Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-25A0505

Original Issue: January 14, 2011

ATA System: 2550

SUBJECT: EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water

Incursion Change

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 © 2011 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Unpublished Work - All Rights Reserved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, KC-10, KDC-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Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

1 of 60

4.0
BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

2 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT

BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 7

A. Effectivity ................................................ 7

1. Airplanes ............................................. 7

2. Spares Affected ......................................... 7

B. Concurrent Requirements ....................................... 7

C. Reason ................................................. 8

D. Description ............................................... 8

E. Compliance .............................................. 8

F. Approval ................................................ 8

G. Manpower ............................................... 9

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 10

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 19

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE [Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD

SUPPORT ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING

SUPPORTS AND INSTALL SUPPORT AT STATION 368 . . . . . . . . . . . . . . . . . . 39

FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING . . . 47

FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS [Group

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

3 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND

RUB STRIP [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

4 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-25A0505

Original Issue: January 14, 2011

ATA System: 2550

SUBJECT: EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water

Incursion Change

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

This service bulletin and a kit of parts provides retrofit instructions to improve water drainage in the lower lobe.

Water coming through the floor panels can accumulate up to 12 gallons in this location and typical aircraft

movement may not remove all the water. There is a potential for water to enter the electronic equipment bay.

Installation of parts assist in water drainage and will prevent water from getting into the electronic equipment

bay. If parts are not installed possible water damage could occur to electronic equipment which could result in

an electrical short and potential loss of several functions essential for safe flight.

Boeing Service Related Problem (SRP) 767-SRP-25-0290 is related to this service bulletin.

ACTION (PRR F06004-1RS)

Install 2 drains, dam and new support structure.

EFFECTIVITY

767-300 and 767-200 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

Boeing recommends that operator accomplish the instructions provided in this bulletin within 24 months after

the Original Issue date on this service bulletin.

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

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

mandatory.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

5 of 60
INDUSTRY SUPPORT INFORMATION

Group 1:

Boeing warranty remedies are available for airplanes in warranty as of November 5, 2009. Please refer to

Paragraph 2.B., Industry Support Information.

Group 2:

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

Group 1:

Airplanes Total Task Hours Elapsed Hours

767-300BCF 16.00 8.50

Group 2:

Airplanes Total Task Hours Elapsed Hours

767-200SF 16.00 8.50

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

6 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-25A0505

Original Issue: January 14, 2011

ATA System: 2550

SUBJECT: EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water

Incursion Change

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

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent

production airplanes. Refer to PRR F06004-1RS for data about this change.

GROUP CONFIGURATION DESCRIPTION

1 - 767-300BCF for VN191-VN195

2 - 767-200SF for VA511

Airplane Models:

767-200, 767-300

Variable Number Group

VA511 2

VN191 - VN195 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

7 of 60
C. Reason

This service bulletin and a kit of parts provides retrofit instructions to improve water drainage in the

lower lobe. Water coming through the floor panels can accumulate up to 12 gallons in this location and

typical aircraft movement may not remove all the water. There is a potential for water to enter the

electronic equipment bay. Installation of parts assist in water drainage and will prevent water from

getting into the electronic equipment bay. If parts are not installed possible water damage could occur

to electronic equipment which could result in an electrical short and potential loss of several functions

essential for safe flight.

Boeing Service Related Problem (SRP) 767-SRP-25-0290 is related to this service bulletin.

D. Description

Installs 2 drains, dam and new support structure.

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

Group 1:

Affected Maintenance Zones

Model Zone

767-300 119, 121, 122

Group 2:

Affected Maintenance Zones

Model Zone

767-200 119, 121, 122

E. Compliance

Boeing recommends that operator accomplish the instructions provided in this bulletin within 24 months

after the Original Issue date on this service bulletin.

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

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

service bulletin mandatory.

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 for all 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.

Original Issue: January 14, 2011

767-25A0505

8 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
G. Manpower

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

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Group 1:

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 1 2 3.00 1.50

Figure 2 2 1.00 0.50

Figure 3 2 3.00 1.50

Figure 4 2 2.50 1.25

Figure 5 2 2.50 1.25

Figure 6 2 3.00 1.50

Close Access 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 16.00 8.50

Group 2:

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 7 2 3.00 1.50

Figure 2 2 1.00 0.50

Figure 3 2 3.00 1.50

Figure 4 2 2.50 1.25

Figure 5 2 2.50 1.25

Figure 8 2 3.00 1.50

Close Access 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 16.00 8.50

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

9 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
H. Weight and Balance Changes

Group 1:

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

767-300BCF +2.6 +408.0

Group 2:

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

767-200SF +3.5 +902.0

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Engineering Change Memo PRR F06004-1RS

b. Boeing Service Related Problem (SRP) 767-SRP-25-0290

c. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-50-01, 20-50-19

d. 767 Aircraft Maintenance Manual (AMM) 25-52-02

e. 767-200SF Structural Repair Manual (SRM) 51-40-02

f. 767-300BCF Structural Repair Manual (SRM) 51, 51, 51-40-02, 51-40-08

2. Data supplied with this Service Bulletin

None.

