### Commercial **Airplane Group**  

# 767 Service Bulletin **ALERT Number: 767-78A0089**  Date: July 19, 2001 Revision 5: June 09, 2009 ATA System: 7831 **SUBJECT:** EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser Deactivation Pin Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2001 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 1 of 66 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 2 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet ............................................ 5 Summary ..................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 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 4. Process Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 21 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 24 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FIGURE 1: SHOP AID HOLDER - INNER INSERT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FIGURE 2: SHOP AID SPANNER - OUTER INSERT. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT. . . . . . 32 FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING [Group 1]. . . . . . . . . . . . . . . 35 FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE . . . . . . . . . . . . . . . . . . . . . . 40 FIGURE 6: NEW INSERT FIT CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 FIGURE 7: INSERT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 8: RECONNECTION OF LINEAR ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . 54 FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 3 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**FIGURE 10: MARK THRUST REVERSER ID PLATE WITH SERVICE BULLETIN NUMBER . . . . . . 60 FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING [Group 2]. . . . . . . . . . . . . . . 62

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 4 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**

### Commercial **Airplane Group**  

# 767 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 767-78A0089** Date: July 19, 2001 Revision 5: June 09, 2009 ATA System: 7831 **SUBJECT:** EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser Deactivation Pin Modification This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION Group 1:**  No more work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4 of this service bulletin. **Group 2:** More work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4 of this service bulletin. Airplanes that delivered with the 315T3222-3 bushing need to replace the 315T3222-3 bushing with the 315T3221-1 bushing. If Group 2 operators previously replaced the 315T3222-3 bushing with the 315T3222-10 bushing, the 315T3222-10 bushing must be replaced by the 315T3221-1 bushing due to inadequate edge margin. Federal Aviation Administration (FAA) Airworthiness Directive 2002-19-11, is related to this service bulletin. **REASON FOR REVISION** This revision is sent to add the 315T3221-1 bushing installation for airplanes delivered with the 315T3222-3 bushing. Revision 4 of this service bulletin added the 315T3222-3 bushing configuration. However, Boeing received a report from an operator that the 315T3222-3 bushing could not be replaced by the 315T3222-10 bushing due to inadequate edge margin. Therefore, this revision replaces the 315T3222-3 bushing with a new 315T3221-1 bushing that will provide adequate edge margin. These sections were changed: 1. In Effectivity - Airplanes, paragraph 1.A.1., airplanes that delivered with the 315T3222-3 bushing configuration were moved to a new Group 2. 2. In Material - Price and Availability, paragraph 2.A., price and ROLT data is added for the new 015T1838-1 and 015T1838-2 kits. Also, notes are added to clarify the correlation of the new kits to the old kits for Group 2 airplanes. 3. In Kits/Parts, paragraph 2.C.1., a table was added for the new 015T1838-1 and 015T1838-2 kits.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 5 of 664. In Work Instructions, paragraph 3.B., Step 4 was added to Work Package 2 for Group 2 airplanes. 5. In Figure 4, Step 5 was added to inspect for cracks, and Step 11 was changed to wet install the fasteners. 6. Figure 11 was added for Group 2 airplanes. 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** July 19, 2001 Original Issue: May 30, 2002 Revision 1: March 13, 2003 Revision 2: December 18, 2003 Revision 3: March 06, 2008 Revision 4: June 09, 2009 Revision 5:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 6 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**

### Commercial **Airplane Group**  

# 767 Service Bulletin **ALERT Summary**  **Number: 767-78A0089** Date: July 19, 2001 Revision 5: June 09, 2009 ATA System: 7831 **SUBJECT:** EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser Deactivation Pin Modification THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None **BACKGROUND** The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin. This service bulletin provides modification instructions to improve the thrust reverser deactivation pin's structural integrity. This modification will ensure non-deployment of a deactivated thrust reverser. Four partial deployments of improperly deactivated thrust reversers have been reported by operators with PW4000 engines. These occurred during landing, with up to 12 inches of the reverser deployed. Investigation of these events found that the, motorized isolation valve was not locked-out, as required by the 767 Dispatch Deviations Guide. This allowed hydraulic pressure to be available to the actuators when the reverser levers were activated on landing. The pin insert, located on each reverser sleeve, did not completely resist the deployment loads and twisted out of place allowing movement of the deactivated thrust reverser. The JT9D thrust reverser design is similar to the PW4000 thrust reverser design. Further investigation and analysis by Boeing has also found that the current deactivation pin arrangement may not always restrain a reverser against a full powered deployment. The improved deactivation pin modification consists of: (1) replacing the pin insert with one that has increased load carrying capability, (2) the bushing in the aft cascade ring is replaced with one that allows clearance for the new insert and (3) the deactivation pin is replaced with a longer one which will engage the cascade bushing despite any tolerances in the reverser. Boeing Service Related Problem (SRP) 767-SRP-78-0042 is related to this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 7 of 66**ACTION (PRR B13498-R)** For each reverser half, replace the aft cascade bushing, sleeve insert, and the deactivation pin with new components. **EFFECTIVITY** All JT9D powered 767 airplanes. **COMPLIANCE** Boeing recommends incorporation of this service bulletin within 24 months after November 5, 2002. Federal Aviation Administration (FAA) Airworthiness Directive 2002-19-11, Amendment 39-12891, is related to this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the changes given in this service bulletin. **MANPOWER** Total Man-hours - 17 Hours for each engine Elapsed Time - 8.5 Hours **MATERIAL INFORMATION** Boeing Supplied Kits. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 8 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 9 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 10 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplane Group**  

# 767 Service Bulletin **ALERT Number: 767-78A0089**  Date: July 19, 2001 Revision 5: June 09, 2009 ATA System: 7831 **SUBJECT:** EXHAUST (JT9D ENGINE) - Thrust Reverser Sleeve - Improved Thrust Reverser Deactivation Pin Modification THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624T001, Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 767 airplanes with JT9D engines with 315T3222-4, 315T3222-5, or 315T3222-6 bushings as part of the aft cascade ring - 1
767 airplanes with JT9D engines with 315T3222-3 bushings as part of the aft cascade ring - 2

