757 AMM 25-27-01.

(4) The passenger seats, as referenced in 757 AMM 25-25-01.

2. Set the L and R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. 

Refer to 757 AMM 21-00-01.

a. Remove the DO-NOT-OPERATE tag from the switch-lights.

b. Make sure the INOP lights go off, and the ON lights go on.

3. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to 

757 AMM 21-00-00.

a. Remove the DO-NOT-OPERATE tag from the selectors.

b. Make sure the PACK OFF lights go off.

4. Put the pneumatic system back to service condition. Refer to 757 AMM 36-00-00.

5. Put the electrical power back to service condition, as given in 757 AMM 24-22-00.

6. Put the airplane back to a serviceable condition.

Part IX - Close Access - Group 2

1. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center 

Section.

a. Install the air conditioning ducts as shown in Figure 9.

b. Do a leak test of the air conditioning ducts as given in757 AMM 21-23-06 "Do the Riser Duct 

Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser 

duct.

c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in

757 AMM 25-50-03.

d. Between BS 900 and 1040, install:

(1) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.

(2) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(3) The floor covering, as referenced in 757 AMM 25-27-01.

2. Set the L and R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. 

Refer to 757 AMM 21-00-01.

a. Remove the DO-NOT-OPERATE tag from the switch-lights.
 

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b. Make sure the INOP lights go off, and the ON lights go on.

3. Set the L and R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to 

757 AMM 21-00-00.

a. Remove the DO-NOT-OPERATE tag from the selectors.

b. Make sure the PACK OFF lights go off.

4. Put the pneumatic system back to service condition. Refer to 757 AMM 36-00-00.

5. Put the electrical power back to service condition, as given in 757 AMM 24-22-00.

6. Put the airplane back to a serviceable condition.

PART X - Close Access - Group 3

1. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center 

Section.

a. Install the air conditioning ducts on the mix manifold as shown in Figure 8.

b. Do a leak test of the air conditioning ducts as given in 757 AMM 21-23-06 "Do the Riser Duct 

Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser 

duct.

c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in

757 AMM 25-50-03.

2. Set the L and R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. 

Refer to 757 AMM 21-00-01.

a. Remove the DO-NOT-OPERATE tag from the switch-lights.

b. Make sure the INOP lights go off, and the ON lights go on.

3. Set the L and R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to 

757 AMM 21-00-00.

a. Remove the DO-NOT-OPERATE tag from the selectors.

b. Make sure the PACK OFF lights go off.

4. Put the pneumatic system back to service condition. Refer to 757 AMM 36-00-00.

5. Put the electrical power back to service condition, as given in 757 AMM 24-22-00.

6. Put the airplane back to a serviceable condition.
 

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PART XI - Thickness Measurement Inspection - Group 4, Configuration 2 Airplanes

1. Review the maintenance records for the airplane to determine if there was a minimum of 0.005 

inch of new Secondary Fuel Barrier applied. If a minimum of 0.005 inch of new Secondary Fuel 

Barrier was applied, then no further action is required in that area.

2. If the thickness of the Secondary Fuel Barrier can not be determined from the maintenance 

records or if there was not a minimum of 0.005 inch of new Secondary Fuel Barrier added, then 

go to Step 3.

3. Supply external power to the airplane, as given in 757 AMM 24-22-00.

4. Release the pressure from the pneumatic system; refer to 757 AMM 36-00-00.

5. Set the L and R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to 

757 AMM 21-00-00.

a. Make sure the PACK OFF lights come on.

b. Put a DO-NOT-OPERATE tag on the selectors.

6. Set the L and R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel P5. 

Refer to 757 AMM 21-00-01.

a. Make sure the INOP lights go on, and the ON lights go off.

b. Put a DO-NOT-OPERATE tag on the switch-lights.

7. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section.

a. Between BS 900 and 1040, remove:

(1) The passenger seats, as referenced in 757 AMM 25-25-01.

(2) The floor covering, as referenced in 757 AMM 25-27-01.

(3) The floor panels, as referenced in 757 AMM 25-50-04 and 757 AMM 53-01-01.

(4) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.

b. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1.

c. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in 757 

AMM 25-50-03.

8. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figure 5 

and Figure 6.

NOTE: The thickness measurements below includes a 0.002 inch layer of primer.

a. If the thickness is less than 0.007 inch, apply a minimum of 0.005 inch new Secondary Fuel 

Barrier as given in Part XII - Application of More Secondary Fuel Barrier. 
 

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b. If the thickness is greater than 0.012 inch, but less than or equal to 0.017 inch, apply a 

minimum of 0.005 inch new Secondary Fuel Barrier as given in Part XII - Application of More 

Secondary Fuel Barrier.

NOTE: Thicknesses between 0.007 inch and 0.012 inch do not require the application of

the additional 0.005 inch secondary fuel barrier. Overcoating is allowed in this

thickness range to make the repair of adjacent areas more efficient.

c. If the thickness is greater than 0.017 inch, but less than or equal to 0.037 inch it must have 

a transparent quality and it must be overcoated with a minimum of 0.005 inch of new 

Secondary Fuel Barrier as given in Part XII - Application of More Secondary Fuel Barrier. 

NOTE: A transparent quality makes it easy to see a crack in the structure. An applied

secondary fuel barrier that is not transparent must be removed. Repair as given in

Step 10.

d. If the thickness is more than 0.037 inch, the secondary fuel barrier is NOT permitted. Repair 

as given in Step 10.

NOTE: Do NOT measure on top of the other sealants. There is no limit to the thickness of

secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental

Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant).

9. Record the thickness data in the Inspection Worksheets given in Appendix A, and retain the 

worksheet with the airplane maintenance records for future reference. 

10. Repair the Secondary Fuel Barrier where removal and reappliation is required.

a. Remove the secondary fuel barrier as given in 757 AMM 28-11-00.

NOTE: 757 AMM 28-11-00 does not directly address removal of large areas of BMS 5-81

sealant. It is permissible to remove the bulk of the sealant with the use of plastic or

wooden scrapers. Boeing production typically uses plastic scrapers.

b. If not already applied, apply a cap seal to the top side of the fasteners as specified in SOPM 

20-50-19. Refer to Figure 3, View J-J.

c. Apply the secondary fuel barrier as given in 757 AMM 28-11-00.

11. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center 

Section.

a. Install the air conditioning ducts on the mix manifold as shown in Figure 8.

b. Do a leak test of the air conditioning ducts as given in 757 AMM 21-23-06 "Do the Riser Duct 

Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser 

duct.

c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in

757 AMM 25-50-03.

d. Between BS 900 and 1040, install:
 

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(1) The sidewall lining (panels and carpet risers), as referenced in 757 AMM 25-21-02.

(2) The floor panels, as referenced in AMM 25-50-04 and 53-01-01.

(3) The floor covering, as referenced in AMM 25-27-01.

(4) The passenger seats, as referenced in AMM 25-25-01.

12. Set the L and R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. 

Refer to AMM 21-00-01.

a. Remove the DO-NOT-OPERATE tag from the switch-lights.

b. Make sure the INOP lights go off, and the ON lights go on.

13. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to 

AMM 21-00-00.

a. Remove the DO-NOT-OPERATE tag from the selectors.

b. Make sure the PACK OFF lights go off.

14. Put the pneumatic system back to service condition. Refer to AMM 36-00-00.

15. Put the electrical power back to service condition, as given in AMM 24-22-00.

16. Put the airplane back to a serviceable condition.

Part XII - Application of More Secondary Fuel Barrier

1. Lightly sand the area with 180 grit aluminum oxide or finer abrasive paper. Remove as little of 

the sealant film as possible. Do not sand to bare metal.

2. Remove residue with clean wipers

3. Prepare the secondary fuel barrier sealant (BMS 5-81, Type II) as given in AMM 28-11-00.

4. Apply one or two layers of BMS 5-81, Type II sealant with a flat, bristle brush. Take all reasonable 

precautions to prevent or minimize sag areas.

a. For horizontal surfaces, let the sealant dry a minimum of 1/2 hour between layers.

b. For vertical surfaces, let the sealant dry a minimum of 2 hours between layers.

