January 16, 2003

Revision 2: June 02, 2006 767-49A0035

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 52

Commercial

Airplane

Group 767

Service Bulletin

Number: 767-49A0035

Date: January 16, 2003

Revision 2: June 02, 2006

ATA System: 4915

SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 

Modification

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2003 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable 

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third 

parties. Treatment of the document and the information it contains is governed by contract with Boeing. For 

more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, 

MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or 

its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document 

or otherwise.
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BOEING SERVICE BULLETIN 767-49A0035

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 Table of Contents

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BOEING SERVICE BULLETIN 767-49A0035

Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

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

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 26

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

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

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

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 30

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 31

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 1: Modify The Aft Air-intake Duct Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly . . . . . . . . . . . . . . . 38

FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly . . . . . . . . . . . . . . . . . . 42

FIGURE 4: Air-Intake Duct And Dripshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . 47

APPENDIX A: WET POTTING OF INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
 Table of Contents

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Revision 2: June 02, 2006 767-49A0035

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Commercial

Airplane

Group 767

Service Bulletin

Number: 767-49A0035 Revision Transmittal Sheet

Date: January 16, 2003

Revision 2: June 02, 2006

ATA System: 4915

SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 

Modification

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed as shown in the previous revisions of this service bulletin.

REASON FOR REVISION

The data given in Information Notice 767-49-0035 IN 02 is included in this revision. The Information Notice 

advised operators that it was unnecessary to remove the forward intake duct. The steps to remove the forward 

intake duct have been removed from the Accomplishment Instructions and from Figure 1. 

Validation information has been added to the Reason and Background paragraphs. 

The manpower required for the airplane rework has been reduced from 3.0 hours to 2.0 hours. 

A note has been added to Figure 1 to make it easier to remove the aft air-intake duct.

A note to show the reason for the large fastener holes has been added to Figure 2.

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

paragraph for changes.

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

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: January 16, 2003

Revision 1: December 11, 2003

Revision 2: June 2, 2006
 

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Commercial

Airplane

Group 767

Service Bulletin

Number: 767-49A0035 Summary

Date: January 16, 2003

Revision 2: June 02, 2006

ATA System: 4915

SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 

Modification

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Boeing Service Related Problem (SRP) 767-27-0147 is related to this service bulletin.

Incorporation of this change will prevent APU air intake duct water leakage from contributing to stiff operation 

of the elevator pitch control system and any other related pitch control issues.

Two instances of stiff operation of the elevator pitch control system have been reported. An investigation 

revealed that water can occasionally leak from the joint, in the air-intake duct for the Auxiliary Power Unit (APU), 

aft of Station 1809.5. The water can leak from the duct joint onto the elevator center-auto-pilot servo Linear 

Variable Differential Transducer (LVDT). 

 A dripshield can be installed under the aft air-intake duct to prevent water from reaching the LVDT.

As a part of a service bulletin validation program, this change was completed on airplane VN027 by Revision 

01 of this service bulletin. 

ACTION (PRR B12901-029S)

The 015T1729-8 Top Kits have been placed under management control, such that one 015T1729-8 Top Kit is 

available to each operator to use as a first incorporation unit in order to generate a spare unit for component 

rework. This will minimize airplane downtime and lessen the impact to maintenance operations.

Follow accomplishment instructions under “Component Work - Aft Air-Intake Duct Assembly Modification” to 

rework an existing Aft Air-intake Duct assembly into the equivalent production aft Air-intake Duct assembly. Use 

components from the 015T1729-7 Top Kit.

Follow accomplishment instructions under “Airplane Work - Duct Replacement And Dripshield Installation” to 

install a new Dripshield on either a new 353T0252-11 Aft Air-intake Duct, from a 015T1729-8 Top Kit, or a 

reworked Aft Air-intake Duct made from a 015T1729-7 Top Kit. 
 

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BOEING SERVICE BULLETIN 767-49A0035

EFFECTIVITY

All 767airplanes, line numbers 1 through 890, except 767-400ER airplanes.

COMPLIANCE

Boeing recommends incorporation of this service bulletin at a convenient opportunity when airplane and 

manpower are available, not to exceed 18 months after the receipt of revision one of this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of April 27, 2001. Please refer to 

Paragraph 2.B., Industry Support Information.

MANPOWER

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

Airplanes Total Task 

Hours

Elapsed 

Hours

Airplane Work - Duct 

Replacement And Dripshield 

Installation

2.0 2.0

Components Total Task 

Hours

Elapsed 

Hours

Component Work - Aft AirIntake Duct Assembly 

Modification

1.0 1.0
 

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BOEING SERVICE BULLETIN 767-49A0035

FWD

DUCT ASSEMBLY

AFT AIR-INTAKE

REWORK AN EXISTING

EITHER REPLACE OR

STA

1843

INSTALL A NEW

DRIPSHIELD

SEE A

A

V86832
 

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Commercial

Airplane

Group 767

Service Bulletin

Number: 767-49A0035

Date: January 16, 2003

Revision 2: June 02, 2006

ATA System: 4915

SUBJECT: AIRBORNE AUXILIARY POWER - Power Plant - APU Air Intake Duct - Dripshield 

Modification

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-24T001 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 B12901-29S for data about this change.

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

767 AIRCRAFT ONE, INC. (ONI)

1 VA510–VA512

ABX AIR (ABX)

1 VA301 VA304 VA803 VA807–VA809

VB101–VB123 VB125 VB302

AEROFLOT (ARO)

1 VN471–VN472 VS216–VS217 VS321–VS324 VS392

AEROMEXICO (AMX)

1 VF071–VF072 VF091 VF093 VS211

GROUP CONFIGURATION DESCRIPTION

1 - All 767airplanes, line numbers 1 through 890, 

except 767-400ER airplanes.
 