Airplane Models: 767-200, 767-300 **Group Variable Number**  2 VA001 - VA011 1 VA012 - VA020 2 VA701 1 VA702 - VA719

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 11 of 66**Group Variable Number**  2 VA801 1 VA802 - VA810 2 VB001 1 VB002 1 VB201 - VB202 1 VB281 - VB284 1 VB301 - VB302 1 VB371 - VB373 1 VE001 - VE003 1 VE021 - VE023 1 VE041 - VE043 1 VE061 - VE069 1 VE083 - VE084 1 VK001 - VK011 1 VK021 - VK022 2. Spares Affected None **B. Concurrent Requirements** None **C. Reason** The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin. This service bulletin provides modification instructions to improve the thrust reverser deactivation pin's structural integrity. This modification will ensure non-deployment of a deactivated thrust reverser. Four partial deployments of improperly deactivated thrust reversers have been reported by operators with PW4000 engines. These occurred during landing, with up to 12 inches of the reverser deployed. Investigation of these events found that the, motorized isolation valve was not locked-out, as required by the 767 Dispatch Deviations Guide. This allowed hydraulic pressure to be available to the actuators when the reverser levers were activated on landing. The pin insert, located on each reverser sleeve, did not completely resist the deployment loads and twisted out of place allowing movement of the deactivated thrust reverser. The JT9D thrust reverser design is similar to the PW4000 thrust reverser design. Further investigation and analysis by Boeing has also found that the current deactivation pin arrangement may not always restrain a reverser against a full powered deployment.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 12 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The improved deactivation pin modification consists of: (1) replacing the pin insert with one that has increased load carrying capability, (2) the bushing in the aft cascade ring is replaced with one that allows clearance for the new insert and (3) the deactivation pin is replaced with a longer one which will engage the cascade bushing despite any tolerances in the reverser. Boeing Service Related Problem (SRP) 767-SRP-78-0042 is related to this service bulletin. Revision 2 is sent to add a stowage bracket for the thrust reverser deactivation pin. Revision 3 is sent to add instructions to add instructions for part marking the thrust reverser ID plate with the service bulletin number and to correct the existing part nomenclature in the Parts Modified and Reidentified table (formerly Existing Parts Accountability). Revision 4 is sent to include missing configuration for 315T3222-3 bushing replacement in the aft cascade ring. Revision 5 is sent to add the 315T3221-1 bushing installation for airplanes delivered with the 315T3222-3 bushing. Revision 4 of this service bulletin added the 315T3222-3 bushing configuration. However, Boeing received a report from an operator that the 315T3222-3 bushing could not be replaced by the 315T3222-10 bushing due to inadequate edge margin.Therefore, this revision replaces the 315T3222-3 bushing with a new 315T3221-1 bushing that will provide adequate edge margin. These sections were changed: 1. In Effectivity - Airplanes, paragraph 1.A.1., airplanes that delivered with the 315T3222-3 bushing configuration were moved to a new Group 2. 2. In Material - Price and Availability, paragraph 2.A., price and ROLT data is added for the new 015T1838-1 and 015T1838-2 kits. Also, notes are added to clarify the correlation of the new kits to the old kits for Group 2 airplanes. 3. In Kits/Parts, paragraph 2.C.1., a table was added for the new 015T1838-1 and 015T1838-2 kits. 4. In Work Instructions, paragraph 3.B., Step 4 was added to Work Package 2 for Group 2 airplanes. 5. In Figure 4, Step 5 was added to inspect for cracks, and Step 11 was changed to wet install the fasteners. 6. Figure 11 was added for Group 2 airplanes. **D. Description** For each reverser half, replace the aft cascade bushing, sleeve insert, and the deactivation pin with new components. The changes in this service bulletin will not change the Engine Indication and Crew Alerting System (EICAS). Revision 4 - No more work is necessary on airplanes changed as shown in the initial release and Revision 1, Revision 2 or Revision 3 of this service bulletin. Revision 5 -

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 13 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Group 1:**  No more work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4 of this service bulletin. **Group 2:** More work is necessary on airplanes changed as shown in Revision 2, Revision 3, or Revision 4 of this service bulletin. Airplanes that delivered with the 315T3222-3 bushing need to replace the 315T3222-3 bushing with the 315T3221-1 bushing. If Group 2 operators previously replaced the 315T3222-3 bushing with the 315T3222-10 bushing, the 315T3222-10 bushing must be replaced by the 315T3221-1 bushing due to inadequate edge margin. The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 425, 426 767-200, 767-300 **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 425, 426 767-200 **E. Compliance** Boeing recommends incorporation of this service bulletin within 24 months after November 5, 2002. Federal Aviation Administration (FAA) Airworthiness Directive 2002-19-11, Amendment 39-12891, is related to 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 14 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (a) of AD 2002-19-11. All provisions of AD 2002-19-11 that are not specifically referenced in the above statement remain fully applicable and must be complied with. Before using this AMOC, notify your appropriate principal inspector (PI) in the FAA Flight Standards District Office (FSDO), or lacking a PI, your local FSDO. This approval is subject to the following condition: If in the future the Seattle Aircraft Certification Office (SACO) determines that this AMOC does not provide an acceptable level of safety, the SACO may revoke or revise the terms of the AMOC following notice to the requester and a seven-day opportunity for the requester to comment on the revocation or proposed revision. **G. Manpower** The table below shows an estimate of the man-hours necessary to do this modification for each engine. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. **Elapsed Time (Hours) Man-Hours**  **Number of Persons Task**  1.0 2.0 2 Open 6.5 13.0 2 Modification 1.0 2.0 2 Close 8.5 17.0 TOTAL FOR EACH ENGINE **H. Weight and Balance Changes Change in Moment**  **Change in Weight (Pound-Inches)**  **(Pounds) Airplane**  + 330.0 + 0.4 All
**I. Electrical Load Data** Not changed

