### Commercial **Airplanes** 

# 767 Service Bulletin
**Number: 767-57A0095** Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 **SUBJECT:** WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 1 of 60 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 2 of 60 **BOEING SERVICE BULLETIN 767-57A0095**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 16 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 20 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 23 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE. . . . . 28 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE. . . . . 32 FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE. . . . . . . 36 FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE. . . . . . . 40 FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL. . . . . . . . . 44 FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL. . . . . . . . . 49 Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . 54

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 3 of 60 **BOEING SERVICE BULLETIN 767-57A0095**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 4 of 60 **BOEING SERVICE BULLETIN 767-57A0095**

BLANK PAGE

### Commercial **Airplanes** 

# 767 Service Bulletin **Revision Transmittal Sheet Number: 767-57A0095**  Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 **SUBJECT:** WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes changed in accordance with the original issue or revision 1 of this service bulletin. **REASON FOR REVISION** This revision is sent to add the option for operators to make their own drain tubes and add some optional materials to the service bulletin. A cross reference table is added to the special tooling section to show the equivalent part numbers for operators who want to order special tools from the Boeing Parts Page. This revision also adds a female 3/8 inch square drive socket as an alternative to the wrench. The references to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 are removed from the SB. In addition to these changes, the term "as given in/as shown in" is changed to "Refer to, as an accepted procedure" to comply with the latest SB standards on non-FAA approved manuals. Figure references are also updated to say "in accordance with" instead of "as shown in" to comply with latest SB standards. The changes to this service bulletin are as follows: – Summary - Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related to this service bulletin is updated. – Paragraph 1.E., Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related to this service bulletin is updated. – Paragraph 1.F., Approval - Alternative Method of Compliance (AMOC) approval paragraph removed. – Paragraph 1.J.1., Existing Data - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. – Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added. – Paragraph 2.A., Material - Price and Availability - Pricing information updated. – Paragraph 2.C.1., Kits/Parts - New footnote (d) is added to 015T1772-2 drain tube in top kit table to give operators the option to make the drain tube. – Paragraph 2.C.2., Parts and Materials Supplied by the Operator - BMS 3-33 is added as an option to BMS 3-24. Also the name for "MIL-C-5541 Class 1A (Alodine 600)" changed to "Alodine 600 (Alodine 1600/1660 Optional)" – Paragraph 2.C.2., Parts and Materials Supplied by the Operator - New footnotes (b) and (c) added. – Paragraph 2.E., Special Tooling - Price and Availability - Special tooling cross-reference chart added to show the required special tooling part numbers to use when ordering from Boeing Part Page.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 5 of 60– Figure 3 and Figure 4, Sheet 2, View A - Tolerance added to the 0.30 dimensions. – Figure 3 and Figure 4, Step 7 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660 Optional)". – Figure 3 and Figure 4, Footnote (e) - Dimension value 0.30 is added. – Figure 5 and Figure 6, Step 3 - BMS 3-33 is added as an option to BMS 3-24. – Figure 5 and Figure 6, Step 5 - BMS 3-33 is added as an option to BMS 3-24. – Figure 5 and Figure 6, Step 21 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660 Optional)". – Appendix A, Sheet 4 - A female 3/8 inch square drive socket is added to the illustration. – Appendix A, Sheet 5 - Wrench P/N is changed from ST877W-77A-5 to ST2580-77A-5 in the special tooling table and footnote (e) is added to give tool compatibility information. – Appendix A, Step 11 - A note is added to show optional automotive engine oils to SAE No 10. – Appendix A, Step 15 - A female 3/8 inch square drive socket is added as an alternative to the wrench. – Appendix A, Step 16 - A female 3/8 inch square drive socket is added as an alternative to the wrench. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** June 02, 2005 Original Issue: December 19, 2006 Revision 1: December 17, 2009 Revision 2:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 6 of 60 **BOEING SERVICE BULLETIN 767-57A0095**

### Commercial **Airplanes** 

# 767 Service Bulletin **Summary Number: 767-57A0095**  Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 **SUBJECT:** WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement **CONCURRENT REQUIREMENTS** None. **BACKGROUND** Accomplishment of this service bulletin prevents cracks in the number 5 and number 8 slat track housing drain tubes. Cracks in these drain tubes could let fuel drain from the main fuel tanks into the dry bay area of the wings. Fuel from the dry bay areas could subsequently drain on to hot Main Landing Gear (MLG) brakes and possibly result in a fire. One operator told Boeing of a fuel leak on to the MLG as a result of a cracked drain tube at the number 8 slat track housing, no fire was reported. The crack was in a drain tube on a 767 airplane that had incorporated a re-routed drain tube with a flexible part, as given Boeing service bulletin 767-57A0060. An investigation by Boeing found that the drain tube with a flexible part had cracked as a result of a high intensity engine vibration, which was more than the design of the tube permitted. Boeing was told of a second occurrence of a cracked drain tube at the number 8 slat track housing. The crack in the flexible part of the drain tube was found after an airplane had a high intensity engine vibration. During flight, an airplane had vibration from the number 2 engine (Pratt & Whitney PW4000) as a result of a second stage turbine blade failure. The engine was subsequently shut-down and the airplane was diverted. After the airplane had landed fuel leakage was seen from the pylon area by maintenance personnel. This problem affects airplane line numbers 1 thru 921. Airplanes after line number 921 have a production design change which installs the new drain tube without a flexible part. This service bulletin gives instructions to replace a drain tube assembly which has a flexible part with a new aluminum drain tube without a flexible part, at the number 5 and number 8 slat track housing. Boeing tests have shown that the new aluminum drain tubes are stronger and more resistant to damage during high intensity engine vibrations. Boeing Service Related Problem (SRP) 767-SRP-57-0160 is related to this service bulletin. As a part of a service bulletin validation program, the change described in Boeing service bulletin 767-57A0094, which is equivalent to the change given in this service bulletin, was completed on a 767-200ER airplane after the initial release of service bulletin 767-57A0094. The change completed on the 767-200ER airplane is equivalent to the change given in the release of Revision 1 of this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 7 of 60**ACTION (PRR B12901-53S)** Defuel the left and right wing main fuel tanks. Open the applicable left and right wing fuel tank access panels to get access to the number 5 and number 8 slat track housing drain tubes. Remove the existing drain tube assemblies that have a flexible part. Prepare and install new aluminum drain tubes without a flexible part at the two locations. Close the left and right wing main tank fuel bay access panels. Refuel the left and right wing main tanks. Inspect the left and right wing main tank dry bay to make sure there is no fuel leakage from the new drain tube installations. Close the left and right wing main tank dry bay access panels. **EFFECTIVITY** 767-400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date of this service bulletin. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **MANPOWER Elapsed Hours**  **Total Task Hours** 20 43
**MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 8 of 60 **BOEING SERVICE BULLETIN 767-57A0095**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 9 of 60 **BOEING SERVICE BULLETIN 767-57A0095**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 10 of 60 **BOEING SERVICE BULLETIN 767-57A0095**

