Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-25-0482

Original Issue: February 24, 2011

Revision 1: February 21, 2012

ATA System: 2521 5313

SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel -

Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support

Structure

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

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Copyright © 2011 The Boeing Company

Unpublished Work - All Rights Reserved

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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.

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3.0
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BLANK PAGE
Table of Contents

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

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

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 16

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 25

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL . . . . . . . . . . 30

FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION . . . . . . . 33

FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 1] . . . . . . . . . 40

FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 2] . . . . . . . . . 43

FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL . . . . . . . . . 46

FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION . . . . . . . 49

FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 1] . . . . . . . . . 56

FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 2] . . . . . . . . . 59

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BOEING SERVICE BULLETIN 777-25-0482
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BOEING SERVICE BULLETIN 777-25-0482

BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 777-25-0482

Original Issue: February 24, 2011

Revision 1: February 21, 2012

ATA System: 2521 5313

SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel -

Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support

Structure

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.

REASON FOR REVISION

This revision is sent to incorporate changes found during the validation of this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane WD796 by Service

Bulletin 777-25-0482 Original Issue before the release of Revision 01 of this service bulletin. The change

completed on airplane WD796 by Service Bulletin 777-25-0482 Original Issue is equivalent to the release of

Revision 01of this service bulletin. Airplane WD796 has the configuration of a Group 2 airplane.

These sections are changed:

1. Summary - Background - Validation statement added.

2. Summary - Manpower - Time for access and restoring access added.

3. Paragraph 1.C., Reason - Validation statement added.

4. Paragraph 1.G., Manpower - Time for access and restoring access added.

5. Paragraph 1.J.1, Existing Data - Standard Wiring Practices Manual (SWPM) and 777 Aircraft Maintenance

Manual (AMM) references added.

6. Paragraph 2.C.1., Kits/Parts - Changed part number for 1 bolt.

7. Paragraph 3.A., General Information - Current general notes added.

8. Paragraph 3.B., Work Instructions - Instruction for Access and Restoring Access added.

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9. Figures 3, and 4:

a. Changed part number for 1 bolt in Step Table.

b. Added information to relocate ground if required.

10. Figure 6:

a. Instruction is added to the Step Table regarding a possibly blocked ceiling panel insert.

11. Figures 7, and 8:

a. Changed part number for 1 bolt in Step Table.

b. Added information to relocate ground if required.

c. In Step 1 and Step 3 of Step Tables, changed More Data for Bushing to Far Side from Near Side.

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: February 24, 2011

Revision 1: February 21, 2012

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BOEING SERVICE BULLETIN 777-25-0482
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Summary Number: 777-25-0482

Original Issue: February 24, 2011

Revision 1: February 21, 2012

ATA System: 2521 5313

SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel -

Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support

Structure

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin provides instructions and a kit of parts to strengthen the structure which supports the forward

lowered ceiling panels for some 777 model airplanes. If you do not do this service bulletin and a 9G forward

load condition occurs, the forward lowered ceiling panels and support structure could become dislodged and

injure personnel or interfere with emergency evacuation.

The possibility of a 9G forward load when landing is small. No operator has reported dislodged ceiling panels

from such a load. The support structure was found to be under strength during the design review of a new section

41 lowered ceiling configuration.

Only airplanes incorporating the Overhead Space Utilization (OSU) option would have under strength structure.

The OSU option includes overhead stowage boxes in the ceiling inboard of left and right door 1. The under

strength area supports lowered ceiling panels immediately aft of these overhead stowage boxes. This service

bulletin provides for increasing strength by installing thicker structure and an additional load path on each side.

Boeing Service Related Problem (SRP) 777-SRP-25-0289 is related to this service bulletin. This SRP is described

in Fleet Team Digest Article 777 FTD 25-09010.

As a part of a service bulletin validation program, this change was completed on airplane WD796 by Service

Bulletin 777-25-0482 Original Issue before the release of Revision 01 of this service bulletin. The change

completed on airplane WD796 by Service Bulletin 777-25-0482 Original Issue is equivalent to the release of

Revision 01of this service bulletin. Airplane WD796 has the configuration of a Group 2 airplane.

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ACTION (PRR 62224)

In the forward lowered ceiling area, remove the forward overhead stowage bin modules and adjacent aft ceiling

panel to expose the support structure for the lowered ceiling panels in section 41. Disconnect a tie rod and

remove two C-channels and related brackets from both left and right side ceiling panel support structure. Install

new support channel assemblies composed of C-channels having thicker cross sections. The new assemblies

also include fittings for attaching two tie rods in place of fittings for attaching one tie rod. Add a new load path

on each side by adding new fittings to the rails above the changed structure and adding new tie rods between

the fittings on new support structure and the new fittings on the rails above. If a ground stud occupies a hole

required for the new fitting, relocate the ground to an adjacent hole. Reconnect the existing tie rods.