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 15 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT J. References**  1. Existing Data: a. Service Related Problem (SRP) 767-SRP-78-0042 b. Engineering Change Memo PRR B13498-R c. 767 Maintenance Planning Data (MPD) Section 4 "Access Doors and Panels" d. Component Maintenance Manual (CMM) 71-11-31, 78-31-14 e. Standard Overhaul Practices Manual (SOPM) 20-20-02, 20-50-10, 20-50-19 f. 767 Aircraft Maintenance Manual (AMM) 27-62-00, 51-31-01, 71-11-04, 78-31-00 g. FAA Airworthiness Directive 2002-19-11 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None 4. Process Data: None **K. Publications Affected Chapter-Section**  **Publication** 71-11, 78-31 767 Component Maintenance Manual 78-31 767 Illustrated Parts Catalog **L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 16 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT 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. Kit availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

**Group 1: Unit Price thru Sep**  **30/01 ROLT**  **(weeks) Name**  **Kit Number** No Longer Available

- Top Kit - 767 315T4026-9 No Longer Available

- C - Duct Kit - Spares Only 315T4026-8 $7,322 24 C - Duct Kit - Spares Only 315T4026-25 $14,644 24 Top Kit - 767 315T4026-26 $1,268 21 Supplemental 315T4026-27 **Group 1: NO** **TE:** For future purchase orders, Top Kit 315T4026-25 replaces Top Kit 315T4026-8 and Top Kit 315T4026-26 replaces Top Kit 315T4026-9. For previous purchase orders, Supplemental Top Kit 315T4026-27 is needed to complete Top Kits 315T4026-8 and 315T4026-9. Boeing can supply the kits/parts 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 to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. **Group 2:**
**Unit Price thru DEC 31, 2009**  **ROLT (Weeks)**  **QTY Date**  **Name Kit Number**  $9,986.00 30 10 July 1, 2009 Top Kit - (JT9D Engine) Thrust Reverser Deactivation Pin Change 015T1838-1

$3,523.00 30 4 June 4, 2009 Supplemental Kit - Thrust Reverser Deactivation Pin - Bushing Replacement 015T1838-2

**Group 2: NO** **TE:** The 015T1838-1 Top Kit replaces the 315T4026-25 or 315T4026-26 Top Kits.The 015T1838-1 Top Kit provides the parts necessary for each engine. **Group 2: NO** **TE:** If operators previously purchased the 315T4026-25 Top Kit, one 015T1838-2 Supplemental Kit can be purchased to provide the parts needed for each engine.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 17 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Group 2:**  **NO TE:**  If operators previously purchased the 315T4026-26 Top Kit, two 015T1838-2 Supplemental Kits can be purchased to provide the parts needed for each airplane. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Send purchase orders and letters about the supply data to the Director of Spares and refer to this service bulletin number. **B. Industry Support Information** Boeing warranty remedies are not available for the changes given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **Group 1: NO** **TE:** One 315T4026-26 top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. **Group 2: NO** **TE:** One 015T1838-1 top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each engine.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 18 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Group 1:** 
**Kit 315T4026 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -5**  **-6 -7**  **-8 -9**  **-27** (d) (f) Top Kit - 767

. . . . - . 315T4026-9 (e) (f) Engine Kit - Spares Only . . . - . . 315T4026-8 (f) Supplemental Top Kit . . . . . - 315T4026-27

Pin Installation

. . - 2 4

. 315T4026-7 Insert Installation

. - . 2 4

. 315T4026-6 Bushing Installation

- . . 2 4

. 315T4026-5 315T1604-1, 315T1604-2, 315T1604-3, 315T1604-4 or 315T1604-5 Pin

. . 1

. . . 315T1604-6

315T3222-4, 315T3222-5 or 315T3222-6 Bushing 1

. . . . . 315T3222-10

(a) (b) 315T3563-1 Insert Assembly

. 1

. . . . 315T4027-1 (c) Blind Rivet 4

. . . . . MS90353-0603 Kit, Deactivation Pin - Right T/R . . . . . 1 015T0196-2
Kit, Deactivation Pin - Left T/R . . . . . 1 015T0196-3 (a) The outer insert part number is 315T4027-2. (b) The inner insert part number is 315T4027-4. (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 012W6100 are used to determine the part numbers used as substitutes. (d) The Top Kit 315T4026-9 has been replaced by Top Kit 315T4026-26. (e) The Spares Top Kit 315T4026-8 has been replaced by Spares Top Kit 315T4026-25. (f) The Supplemental Top Kit 315T4026-27 is needed to complete Top Kits 315T4026-8 and 315T4026-9.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 19 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Group 1:** 
**Kit 315T4026 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -25**  **-26** (a) Top Kit - 767

. - 315T4026-26 (b) Engine Kit - Spares Only

- . 315T4026-25 Pin Installation 2 4 315T4026-7 Insert Installation 2 4 315T4026-6 Bushing Installation 2 4 315T4026-5 Kit, Deactivation Pin - Right T/R 1 2 015T0196-2
Kit, Deactivation Pin - Left T/R 1 2 015T0196-3 (a) The Top Kit 315T4026-9 has been replaced by Top Kit 315T4026-26 (b) The Spares Top Kit 315T4026-8 has been replaced by Spares Top Kit 315T4026-25. **Group 1:**
**Kit 015T0196 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -2**  **-3** Kit, Deactivation Pin - Right T/R - . 015T0196-2
Kit, Deactivation Pin - Left T/R . - 015T0196-3 Bracket Assy 1

. 015T0196-4 Bracket Assy

. 1 015T0196-5 Hi-Lok 4 4 BACB30NX6K3X Collar 4 4 BACC30M6

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 20 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Group 2:** 
**Kit 015T1838 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -1**  **-2** Group 2 airplanes (a) Supplemental Kit - Thrust Reverser Deactivation Pin - Bushing Replacement . - 015T1838-2

Group 2 airplanes (a) Top Kit - (JT9D Engine) Thurst Reverser Deactivation Pin Change - . 015T1838-1