BLANK PAGE

### Commercial **Airplanes** 

# 767 Service Bulletin
**Number: 767-57A0095** Original Issue: June 02, 2005 Revision 2: December 17, 2009 ATA System: 5740 2781 2811 **SUBJECT:** WINGS - Leading Edge and Leading Edge Devices - Number 5 and Number 8 Slat Track Housing Drain Tube Replacement
**1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-53S for data about this change.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-400ER airplanes, Line Numbers 758 thru 878, that have a drain tube with a flexible part installed at the no.5 and no.8 slat track housing. Two doublers are installed at rib no.9 and there is a 2 jumper electrostatic bond configuration - 1

Airplane Models: 767-400ER **Group Variable Number**  1 VQ001 - VQ021 1 VQ071 - VQ086 2. Spares Affected None. **B. Concurrent Requirements** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 11 of 60**C. Reason** Accomplishment of this service bulletin prevents cracks in the number 5 and number 8 slat track housing drain tubes. Cracks in these drain tubes could let fuel drain from the main fuel tanks into the dry bay area of the wings. Fuel from the dry bay areas could subsequently drain on to hot Main Landing Gear (MLG) brakes and possibly result in a fire. One operator told Boeing of a fuel leak on to the MLG as a result of a cracked drain tube at the number 8 slat track housing, no fire was reported. The crack was in a drain tube on a 767 airplane that had incorporated a re-routed drain tube with a flexible part, as given Boeing service bulletin 767-57A0060. An investigation by Boeing found that the drain tube with a flexible part had cracked as a result of a high intensity engine vibration, which was more than the design of the tube permitted. Boeing was told of a second occurrence of a cracked drain tube at the number 8 slat track housing. The crack in the flexible part of the drain tube was found after an airplane had a high intensity engine vibration. During flight, an airplane had vibration from the number 2 engine (Pratt & Whitney PW4000) as a result of a second stage turbine blade failure. The engine was subsequently shut-down and the airplane was diverted. After the airplane had landed fuel leakage was seen from the pylon area by maintenance personnel. This problem affects airplane line numbers 1 thru 921. Airplanes after line number 921 have a production design change which installs the new drain tube without a flexible part. This service bulletin gives instructions to replace a drain tube assembly which has a flexible part with a new aluminum drain tube without a flexible part, at the number 5 and number 8 slat track housing. Boeing tests have shown that the new aluminum drain tubes are stronger and more resistant to damage during high intensity engine vibrations. Boeing Service Related Problem (SRP) 767-SRP-57-0160 is related to this service bulletin. As a part of a service bulletin validation program, the change described in Boeing service bulletin 767-57A0094, which is equivalent to the change given in this service bulletin, was completed on a 767-200ER airplane after the initial release of service bulletin 767-57A0094. The change completed on the 767-200ER airplane is equivalent to the change given in Revision 1 of this service bulletin. Revision 1 of this service bulletin was sent to change the sequence of the work instructions and to change the safety wire part number, as a result of the airplane validation. The validation found that the step to close the main wing tank access panels was incorrectly located after the refuel step. The validation also found that the minimum fuel quantity note was incorrectly located after the dry bay inspection step. Special tools required to roller swage the drain tubes onto the ferrules, are specified in this revision. The changes to this service bulletin are as follows: — The Summary, Background paragraph and Paragraph 1.C., Reason, are changed to include the airplane validation data. — The Summary, Compliance paragraph and Paragraph 1.E., Compliance, are revised to change the recommended compliance time from 24 months after the initial release of this service bulletin, to 24 months after the Revision 1 release of this service bulletin. The compliance time is changed due to the special roller swage tools required to accomplish this service bulletin, and the difficulty operators have experienced with special roller swage tool procurement. — Paragraph 1.G., Manpower, is changed to agree with the resequenced steps to close the main wing tank fuel bay access panels prior to the refuel step, in Paragraph 3.B., Work Instructions.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 12 of 60 **BOEING SERVICE BULLETIN 767-57A0095**— Paragraph 2.C.2., Parts and Materials Supplied by the Operator, is changed to correct the safety wire part number from NASM20995AB32 to MS20995AB32, and to delete the BACT11SD08 tape. — Paragraph 2.E., Special Tooling - Price and Availability, is changed to include the special roller swage tools data. — Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin, is changed to include the special roller swage tools data. — Paragraph 3.B., Work Instructions, for all airplane groups, are changed to resequence the steps to close the main wing tank fuel bay access panels prior to the refuel step, and to move the minimum fuel quantity note for the fuel leakage inspection to the refuel step. — Figures 3 and 4 are changed to delete the BACT11SD08 tape and the reference to BAC5001. — Figures 5 and 6 are changed to correct the safety wire part number from NASM20995AB32 to MS0995AB32. — Appendix A, Roller Swaging - Wiggins Type Ferrules, is changed to: switch the heading from Roller Swaging - Wiggins Type Ferrules to Drain Tube Roller Swage Instructions; identify the required special roller swage tools, add illustrations to depict special roller swage tools usage, and delete the groove fill acceptance criteria. Revision 2 is sent to add the option for operators to make their own drain tubes and add some optional materials to the service bulletin. A cross reference table is added to the special tooling section to show the equivalent part numbers for operators who want to order special tools from the Boeing Parts Page. This revision also adds a female 3/8 inch square drive socket as an alternative to the wrench. The references to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 are removed from the SB. In addition to these changes, the term "as given in/as shown in" is changed to "Refer to, as an accepted procedure" to comply with the latest SB standards on non-FAA approved manuals. Figure references are also updated to say "in accordance with" instead of "as shown in" to comply with latest SB standards. These sections were changed: – Summary - Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related to this service bulletin is updated. – Paragraph 1.E., Compliance - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. Information related to the future release of Airworthiness Directive related to this service bulletin is updated. – Paragraph 1.F., Approval - Alternative Method of Compliance (AMOC) approval paragraph removed. – Paragraph 1.J.1., Existing Data - Reference to Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2001-14-19 is removed. – Paragraph 1.K., Publications Affected - Damage Tolerance Inspections (DTI) information added. – Paragraph 2.A., Material - Price and Availability - Pricing information updated. – Paragraph 2.C.1., Kits/Parts - New footnote (d) is added to 015T1772-2 drain tube in top kit table to give operators the option to make the drain tube. – Paragraph 2.C.2., Parts and Materials Supplied by the Operator - BMS 3-33 is added as an option to BMS 3-24. Also the name for "MIL-C-5541 Class 1A (Alodine 600)" changed to "Alodine 600 (Alodine 1600/1660 Optional)" – Paragraph 2.C.2., Parts and Materials Supplied by the Operator - New footnotes (b) and (c) added. – Paragraph 2.E., Special Tooling - Price and Availability - Special tooling cross-reference chart added to show the required special tooling part numbers to use when ordering from Boeing Part Page. – Figure 3 and Figure 4, Sheet 2, View A - Tolerance added to the 0.30 dimensions. – Figure 3 and Figure 4, Step 7 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660 Optional)". – Figure 3 and Figure 4, Footnote (e) - Dimension value 0.30 is added.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 13 of 60 **BOEING SERVICE BULLETIN 767-57A0095**– Figure 5 and Figure 6, Step 3 - BMS 3-33 is added as an option to BMS 3-24. – Figure 5 and Figure 6, Step 5 - BMS 3-33 is added as an option to BMS 3-24. – Figure 5 and Figure 6, Step 21 - "MIL-C-5541, Class 1A" is changed to "Alodine 600 (Alodine 1600/1660 Optional)". – Appendix A, Sheet 4 - A female 3/8 inch square drive socket is added to the illustration. – Appendix A, Sheet 5 - Wrench P/N is changed from ST877W-77A-5 to ST2580-77A-5 in the special tooling table and footnote (e) is added to give tool compatibility information. – Appendix A, Step 11 - A note is added to show optional automotive engine oils to SAE No 10. – Appendix A, Step 15 - A female 3/8 inch square drive socket is added as an alternative to the wrench. – Appendix A, Step 16 - A female 3/8 inch square drive socket is added as an alternative to the wrench. **D. Description** Defuel the left and right wing main fuel tanks. Open the applicable left and right wing fuel tank access panels to get access to the number 5 and number 8 slat track housing drain tubes. Remove the existing drain tube assemblies that have a flexible part. Prepare and install new aluminum drain tubes without a flexible part at the two locations. Close the left and right wing main tank fuel bay access panels. Refuel the left and right wing main tanks. Inspect the left and right wing main tank dry bay to make sure there is no fuel leakage from the new drain tube installations. Close the left and right wing main tank dry bay access panels. Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. Revision 2 - No more work is necessary on airplanes changed in accordance with the original issue or revision 1 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 532, 533, 632, 633 767-400ER **E. Compliance** Boeing recommends that this service bulletin is done no later than 24 months after the Revision 1 date of this service bulletin. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 14 of 60 **BOEING SERVICE BULLETIN 767-57A0095 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 service 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. **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