EFFECTIVITY

777-200, -200LR and -300ER airplanes incorporating Overhead Space Utilization (OSU) option. Refer to

Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Boeing recommends that the changes given in this service bulletin be done within 5 years after the original issue

date of this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of January 16, 2008. Please refer to

Paragraph 2.B., Industry Support Information.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

All 22.50 12.00

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN 777-25-0482
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BOEING SERVICE BULLETIN 777-25-0482

BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

SPECIAL ATTENTION

Number: 777-25-0482

Original Issue: February 24, 2011

Revision 1: February 21, 2012

ATA System: 2521 5313

SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel -

Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support

Structure

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D624W001 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 62224 for data about this change.

GROUP CONFIGURATION DESCRIPTION

777-200 and 777-300ER Airplanes with Overhead Space Utilization

(OSU) Option and line number from 423 through 494.

1 -

777-200, 777-200LR, and 777-300ER Airplanes with Overhead Space

Utilization (OSU) Option and line number from 497 through 751.

2 -

Airplane Models:

777-200, 777-200LR, 777-300ER

Variable Number Group

WC221 - WC222 2

WC301 - WC306 1

WC307 - WC308 2

WC381 - WC388 1

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Variable Number Group

WC389 - WC395 2

WC486 - WC493 2

WC506 - WC508 2

WC531 - WC536 2

WC546 - WC548 2

WC556 2

WC566 - WC567 2

WD001 - WD002 2

WD011 - WD015 2

WD031 - WD036 2

WD066 - WD067 2

WD501 - WD502 1

WD503 - WD510 2

WD521 - WD526 1

WD527 - WD539 2

WD546 - WD552 2

WD561 1

WD562 - WD573 2

WD581 - WD591 2

WD606 - WD609 2

WD621 - WD632 2

WD651 - WD661 2

WD671 - WD675 2

WD741 - WD750 2

WD761 - WD770 2

WD786 - WD788 2

WD796 - WD804 2

WD826 - WD830 2

WD871 - WD875 2

WD911 - WD912 2

WD936 - WD939 2

WD966 2

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BOEING SERVICE BULLETIN 777-25-0482
2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin provides instructions and a kit of parts to strengthen the structure which supports

the forward lowered ceiling panels for some 777 model airplanes. If you do not do this service bulletin

and a 9G forward load condition occurs, the forward lowered ceiling panels and support structure could

become dislodged and injure personnel or interfere with emergency evacuation.

The possibility of a 9G forward load when landing is small. No operator has reported dislodged ceiling

panels from such a load. The support structure was found to be under strength during the design review

of a new section 41 lowered ceiling configuration.

Only airplanes incorporating the Overhead Space Utilization (OSU) option would have under strength

structure. The OSU option includes overhead stowage boxes in the ceiling inboard of left and right door

1. The under strength area supports lowered ceiling panels immediately aft of these overhead stowage

boxes. This service bulletin provides for increasing strength by installing thicker structure and an

additional load path on each side.

Boeing Service Related Problem (SRP) 777-SRP-25-0289 is related to this service bulletin. This SRP

is described in Fleet Team Digest Article 777-FTD-25-09010.

Revision 01 is sent to make changes found to be required during validation of the service bulletin.

Changes include adding access instructions, reducing the grip length of a bolt, relocating a ground

stud if required, and installing a bushing far side instead of near side.

As a part of a service bulletin validation program, this change was completed on airplane WD796 by

Service Bulletin 777-25-0482 Original Issue before the release of Revision 01 of this service bulletin.

The change completed on airplane WD796 by Service Bulletin 777-25-0482 Original Issue is equivalent

to the release of Revision 01of this service bulletin. Airplane WD796 has the configuration of a Group

2 airplane.

The data given in Information Notice 777-25-0482 IN 01 is included in this revision.

D. Description

In the forward lowered ceiling area, remove the forward overhead stowage bin modules and adjacent

aft ceiling panel to expose the support structure for the lowered ceiling panels in section 41. Disconnect

a tie rod and remove two C-channels and related brackets from both left and right side ceiling panel

support structure. Install new support channel assemblies composed of C-channels having thicker

cross sections. The new assemblies also include fittings for attaching two tie rods in place of fittings

for attaching one tie rod. Add a new load path on each side by adding new fittings to the rails above

the changed structure and adding new tie rods between the fittings on new support structure and the

new fittings on the rails above. If a ground stud occupies a hole required for the new fitting, relocate

the ground stud to an adjacent hole. Reconnect the existing tie rods.

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BOEING SERVICE BULLETIN 777-25-0482
Airplanes are divided into two groups because of a difference in the width of the new tie rod fitting and

the lattice rail to which the fitting is attached. The work is the same for both groups.

Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of

this service bulletin.

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

777-200, 777-300ER 221, 222, 223, 224

Group 2:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777- 221, 222, 223, 224

300ER

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Boeing recommends that the changes given in this service bulletin be done within 5 years after the

original issue date of this service bulletin.

F. Approval

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

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

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

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

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

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

before incorporating this service bulletin.