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BOEING SERVICE BULLETIN 767-49A0035

AEROSVIT (UKA)

1 VN155 VN157

AEROTURBINE (AUB)

1 VB051 VB054–VB055 VB321–VB322

AIR ALGERIE (ALG)

1 VK131–VK133

AIR ATLANTA EUROPE LIMITED (AUP)

1 VB326–VB327 VL011

AIR ATLANTA ICELANDIC (AID)

1 VN153 VN557

AIR CANADA (ACN)

1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202

VN051–VN054 VN056–VN062 VN531 VN536

VN541–VN542 VN546–VN547 VN751–VN752 VN811–VN812

VN931–VN936 VS381–VS382 VS546–VS549

AIR CHINA (BEJ)

1 VE064 VE083–VE086 VK161–VK164 VN388

VS206 VS208 VS274 VS307

AIR DO (HIA)

1 VS176–VS177

AIR EUROPA (ARE)

1 VN421 VS291–VS293

AIR GABON (GBN)

1 VE021

AIR MADAGASCAR (MAD)

1 VN167 VN731

AIR MAURITIUS (MAU)

1 VF001–VF002

AIR NEW ZEALAND (ANZ)

1 VN652–VN658 VS112–VS113

AIR NIUGINI (NIU)

1 VN651

AIR PACIFIC (APC)

1 VN676

AIR SAHARA (SAQ)

1 VN495
 

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AIR SEYCHELLES (ASY)

1 VL941 VS526

AIR ZIMBABWE (ZMB)

1 VF061–VF062

ALITALIA (ALI)

1 VL701–VL702 VN422–VN427 VN732 VN813

VS366–VS367 VS401

ALL NIPPON AIRWAYS (ANA)

1 VK081–VK113 VN191–VN198 VR401 VS721–VS727

VT501

AMERICAN AIRLINES (AAL)

1 VA501–VA509 VA513–VA525 VA527–VA530 VN001–VN041

VS196–VS203

ANSETT AUSTRALIA (ANS)

1 VB053

ARKEFLY (HXL)

1 VN165 VN225

ASIANA AIRLINES (AAR)

1 VK143–VK148 VR426 VW851

AUSTRALIAN AIRLINES (AUF)

1 VN089–VN092 VS486

AUSTRIAN (AUL)

1 VN242–VN243 VN671 VS301–VS303

AVIANCA (AVI)

1 VE171–VE172 VF092 VF161 VN152

VN532

AVIATION COMPANY POLET (PLF)

1 VF051

AWAS (AWW)

1 VB325

BATAVIA AIR (BTV)

1 VA806

BELAIR AIRLINES (BLB)

1 VL932

BELLVIEW AIRLINES (BEB)

1 VE125–VE126
 

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BOEING SERVICE BULLETIN 767-49A0035

BLUE CITY HOLDING (BCY)

1 VE069

BLUE PANORAMA AIRLINES (BPA)

1 VL911 VN174 VN681 VS061

BOEING (TBC)

1 VA001

BRA TRANSPORTES AEREOS (BRW)

1 VN376

BRAVO AIRLINES (BVA)

1 VE104

BRITISH AIRWAYS (BAB)

1 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137

VS246–VS248

CAMEROON AIRLINES (CAM)

1 VA801 VS308

CHINA EASTERN YUNNAN AIRLINES (YUN)

1 VL871–VL873

CONDOR (CDF)

1 VN683–VN691

CONTINENTAL AIRLINES (CAL)

1 VR051–VR060

CONVIASA S.A. (VSS)

1 VN500

DELTA AIR LINES (DAL)

1 VA302–VA303 VA305–VA306 VA308–VA315 VK032

VK035–VK056 VL753 VN251–VN276 VN301–VN306

VR471–VR472 VS066–VS070 VS073–VS078 VS266–VS273

VS466–VS472

EL AL ISRAEL AIRLINES (ELA)

1 VB281–VB284 VF101–VF102 VN682

ERITREAN AIR LINES (ERJ)

1 VE066 VN211

ETHIOPIAN AIRLINES (ETH)

1 VE002 VS306 VS506–VS507

ETIHAD AIRWAYS (ETI)

1 VS391
 

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BOEING SERVICE BULLETIN 767-49A0035

EUROATLANTIC AIRWAYS (MAE)

1 VN151 VN551 VN561–VN562

EVA AIR (EVA)

1 VN791–VN792

EVERGREEN AIR CENTER (EAC)

1 VE061

FIRST CHOICE AIRWAYS (ATZ)

1 VL751–VL752 VL754 VN921

FLYJET LIMITED (FJE)

1 VE117

GE CAPITAL CORPORATION (GEF)

1 VA307 VB443 VE123

GULF AIR (GUL)

1 VL004–VL006 VN307–VN310 VN313–VN314

HAINAN AIRLINES (HNA)

1 VS426 VS496–VS497

HAWAIIAN AIRLINES (HWI)

1 VK031 VK033–VK034 VN171–VN173 VN381

VS309–VS311 VS821 VS841

ICELANDAIR (ICE)

1 VN158 VN163 VN537

ITOCHU CORPORATION (CIT)

1 VF181–VF184

JAL INTERNATIONAL (JAL)

1 VB371–VB373 VK001–VK016 VK021–VK022 VK181

VK186 VR441 VR461 VS701–VS703

JET FREIGHT (JFO)

1 VE067–VE068

KALAIR (BERMUDA) (KLB)

1 VN311

KENYA AIRWAYS (KEN)

1 VK141 VL003 VS331–VS333

KLM - ROYAL DUTCH AIRLINES (KLM)

1 VL894–VL900 VS136–VS137

KRASAIR (ZXD)

1 VE001 VE022–VE023
 

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BOEING SERVICE BULLETIN 767-49A0035

LAB (LAB)

1 VL001–VL002

LAM (LAM)