5. Refer to AMM 28-11-00 for cure rates.
 FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 3 AND GROUP 

4 AIRPLANES

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FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 3 AND GROUP 

4 AIRPLANES

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Disconnect Duct Assembly 21-21-00 2 At each end; put covers 

over all open duct ends.

2 Remove Duct Assembly - 2 -

FWD

COMPARTMENT

TO PASSENGER

(2 EACH SIDE)

1 2

CONNECTOR

SERVICE

GROUND AIR

MIX MANIFOLD

V88149

(SHEET 1 OF 1)
 FIGURE 2: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 2 AIRPLANES

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FIGURE 2: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 2 AIRPLANES

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Disconnect Duct Assembly 21-21-00 1 At each end; put covers 

over all open duct ends.

2 Remove Duct Assembly - 1 -

MANIFOLD

MIX

MIX MANIFOLD

CONNECTOR

SERVICE

GROUND AIR

1 2

COMPARTMENT

TO MAIN CARGO

FWD

V88150

(SHEET 1 OF 1)
 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

FWD

900

STA

0

BL

45.50

RBL

45.50

LBL

900

STA

1 SPAR

FRONT

A

A

B B

0

BL

24.75

LBL

24.75

RBL

45.50

LBL

45.50

RBL

A-A

G

C

J J

F

70.50

RBL

70.50

LBL

3 FUEL BARRIER

SECONDARY 2

V83156

I I

D

D

C

G

E

E

F

H

H

(SHEET 1 OF 5)
 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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FUEL BARRIER

SECONDARY FUEL BARRIER

SECONDARY

TYPICAL

C-C

FUEL BARRIER

SECONDARY

LOWER CHORD

CAP SEAL

TYPICAL

D-D

FUEL BARRIER

SECONDARY

SPAR WEB

FRONT

FRONT SPAR MIN

1.50

UPPER PANEL INBD

FITTING

SHEAR

2 3

2 3

MIN

1.00

TYPICAL

B-B

2 3

FWD

MIN

1.0

MIN

1.0

MIN

1.0

MIN

1.0

FITTING

SIDE 2 3

FWD

V83188

(SHEET 2 OF 5)
 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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1.00

MIN

TYPICAL OUTBOARD OF BBL 45.50

E-E

FUEL BARRIER

SECONDARY

1.50

TYPICAL INBOARD OF BBL 45.50

F-F

FUEL BARRIER

SECONDARY

1.00

MIN

FUEL BARRIER

SECONDARY

TYPICAL

G-G

MIN

1.00

FRONT SPAR

SKIN

LOWER CHORD

FRONT SPAR

1.00

MIN STIFFENER

SPAR

FRONT

CHORD-BODY

2 3

FWD

STIFFENER

SPAR

FRONT

CHORD-BODY

2 3

FWD

2 3

INBD

FWD

FITTING

SIDE

0.50 MIN

V83190

(SHEET 3 OF 5)
 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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FUEL BARRIER

SECONDARY

OF BBL 45.50

TYPICAL OUTBOARD

H-H

MIN

0.50

FUEL BARRIER

SECONDARY

FRONT SPAR WEB

TYPICAL

I-I

STIFFENER

1.00

MIN

1.00

MIN

FUEL BARRIER

SECONDARY

INBD

FWD

4 (7 PLACES)

CAP SEAL

TYPICAL

J-J

2 3

FWD

2 3

FWD

CHORD

ANGLE

SPLICE

SPAR

FRONT

2 3

V88211

(SHEET 4 OF 5)
 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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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 one side of the airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Front Spar - Remove dirt/debris from 

the area

2 Identify Secondary Fuel 

Barrier

Visual Inspection - (a)

3

Examine Front Spar Detailed Visual 

Inspection

- (b) (c)

Remove Corrosion 

Inhibiting 

Compound

BMS 3-23 or 

BMS 3-29 or

BMS 3-35

- This is only necessary if 

it is difficult to identify a 

layer of Secondary Fuel 

Barrier. Refer to 

BSOPM 20-41-05 and 

20-60-01 for removal.

4 Verify Cap seal - 7 See View J-J

 (a) Look for a glossy finish, a clear to brown (or yellow) color, and a rubber-like texture.