5.0 20.0 4 Defuel 3.0 6.0 2 Prepare for Fuel Tank Access 1.0 2.0 2 Open Panels 1.5 1.5 1 FIGURE 1 1.5 1.5 1 FIGURE 2 as necessary FIGURE 3 as necessary FIGURE 4 2.0 2.0 1 FIGURE 5 2.0 2.0 1 FIGURE 6 0.5 1.0 2 Close Wing Main Tank Panels 2.0 4.0 2 Refuel 1.0 2.0 2 Inspect 0.5 1.0 2 Close Wing Dry Bay Panels

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 15 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

20.0 43.0 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Engineering Change Memo PRR B12901-53S. b. Service Related Problem (SRP) 767-SRP-57-0160. c. 767 Aircraft Maintenance Manual (AMM) 06-44-00, 12-11-01, 28-11-00, 28-26-00. d. Boeing Standard Wiring Practices Manual (SWPM) 20-20-00. e. Boeing Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-43-03, 20-50-02, 20-50-07, 20-50-10, 20-60-02. f. Boeing Parts Standards Document D-590. g. Boeing Drawing 012W6100. 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  DRAIN TUBE INSTL - SLAT TRACK HOUSING, WING 112T2019 This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators. **K. Publications Affected Chapter-Section** 

**Publication** 57-21 767 Illustrated Parts Catalog

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 16 of 60 **BOEING SERVICE BULLETIN 767-57A0095**1. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 17 of 60 **BOEING SERVICE BULLETIN 767-57A0095**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 18 of 60 **BOEING SERVICE BULLETIN 767-57A0095**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.
**Unit Price thru Dec 31/09**  **ROLT (Weeks)**  **QTY Date**  **Name Kit Number**  $1,117.00 20 1 Aug 18/04 Top Kit - Slat Track Housing - Drain Tube Replacement 015T1772-1 25 Oct 14/04 25 Nov 11/04 25 Dec 13/04 25 Jan 19/05 25 Feb 16/05 25 Mar 16/05 25 Apr 13/05 9 May 11/05 The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Mail to: Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 19 of 60 **BOEING SERVICE BULLETIN 767-57A0095 NOTE:**  One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane.
**Kit 015T1772 Notes**  **Existing Part Number Name**  **QTY New Part Number** **-1**

- Top Kit - Slat Track Housing - Drain Tube Replacement - 015T1772-1 (a) (d) 200-030-0001-501 Tube 2 015T1772-2 AS1716D08 Ferrule - Flexible 4 AS1716D08 AN735C8 Clamp, Loop 2 AN735DC8 305B387S8 Coupling - Flexible 2 AS1712D08 355B387S8 Coupling - Half 2 AS1713D08 BACJ40AC44-6 or BACJ40AC44-8 Bonding Jumper 4 BACJ40A20-8
BACN10YR3CD Nut 6 BACN10YR3CD (b) BACS12GU3K9 Screw 2 BACS12HN3-9 (c) MS29513-114 Packing, Preformed 6 MS29513-114 NAS1149D0316H or NAS1149D0316J Washer 16 NAS1149D0316H

