January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 52 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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or otherwise.**BLANK PAGE** January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

BLANK PAGE**Table of Contents** January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 52 

### 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1**Table of Contents** January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

BLANK PAGEJanuary 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 52 

### 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, 2006January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

BLANK PAGEJanuary 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 52 

### 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.January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 52 

### 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 1.0January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 52 

### 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



### AV86832January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

BLANK PAGEJanuary 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 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

**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.January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 52 

### 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 VN495January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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–VE126January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 52 

### 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 VS391January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 52 

### 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–VE023January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 52 

### 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 VE041January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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 VN234January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 52 

### 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 1January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 52 

### 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**January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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**January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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**January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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**January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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 AssemblyModification” 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.January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**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 1.0January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**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 (Pound Inches)**  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 SYSTEMJanuary 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**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 49-15-01January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**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 $18985.00January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**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**  **Number Notes -8 -7**  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.January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**015T1729-3 SUBKIT, INTAKE DUCT, DRIPSHIELDCONVERSION - AUX. PWR. SYS.**  **New Part Number**  **QTY Name**  **Existing Part Number Notes**  **-3** 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.January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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.January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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 1January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

BLANK PAGEJanuary 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**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.January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

Follow accomplishment instructions under “Airplane Work - Duct Replacement AndDripshield 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 Replacem**  **ent 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** January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**FIGURE 1: Modify The Aft Air-intake Duct Assembly**

AFT AIR-INTAKE DUCT ASSEMBLY SLIP RING

(6 LOCATIONS) FASTENER SLIP RING A

A 1 3 1

1

UP FWD SEE A



### AV86901

**(SHEET 1 OF 3) FIGURE 1: Modify The Aft Air-intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 52 

### 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

3V86909 FWD

**(SHEET 2 OF 3) FIGURE 1: Modify The Aft Air-intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 52 

### 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 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 keptSlip 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**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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

A A

UP FWD SEE A



### AV86938

**(SHEET 1 OF 4) FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

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

6 4 2

7 5 3 1

5 3 1 

### B B SEEV86939

**(SHEET 2 OF 4) FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 52 

### 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 AFT AIR-INTAKE SLIP RING SLIP RING

FASTENER SLIP RING

FASTENER SLIP RING

1 5 3 1 5 3

5 1 3 5 1 3 6 2 4 6 2 4 7 7V86940 FWD

**(SHEET 3 OF 4) FIGURE 2: Install Forward Brackets On The Aft Air-Intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 52 

### 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 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 52 

### 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 AV86941 FWD

**(SHEET 1 OF 5) FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 52 

### 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

B SEE 4

3 5 B SEE

2

2 4 3 5 B SEEV86945

**(SHEET 2 OF 5) FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

BRACKETS INSERT 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 5 3 4

FWD UP 2 SEE B FWD UP SEE B UPV86961

**(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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 52 

### 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 5 3 4

5

3 4 2

2V86960

**(SHEET 4 OF 5) FIGURE 3: Install Aft Brackets On The Aft Air-Intake Duct Assembly**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 52 

### 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 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

**FIGURE 4: Air-Intake Duct And Dripshield Installation**

AFT AIR-INTAKE (REFERENCE) DUCT ASSEMBLY FORWARD AIR-INTAKE SLIP RING

DUCT ASSEMBLY SEE A

UP FWD

1 1

1



### A B SEEV86963

**(SHEET 1 OF 4) FIGURE 4: Air-Intake Duct**  **And Dripshield Installation** January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 52 

### BOEING SERVICE BULLETIN 767-49A0035

DUCT ASSEMBLY AFT AIR-INTAKE

DRIPSHIELD FASTENERS

UP

FWD 

### B 2 2 D SEE

SEE CV86971

**(SHEET 2 OF 4) FIGURE 4: Air-Intake Duct And Dripshield Installation**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 52 

### 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
1V86967

**(SHEET 3 OF 4) FIGURE 4: Air-Intake Duct**  **And Dripshield Installation** January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 52 

### 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**  January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 52 

### 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** January 16, 2003 Revision 2: June 02, 2006 767-49A0035 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 52 

### 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

1V87042