### Commercial **Airplanes** 

# 757 Service Bulletin **Number: 757-57-0060** Original Issue: January 09, 2003 Revision 4: December 07, 2012 ATA System: 5710 2810 **SUBJECT:** WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2003 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, DreamlinerTM, 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 Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management Company.

Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 1 of 65 3.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 2 of 65 **BOEING SERVICE BULLETIN 757-57-0060**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 20 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 23 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 24 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 3 AND GROUP 4 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 2: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 2 AIRPLANES . . . 38 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND GROUP 4, CONFIGURATION 1 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . 39 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND GROUP 4, CONFIGURATION 1 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND GROUP 4 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND GROUP 4 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 3 of 65 **BOEING SERVICE BULLETIN 757-57-0060**FIGURE 7: INSPECTION AND APPLICATION OF SECONDARY FUEL BARRIER - GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 FIGURE 8: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 1, GROUP 3 AND GROUP 4 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 FIGURE 9: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 2 AIRPLANES . 62 Appendix A: RECORD OF THICKNESS MEASUREMENTS. . . . . . . . . . . . . . . . . . . . . . . . 63

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 4 of 65 **BOEING SERVICE BULLETIN 757-57-0060**

### Commercial **Airplanes** 

# 757 Service Bulletin **Revision Transmittal Sheet Number: 757-57-0060**  Original Issue: January 09, 2003 Revision 4: December 07, 2012 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** Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM: 2011-NM-070-AD, is related to this service bulletin. No more work is necessary on the airplane(s) changed in accordance with the Revision 2 or 3 of this service bulletin.

**REASON FOR REVISION**
This revision is sent to change the quantity of locations listed in Figure 6, Sheet 5 of 5, Step 2 in order to match the view shown in Figure 6, sheet 1 of 5 and the Upper Panel (TP) table in Appedix A. These sections were changed: 1. In Summary Compliance, Added NPRM 2. In Paragraph 1.C. Reason, Added Revision 4 description. 3. In Paragraph 1.E. Compliance, Added NPRM 4. In Paragraph 1.J. References, Added NPRM, 5. In Paragraph 3.A. Updated General Notes. 6. In Figure 6, Added new View F-F and changed Step 2. RTP and LTP quantity to match locations shown in the Figure and listed in Appendix A, Inspection Worksheets. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 5 of 65**REVISION HISTORY** January 09, 2003 Original Issue: April 10, 2003 Revision 1: May 24, 2007 Revision 2: May 09, 2012 Revision 3: December 07, 2012 Revision 4:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 6 of 65 **BOEING SERVICE BULLETIN 757-57-0060**

### Commercial **Airplanes** 

# 757 Service Bulletin **Summary Number: 757-57-0060**  Original Issue: January 09, 2003 Revision 4: December 07, 2012 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. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected NO Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes Yes Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 7 of 65**Reference Affected**  **Planning Data** Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin Yes Special Tooling Required

**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. **EFFECTIVITY** Airplane Models 757-200, 757-200CB and 757-200PF; Line numbers 1 thru 964; divided into four groups. **COMPLIANCE** Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-070-AD, is related to this service bulletin. 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 757 airplanes. Please refer to Paragraph 2.B., Industry Support Information.

**MANPOWER** See Paragraph 1.G Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 8 of 65 **BOEING SERVICE BULLETIN 757-57-0060**Refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 9 of 65 **BOEING SERVICE BULLETIN 757-57-0060**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 10 of 65 **BOEING SERVICE BULLETIN 757-57-0060**

BLANK PAGE

### Commercial **Airplanes** 

# 757 Service Bulletin **Number: 757-57-0060** Original Issue: January 09, 2003 Revision 4: December 07, 2012 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.
**DESCRIPTION CONFIGURATION**  **GROUP** 757-200 Airplanes

