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.

ECCN: 9E991

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Unpublished Work - All Rights Reserved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.

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3.0
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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

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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

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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.

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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.

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: July 19, 2001

Revision 1: May 30, 2002

Revision 2: March 13, 2003

Revision 3: December 18, 2003

Revision 4: March 06, 2008

Revision 5: June 09, 2009

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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.

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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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
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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.

GROUP CONFIGURATION DESCRIPTION

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

Variable Number Group

VA001 - VA011 2

VA012 - VA020 1

VA701 2

VA702 - VA719 1

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Variable Number Group

VA801 2

VA802 - VA810 1

VB001 2

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 1

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.

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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 -

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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

Model Zone

767-200, 767-300 425, 426

Group 2:

Affected Maintenance Zones

Model Zone

767-200 425, 426

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.

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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.

Task Number of Persons Man-Hours Elapsed Time (Hours)

Open 2 2.0 1.0

Modification 2 13.0 6.5

Close 2 2.0 1.0

TOTAL FOR EACH ENGINE 17.0 8.5

H. Weight and Balance Changes

Change in Weight Change in Moment

Airplane (Pounds) (Pound-Inches)

All + 0.4 + 330.0

I. Electrical Load Data

Not changed

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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

Publication Chapter-Section

767 Component Maintenance Manual 71-11, 78-31

767 Illustrated Parts Catalog 78-31

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 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)

Kit Number Name

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

315T4026-8 C - Duct Kit - Spares Only - No Longer Available

315T4026-25 C - Duct Kit - Spares Only 24 $7,322

315T4026-26 Top Kit - 767 24 $14,644

315T4026-27 Supplemental 21 $1,268

Group 1:

NOTE: 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)

Kit Number Name Date QTY

July 1, 10 30 $9,986.00

2009

Top Kit - (JT9D Engine)

Thrust Reverser

Deactivation Pin Change

015T1838-1

June 4, 4 30 $3,523.00

2009

Supplemental Kit -

Thrust Reverser

Deactivation Pin -

Bushing Replacement

015T1838-2

Group 2:

NOTE: 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:

NOTE: 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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
Group 2:

NOTE: 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:

NOTE: 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:

NOTE: 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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
Group 1:

Kit 315T4026

Existing Part Notes

Number

New Part Number QTY Name

-27 -9 -8 -7 -6 -5

315T4026-9 . - . . . . Top Kit - 767 (d) (f)

Engine Kit - Spares (e) (f)

Only

315T4026-8 . . - . . .

Supplemental Top (f)

Kit

315T4026-27 - . . . . .

315T4026-7 . 4 2 - . . Pin Installation

315T4026-6 . 4 2 . - . Insert Installation

315T4026-5 . 4 2 . . - Bushing Installation

315T1604-1,

315T1604-2,

315T1604-3,

315T1604-4 or

315T1604-5

315T1604-6 . . . 1 . . Pin

315T3222-4,

315T3222-5 or

315T3222-6

315T3222-10 . . . . . 1 Bushing

315T4027-1 . . . . 1 . Insert Assembly 315T3563-1 (a) (b)

MS90353-0603 . . . . . 4 Blind Rivet (c)

Kit, Deactivation Pin

- Right T/R

015T0196-2 1 . . . . .

Kit, Deactivation Pin

- Left T/R

015T0196-3 1 . . . . .

(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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
Group 1:

Kit 315T4026

Existing Part Notes

Number

New Part Number QTY Name

-26 -25

315T4026-26 - . Top Kit - 767 (a)

315T4026-25 . - Engine Kit - Spares Only (b)

315T4026-7 4 2 Pin Installation

315T4026-6 4 2 Insert Installation

315T4026-5 4 2 Bushing Installation

Kit, Deactivation Pin -

Right T/R

015T0196-2 2 1

Kit, Deactivation Pin -

Left T/R

015T0196-3 2 1

(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

Existing Part Notes

Number

New Part Number QTY Name

-3 -2

Kit, Deactivation Pin -

Right T/R

015T0196-2 . -

Kit, Deactivation Pin -

Left T/R

015T0196-3 - .