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

Drawing Number Title

453T1104 SUPP0RT INSTALLATION - END LINING, STA 355,

657T4640 LINING INSTL - CEILING, FWD LWR CARGO COMPT, MOD

657T4641 SUPPORT INSTL - CEILING, FWD LWR CARGO COMPT, MOD

845T3108 LINING INSTL - CEILING, LWR CARGO COMPT, MOD

845T3109 SUPPORT INSTL - CEILING, LWR CARGO COMPT (MOD)

845T3154 STA 355 ENDWALL ASSY - REWORK INSTL

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

10 of 60

BOEING SERVICE BULLETIN 767-25A0505

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

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

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

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

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

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

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

11 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

12 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

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

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

kit is subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

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

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

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

2. Fax to (206) 662-7145

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

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

Unit Price as of the original

issue date of this Service

Bulletin (US Dollars)

Kit Number Name QTY

767-300BCF Water Management 1 $27,077.00

Retrofit Kit

880T0026-1

767-200SF Water Management Retrofit 1 $26,844.00

Kit

880T0026-2

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

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

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

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

2. Fax to (206) 662-7145

B. Industry Support Information

Group 1:

Boeing warranty remedies are available for 767 airplanes in warranty as of November 5, 2009. For

task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

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

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

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

Group 2:

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

13 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
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.

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

the Operator, are necessary for each airplane.

Group 1:

Kit 880T0026-1

New Part Number QTY Name Existing Part Number Notes

767-300BCF Water Management Retrofit Kit880T0026-1 -

845T3108-21 1 CEILING LINER 845T3108-11

845T3108-22 1 CEILING LINER 845T3108-12

845T3108-23 1 CEILING LINER 845T3108-13

845T3108-32 1 CEILING LINER 845T3108-12

845T3109-41 1 SUPPORT ASSY 845T3109-29

845T3109-42 1 SUPPORT ASSY 657T1137-1

Or

IDR-767-25-0406-0065-5

Or

IDR-767-25-0420-0010-5

Or

IDR-767-25-0424-0017-5

Or

IDR-767-25-0433-0002-5

845T3109-47 4 SUPPORT

845T3109-48 1 TUBE

845T3109-49 1 TUBE

845T3109-51 1 SUPPORT ASSY

845T3109-52 2 SPUD ASSY

845T3109-53 1 CLOSURE BLOCK DETAIL

845T3109-58 1 CLOSURE BLOCK DETAIL

845T3109-61 1 LEFT SUPPORT ASSY 845T3109-25

845T3109-62 1 SUPPORT ASSY

845T3109-64 1 RIGHT SUPPORT ASSY 845T3109-25

845T3109-70 1 SUPPORT ASSY

845T3109-71 1 SUPPORT ASSY

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

14 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
Group 1:

Kit 880T0026-1

New Part Number QTY Name Existing Part Number Notes

845T3109-73 1 SUPPORT ASSY 453T1541-1

845T3109-75 1 SUPPORT ASSY

845T3154-14 2 SUPPORT ASSY

845T3154-15 1 SUPPORT ASSY 453T1602-6

845T3154-16 1 SUPPORT ASSY 453T1602-7

845T3154-17 1 SUPPORT ASSY 453T1602-8

BACB30NT3K2 10 BOLT, PAN HD, CROSS (a)

BACB30VT5HK3 4 BOLT, PROTRUDING HD (a)

BACB30VT6K5 20 BOLT (a)

BACC10D616A 12 CLAMP, LOOP (a)

BACC10DK16 6 CLAMP, LOOP (a)

BACC10JB022C040 4 CLAMP, HOSE (a)

BACN10JC3CD 7 NUT (a)

BACN10YR08CM 14 NUT (a)

BACN10YR3CM 16 NUT (a)

BACN10ZV08 4 NUT (a)

BACN10ZV3 20 NUT (a)

BACR15BB4D5C 12 RIVET, UNIVERSAL HEAD (a)

BACR15BB5D5C 20 RIVET (a)

BACR15BB5D6C 10 RIVET, UNIVERSAL HD (a)

BACS12ER3K6 36 SCREW, 100 DEG HEAD (a)

BACS12FA08K15 4 SCREW (a)

BACS12FA08K22 4 SCREW, WASHER HEAD (a)

BACS12FA3K10 10 FAIRING SCREWS (a)