Bracket Assy 1

. 015T0196-4 Bracket Assy 1

. 015T0196-5 315T1604-1, 315T1604-2, 315T1604-3, 315T1604-4 or 315T1604-5 Pin 2

. 315T1604-6

315T3222-3 Bushing Plate 2 2 315T3221-1 (b) (c) 315T3563-1 Insert Assembly 2

. 315T4027-1 Hi-Lock 8

. BACB30NX6K3X Bolt, Blind 8 8 BACB30VX6A03U Collar 8

. BACC30M6 (a) One kit provides the quantity of parts needed for each engine. (b) The outer insert part number is 315T4027-2. (c) The inner insert part number is 315T4027-4. 2. Parts and Materials Supplied by the Operator:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 21 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Notes**  **Name QTY**  **Part Number / Specification**  (a) (b) Screw 2 NAS1351-01-6 (c) Screw 2 NAS1351-02-4 (f) Cotter Pin 12 MS24665-153 (k) Antisieze Lubricant 16 oz BMS 3-28 or BAC 5008 Type 7-3 (e) Adhesive (Liquid Shim) 4 oz BMS 5-141 (d) Sealant 16 oz BMS 5-26 Type 1 or Type 2 (e) Potting Compound 8 oz BMS 5-28, Type 6 (e) Thread Adhesive 4 oz Loctite 242 (d) Transfer Punch 5 15156 (b) Vacuum Bag Sealant Tape 12 in AP200Y or GS43MR (a) NAS1351-02-6 may be substituted for the part listed. (b) This part is used in FIGURE 1. (c) This part is used in FIGURE 2. (d) This part is used in FIGURE 4 and FIGURE 11 . (e) This part is used in FIGURE 7. (f) This part is used in FIGURE 8. (g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (h) Pacific Distributing Inc. (206340), 7118 Beacon Ave. South, Seattle, WA 98108. (i) Airtech International, 5700 Skylab Rd., Huntington Beach, CA 92647. (j) Other similar "clay type adhesive" or Thick Double Back Tape may be substituted. (k) This part is used in the Accomplishment Instructions during preassembly to lubricate the pin or helicoil threads.
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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 22 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Notes**  **New Part Number Name**  **QTY Existing Part**  **Number** (a) (b) 315T3204-21 Aft Cascade Ring Assy 2 315T3204-5 (a) (b) 315T3204-22 Aft Cascade Ring Assy 2 315T3204-6 (a) (b) 315T3204-21 Aft Cascade Ring Assy 2 315T3204-7 (a) (b) 315T3204-22 Aft Cascade Ring Assy 2 315T3204-8 (a) (c) 315T4026-17 T/R Sleeve Assy 2 315T3500-1 (a) (c) 315T4026-18 T/R Sleeve Assy 2 315T3500-2 (a) (c) 315T4026-19 T/R Sleeve Assy 2 315T3500-21 (a) (c) 315T4026-20 T/R Sleeve Assy 2 315T3500-22 (a) (c) 315T4026-21 T/R Sleeve Assy 2 315T3500-23 (a) (c) 315T4026-22 T/R Sleeve Assy 2 315T3500-24 (a) (c) 315T4026-23 T/R Sleeve Assy 2 315T3500-27 (a) (c) 315T4026-24 T/R Sleeve Assy 2 315T3500-28 (a) Make the change given in this service bulletin. (b) This is the part number for the new equivalent or replacement part. (c) This is the part number after the change given in this service bulletin 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 23 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT Group 1:** 
**Name Part Number**  **Quantity** Engine Kit - Spares Only 315T4026-25 1 **Group 2:**
**Name Part Number**  **Quantity** Top Kit - (JT9D Engine) Thurst Reverser Deactivation Pin Change 015T1838-1 1