- Washer - Plain 2 NAS1149D0332H NAS1149D0363H Washer 2 NAS1149D0363H (a) Discard the existing part. (b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D590 and Boeing Drawing 012W6100 are used to determine the part numbers used as substitutes. (c) There are more parts than are necessary. (d) Optional to make drain tube, operators can make the drain tube from raw stock tubing material 6061-T6 in accordance with WW-T-700/6 or AMS 4083 or AMS-T-7081, with a nominal Outer Diameter of 0.5 inch, and a nominal wall thickness of 0.035 inch. 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Specification**  (c) Chemical Conversion Coating 1/2 pint Alodine 600 (Alodine 1600/1660 Option- al) (a) Corrosion Resistant Finish 1/2 pint BMS 10-20, Type II Safety Wire 12 inches MS20995AB32

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 20 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Notes**  **Name QTY**  **Part Number / Specification** (a) Grease 1/4 pint BMS 3-24 (BMS 3-33 Optional) Solvent 1/2 pint Denatured Alcohol (b) Lubricant 1/4 pint SAE No. 10 Automotive Motor Oil (Mas- terdraw B1767C Optional)(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Any SAE "10W-xx" (10W-20, 10W-30, 10W-40, etc) automotive engine oil is an acceptable substitute for SAE No.10 automotive engine oil. (c) Refer to SOPM 20-43-03 as an accepted procedure for the application of Chemical Conversion Coating.
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** The operator can supply the special tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. The special tools may be purchased from the suppliers shown below. Tool price and availability data are not given.
**Notes Name**  **QTY Tool Part Number**  (b) (c) Wrench 1 ST2580-77A-5 (a) (b) (c) Frame 1 ST877W-F (a) (b) (c) Die Block 1 ST877W-DF-D-08-1-1 (a) (b) (c) Die Block 1 ST877W-DF-D-08-1-2 (Optional) (e) (h) Swage Block 1 DB6305H8 (Optional) (a) (b) (c) Die Block Holder 1 ST877W-DH-1 (e) (g) Swage Block Holder 1 DH6305-1 (Optional) (a) (d) Tube Expander 1 ST877W-E-8-035

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 21 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Notes**  **Name QTY**  **Tool Part Number** (a) (f) Tube Expander 1 B9108-35 (Optional) (e) (f) Tube Expander 1 B8308-35 (Optional) (a) This tool can be purchased from: Monaghan & Associates, Inc. Elliot Tool Technologies 1760 Tuttle Avenue P.O. Box 1165-45401 Dayton, Ohio 45403-3428. Phone: 937-253-7706. Toll Free: 800-332-0447. Fax: 937-259-9241. Contact: Ken MacDonald, Sales Engineer. Email: sales@monaghaninc.com (b) This tool can be purchased from: New Tech Industries, Inc. 7911 44th Avenue West Mukilteo, Washington 98275. Phone: 425-778-1200. Fax: 425-743-3566. Contact: Tom Bigelow, President. Email: tom@newtechind.com (c) This tool can be purchased from: Precise Tool and Gage Co., Inc. 30540 S.E. 84th St., Unit 2 Preston, Washington 98050. Phone: 206-623-1120, 425-222-9567. Fax: 425-222-9568. Contact: Brad Schulz, Sales Rep. Email: ptg@precisetoolco.com (d) This tool can be purchased from: E.F. Bailey Company 5610 Fourth Avenue South Seattle, Washington 98108. Phone: 206-607-4840. Fax: 206-607-5440. Contact: Ted McBurney, Sales Rep. (e) This tool can be purchased from: Adel Wiggins Group Transdigm, Inc. 5000 Triggs Street Los Angeles, California 90022. Phone: 323-881-7654. Contact: Terri Roane, Boeing Account Rep. Email: TRoane@AdelWiggins.com (f) This tool is equivalent to the ST877W-E-8-035 Tube Expander. (g) This tool is equivalent to the ST877W-DH-1 Die Block Holder. (h) This tool is equivalent to the ST877W-DF-D-08-1-1 Die Block.

Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the date the tools will be used. If there is a limit in the quantity of available tools, a supply sequence is given by Spares.

**PURCHASE DATA:**
**Name Boeing Part Page Number (a)**  **Tool Part Number** Wrench ST2580-77A5 ST2580-77A-5 Frame ST877WF ST877W-F Die Block Holder (Swage Block Holder)ST877WDH1 (DH6305-1Optional) ST877W-DH-1

Die Block (Swage Block) ST877WDFD08-1-1 (ST877WDFD08-1-2 or DB6305H8 Optional) ST877W-DF-D-08-1-1

