### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Number: 757-54A0047**  Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 1 of 79 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 2 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 29 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 32 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 33 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 FIGURE 1: ACCESS FOR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE. . . . . . . . . . . . . . 44 FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD. . . . 46 FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE. . . . . . . . . . . . 49 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE. . . . . . . . . . 52 FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE. . . . . . . . 54 FIGURE 7: THIS FIGURE HAS BEEN DELETED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND. . . . . . . . . . . . . . . . . . . . . 58 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE. . . . . . . . . . . . . . . . . . . . . 60 FIGURE 10: SEAL COVER PLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS. . . . . . . 64

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 3 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**FIGURE 12: NACELLE/PYLONS - ALTERNATIVE ACCESS TO THE CRITICAL HORIZONTAL FLANGE FASTENERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS . . 68 FIGURE 14: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 1 STRUT . 70 FIGURE 15: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 2 STRUT . 75

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 4 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 757-54A0047** Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and Change This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** More work is necessary on the airplanes changed in accordance with the original issue, Revision 1, Revision 2, Revision 3 or Revision 4 of this service bulletin. Replace the fasteners on the horizontal and vertical flange as given in this service bulletin. Federal Aviation Administration (FAA) Airworthiness Directive (AD) AD 2004-12-07 and AD 2008-05-10 are related to this service bulletin. No airplanes were added or removed from this service bulletin effectivity. **REASON FOR REVISION** This revision is sent to revise the compliance information and to give terminating action details. These sections were changed: 1. Subject revised. 2. Summary Background and Action - More information is added. 3. Summary Compliance - New AD information added 4. Summary Industry Support Information - Reimbursement details added. 5. Summary Manpower terminating action hours added. 6. Summary Material Information Revised. 7. Paragraph 1.C., Reason - Terminating action added. 8. Paragraph 1.D., Description - Terminating action added. 9. Paragraph 1.E., Compliance - Terminating action compliance information and new AD information added.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 5 of 7910. Paragraph 1.G., Manpower - New manpower tables added. 11. Paragraph 1.H., Weight and Balance Changes - Table added. 12. Paragraph 1.J.1., Existing Data - PRR and Boeing Service Letter reference added. 13. Paragraph 1.K., Publications Affected - Table added. 14. Paragraph 2.A., Material - Price and Availability - New kit supply information added. 15. Paragraph 2.B., Industry Support Information - Reimbursement details added. 16. Paragraph 2.C.1., Kit/Parts - New kit added. 17. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Alternatives information revised. 18. Paragraph 3.A., General Information - Notes revised. 19. Paragraph 3.B., Work Instructions - Part I, Step 4.b. and Step 5.a.1. Revised. Part II, Step 2.a.1. Revised. Part III, Step 5. Revised. Part IV, Step 2.b.1 note added. Part V added. 20. FIGURE 4, 5 and 6 - Fastener code illustration added. 21. FIGURE 8 - Alternatives information revised. 22. FIGURE 9 - Alternatives information revised. 23. FIGURE 11- Fastener code illustration added. 24. FIGURE 14 and 15 added. The data given in Information Notice 757-54A0047 IN 02 is included in this revision. The information notice gives the removal of the common nozzle exhaust collector as an option to the removal of the engine. 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** November 13, 2003 Original Issue: March 24, 2005 Revision 1: January 31, 2007 Revision 2: June 27, 2007 Revision 3: June 24, 2010 Revision 4: Revision 5:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 6 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Summary**  **Number: 757-54A0047** Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and 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 gives the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and to do an inspection and repair of the four critical fastener holes on the horizontal flange. Terminating Instructions replace the fasteners on the horizontal and vertical flange with larger fasteners. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. **Service History Report**  **Strut Cycles**  **Hours Date**  One bolt sheared in horizontal flange. Four bolts loose in vertical flange. - 10,284 29,451 12/93 Four bolts loose in vertical flange of both struts. No. 1 & 2 9,358 25,768 11/96 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. No. 1 & 2

- - 06/98 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. No. 1 & 2 21,749 55,789 11/99

Sixteen bolts loose in horizontal flange. No. 1 & 2 20,161 46,459 01/01 Two bolts loose in vertical flange. No. 1 13,662 49,019 09/01

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 7 of 79**Service History Report**  **Strut Cycles**  **Hours Date**  Two bolt heads cracked.

- 14,633 23,423 01/02 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. No. 1 & 2 12,493 16,601 04/02 Migrated shim between bulkhead and vertical flange of fitting. No. 1 & 2 15,522 43,822 05/02 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. No. 2 15,900 46,758 06/02 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. No. 1 20,090 49,807 12/02

Two loose bolts in vertical flange.

- 22,111 50,841 04/03 Three loose bolts in vertical flange. No. 1 9,991 30,072 09/03 Migrated shims between bulkhead and vertical flange of fitting. No. 1 & 2 26,914 60,715 09/03 Three loose bolts in vertical flange. No. 2 15,004 44,985 10/03 Three loose bolts in vertical flange. No. 2 7,922 12,368 01/04 Four loose bolts in vertical flange. No. 1 7,592 12,119 02/04 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. No. 1 13,083 44,423 04/06

In addition, one operator found a strut torque bulkhead fitting with loose fasteners and cracks at the joint common to the strut diagonal brace fitting on two airplanes with the Strut Improvement Program (SIP) incorporated during production. One airplane had been inspected for loose fasteners in 2006 per service bulletin 75-54A0047 Revision 01 with no findings. Since that inspection, the airplane had accumulated less than 3000 flight cycles. The loose fasteners and cracks were found during an engine change while the area was exposed. Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130 are related to this service bulletin. **ACTION (PRR 54530-291RS)** Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 8 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A borescope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection and repair of the four critical fastener holes on the horizontal flange. For service bulletin terminating action, replace the fasteners on the horizontal and the vertical flange with larger fasteners. As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. **EFFECTIVITY** 757-200/-200CB and -200PF airplanes line numbers 1 thru 1048, powered by Rolls Royce engines. **COMPLIANCE** Refer to Paragraph 1.E., Compliance. Federal Aviation Administration (FAA) Airworthiness Directives (AD) AD 2004-12-07 and AD 2008-05-10 are related to this service bulletin. The FAA will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin. For customers who have already ordered and/or, installed the 757 SIP Top Kit 012N8041-1 please submit a claim for reimbursement of your purchase of Supplemental Kit 012N8931-23. When submitting your claim, please include your SIP (SB 757-54-0035) Top Kit incorporation date. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  22.0 (a) 44.0 (a) All 26.0 (b) 74.0 (b) All (Engine Re- moved) 23.0 (b) 46.0 (b) All (Common Nozzle Exhaust Removed) (a) Inspections only. Does not include time to make repairs if loose fasteners or cracks are found. (b) For increased diameter fastener installation terminating action.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 9 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT 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: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 10 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 757 Service Bulletin **ALERT Number: 757-54A0047**  Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 **SUBJECT:** NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and 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 Refer to Service Bulletin Index Document D6-24N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 757-200/-200CB/-200PF airplanes line number 1 thru 735, powered by Rolls Royce engines. - 1
Airplanes without SB 757-54-0035 incorporation. 1 Airplanes with SB 757-54-0035 incorporation. 2 757-200/-200PF airplanes line number 736 thru 1048, powered by Rolls Royce engines. - 2

Airplane Models: 757-200, 757-200CB, 757-200PF **Group Variable Number**  1 NA002 - NA028