 (b) Use a flashlight. Hold it 10 to 20 degrees to the inspection area.

 (c) Look for defective layers of secondary fuel barrier as specified in Part IV - Inspection of the 

Secondary Fuel Barrier - Group 1 and Group 2, in the Work Instructions.

(SHEET 5 OF 5)
 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

FWD

900

STA

0

BL

24.75

RBL

45.50

RBL

70.50

RBL

24.75

LBL

45.50

LBL

70.50

LBL

900

STA

TOP PANEL 1

1040

STA

208.1

WL

1040

STA

V83384

B

E

E

H

H

D

D

B

C

C

A

A

G

G

M

M

O

O

P

P

N

N

(SHEET 1 OF 7)
 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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RIGHT SIDE SHOWN, LEFT SIDE SAME

A-A

TYPICAL EDGE

PANEL

CHORD UPPER

PANEL

SKIN

PLUS

MIN

1.00

STA 975.5 TO 1040

TYPICAL BEAM

B-B

LOWER CHORD

FLOOR BEAM

WEB

BEAM

FLOOR

PANEL

UPPER

C-C

ASSEMBLY

PLUG

MIN

0.50

PANEL

UPPER

TYPICAL ALL BRACKETS

D-D

PANEL

UPPER

BRACKET

SUPPORT

MIN

1.00

MIN

0.75 2 3

BEAM

CREASE

2 3

2 3

INBD

FWD

2 3

FWD

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

V83457

(SHEET 2 OF 7)
 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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E-E

F-F

RIGHT SIDE SAME

LEFT SIDE SHOWN,

G-G

SPLICE

LONGERON

AND SEALANT

COMPOUND

EXISTING

F F

BEAM

STUB

MIN

1.00

PANEL

UPPER

CHORD

PLUS

MIN

0.25

2 3

70.50

RBL

70.50

RBL

INBD

FWD

PANEL

UPPER

BEAM

STUB

CHORD

PLUS 2 3

INBD

MIN

2.00

INBD

900

STA

SKIN

BODY

CHORD

PLUS

FRAME

PANEL

UPPER

SPAR

FRONT

2 3

208.10

WL

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

FUEL BARRIER

SECONDARY

SEALANT

EXISTING

V83468

(SHEET 3 OF 7)
 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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INBD

FWD

PANEL

UPPER

REAR SPAR

1.00 MIN

1.00 MIN MIN

1.00

MIN

1.00

1040

STA

FRAME

FITTING

KICK

2 3

MIN

2.00

MIN

1.00

MIN

1.00

70.50

LBL

PANEL

UPPER

KICK FITTING

FRAME

UPPER CHORD

REAR SPAR

1040

STA

2 3

70.50

LBL

45.50

LBL

24.75

LBL

0

BL

BEAM

FLOOR

CHORD

PLUS PANEL

UPPER

1024

STA

MIN

1.00

BEAM

FLOOR

BEAM

FLOOR

1040

STA

INBD

FWD

2 3

2 3

DO NOT BLOCK

DRAIN PATH -

OF KICK FITTING

TYPICAL OUTSIDE WALLS

I-I

SEALANT

EXISTING

H-H

J-J

FRAME

V83505

L

L

K

K

I

I

J J

(SHEET 4 OF 7)
 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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BOEING SERVICE BULLETIN 757-57-0060