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:

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BOEING SERVICE BULLETIN 777-25-0482
• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Group 1:

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 2.00 1.00

Figure 1 2 2.50 1.25

Figure 2 2 6.00 3.00

Figure 3 1 0.75 0.75

Figure 5 2 2.50 1.25

Figure 6 2 6.00 3.00

Figure 7 1 0.75 0.75

Close Access 2 2.00 1.00

TOTAL FOR EACH AIRPLANE 22.50 12.00

Group 2:

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 2.00 1.00

Figure 1 2 2.50 1.25

Figure 2 2 6.00 3.00

Figure 4 1 0.75 0.75

Figure 5 2 2.50 1.25

Figure 6 2 6.00 3.00

Figure 8 1 0.75 0.75

Close Access 2 2.00 1.00

TOTAL FOR EACH AIRPLANE 22.50 12.00

H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

777-200 +5.3 +2053.3

777-300 +5.3 +940.2

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BOEING SERVICE BULLETIN 777-25-0482
I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Engineering Change Memo PRR 62224

b. Standard Wiring Practices Manual (SWPM) 20-20-10

c. 777 Aircraft Maintenance Manual (AMM) 25-21-07, 25-28-07

d. 777 Fleet Team Digest (FTD) 25-09010

e. Service Related Problem (SRP) 777-SRP-25-0289

f. 777-200 Structural Repair Manual (SRM) 51-20-01, 51-20-10, 51-40-08

g. 777-300 Structural Repair Manual (SRM) 51-20-01, 51-20-10, 51-40-08

2. Data supplied with this Service Bulletin

None.

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

Drawing Number Title

413W1200 TIE ROD INSTL-LOWERED CEILING

413W1201 SUPPORT STRUCTURE INSTL - LOWERED CEILING, DOOR 1

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

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

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

Publication Chapter-Section

777 Illustrated Parts Catalog 53-13

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

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BOEING SERVICE BULLETIN 777-25-0482
L. Interchangeability and Intermixability of Parts

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

information.

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BOEING SERVICE BULLETIN 777-25-0482
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BOEING SERVICE BULLETIN 777-25-0482

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

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

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

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

Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

Group 1:

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the original issue

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name Date QTY

October 13, 1 514 $13,329.00

2011

TOP KIT - REWORK

OF OSU TYPE SECTION 41 LOWERED

CEILING SUPPORT

STRUCTURE, GROUP

1

005W3441-1

February 10, 6 514 $13,329.00

2012

TOP KIT - REWORK

OF OSU TYPE SECTION 41 LOWERED

CEILING SUPPORT

STRUCTURE, GROUP

1

005W3441-1

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BOEING SERVICE BULLETIN 777-25-0482
Group 2:

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the original issue

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name Date QTY

October 13, 25 514 $13,329.00

2011

TOP KIT - REWORK

OF OSU TYPE SECTION 41 LOWERED

CEILING SUPPORT

STRUCTURE, GROUP

1

005W3441-2

B. Industry Support Information

Boeing warranty remedies are available for 777 airplanes in warranty as of January 16, 2008. For task

hour 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.

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: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by

the Operator, are necessary for each airplane. The Top Kit is divided into Figure kits for

each installation figure shown in the table below.

Figure Kit

Top Kit 2 3 4 6 7 8

005W3441-1 1 1 - 1 1 -

005W3441-2 1 - 1 1 - 1

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BOEING SERVICE BULLETIN 777-25-0482
Group 1:

KIT 005W3441-1

NOTES

Existing Part

Name Number

Figure

New Part Number

2 3 6 7

QTY

413W1221-105B (a),(b)

AND 413W1221-

113B AND

413W1221-35B

AND 413W1221-7

SUPPORT

STRUCTURE ASSY - LOWERED

CEILING, SECT 41

413W1210-105B 1

413W1221-106B (a),(b)

AND 413W1221-

113B AND

413W1221-35 AND

413W1221-7

SUPPORT

STRUCTURE ASSY - LOWERED

CEILING, SECT 41

413W1210-106B 1

413W1221-246B 2 2 GUSSET 413W1221-55B (a),(b)

413W1221-269B 1 1 GUSSET 413W1221-31B (a),(b)

413W1221-270B 1 1 GUSSET 413W1221-33B (a),(b)

413W1221-271B 1 1 ANGLE 413W1221-35B (a),(b)

CORNER BRACK- 413W1221-60B (a),(b)

ET

413W1221-272B 1 1

CORNER BRACK- 413W1221-60B (a),(b)

ET

413W1221-273B 1 1

MISCELLANEOUS

- MACHINE PART

422W2165-111 1 1

777081-178 1 1 TIE ROD ASSY

BACB28AK04-024 2 2 BUSHING

BACB28AK04-038 1 1 BUSHING

BACB30NR4K15 2 2 BOLT (c)

BACB30NR4K17 1 1 BOLT, HEX HEAD (c)

BOLT, PROTRUD- (c)