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 11 of 79**Group Variable Number**  1 NA191 - NA199 1 NA201 - NA239 1 NA301 - NA305 1 NA341 - NA352 1 NA391 - NA399 1 NA401 - NA408 1 NA441 - NA447 1 NB021 - NB023 1 NB036 - NB041 1 NB051 - NB053 1 NB061 - NB073 1 NB079 1 NB131 - NB148 1 NB161 - NB162 1 NB201 - NB204 1 NB221 - NB225 2 NB226 - NB228 2 NB230 1 NB236 1 NB239 1 NB261 - NB267 1 NB291 - NB299 1 NB301 - NB302 1 NB311 - NB312 1 NB321 - NB331 1 NB421 - NB438 1 NB446 1 NB451 - NB454 1 NB501 - NB523 1 NB561 2 NB571 2 NB581 - NB583 1 NC058 - NC061

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 12 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Group**  **Variable Number** 2 NC062 1 NC936 - NC950 1 NC971 - NC974 1 ND001 - ND007 1 ND011 - ND059 1 ND111 - ND113 1 ND161 - ND199 1 ND201 - ND203 1 ND221 - ND225 1 ND241 - ND248 1 ND301 - ND317 2 ND318 - ND322 2 ND401 1 ND891 1 ND895 2 NJ001 - NJ004 2 NJ031 - NJ032 2 NN001 - NN002 2 NN051 - NN052 1 NS601 - NS610 2 NS611 - NS616 2 NT001 - NT009 2 NT201 - NT202 2 NT231 - NT234 2 NT237 - NT240 2 NT242 2 NT245 - NT248 2 NT281 - NT289 2 NT381 - NT386 2 NT401 - NT409 2 NT411 - NT412 2 NT426 - NT427 2 NT431 - NT432

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 13 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Group**  **Variable Number** 2 NT436 - NT438 2 NT446 2 NT731 - NT769 2 NT861 - NT862 2 NT901 - NT916 2 NT971 - NT985 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** This service bulletin gives the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and do an inspection and repair of the four critical fastener holes on the horizontal flange. Terminating instructions replace the fasteners on the horizontal and vertical flange with larger fasteners. Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting.

**Service History Report**  **Strut Cycles**  **Hours Date**  One bolt sheared in horizontal flange. Four bolts loose in vertical flange. - 10,284 29,451 12/93 Four bolts loose in vertical flange of both struts. No. 1 & 2 9,358 25,768 11/96 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2. No. 1 & 2

- - 06/98 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts. No. 1 & 2 21,749 55,789 11/99

Sixteen bolts loose in horizontal flange. No. 1 & 2 20,161 46,459 01/01 Two bolts loose in vertical flange. No. 1 13,662 49,019 09/01 Two bolt heads cracked.

- 14,633 23,423 01/02 Two bolts loose in horizontal flange of Strut No. 1. Three bolts loose in horizontal flange of Strut No. 2. No. 1 & 2 12,493 16,601 04/02

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 14 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Service History**  **Report Strut**  **Cycles Hours**  **Date** Migrated shim between bulkhead and vertical flange of fitting. No. 1 & 2 15,522 43,822 05/02 Four bolts loose in vertical flange. Five bolts loose in horizontal flange. No. 2 15,900 46,758 06/02 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations. No. 1 20,090 49,807 12/02

Two loose bolts in vertical flange.

- 22,111 50,841 04/03 Three loose bolts in vertical flange. No. 1 9,991 30,072 09/03 Migrated shims between bulkhead and vertical flange of fitting. No. 1 & 2 26,914 60,715 09/03 Three loose bolts in vertical flange. No. 2 15,004 44,985 10/03 Three loose bolts in vertical flange. No. 2 7,922 12,368 01/04 Four loose bolts in vertical flange. No. 1 7,592 12,119 02/04 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange. No. 1 13083 44,423 04/06