- 1 757-200CB and 757-200PF Airplanes

- 2 757-200 Airplanes that only require inspection of the front spar center section. - 3
757-200 Airplanes previously in Group 1 that could have fuel vapor barrier material applied that was thinned with lacquer thinner. - 4
Group 4 Airplanes that have not incorporated previous releases of Service Bulletin 757-57-0060. 1
Group 4 Airplanes that have incorporated previous releases of Service Bulletin 757-57-0060. 2

Airplane Models: 757-200, 757-200CB, 757-200PF **Group Variable Number**  1 NA001 - NA028 1 NA191 - NA199 1 NA201 - NA239

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 11 of 65**Group Variable Number**  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 NB451 - NB454 1 NB501 - NB523 1 NB561 1 NB571 1 NB581 - NB583 1 NC001 - NC033

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 12 of 65 **BOEING SERVICE BULLETIN 757-57-0060 Group**  **Variable Number** 1 NC041 - NC042 1 NC051 - NC052 1 NC056 - NC062 1 NC066 - NC084 1 NC091 - NC094 1 NC151 1 NC161 2 NC901 - NC951 2 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 2 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 NN001 3 NN002 1 NP901 - NP904 2 NS601 - NS616 2 NT001 - NT004

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 13 of 65 **BOEING SERVICE BULLETIN 757-57-0060 Group**  **Variable Number** 1 NT005 - NT007 4 NT008 - NT009 1 NT201 - NT202 1 NT231 - NT233 4 NT234 1 NT237 - NT238 4 NT239 3 NT240 1 NT242 3 NT245 - NT246 1 NT281 - NT282 4 NT283 - NT285 1 NT286 - NT287 3 NT288 - NT289 1 NT341 - NT344 4 NT345 1 NT351 - NT352 4 NT353 - NT360 4 NT371 - NT373 3 NT375 1 NT376 - NT378 3 NT379 1 NT381 - NT382 4 NT383 3 NT384 1 NT401 - NT403 4 NT404 - NT409 1 NT411 - NT412 1 NT426 - NT427 4 NT431 - NT432 4 NT436 - NT437 3 NT438 4 NT441 - NT442

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 14 of 65 **BOEING SERVICE BULLETIN 757-57-0060 Group**  **Variable Number** 3 NT446 1 NT701 - NT708 4 NT709 - NT716 1 NT717 - NT723 3 NT724 - NT730 1 NT731 - NT736 4 NT737 - NT742 3 NT743 - NT744 1 NT751 - NT760 4 NT761 - NT768 1 NT769 1 NT791 - NT794 4 NT795 - NT796 1 NT861 4 NT862 1 NT881 - NT882 4 NT883 - NT885 4 NT901 - NT908 1 NT909 - NT913 3 NT914 - NT916 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 15 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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. Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin. 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. Revision 3 is sent to reference possibly release an Airworthiness Directive, to revise the Industry Support information, to add Damage Tolerance Information and to delete reference to the upper panel from the Work Instruction. Revision 4 is sent to change the quantity of locations listed in Figure 6, Sheet 5 of 5, Step 2 in order to match the view shown in Figure 6, sheet 1 of 5 and the Upper Panel (TP) table in Appedix A. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 16 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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 The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1, 4:**
**Affected Maintenance Zones Zone**  **Model** 133, 134 757-200, 757-200PF **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 133, 134 757-200CB, 757-200PF **Group 3:**
**Affected Maintenance Zones Zone**  **Model** 133, 134 757-200 **E. Compliance** Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-070-AD, is related to this service bulletin. 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. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 17 of 65 **BOEING SERVICE BULLETIN 757-57-0060 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 **Elapsed Hours Task-Hours**  **Number of Persons**  **Task**
6.5 13.0 2 Open Access 4.0 8.0 2 Inspection 6.0 6.0 1 Thickness Measurement 6.5 6.5 1 Secondary Fuel Barrier Ap- plication 7.5 15.0 2 Close Access 30.5 48.5 TOTAL FOR EACH AIRPLANE Group 2 ONLY **Elapsed Hours Task-Hours**  **Number of Persons**  **Task**
4.0 8.0 2 Open Access 4.0 8.0 2 Examine 6.0 6.0 1 Thickness Measurement 6.5 6.5 1 Secondary Fuel Barrier Ap- plication 5.0 10.0 2 Close Access 25.5 38.5 TOTAL FOR EACH AIRPLANE Group 3 ONLY **Elapsed Hours Task-Hours**  **Number of Persons**  **Task**
2.0 4.0 2 Open Access