ING HD

BACB30NX5HK3 8 8

BACB30VF3K5 4 4 BOLT (c)

BOLT, 100 DEG (c)

HEX DR

BACB30YP5K4 12 12

COLLAR,

PRELOAD

BACC30BH5 10 10

BACC30BL5 12 12 COLLAR, SHEAR

BACN10YR4CD 3 3 NUT

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BOEING SERVICE BULLETIN 777-25-0482
Group 1:

KIT 005W3441-1

NOTES

Existing Part

Name Number

Figure

New Part Number

2 3 6 7

QTY

BACR15BB4D6C 5 5 RIVET (c)

RIVET, UNIVER- (c)

SAL HD

BACR15FT5D6C 12 13

RIVET, UNIVER- (c)

SAL HD

BACR15FT5D7C 10 10

BACR15GF4D6 5 5 RIVET (c)

SHIM, LAMINATEDBACS40R009D024F 1 1

BACW10BP4CD 3 3 WASHER

BACW10BP4DP 3 3 WASHER

(a) Discard the existing part.

(b) You cannot use the existing part to replace the new or changed part.

(c) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip

length longer than indicated.

Group 2:

KIT 005W3441-2

NOTES

Existing Part

Name Number

Figure

New Part Number

2 4 6 8

QTY

413W1221-105B (a), (b)

AND 413W1221-

113B AND

413W1221-35 AND

413W1221-7

SUPPORT

STRUCTURE ASSY - LOWERED

CEILING, SECT 41

413W1210-105B 1

413W1221-106B (a), (b)

AND 413W1221-

113B AND

413W1221-35 AND

413W1221-7

SUPPORT

STRUCTURE ASSY - LOWERED

CEILING, SECT 41

413W1210-106B 1

413W1221-246B 2 2 GUSSET 413W1221-55B (a), (b)

413W1221-269B 1 1 GUSSET 413W1221-31B (a), (b)

413W1221-270B 1 1 GUSSET 413W1221-33B (a), (b)

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BOEING SERVICE BULLETIN 777-25-0482
Group 2:

KIT 005W3441-2

NOTES

Existing Part

Name Number

Figure

New Part Number

2 4 6 8

QTY

413W1221-271B 1 1 ANGLE 413W1221-35B (a), (b)

CORNER BRACK- 413W1221-60B (a), (b)

ET

413W1221-272B 1 1

CORNER BRACK- (a), (b)

ET

413W1221-273B 1 1

MISCELLANEOUS

- MACHINE PART

422W2165-108 1 1

777081-178 1 1 TIE ROD ASSY

BACB28AK04-024 2 2 BUSHING

BACB28AK04-038 1 1 BUSHING

BACB30NR4K15 2 2 BOLT (c)

BACB30NR4K17 1 1 BOLT, HEX HEAD (c)

BOLT, PROTRUD- (c)

ING HD

BACB30NX5HK3 8 8

BACB30VF3K5 4 4 BOLT (c)

BOLT, 100 DEG (c)

HEX DR

BACB30YP5K4 12 12

COLLAR, (c)

PRELOAD

BACC30BH5 10 10

BACC30BL5 12 12 COLLAR, SHEAR

BACN10YR4CD 3 3 NUT

BACR15BB4D6C 5 5 RIVET (c)

RIVET, UNIVER- (c)

SAL HD

BACR15FT5D6C 12 13

RIVET, UNIVER- (c)

SAL HD

BACR15FT5D7C 10 10

BACR15GF4D6 5 5 RIVET (c)

SHIM, LAMINATEDBACS40R009D024F 1 1

BACW10BP4CD 3 3 WASHER

BACW10BP4DP 3 3 WASHER

(a) Discard the existing part.

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BOEING SERVICE BULLETIN 777-25-0482
Group 2:

KIT 005W3441-2

NOTES

Existing Part

Name Number

Figure

New Part Number

2 4 6 8

QTY

(b) You cannot use the existing part to replace the new or changed part.

(c) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip

length longer than indicated.

2. Parts and Materials Supplied by the Operator

Part Number / QTY Name Notes

Specification

BMS 10-11, Type I 2 oz Primer (a)

BMS 10-83, Type 2 oz Paint (a)

III Enamel, Boeing

Color 8328

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

supplier data.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

NOTE: Parts below are not replaced individually but are replaced by a part of an assembly as

explained in the Notes column.