BACS12FA3K14 50 SCREW, WASHER HEAD (a)

BACS12FA3K8 212 SCREW, WASHER HEAD (a)

BACS12GU3K10 6 SCREW (a)

BACS12GX08A16 4 SCREW (a)

BACS12GX08A22 4 SCREW (a)

BACS12GX3A8 11 SCREW (a)

BACS12HJ3K6 10 SCREW (a)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

15 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
Group 1:

Kit 880T0026-1

New Part Number QTY Name Existing Part Number Notes

BACS38K1 4 STRAP (a)

BACS40R008D010F 6 SHIM,LAMINATED (a)

BACS40R008D012F 8 SHIM,LAMINATED (a)

BACW10P136AL 10 WASHER (a)

BACW10P151AL 10 WASHER, PLAIN (a)

BACW10P183AL 4 WASHER, PLAIN (a)

NAS1149D0332J 13 WASHER (a)

(a) There are more parts than are necessary.

Group 2:

Kit 880T0026-2

New Part Number QTY Name Existing Part Number Notes

767-200SF Water Management

Retrofit Kit

880T0026-2 -

657T4640-41 1 CEILING LINER 657T4640-7

657T4640-42 1 CEILING LINER 657T4640-32

657T4640-43 1 CEILING LINER 657T4640-29

657T4640-44 1 CEILING LINER 657T4640-32

845T3109-41 1 SUPPORT ASSY

845T3109-42 1 SUPPORT ASSY 657T1137-4

845T3109-47 4 SUPPORT

845T3109-48 1 TUBE

845T3109-49 1 TUBE

845T3109-51 1 SUPPORT ASSY

845T3109-52 2 SPUD ASSY

845T3109-53 1 CLOSURE BLOCK DETAIL

845T3109-58 1 CLOSURE BLOCK DETAIL

845T3109-61 1 LEFT SUPPORT ASSY 845T3109-25

845T3109-62 1 SUPPORT ASSY 657T4661-12

845T3109-64 1 RIGHT SUPPORT ASSY 657T4661-13

845T3109-70 1 SUPPORT ASSY

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

16 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
Group 2:

Kit 880T0026-2

New Part Number QTY Name Existing Part Number Notes

845T3109-71 1 SUPPORT ASSY

845T3109-73 1 SUPPORT ASSY 453T1541-1

845T3109-75 1 SUPPORT ASSY

845T3154-14 2 SUPPORT ASSY

845T3154-15 1 SUPPORT ASSY 453T1602-6

845T3154-16 1 SUPPORT ASSY 453T1602-7

845T3154-17 1 SUPPORT ASSY 453T1602-8

BACB30NT3K2 10 BOLT, PAN HD, CROSS (a)

BACB30VT5HK3 4 BOLT, PROTRUDING HD (a)

BACB30VT6K5 20 BOLT (a)

BACC10D616A 12 CLAMP, LOOP (a)

BACC10DK16 6 CLAMP, LOOP (a)

BACC10JB022C040 4 CLAMP, HOSE (a)

BACN10JC3CD 7 NUT (a)

BACN10YR08CM 14 NUT (a)

BACN10YR3CM 16 NUT (a)

BACN10ZV08 4 NUT (a)

BACN10ZV3 20 NUT (a)

BACR15BB4D5C 12 RIVET, UNIVERSAL HEAD (a)

BACR15BB5D5C 20 RIVET (a)

BACR15BB5D6C 10 RIVET, UNIVERSAL HD (a)

BACS12ER3K6 36 SCREW, 100 DEG HEAD (a)

BACS12FA08K15 4 SCREW (a)

BACS12FA08K22 4 SCREW, WASHER HEAD (a)

BACS12FA3K10 10 FAIRING SCREWS (a)

BACS12FA3K14 50 SCREW, WASHER HEAD (a)

BACS12FA3K8 212 SCREW, WASHER HEAD (a)

BACS12GU3K10 6 SCREW (a)

BACS12GX08A16 4 SCREW (a)

BACS12GX08A22 4 SCREW (a)

BACS12GX3A8 11 SCREW (a)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

17 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
Group 2:

Kit 880T0026-2

New Part Number QTY Name Existing Part Number Notes

BACS12HJ3K6 10 SCREW (a)

BACS38K1 4 STRAP (a)

BACS40R008D010F 6 SHIM,LAMINATED (a)

BACS40R008D012F 8 SHIM,LAMINATED (a)

BACW10P136AL 10 WASHER (a)

BACW10P151AL 10 WASHER, PLAIN (a)

BACW10P183AL 4 WASHER, PLAIN (a)

NAS1149D0332J 13 WASHER (a)

(a) There are more parts than are necessary.