1 VF162

LAN AIRLINES (LAN)

1 VL703 VN063–VN064 VN166 VN168

VN753 VN966–VN971 VR251 VR256–VR260

VS111 VS131–VS133

LOT POLISH AIRLINES (LOT)

1 VF041–VF042 VN233 VN291–VN293

MALEV HUNGARIAN AIRLINES (HGA)

1 VF171–VF172

MARTINAIR HOLLAND (MTH)

1 VN221–VN224 VN385 VN672

MAXJET AIRWAYS (SLQ)

1 VB301 VE063

MEXICANA (CMA)

1 VN154

MID EAST JET (SKL)

1 VF251

MYTRAVEL AIRWAYS (GUE)

1 VN951–VN953

NATIONWIDE AIRLINES (NWR)

1 VN556

NEOS (NEO)

1 VL892

NORTH AMERICAN AIRLINES (NNA)

1 VL755 VN922 VS316

PB AIR (PBJ)

1 VK142

PEGASUS AVIATION FINANCE (PSF)

1 VN638

PHOENIX AIRCRAFT LEASING, INC. (PLB)

1 VA810

PHOENIX AVIATION (PHX)

1 VE041
 

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PLUNA (PLU)

1 VN436

QANTAS (QAN)

1 VN081–VN088 VN093–VN099 VN115–VN117 VN123

VN130–VN132 VS186–VS187

ROYAL AIR MAROC (RAM)

1 VN636 VS336–VS337

ROYAL BRUNEI AIRLINES (RBA)

1 VN372 VN382–VN384 VN386–VN387

SAS (SAS)

1 VN156 VN164

SHANGHAI AIRLINES (SHA)

1 VK171 VR421–VR423 VS207

SHEIKH MUSTAFA EDREES (SME)

1 VA804

SKYMARK AIRLINES (SKM)

1 VN637 VS231 VS261–VS263

STAR AIR (SBJ)

1 VB323 VB328 VB441–VB442 VB444

VE101–VE103

STATE AIR COMPANY "BERKUT" (ORE)

1 VR081

TAMPA CARGO (TMP)

1 VE121–VE122 VE124

TEEBAH AIRLINES (EBH)

1 VA710

THE SULTAN'S FLIGHT (BWN)

1 VF180

THOMSONFLY (BRI)

1 VB329–VB332 VL912–VL914 VS051–VS056

TRANSAERO AIRLINES (TRX)

1 VE116 VE118 VE143 VN371

VN631–VN633

TUI AIRLINES BELGIUM (TLB)

1 VN234
 

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BOEING SERVICE BULLETIN 767-49A0035

UNITED AIRLINES (UAL)

1 VA002–VA012 VA014–VA020 VN491–VN494 VN496–VN499

VN501–VN513 VS091–VS104

UPS (UPS)

1 VR201–VR211 VW701–VW721

US AIRWAYS (USA)

1 VE141–VE142 VE144–VE149 VE151–VE152

UZBEKISTAN AIRWAYS (UZB)

1 VL806–VL807

VARIG AIRLINES (VAR)

1 VN055 VN231–VN232

VIETNAM AIRLINES (VIE)

1 VN972

VOLARE AIRLINES (VLR)

1 VL931

YONA (IOP)

1 VN312

ZOOM AIRLINES (YFM)

1 VL891 VL893 VN634–VN635

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

VA001–VA020 1

VA301–VA315 1

VA501–VA530 1

VA701–VA719 1

VA801–VA810 1

VB001–VB002 1

VB051–VB055 1

VB101–VB125 1

VB201–VB202 1

VB251–VB253 1

VB281–VB284 1

VB301–VB302 1

VB321–VB332 1

VB371–VB373 1

VB401 1

VB441–VB444 1
 

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BOEING SERVICE BULLETIN 767-49A0035

VE001–VE003 1

VE021–VE023 1

VE041–VE043 1

VE061–VE069 1

VE083–VE086 1

VE101–VE104 1

VE116–VE118 1

VE121–VE126 1

VE141–VE152 1

VE171–VE172 1

VF001–VF002 1

VF041–VF042 1

VF051 1

VF061–VF062 1

VF071–VF072 1

VF091–VF093 1

VF101–VF102 1

VF161–VF162 1

VF171–VF172 1

VF180–VF184 1

VF251 1

VK001–VK016 1

VK021–VK022 1

VK031–VK056 1

VK081–VK113 1

VK131–VK133 1

VK141–VK148 1

VK161–VK164 1

VK171 1

VK181 1

VK186 1

VL001–VL006 1

VL011 1

VL701–VL703 1

VL751–VL755 1

VL806–VL807 1

VL871–VL873 1

VL891–VL900 1

VL911–VL914 1

Variable Group
 

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VL931–VL932 1

VL941 1

VN001–VN041 1

VN051–VN064 1

VN081–VN099 1

VN111–VN127 1

VN130–VN137 1

VN151–VN158 1

VN163–VN168 1

VN171–VN174 1

VN191–VN198 1

VN211–VN212 1

VN221–VN225 1

VN231–VN234 1

VN241–VN243 1

VN251–VN276 1

VN291–VN293 1

VN301–VN314 1

VN371–VN372 1

VN376 1

VN381–VN388 1

VN421–VN427 1

VN436 1

VN471–VN472 1

VN491–VN513 1

VN531–VN532 1

VN536–VN537 1

VN541–VN542 1

VN546–VN547 1

VN551 1

VN556–VN557 1

VN561–VN562 1

VN631–VN638 1

VN651–VN658 1

VN671–VN672 1

VN676 1

VN681–VN691 1

VN731–VN732 1

VN751–VN753 1

Variable Group
 

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VN791–VN792 1

VN811–VN813 1

VN921–VN922 1

VN931–VN936 1

VN951–VN953 1

VN966–VN972 1

VR051–VR060 1

VR081 1

VR201–VR211 1

VR251 1

VR256–VR260 1

VR401 1

VR421–VR423 1

VR426 1

VR441 1

VR461 1

VR471–VR472 1

VS051–VS056 1

VS061 1

VS066–VS070 1

VS073–VS078 1

VS091–VS104 1

VS111–VS113 1

VS131–VS133 1

VS136–VS137 1

VS176–VS177 1

VS186–VS187 1

VS196–VS203 1

VS206–VS208 1

VS211 1

VS216–VS217 1

VS231 1

VS246–VS248 1

VS261–VS263 1

VS266–VS274 1

VS291–VS293 1

VS301–VS303 1

VS306–VS311 1

VS316 1

Variable Group
 

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2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts 

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for 

the recommended use.