In addition, one operator found a strut torque bulkhead fitting with loose fasteners and cracks at the joint common to the strut diagonal brace fitting on two airplanes with the Strut Improvement Program (SIP) incorporated during production. One airplane had been inspected for loose fasteners in 2006 per service bulletin 75-54A0047 Revision 01 with no findings. Since that inspection, the airplane had accumulated less than 3000 flight cycles. The loose fasteners and cracks were found during an engine change while the area was exposed. Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur. Boeing Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130 are related to this service bulletin. Revision 01 is sent to give migration limits for the shims in the diagonal brace load path. The inspection given in the initial release of this service bulletin made it necessary to repair a loose shim before an airplane could be put back in service. With these new migration limits, an airplane can be put back in service with a migrated shim if the inspection finds that it is in the permitted limits. The bulkhead crack repair as given in the initial release has been deleted. If cracks are found, they will be reviewed on a case-by-case basis.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 15 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**A new repair is added for the shims in the diagonal brace load path. There are now 4 repairs and 1 repair that has been deleted. For identification, they are referred to as Interim Repairs I, II, III, IV and V. Interim Repair I is almost the same as the one given in the initial release and replaces the two shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Interim Repairs II and III are the same as those given in the initial release. Interim Repair II installs oversize fasteners in the vertical flange of the fitting, and Interim Repair III installs oversize fasteners in the horizontal flange of the fitting. Interim Repair IV is the same bulkhead crack repair given in the initial release and has been deleted. Interim Repair V is new and gives the instructions to cut and remove the exposed plies of the shims as a repair for shim migration of 0.50, or less These sections of the service bulletin were changed with revision 01: — Compliance - Decreased repeat inspection thresholds to address additional in service reports where loose fasteners were found on airplanes with less than 12,000 flight cycles. Also, added compliance information for airplanes line numbers 736 thru 1048 to address additional reports of loose fasteners on airplanes with the latest configuration. — Reason and Description - Add six reports to the service history table. — Effectivity - Added 757-200/-200CB and 200PF airplanes with RB211 engines, Line numbers 736 thru 1048. — Work Instructions, Part I, Step 2 - Add shim migration limits to show the necessary work if shim migration is found during the inspection. — Figure 2 - Add instructions to measure and record the distance a shim has moved from the installed position, if the shim shows signs of movement during the inspection. — Figure 4 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair I. — Make corrections to the illustration and instructions to show the replacement of two shims. One on the left flange of the fitting and one on the right flange of the fitting. — Add a step is to apply sealant around the outer edge of the shim. — Add a step to increase the hole diameter after shim is in place. — Removed repair instructions for cracks.
— Figure 5 - Make changes to the figure as follows: — Change the figure title to show that it is Interim Repair II. — Removed repair instructions for cracks.
— Figure 6 - Make changes to the figure as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 16 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**— Change the figure title to show that it is Interim Repair III. — Removed repair instructions for cracks.
— Figure 7 - Deleted. — Figure 9 - Add this new figure to give the instructions for Interim Repair V. — Figure 10 - Added this new figure to give instructions for sealing removed parts. Revision 02 was sent to give revised inspection schedule and repair requirements. Instructions are added to inspect for cracking at four critical horizontal flange fasteners holes if one or more loose fasteners is found. Also, do a one-time inspection and repair of the four critical faster holes on the horizontal flange. Figure 11, Interim Repair VI is new and gives location and instruction for the four critical horizontal flange fastener locations. These sections of the service bulletin were changed with revision 02: — Summary - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Action section. Added one report to the Service History in Background section. — Planning - Added revised inspection intervals in the Compliance section. Added horizontal flange one-time critical fastener inspection and repair requirement in the Description section. Added one report to the Service History in the Reason section. Added Manpower hours for Part IV inspection. — Accomplishment Instructions - Revised access instructions. Added inspections, critical fastener identification, locations, compliance requirement Notes and Part IV inspection. — Figure 6 - Added HFEC inspections to aluminum bulkhead and steel web with NDT references. — Figure 11 - Added, for critical horizontal flange fastener locations, HFEC inspections to aluminum bulkhead and steel web with NDT references. — All references to AD 2004-12-07 are changed to AD 2005-12-04. Revision 03 was sent to give revised inspection compliance times and replace the phrase "one time inspection" with "inspection" when referring to the Part IV inspection of the critical fastener holes on the horizontal flange . These sections of the service bulletin were changed with revision 03: — Summary - Compliance information is deleted from the Compliance section. — Paragraph 1.E., Compliance - Compliance times are revised and presented in a tabular format. — Summary, Planning Information, Work Instructions: replaced the words "one time inspection" with "inspection". Revision 04 was sent to revise the compliance information and to give an alternative method of accessing the critical fasteners at the strut-to-diagonal brace fitting. It was also sent to add more instructions for inspecting the aft torque bulkhead. The following sections were changed:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 17 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**1. Subject revised. 2. More information is added to the Background and Reason sections. 3. Summary Compliance - New AD information added. 4. Paragraph 1.D., Description - Affected maintenance zones are added. 5. Paragraph 1.E., Compliance - The compliance information is revised. 6. Paragraph 1.F., Approval - An Alternative Method of Compliance (AMOC) statement is added, and the Federal Aviation Administration (FAA) Airworthiness Directives (AD) reference is changed. 7. Paragraph 1.G., Manpower - Added a new manpower table and changed manpower information. 8. Paragraph 1.J.1., Existing Data - Service Related Problem (SRP), Nondestructive Test (NDT) and the FAA (AD) reference is changed. 9. Paragraph 1.K., Publications Affected - A Damage Tolerance Based Structural Inspection statement is added. 10. Paragraph 3.A., General Information - Added new standard Note 1 and Note 7. 11. Paragraph 3.B., Work Instructions - More inspection instructions are added to Part II and Part IV. 12. FIGURE 3 - A new view and more inspection instructions are added. 13. FIGURE 12 and FIGURE 13 are added. Revision 05 is sent to give SB terminating instructions and the compliance information for the terminating instructions. The following sections are changed: 1. Summary Background and Action - More information is added. 2. Summary Industry Support Information - Reimbursement details added. 3. Summary Manpower terminating action hours added. 4. Summary Material Information Revised. 5. Paragraph 1.C., Reason - Terminating action added. 6. Paragraph 1.D., Description - Terminating action added. 7. Paragraph 1.E., Compliance - The terminating action compliance information added. 8. Paragraph 1.G., Manpower - New manpower tables added. 9. Paragraph 1.H., Weight and Balance Changes - Table added. 10. Paragraph 1.J.1., Existing Data - PRR and Boeing Service Letter reference added.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 18 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**11. Paragraph 1.K., Publications Affected - Table added. 12. Paragraph 2.A., Material - Price and Availability - New kit supply information added. 13. Paragraph 2.B., Industry Support Information - Reimbursement details added. 14. Paragraph 2.C.1., Kits/Parts - New kit added. 15. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Alternatives information revised. 16. Paragraph 3.A., General Information - Notes Revised. 17. Paragraph 3.B., Work Instructions - Part I, Step 4.b. and Step 5.a.1. Revised. Part II, Step 2.a.1. Revised. Part III, Step 5. Revised. Part IV, Step 2.b.1 note added. Part V added. 18. FIGURE 4, FIGURE 5 and FIGURE 6 - Fastener code illustration added. 19. FIGURE 8 - Alternatives information revised. 20. FIGURE 9 - Alternatives information revised. 21. FIGURE 11 - Fastener code illustration added. 22. FIGURE 14 and FIGURE 15 added. **D. Description** Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs. Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A borescope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners. If loose fasteners are found or shim migration is beyond limits, do an inspection of the four critical fastener holes on the horizontal flange. For service bulletin terminating action, replace the fasteners on the horizontal and the vertical flange with larger fasteners. As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections. Revision 01 - More work is necessary on airplanes changed as shown in the initial release of this service bulletin. Repeat inspections are required for airplanes that have incorporated Service Bulletin 757-54-0035.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 19 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**Revision 02 - More work is necessary on airplanes changed as shown in the initial release and revision 01 of this service bulletin. Instructions are added to do a one-time inspection and repair of the four critical fastener holes on the horizontal flange. Revision 03 - No more work is necessary on airplanes changed as shown in the Original issue, Revision 1, or Revision 2 of this service bulletin, however the conditions and the compliance time for doing the inspection of the four critical fasteners on the horizontal flange have changed. Revision 04 - More work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2 or Revision 3 of this service bulletin. On airplanes without conclusive records of previous inspections, do a one time open hole High Frequency Eddy Current (HFEC) inspection or ultrasonic inspection of the four critical fastener holes in the horizontal flange as given in this service bulletin. Revision 05 - More work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2, Revision 3 or Revision 4 of this service bulletin. Replace the fasteners on the horizontal and vertical flange as given in this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 433, 443 757-200, 757-200CB, 757- 200PF **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 433, 443 757-200, 757-200PF **E. Compliance** Federal Aviation Administration (FAA) Airworthiness Directives (AD) AD 2004-12-07 and AD 2008-05-10 are related to this service bulletin. The FAA will possibly release another 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: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 20 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque**  **Bulkhead. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition**

- - Within 90 days of the date of Revision 3 of this service bulletin. Inspect the four criticalfasteners in the horizontal flange in accordancewith Part IV unless already accomplished inaccordance with Revision 2, Revision 3 orRevision 4 of this service bulletin. All airplane struts that had findings on the horizontal orvertical fasteners or the shims whichlead to a rejection while doing Revision 1 or the original issue of thisservice bulletin, and all airplanes that had equivalent findings prior tothe original Issue of this service bulletin. (a)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 21 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque**  **Bulkhead. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition** 1800 flight cycles. Within 1800 flight cy-cles from the last inspection for loosefasteners and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, Step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection ofthe bulkhead in accordance with Part II, Step 3.Group 1 Configuration 1

OR 3000 flight cycles. Within 1800 flight cy-cles from the last inspection for loosefasteners and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, Step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspectionand an ultrasonic inspection of the bulkhead in accordance with Part II, Step 3. 3000 flight cycles. (b) (c)Within 3,000 flight cycles from the last inspection for loosefasteners and migrated shims per this service bulletin or from installation of SB 757- 54-0035, Revision 3,Revision 4, or Revision 5. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, Step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection ofthe bulkhead in accordance with Part II, Step 3.Group 1 Configuration 2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 22 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque**  **Bulkhead. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition** 3000 flight cycles. (b)Within 3,000 flight cycles from the last inspection for loosefasteners and migrated shims per this service bulletin. Within 90 days of the date of Revision 4 of this service bulletin.Inspect the shim installation in accordancewith Part I, step 3. Inspect all four fasteners in the vertical flange in accordance with Part I,Step 5. Inspect the fasteners in the horizontal flange in accordance with Part II, Step 2. Do a detailed inspection ofthe bulkhead in accordance with Part II, Step 3. Group 2

- - Within 90 days of the date of Revision 4 of this service bulletin. Do an open hole HighFrequency Eddy Current (HFEC) inspection at the critical fastener location in accordance with Work Instructions Part IV, Step 2.a.Airplanes without conclusiverecords of previous inspection.

OR

- - Within 90 days of the date of Revision 4 of this service bulletin.Do an ultrasonic inspection of the critical fastener holes in the horizontal flange in accordance with Work Instructions Part IV, Step 2.b.

- - Before further flight after completing all inspections. Repair in accordance with Part I, Step 4.a.Total cumulative shim movement equal to or less than 0.50 inch.

- - Before further flight after completing all inspections. Repair in accordance with Part I, Step.4.b.Total cumulative shim movement more than 0.50 inch.