**E. Special Tooling - Price and Availability** Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the date the tools will be used. If there is a limit in the quantity of available rental tools, a supply sequence is given by Spares. Purchase Data:
**Price thru DEC 31, 2009**  **Name Tool Kit Number**  $7,500.00 Hole Saw with Pilot MIT315T4500 The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Price date, new price data is applicable. Prices are in United States dollars. Terms: Net 30 days. **F. Special Tooling Necessary to do this Service Bulletin** To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available.
**Name Tool Kit Number**  Hole Saw with Pilot MIT315T4500 Note: An operator approved equivalent tool or tools may be used instead of the tool(s) called for in this bulletin. The alternate tool(s) must produce the same or better end item affect to the modified part.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 24 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION NO** **TE:** 1. The paragraphs identified with a letter give the general work instructions. The instructions identified with numbers on the figures give the recommended sequence of steps. 2. 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 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. 3. In this service bulletin, all references to Boeing airplane documentation (i.e. AMM, BSOPM, etc.) imply the use of your equivalent procedure(s) to these references as acceptable, unless otherwise stated. 4. Alternative fasteners are given in 767 Structural Repair Manual, Chapter 51. 5. Obey all of the warnings and cautions given in the specified manual sections. 6. An operator approved equivalent tool or tools may be used instead of a tool called for in this bulletin. The alternate tool(s) must produce the same or better end item affect to the modified part. **B. WORK INSTRUCTIONS**
**W ORK P**  **A CKA** **GE I - Pre-Modification Preparation** 1. Make the shop aid tools shown in FIGURE 1, "Holder - Inner Insert" and FIGURE 2, "Spanner - Outer Insert". These are required to install the new two piece insert. 2. Test install the pin, part number 315T4026-7, into the insert, part number 315T4026-6 (tighten until the pin head is seated against the insert). This will test its function and reduce the initial tear torque.The initial check is necessary to eliminate the possibility of dislodging the insert after it has been potted into the thrust reverser sleeve. An antisieze lubricant may be added to the threads of the pin or helicoil to ease installation of the pin into the insert. **W ORK P**  **A CKA** **GE II - Modification pr ocedures f** **or a thrust re ver** **ser that is installed on an airplane** 1. Do the Thrust Reverser Deactivation procedures, for all engines, as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 25 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT W**  **ARNING:** DO THE DEACTIVATION PROCEDURE FOR THE AUTOMATIC SPEED BRAKE CONTROL SYSTEM. IF YOU DO NOT DO THIS, THE AUTOMATIC SPEED BRAKES CAN MOVE QUICKLY WHEN YOU MOVE THE THRUST LEVERS. THIS CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. a. Make sure the forward thrust levers are in the idle position and attach the DO-NOT-OPERATE tags. b. Make sure the reverse thrust levers are in the fully stowed position and attach the DO-NOT-OPERATE tags. c. Deactivate the Isolation Valve for ground maintenance as shown in 767 AMM 78-31-00, "Thrust Reverser Deactivation and Activation For Ground Maintenance". However, since the T/R sleeve will be manually translated in FIGURE 3, do not install the deactivation pin in the side of the T/R sleeve. 2. To get access to the AFT cascade ring and reverser sleeve insert, translate the reverser by your hand as shown in FIGURE 3.
3. **Group 1:** Replace the pin bushing square, in the aft cascade ring, as shown in FIGURE 4.
4. **Group 2:** Replace the pin bushing square in the aft cascade ring, as shown in FIGURE 11. 5. Remove the insert as shown in FIGURE 5. 6. Do a fit check of the new two piece insert (without liquid shim and potting) as shown in FIGURE 6. 7. Install the new two piece insert (with liquid shim and potting) as shown in FIGURE 7. 8. After the potting and liquid shim have cured, reconnect the linear actuators as shown in FIGURE 8. 9. Install the new deactivation pin. Be sure it can be installed all the way; then remove the deactivation pin. 10. Install the screw plug, part number BACB30VF8K2 (part number AIC1195-8-2 is optional but not preferred), into the hole of the outer insert (where the deactivation pin was inserted) and tighten the screw plug to 120-150 pound-inches (13.6-17.0 newton-meters). 11. Open the fan cowl as shown in 767 AMM 71-11-04. Install a new stowage bracket and replace the stowed deactivation pin as shown in FIGURE 9. 12. Mark the service bulletin number on each thrust reverser ID plate as shown in FIGURE 10. 13. Manually Extend and Retract the reverser as shown in 767 AMM 78-31-00 (Manual Method) to check the thrust reverser operation and the rod end gap of the center locking actuator. 14. Do the following Thrust Reverser Activation procedures as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 26 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**a. Activate the Isolation Valve for ground maintenance as shown in 767 AMM 78-31-00, "Thrust Reverser Deactivation and Activation For Ground Maintenance". b. Do the activation procedure for the speed brake control system as shown in 767 AMM 27-62-00. c. Remove the DO-NOT-OPERATE tags from the reverse thrust levers and the forward thrust levers. 15. Extend and retract the thrust reverser three times with hydraulic power to make sure it operates correctly and the flight compartment indications are correct as shown in 767 AMM 78-31-00. 16. Return the airplane to service condition. **W ORK P**  **A CKA** **GE III - Modification pr ocedures f** **or a spare thrust re ver** **ser** 1. If not previously made, make the shop aid tools shown in FIGURE 1, "Holder - Inner Insert" and FIGURE 2, "Spanner - Outer Insert". These are required to install the new two piece insert. 2. To get access to the AFT cascade ring and reverser sleeve insert, translate the reverser by your hand as shown in FIGURE 3. 3. Replace the pin bushing square, in the aft cascade mounding ring, as shown in FIGURE 4. 4. Remove the insert as shown in FIGURE 5. 5. Do a fit check of the new two piece insert (without liquid shim and potting) as shown in FIGURE 6. 6. Install the new two piece insert (with liquid shim and potting) as shown in FIGURE 7. 7. After the potting and liquid shim have cured, reconnect the linear actuators as shown in FIGURE 8. 8. Install the new deactivation pin. Be sure it can be installed all the way; then remove the deactivation pin. 9. Install the screw plug, part number BACB30VF8K2 (part number AIC1195-8-2 is optional but not preferred), into the hole of the outer insert (where the deactivation pin was inserted) and tighten the screw plug to 120-150 pound-inches (13.6-17.0 newton-meters). 10. Install a new stowage bracket and replace the stowed deactivation pin as shown in FIGURE 9. 11. Mark the service bulletin number on each thrust reverser ID plate as shown in FIGURE 10. 12. Do the following thrust reverser tests as shown in the CMM 78-31-14: a. Manually Extend and Retract the reverser to check the thrust reverser operation and the rod end gap of the center locking actuator. b. Extend and retract the thrust reverser three times with hydraulic power to make sure it operates correctly.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5: June 09, 2009 27 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 1: SHOP AID HOLDER - INNER INSERT**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 28 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts associated with the shop aid tool.
**NOTES QTY**  **MATERIAL NAME**  **TASK STEP**  Thickness is 0.112 - 0.100. 1 2024 or Stock Layout 1 7075 or Other Suitable Aluminum Alloy 1 - - Hole Drill 2 or other steel alloy screw or pin with a diameter of 0.073 - 0.0695 and a final length as shown. (Threads are not required.) 2 NAS1351-01-6 Screw Install 3

or other steel alloy screw or pin with a diameter of 0.0860 - 0.0822. Final length as shown. (Threads are not required.) (NAS1351-02-6 optional)

So that inner insert will adhear to tool. (Approx. area each location is 1/4 X 1/2 X 1/16 to 1/8.) 2 GS43MR or Vacuum Bag Sealant Tape Install 4 (AP200Y or any other type) as: "PW4000/JT9D T/R (767-78A0080, 767-78A0089, or 747-78A2165) Holder - Inner Insert" Shop Aid Tool Identify 5

**FIGURE 1: SHOP AID HOLDER - INNER INSERT (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 29 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 2: SHOP AID SPANNER - OUTER INSERT**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 30 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts associated with the shop aid tool.
**NOTES QTY**  **MATERIAL NAME**  **TASK STEP**  Thickness is 0.112 - 0.100. 1 2024 or Stock Layout / Cut 1 7075 or Other Suitable Aluminum Alloy or other steel alloy screw or pin, diameter of 0.0860 - 0.0822, with a final length as shown. (Threads are not required.) 2 NAS1351-02-4 Screw Install 2

as: "PW4000/JT9D T/R (767-78A0080, 767-78A0089, or 747-78A2165) Spanner - Outer Insert" Shop Aid Tool Identify 3

**FIGURE 2: SHOP AID SPANNER - OUTER INSERT (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 31 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 32 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts associated with one reverser sleeve.

**FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 33 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** WARNING: FAILURE TO FOLLOW THE DEACTIVATION PROCEDURES GIVEN IN THE GENERAL ACCOMPLISHMENT INSTRUCTIONS MAY RESULT IN SERIOUS INJURY AND/OR DAMAGE TO THE THRUST REVERSER. Reference 767 MPD Section 4, and 767 AMM 78-31-00. 3 415CL (left engine outboard) Upper Hydraulic Actuator Access Panel: Remove / Keep 1 416CR (left engine inboard) 426CR (right engine outboard) 425CL (right engine inboard) 415DL (left engine outboard) Middle Hydraulic Actuator Access Panel: 416DR (left engine inboard) 426DR (right engine outboard) 425DL (right engine inboard) 415EL (left engine outboard) Lower Hydraulic Actuator Access Panel: 416ER (left engine inboard) 426ER (right engine outboard) 425EL (right engine inboard) 3 MS24665-153 Cotter Pin Remove 2 3 BACN10JD105 Nut Remove / Keep 6 AN960-516 Washer 3 NAS6705D18 Bolt 3 NAS74A5E006P Bushing by hand, all the way to the deploy position. 1 - - Reverser Sleeve Translate 3

**FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 34 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 35 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 36 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one reverser sleeve.

**FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 37 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** CAUTION: PRIOR TO MAKING ANY CHANGES TO THE THRUST REVERSER, TEST INSTALL THE NEW DEACTIVATION PIN INTO THE HELICOIL OF THE NEW OUTER INSERT (TIGHTEN UNTIL THE PIN HEAD IS SEATED AGAINST THE INSERT).THIS WILL CHECK ITS FUNCTION AND REDUCE THE INITIAL TEAR TORQUE.THE INITIAL CHECK IS NECESSARY TO ELIMINATE THE POSSIBILITY OF DISLODGING THE INSERT AFTER IT HAS BEEN POTTED INTO THE THRUST REVERSER SLEEVE. AN ANTISIEZE LUBRICANT MAY BE ADDED TO THE THREADS OF THE PIN OR HELICOIL TO EASE INSTALLATION OF THE PIN INTO THE INSERT. slowly, by your hand, towards stow until the cascade bushing square (which receives the end of the deactivation pin) is centered as shown. 1 - - Reverser Sleeve Move 1

by drilling out countersunk rivet heads. 1 315T3222-4, -5, or -6 Bushing Square Remove 2 Note: To ensure complete rivet removal, it is recommended to apply a tape or putty to the back side of rivet to contain it while it is tapped out of the hole. Remove the tape/putty with rivet thru the deactivation pin hole. 1 - - Hole Chamfer 3 to a diameter of 0.199 - 0.201. 4 - - Rivet Holes Oversize 4 Dye penetrant inspect for cracks. Refer to SOPM 20-20-02 as an accepted procedure. (a) 4 - - Rivet Holes Inspect 5

into the rivet holes. 4 15156 Transfer Punch Put 6 in PROPER orientation as shown to transfer the center mark of the transfer punch to the bushing plate. 1 315T3222-10 Bushing Plate Mount 7

from cascade ring. 1 315T3222-10 Bushing Plate Remove into bushing plate. Diameter is 0.199 - 0.202. 4 - - Rivet Holes Drill

4 15156 Transfer Punch Remove 8 on cascade ring of any previous sealant in the area the bushing plate will cover. Ref. 767 AMM 51-31-01. - - - Surface Clean 9

to cascade ring. The area for the bushing plate. Ref. 767 AMM 51-31-01. - BMS5-26 Fay Seal Apply 10

in PROPER orientation as shown. 1 315T3222-10 Bushing Plate Install 11 Wet install with BMS5-26. Refer 4 MS90353-0603 Blind Rivet

**FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 38 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** to SOPM 20-50-19 as an accepted procedure. with BMS5-26. Ref. 767 AMM 51-31-01. - - - Bushing Plate Edges Fillet Seal to new part number shown in Paragraph 2.C.3., Parts Modified and Reidentified and the SOPM 20-50-10, Paragraph 6, Rubber Stamping. 1 ( ) Aft Cascade Ring Part Number Change 12

Note: The part mark may be placed at any convenient location on the aft cascade ring assembly and may be hidden by other structures. (a) If cracks are found, repair or replace as necessary. Refer to CMM 71-11-31 as an accepted procedure.

**FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 39 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 40 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 41 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts associated with one reverser sleeve.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  slowly, by your hand, to the deploy position. 1 - - Reverser Sleeve Move 1 in the deactivation pin hole. 1 MIT315T4500-3 Saw Pilot Bushing Thread 2 to installed pilot 1 MIT315T4500-2/-5 Hole Saw with Arbor Locate 3 WARNING: CUTTING OUT THE INSERT WILL CAUSE A FINE DUST. BE SURE YOU WEAR A DUST MASK OR RESPIRATOR. USE A VACUUM TO REMOVE DUST DURING THE SAWING OPERATION AND FOR CLEANUP, AFTER THE INSERT IS REMOVED. "drill" down between 0.70 - 0.80 inches. When you first start to cut (the outer carbon panel), you will get brown dust. When you go the potting, you will get yellow/white dust. Then as you start to get brown dust (the inner carbon panel) the insert will start to spin. 1 - - Inbedded Insert Cut Out 4

when it spins within the hole. - - Inbedded Insert Remove back into the hole, so that the hole can act as a guide, for the saw to cut thru the inner panel of the sleeve. 1 MIT315T4500-2/-5 Hole Saw with Arbor Locate 5

to complete the hole. Be sure cutting pressure is such as to create the best possible edge corner when cutter passes thru the inner panel. - - - Inner panel of the sleeve Cut thru 6

**FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 42 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 6: NEW INSERT FIT CHECK**  **(SHEET 1 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 43 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 6: NEW INSERT FIT CHECK**  **(SHEET 2 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 44 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 6: NEW INSERT FIT CHECK**  **(SHEET 3 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 45 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one reverser sleeve.