015T0196-4 . 1 Bracket Assy

015T0196-5 1 . Bracket Assy

BACB30NX6K3X 4 4 Hi-Lok

BACC30M6 4 4 Collar

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
Group 2:

Kit 015T1838

Existing Part Notes

Number

New Part Number QTY Name

-2 -1

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 . -

015T0196-4 . 1 Bracket Assy

015T0196-5 . 1 Bracket Assy

315T1604-1,

315T1604-2,

315T1604-3,

315T1604-4 or

315T1604-5

315T1604-6 . 2 Pin

315T3221-1 2 2 Bushing Plate 315T3222-3

315T4027-1 . 2 Insert Assembly 315T3563-1 (b) (c)

BACB30NX6K3X . 8 Hi-Lock

BACB30VX6A03U 8 8 Bolt, Blind

BACC30M6 . 8 Collar

(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:

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
Part Number / QTY Name Notes

Specification

NAS1351-01-6 2 Screw (a) (b)

NAS1351-02-4 2 Screw (c)

MS24665-153 12 Cotter Pin (f)

BMS 3-28 or BAC 16 oz Antisieze Lubricant (k)

5008 Type 7-3

BMS 5-141 4 oz Adhesive (Liquid Shim) (e)

BMS 5-26 Type 1 16 oz Sealant (d)

or Type 2

BMS 5-28, Type 6 8 oz Potting Compound (e)

Loctite 242 4 oz Thread Adhesive (e)

15156 5 Transfer Punch (d)

AP200Y or 12 in Vacuum Bag Sealant Tape (b)

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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
Existing Part QTY Name New Part Number Notes

Number

315T3204-5 2 Aft Cascade Ring Assy 315T3204-21 (a) (b)

315T3204-6 2 Aft Cascade Ring Assy 315T3204-22 (a) (b)

315T3204-7 2 Aft Cascade Ring Assy 315T3204-21 (a) (b)

315T3204-8 2 Aft Cascade Ring Assy 315T3204-22 (a) (b)

315T3500-1 2 T/R Sleeve Assy 315T4026-17 (a) (c)

315T3500-2 2 T/R Sleeve Assy 315T4026-18 (a) (c)

315T3500-21 2 T/R Sleeve Assy 315T4026-19 (a) (c)

315T3500-22 2 T/R Sleeve Assy 315T4026-20 (a) (c)

315T3500-23 2 T/R Sleeve Assy 315T4026-21 (a) (c)

315T3500-24 2 T/R Sleeve Assy 315T4026-22 (a) (c)

315T3500-27 2 T/R Sleeve Assy 315T4026-23 (a) (c)

315T3500-28 2 T/R Sleeve Assy 315T4026-24 (a) (c)

(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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
Group 1:

Quantity Part Number Name

1 315T4026-25 Engine Kit - Spares Only

Group 2:

Quantity Part Number Name

Top Kit - (JT9D Engine) Thurst

Reverser Deactivation Pin

Change

1 015T1838-1

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

Tool Kit Number Name

MIT315T4500 Hole Saw with Pilot $7,500.00

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.

Tool Kit Number Name

MIT315T4500 Hole Saw with Pilot

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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

NOTE: 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

WORK PACKAGE 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.

WORK PACKAGE II - Modification procedures for a thrust reverser that is installed on an airplane

1. Do the Thrust Reverser Deactivation procedures, for all engines, as follows:

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
WARNING: 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:

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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.

WORK PACKAGE III - Modification procedures for a spare thrust reverser

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.

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
FIGURE 1: SHOP AID HOLDER - INNER INSERT

(SHEET 1 OF 2)

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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.

STEP TASK NAME MATERIAL QTY NOTES

1 Layout Stock 2024 or 1 Thickness is 0.112 - 0.100.

7075 or

Other Suitable

Aluminum Alloy

2 Drill Hole - - 1

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.)

3 Install Screw NAS1351-01-6 2

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.)