- - Before further flight after completing all inspections. Repair in accordance with Part I, Step 5.a.(2) AND Inspect and repair in accordance with Part I, Step 5.a.(3)Rejected fastener in the vertical flange.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 23 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Table 1: Inspection of Fasteners, Fastener Holes and Bulkhead Flange at the Nacelle Strut Torque**  **Bulkhead. Repeat Interval**  **Compliance Time (Whichever Occurs later) Action**  **Condition**

- - Before further flight after completing all inspections. Repair in accordance with Part II, Step 2.a.(2) AND Inspect and repair in accordance with Part II, Step 2.a.(3)Rejected fastener in the horizontal flange.

- - Before further flight. Contact Boeing for re- pair instructions and do the repair. Any crack found in the bulkhead flange or thevertical stiffeners or the access door cutout edge.

- - Before further flight. Contact Boeing for re- pair instructions and do the repair. Any crack found in any critical fastener hole.

- - Within 9000 flight cy-cles or 54 months after the Revision 5 date of this service bulletin, whichever comes first. Replace the horizontaland vertical flange fasteners in the strut-to-diagonal brace fitting in accordance with Part V. (c)Group 1 Configuration 2; Group 2

(a) Findings on Group 1, Configuration 2 airplane struts prior to service bulletin 757-54-0035 incorporation are excluded from this condition. (b) Accomplishment of the fastener replacement in accordance with Work Instructions Part V, terminates the requirements for these repeat inspections. (c) No action is required for Group 1 Configuration 2 airplanes that have incorporated Revision 5 of SB 757-54-0035. **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 24 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**The Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the accomplishment of the fastener replacement specified in Part V of Service Bulletin (SB) 757-54A0047, Revision 5, as an AMOC to the fastener installation specified in SB 757-54-0035, Revision 1, dated April 15, 1999; or Revision 2, dated June 13, 2002, as required by paragraphs (b) and (d) of AD 2004-12-07 , for these fastener locations only. When SB 757-54A0047, Revision 5, specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (h) of AD 2004-12-07 . All provisions of AD 2004-12-07 , including the compliance times, that are not specifically referenced in the preceding sentences remain fully applicable and must be complied with accordingly. The manager of the FAA Seattle ACO approves the accomplishment of the applicable inspections, investigative and corrective actions with the corresponding compliance times specified in Table 1 under paragraph 1.E., "Compliance," of SB 757-54A0047, Revision 5, as an AMOC to the corresponding inspection, investigative and corrective actions with the corresponding compliance times, specified in SB 757-54A0047 Revision 3, dated June 27, 2007 as required by paragraphs (g), (h), and (l) of AD 2008-05-10 . When SB 757-54A0047, Revision 5, specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (q) of AD 2008-05-10 . All provisions of AD 2008-05-10 , that are not specifically referenced in the preceding sentences remain fully applicable and must be complied with accordingly. The manager of the FAA Seattle ACO approves the accomplishment of the modification procedures (Part V of the Work Instructions) specified in Table 1 under paragraph 1.E., "Compliance," of SB 757-54A0047, Revision 5, as an AMOC to the inspection, investigative and corrective actions, specified in SB 757-54A0047, Revision 3, dated June 27, 2007, as required by paragraphs (g), (h) and (l) of AD 2008-05-10 . When SB 757-54A0047, Revision 5, specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (q) of AD 2008-05-10 . All provisions of AD 2008-05-10 , that are not specifically referenced in the preceding sentences remain fully applicable and must be complied with accordingly. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this inspection and repair for each strut. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace. — Time to schedule the work. — Time to examine the work. — Time to cure the materials. — Time to make the parts. — Time to find the tools.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 25 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Part I - Inspection - Fasteners and Shim - Vertical Flange** **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

6.0 12.0 2 Open Access 1.0 2.0 2 Inspect

- - - Repair (a) 7.0 14.0 2 Close Access 14.0 28.0 TOTAL FOR EACH STRUT (a) An estimate for the task-hours necessary to do the repair is not given. **Part II - Inspection - Fasteners - Horizontal Flange Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

1.0 2.0 2 Open Access 6.0 12.0 2 Inspect

- - - Repair (a) 1.0 2.0 2 Close Access 8.0 16.0 TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) More time can be necessary for the removal of the engine, diagonal brace, and precooler. **Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Engine Removed) Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

2.5 10.0 4 Open Access (En- gine Removed) 1.0 2.0 2.0 Inspect Option 1 2.0 4.0 2.0 Inspect Option 2

- - - Repair (a) 3.0 12.0 4 Close Access (En- gine Removed) 3.0 6.0 3 Trim and Check En- gine 8.5 (b) 28.0 (b) TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 26 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Engine Removed)**  **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task** (b) Total does not include inspection estimate. Add inspection estimate for option used to total shown to arrive at revised total. **Part IV - Inspection - Critical Fastener Holes on the Horizontal Flange (Common Nozzle Exhaust Removed)**  **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

3.5 7.0 2 Open Access (Common Nozzle Exhaust Removed) 1.0 2.0 2.0 Inspect Option 1 2.0 4.0 2.0 Inspect Option 2

- - - Repair (a) 3.5 7.0 2 Close Access (Common Nozzle Exhaust Removed) 7.0 (b) 14.0 (b) TOTAL FOR EACH STRUT (b) (a) An estimate for the task-hours necessary to do the repair is not given. (b) Total does not include inspection estimate. Add inspection estimate for option used to total shown to arrive at revised total. **Part V - Fastener Replacement - Horizontal and Vertical Flange (Engine Removed) Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

2.5 10.0 4 Open Access (En- gine Removed) 1.0 2.0 2 Inspect 3.5 7.0 2 Change 3.0 12.0 4 Close Access (En- gine Removed) 3.0 6.0 3 Trim and Check En- gine 13.0 37.0 TOTAL FOR EACH STRUT

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 27 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Part V - Fastener Replacement - Horizontal and Vertical Flange (Common Nozzle Exhaust**  **Removed) Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

3.5 7.0 2 Open Access (Common Nozzle Exhaust Removed) 1.0 2.0 2 Inspect 3.5 7.0 2 Change 3.5 7.0 2 Close Access (Common Nozzle Exhaust Removed) 11.5 23 TOTAL FOR EACH STRUT **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Engineering Change Memo PRR 54530-291RS. b. Boeing Parts Standards Document D-590. c. Boeing Service Bulletin 757-54-0035 'NACELLES/PYLONS Rolls Royce RB211 Powered Airplanes - Nacelle Strut and Wing Structure Improvement'. d. Boeing Service Letter 757-SL-51-022. e. Boeing Service Related Problem (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130. f. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-12-07 and 2008-05-10. g. Standard Overhaul Practices Manual (SOPM) 20-43-03 and 20-50-19.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 28 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**h. 757 Aircraft Maintenance Manual (AMM) 54-51-02, 54-53-01, 54-53-02, 71-00-02, 71-11-07, 78-11-04 and 78-31-00. i. 757 Non-Destructive Testing (NDT) Manual Part 4, 54-50-02, Part 6, 51-00-14, Part 6, 51-00-16 and Part 6, 51-00-17. j. Boeing Drawing 65-88700. 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  Spar Installation - Lower Nacelle Strut 311N5042 Torque Bulkhead Installation 311N5045 Seal Application - Nacelle Strut 311N5062 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: **Chapter-Section Publication**  54-51 757 Illustrated Parts Catalog 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 affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. **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: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 29 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 30 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 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 **REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION** 
**Unit Price as of the Revision 05** **date of this Ser vice Bulletin (US**  **Dollars) ROLT as of the**  **Revision 05 date**