**FIGURE 6: NEW INSERT FIT CHECK (SHEET 4 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 46 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** for sharp edges. Remove as necessary. Hole sides should be clean with no ragged edges and sides are not broken through. 1 - - Hole Inspect 1

diameter. It should be 1.1865 - 1.1885 inches. If diameter is less than this, use a reamer to be within the above diameter. 1 - - Hole Measure

to be sure their shoulders will fit in the hole. 1 315T4027-4 Inner Insert Check 2 1 315T4027-2 Outer Insert Note: If they do not fit, Ream hole to 1.1885 -1.1905 inches in diameter. Be sure to remove sharp edges on both sides. Be sure not to remove any material from the face of the sleeve. to holder tool. 1 315T4027-4 Inner Insert Attach 3 as shown. Do not remove holder tool from inner insert. 1 315T4027-4 Inner Insert Install 4
CAUTION: BE SURE NOT TO TIGHTEN SO AS TO SQUISH THE REVERSER SLEEVE PANEL.TIGHTEN ONLY HAND SNUG SO AS TO BE REMOVABLE LATER. ADJUST TIGHTENING SO THAT THE INJECTION HOLES, OF THE OUTER INSERT, ARE VERTICAL. Use spanner to tighten. 1 315T4027-2 Outer Insert Install 5 Note: To pull the inner insert into the hole, you may have to use the deactivation pin by screwing it in the outer insert up to a 1/8 turn and then gently, with a slight wiggle, pull outward. from inner insert. 1 - - Holder Tool Release 6 from access. 1 - - Holder Tool Remove thru the gap between the sleeve and cascades to be sure insert is in the hole. Look to see that the top edge of the insert has the same relationship, to the inner sleeve, as the bottom edge. Look to see that the FWD edge has the same relationship to the sleeve as the AFT edge. 1 315T4027-4 Inner Insert Look At 7

for a gap of 0.004 inches, or less, at the FWD and AFT edges with the sleeve. The top edge should have the similar relationship, to the sleeve, as the bottom edge. 1 315T4027-2 Outer Insert Check 8

Note: If you do not get the conditions given in STEP 7 & 8, than it may be necessary to remove material from the side of the hole to make the insert fit evenly. Do NOT remove more than 0.030 inches, total, from the side of the hole. Do NOT remove material from the face of the sleeve.

**FIGURE 6: NEW INSERT FIT CHECK (SHEET 5 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 47 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** CAUTION: WHEN MOVING SLEEVE, USE A SLOW RATE OF MOVEMENT AND BE CAREFUL NOT TO DAMAGE ACTUATORS WITH CLEVISES ON THE SLEEVE. slowly, by your hand, towards stow. Be sure the actuators fit into their clevises on the sleeve. 1 - - Reverser Sleeve Move 9

CAUTION: DO NOT SCREW IN DEACTIVATION PIN INTO THE OUTER INSERT. into outer insert. 1 315T1604-6 New Deactivation Pin Place 10 goes into bushing without the pin being screwed in. - - - Pin End Verify

1 315T1604-6 New Deactivation Pin Remove to the deploy position. 1 - - Reverser sleeve Move 11 1 315T4027-2 Outer Insert Remove 12 1 315T4027-4 Inner Insert

**FIGURE 6: NEW INSERT FIT CHECK (SHEET 6 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 48 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 7: INSERT INSTALLATION**  **(SHEET 1 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 49 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 7: INSERT INSTALLATION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 50 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one reverser sleeve.

**FIGURE 7: INSERT INSTALLATION (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 51 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** on outer surface of sleeve panel as shown.You may go beyond the flange diameter of the outer insert by 0.150 inches. - - - Paint Remove 1

Ref. 767 AMM 51-31-01. 1 - - Hole Clean 2 to inner and outer inserts as shown. Apply enough to fill gaps under flanges when inserts are installed. Ref. 767 AMM 51-31-01. - BMS5-141 Adhesive (liquid Shim) Apply 3

to thread of outer insert.

- Loctite 242 Thread Adhesive Apply 4 to holder tool. 1 315T4027-4 Inner Insert Attach 5 as shown. Do not remove holder tool from inner insert. 1 315T4027-4 Inner Insert Install 6
CAUTION: BE SURE NOT TO TIGHTEN SO AS TO SQUISH THE REVERSER SLEEVE PANEL. ADJUST TIGHTENING SO THAT THE INJECTION HOLES, OF THE OUTER INSERT, ARE VERTICAL. Use spanner to tighten. 1 315T4027-2 Outer Insert Install 7 NOTE: To pull the inner insert into the hole, you may have to use the deactivation pin by screwing it in the outer insert up to a 1/8 turn and then gently, with a slight wiggle, pull outward.Then, remove deactivation pin and finish tightening insert. from inner insert. 1 - - Holder Tool Release 8 from access. 1 - - Holder Tool Remove from outer insert 1 Spanner Tool thru the gap between the sleeve and cascade to be sure insert is in the hole. Also look to see that the top edge of the insert has the same relationship, to the inner 1 315T4027-4 Inner Insert Look At 9

sleeve, as the bottom edge. Look to see that the FWD edge has the same relationship to the sleeve as the AFT edge. Be sure adhesive fills all gaps between insert and sleeve panel. for a gap of 0.004 inches or less at the FWD and AFT edges with the sleeve. The top edge should have the same relationship, to the sleeve, as the bottom edge. Be sure adhesive fills all gaps between insert and sleeve panel. 1 315T4027-2 Outer Insert Check 10

**FIGURE 7: INSERT INSTALLATION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 52 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** 11 deactivation pin hole, to prevent potting compound from getting in. 1 315T4027-2 Outer Insert Tape in lower hole, slowly, until it comes out the upper hole in a long stream, without air. - BMS5-28, Type 6 Potting Compound Inject 12

shut and let compound cure. 2 - - Injections Holes Tape to new part number shown in Paragraph 2.C.3., Parts Modified and Reidentified and the SOPM 20-50-10, Paragraph 6, Rubber Stamping. 1 ( ) Reverser Sleeve Part Number Change 13

Note: The part mark may be placed at any convenient location on the thrust reverser sleeve except the decorative finish side of the outer sleeve and may be hidden by other structures.