MIN

1.00

MIN

1.00

SPAR

REAR

1040

STA

FITTING

KICK

PANEL

UPPER

SPACER

FRAME

SEAL

INJECTION

FILLET AND

EXISTING

FWD

2 3

FWD

SPAR

PANEL REAR

UPPER

BEAM WEB

FLOOR FITTING

SEAL

PRE-PACK

DECK

PRESSURE

ANGLE

ATTACH

1040

STA

MIN

1.00

MIN

1.00

2 3

DO NOT BLOCK

DRAIN PATH -

FWD

2 3

SEAL

INJECTION

FILLET AND

EXISTING

PANEL

UPPER

PLUS CHORD

DOUBLE

MIN

1.00

MIN

0.75

SPAR

FRONT

900

STA

DO NOT BLOCK

DRAIN PATH -

RIGHT SIDE SAME

LEFT SIDE SHOWN,

M-M

OF KICK FITTING

TYPICAL, INSIDE WALLS

K-K

L-L

MIN

1.00

MIN

2.00

MIN

0.75

PANEL

UPPER

SEAL

INJECTION

FILLET AND

EXISTING 1040

STA

2 3

MIN

2.00

PLUS CHORD

DOUBLE

SPAR

REAR

RIGHT SIDE SAME

LEFT SIDE SHOWN,

N-N

FWD

V83651

(SHEET 5 OF 7)
 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

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24.75

RBL

208.1

WL

MIN

1.00

BEAM

FLOOR

UPPER PANEL

TYPICAL FROM STA 900 TO STA 975.5

O-O

MIN

1.00

MIN

1.00

FITTING

TENSION

UPPER PANEL

BEAM

FLOOR

(15 PLACES)

TYPICAL AT TENSION TIE FITTINGS

P-P

2 3

2 3

N40227

(SHEET 6 OF 7)
 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4, CONFIGURATION 1 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Upper Panel - Remove dirt/debris from 

the area

2 Identify Secondary Fuel 

Barrier

Visual Inspection - (a)

3

Examine Upper Panel Detailed Visual 

Inspection

- (b) (c)

Remove Corrosion 

Inhibiting 

Compound

BMS 3-23 or 

BMS 3-29 or 

BMS 3-35

- This is only necessary if 

it is difficult to identify a 

layer of Secondary Fuel 

Barrier. Refer to 

BSOPM 20-41-05 and 

20-60-01 for removal.

 (a) Look for a glossy finish, clear to brown (or yellow) color, and a rubber-like texture.

 (b) Use a flashlight. Hold it 10 to 20 degrees to the inspection area.

 (c) Look for defective layers of secondary fuel barrier as specified in Part IV - Inspection of the 

Secondary Fuel Barrier - Group 1 and Group 2 and Group 4, Configuration 1 in the Work 

Instructions.

(SHEET 7 OF 7)
 FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

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BOEING SERVICE BULLETIN 757-57-0060

FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

BFAW (BODY FRAME ASSEMBLY WEB)

BFS (BODY FRAME STIFFENER)

FSS (FRONT SPAR STIFFENER)

FSW (FRONT SPAR WEB)

INSPECTION POINTS

(SEE APPENDIX A)

A

A

B

C

C

B

FWD

0

BL

70.50

RBL

70.50

LBL

900

STA

1

FSW 1

FSS 5

FSS 1

BFAW 2

FSS 10

FSS 6

BFS 4

BFS 3

FSS 15

FSS 11

FSS 20

FSS 16

FSS 25

FSS 21

FSS 26

FSS 30

FRONT SPAR

FSS 35

FSS 31

FSS 40

FSS 36

FSW INSPECTION POINTS)

(TYPICAL BETWEEN

5.0

4.0

FSS 46

FSS 41

FSS 45

FSS 50

FSS 55

FSS 51

FSS 59

14

FSW

BFS 2

FSS 64

BFS 1

BFAW 1

FSS 60

FSS 56

900

STA

V83664

(SHEET 1 OF 3)
 FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

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BOEING SERVICE BULLETIN 757-57-0060

TYPICAL FSW

(14 PLACES)

X

X/2

0.5

FRONT SPAR WEB

TYPICAL FSS

(64 PLACES)

STIFFENER

STIFFENER

TYPICAL

A-A

TYPICAL

C-C

FRAME

ASSY

SEAL

CAP

SKIN

FRONT

SPAR

TYPICAL

D-D

X

X/2

SPAR

(2 PLACES)

TYPICAL BFAW

FRONT

ASSY

FRAME

X

X/2

UPPER

PANEL

TYPICAL

B-B

(4 PLACES)

TYPICAL BFS

FRAME

FRONT

(TYPICAL)

STRINGER

ASSY

SKIN

(TYPICAL)

CAP SEAL SPAR

OF STIFFENER ONLY

INSPECT THIS SIDE

D

D

FWD

INBD FWD

1 2 1 2

1 2

1 2

1 2

V83665

(SHEET 2 OF 3)
 FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 68

BOEING SERVICE BULLETIN 757-57-0060

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 one airplane. 