**of this Service Bulletin (Calendar**  **Days) QTY**  **Date Name**  **Kit Number**

$750.00 722 4 3/18/11 TOP KIT, RETROFIT - NACELLE STRUT TO DIAGONAL BRACE FITTING FASTENER REPLACEMENT 012N8931-23

**B. Industry Support Information** Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin. For customers who have already ordered and/or, installed the 757 SIP Top Kit 012N8041-1 please submit a claim for reimbursement of your purchase of Supplemental Kit 012N8931-23. When submitting your claim, please include your SIP (SB 757-54-0035) Top Kit incorporation date. **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. The Top Kit is divided into Figure kits for each installation figure shown in the table below. **Figure Kit 15**  **14 Top Kit**  1 1 012N8931-23

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 31 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT ALL** 
**KIT 012N8931-23**

**NOTES Existing Part**  **Number Name**  **Figure**

**New Part Number 15**  **14 QTY**  BOLT, 12 PT HEAD 6 6 BACB30US7K12
BOLT, 12 PT HEAD 4 4 BACB30US8K12
BOLT, HEX DRIVE 2 2 BACB30YK14K11 COLLAR 2 2 BACC30BH14S NUT 6 6 BACN10HR7CD NUT 4 4 BACN10HR8CS WASHER 6 6 BACW10BP7ACU WASHER 6 6 BACW10BP7DP WASHER 4 4 BACW10BP8CD WASHER, PLAIN 4 4 BACW10BP8PTU 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Speci-**  **fication** (a) Chemical Conversion Treatment 4 oz. Type 2, Class A

- Primer 8 oz. BMS 10-11, Type 1 (c) Sealant 1 pt. BMS 5-63 (c) (d) Primer 8 oz. DAPCO 1-400 (e) Primer 8 oz. DC 1200

- Sealant 1 pt. DC 93-006

- Leveling Compound 1 qt. DC 3110 (f)

- - RTV 560 (f)

- - RTV 3 (f)

- - RTV 60 2.50 x 2.50 x 0.080 (g) CRES Plate

- 301 SS 1/2 Hard (h) Bolt

- BACB30*

- Collar

- BACC30*

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 32 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT Notes**  **Name QTY**  **Part Number / Speci- fication**  (i) BACS40R015C027F optional Shim, Laminated 2 BACS40R015B027F (j) Filler, Radius 2 BACF3H10JT010HG (a) Can be necessary if you make the radius filler shown in FIGURE 6. Refer to SOPM 20-43-03 as an accepted procedure, for data about the Chemical Conversion Treatment. (b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) DAPCO 1-400 primer and BMS 5-63, Type II sealant is optional for Dow Corning 1200 primer and Dow Corning 93-006 sealant application. (d) Primer is necessary if BMS 5-63 is applied over rubber/silicon substrates. (e) Use with DC 93-006 and DC 3110. (f) Alternative to DC 3110. (g) Can be necessary if a crack is found in the aft bulkhead that cannot be repaired with the installation of an oversize fastener. (h) See the Paragraph 3.B., Work Instructions, FIGURE 4, FIGURE 5, FIGURE 6, and FIGURE 7, for the oversize bolt/collars that can be necessary if the inspections find a loose shim and/or damaged fasteners. (i) Can be necessary if loose shims are found during the inspection. (j) Can be necessary if oversize fasteners are installed as shown in FIGURE 6. Instructions are also given to make the filler from 0.063 thick 2024-T3, T4, T42, or 7075-T6 Bare Aluminum Sheet.
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** A borescope, or other inspection aids, can be necessary to do the inspection of the fasteners in the horizontal flange of the strut-to-diagonal brace fitting. Also, 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: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 33 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 34 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 Structural Repair Manual (SRM) Chapter 51. – Torque limits to tighten nuts and bolts are in SRM Chapter 51. 5. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. Alternate fasteners are listed in SRM Chapter 51. 6. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 7. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 35 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**8. 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. 9. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 10. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. **B. WORK INSTRUCTIONS PART I - INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE - ALL AIRPLANES**  1. Do the Thrust Reverser Deactivation for Ground Maintenance. Refer to 757 AMM 78-31-00 as an accepted procedure. **WARNING:**DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENT THE OPERATION OF THE THRUST REVERSER. THE ACCIDENTAL OPERATION OF THE THRUST REVERSER CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 2. Get access for the inspection of the fasteners and shim in the vertical flange in accordance with FIGURE 1. 3. Do the detailed inspection of the shim installation between the vertical flange and bulkhead in accordance with FIGURE 2: a. For Group 1 and Group 2 airplanes: If the shim installation shows signs of movement and is rejected: Continue with Step 4, below. **NOTE:**All Part I and Part II inspections can be accomplished before repairs are done. b. If the shim installation is satisfactory: Continue with the detailed inspection of the four fasteners in the vertical flange in accordance with step 5, below. 4. Do the repairs to the shim installation between the vertical flange and the bulkhead as given below:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 36 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**a. If the shim(s) total cumulative movement is 0.50 or less: Do the Interim Repair V in accordance with FIGURE 9. Record the amount of total shim movement and save for future inspections. b. If the shim(s) total cumulative movement is more than 0.50: Remove the engine or, as an option, remove the common nozzle exhaust. Refer to 757 AMM 71-00-02 as an accepted procedure , or remove the common nozzle exhaust in accordance with FIGURE 12 . Do the Interim Repair I in accordance with FIGURE 4. Also, do the inspection and repair of the four critical fastener holes on the horizontal flange in accordance with Part IV. 5. Do the detailed inspection of the four fasteners in the vertical flange in accordance with FIGURE 2: a. If one or more of the four fasteners are rejected: (1) Remove the engine or, as an option, remove the common nozzle exhaust. Refer to 757 AMM 71-00-02 as an accepted procedure, or remove the common nozzle exhaust in accordance with FIGURE 12 . **NOTE:**All Part I and Part II inspections can be accomplished before the repairs are done. (2) At the locations where the fasteners are rejected in the vertical flange: Remove the fastener, increase the hole diameter and install oversize fasteners as shown for Interim Repair II in accordance with FIGURE 5. (3) Do the inspection and repair of the four critical fastener holes on the horizontal flange in accordance with Part IV. **PART II - INSPECTION - FASTENERS - HORIZONTAL FLANGE - ALL AIRPLANES** 1. Get more access, and removal of the leveling compound, for the inspection of the fasteners in the horizontal flange in accordance with FIGURE 1. 2. Do the detailed inspection of the sixteen fasteners that hold the strut to the horizontal flange of the strut-to-diagonal brace fitting in accordance with FIGURE 3: a. If one or more of the sixteen fasteners are rejected: (1) Remove the engine or, as an option, remove the common nozzle exhaust. Refer to 757 AMM 71-00-02 as an accepted procedure , or remove the common nozzle exhaust in accordance with FIGURE 12 .