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 18 of 65 **BOEING SERVICE BULLETIN 757-57-0060 Elapsed Hours**  **Task-Hours Number of**  **Persons Task** 
4.0 8.0 2 Inspection 6.5 6.5 1 Secondary Fuel Barrier Ap- plication 3.0 6.0 2 Close Access 15.5 24.5 TOTAL FOR EACH AIRPLANE Group 4, Configuration 2 ONLY **Elapsed Hours Task-Hours**  **Number of Persons**  **Task**
6.5 13.0 2 Open Access 6.0 6.0 1 Thickness Measurement 6.5 6.5 1 Secondary Fuel Barrier Ap- plication 7.5 15.0 2 Close Access 26.5 40.5 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane** 
+ 2,000 + 2 Passenger 757-200 + 2,000 + 2 Cargo 757-200CB / 757-200PF
**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 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 19 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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 m. Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-070-AD, is related to this service bulletin. 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  Seal Application - Secondary Fuel Barrier Coating, Wing Center Section 110N0004 Terminal Fitting Installation - Wing / Body Joint, Front Spar 112N2010 Bulkhead Installation, Front Spar Body Station 900 144N2101 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** 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.
**L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 20 of 65 **BOEING SERVICE BULLETIN 757-57-0060 M. Software Accomplishment Summary**  Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 21 of 65 **BOEING SERVICE BULLETIN 757-57-0060**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 22 of 65 **BOEING SERVICE BULLETIN 757-57-0060**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  None. **B. Industry Support Information** Boeing warranty remedies are available for for Group 1, Group 2, Group 3, and, Group 4 - Configuration1, 757 airplanes in warranty as of September 22, 2000. Boeing warranty remedies are available for Group 4 - Configuration 2, 757 airplanes in warranty as of October 8, 2004. 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:
**Notes Name**  **QTY Part Number / Specification**  Abrasive Paper, Aluminum Oxide 20 Sheets 180 to 400 grit (a) Sealant, Secondary Fuel Barrier 40 oz. BMS 5-81, Type II (a) Organic Corrosion Inhibiting Compound 1 Pint BMS 3-23, Type II, Class 2 (a) Advanced Organic Corrosion Inhibiting Com- pounds (CIC) 1 Pint BMS 3-29 (a) Heavy Duty Corrosion Inhibiting Compound 1 Pint BMS 3-35 (a) Chemical and Solvent Resistant Finish 1 Pint BMS 10-11, Type I (a) (b) Pressure and Environmental Sealant - Chro- mate Type 1 Pint BMS 5-95, Type 1, Class B-1/2, B -2 or B-4 (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
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 23 of 65 **BOEING SERVICE BULLETIN 757-57-0060 D. Parts Necessary to Change Spares**  None. **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.
**Name Tool Number**  Dualscope MP20 (a) (b) 602-816 ETA 3.3H Probe (a) (b) 602-128 (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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 24 of 65 **BOEING SERVICE BULLETIN 757-57-0060 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. 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 and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in SRM Chapter 51 5. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 6. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. 7. The necessary conditions for selection of clamp type and size are included in SWPM 20-10-12. If any wire bundle support clamp specified in this service bulletin does not make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted procedure to select a clamp that fits correctly. 8. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 9. A Detailed Inspection is defined as: 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 procedures may be required.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 25 of 65 **BOEING SERVICE BULLETIN 757-57-0060**10. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words"as given" or "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 11. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 12. Refer to Appendix A for Thickness Measurement Inspection-Upper Panel-Group 1, Group 2, and Group 4 Airplanes 13. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 14. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 15. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 16. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. 17. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data. **B. WORK INSTRUCTIONS** 1. 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. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 26 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 27 of 65 **BOEING SERVICE BULLETIN 757-57-0060**(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 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. (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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 28 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 29 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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. **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).