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Front Spar Remove dirt/debris from 

the area

2

Measure/

Make Sure/ 

Record

Secondary Fuel 

Barrier

(a) (b) (c)

Front Spar Web FSW 14 See View A-A

Front Spar 

Stiffeners

FSS 64 See View A-A

Body Frame Assy 

Web

BFAW 2 See View B-B

Body Frame 

Stiffener

BFS 4 See View C-C and D-D

 (a) Use a Non-Conductive Coating Thickness Gage to measure the thickness of the applied secondary fuel barrier. (Refer to Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.)

 (b) Deleted - See Accomplishment Instructions for thickness limits.

 (c) Record the measurements on the Inspection Worksheets in Appendix A.

(SHEET 3 OF 3)
 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

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BOEING SERVICE BULLETIN 757-57-0060

FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

FWD

E

E

A

A

C

C

900

STA

0

BL

24.75

RBL

45.50

RBL

70.50

RBL

24.75

LBL

45.50

LBL

70.50

LBL

900

STA

TOP PANEL

1040

STA

208.1

WL

1040

STA

LSOB (LEFT SIDE OF BODY)

RSOB (RIGHT SIDE OF BODY)

INSPECTION POINTS

FB (FLOOR BEAM)

LTP (LEFT TOP PANEL)

RTP (RIGHT TOP PANEL)

(SEE APPENDIX A)

LSOB 10

LSOB 1

FB 50

FB 41

LTP 8

LTP 5

FB 40

LTP 4

FB 31

LTP 1

FB 21

FB 30

RTP 14

RTP 11

FB 20

FB 11

FB 10

RTP 10

RTP 7

FB 1

RSOB 1

RSOB 10

1

RTP 1

RTP 6

LTP 9

LTP 14

V83728

(SHEET 1 OF 5)
 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

5.0

5.0

3.0

3.0

11.0

13.0

(TYPICAL)

11.0

(TYPICAL)

13.0

TYPICAL FLOOR BEAM INSPECTION POINT

UPPER PANEL

B-B

FLOOR BEAM

0.50

OF THE WEB ONLY

INSPECT THIS SIDE

B

B

FWD

INBD

900

STA

920

STA

940

STA

960

STA

980

STA

1000

STA

1020

STA

1032.3

STA

1040

STA

TYPICAL FLOOR BEAM INSPECTION POINTS

A-A

FLOOR BEAM

10 PLACES PER

1 2

1 2

V84894

(SHEET 2 OF 5)
 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

PANEL

UPPER

5.0

C-C

PLUS

CHORD

LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE

TYPICAL SIDE-OF-BODY INSPECTION POINTS

10 PLACES

BEAM

STUB

LSOB 1 LSOB 10

1020

STA

1000

STA

980

STA

960

STA

920

STA SPAR

FRONT REAR

SPAR

5.0

3.0

(TYPICAL)

11.0

13.0

(TYPICAL)

3.0

11.0

13.0

BEAM

CREASE

CHORD

PLUS

SKIN

BODY 0.5

CENTER SECTION

UPPER PANEL OF

D-D

940

STA

D

D

FWD

INBD

UP

INBD

1 2

1 2

V84895

(SHEET 3 OF 5)
 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

(16 PLACES)

TYPICAL UPPER PANEL INSPECTION POINTS

FLOOR

BEAM

FLOOR

BEAM PANEL

E-E

REAR

SPAR 1000

STA

980

STA

FB

UPPER TO FLOOR BEAM WEB

FLOOR BEAM WEB

TYPICAL

X/2

X

26.0

24.0

26.0

24.0

(TYPICAL)

RBL

24.75

RBL

45.50

FWD

1 2

V84897

(SHEET 4 OF 5)
 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND 

GROUP 4 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 68

BOEING SERVICE BULLETIN 757-57-0060

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Clean Front Spar and 

Upper Panel

Remove dirt/debris from 

the area

2

Measure/

Make Sure/ 

Record

Secondary Fuel 

Barrier

- (a) (b) (c)

Floor Beam FB 50 10 locations each, on the 

right and left side. See 

View A-A and B-B

Side of Body RSOB and LSOB 20 10 locations each, on the 

right and left side. See 

View C-C and D-D

Upper Panel RTP and LTP 16 8 locations each, on the 

right and left side. See 

View E-E

 (a) Use a Non-Conductive Coating Thickness Gage to measure the thickness of the applied secondary fuel barrier. (Refer to Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.)