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 37 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT NOTE:** All Part I and Part II inspections can be accomplished before repairs are done. (2) Remove the rejected fastener, inspect the fastener hole for cracking, increase the hole diameters and install oversize fasteners as shown for Interim Repair III in accordance with FIGURE 6. (3) Do the inspection and repair of the four critical horizontal flange fastener holes on the horizontal flange in accordance with Part IV. 3. Inspect the bulkhead in the area around the access door cutout and around the critical fasteners in the horizontal flange in accordance with FIGURE 3. As an option, an ultrasonic inspection of the bulkhead around the fasteners in the horizontal flange, in accordance with FIGURE 13, may also be performed. Performance of the optional ultrasonic inspection revises the repetitive inspection interval of this area. a. If any crack is found in the bulkhead or the access door cutout edge, contact Boeing for repair instructions and do the repair. b. If no crack is found in the bulkhead or the access door cutout edge, do repeat inspections in accordance with Paragraph 1.E., Compliance. **PART III - CLOSE ACCESS - ALL AIRPLANES** 1. Apply new sealant in accordance with FIGURE 8. 2. Apply the leveling compound in accordance with FIGURE 8. 3. Install and seal the covers in accordance with FIGURE 10. 4. Install the remaining components that were removed to get access for the inspection. 5. If necessary, install the engine. Refer to 757 AMM 71-00-02 as an accepted procedure , or install the common nozzle exhaust. Refer to 757 AMM 78-11-04 as an accepted procedure. 6. Put the airplane back to a serviceable condition. 7. Schedule the airplane for the repeat inspection at the time in accordance with Paragraph 1.E., Compliance. **PART IV - INSPECTION - CRITICAL FASTENER HOLES ON THE HORIZONTAL FLANGE** 1. If not already done get access in accordance with FIGURE 1. 2. Inspect the critical fastener holes in the horizontal flange using one of the options that follow: a. Option 1 - High Frequency Eddy Current (HFEC) inspection. (1) Get additional access by removing the engine, if not already done. Refer to 757 AMM 71-00-02 as an accepted procedure, or remove the common nozzle exhaust in accordance with FIGURE 12. (2) Remove the fasteners and do an HFEC inspection in accordance with FIGURE 11.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 38 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**(a) If any crack is found, contact Boeing for repair instructions and do the repair. (3) At locations where the critical fastener hole was rejected, increase the hole size and install an oversize fastener in accordance with FIGURE 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener in accordance with FIGURE 11. (4) At locations where the fastener hole was not rejected, install the same size fastener as was removed in accordance with FIGURE 11. Oversize only if warranted by the hole condition, otherwise install the same size fastener in accordance with FIGURE 11. b. Option 2 - Ultrasonic Inspection: (1) Do an ultrasonic inspection in accordance with FIGURE 13. **NOTE:**If FIGURE 13 Step 1 ultrasonic inspection was done on the holes while doing Part II, Step 3., the holes inspected do not need to be inspected again. (a) If any crack is found, contact Boeing for repair instructions and do the repair. (b) If no crack is found, do the repeat inspections in accordance with Paragraph 1.E., Compliance. **PART V - FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE** 1. Replace the fasteners in the horizontal and vertical flange of the strut-to-diagonal brace fitting on the No. 1 Strut as follows: a. Remove the engine or, as an option, remove the common nozzle exhaust. Refer to 757 AMM 71-00-02 as an accepted procedure, or remove the common nozzle exhaust in accordance with FIGURE 12. b. Remove the twelve fasteners in the horizontal and vertical flange and Increase the hole diameters in accordance with FIGURE 14. (1) If any hole diameter is larger than the diameter given in FIGURE 14, contact Boeing for repair instructions and do the repair. c. Do the eddy current inspection of the twelve holes in the horizontal and vertical flange in accordance with FIGURE 14. (1) If any crack is found, contact Boeing for repair instructions and do the repair. (2) If no crack found, install new fasteners in accordance with FIGURE 14. 2. Replace the fasteners in the horizontal and vertical flange of the strut-to-diagonal brace fitting on the No. 2 Strut as follows:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 39 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**a. Remove the engine or, as an option, remove the common nozzle exhaust. Refer to 757 AMM 71-00-02 as an accepted procedure, or remove the common nozzle exhaust in accordance with FIGURE 12. b. Remove the twelve fasteners in the horizontal and vertical flange and Increase the hole diameters in accordance with FIGURE 15. (1) If any hole diameter is larger than the diameter given in FIGURE 15, contact Boeing for repair instructions and do the repair. c. Do the eddy current inspection of the twelve holes in the horizontal and vertical flange in accordance with FIGURE 15. (1) If any crack is found, contact Boeing for repair instructions and do the repair. (2) If no crack found, Install new fasteners in accordance with FIGURE 15.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5: June 09, 2011 40 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 1: ACCESS FOR INSPECTION**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 41 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 1: ACCESS FOR INSPECTION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 42 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut.
**NOTES QTY**  **REFERENCES NAME**  **TASK STEP** 

- 1 Refer to 757 AMM54-53-02 as an accepted procedure. Access Door Open or Remove 1

- 1

- Clamp Loosen 2

- 1

- Boot Seal Move 3

- 1

- Cover Remove 4

- 1 Refer to 757 AMM54-53-01 as an accepted procedure. Cover Plate Remove 5

Remove the seal between the strut and the common nozzle fairing. 1 Refer to 757 AMM71-11-07 as an accepted procedure. Seal Remove 6

As necessary, remove the leveling compound from the area around the fasteners. - - Leveling Com- pound Remove 7

**FIGURE 1: ACCESS FOR INSPECTION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 43 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 44 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**NOTES PROCEDURE**  **NAME TASK**  **STEP** (a) Detailed Inspection Shim Installation (left shim) Inspect 1 (b)

- Shim Migration (left shim) Measure/Record 2 (a) Detailed Inspection Shim Installation (right shim) Inspect 3 (b)

- Shim Migration (right shim) Measure/Record 4 (c) Four locations Detailed Inspection Fastener Inspect 5 (a) Look for signs of damaged sealant around the outer edge of the shim. Look for signs that show movement of the shim. Reject a shim that shows signs of movement. (b) Measure and record the horizontal movement and the vertical movement of the shim from the installed position. Add the movement in each direction together to obtain the total movement of the shim at this inspection. This movement must be added to all previous measurements to obtain total cumulative movement of the shim(s). This data is used during the repeat inspection and to make decisions about repairs. Data necessary for the repeat inspection and to make decisions about repairs are: (i) The shims have not moved from the installed position. (ii) The shim total cumulative movement is 0.50, or less. (iii)The shim total cumulative movement is more than 0.50. (c) Look at the two sides of the fastener installation for signs of damaged sealant. Remove the sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar.

**FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 45 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 46 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 47 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**NOTES PROCEDURE**  **NAME TASK**  **STEP** (a) (b) Detailed Inspection Fastener Inspect 1 Eight locations. (a) (b) Detailed Inspection Fastener Inspect 2 Eight locations. (c) Detailed Inspection Access Door Cutout Inspect 3 (d) Detailed Inspection Bulkhead Inspect 4(a) Use a borescope, or other inspection aids if necessary, to view the lower surface of the fasteners installation. (b) Look at the two sides of the fastener installation for signs of damaged paint and/or sealant. Remove the paint and/or sealant from the head, or collar, if there are signs of damage. Look for signs of movement, such as debris around the head or collar. Look for gaps under the head or collar. Reject a fastener that shows signs of movement, or that has gaps under the head or collar. (c) Do a detailed inspection of the edge of the access door cutout for cracking at the forward and aft side of the cutout. (d) Do a detailed inspection of the bulkhead for cracking in the area shown.

**FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 48 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 49 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 the replacement of one shim.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  (left bolts and/or right bolts). 2

- Fastener Remove 1 (left shim and/or right shim). 1

- Shim Remove 2 (a) 2

- Fastener Hole Inspect 3

- - Clearance Measure 4 (b) BACS40R015C027F is optional. (c) 1 BACS40R015B027F Shim Adjust Drill holes in shim to agree with hole diameters in fitting. 2

- Holes Drill

- - Shim Clean/Deburr To mating surfaces.

- DC93-006 Sealant Apply

- - Shim Install Increase diameter by 0.0156 2

- Holes Ream 5 See Code A1 and A2. 2

- Fastener Install 6 (a) Do an eddy current inspection of the holes through the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT Part 6, 51-00-16. If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. (b) Remove laminations to adjust the shim thickness. Remove all sharp edges. The maximum clearance permitted with the shim in position is 0.005. (c) Alternative: Make a solid shim from 2024-T3, or 2024-T4, -T81, T861, or 7075-T6. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 as an accepted procedure, for data about the chemical conversion treatment.

**FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 50 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**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. 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 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4526 - 0.4536 BACB30NX14K10X Bolt A1

- BACC30BH14S Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4682 - 0.4692 BACB30NX14K10Y Bolt A2

- BACC30AC14S Collar

**FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 51 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 52 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP** 

- - - Fastener Remove 1 (a)

- - Fastener Hole Inspect 2 See Codes A1 and A2.

- - Fastener Install 3 (a) Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT Part 6, 51-00-16. If you get an indication of a crack: Contact Boeing for repair instructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions.

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. 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 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4526 - 0.4536 BACB30NX14K10X Bolt A1

- BACC30BH14S Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4682 - 0.4692 BACB30NX14K10Y Bolt A2

- BACC30AC14S Collar

**FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 53 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 54 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP** 

- - - Fastener Remove 1 (a)

- - Fastener Hole Inspect See Codes B1 and B2

- - Fastener Install

- - - Fastener Remove 2 (a)

- - Fastener Hole Inspect See Codes C1 and C2

- - Fastener Install

- - - Fastener Remove 3 (a)

- - Fastener Hole Inspect (b)

- - Radius Filler Make/Install See Codes D1 and D2

- - Fastener Install (a) Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT, Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, in accordance with 757 NDT, Part 6, 51-00-17: If you get an indication of a crack: Contact Boeing for repairinstructions and repair prior to further flight. If you do not get an indication of a crack: Increase the diameter of the hole by 0.0156 and continue with the instructions. (b) If necessary, make and install a radius filler below the seal retainer at these fastener locations. Install Radius Filler BACF3H10JT010HG, or make the filler from 0.063 thick 2024-T3, -T4, -T42, or 7075-T6 Bare Aluminum Sheet as shown. Apply a Chemical Conversion Treatment, Type 2, Class A, and onelayer of Primer BMS 10-11, Type I to the bare aluminum. Refer to SOPM 20-43-03 as an accepted procedure, for data about the chemical conversion treatment. Install the filler with Sealant BMS 5-63 or Dow Corning 93-006.

**FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 55 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**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. 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 D590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30YK12K11X Bolt B1

- BACC30CP12C Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30YK12K11Y Bolt B2

- BACC30CP12CY Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30MC12A6U Bolt C1

- BACC30BH12S Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30MD12A6U Bolt C2

- BACC30AC12S Collar (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30FP12A11U Bolt D1

- BACC30AB12SY Collar (a) Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30KK12A11U Bolt D2

- BACC30AC12S Collar (a) If the installation of the radius filler is necessary, fasteners with longer grip lengths will also be necessary.

**FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 56 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 7: THIS FIGURE HAS BEEN DELETED**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 57 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 58 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  (a) (b) If the shim was replaced during the repair procedures, apply primer and a fillet seal around the outer edge of the shim/fitting flange. - Dow Corning 1200 Primer Apply 1 Dow Corning 93-006 Sealant

(a) (b) Apply to all locations where sealant was removed for the inspections and/or fastener replacement. - Dow Corning 1200 Primer Apply 2

- Dow Corning 93-006 Sealant
(c) (d)

- Dow Corning 1200 Primer Apply 3 Optional compound is RTV560, RTV3 or RTV60. - Dow Corning 3110 Leveling Compound (a) DAPCO 1-400 primer and BMS 5-63, Type II sealant is optional for Dow Corning 1200 primer and Dow Corning 93-006 sealant application. (b) Before the sealant is applied, let the primer dry. Let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours. Let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (c) Before the Dow Corning 3110 compound is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (d) You can mix solvent BMS 3-2, Type II, with the leveling compound to make it more liquid. The maximum quantity of solvent permitted in the mixture is 20 percent when measured by weight.

**FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 59 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  **CAUTION:** DO NOT INSTALL A NEW COLLAR OR TRY TO TIGHTEN EXISTING COLLAR IN AN ATTEMPT TO TIGHTEN THE JOINT BETWEEN THE FITTING AND BULKHEAD AS STRUCTURAL DAMAGE MAY OCCUR.

- - - Exposed plies (left shim) Cut 1

- - BMS 10-11, Type 1 Primer Apply 2 (a)

- Dow Corning 1200 Primer Apply 3 (a) (b) Seal edges - Dow Corning 93-006 Sealant Apply 4

- - - Exposed plies (right shim) Cut 5

- - BMS 10-11, Type 1 Primer Apply 6 (a) Dow Corning 1200 Primer Apply 7

**FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 60 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) (b) Seal edges - Dow Corning 93-006 Sealant Apply 8 (a) DAPCO 1-400 primer and BMS 5-63, Type II sealant is optional for Dow Corning 1200 primer and Dow Corning 93-006 sealant application. (b) Before the sealant is applied, let the primer dry. Let the DAPCO 1-400 primer dry for a minimum of 1 hour and a maximum of 16 hours. Let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours.

**FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 61 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 10: SEAL COVER PLATES**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 62 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut
**NOTES REFERENCE**  **QTY NAME**  **TASK STEP** 

- - 1 Cover Install 1 (a) (c) Refer to SOPM 20-50-19 as an accepted procedure. -- Primer DC 1200 Sealant DC93-006 Apply 2

- Refer to 757 AMM 54-53-01 as an accepted procedure. 1 Cover Plate Install 3

(b)

- 1 Boot Seal Move 4 Tighten Clamp

- 1 Clamp Adjust 5 (a) Apply Intermediate liquid control fillet seal around entire periphery of the cover. Before the Dow Corning 93-006 sealant is applied, let the Dow Corning 1200 primer dry for a minimum of 1 hour and a maximum of 24 hours. (b) Move the Boot Seal back to the original position as necessary. (c) DAPCO 1-400 primer and BMS 5-63, Type II sealant is optional for Dow Corning 1200 primer and Dow Corning 93-006 sealant application. Before the BMS 5-63 Type II sealant is applied, let the DAPCO 1- 400 primer dry for a minimum of 1 hour and a maximum of 16 hours.

**FIGURE 10: SEAL COVER PLATES (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 63 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 64 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut.
**MORE DATA QTY**  **PART NUMBER NAME**  **TASK STEP** 

- - - Fastener Remove 1 (a) (b) 4

- Fastener Hole Inspect 2 Refer to Codes B0, B1 and B2

- - Fastener Install 3 (a) Do an eddy current inspection of the hole(s) through the titanium fitting in accordance with 757 NDT,Part 6, 51-00-14. Do an eddy current inspection of the holes through the aluminum bulkhead in accordance with 757 NDT, Part 6, 51-00-16. Do an eddy current inspection of the holes through the steel web, in accordance with 757 NDT, Part 6, 51-00-17. (b) Measure the hole diameter. If the hole is true and round, and the diameter is within the limits allowed for installation of the same size fastener, do not increase the hole size. Otherwise, increase the hole size to remove damage

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. 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 65-88700 is used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3745 - 0.3755 BACB30YK12K11 Bolt B0

- BACC30CP12C Collar

**FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 65 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT NOTES**  **HOLE DIA PART NUMBER**  **NAME CODE**  Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.3901 - 0.3911 BACB30YK12K11X Bolt B1

- BACC30CP12C Collar Install wet with Sealant BMS 5-63 or Dow Corning 93-006. 0.4057 - 0.4067 BACB30YK12K11Y Bolt B2

- BACC30CP12CY Collar

**FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 66 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 one strut.
**MORE DATA QTY**  **PART NUMBER NAME**  **TASK STEP**  Refer to 757 AMM 78-11-04 as an accepted procedure. 1

- Common Nozzle Exhaust Remove 1

(a) 1

- (Diagonal Brace) Load Release 2 (a) Remove the load from the diagonal brace. Refer to 757 AMM 54-51-02 as an accepted procedure.