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 30 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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 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. (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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 31 of 65 **BOEING SERVICE BULLETIN 757-57-0060**(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. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 32 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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 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. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 33 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 34 of 65 **BOEING SERVICE BULLETIN 757-57-0060**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: (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. (4) The passenger seats, as referenced in 757 AMM 25-25-01.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 35 of 65 **BOEING SERVICE BULLETIN 757-57-0060**12. 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. 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 757 AMM 36-00-00. 15. Put the electrical power back to service condition, as given in 757 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 757 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 757 AMM 28-11-00 for cure rates.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4: December 07, 2012 36 of 65 **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.
**NOTES QTY**  **REFERENCES NAME**  **TASK STEP**  At each end; put covers over all open duct ends. 2 21-21-00 Duct Assembly Disconnect 1

- 2
- Duct Assembly Remove 2

**FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 3 AND GROUP 4 AIRPLANES**  **(SHEET 1 OF 1)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 37 of 65 **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.
**NOTES QTY**  **REFERENCES NAME**  **TASK STEP**  At each end; put covers over all open duct ends. 1 21-21-00 Duct Assembly Disconnect 1

- 1
- Duct Assembly Remove 2

**FIGURE 2: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 2 AIRPLANES (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 38 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 1 OF 5)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 39 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 2 OF 5)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 40 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 3 OF 5)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 41 of 65 **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 side of the airplane.

**FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND GROUP 4, CONFIGURATION 1 AIRPLANES**  **(SHEET 4 OF 5)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 42 of 65 **BOEING SERVICE BULLETIN 757-57-0060 NOTES**  **QTY REFERENCES**  **NAME TASK**  **STEP** Remove dirt/debris from the area - Front Spar Clean 1 (a)

- Visual Inspection Secondary Fuel Barrier Identify 2 (b) (c)

- Detailed Visual In- spection Front Spar Examine 3 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. - BMS 3-23 or BMS 3-29 or BMS 3-35 Corrosion Inhibiting Compound Remove

See View J-J 7
- Cap seal Verify 4 (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.

**FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1, GROUP 2 AND GROUP 4, CONFIGURATION 1 AIRPLANES**  **(SHEET 5 OF 5)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 43 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 1 OF 7)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 44 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 2 OF 7)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 45 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 3 OF 7)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 46 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 4 OF 7)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 47 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4, CONFIGURATION 1 AIRPLANES (SHEET 5 OF 7)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 48 of 65 **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.

**FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND GROUP 4, CONFIGURATION 1 AIRPLANES**  **(SHEET 6 OF 7)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 49 of 65 **BOEING SERVICE BULLETIN 757-57-0060 NOTES**  **QTY REFERENCES**  **NAME TASK**  **STEP** Remove dirt/debris from the area - Upper Panel Clean 1 (a)

- Visual Inspection Secondary Fuel Barrier Identify 2 (b) (c)

- Detailed Visual In- spection Upper Panel Examine 3 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. - BMS 3-23 or BMS 3-29 or BMS 3-35 Corrosion Inhibiting Compound Remove

(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.

**FIGURE 4: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1, GROUP 2 AND GROUP 4, CONFIGURATION 1 AIRPLANES**  **(SHEET 7 OF 7)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 50 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND**  **GROUP 4 AIRPLANES (SHEET 1 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 51 of 65 **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.

**FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND GROUP 4 AIRPLANES**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 52 of 65 **BOEING SERVICE BULLETIN 757-57-0060 NOTES**  **QTY REFERENCES**  **NAME TASK**  **STEP** Remove dirt/debris from the area Front Spar Clean 1 (a) (b) (c) Secondary Fuel Barrier Measure/ Make Sure/ Record 2
See View A-A 14 FSW Front Spar Web See View A-A 64 FSS Front Spar Stiffen- ers See View B-B 2 BFAW Body Frame Assy Web See View C-C and D-D 4 BFS Body Frame Stiffen- er (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.

**FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1, GROUP 2 AND GROUP 4 AIRPLANES**  **(SHEET 3 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 53 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4 AIRPLANES (SHEET 1 OF 5)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 54 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4 AIRPLANES (SHEET 2 OF 5)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 55 of 65 **BOEING SERVICE BULLETIN 757-57-0060 FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND**  **GROUP 4 AIRPLANES (SHEET 3 OF 5)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 56 of 65 **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.

**FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND GROUP 4 AIRPLANES**  **(SHEET 4 OF 5)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 57 of 65 **BOEING SERVICE BULLETIN 757-57-0060 NOTES**  **QTY REFERENCES**  **NAME TASK**  **STEP** Remove dirt/debris from the area Front Spar and Upper Panel Clean 1 (a) (b) (c)

- Secondary Fuel Barrier Measure/ Make Sure/ Record 2
10 locations each, on the right and left side. See View A-A and B-B 50 FB Floor Beam

10 locations each, on the right and left side. See View C-C and D-D 20 RSOB and LSOB Side of Body

14 locations each, on the right and left side. See View E-E and View F-F 28 RTP and LTP Upper Panel

(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.

**FIGURE 6: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1, GROUP 2 AND GROUP 4 AIRPLANES**  **(SHEET 5 OF 5)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 58 of 65 **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.

**FIGURE 7: INSPECTION AND APPLICATION OF SECONDARY FUEL BARRIER - GROUP 3 AIRPLANES (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 59 of 65 **BOEING SERVICE BULLETIN 757-57-0060 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** It must be a minimum of 1.50 inches - BMS 5-81 Secondary Fuel Barrier Measure / Make Sure 1

**FIGURE 7: INSPECTION AND APPLICATION OF SECONDARY FUEL BARRIER - GROUP 3 AIRPLANES (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 60 of 65 **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.
**NOTES QTY**  **REFERENCES NAME**  **TASK STEP** 

- 2 21-21-00 Duct Assembly Install 1 At each end; put covers over all open duct ends. 2
- Duct Assembly Connect 2

**FIGURE 8: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 1, GROUP 3 AND GROUP 4 AIRPLANES**  **(SHEET 1 OF 1)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 61 of 65 **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.
**NOTES QTY**  **REFERENCES NAME**  **TASK STEP** 

- 1 21-21-00 Duct Assembly Install 1 At each end; put covers over all open duct ends. 1
- Duct Assembly Connect 2

**FIGURE 9: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 2 AIRPLANES (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 62 of 65 **BOEING SERVICE BULLETIN 757-57-0060**Record the thickness measurements from Figures 5 and 6 on the following worksheets. FRONT SPAR - STIFFENERS (FSS)
0. in. FSS 49 0. in. FSS 33 0. in. FSS 17 0. in. FSS 1 0. in. FSS 50 0. in. FSS 34 0. in. FSS 18 0. in. FSS 2 0. in. FSS 51 0. in. FSS 35 0. in. FSS 19 0. in. FSS 3 0. in. FSS 52 0. in. FSS 36 0. in. FSS 20 0. in. FSS 4 0. in. FSS 53 0. in. FSS 37 0. in. FSS 21 0. in. FSS 5 0. in. FSS 54 0. in. FSS 38 0. in. FSS 22 0. in. FSS 6 0. in. FSS 55 0. in. FSS 39 0. in. FSS 23 0. in. FSS 7 0. in. FSS 56 0. in. FSS 40 0. in. FSS 24 0. in. FSS 8 0. in. FSS 57 0. in. FSS 41 0. in. FSS 25 0. in. FSS 9 0. in. FSS 58 0. in. FSS 42 0. in. FSS 26 0. in. FSS 10 0. in. FSS 59 0. in. FSS 43 0. in. FSS 27 0. in. FSS 11 0. in. FSS 60 0. in. FSS 44 0. in. FSS 28 0. in. FSS 12 0. in. FSS 61 0. in. FSS 45 0. in. FSS 29 0. in. FSS 13 0. in. FSS 62 0. in. FSS 46 0. in. FSS 30 0. in. FSS 14 0. in. FSS 63 0. in. FSS 47 0. in. FSS 31 0. in. FSS 15 0. in. FSS 64 0. in. FSS 48 0. in. FSS 32 0. in. FSS 16 FRONT SPAR - WEB (FSW)
0. in. FSW 8 0. in. FSW 1 0. in. FSW 9 0. in. FSW 2 0. in. FSW 10 0. in. FSW 3 0. in. FSW 11 0. in. FSW 4 0. in. FSW 12 0. in. FSW 5 0. in. FSW 13 0. in. FSW 6 0. in. FSW 14 0. in. FSW 7 BODY FRAME - STIFFENER (BFS) **Right Side Left Side**  0. in. BFS 1 0. in. BFS 3 0. in. BFS 2 0. in. BFS 4