Tube Expander ST877WE8-035 (B9108-35 or B8308-35 Optional) ST877W-E-8-035

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 22 of 60 **BOEING SERVICE BULLETIN 767-57A0095 PURCHASE DATA:** 
**Name Boeing Part Page Number (a)**  **Tool Part Number** (a) Use the special Boeing part page number when ordering from the Boeing Part Page. The Boeing Part Page only lets entries with dashes "-" between numbers be entered. The user will be alerted to this, if the unmodified, tool part number is entered. The Tools are subject to the terms and conditions of the Boeing standard purchase order acknowledgement. After the Price date, new price data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin number and submit purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Mail to: Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA (Service Bulletin 767-57A0095) **F. Special Tooling Necessary to do this Service Bulletin** To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available.
**Notes Name**  **QTY Tool Part Number**  Wrench 1 ST2580-77A-5 (a) Frame 1 ST877W-F (b) Die Block Holder (Swage Block Holder) 1 ST877W-DH-1 (DH6305-1 Optional) (c) Die Block (Swage Block) 1 ST877W-DF-D-08-1-1 (ST877W-DF-D-08-1-2 or DB6305H8 Optional) (d) Tube Expander 1 ST877W-E-8-035 (B9108-35 or B8308-35 Optional) (a) This tool is optional. The ST877W-DH-1 die block holder (or DH6305-1swage block holder) may be clamped in a securely mounted bench vise, for the roller swage process. (b) A DH6305-1 swage block holder may be used in place of the ST877W-DH-1 die block holder.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 23 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Notes**  **Name QTY**  **Tool Part Number** (c) Either a ST877W-DF-D-08-1-2 die block (no link installed) or a DB6305H8 swage block may be used in place of the ST877W-DF-D-08-1-1 die block. (d) Either a B9108-35 tube expander or a B8308-35 tube expander may be used in place of the ST877W-E-8-035 tube expander.
**NOTE:** The above special tools are reusable. The special tools may be used to accomplish this service bulletin on multiple airplanes, with proper use and care.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 24 of 60 **BOEING SERVICE BULLETIN 767-57A0095 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Angular tolerance is plus or minus 2 degrees – Torque limits to tighten nuts and bolts are in 767-400 Structural Repair Manual, Chapter 51. 5. Use the approved fastener and process material substitutions in accordance with 767-400 Structural Repair Manual, Chapter 51. Alternate fasteners are listed in 767-400 Structural Repair Manual, Chapter 51 and Boeing Drawing 012W6100. 6. If the length of any fastener specified in this service bulletin does not meet the installation standards in 767-400 Structural Repair Manual, Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in 767-400 Structural Repair Manual, Chapter 51 may be used. 7. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 25 of 60 **BOEING SERVICE BULLETIN 767-57A0095 B. WORK INSTRUCTIONS**  **WARNING:** DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR WEATHER RADAR DURING THE DEFUEL PROCEDURES. THE OPERATION OF THE HF COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN EXPLOSION TO OCCUR. 1. Defuel the main tank of the left and right wing. Refer to 767 AMM 28-26-00 as an accepted procedure. **WARNING:** OBEY THE PURGING AND FUEL TANK ENTRY PRECAUTIONS. FAILURE TO OBEY THE PURGING AND FUEL TANK ENTRY PRECAUTIONS CAN CAUSE SERIOUS INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO EQUIPMENT. 2. Prepare to go into the main fuel tank, inboard of rib no.10, of the left and right wing. Refer to 767 AMM 28-11-00 as an accepted procedure. **WARNING:** DO NOT USE AIRPLANE ELECTRICAL POWER WHEN FUEL TANK ACCESS DOORS ARE REMOVED. A FIRE OR EXPLOSION CAN OCCUR IF FUEL VAPOR IS IGNITED BY SPARK(S) FROM ELECTRICAL EQUIPMENT. A FIRE OR EXPLOSION CAN CAUSE SERIOUS INJURY OR DEATH TO PERSONS AND CAN CAUSE DAMAGE TO EQUIPMENT. 3. Open the left and right wing main tank and dry bay access panels listed below, to get access to the number 5 and number 8 slat track housing drain tube assemblies. Refer to 767 AMM 06-44-00.
**Location Panel Number**  LEFT WING DRY BAY 533AB RIGHT WING DRY BAY 633AB LEFT WING MAIN TANK 532FB RIGHT WING MAIN TANK 632FB 4. Remove the existing drain tube assembly that has a flexible part at the number 5 slat track housing in accordance with FIGURE 1. 5. Remove the existing drain tube assembly that has a flexible part at the number 8 slat track housing in accordance with FIGURE 2. 6. Prepare the new drain tube for installation at the number 5 slat track housing in accordance with FIGURE 3. 7. Prepare the new drain tube for installation at the number 8 slat track housing in accordance with FIGURE 4. 8. Install the new drain tube at the number 5 slat track housing in accordance with FIGURE 5. 9. Install the new drain tube at the number 8 slat track housing in accordance with FIGURE 6. 10. Close the left and right wing main tank access panels listed below. Refer to 767 AMM 06-44-00.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 26 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Location**  **Panel Number** LEFT WING MAIN TANK 532FB RIGHT WING MAIN TANK 632FB
**WARNING:** DO NOT PUT GROUND EQUIPMENT UNDER THE WINGTIPS DURING THE REFUEL PROCEDURES. THE WINGS MOVE DOWN UNDER THE WEIGHT OF THE FUEL AND THE WINGTIPS MOVE THE MOST. BECAUSE THE FUEL TANKS ARE VENTED THROUGH THE WINGTIPS, A DANGEROUS AND EXPLOSIVE MIXTURE AROUND THE WINGTIPS CAN OCCUR. **WARNING:** DO NOT OPERATE THE HF COMMUNICATIONS SYSTEM OR THE WEATHER RADAR DURING THE REFUEL PROCEDURES. THE OPERATION OF THE HF COMMUNICATIONS SYSTEM OR THE WEATHER RADAR COULD CAUSE AN EXPLOSION TO OCCUR. 11. Refuel the main tank of the left and right wing. Refer to 767 AMM 12-11-01 as an accepted procedure. **NOTE:** A minimum of 4400 U.S. gallons of fuel is necessary in the main tanks to do a satisfactory inspection for leakage. 12. Do a general visual inspection of the dry bay area in the left and right wing to make sure there is no fuel leakage from the new drain tube installations. 13. Close the left and right wing dry bay access panels listed below. Refer to 767 AMM 06-44-00.
**Location Panel Number**  LEFT WING DRY BAY 533AB RIGHT WING DRY BAY 633AB 14. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2: December 17, 2009 27 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 28 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 29 of 60 **BOEING SERVICE BULLETIN 767-57A0095**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 the left wing.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  1 BACS12GU3K8 Screw Remove/Keep 1 2 BACN10YR3CD Nut Remove/Keep 2 one of the two types of washer could be installed. 3 NAS1149D0316H or NAS1149D0316J Washer Remove/Keep 3

2 NAS1149D0363H Washer Remove/Keep 4 1 BACS12GU3K9 Screw Remove 5 1 BACN10YR3CM Nut Remove 6 3 NAS1149D0316R Washer Remove 7 2 NAS1149D0363R Washer Remove 8

**FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 30 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** one of the two types of washer could be installed. 1 NAS1149D0316H or NAS1149D0316J Washer Remove 9

1 BACJ40AC44-6 Bonding Jumper Remove 10 1 BACJ40AC44-8 Bonding Jumper Remove 11 1 AN735C8 Bonding Clamp Remove 12 1 AN735DC8 Bonding Clamp Remove/Keep 13

- - Lockwire Remove 14 1 355B387S8 Coupling Assembly

- - Lockwire Remove 15 1 305B387S8 Coupling Assembly 1 200-030-0001-501 Drain Tube Assembly Remove 16

**FIGURE 1: DRAIN TUBE ASSEMBLY AT NUMBER 5 SLAT TRACK HOUSING - REMOVE (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 31 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 32 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 33 of 60 **BOEING SERVICE BULLETIN 767-57A0095**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 the right wing.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  1 BACS12GU3K8 Screw Remove/Keep 1 2 BACN10YR3CD Nut Remove/Keep 2 one of the two types of washer could be installed. 3 NAS1149D0316H or NAS1149D0316J Washer Remove/Keep 3