 (b) Deleted - See Accomplishment Instructions for thickness limits.

 (c) Record the measurements on the Inspection Worksheets in Appendix A.

(SHEET 5 OF 5)
 FIGURE 7: INSPECTION AND APPLICATION OF SECONDARY FUEL BARRIER - GROUP 3 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

FIGURE 7: INSPECTION AND APPLICATION OF SECONDARY FUEL BARRIER - GROUP 3 AIRPLANES

FUEL BARRIER

SECONDARY

LOWER CHORD

FRONT SPAR

SPAR WEB

FRONT

MIN

1.5

TO FRONT SPAR WEB AND LOWER CHORD

TYPICAL MINIMUM COVERAGE COMMON

B-B

A-A

MIN

1.5

FWD

FWD

1

LOWER CHORD FRONT SPAR WEB

FRONT SPAR

166

WL SPAR

FRONT ALLOWED

OVERSPRAY

0

BL

24.75

RBL

45.50

RBL

70.50

RBL

24.75

LBL

45.50

LBL

70.50

LBL

900

STA

900

STA

0

BL

24.75

LBL

24.75

RBL

1

V83765

B

B

A

A

(SHEET 1 OF 2)
 FIGURE 7: INSPECTION AND APPLICATION OF SECONDARY FUEL BARRIER - GROUP 3 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

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 one airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1 Measure / Make 

Sure

Secondary Fuel 

Barrier

BMS 5-81 - It must be a minimum of 

1.50 inches

(SHEET 2 OF 2)
 FIGURE 8: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 1, GROUP 3 AND 

GROUP 4 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

FIGURE 8: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 1, GROUP 3 AND 

GROUP 4 AIRPLANES

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Install Duct Assembly 21-21-00 2 -

2 Connect Duct Assembly - 2 At each end; put covers 

over all open duct ends.

FWD

COMPARTMENT

TO PASSENGER

(2 EACH SIDE)

1 2

CONNECTOR

SERVICE

GROUND AIR

MIX MANIFOLD

V88223

(SHEET 1 OF 1)
 FIGURE 9: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 2 AIRPLANES

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

FIGURE 9: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 2 AIRPLANES

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 one airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Install Duct Assembly 21-21-00 1 -

2 Connect Duct Assembly - 1 At each end; put covers 

over all open duct ends.

MANIFOLD

MIX

MIX MANIFOLD

CONNECTOR

SERVICE

GROUND AIR

1 2

COMPARTMENT

TO MAIN CARGO

FWD

V88224

(SHEET 1 OF 1)
 APPENDIX A: RECORD OF THICKNESS MEASUREMENTS

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

APPENDIX A: RECORD OF THICKNESS MEASUREMENTS

Record the thickness measurements from Figures 5 and 6 on the following worksheets.

FRONT SPAR - STIFFENERS (FSS)

FRONT SPAR - WEB (FSW)

BODY FRAME - STIFFENER (BFS)

BODY FRAME ASSEMBLY WEB (BFAW)

FSS 1 0. in. FSS 17 0. in. FSS 33 0. in. FSS 49 0. in.

FSS 2 0. in. FSS 18 0. in. FSS 34 0. in. FSS 50 0. in.

FSS 3 0. in. FSS 19 0. in. FSS 35 0. in. FSS 51 0. in.

FSS 4 0. in. FSS 20 0. in. FSS 36 0. in. FSS 52 0. in.

FSS 5 0. in. FSS 21 0. in. FSS 37 0. in. FSS 53 0. in.

FSS 6 0. in. FSS 22 0. in. FSS 38 0. in. FSS 54 0. in.

FSS 7 0. in. FSS 23 0. in. FSS 39 0. in. FSS 55 0. in.