2. Parts and Materials Supplied by the Operator

Part Number / QTY Name Notes

Specification

657T4640-101 1 Roll TAPE - SEALING (a) (b)

Equivalent to BMS 5-146, Class 1,

Type I, Grade A.

657T4640-102 1 Roll TAPE - DOUBLEBACK (a) (c)

Equivalent to BMS 5-133, Class 1,

Type IV.

1 Sealant (d)

Quart

Pro-Seal 870

BMS 5-95, Class B.

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

supplier data.

(b) Can be procured from 3M Company, 1425 Stokke Parkway, Menomonie, WI 54751.

(c) Can be procured from Orcon Corporation, 1570 Atlantic Street, Union City, CA 94587–3299

(d) Can be procured from PRC-DeSoto International, Incorporated, Post Office Box 1800,

Sylmar, CA 91342-3728

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

18 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

19 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

20 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

NOTE: 1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

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

definition of the acronyms.

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

4. 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 in 767-300BCF SRM 51 Structural

Repair Manual (SRM) 51

– Torque limits to tighten nuts and bolts are in 767-300BCF SRM 51.

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

767-300BCF SRM 51. Alternate fasteners are listed in 767-300BCF SRM 51 and

Boeing Drawing 012W6100.

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

installation standards in 767-300BCF SRM 51, then a fastener of the same

specification, or an approved substitute, with a length which meets the installation

standards in 767-300BCF SRM 51 may be used.

7. Fay surface seal the lower surface of z-support bracket assy and the upper surface

of drain fitting using BMS 5-95. Within the sealant's application time, apply sealant

to upper surface of the fitting. Apply sealant to the surface with sufficient thickness

required to fill the assembled faying surfaces and to give continuous and visible

squeeze-out at the faying surface joints. Refer to SOPM 20-50-19 as an accepted

procedure.

8. Apply BMS 5-95, Class "C" sealant to fasteners using method 2. Extruded sealant

shall be continuous to indicate adequate sealing. Do not remove sealant from fastener

threads prior to nut installation. Apply Class "B" sealant fillet around fastener after

installation. Apply sealant so as to form a visually uniform coating which completely

covers the fastener. Application to be completed within application time of sealant.

Refer to SOPM 20-50-19 as an accepted procedure.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

21 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
9. Proper routing for right side hose into the bilge shall be determined by mock-up.

Extra length of tubing was provided by design. Trim the excess as required when

proper routing is accomplished. If required, usage of two extra plastic straps

BACS38K1 is acceptable.

10. Proper routing for left side hose shall be determined by mock-up. The supports

brackets shall be installed to the cargo bulkhead approximately 16 inches apart, with

a tolerance of +/- 2.50 inches. Horizontal adjustment of about 0.6 inches is permitted

by support bracket design. Extra length of tubing was provided by design - trim the

excess as required when proper routing is accomplished. If required, usage of extra

two plastic straps BACS38K1 is acceptable.

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

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

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

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

must be used.

B. WORK INSTRUCTIONS

Group 1:

1. Gain access to forward side of cargo bulkhead through door 119AL.

2. Gain access to aft side of cargo bulkhead through the forward cargo door.

3. Remove ceiling liners and structure in accordance with FIGURE 1.

4. Install cargo bulkhead support in accordance with FIGURE 2.

5. Install right side ceiling supports in accordance with FIGURE 3.

6. Install left side ceiling supports and install support (secondary dam) at station 368 in accordance

with FIGURE 4.

7. Install drain tubing in accordance with FIGURE 5.

8. Install ceiling panels in accordance with FIGURE 6.

9. Put the airplane back to a serviceable condition.

Group 2:

1. Gain access to forward side of cargo bulkhead through door 119AL.

2. Gain access to aft side of cargo bulkhead through the forward cargo door.

3. Remove ceiling liners and structure in accordance with FIGURE 7.

4. Install cargo bulkhead support in accordance with FIGURE 2.

5. Install right side ceiling supports in accordance with FIGURE 3.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

22 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
6. Install left side ceiling supports and install support (secondary dam) at station 368 in accordance

with FIGURE 4.

7. Install drain tubing in accordance with FIGURE 5.

8. Install ceiling panels in accordance with FIGURE 8.

9. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

23 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
This Figure applies only to: Group 1.

FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 1 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

24 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 2 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

25 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 3 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

26 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane..