2 NAS1149D0363H Washer Remove/Keep 4 1 BACS12GU3K9 Screw Remove 5 1 BACN10YR3CM Nut Remove 6 3 NAS1149D0316R Washer Remove 7 2 NAS1149D0363R Washer Remove 8

**FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 34 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** one of the two types of washer could be installed. 1 NAS1149D0316H or NAS1149D0316J Washer Remove 9

1 BACJ40AC44-6 Bonding Jumper Remove 10 1 BACJ40AC44-8 Bonding Jumper Remove 11 1 AN735C8 Bonding Clamp Remove 12 1 AN735DC8 Bonding Clamp Remove/Keep 13

- - Lockwire Remove 14 1 355B387S8 Coupling Assembly

- - Lockwire Remove 15 1 305B387S8 Coupling Assembly 1 200-030-0001-501 Drain Tube Assembly Remove 16

**FIGURE 2: DRAIN TUBE ASSEMBLY AT NUMBER 8 SLAT TRACK HOUSING - REMOVE (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 35 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 36 of 60 **BOEING SERVICE BULLETIN 767-57A0095**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 the left wing.

**FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 37 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** to make one end fully agree with the drain tube attached to the slat track housing. 1 015T1772-2 Drain Tube Align 1

(a)

- Measure (b)

- Bend 2 (c)

- Cut 3 (d)

- Deburr 4 the outer surface to remove oil and grease. Refer to SOPM 20-30-03 asan accepted procedure. - Clean 5

one on each end of the drain tube as shown. 2 AS1716D08 Ferrule - Flexible Install (New) 6

the drain tube ontoeach ferrule,in accordance with Appendix A. - Roller Swage

to the inner and outer surface of the drain tube. Refer to SOPM 20-43-03 asan accepted procedure. - Alodine 600 (Alodine 1600/1660 Optional) Chemical Conversion Coating Apply 7

(e) 1 layer BMS 10-20, Type II Corrosion Resistant Finish Apply 8 (f)

- Marking Apply 9 with a rubber stamp to reidentify the drain tube. Refer to SOPM 20-50-10 asan accepted procedure. - 015T1772-3 Part Mark Apply 10

(a) the bend angle necessary to make the other end of the drain tube fully agree with doubler at rib no. 9. (b) with standard bend radius tools, to agree with the measurements. After the tube is bent, an end to end distance tolerance of + or - 0.03 inches is permitted.

**FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 38 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (c) to make one end parallel with the end of the drain tube attached to the slat track housing and one end perpendicular with the doubler at rib no. 9. Cut the tube as necessary to keep the clearance dimensions at each end of the tube as shown. (d) Flat deburr and square both drain tube ends to within 0.005 inch. Radius all sharp edges to between 0.02 and 0.06 inch. (e) to all of the inner surface, the specified area of the outer surface of the drain tube and each ferrule. Refer to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures. Do not apply BMS 10-20, Type II to the 0.30 dimension shown at the end of the each ferrule. (f) Apply an arrow that points to rib no. 9, with a rubber stamp to the drain tube outer surface, to identify the direction of flow. Refer to SOPM 20-50-10 as an accepted procedure.

**FIGURE 3: NEW DRAIN TUBE FOR NUMBER 5 SLAT TRACK HOUSING - PREPARE (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 39 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 40 of 60 **BOEING SERVICE BULLETIN 767-57A0095**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 the right wing.

**FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 41 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** to make one end fully agree with the drain tube attached to the slat track housing. 1 015T1772-2 Drain Tube Align 1

(a)

- Measure (b)

- Bend 2 (c)

- Cut 3 (d)

- Deburr 4 the outer surface to remove oil and grease. Refer to SOPM 20-30-03 asan accepted procedure. - Clean 5

one on each end of the drain tube as shown. 2 AS1716D08 Ferrule - Flexible Install (New) 6

the drain tube ontoeach ferrule,in accordance with Appendix A. - Roller Swage

to the inner and outer surface of the drain tube. Refer to SOPM 20-43-03 asan accepted procedure. - Alodine 600 (Alodine 1600/1660 Optional) Chemical Conversion Coating Apply 7

(e) 1 layer BMS 10-20, Type II Corrosion Resistant Finish Apply 8 (f)

- Marking Apply 9 with a rubber stamp to reidentify the drain tube. Refer to SOPM 20-50-10 asan accepted procedure. - 015T1772-3 Part Mark Apply 10

(a) the bend angle necessary to make the other end of the drain tube fully agree with doubler at rib no. 9. (b) with standard bend radius tools, to agree with the measurements. After the tube is bent, an end to end distance tolerance of + or - 0.03 inches is permitted.

**FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 42 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (c) to make one end parallel with the end of the drain tube attached to the slat track housing and one end perpendicular with the doubler at rib no. 9. Cut the tube as necessary to keep the clearance dimensions at each end of the tube as shown. (d) Flat deburr and square both drain tube ends to within 0.005 inch. Radius all sharp edges to between 0.02 and 0.06 inch. (e) to all of the inner surface, the specified area of the outer surface of the drain tube and each ferrule. Refer to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures. Do not apply BMS 10-20, Type II to the 0.30 dimension shown at the end of the each ferrule. (f) Apply an arrow that points to rib no. 9, with a rubber stamp to the drain tube outer surface, to identify the direction of flow. Refer to SOPM 20-50-10 as an accepted procedure.

**FIGURE 4: NEW DRAIN TUBE FOR NUMBER 8 SLAT TRACK HOUSING - PREPARE (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 43 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL**  **(SHEET 1 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 44 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 45 of 60 **BOEING SERVICE BULLETIN 767-57A0095**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 the left wing.

**FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 46 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) 1 015T1772-3 Drain Tube Align 1 (b) Install (New) (c) 1 MS29513-114 Packing, Preformed Install (New) 2 (d)

- BMS 3-24 (BMS 3-33 optional) Grease Apply 3 Engage the coupling nut and tighten by hand. 1 AS1713D08 Coupling Assembly, Half Install (New)

(c) 2 MS29513-114 Packing, Preformed Install (New) 4 (e)

- BMS 3-24 (BMS 3-33 optional) Grease Apply 5 (f) 1 AS1712D08 Coupling Assembly Install (New) to safety each coupling. Refer to SOPM 20-50-02 asan accepted procedure. - MS20995AB32 Wire Install (New) 6

(g)

- Finish Remove 7 (h) 1 AN735DC8 Bonding Clamp Install (New) 1 BACJ40A20-8 Bonding Jumper Install (New) 8 1 BACJ40A20-8 Bonding Jumper Install (New) 9 4 NAS1149D0316H Washer Install (New) 10 1 NAS1149D0332H Washer Install (New) 11 1 NAS1149D0363H Washer Install (New) 12 1 BACS12HN3-9 Screw Install (New) 13 1 BACN10YR3CD Nut Install (New) 14 1 AN735DC8 Bonding Clamp Install (Kept) 15 3 NAS1149D0316H or NAS1149D0316J Washer Install (Kept) 16

2 NAS1149D0363H Washer Install (Kept) 17 1 BACS12GU3K8 Screw Install (Kept) 18 2 BACN10YR3CD Nut Install (Kept) 19 (i)

- Designated Bond (Electrostatic) Electrical Resistance Measure 20

**FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 47 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (j)

- Alodine 600 (Alodine 1600/1660 Optional) Chemical Conversion Coating Apply 21 (k) 1 layer BMS 10-20, Type II Corrosion Resistant Finish (a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where it aligns with the drain tube attached to the slat track housing and the doubler. (b) Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube attached to the slat track housing and the ferrule of the new drain tube, before the coupling is installed.(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the same configuration as shown. (d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure. (f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your hand. A correctly tightened coupling will agree with gage tolerance shown. (g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 20-20-00 as an accepted procedure. (h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an accepted procedure. (i) between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is attached to the slat track housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches away from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. Refer to SWPM 20-20-00 as an accepted procedure. (j) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-43-03 as an accepted procedure. (k) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures.

**FIGURE 5: NEW DRAIN TUBE AT NUMBER 5 SLAT TRACK HOUSING - INSTALL (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 48 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL**  **(SHEET 1 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 49 of 60 **BOEING SERVICE BULLETIN 767-57A0095 FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 50 of 60 **BOEING SERVICE BULLETIN 767-57A0095**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 the right wing.

**FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 51 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) 1 015T1772-3 Drain Tube Align 1 (b) Install (New) (c) 1 MS29513-114 Packing, Preformed Install (New) 2 (d)

- BMS 3-24 (BMS 3-33 optional) Grease Apply 3 Engage the coupling nut and tighten by hand. 1 AS1713D08 Coupling Assembly, Half Install (New)

(c) 2 MS29513-114 Packing, Preformed Install (New) 4 (e)

- BMS 3-24 (BMS 3-33 optional) Grease Apply 5 (f) 1 AS1712D08 Coupling Assembly Install (New) to safety each coupling. Refer to SOPM 20-50-02 asan accepted procedure. - MS20995AB32 Wire Install 6

(g)

- Finish Remove 7 (h) 1 AN735DC8 Bonding Clamp Install (New) 1 BACJ40A20-8 Bonding Jumper Install (New) 8 1 BACJ40A20-8 Bonding Jumper Install (New) 9 4 NAS1149D0316H Washer Install (New) 10 1 NAS1149D0332H Washer Install (New) 11 1 NAS1149D0363H Washer Install (New) 12 1 BACS12HN3-9 Screw Install (New) 13 1 BACN10YR3CD Nut Install (New) 14 1 AN735DC8 Bonding Clamp Install (Kept) 15 3 NAS1149D0316H or NAS1149D0316J Washer Install (Kept) 16

2 NAS1149D0363H Washer Install (Kept) 17 1 BACS12GU3K8 Screw Install (Kept) 18 2 BACN10YR3CD Nut Install (Kept) 19 (i)

- Designated Bond (Electrostatic) Electrical Resistance Measure 20

**FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 52 of 60 **BOEING SERVICE BULLETIN 767-57A0095 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (j)

- Alodine 600 (Alodine 1600/1660 Optional) Chemical Conversion Coating Apply 21 (k) 1 layer BMS 10-20, Type II Corrosion Resistant Finish (a) Make sure each end of the new drain tube has an axial tolerance of less than 4 degrees where it aligns with the drain tube attached to the slat track housing and the doubler. (b) Make sure a clearance of 0.150 + or - 0.050 inches exists between the ferrule of the drain tube attached to the slat track housing and the ferrule of the new drain tube, before the coupling is installed.(c) Make sure the packing, preformed and retaining washers in the coupling are installed in the same configuration as shown. (d) lightly, to the coupling nut and retaining washers (which are included in the coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure.(e) lightly, to the coupling nut, coupling body and retaining washers (which are included in the coupling assembly) before installation. Refer to SOPM 20-50-07 as an accepted procedure. (f) Move the retainer halves quickly into position, engage the coupling nut and tighten with your hand. A correctly tightened coupling will agree with gage tolerance shown. (g) from the area of the new drain tube that will be covered by the bonding clamp. Refer to SWPM 20-20-00 as an accepted procedure. (h) Make sure all contact surfaces for bonding parts are prepared. Refer to SWPM 20-20-00 as an accepted procedure. (i) between the bracket on the stiffener at rib no. 9 and the bonding clamp on the drain tube that is attached to the slat track housing. Make sure each of the probes of the multimeter are a minimum of 0.25 inches away from the bonding clamp and bracket. Electrical resistance must not be more than 0.010 ohms. Refer to SWPM 20-20-00 as an accepted procedure. (j) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-43-03 as an accepted procedure. (k) if necessary, to areas of the outer surfaces of the drain tubes that were made bare during the installation of the bonding clamp and the electrical resistance measurement. Refer to SOPM 20-41-02 and SOPM 20-60-02 as accepted procedures.

**FIGURE 6: NEW DRAIN TUBE AT NUMBER 8 SLAT TRACK HOUSING - INSTALL (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 53 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS**  **(SHEET 1 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 54 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS**  **(SHEET 2 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 55 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS**  **(SHEET 3 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 56 of 60 **BOEING SERVICE BULLETIN 767-57A0095 Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS**  **(SHEET 4 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 57 of 60 **BOEING SERVICE BULLETIN 767-57A0095**The following special tooling is required to roller swage the 015T1772-2 drain tube onto the AS1716D08 ferrules:
**Notes Description**  **Part Number Quantity**  (a) Frame ST877W-F 1 (c) Die Block Holder (Swage Block Holder) ST877W-DH-1 (DH6305- 1 Optional) 1 (b) Die Block (Swage Block) ST877W-DF-D-08-1-1 (ST877W-DF-D-08-1-2 or DB6305H8 Optional) 1