**Appendix A: RECORD OF THICKNESS MEASUREMENTS (SHEET 1 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 63 of 65 **BOEING SERVICE BULLETIN 757-57-0060**BODY FRAME ASSEMBLY WEB (BFAW) **Right Side Left Side**  0. in. BFAW 1 0. in. BFAW 2 SIDE OF BODY (SOB) **Right Side Left Side**  0. in. RSOB 1 0. in. LSOB 1 0. in. RSOB 2 0. in. LSOB 2 0. in. RSOB 3 0. in. LSOB 3 0. in. RSOB 4 0. in. LSOB 4 0. in. RSOB 5 0. in. LSOB 5 0. in. RSOB 6 0. in. LSOB 6 0. in. RSOB 7 0. in. LSOB 7 0. in. RSOB 8 0. in. LSOB 8 0. in. RSOB 9 0. in. LSOB 9 0. in. RSOB 10 0. in. LSOB 10 UPPER PANEL (TP) **Right Side Left Side**  0. in. RTP 1 0. in. LTP 1 0. in. RTP 2 0. in. LTP 2 0. in. RTP 3 0. in. LTP 3 0. in. RTP 4 0. in. LTP 4 0. in. RTP 5 0. in. LTP 5 0. in. RTP 6 0. in. LTP 6 0. in. RTP 7 0. in. LTP 7 0. in. RTP 8 0. in. LTP 8 0. in. RTP 9 0. in. LTP 9 0. in. RTP 10 0. in. LTP 10 0. in. RTP 11 0. in. LTP 11 0. in. RTP 12 0. in. LTP 12 0. in. RTP 13 0. in. LTP 13

**Appendix A: RECORD OF THICKNESS MEASUREMENTS (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 64 of 65 **BOEING SERVICE BULLETIN 757-57-0060 Right Side**  **Left Side** 0. in. RTP 14 0. in. LTP 14 FLOOR BEAM (FB)
0. FB 41 0. FB 31 0. FB 21 0. FB 11 0. FB 1 0. FB 42 0. FB 32 0. FB 22 0. FB 12 0. FB 2 0. FB 43 0. FB 33 0. FB 23 0. FB 13 0. FB 3 0. FB 44 0. FB 34 0. FB 24 0. FB 14 0. FB 4 0. FB 45 0. FB 35 0. FB 25 0. FB 15 0. FB 5 0. FB 46 0. FB 36 0. FB 26 0. FB 16 0. FB 6 0. FB 47 0. FB 37 0. FB 27 0. FB 17 0. FB 7 0. FB 48 0. FB 38 0. FB 28 0. FB 18 0. FB 8 0. FB 49 0. FB 39 0. FB 29 0. FB 99 0. FB 9 0. FB 50 0. FB 40 0. FB 30 0. FB 20 0. FB 10

**Appendix A: RECORD OF THICKNESS MEASUREMENTS (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 09, 2003 757-57-0060 Revision 4 December 07, 2012 65 of 65 **BOEING SERVICE BULLETIN 757-57-0060**