Existing Part Number Name QTY Notes

413W1221-

245B (a)

413W1221-105B Member 1

413W1221-

267B (a) , (b)

413W1221-113B Member 2

413W1221-33

(a) , (b) ,

413W1221-270

(c) , (d)

413W1221-33 Gusset 4

413W1221-35

(a) , (b) ,

413W1221-271

(c) , (d)

413W1221-35 Angle 4

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BOEING SERVICE BULLETIN 777-25-0482
Existing Part Number Name QTY Notes

413W1221-269

(a) , (b)

413W1224-7 Fitting Assy 2

413W1221-269

(a) , (d)

413W1221-31 Gusset 2

413W1221-246

(c) , (d)

413W1221-55 Gusset 4

qty (2)

413W1221-273

and qty (2)

413W1221-272

(c) , (d)

413W1221-60 Angle 4

413W1221-

268B (b)

413W1221-106B Member 1

(a) Part of Support Structure Assy 413W1210-105B

(b) Part of Support Structure Assy 413W1210-106B

(c) Part in installation of Support Structure Assy 413W1210-105B

(d) Part in installation of Support Structure Assy 413W1210-106B

D. Parts Necessary to Change Spares

None.

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. But, 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.

Operators may choose to fabricate locating templates. Refer to FIGURE 2, Step 1, and to FIGURE 6,

Step 1, for information.

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BOEING SERVICE BULLETIN 777-25-0482
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BOEING SERVICE BULLETIN 777-25-0482

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque limits to tighten nuts and bolts are in SRM Chapter 51

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

6. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

7. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

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BOEING SERVICE BULLETIN 777-25-0482
8. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

9. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

10. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

11. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

B. WORK INSTRUCTIONS

1. Access:

a. Remove overhead stowage box and module inboard of Door 1 left and right. Refer to 777

AMM 25-28-07 as an accepted procedure.

b. Remove lowered ceiling panel(s) immediately aft of overhead stowage box opening. Refer to

777 AMM 25-21-07 as an accepted procedure.

2. Remove specific left side lowered ceiling support structure members in accordance with FIGURE

1.

3. Install new left side lowered ceiling support structure members in accordance with FIGURE 2.

4. Install new left side tie rod attach fitting and tie rods on:

a. Group 1:

In accordance with FIGURE 3.

b. Group 2:

In accordance with FIGURE 4.

5. Remove specific right side lowered ceiling support structure members in accordance with FIGURE

5.

6. Install new right side lowered ceiling support structure members in accordance with FIGURE 6.

7. Install new right side tie rod attach fitting and tie rods on:

a. Group 1:

In accordance with FIGURE 7.

b. Group 2:

In accordance with FIGURE 8.

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BOEING SERVICE BULLETIN 777-25-0482
8. Restore Access:

a. Install lowered ceiling panel(s) immediately aft of overhead stowage box opening. Refer to

777 AMM 25-21-07 as an accepted procedure.

b. Install overhead stowage box and module inboard of Door 1 left and right. Refer to 777 AMM

25-28-07 as an accepted procedure.

9. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Disconnect at lower

end. Leave upper

end attached. Rotate

tie rod up and out of

work area and secure it temporarily.

1 Disconnect Tie Rod 777084-181 1

Remove Bolt BACB30NR4K14 1

Remove Washer NAS1149D0432J 2

Remove Bushing BACB28Y4C024 1

Remove Nut BACN10YR4CD 1

2 Remove Rivet BACR15FT5D*C 13

3 Remove Rivet BACR15GF4D* 2

4 Remove Bolt BACB30NX5HK3 4

Remove Collar BACC30BH5 4

Remove the following parts as an assembly:SUPPORT STRUC- - 1

TURE ASSY

5 Remove

Remove Member 413W1221-105B 1

Remove Member 413W1221-113B 1

Remove Gusset 413W1221-33 2

Remove Angle 413W1221-35 2

Remove Fitting Assy 413W1224-7 1

Remove Gusset 413W1221-31 1

Remove Gusset 413W1221-55 2

Remove Angle 413W1221-60 2

6 Inspect Structure - - (a)

(a) Do a general visual inspection of the existing structure in the area of rework. Remove nicks, scratches,

gouges and/or minor corrosion, and protect all exposed aluminum in and around the repair areas in accordance with 777-200 SRM 51-20-01 or 777-300 SRM 51-20-01 as applicable.

FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 1 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 2 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 3 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Use existing ceiling

panel as locating

template (or fabricate similar rigid

template). Make

sure that ceiling

panel can be installed and that tie

rods align with new

Support Structure

Assy before attaching gussets and angles.

SUPPORT STRUC- 413W1210-105B 1

TURE ASSY - LOWERED CEILING, SECT

41

1 Install (New)

2 Install (New) GUSSET 413W1221-246B 2

Use existing holes in

rail. Drill new holes

in gusset.

RIVET, UNIVERSAL BACR15FT5D6C 4

HD

Install (New)

Use pilot holes in

Step 2 gusset. Drill

new holes in Step 1

Support Structure

Assy.

RIVET, UNIVERSAL BACR15FT5D7C 4

HD

3 Install (New)

4 Install (New) GUSSET 413W1221-269B 1

Use existing holes in

rail. Drill new holes

in gusset.

RIVET, UNIVERSAL BACR15FT5D6C 3

HD

Install (New)

Use pilot holes in

Step 4 gusset. Drill

new holes in Step 1

Support Structure

Assy.