(d) Tube Expander ST877W-E-8-035 (B9108- 35 or B8308-35 Optional) 1 (e) Wrench ST2580-77A-5 1 (a) The use of the ST877W-F Frame is optional. The ST877W-DH-1 die block holder (or the DH6305-1swage block holder) may be installed in a sturdy bench vise, instead of in the ST877W-F Frame. (b) Either a ST877W-DF-D-08-1-2 die block (no link installed) or a DB6305H8 swage block may be used in place of the ST877W-DF-D-08-1-1 die block. (c) A DH6305-1 swage block holder may be used in place of the ST877W-DH-1 die block holder. (d) Either a B9108-35 tube expander or a B8308-35 tube expander may be used in place of the ST877W-E-8-035 tube expander. (e) This tool is only compatible with the ST877W-E-8-035 and the B9108-35 tube expander. A female 3/8 inch square drive socket can be used for the B8308-35 tube expander. 1. Make sure the AS1716D08 ferrule internal swage grooves are free of debris and/or lubricant. 2. Make sure the outside surface of the 015T1772-2 drain tube is free of scratches and/or gouges in the swaging areas. Scratches and/or gouges on the drain tube outside surface swaging areas are not acceptable. If the drain tube outside surface has a scratch and/or gouge in the swaging area that is deeper than 0.001 inch after polishing, the part must be replaced. 3. Make sure the outside surface of the 015T1772-2 drain tube is free of debris and/or lubricant in the swaging areas. 4. Attach the ST877W-F frame to a sturdy workbench, if the ST877W-DH-1 die block holder will be installed in the frame. Refer to Item 5 below. 5. Install the ST877W-DH-1 die block holder on the ST877W-F frame. Two 0.5000-13 x (length required) steel fasteners (operator supplied) are required to secure the die block holder to the frame. Optional to secure the die block holder in a sturdy bench vise, instead of on the ST877W-F frame. The 0.5000-13 x (length required) steel fasteners are not required if the die block holder is secured in a bench vise, instead of the frame.

**Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS (SHEET 5 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 58 of 60 **BOEING SERVICE BULLETIN 767-57A0095**6. Clean the ST877W-DF-D-08-1-1 die block halves using Denatured Alcohol and a clean cloth, to ensure the die block halves ferrule cavities are free of debris and/or lubricant. 7. Insert the AS1716D08 ferrule into the ST877W-DF-D-08-1-1 die block half cavity and close the die block halves. 8. Install the ST877W-DF-D-08-1-1 die block halves (and AS1716D08 ferrule) into the ST877W-DH-1 die block holder. The flanged end of the AS1716D08 ferrule must be located adjacent to the die block stop in the die block holder. Align the die block split lines approximately perpendicular to the die block holder split line. 9. Torque the ST877W-DH-1 die block holder clamping fastener to 100 foot-pounds. Make sure the ST877W-DF-D-08-1-1 die block halves are fully against the die block holder stop, prior to torque application. 10. Clean the rollers and to the tapered mandrel of the ST877W-E-8-035 tube expander, using Denatured Alcohol solvent and a clean cloth. 11. Apply SAE No. 10 automotive engine oil lubricant to the rollers and to the tapered end of the ST877W-E-8-035 tube expander. Optional to use Masterdraw B1767C lubricant. **NOTE:** Any SAE "10W-xx" (10W-20, 10W-30, 10W-40, etc) automotive engine oil is an acceptable substitute for SAE No.10 automotive engine oil. 12. Insert the 015T1772-2 drain tube into the AS1716D08 ferrule until it contacts the ferrule tube stop. Hold the drain tube squarely against the ferrule tube stop until the swage process is completed. 13. Insert the ST877W-E-8-035 tube expander into ST877W-DF-D-08-1-1 die block, opposite the 015T1772-2 drain tube. 14. Push the exposed end of the mandrel towards the ST877W-E-8-035 tube expander body and rotate the mandrel by hand clockwise, to start the tube expander self-feeding action. 15. Install the ST2580-77A-5 wrench or a female 3/8 inch square drive socket (as applicable), on the end of the tube expander mandrel. 16. Torque the ST2580-77A-5 wrench (or female 3/8 inch square drive socket) to 16 - 20 inch-pounds. The mandrel end will advance into the tube expander body as it rotates. Ten or more complete turns of the wrench may be necessary to reach the required torque. 17. Rotate the mandrel counterclockwise to loosen and remove the ST877W-E-8-035 tube expander. 18. Loosen the ST877W-DH-1 die block holder clamping fastener to remove the ST877W-DF-D-08-1-1 die block and swaged drain tube/ferrule. 19. Remove the swaged drain tube/ferrule from the ST877W-DF-D-08-1-1 die block halves. 20. Remove lubricant residue from the swaged drain tube/ferrule with a clean cloth.

**Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS (SHEET 6 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 59 of 60 **BOEING SERVICE BULLETIN 767-57A0095**21. Do a General Visual Inspection of the swaged joint, to check for die parting-line welts on the external AS1716D08 ferrule surfaces. External die parting-line welts exceeding 0.002 inch height on O-ring sealing areas, or 0.004 inch height in non-seal areas, are not acceptable and the parts must be replaced. 22. Do a General Visual Inspection of the swaged joint, to check for 015T1772-2 drain tube extrusion beyond the AS1716D08 ferrule flange end face. Drain tube extrusion beyond the ferrule flange end face is not acceptable and the parts must be replaced. 23. Do a General Visual Inspection of the swaged joint, to check for signs of AS1716D08 ferrule flange shearing, due to linear tubing expansion from the roller swage process. Ferrule flange shearing is not acceptable and the parts must be replaced. 24. Do a General Visual Inspection of the swaged joint, to check for scratches and/or die marks on the AS1716D08 ferrule flange. Scratches and/or die marks on the ferrule flange are not acceptable and the parts must be replaced. 25. Do a General Visual Inspection of the swaged joint, to check for visible gaps between the AS1716D08 ferrule tube stop and the end of the 015T1772-2 drain tube. Visible gaps between the ferrule stop and the end of the drain tube are not acceptable and the parts must be replaced. 26. Do a General Visual Inspection of the swaged joint, to check for longitudinal AS1716D08 ferrule cracks. Longitudinal ferrule cracks are not acceptable and the parts must be replaced.

**Appendix A: DRAIN TUBE ROLLER SWAGE INSTRUCTIONS (SHEET 7 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 02, 2005 767-57A0095 Revision 2 December 17, 2009 60 of 60 **BOEING SERVICE BULLETIN 767-57A0095**