Vacuum Bag Sealant GS43MR or 2

Tape

4 Install

(AP200Y or

any other type)

as: "PW4000/JT9D T/R (767-78A0080, 767-78A0089, or

747-78A2165) Holder - Inner Insert"

5 Identify Shop Aid Tool

FIGURE 1: SHOP AID HOLDER - INNER INSERT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
FIGURE 2: SHOP AID SPANNER - OUTER INSERT

(SHEET 1 OF 2)

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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.

STEP TASK NAME MATERIAL QTY NOTES

Layout / Stock 2024 or 1 Thickness is 0.112 - 0.100.

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 Install Screw NAS1351-02-4 2

as: "PW4000/JT9D T/R (767-78A0080, 767-78A0089, or

747-78A2165) Spanner - Outer Insert"

3 Identify Shop Aid Tool

FIGURE 2: SHOP AID SPANNER - OUTER INSERT

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT

(SHEET 1 OF 3)

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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)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

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.

Upper Hydraulic 415CL (left engine outboard) 3

Actuator Access

Panel:

Remove /

Keep

1

416CR (left engine inboard)

426CR (right engine outboard)

425CL (right engine inboard)

Middle Hydraulic 415DL (left engine outboard)

Actuator Access

Panel: 416DR (left engine inboard)

426DR (right engine outboard)

425DL (right engine inboard)

Lower Hydraulic 415EL (left engine outboard)

Actuator Access

Panel: 416ER (left engine inboard)

426ER (right engine outboard)

425EL (right engine inboard)

2 Remove Cotter Pin MS24665-153 3

Remove / Nut BACN10JD105 3

Keep Washer AN960-516 6

Bolt NAS6705D18 3

Bushing NAS74A5E006P 3

by hand, all the way to

the deploy position.

3 Translate Reverser Sleeve - - 1

FIGURE 3: REVERSER SLEEVE TRANSLATION - ACCESS TO BUSHING AND INSERT

(SHEET 3 OF 3)

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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)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING

(SHEET 2 OF 5)

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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)

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July 19, 2001

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

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 Move Reverser Sleeve - - 1

by drilling out countersunk rivet

heads.

2 Remove Bushing Square 315T3222-4, -5, or -6 1

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.

3 Chamfer Hole - - 1

4 Oversize Rivet Holes - - 4 to a diameter of 0.199 - 0.201.

Dye penetrant inspect for cracks.

Refer to SOPM 20-20-02 as an

accepted procedure. (a)

5 Inspect Rivet Holes - - 4

6 Put Transfer Punch 15156 4 into the rivet holes.

in PROPER orientation as shown

to transfer the center mark of the

transfer punch to the bushing

plate.

7 Mount Bushing Plate 315T3222-10 1

Remove Bushing Plate 315T3222-10 1 from cascade ring.

into bushing plate. Diameter is

0.199 - 0.202.

Drill Rivet Holes - - 4

8 Remove Transfer Punch 15156 4

on cascade ring of any previous

sealant in the area the bushing

plate will cover. Ref. 767 AMM

51-31-01.

9 Clean Surface - - -

to cascade ring. The area for the

bushing plate. Ref. 767 AMM

51-31-01.

10 Apply Fay Seal BMS5-26 -

11 Install Bushing Plate 315T3222-10 1 in PROPER orientation as shown.

Blind Rivet MS90353-0603 4 Wet install with BMS5-26. Refer

FIGURE 4: BUSHING REPLACEMENT - AFT CASCADE RING

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

to SOPM 20-50-19 as an

accepted procedure.

with BMS5-26. Ref. 767 AMM

51-31-01.

Fillet Seal Bushing Plate Edges - - -

to new part number shown in

Paragraph 2.C.3., Parts Modified

and Reidentified and the SOPM

20-50-10, Paragraph 6, Rubber

Stamping.

Aft Cascade Ring ( ) 1

Part Number

12 Change

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)

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ALERT ALERT
FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE

(SHEET 2 OF 3)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

slowly, by your hand, to the

deploy position.