B. Concurrent Requirements

None.

C. Reason

Boeing Service Related Problem (SRP) 767-27-0147 is related to this service bulletin.

Incorporation of this change will prevent APU air intake duct water leakage from contributing to stiff 

operation of the elevator pitch control system and any other related pitch control issues.

Two instances of stiff operation of the elevator pitch control system have been reported. An 

investigation revealed that water can occasionally leak from the joint, in the air-intake duct for the 

Auxiliary Power Unit (APU), aft of Station 1809.5. The water can leak from the duct joint onto the 

elevator center-auto-pilot servo Linear Variable Differential Transducer (LVDT). 

A dripshield can be installed under the aft air-intake duct to prevent water from reaching the LVDT.

VS321–VS324 1

VS331–VS333 1

VS336–VS337 1

VS366–VS367 1

VS381–VS382 1

VS391–VS392 1

VS401 1

VS426 1

VS466–VS472 1

VS486 1

VS496–VS497 1

VS506–VS507 1

VS526 1

VS546–VS549 1

VS701–VS703 1

VS721–VS727 1

VS821 1

VS841 1

VT501 1

VW701–VW721 1

VW851 1

Variable Group
 

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Revision 1 is sent to prevent an interference condition found on a production airplane. New kits, 

provided by this revision, allow the dripshield to be installed further away from an adjacent hydraulic 

tube. None of the original Top kits 015T1729-1 and -2 were shipped to operators. Top kits 015T1729-

1 and -2 have been replaced by Top kits 015T1729-7 and -8 respectively. The dripshield 353T0263-

1, contained in the original top kits, has been replaced by dripshield 353T0263-2.

The compliance time was changed to add "not to exceed 18 months after the receipt of revision one 

of this service bulletin."

This revision also provides after rework part numbers for existing Aft Air-intake ducts that are 

reworked by this service bulletin and do not have a production equivalent after rework part number.

Revision 2 is sent to incorporate the intent of 767-49A0035R01, IN02. The steps to remove the 

forward intake duct have been removed from the Accomplishment Instructions and from Figure 1. 

Validation information has been added to the Reason and Background paragraphs. The manpower 

required for the airplane rework has been reduced from 3.0 hours to 2.0 hours. A note has been 

added to Figure 1 to make it easier to remove the aft air-intake duct. A note to show the reason for 

the large fastener holes has been added to Figure 2.

As a part of a service bulletin validation program, this change was completed on airplane VN027 by 

Revision 01 of this service bulletin. 

D. Description

The 015T1729-8 Top Kits have been placed under management control, such that one 015T1729-8 

Top Kit is available to each operator to use as a first incorporation unit in order to generate a spare 

unit for component rework. This will minimize airplane downtime and lessen the impact to 

maintenance operations.

Follow accomplishment instructions under “Component Work - Aft Air-Intake Duct Assembly 

Modification” to rework an existing Aft Air-intake Duct assembly into the equivalent production aft Airintake Duct assembly. Use components from the 015T1729-7 Top Kit.

Follow accomplishment instructions under “Airplane Work - Duct Replacement And Dripshield 

Installation” to install a new Dripshield on either a new 353T0252-11 Aft Air-intake Duct, from a 

015T1729-8 Top Kit, or a reworked Aft Air-intake Duct made from a 015T1729-7 Top Kit. 

Revision 1 - No more work is necessary because no parts were available to make the change on 

airplanes shown in the initial release of this service bulletin.

Revision 2 - No more work is necessary on airplanes changed as shown in the previous revisions of 

this service bulletin.

E. Compliance

Boeing recommends incorporation of this service bulletin at a convenient opportunity when airplane 

and manpower are available, not to exceed 18 months after the receipt of revision one of this service 

bulletin.
 

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F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes 

specified in this service bulletin comply with the applicable regulations and are FAA approved, as well 

as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/

JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval 

were based on the airplane in its original Boeing delivery configuration or as modified by other 

approved Boeing changes.

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

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

approval before incorporating this service bulletin.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this change 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.

Airplane Work - Duct Replacement And Dripshield Installation

Component Work - Aft Air-Intake Duct Assembly Modification

Task

Number of 

Persons Task-Hours Elapsed Hours

Access 1 0.50 0.50

Replace Duct 1 1.0 1.0

Install Dripshield 1 0.5 0.5

Total per Airplane 2.00 2.00

Task

Number of 

Persons Task-Hours Elapsed Hours

Change Duct 1 1.0 1.0

Total per Airplane 1.0 1.0
 

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H. Weight and Balance Changes

I. Electrical Load Data

Not applicable.

J. References

1. Existing Data:

a. Engineering Change Memo PRR B12901-29S

b. Service Related Problem (SRP) 767-SRP-27-0147

c. 767 Maintenance Manual (AMM) Subject 49-15-01

d. BSOPM 20-50-10

2. Data supplied with this Service Bulletin:

None.

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

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

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

not be applicable to all airplane configurations or operators.