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove CEILING LINER 845T3108-11 1 (a)

2 Remove CEILING LINER 845T3108-12 1 (a) (b)

3 Remove CEILING LINER 845T3108-13 1 (a) (b)

IDR-767-25-0406-0087- 2 (c) For VN191

3

4 Remove SUPPORT BRACKET

IDR-767-25-0420-0081- 2 (c) For VN192

3

Remove SUPPORT BRACKET

IDR-767-25-0424-0065- 2 (c) For VN193

3

Remove SUPPORT BRACKET

IDR-767-25-0433-0044- 2 (c) For VN194

3

Remove SUPPORT BRACKET

Remove SUPPORT BRACKET 657T4664-1 2 (c) For VN195

IDR-767-25-0406-0065- 1 For VN191

5

STABILIZATION

STRAP ASSY

5 Remove

IDR-767-25-0420-0010- 1 For VN192

5

STABILIZATION

STRAP ASSY

Remove

IDR-767-25-0424-0017- 1 For VN193

5

STABILIZATION

STRAP ASSY

Remove

IDR-767-25-0433-0002- 1 For VN194

5

STABILIZATION

STRAP ASSY

Remove

STABILIZATION 657T1137-4 1 For VN195.

STRAP ASSY

Remove

6 Remove SUPPORT ASSY 845T3109-25 1

7 Remove SUPPORT ASSY 845T3109-29 1

8 Remove SUPPORT 453T1602-6 1

9 Remove SUPPORT 453T1602-7 1

10 Remove SUPPORT 453T1602-8 1

(a) Refer to 767 AMM 25-52-02 as an accepted procedure.

(b) Panel can be used as a template to layout cut-outs in the new panels.

(c) Plug any open holes left by removing the support brackets with AD rivet. Refer to 767-300BCF SRM 51-

40-02 as an accepted procedure.

FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 4 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

27 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT

ASSEMBLIES

(SHEET 1 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

28 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT

ASSEMBLIES

(SHEET 2 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

29 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Install (New) SUPPORT ASSY 845T3154-15 1

2 Install (New) SUPPORT ASSY 845T3154-16 1

3 Install (New) SUPPORT ASSY 845T3154-17 1

4 Install (New) SUPPORT ASSY 845T3154-14 2

SCREW, 100 DEG BACS12ER3K6 8 (a)

HEAD

5 Install (New)

SCREW, 100 DEG BACS12ER3K6 8

HEAD

6 Install (New)

SCREW, 100 DEG BACS12ER3K6 2 (a)

HEAD

7 Install (New)

SCREW, 100 DEG BACS12ER3K6 1 (a)

HEAD

8 Install (New)

SCREW, 100 DEG BACS12ER3K6 2 (a)

HEAD

9 Install (New)

SCREW, 100 DEG BACS12ER3K6 6 (a)

HEAD

10 Install (New)

(a) Drill 0.2180 - 0.2290 diameter hole from hole in existing structure. Countersink 0.2610 - 0.2710 X 100

degree (near side). Refer to 767-300BCF SRM 51-40-08 as an accepted procedure.

FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT

ASSEMBLIES

(SHEET 3 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

30 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 1 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

31 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 2 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

32 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 3 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

33 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 4 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

34 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 5 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

35 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane..

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove SUPPORT ASSY 453T1541-1 1

Gap to be 0.1500 +/-

0.0100 between

Support Assemblies.

2 Install (New) SUPPORT ASSY 845T3109-42 1

Fay seal mating surfaces of cargo bulkhead support assembly with BMS 5-95.

Refer to SOPM 20-

50-19 as an accepted procedure.

Gap to be 0.1500 +/-

0.0100 between

Support Assemblies.

3 Install (New) SUPPORT ASSY 845T3109-62 1

BOLT, PAN HD, BACB30NT3K2 2 (a)

CROSS

4 Install (New)

5 Install (New) SUPPORT ASSY 845T3109-51 1 (b)

Drill 0.1610 / 0.1640

diameter holes from

pilot holes in Support Assy.

BOLT, PROTRUDING BACB30VT5HK3 2

HD

Install (New)

Install (New) NUT BACN10ZV08 2

Install (New) WASHER, PLAIN BACW10P183AL 2

RIGHT SUPPORT AS- 845T3109-64 1

SY

6 Install (New)

Install (New) SHIM,LAMINATED BACS40R008D012F 2 (c)

BOLT, PAN HD, BACB30NT3K2 2 (a)

CROSS

Install (New)

Drill holes from pilot

holes in Support Assy.

RIVET, UNIVERSAL BACR15BB5D6C 4

HD

Install (New)

FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 6 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

36 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

7 Install (New) SUPPORT ASSY 845T3109-73 1

Drill from holes in

existing structure.

Install (New) RIVET BACR15BB5D5C 2

Install (New) BOLT BACB30VT6K5 1

Install under head of

bolt.

Install (New) WASHER, PLAIN BACW10P151AL 1

Install (New) NUT BACN10ZV3 1 (d)

8 Install (New) BOLT BACB30VT6K5 4

Install under head of

bolt.