RIVET, UNIVERSAL BACR15FT5D6C 2

HD

5 Install (New)

Ceiling Panel or Tem- - 1

plate

6 Remove

FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 4 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
STEP TASK NAME IDENTIFICATION QTY MORE DATA

7 Install (New) GUSSET 413W1221-270B 1

Use shim if required

between new gusset

and existing rail. Remove 0.003 thick

laminations as necessary. A gap of

0.005 max is permitted between rail and

gusset before fastener installation.

Install (New) SHIM, LAMINATED BACS40R009D024F 1

Use existing holes in

rail. Drill new holes

in gusset and shim.

Install with countersunk head on ceiling

panel side of rail.

Install (New) RIVET BACR15GF4D6 2

Use pilot holes in

Step 7 gusset. Drill

new holes in Step 1

Support Structure

Assy. Install with

countersunk head

on ceiling panel side

of rail.

8 Install (New) RIVET BACR15GF4D6 2

9 Install (New) ANGLE 413W1221-271B 1

Use existing holes in

rail. Drill holes in angle.

RIVET, UNIVERSAL BACR15FT5D7C 4

HD

Install (New)

Use pilot holes in

Step 9 angle. Drill

holes in Step 1 Support Structure Assy.

10 Install (New) RIVET BACR15BB4D6C 4

11 Install (New) CORNER BRACKET 413W1221-272B 1

Use existing hole in

rail. Drill new hole

0.161 - 0.164 in. dia.

in bracket. Install

with head on bracket

side. (a)

BOLT, PROTRUDING BACB30NX5HK3 1

HD

Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 1 Collar on rail side.

FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 5 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Use pilots in Step 11

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail. Install with

head on bracket

side.

BOLT, PROTRUDING BACB30NX5HK3 3

HD

12 Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 3 Collar on rail side.

Use pilots in Step 11

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail or Step 1 Support Structure Assy.

Install with countersunk head on rail or

Support Structure

Assy side.

BOLT, 100 DEG HEX BACB30YP5K4 6

DR

13 Install (New)

Collar on bracket

side.

Install (New) COLLAR, SHEAR BACC30BL5 6

14 Install (New) CORNER BRACKET 413W1221-273B 1

Use existing hole in

rail. Drill new hole

0.161 - 0.164 in. dia.

in bracket. Install

with head on bracket

side. (a)

BOLT, PROTRUDING BACB30NX5HK3 1

HD

Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 1 Collar on rail side.

Use pilots in Step 14

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail. Install with

head on bracket

side.

BOLT, PROTRUDING BACB30NX5HK3 3

HD

15 Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 3 Collar on rail side.

FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 6 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
STEP TASK NAME IDENTIFICATION QTY MORE DATA

Use pilots in Step 14

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail or Step 1 Support Structure Assy.

Install with countersunk head on rail or

Support Structure

Assy side.

BOLT, 100 DEG HEX BACB30YP5K4 6

DR

16 Install (New)

Collar on bracket

side.

Install (New) COLLAR, SHEAR BACC30BL5 6

(a) Remaining open holes are acceptable.

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

COLLAR, PRELOAD BACC30BH5 2

RIVET BACR15BB4D6C 1

RIVET, UNIVERSAL BACR15FT5D6C 3

HD

RIVET, UNIVERSAL BACR15FT5D7C 2

HD

RIVET BACR15GF4D6 1

FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 7 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
This Figure applies only to: Group 1.

FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
Step Task Name Identification Qty More Data

1 Install (Kept) Tie Rod 777084-181 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Near side

Install (New) WASHER BACW10BP4DP 1 Far side

Install (New) NUT BACN10YR4CD 1 Far side.

MISCELLANEOUS - 422W2165-111 1 (a)

MACHINE PART

2 Install (New)

Install 2 near side, 2

far side. (b) , (c)

Install (New) BOLT, 100 DEG HEAD BACB30VF3K5 4

3 Install (New) TIE ROD ASSY 777081-178 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Near side.

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

4 Install (New) BOLT, HEX HEAD BACB30NR4K17 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-038 1 Near side.

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

(a) Maximum gap allowed between part and rail before fastener installation is .003 in. Install shim if required

in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51-20-10.

(b) For countersink information, refer to 777-200 SRM 51-40-08 or 777-300 SRM 51-40-08 as an accepted

procedure.

(c) If a required hole is used for a ground, relocate ground to nearest unused hole. Refer to SWPM 20-20-

10 as an accepted procedure.

FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 3 OF 3)

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This Figure applies only to: Group 2.

FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 1 OF 3)

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FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
Step Task Name Identification Qty More Data

1 Install (Kept) Tie Rod 777084-181 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Near side

Install (New) WASHER BACW10BP4DP 1 Far side

Install (New) NUT BACN10YR4CD 1 Far side.