Top Kit Airplane Model

Change in 

Weight (Pounds)

Change in 

Moment (PoundInches)

015T1729-7 767-200 +1.9 +3438.0

767-300 +1.9 +3688.9

015T1729-8 767-200 +1.7 +3076.0

767-300 +1.7 +3300.5

Drawing Number Title

353T0252 INLET DUCT ASSY TRANSITION - AUX POWER SYSTEM

353T0200 INTAKE DUCT INSTL - AUXILIARY POWER SYSTEM
 

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K. Publications Affected

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability 

information.

Publication Chapter-Section

767 Maintenance Manual 49-15-01

767 Illustrated Parts Catalog 49-15-01
 

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2. MATERIAL INFORMATION

A. Material - Price and Availability

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

Paragraph 2.D., Parts Necessary to Change Spares as shown below. If there is a limit in the quantity 

(QTY) of 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

The kits are subject to the terms and conditions of the Boeing standard purchase order 

acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States 

dollars. Terms: Net 30 days.

NOTE:The 015T1729-8 Top Kits have been placed under management control, such that one 

015T1729-8 Top Kit is available to each operator to use as a first incorporation unit in order to 

generate a spare unit for component rework. This will minimize airplane downtime and lessen 

the impact to maintenance operations.

B. Industry Support Information

Boeing warranty remedies are available for 767 airplanes in warranty as of April 27, 2001. For manhour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing 

Commercial Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be 

supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service 

bulletin number and reference the airplane variable numbers in your purchase order.

 Number Name Date QTY

ROLT 

(Weeks)

Unit Price thru

March 01, 2004

015T1729-7 Top Kit, Duct Rework 

Installation

3/25/04 14 20 $1462.00

4/08/04 10 20 $1462.00

4/22/04 10 20 $1462.00

5/06/04 10 20 $1462.00

5/20/04 10 20 $1462.00

6/04/04 10 20 $1462.00

6/18/04 10 20 $1462.00

7/02/04 10 20 $1462.00

7/19/04 10 20 $1462.00

8/02/04 10 20 $1462.00

8/16/04 12 20 $1462.00

015T1729-8 Top Kit, Duct 

Replacement 

Installation

3/25/04 10 19 $18985.00

4/08/04 10 19 $18985.00

4/22/04 10 19 $18985.00

5/06/04 5 19 $18985.00
 

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C. Parts Necessary For Each Airplane

1. Kits/Parts:

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

NOTE:The 015T1729-8 Top Kits have been placed under management control, such that one 

015T1729-8 Top Kit is available to each operator to use as a first incorporation unit in order 

to generate a spare unit for component rework. This will minimize airplane downtime and 

lessen the impact to maintenance operations

NOTE:One 015T1729-8 top kit is necessary for the first airplane in each operators’ fleet, and one 

015T1729-7 top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied 

by the Operator, are necessary for all remaining airplanes in each operators’ fleet.

015T1729 KIT, INTAKE DUCT, DRIPSHIELD CONVERSON - AUX. PWR. SYS.

New Part 

Number

QTY

Name

Existing Part 

-8 -7 Number Notes

015T1729-7 . - Top Kit, Duct 

Rework Installation

- (f)

015T1729-8 - . Top Kit, Duct 

Replacement 

Installation

- (f)

015T1729-3 - 1 Subkit, Intake Duct, 

Drip Shield 

Conversion

- -

353T0263-2 1 1 Dripshield - (b) (g)

353T0252-11 1 - Aft Air-intake Duct 

Assembly

353T0252-() (a) (b) 

(c) (e)

BACB30NM3K2 4 4 Bolt - (d)

NAS1149D0316J 4 4 Washer - (d)

(a) Discard or rework the existing part. 

(b) The 353T0252-11 part is used in production.

(c) You can not use the existing part to replace the new or changed part without 

rework.

(d) 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 D-590 and Boeing Drawing 012T2100 are 

used to determine the part numbers used as substitutes.

(e) There is no production part number for the reworked Aft Air-intake Duct 

assembly. Use the new retrofit part numbers shown in Paragraph 2.C.3. “Parts 

Modified and Re-identified” to identify on the duct that it has been reworked by 

this service bulletin. Use BSOPM 20-50-10 part marking procedure.

(f) Revision 1 replaced Top Kits 015T1729-1 and -2 with Top Kits 015T1729-7 

and -8 respectively.

(g) Revision 1 replaced dripshield 353T0263-1 with dripshield 353T0263-2.
 

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015T1729-3 SUBKIT, INTAKE DUCT, DRIPSHIELDCONVERSION - AUX. 

PWR. SYS.

New Part 

Number

QTY

Name

Existing Part 

-3 Number Notes

015T1729-3 - Subkit, Intake Duct, 

Drip Shield 

Conversion

- -

015T1729-6 1 Mylar Template - -

015T1729-4 2 Bracket Assembly 353T0256-2 (a)

353T0256-6 2 Bracket Assembly - (b)

BACB30NM3K2 4 Bolt - (c)

BACB30NX5HK3 4 Bolt - (c)

BACC30AB5C 4 Collar - (c)

BACI12AC3CD 4 Insert, Blind - (c)

NAS1149C0332R 4 Washer - (c)

(a) Discard the existing part. 

(b) This part is used in production.

(c) 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 D-590 and Boeing 

Drawing 012T1200 are used to determine the part numbers used as 

substitutes.
 

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2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

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

number of parts changed on each airplane.

Part Number / 

Specification QTY Name Notes

BMS 5-28, Type 

18 (a)

4 Oz. Potting Compound -

BMS 5-28, Type 

19, 20 or 30 (a)

- Optional Potting Compound -

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

supplier data.