Install (New) WASHER, PLAIN BACW10P151AL 4

Install (New) NUT BACN10ZV3 4 (d)

Install in accordance

with Accomplishment Instructions,

General Information

Note 7 and 8.

9 Install (New) SPUD ASSY 845T3109-52 1

Install in accordance

with Accomplishment Instructions,

General Information

Note 7 and 8.

Install (New) SCREW BACS12HJ3K6 4

Install in accordance

with Accomplishment Instructions,

General Information

Note 7 and 8.

Install (New) NUT BACN10YR3CM 4

CLOSURE BLOCK 845T3109-58 1 (e) (f)

DETAIL

10 Install (New)

11 Install (New) SUPPORT ASSY 845T3109-70 1 (f)

SCREW, WASHER BACS12FA3K8 4

HEAD

12 Install (New)

13 Install (New) SCREW BACS12FA08K15 1 (g)

Install in accordance

with Accomplishment Instructions,

General Information

Note 8.

Install (New) NUT BACN10YR08CM 1

FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 7 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

37 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

SCREW, WASHER BACS12FA08K22 1 (g)

HEAD

14 Install (New)

Install (New) NUT BACN10YR08CM 1

15 Install (New) SCREW BACS12GX08A16 1 (g) (h)

Install (New) NUT BACN10YR08CM 1

16 Install (New) SCREW BACS12GX08A22 1 (g) (h)

Install (New) NUT BACN10YR08CM 1

17 Install (New) SCREW BACS12GX3A8 1 (i)

18 Apply SEALANT PRO-SEAL 870 - (j)

(a) Leave a 0.005-0.010 clearance between bolt head and support structure.

(b) Locate support assy Fwd/Aft, by mock-up. A good location shall perfectly nest the two small structural

supports and shall clear all other structural parts and adjacent fasteners. If needed, it is acceptable to locally trim this support assy, along the edge, without compromising the edge margins. Trim area shall not

be more than 0.1 inch from the part trimline and shall not exceed 0.5 inches in length.

(c) Strip .003 laminations if and as required. Install shims wet and finish cut edges with BMS 10-11, type 1

yellow primer. Refer to SOPM 20-41-02 as an accepted procedure.

(d) Torque nut to 20-25 In-Lbs. Refer to SOPM 20-50-01 as an accepted procedure.

(e) The aft face of cargo bulkhead support assembly and the aft face of closure block detail need to be flush.

(f) Fay seal all mating surfaces with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure.

(g) Drill hole through mating parts from hole in 845T3109-58 to 0.1920 - 0.2030 diameter.

(h) Countersink near side 0.332 - 0.319 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted

procedure.

(i) Countersink near side 0.385 - 0.371 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted

procedure.

(j) Fillet seal all visible edges and gap seal all gaps with BMS 5-95. Refer to SOPM 20-50-19 as an accepted

procedure.

FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING

SUPPORTS

(SHEET 8 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

38 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 1 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

39 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 2 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

40 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 3 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

41 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 4 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

42 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 5 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

43 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane..

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Gap to be 0.1500 +/-

0.0100 between

Support Assemblies.

1 Install (New) SUPPORT ASSY 845T3109-41 1

2 Install (New) LEFT SUPPORT ASSY 845T3109-61 1

Install (New) SHIM,LAMINATED BACS40R008D012F 2 (a)

BOLT, PAN HD, BACB30NT3K2 2 (b)

CROSS

Install (New)

Drill holes from pilot

holes in Support Assy.

RIVET, UNIVERSAL BACR15BB5D6C 4

HD

Install (New)

FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 6 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

44 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

3 Install (New) BOLT BACB30VT6K5 1

Install under head of

bolt.

Install (New) WASHER BACW10P136AL 1

Install (New) NUT BACN10ZV3 1 (c)

Install in accordance

with Accomplishment Instructions,

General Information

Note 7 and 8.

4 Install (New) SPUD ASSY 845T3109-52 1

Install in accordance

with Accomplishment Instructions,

General Information

Note 7 and 8.

Install (New) SCREW BACS12HJ3K6 4

Install in accordance

with Accomplishment Instructions,

General Information

Note 7 and 8.

Install (New) NUT BACN10YR3CM 4

CLOSURE BLOCK 845T3109-53 1 (d) (e)

DETAIL

5 Install (New)

6 Install (New) SUPPORT ASSY 845T3109-71 1 (e)

SCREW, WASHER BACS12FA3K8 4

HEAD

7 Install (New)

8 Install (New) SCREW BACS12FA08K15 1 (f)

Install in accordance

with Accomplishment Instructions,

General Information

Note 8.