1 Move Reverser Sleeve - - 1

2 Thread Saw Pilot Bushing MIT315T4500-3 1 in the deactivation pin hole.

3 Locate Hole Saw with Arbor MIT315T4500-2/-5 1 to installed pilot

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.

4 Cut Out Inbedded Insert - - 1

Remove Inbedded Insert - - when it spins within the hole.

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.

5 Locate Hole Saw with Arbor MIT315T4500-2/-5 1

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

6 Cut thru

FIGURE 5: INSERT REMOVAL FROM REVERSER SLEEVE

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 6: NEW INSERT FIT CHECK

(SHEET 1 OF 6)

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ALERT ALERT
FIGURE 6: NEW INSERT FIT CHECK

(SHEET 2 OF 6)

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ALERT ALERT
FIGURE 6: NEW INSERT FIT CHECK

(SHEET 3 OF 6)

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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)

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ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

for sharp edges. Remove as

necessary. Hole sides should be

clean with no ragged edges and

sides are not broken through.

1 Inspect Hole - - 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.

Measure Hole - - 1

to be sure their shoulders will fit

in the hole.

2 Check Inner Insert 315T4027-4 1

Outer Insert 315T4027-2 1

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.

3 Attach Inner Insert 315T4027-4 1 to holder tool.

as shown. Do not remove holder

tool from inner insert.

4 Install Inner Insert 315T4027-4 1

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.

5 Install Outer Insert 315T4027-2 1 Use spanner to tighten.

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.

6 Release Holder Tool - - 1 from inner insert.

Remove Holder Tool - - 1 from access.

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.

7 Look At Inner Insert 315T4027-4 1

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.

8 Check Outer Insert 315T4027-2 1

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)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

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.

9 Move Reverser Sleeve - - 1

CAUTION: DO NOT SCREW IN DEACTIVATION PIN INTO THE OUTER INSERT.

10 Place New Deactivation Pin 315T1604-6 1 into outer insert.

goes into bushing without the pin

being screwed in.

Verify Pin End - - -

Remove New Deactivation Pin 315T1604-6 1

11 Move Reverser sleeve - - 1 to the deploy position.

12 Remove Outer Insert 315T4027-2 1

Inner Insert 315T4027-4 1

FIGURE 6: NEW INSERT FIT CHECK

(SHEET 6 OF 6)

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ALERT ALERT
FIGURE 7: INSERT INSTALLATION

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 7: INSERT INSTALLATION

(SHEET 2 OF 5)

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July 19, 2001

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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)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

on outer surface of sleeve panel

as shown.You may go beyond

the flange diameter of the outer

insert by 0.150 inches.

1 Remove Paint - - -

2 Clean Hole - - 1 Ref. 767 AMM 51-31-01.

to inner and outer inserts as

shown. Apply enough to fill gaps

under flanges when inserts are

installed. Ref. 767 AMM

51-31-01.

Adhesive (liquid BMS5-141 -

Shim)

3 Apply

4 Apply Thread Adhesive Loctite 242 - to thread of outer insert.

5 Attach Inner Insert 315T4027-4 1 to holder tool.

as shown. Do not remove holder

tool from inner insert.

6 Install Inner Insert 315T4027-4 1

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.

7 Install Outer Insert 315T4027-2 1 Use spanner to tighten.

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.

8 Release Holder Tool - - 1 from inner insert.

Remove Holder Tool - - 1 from access.

Spanner Tool 1 from outer insert

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

9 Look At Inner Insert 315T4027-4 1

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.

10 Check Outer Insert 315T4027-2 1

FIGURE 7: INSERT INSTALLATION

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

11 deactivation pin hole, to prevent

potting compound from getting in.

Tape Outer Insert 315T4027-2 1

in lower hole, slowly, until it

comes out the upper hole in a

long stream, without air.

12 Inject Potting Compound BMS5-28, Type 6 -

Tape Injections Holes - - 2 shut and let compound cure.

to new part number shown in

Paragraph 2.C.3., Parts Modified

and Reidentified and the SOPM

20-50-10, Paragraph 6, Rubber

Stamping.