Existing Part 

Number QTY Name New Part Number Notes

353T0252- 1 1 Aft Air-intake Duct 

Assembly

015T1729-9 (a) (b) (c)

353T0252- 5 1 Aft Air-intake Duct 

Assembly

015T1729-10 (a) (b) (c)

353T0252- 6 1 Aft Air-intake Duct 

Assembly

015T1729-11 (a) (b) (c)

353T0252- 8 1 Aft Air-intake Duct 

Assembly

015T1729-12 (a) (b) (c)

353T0252- 9 1 Aft Air-intake Duct 

Assembly

015T1729-13 (a) (b) (c)

(a) Make the change given in this service bulletin.

(b) The 015T1729-( ) retrofit part numbers shown are the new part numbers after the duct is 

reworked by the change given in this service bulletin. Use BSOPM 20-50-10 part marking 

procedure.

(c) The 353T0252-11 duct part number is used in production.
 

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4. Parts Removed and Not Replaced:

D. Parts Necessary to Change Spares

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

E. Special Tooling - Price and Availability

None

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin except Mylar 

Template 015T1729-6, provided in subkit 015T1729-3, and maintenance and overhaul tools in the 

manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to 

make sure all necessary tools are available.

Existing 

Part Number Name QTY Notes

353T0256-2 Bracket Assembly 2 -

Part Number Name QTY

015T1729-3 Subkit, Intake Duct, 

Drip Shield 

Conversion

1
 

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BLANK PAGE
 

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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

NOTE:

1. Use sufficient precautions to make sure that the system components, airplane electrical 

wires and structures, are not damaged by drills, metal shavings and other contamination 

while you do work. Metal shavings or contamination left in the airplane can touch wire 

bundles and cause chafing damage to electrical wires. Chafed wires can cause arcing 

damage.

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. 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.

5. 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

— Hole dimensions for standard solid rivets are given in 767 Structural Repair Manual, 

Chapter 51

— Torque limits to tighten nuts and bolts are given in 767 Structural Repair Manual, 

Chapter 51.

6. For approved fastener and process material substitutions, refer to 767 Structural Repair 

Manual, Chapter 51, Alternate fasteners are given in 767 Structural Repair Manual 

Chapter 51 and Boeing Drawing 012T2100.

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

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

longer or shorter may be used

8. The 015T1729-8 Top Kits have been placed under management control, such that one 

015T1729-8 Top Kit is available to each operator to use as a first incorporation unit in order 

to generate a spare unit for component rework. This will minimize airplane downtime and 

lessen the impact to maintenance operations.

9. The work instructions are divided into two instruction packages: The “Airplane Work - Duct 

Replacement and Dripshield Installation” and the “Component Work - Aft Air-Intake Duct 

Assembly Modification” instructions.

Follow accomplishment instructions under “Component Work - Aft Air-intake Duct 

Assembly Modification” to rework an existing Aft Air-intake Duct assembly into the 

equivalent production aft Air-intake Duct assembly. Use components from the 015T1729-

7 Top Kit.
 

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Follow accomplishment instructions under “Airplane Work - Duct Replacement And 

Dripshield Installation” to install a new Dripshield on either a new 353T0252-11 Aft Airintake Duct, from a 015T1729-8 Top Kit, or a reworked Aft Air-intake Duct made from a 

015T1729-7 Top Kit.

B. WORK INSTRUCTIONS

Airplane Work - Duct Replacement And Dripshield Installation

1. Get access and remove the aft Air-intake duct components from the airplane:

a. On the first airplane in each operators’ fleet, use 767 AMM 49-15-01 instructions to get 

access and remove the aft Air-intake duct components from the airplane. 

b. On all remaining airplanes in each operators’ fleet, get access and remove the aft Air-intake 

duct components from the airplane as shown in Figure 1.

2. Install an aft Air-intake Duct assembly and a Dripshield on the airplane as shown in Figure 4:

a. On the first airplane in each operators’ fleet, install a new aft Air-intake Duct assembly 

352T0252-11, from the 015T1729-8 Top Kit. 

b. On all remaining airplanes in each operators’ fleet, install a reworked aft Air-intake Duct 

assembly, made from a 015T1729-7 Top Kit. 

Rework the aft Air-intake Duct assembly by following the “Component Work - Aft Air-Intake 

Duct Assembly Modification” instructions below.

Component Work - Aft Air-Intake Duct Assembly Modification 

1. Replace the two forward brackets, located on the bottom of the aft Air-intake Duct assembly, as 

shown in Figure 2.

2. Install two aft brackets, on the bottom of the aft Air-intake Duct assembly, as shown in Figure 3.
 FIGURE 1: Modify The Aft Air-intake Duct Assembly

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FIGURE 1: Modify The Aft Air-intake Duct Assembly

AFT AIR-INTAKE

DUCT ASSEMBLY

SLIP RING

(6 LOCATIONS)

FASTENER

SLIP RING

A

A

1

1 3

1

UP

FWD

SEE A

A

V86901

(SHEET 1 OF 3)
 FIGURE 1: Modify The Aft Air-intake Duct Assembly

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BOEING SERVICE BULLETIN 767-49A0035

(2 LOCATIONS)

BRACKET

(4 LOCATIONS)

FASTENER

A-A

SLIP RING

DUCT ASSEMBLY

AFT AIR-INTAKE

FASTENER

FASTENER FASTENER

B-B

(2 LOCATIONS)

FASTENER

BRACKET

SLIP RING

B

B

2

2

UP

FWD

3

3

3 3

2

3

2

3

V86909

FWD

(SHEET 2 OF 3)
 FIGURE 1: Modify The Aft Air-intake Duct Assembly

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

numbers shown below are the total number of parts necessarily for each step.

STEP TASK NAME PART NUMBER QTY NOTES

1

Remove Aft Air-intake Duct 

Assembly

 - 1 keep. Use 767 AMM 49-

15-01

Slip Ring - 1 keep

Slip Ring Fastener - 6 keep

NOTE: Remove the fasteners and sealant from the aft end of the duct. Remove the 6 fasteners that 

connect the aft air-intake duct to the slip ring. Push the slip ring slightly forward. Shake the aft duct until 

it becomes loose and drops down. 