**FIGURE 12: NACELLE/PYLONS - ALTERNATIVE ACCESS TO THE CRITICAL HORIZONTAL FLANGE FASTENERS**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 67 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 68 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**NOTES REFERENCES**  **PROCEDURE NAME**  **TASK STEP** 

- In accordance with 757 NDT Part 4, 54- 50-02. Ultrasonic Inspection Fasteners Inspect 1

**FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 69 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 14: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 1 STRUT**  **(SHEET 1 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 70 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 14: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 1 STRUT**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 71 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 No. 1 Strut.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  12

- Fastener Remove 1 0.4995 - 0.5005 diameter. 4

- Fastener Hole Drill / Ream 2
0.4370 - 0.4380 diameter. 8

- Fastener Hole Drill / Ream 3 (a) 12

- Fastener Hole Inspect 4 (b) See Code A. 2

- Fastener Install (New) 5 (c) See Code B. 4

- Fastener Install (New) 6 (d) See Code C. 6

- Fastener Install (New) 7(a) Do an open hole High Frequency Eddy Current (HFEC) inspection for cracks in the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an HFEC inspection for cracks in the aluminum bulkheadin accordance with 757 NDT Part 6, 51-00-16. Do an HFEC inspection for cracks in the steel web, in accordance with 757 NDT Part 6, 51-00-17. (b) Make sure that the fastener head is clear of the radius of the bulkhead. Temporarily install the lower two code B fasteners to make sure adequate clearance exists. Spotface the holes in the bulkhead, if necessary, for correct fastener head installation. Spotface 0.875 diameter, 0.062-0.090 radius, 0.010 maximum depth. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of BMS 10-11, Type 1 to the bare aluminum. (c) Make sure that the lower fastener head is clear of the code A fastener head. Make sure that all the washers are clear of the radius of the bulkhead. Spotface the holes in the bulkhead, if necessary, for correct fastener head installation. Spotface 1.062 diameter, 0.062-0.090 radius, 0.010 maximum depth. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of BMS 10-11, Type 1 to the bare aluminum. (d) Make sure that the Washer installed between the nut and the bulkhead is clear of the radius of the bulkhead. Spotface the holes in the bulkhead, if necessary, for correct washer installation. Spotface 1.000 diameter, 0.062-0.090 radius, 0.010 maximum depth. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of BMS 10-11, Type 1 to the bare aluminum.

**FIGURE 14: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 1 STRUT (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 72 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**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. The QTY numbers shown below are the number of fasteners necessary for this figure. 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 D590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.
**MORE DATA HOLE DIA**  **QTY IDENTIFICATION**  **NAME CODE**  Install wet with sealant BMS 5-63. 0.4370 - 0.4380 2 BACB30YK14K11 BOLT, HEX DRIVE A

- - 2 BACC30BH14S COLLAR Install wet with sealant BMS 5-63. 0.4995 - 0.5005 4 BACB30US8K12 BOLT, 12 PT HEAD B
Install under the head of the bolt. - 4 BACW10BP8CD WASHER

Install under the nut.

- 4 BACW10BP8PTU WASHER, PLAIN (a)

- 4 BACN10HR8CS NUT (b) Install wet with sealant BMS 5-63. 0.4370 - 0.4380 6 BACB30US7K12 BOLT, 12 PT HEAD C
Install under the head of the bolt. - 6 BACW10BP7ACU WASHER

Install under the nut.

- 6 BACW10BP7DP WASHER

- - 6 BACN10HR7CD NUT (a) Tighten the nuts to a torque range of 1070 - 1140 inch-pounds.

**FIGURE 14: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 1 STRUT (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 73 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** (b) Tighten the bolts to a torque range of 815 - 865 inch-pounds.

**FIGURE 14: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 1 STRUT (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 74 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 15: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 2 STRUT**  **(SHEET 1 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 75 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT FIGURE 15: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 2 STRUT**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 76 of 79 **BOEING SERVICE BULLETIN 757-54A0047 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 No. 2 Strut.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  12

- Fastener Remove 1 0.4995 - 0.5005 diameter. 4

- Fastener Hole Drill / Ream 2
0.4370 - 0.4380 diameter. 8

- Fastener Hole Drill / Ream 3 (a) 12

- Fastener Hole Inspect 4 (b) See Code A. 2

- Fastener Install (New) 5 (c) See Code B. 4

- Fastener Install (New) 6 (d) See Code C. 6

- Fastener Install (New) 7(a) Do an open hole High Frequency Eddy Current (HFEC) inspection for cracks in the titanium fitting in accordance with 757 NDT Part 6, 51-00-14. Do an HFEC inspection for cracks in the aluminum bulkheadin accordance with 757 NDT Part 6, 51-00-16. Do an HFEC inspection for cracks in the steel web, in accordance with 757 NDT Part 6, 51-00-17 (b) Make sure that the fastener head is clear of the radius of the bulkhead. Temporarily install the lower two code B fasteners to make sure adequate clearance exists.Spotface the holes in the bulkhead, if necessary, for correct fastener head installation. Spotface 0.875 diameter, 0.062-0.090 radius, 0.010 maximum depth. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of BMS 10-11, Type 1 to the bare aluminum. (c) Make sure that the lower fastener head is clear of the code A fastener head. Make sure that all the washers are clear of the radius of the bulkhead. Spotface the holes in the bulkhead, if necessary, for correct fastener head installation. Spotface 1.062 diameter, 0.062-0.090 radius, 0.010 maximum depth. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of BMS 10-11, Type 1 to the bare aluminum. (d) Make sure that the Washer installed between the nut and the bulkhead is clear of the radius of the bulkhead. Spotface the holes in the bulkhead, if necessary, for correct washer installation. Spotface 1.000 diameter, 0.062-0.090 radius, 0.010 maximum depth. Apply a Chemical Conversion Treatment, Type 2, Class A, and two layers of BMS 10-11, Type 1 to the bare aluminum.

**FIGURE 15: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 2 STRUT (SHEET 3 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 77 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**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. The QTY numbers shown below are the number of fasteners necessary for this figure. 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 D590 and Boeing drawing 65-88700 is used to determine the part numbers used as substitutes.
**MORE DATA HOLE DIA**  **QTY IDENTIFICATION**  **NAME CODE**  Install wet with sealant BMS 5-63. 0.4370 - 0.4380 2 BACB30YK14K11 BOLT, HEX DRIVE A

- - 2 BACC30BH14S COLLAR Install wet with sealant BMS 5-63. 0.4995 - 0.5005 4 BACB30US8K12 BOLT, 12 PT HEAD B
Install under the head of the bolt. - 4 BACW10BP8CD WASHER

Install under the nut.

- 4 BACW10BP8PTU WASHER, PLAIN (a)

- 4 BACN10HR8CS NUT (b) Install wet with sealant BMS 5-63. 0.4370 - 0.4380 6 BACB30US7K12 BOLT, 12 PT HEAD C
Install under the head of the bolt. - 6 BACW10BP7ACU WASHER

Install under the nut.

- 6 BACW10BP7DP WASHER

- - 6 BACN10HR7CD NUT (a) Tighten the nuts to a torque range of 1070 - 1140 inch-pounds.

**FIGURE 15: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 2 STRUT (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 78 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT MORE DATA**  **HOLE DIA QTY**  **IDENTIFICATION NAME**  **CODE** (b) Tighten the bolts to a torque range of 815 - 865 inch-pounds.

**FIGURE 15: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 2 STRUT (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 13, 2003 757-54A0047 Revision 5 June 09, 2011 79 of 79 **BOEING SERVICE BULLETIN 757-54A0047 ALERT**  **ALERT**