FSS 8 0. in. FSS 24 0. in. FSS 40 0. in. FSS 56 0. in.

FSS 9 0. in. FSS 25 0. in. FSS 41 0. in. FSS 57 0. in.

FSS 10 0. in. FSS 26 0. in. FSS 42 0. in. FSS 58 0. in.

FSS 11 0. in. FSS 27 0. in. FSS 43 0. in. FSS 59 0. in.

FSS 12 0. in. FSS 28 0. in. FSS 44 0. in. FSS 60 0. in.

FSS 13 0. in. FSS 29 0. in. FSS 45 0. in. FSS 61 0. in.

FSS 14 0. in. FSS 30 0. in. FSS 46 0. in. FSS 62 0. in.

FSS 15 0. in. FSS 31 0. in. FSS 47 0. in. FSS 63 0. in.

FSS 16 0. in. FSS 32 0. in. FSS 48 0. in. FSS 64 0. in.

FSW 1 0. in. FSW 8 0. in.

FSW 2 0. in. FSW 9 0. in.

FSW 3 0. in. FSW 10 0. in.

FSW 4 0. in. FSW 11 0. in.

FSW 5 0. in. FSW 12 0. in.

FSW 6 0. in. FSW 13 0. in.

FSW 7 0. in. FSW 14 0. in.

Left Side Right Side

BFS 3 0. in. BFS 1 0. in.

BFS 4 0. in. BFS 2 0. in.

Left Side Right Side

BFAW 2 0. in. BFAW 1 0. in.
 APPENDIX A: RECORD OF THICKNESS MEASUREMENTS

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

SIDE OF BODY (SOB)

UPPER PANEL (TP)

FLOOR BEAM (FB)

Left Side Right Side

LSOB 1 0. in. RSOB 1 0. in.

LSOB 2 0. in. RSOB 2 0. in.

LSOB 3 0. in. RSOB 3 0. in.

LSOB 4 0. in. RSOB 4 0. in.

LSOB 5 0. in. RSOB 5 0. in.

LSOB 6 0. in. RSOB 6 0. in.

LSOB 7 0. in. RSOB 7 0. in.

LSOB 8 0. in. RSOB 8 0. in.

LSOB 9 0. in. RSOB 9 0. in.

LSOB 10 0. in. RSOB 10 0. in.

Left Side Right Side

LTP 1 0. in. RTP 1 0. in.

LTP 2 0. in. RTP 2 0. in.

LTP 3 0. in. RTP 3 0. in.

LTP 4 0. in. RTP 4 0. in.

LTP 5 0. in. RTP 5 0. in.

LTP 6 0. in. RTP 6 0. in.

LTP 7 0. in. RTP 7 0. in.

LTP 8 0. in. RTP 8 0. in.

LTP 9 0. in. RTP 9 0. in.

LTP 10 0. in. RTP 10 0. in.

LTP 11 0. in. RTP 11 0. in.

LTP 12 0. in. RTP 12 0. in.

LTP 13 0. in. RTP 13 0. in.

LTP 14 0. in. RTP 14 0. in.

FB 1 0. FB 11 0. FB 21 0. FB 31 0. FB 41 0. 

FB 2 0. FB 12 0. FB 22 0. FB 32 0. FB 42 0. 

FB 3 0. FB 13 0. FB 23 0. FB 33 0. FB 43 0. 

FB 4 0. FB 14 0. FB 24 0. FB 34 0. FB 44 0. 

FB 5 0. FB 15 0. FB 25 0. FB 35 0. FB 45 0. 

FB 6 0. FB 16 0. FB 26 0. FB 36 0. FB 46 0. 

FB 7 0. FB 17 0. FB 27 0. FB 37 0. FB 47 0. 
 APPENDIX A: RECORD OF THICKNESS MEASUREMENTS

January 09, 2003

Revision 2: May 24, 2007 757-57-0060

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BOEING SERVICE BULLETIN 757-57-0060

FB 8 0. FB 18 0. FB 28 0. FB 38 0. FB 48 0. 

FB 9 0. FB 99 0. FB 29 0. FB 39 0. FB 49 0. 

FB 10 0. FB 20 0. FB 30 0. FB 40 0. FB 50 0.