2

Bracket 253T0256-2 2 discard

Bracket Fastener - 2 keep

3

Re-install Slip Ring - 1 kept

Slip Ring Fastener - 4 of 6 kept. Keep remaining two slip ring fasteners for installation later.

(SHEET 3 OF 3)
 FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly

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FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly

A

A

UP

FWD

SEE A

A

V86938

(SHEET 1 OF 4)
 FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly

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RING

SLIP

RING

SLIP

(4 LOCATIONS)

FASTENER

(2 LOCATIONS)

FASTENER

BRACKET

(2 LOCATIONS)

A-A

AFT AIR-INTAKE

DUCT ASSEMBLY

DUCT ASSEMBLY

AFT AIR-INTAKE

B

B

UP

FWD

UP

FWD

7

7

2 4 6

1 3 5 7

1 3 5

B

SEE B

V86939

(SHEET 2 OF 4)
 FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

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

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

NOTE:Use components from the 015T1729-7 Top Kit.

STEP TASK NAME PART NUMBER QTY NOTES

1 Install Bracket Assembly 015T1729-4 2 on Slip Ring

Slip Ring Fastener - 2 kept

2

Mark Fastener Hole - 4 locations on brackets. 

Use holes in aft airintake duct as a guide

3 Remove Bracket Assembly 015T1729-4 2 temporarily and keep

Slip Ring Fastener - 2 temporarily and keep

4

Drill Fastener Hole - 4 0.192 to 0.202 inch 

diameter. Two in each 

bracket. These fastener 

holes are larger then 

normal. The larger hole 

allows for some 

adjustment of the 

bracket.

5 Install Bracket Assembly 015T1729-4 2 loose on Slip Ring

Slip Ring Fastener - 2 kept

B-B

BRACKET

BRACKET

FASTENER

FASTENER

(6 LOCATIONS)

FASTENER

DUCT ASSEMBLY

SLIP RING AFT AIR-INTAKE

SLIP RING

FASTENER

SLIP RING

FASTENER

SLIP RING

1 5 3

1 5 3

1 3 5

1 3 5

2 4 6

2 4 6

7

7

V86940

FWD

(SHEET 3 OF 4)
 FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly

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BOEING SERVICE BULLETIN 767-49A0035

6

Install Bolt BACB30NX5HK3 4 -

Collar BACC30AB5C 4 -

7 Remove Slip Ring - 1 keep 

Slip Ring Fastener - 6 keep 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 4 OF 4)
 FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly

A-A

BRACKETS

FORWARD

ASSEMBLY

AIR-INTAKE DUCT

BOTTOM OF AFT

BRACKETS

NEW AFT

A

A

B

B

UP

FWD

6

5

SEE A

V86941

FWD

(SHEET 1 OF 5)
 FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

B-B

TEMPLATE

MYLAR

FOR INSERTS

HOLE LOCATION

AIR-INTAKE DUCT

BOTTOM OF AFT

ASSEMBLY

BRACKETS

AGAINST THE FORWARD

WILL BE USED TO BUTT

THIS TRIMMED EDGE

NEW FORWARD

BRACKET

NEW FORWARD

BRACKET

MARK

ALIGNMENT

HOLE LOCATION

FOR INSERTS

ALIGNMENT

MARK

C

C

UP

FWD

1

SEE B

3 4 5

SEE B

2

2

3 4 5

SEE B

V86945

(SHEET 2 OF 5)
 FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

INSERT BRACKETS

INSERT

C-C

ALIGNMENT

HOLE LOCATION

TEMPLATE

MYLAR

NOT SAG IN THIS AREA

MYLAR TEMLATE SHOULD TEMPLATE

MYLAR

D-D

D

D

A 6

3 4 5

3 4 5

FWD

UP

2

SEE B

FWD

UP

SEE B

UP

V86961

(SHEET 3 OF 5)
 FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly

January 16, 2003

Revision 2: June 02, 2006 767-49A0035

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BOEING SERVICE BULLETIN 767-49A0035

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

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

MYLAR TEMPLATE

BRACKET HOLES

FROM CENTER OF

USE TO LOCATE

BRACKET HOLES

FROM CENTER OF

USE TO LOCATE

FOR INSERTS

HOLE LOCATION

HOLE LOCATION

FOR INSERTS

BRACKETS

BUTT AGAINST THE

WILL BE USED TO

THIS TRIMMED EDGE

FWD

B

3 4 5

3 4 5

2

2

V86960

(SHEET 4 OF 5)
 FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

NOTE:Use components from the 015T1729-7 Top Kit.

STEP TASK NAME PART NUMBER QTY NOTES

1 Place Mylar Template 015T1729-6 1 on the bottom of the Airintake duct

2

Align Marks - 2 on the Mylar Template 

with holes in the two 

forward brackets

NOTE: Make sure the edge of the Mylar Template butts up against the aft surface of the two 

forward brackets, and make sure the mylar does not sag.