Install (New) NUT BACN10YR08CM 1

SCREW, WASHER BACS12FA08K22 1 (f)

HEAD

9 Install (New)

Install (New) NUT BACN10YR08CM 1

10 Install (New) SCREW BACS12GX08A16 1 (f) (g)

Install (New) NUT BACN10YR08CM 1

11 Install (New) SCREW BACS12GX08A22 1 (f) (g)

Install (New) NUT BACN10YR08CM 1

12 Install (New) SCREW BACS12GX3A8 1 (h)

FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 7 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

45 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

13 Apply SEAL 845T3109 - (i)

14 Install (New) SUPPORT ASSY 845T3109-75 1

15 Install (New) RIVET BACR15BB5D5C 4 Install near side.

(a) Strip .003 laminations if and as required. Install shims wet and finish cut edges with BMS 10-11, type 1

yellow primer. Refer to SOPM 20-41-02 as an accepted procedure.

(b) Leave a 0.005-0.010 clearance between bolt head and support structure.

(c) Torque nut to 20-25 In-Lbs. Refer to SOPM 20-50-01 as an accepted procedure.

(d) The aft face of cargo bulkhead support assembly and the aft face of closure block detail need to be flush.

(e) Fay seal all mating surfaces with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure.

(e) Drill hole through mating parts from hole in 845T3109-58 to 0.1920 - 0.2030 diameter.

(e) Countersink near side 0.332 - 0.319 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted

procedure.

(h) Countersink near side 0.385 - 0.371 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted

procedure.

(i) Fillet seal all visible edges and gap seal all gaps with BMS 5-95. Refer to SOPM 20-50-19 as an accepted

procedure.

FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS

AND INSTALL SUPPORT AT STATION 368

(SHEET 8 OF 8)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

46 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING

(SHEET 1 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

47 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING

(SHEET 2 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

48 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING

(SHEET 3 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

49 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane..

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Install (New) TUBE 845T3109-48 1

2 Install (New) CLAMP, HOSE BACC10JB022C040 1

Remove existing

clamps.

3 Install (New) CLAMP, LOOP BACC10D616A 5

Install (New) SCREW BACS12GX3A8 5

Install (New) WASHER NAS1149D0332J 5

Install (New) NUT BACN10JC3CD 5

Route tube in accordance with Accomplishment Instructions, General Information Note 9.4 Route TUBE 845T3109-48 1

Install (New) STRAP BACS38K1 1

5 Install (New) TUBE 845T3109-49 1

6 Install (New) CLAMP, HOSE BACC10JB022C040 1

Install brackets in

accordance with Accomplishment Instructions, General

Information Note 10.

7 Install (New) SUPPORT 845T3109-47 4

RIVET, UNIVERSAL BACR15BB4D5C 8

HEAD

Install (New)

8 Install (New) CLAMP, LOOP BACC10DK16 4

Install (New) SCREW BACS12GU3K10 4

Install (New) WASHER NAS1149D0332J 4

Install (New) NUT BACN10YR3CM 4

Route tube in accordance with Accomplishment Instructions, General Information Note 10.

9 Route TUBE 845T3109-49 1

Route STRAP BACS38K1 1

FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING

(SHEET 4 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

50 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
This Figure applies only to: Group 1.

FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS

(SHEET 1 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

51 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane..

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Drill 0.1920 - 0.1980

diameter holes from

holes in existing

structure.

1 Drill SUPPORT ASSY 845T3109-51 1

Refer to 767 AMM

25-52-02 as an accepted procedure.

2 Install (New) CEILING LINER 845T3108-21 1

(d)

SCREW, WASHER BACS12FA3K8 51 (a) (b)

HEAD

Install (New)

Install (New) TAPE - SEALING 657T4640-101 -

Refer to 767 AMM

25-52-02 as an accepted procedure.

3 Install (New) CEILING LINER 845T3108-32 1

(c) (d)

Install (New) TAPE - SEALING 657T4640-101 -

Refer to 767 AMM

25-52-02 as an accepted procedure.

4 Install (New) CEILING LINER 845T3108-22 1

(d)

SCREW, WASHER BACS12FA3K8 58 (a) (b)

HEAD

Install (New)

Install (New) TAPE - SEALING 657T4640-101 -

5 Install (New) FAIRING SCREWS BACS12FA3K10 2

Refer to 767 AMM

25-52-02 as an accepted procedure.

6 Install (New) CEILING LINER 845T3108-23 1

(c) (d)

SCREW, WASHER BACS12FA3K8 33 (a) (b)

HEAD

Install (New)

All locations except

those designated for

a different fastener.

Install (New) TAPE - SEALING 657T4640-101 -

SCREW, WASHER BACS12FA3K14 23 (a) (b)

HEAD

7 Install (New)

(a) Drill 0.29 - 0.30 diameter hole through liner from center of existing slotted hole in structure. Refer to 767

AMM 25-52-02 as an accepted procedure.

FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS

(SHEET 2 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

52 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(b) Maintain 0.60 inch edge margin for fasteners.

(c) Align new ceiling panel with previously removed ceiling panel to layout cut-outs and do cuts. Refer to 767

AMM 25-52-02 as an accepted procedure.

(d) Apply tape to cover all joints and seams in ceiling liner and shrouds. At panel edges tape shall extend to

seal edge joint. Centerline of tape to coincide approximately with the centerline of lining attaching fasteners.

Once installed, tape shall not be reused. Splice in new tape if tape is removed for any reason. Refer to

767 AMM 25-52-02 as an accepted procedure.

FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS

(SHEET 3 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

53 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 1 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

54 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 2 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

55 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 3 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

56 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane..

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove / Keep RUB STRIP 657T4640-30 1

2 Remove CEILING LINER 657T4640-7 1 (a)

3 Remove CEILING LINER 657T4640-29 1 (a) (b)

4 Remove CEILING LINER 657T4640-32 1 (a) (b)

5 Remove SUPPORT BRACKET 657T4664-1 3 (c)

STABILIZATION 657T1137-4 1

STRAP ASSY

6 Remove

7 Remove SUPPORT ASSY 845T3109-25 1

8 Remove SUPPORT ASSY 845T3109-29 1

9 Remove SUPPORT 453T1602-6 1

10 Remove SUPPORT 453T1602-7 1

11 Remove SUPPORT 453T1602-8 1

(a) Refer to 767 AMM 25-52-02 as an accepted procedure.

(b) Panel can be used as a template to layout cut-outs in the new panels.

(c) Plug any open holes left by removing the support brackets with AD rivets. Refer to 767-200SF SRM 51-

40-02 as an accepted procedure.

FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND

STRUCTURE

(SHEET 4 OF 4)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

57 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB

STRIP

(SHEET 1 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

58 of 60

BOEING SERVICE BULLETIN 767-25A0505

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 airplane..

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Drill 0.1920 - 0.1980

diameter holes from

holes in existing

structure.

1 Drill SUPPORT ASSY 845T3109-51 1

Refer to 767 AMM

25-52-02 as an accepted procedure.

2 Install (New) CEILING LINER 657T4640-41 1

(d)

SCREW, WASHER BACS12FA3K8 51 (a) (b)

HEAD

Install (New)

Install (New) TAPE - SEALING 657T4640-101 -

Refer to 767 AMM

25-52-02 as an accepted procedure.

3 Install (New) CEILING LINER 657T4640-44 1

(c) (d)

Install (New) TAPE - SEALING 657T4640-101 -

Refer to 767 AMM

25-52-02 as an accepted procedure.

4 Install (New) CEILING LINER 657T4640-42 1

(d)

SCREW, WASHER BACS12FA3K8 58 (a) (b)

HEAD

Install (New)

Install (New) TAPE - SEALING 657T4640-101 -

5 Install (New) FAIRING SCREWS BACS12FA3K10 3

Refer to 767 AMM

25-52-02 as an accepted procedure.

6 Install (New) CEILING LINER 657T4640-43 1

(c) (d)

SCREW, WASHER BACS12FA3K8 33 (a) (b)

HEAD

Install (New)

All locations except

those designated for

a different fastener.

Install (New) TAPE - SEALING 657T4640-101 -

SCREW, WASHER BACS12FA3K14 23 (a) (b)

HEAD

7 Install (New)

8 Install (Kept) RUB STRIP 657T4640-30 1

Install (New) TAPE - DOUBLEBACK 657T4640-102 - (e)

FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB

STRIP

(SHEET 2 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

59 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(a) Drill 0.29 - 0.30 diameter hole through liner from center of existing slotted hole in structure. Refer to 767

AMM 25-52-02 as an accepted procedure.

(b) Maintain 0.60 inch edge margin for fasteners.

(c) Align new ceiling panel with previously removed ceiling panel to layout cut-outs and do cuts. Refer to 767

AMM 25-52-02 as an accepted procedure.

(d) Apply tape to cover all joints and seams in ceiling liner and shrouds. At panel edges tape shall extend to

seal edge joint. Centerline of tape to coincide approximately with the centerline of lining attaching fasteners.

Once installed, tape shall not be reused. Splice in new tape if tape is removed for any reason. Refer to

767 AMM 25-52-02 as an accepted procedure.

(e) Install doubleback tape between ceiling liner and rub strip along entire periphery of rub strip. Doubleback

tape overlap splices allowed.

FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB

STRIP

(SHEET 3 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 14, 2011

767-25A0505

60 of 60

BOEING SERVICE BULLETIN 767-25A0505

ALERT ALERT