**FIGURE 7: INSERT INSTALLATION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 53 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 8: RECONNECTION OF LINEAR ACTUATOR**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 54 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts associated with one reverser sleeve.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  by hand, all the way to stow. Be careful to position the actuators into the clevis of the sleeve. 1 - - Reverser Sleeve Translate 1

3 MS24665-153 Cotter Pin Install 2 3 BACN10JD105 Nut Install / Kept 6 AN960-516 Washer 3 NAS6705D18 Bolt 3 NAS74A5E006P Bushing The actuator access cover panel is install later, after the reverser is checked manually as shown in the AMM. Refer to General Accomplishment Instructions. 3

**FIGURE 8: RECONNECTION OF LINEAR ACTUATOR (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 55 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN**  **REPLACEMENT (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 56 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN**  **REPLACEMENT (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 57 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts associated with one engine reverser.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  from the stowage area on reverser. 2 315T1604-1, 315T1604-2, 315T1604-3, 315T1604-4, or 315T1604--5 Deactivation Pin Remove / Discard 1

8

- Fastener, Existing Remove / Discard 2 Install on right thrust reverser only. Match drill the holes in the bracket assembly to the holes left open by the fastener removal accomplished in step 2. 1 015T0196-4 Bracket Assy Install 3

Install on left thrust reverser only. Match drill the holes in the bracket assembly to the holes left open by the fastener removal accomplished in step 2. 1 015T0196-5

8 BACB30NX6K3X Hi-Lok 8 BACC30M6 Collar in the stowage area on the reverser. 2 315T1604-6 Deactivation Pin Install 4

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener.

**FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN REPLACEMENT**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 58 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes.
**NOTES HOLE**  **DIA PART NUMBER**  **NAME CODE** 
Install with fastener head on the far side. 0.218 - 0.229 BACB30NX6K3X Hi-Lok A

- BACC30M6 Collar

**FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN REPLACEMENT**  **(SHEET 4 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 59 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 10: MARK THRUST REVERSER ID PLATE WITH SERVICE BULLETIN NUMBER**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 60 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**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 each thrust reverser half.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  as shown in SOPM 20-50-10. STAMPED TEXT: SB767-78A0089 R3 - - Modification Number Stamp 1

**FIGURE 10: MARK THRUST REVERSER ID PLATE WITH SERVICE BULLETIN NUMBER (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 61 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 62 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 63 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**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 each thrust reverser half.

**FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 64 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** CAUTION: PRIOR TO MAKING ANY CHANGES TO THE THRUST REVERSER, TEST INSTALL THE NEW DEACTIVATION PIN INTO THE HELICOIL OF THE NEW OUTER INSERT (TIGHTEN UNTIL THE PIN HEAD IS SEATED AGAINST THE INSERT).THIS WILL CHECK ITS FUNCTION AND REDUCE THE INITIAL TEAR TORQUE.THE INITIAL CHECK IS NECESSARY TO ELIMINATE THE POSSIBILITY OF DISLODGING THE INSERT AFTER IT HAS BEEN POTTED INTO THE THRUST REVERSER SLEEVE. AN ANTISIEZE LUBRICANT MAY BE ADDED TO THE THREADS OF THE PIN OR HELICOIL TO EASE INSTALLATION OF THE PIN INTO THE INSERT. slowly, by your hand, towards stow until the cascade bushing square (which receives the end of the deactivation pin) is centered as shown. 1 - - Reverser Sleeve Move 1

by drilling out countersunk rivet heads. 1 315T3222-3 Bushing Square Remove 2 Note: To ensure complete rivet removal, it is recommended to apply a tape or putty to the back side of rivet to contain it while it is tapped out of the hole. Remove the tape/putty with rivet thru the deactivation pin hole. 1 - - Hole Chamfer 3 to a diameter of 0.199 - 0.201. 4 - - Rivet Holes Oversize 4 Dye penetrant inspect for cracks. Refer to SOPM 20-20-02 as an accepted procedure. (a) - - - - Rivet Holes Inspect 5

into the rivet holes. 4 15156 Transfer Punch Put 6 in PROPER orientation as shown to transfer the center mark of the transfer punch to the bushing plate. 1 315T3221-1 Bushing Plate Mount 7

from cascade ring. 1 315T3221-1 Bushing Plate Remove into bushing plate. Diameter is 0.199 - 0.202. 4 - - Rivet Holes Drill

4 15156 Transfer Punch Remove 8 on cascade ring of any previous sealant in the area the bushing plate will cover. Ref. 767 AMM 51-31-01. - - - Surface Clean 9

to cascade ring. The area for the bushing plate. Ref. 767 AMM 51-31-01. - BMS5-26 Fay Seal Apply 10

in PROPER orientation as shown. 1 315T3221-1 Bushing Plate Install 11 Wet install with BMS5-26. Refer 4 BACB30VX6A03U Bolt, Blind

**FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 65 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** to SOPM 20-50-19 as an accepted procedure. with BMS5-26. Ref. 767 AMM 51-31-01. - - - Bushing Plate Edges Fillet Seal to new part number shown in Paragraph 2.C.3., Parts Modified and Reidentified and the SOPM 20-50-10, Paragraph 6, Rubber Stamping. 1 ( ) Aft Cascade Ring Part Number Change 12

Note: The part mark may be placed at any convenient location on the aft cascade ring assembly and may be hidden by other structures. (a) If cracks are found, repair or replace as necessary. Refer to CMM 71-11-31 as an accepted procedure.

**FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. July 19, 2001 767-78A0089 Revision 5 June 09, 2009 66 of 66 **BOEING SERVICE BULLETIN 767-78A0089 ALERT**  **ALERT**