MISCELLANEOUS - 422W2165-108 1 (a)

MACHINE PART

2 Install (New)

Install 2 near side, 2

far side. (b), (c)

Install (New) BOLT, 100 DEG HEAD BACB30VF3K5 4

3 Install (New) TIE ROD ASSY 777081-178 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Near side.

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

4 Install (New) BOLT, HEX HEAD BACB30NR4K17 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-038 1 Near side.

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

(a) Maximum gap allowed between part and rail before fastener installation is .003 in. Install shim if required

in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51-20-10.

(b) For countersink information, refer to 777-200 SRM 51-40-08 or 777-300 SRM 51-40-08 as an accepted

procedure.

(c) If a required hole is used for a ground, relocate ground to nearest unused hole. Refer to SWPM 20-20-

10 as an accepted procedure.

FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL

(SHEET 2 OF 3)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

Disconnect at lower

end. Leave upper

end attached. Rotate

tie rod up and out of

work area and secure it temporarily.

1 Disconnect Tie Rod 777084-181 1

Remove Bolt BACB30NR4K14 1

Remove Washer NAS1149D0432J 2

Remove Bushing BACB28Y4C024 1

Remove Nut BACN10YR4CD 1

2 Remove Rivet BACR15FT5D*C 13

3 Remove Rivet BACR15GF4D* 2

4 Remove Bolt BACB30NX5HK3 4

Remove Collar BACC30BH5 4

Remove the following parts as an assembly:SUPPORT STRUC- - 1

TURE ASSY

5 Remove

Remove Member 413W1221-106B 1

Remove Member 413W1221-113B 1

Remove Gusset 413W1221-33 2

Remove Angle 413W1221-35 2

Remove Fitting Assy 413W1224-7 1

Remove Gusset 413W1221-31 1

Remove Gusset 413W1221-55 2

Remove Angle 413W1221-60 2

6 Inspect Structure - - (a)

(a) Do a general visual inspection of the existing structure in the area of rework. Remove nicks, scratches,

gouges and/or minor corrosion, and protect all exposed aluminum in and around the repair areas in accordance with 777-200 SRM 51-20-01 or 777-300 SRM 51-20-01 as applicable.

FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 1 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 2 OF 7)

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FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 3 OF 7)

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Step Task Name Identification Qty More Data

Use existing ceiling

panel as locating

template (or fabricate similar rigid

template). Make

sure that ceiling

panel can be installed and that tie

rods align with new

Support Structure

Assy before attaching gussets and angles. (b)

SUPPORT STRUC- 413W1210-106B 1

TURE ASSY - LOWERED CEILING, SECT

41

1 Install (New)

2 Install (New) GUSSET 413W1221-246B 2

Use existing holes in

rail. Drill new holes

in gusset.

RIVET, UNIVERSAL BACR15FT5D6C 4

HD

Install (New)

Use pilot holes in

Step 2 gusset. Drill

new holes in Step 1

Support Structure

Assy.

RIVET, UNIVERSAL BACR15FT5D7C 4

HD

3 Install (New)

4 Install (New) GUSSET 413W1221-269B 1

Use existing holes in

rail. Drill new holes

in gusset.

RIVET, UNIVERSAL BACR15FT5D6C 3

HD

Install (New)

Use pilot holes in

Step 4 gusset. Drill

new holes in Step 1

Support Structure

Assy.

RIVET, UNIVERSAL BACR15FT5D6C 2

HD

5 Install (New)

No longer required

after upper gussets

have been installed.

Ceiling Panel or Tem- - 1

plate

6 Remove

FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 4 OF 7)

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Step Task Name Identification Qty More Data

7 Install (New) GUSSET 413W1221-270B 1

Use shim if required

between new gusset

and existing rail. Remove 0.003 thick

laminations as necessary. A gap of

0.005 max is permitted between rail and

gusset before fastener installation.

Install (New) SHIM, LAMINATED BACS40R009D024F 1

Use existing holes in

rail. Drill new holes

in gusset and shim.

Install with countersunk head on ceiling

panel side of rail.

Install (New) RIVET BACR15GF4D6 2

Use pilot holes in

Step 7 gusset. Drill

new holes in Step 1

Support Structure

Assy. Install with

countersunk head

on ceiling panel side

of rail.

8 Install (New) RIVET BACR15GF4D6 2

9 Install (New) ANGLE 413W1221-271B 1

Use existing holes in

rail. Drill holes in angle.

RIVET, UNIVERSAL BACR15FT5D7C 4

HD

Install (New)

Use pilot holes in

Step 9 angle. Drill

holes in Step 1 Support Structure Assy.

10 Install (New) RIVET BACR15BB4D6C 4

11 Install (New) CORNER BRACKET 413W1221-272B 1

Use existing hole in

rail. Drill new hole

0.161 - 0.164 in. dia.

in bracket. Install

with head on bracket

side. (a)

BOLT, PROTRUDING BACB30NX5HK3 1

HD

Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 1 Collar on rail side.

FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 5 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
Step Task Name Identification Qty More Data

Use pilots in Step 11

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail. Install with

head on bracket

side.