3

Transfer Hole Locations - 4 from template to aft Airintake duct

Remove Mylar Template 015T1729-6 1 -

4 Install Insert BACI12AC3CD 4 Use instructions in 

Appendix A

5

Install Bracket Assembly 353T0256-6 2 -

Bolt BACB30NM3K2 4 -

Washer NAS1149C0332R 4 -

6

Change Part 

Number

Aft Air-intake Duct 

Assembly

- 1 as shown in Paragraph 

2.C.3 “Parts Modified 

and Reidentified”

(SHEET 5 OF 5)
 FIGURE 4: Air-Intake Duct And Dripshield Installation

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

FIGURE 4: Air-Intake Duct And Dripshield Installation

(REFERENCE) AFT AIR-INTAKE

DUCT ASSEMBLY

FORWARD AIR-INTAKE

SLIP RING

DUCT ASSEMBLY

SEE A

UP

FWD

1

1

1

A

SEE B

V86963

(SHEET 1 OF 4)
 FIGURE 4: Air-Intake Duct And Dripshield Installation

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

DUCT ASSEMBLY

AFT AIR-INTAKE

DRIPSHIELD

FASTENERS

UP

FWD

B

2

2

SEE D

SEE C

V86971

(SHEET 2 OF 4)
 FIGURE 4: Air-Intake Duct And Dripshield Installation

January 16, 2003

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BOEING SERVICE BULLETIN 767-49A0035

(2 LOCATIONS)

FASTENER

DRIPSHIELD

(2 LOCATIONS)

FASTENER

DRIPSHIELD

(6 LOCATIONS)

SLIP RING FASTENER

FWD

FWD

RING

SLIP

C

2

2

D

2

2

1

1

V86967

(SHEET 3 OF 4)
 FIGURE 4: Air-Intake Duct And Dripshield Installation

January 16, 2003

Revision 2: June 02, 2006 767-49A0035

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BOEING SERVICE BULLETIN 767-49A0035

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

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

STEP TASK NAME PART NUMBER QTY NOTES

1

Install Slip Ring - 1 kept

Slip Ring Fastener - 6 kept

Forward Air-intake 

Duct

- 1 kept. Use 767 AMM 49-

15-01

Aft Air-intake Duct - 1 new or reworked. Use 

767 AMM 49-15-01

2

Install Dripshield 

Assembly

353T0263-2 1 -

Bolt BACB30NM3K2 4 -

Washer NAS1149D0316J 4 -

(SHEET 4 OF 4)
 APPENDIX A: WET POTTING OF INSERTS

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BOEING SERVICE BULLETIN 767-49A0035

APPENDIX A: WET POTTING OF INSERTS

NOTE:THE PROCESS INFORMATION THAT IS SUPPLIED WITH THIS SERVICE BULLETIN IS IN A 

SHORTENED FORM AND WAS UP-T0-DATE WHEN THIS SERVICE BULLETIN WAS PREPARED. 

THE PROCESS INFORMATION SUPPLIED WILL NOT BE KEPT UP-TO-DATE. FOR MORE 

INFORMATION, REFER TO THE APPLICABLE BAC PROCESS AND MATERIAL SPECIFICATIONS.

PROCESS FOR POTTING INSERTS AND EDGES INTO SANDWHICH PANELS (BAC5583)

1. BAC5583 METHOD B - WET POTTING OF INSERTS

A. Locate and drill a 0.686 to 0.691 inch diameter hole in the panel. The hole should be down to, but not 

in contact with the opposite face. Hole depth shall be at least 0.250 inch greater that the insert length.

B. Remove loose particles, including dust from the hole using a suitable method such as vacuuming or 

blow out with clean, dry air.

WARNING: COMPRESSED AIR SHALL NOT BE USED FOR CLEANING PURPOSES EXCEPT

WHERE REDUCED TO LESS THAN 30 PSI AND THEN ONLY WITH EFFECTIVE CHIP

GUARDING AND PERSONAL PROTECTION EQUIPMENT.

C. Do not clean the inserts unless they are contaminated with oil, grease, of similar bond inhibiting 

substances or particles which would prevent bonding of the insert.

D. Profile holes with enough potting compound to ensure that when the insert is installed the bottom of 

the insert will be immersed into the potting.

E. Before the initial gel time is achieved (see Table I, Cure Schedules), push the insert into the hole by 

applying even pressure across the insert-tab until it is flush with the surface (see Detail I).)

F. Inject potting compound into the hole of the insert tab until approximately a.0.25 inch uninterrupted 

stream of potting compound is expelled through the other hole.

G. Inject potting compound into the opposite insert tab hole until approximately a 0.25 inch uninterrupted 

stream of potting compound is expelled through the other hole.

H. Examine the insert to ensure that it is flush (+0.02/-0.02 inch) with panel surface and that the surfaces 

are clean of potting compound. 

I. Remove the excess potting material. Solvent clean in accordance with BSOPM 20-30-03 or operator’s 

equivalent procedure. An approved solvent may be used on fiberglass or paperbase laminate 

surfaces for removing trace potting material. Decorative laminate surfaces should be protected from 

contamination by masking tape, and solvent cleaning if needed.

J. Cure the potting compound as in Table I, Cure Schedules.

K. After initial cure (cure to permit further processing from Table I), remove alignment tabs, protective 

tape, etc. No load (such as torque or pullout for an insert) may be applied until potting is fully cured.

2. PREPARATION OF POTTING COMPOUND
 APPENDIX A: WET POTTING OF INSERTS

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BOEING SERVICE BULLETIN 767-49A0035

A. Combine 50 grams of BMS 5-28, Type 18 (BMS 5-28, Type 19, 20 or 30 Optional) Part A with the 

appropriate amount of Part B in accordance with the manufacturer’s recommendations. Thoroughly 

blend the two components within 6 minutes of mixing. The working life of the mixed potting compound 

at Room Temperature (65 to 85 F) is 12 to 25 minutes.

TABLE I: CURE SCHEDULES

BMS 5-28 

TYPE

GEL TIME 

(minutes)

CURE TO PREMIT 

FURTHER PROCESSING

FULL CURE

18 12-25 3 hours minimum at room 

temperature (b)

5 hours at 125 F (a)

7 days at room temperature (b)

(a) +/- 10 F

(b) 65 to 85 F

COMPOUND

POTTING

INSTALLATION, PROVIDED POTTING FLOWS UNDER INSERT

CORE MAY BE CRUSHED ON INSTALLATION TO INSURE FLUSH

INSERT

PORTS

POTTING

TAB (NAS1837)

PANEL

DETAIL I

1

1

V87042