Reverser Sleeve Part ( ) 1

Number

13 Change

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)

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ALERT ALERT
FIGURE 8: RECONNECTION OF LINEAR ACTUATOR

(SHEET 1 OF 2)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

by hand, all the way to stow. Be

careful to position the actuators

into the clevis of the sleeve.

1 Translate Reverser Sleeve - - 1

2 Install Cotter Pin MS24665-153 3

Install / Nut BACN10JD105 3

Kept Washer AN960-516 6

Bolt NAS6705D18 3

Bushing NAS74A5E006P 3

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)

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ALERT ALERT
FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN

REPLACEMENT

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN

REPLACEMENT

(SHEET 2 OF 4)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

from the stowage area on

reverser.

315T1604-1, 2

315T1604-2,

315T1604-3,

315T1604-4, or

315T1604--5

Remove / Deactivation Pin

Discard

1

Remove / Fastener, Existing - 8

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.

3 Install Bracket Assy 015T0196-4 1

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.

015T0196-5 1

Hi-Lok BACB30NX6K3X 8

Collar BACC30M6 8

in the stowage area on the

reverser.

4 Install Deactivation Pin 315T1604-6 2

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)

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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.

HOLE NOTES

DIA

CODE NAME PART NUMBER

Install with fastener head

on the far side.

0.218 -

0.229

A Hi-Lok BACB30NX6K3X

Collar BACC30M6 -

FIGURE 9: DEACTIVATION PIN STOWAGE BRACKET INSTALLATION AND DEACTIVATION PIN

REPLACEMENT

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
FIGURE 10: MARK THRUST REVERSER ID PLATE WITH SERVICE BULLETIN NUMBER

(SHEET 1 OF 2)

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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.

STEP TASK NAME PART NUMBER QTY NOTES

as shown in SOPM 20-50-10.

STAMPED TEXT:

SB767-78A0089 R3

Modification - -

Number

1 Stamp

FIGURE 10: MARK THRUST REVERSER ID PLATE WITH SERVICE BULLETIN NUMBER

(SHEET 2 OF 2)

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ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING

(SHEET 1 OF 5)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING

(SHEET 2 OF 5)

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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)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

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 Move Reverser Sleeve - - 1

by drilling out countersunk rivet

heads.

2 Remove Bushing Square 315T3222-3 1

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.

3 Chamfer Hole - - 1

4 Oversize Rivet Holes - - 4 to a diameter of 0.199 - 0.201.

Dye penetrant inspect for cracks.

Refer to SOPM 20-20-02 as an

accepted procedure. (a)

5 Inspect Rivet Holes - - - -

6 Put Transfer Punch 15156 4 into the rivet holes.

in PROPER orientation as shown

to transfer the center mark of the

transfer punch to the bushing

plate.

7 Mount Bushing Plate 315T3221-1 1

Remove Bushing Plate 315T3221-1 1 from cascade ring.

into bushing plate. Diameter is

0.199 - 0.202.

Drill Rivet Holes - - 4

8 Remove Transfer Punch 15156 4

on cascade ring of any previous

sealant in the area the bushing

plate will cover. Ref. 767 AMM

51-31-01.

9 Clean Surface - - -

to cascade ring. The area for the

bushing plate. Ref. 767 AMM

51-31-01.

10 Apply Fay Seal BMS5-26 -

11 Install Bushing Plate 315T3221-1 1 in PROPER orientation as shown.

Bolt, Blind BACB30VX6A03U 4 Wet install with BMS5-26. Refer

FIGURE 11: BUSHING REPLACEMENT - AFT CASCADE RING

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 767-78A0089

ALERT ALERT
STEP TASK NAME PART NUMBER QTY NOTES

to SOPM 20-50-19 as an

accepted procedure.

with BMS5-26. Ref. 767 AMM

51-31-01.

Fillet Seal Bushing Plate Edges - - -

to new part number shown in

Paragraph 2.C.3., Parts Modified

and Reidentified and the SOPM

20-50-10, Paragraph 6, Rubber

Stamping.

Aft Cascade Ring ( ) 1

Part Number

12 Change

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)

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ALERT ALERT