BOLT, PROTRUDING BACB30NX5HK3 3

HD

12 Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 3 Collar on rail side.

Use pilots in Step 11

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail or Step 1 Support Structure Assy.

Install with countersunk head on rail or

Support Structure

Assy side.

BOLT, 100 DEG HEX BACB30YP5K4 6

DR

13 Install (New)

Collar on bracket

side.

Install (New) COLLAR, SHEAR BACC30BL5 6

14 Install (New) CORNER BRACKET 413W1221-273B 1

Use existing hole in

rail. Drill new hole

0.161 - 0.164 in. dia.

in bracket. Install

with head on bracket

side. (a)

BOLT, PROTRUDING BACB30NX5HK3 1

HD

Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 1 Collar on rail side.

Use pilots in Step 14

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail. Install with

head on bracket

side.

BOLT, PROTRUDING BACB30NX5HK3 3

HD

15 Install (New)

Install (New) COLLAR, PRELOAD BACC30BH5 3 Collar on rail side.

FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 6 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
Step Task Name Identification Qty More Data

Use pilots in Step 14

bracket. Drill holes

0.161 - 0.164 in. dia.

in rail or Step 1 Support Structure Assy.

Install with countersunk head on rail or

Support Structure

Assy side.

BOLT, 100 DEG HEX BACB30YP5K4 6

DR

16 Install (New)

Collar on bracket

side.

Install (New) COLLAR, SHEAR BACC30BL5 6

(a) Remaining open holes are acceptable.

(b) On some airplanes, the ceiling panel assembly might contain one insert in a location where the support

structure member (existing or new) does not have a hole for a fastener. If such a condition is encountered,

the fastener at this hole location may be omitted. Alternatively, removing the blocked insert and installing

an operator-furnished insert SL2334-3A1, fastener BACS12GU3K5, and washer NAS1149D0332J, in the

panel at the hole location adjacent to the blocked insert is also acceptable. Refer to 777 AMM 25-00-00,

Potted Inserts Repair, and BAC5583 Method B, Wet Potting of Inserts, as accepted procedures.

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

COLLAR, PRELOAD BACC30BH5 2

RIVET BACR15BB4D6C 1

RIVET, UNIVERSAL BACR15FT5D6C 4

HD

RIVET, UNIVERSAL BACR15FT5D7C 2

HD

RIVET BACR15GF4D6 1

FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION

(SHEET 7 OF 7)

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BOEING SERVICE BULLETIN 777-25-0482
This Figure applies only to: Group 1.

FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
Step Task Name Identification Qty More Data

1 Install (Kept) Tie Rod 777084-181 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Far side

Install (New) WASHER BACW10BP4DP 1 Far side

Install (New) NUT BACN10YR4CD 1 Far side.

MISCELLANEOUS - 422W2165-111 1 (a)

MACHINE PART

2 Install (New)

Install 2 near side, 2

far side. (b) , (c)

Install (New) BOLT, 100 DEG HEAD BACB30VF3K5 4

3 Install (New) TIE ROD ASSY 777081-178 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Far side

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

4 Install (New) BOLT, HEX HEAD BACB30NR4K17 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-038 1 Near side.

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

(a) Maximum gap allowed between part and rail before fastener installation is .003 in. Install shim if required

in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51-20-10.

(b) For countersink information, refer to 777-200 SRM 51-40-08 or 777-300 SRM 51-40-08 as an accepted

procedure.

(c) If a required hole is used for a ground, relocate ground to nearest unused hole. Refer to SWPM 20-20-

10 as an accepted procedure.

FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
This Figure applies only to: Group 2.

FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482
Step Task Name Identification Qty More Data

1 Install (Kept) Tie Rod 777084-181 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Far side

Install (New) WASHER BACW10BP4DP 1 Far side

Install (New) NUT BACN10YR4CD 1 Far side.

MISCELLANEOUS - 422W2165-108 1 (a)

MACHINE PART

2 Install (New)

Install 2 near side, 2

far side. (b) , (c)

Install (New) BOLT, 100 DEG HEAD BACB30VF3K5 4

3 Install (New) TIE ROD ASSY 777081-178 1

Install (New) BOLT BACB30NR4K15 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-024 1 Far side

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

4 Install (New) BOLT, HEX HEAD BACB30NR4K17 1 Near side.

Install (New) WASHER BACW10BP4CD 1 Near side.

Install (New) BUSHING BACB28AK04-038 1 Near side.

Install (New) WASHER BACW10BP4DP 1 Far side.

Install (New) NUT BACN10YR4CD 1 Far side.

(a) Maximum gap allowed between part and rail before fastener installation is .003 in. Install shim if required

in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51-20-10.

(b) For countersink information, refer to 777-200 SRM 51-40-08 or 777-300 SRM 51-40-08 as an accepted

procedure.

(c) If a required hole is used for a ground, relocate ground to nearest unused hole. Refer to SWPM 20-20-

10 as an accepted procedure.

FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 777-25-0482