### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-25A0505**  Original Issue: January 14, 2011 ATA System: 2550 **SUBJECT:** EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water Incursion Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 1 of 60 4.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 2 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION........................................ 7 A. Effectivity................................................ 7 1. Airplanes............................................. 7 2. Spares Affected......................................... 7 B. Concurrent Requirements....................................... 7 C. Reason................................................. 8 D. Description............................................... 8 E. Compliance.............................................. 8 F. Approval................................................ 8 G. Manpower............................................... 9 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1. Existing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2. Data supplied with this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 10 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1. Kits/Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 18 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 19 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND STRUCTURE [Group 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING SUPPORTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS AND INSTALL SUPPORT AT STATION 368. . . . . . . . . . . . . . . . . . 39 FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING . . . 47 FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS [Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND STRUCTURE [Group 2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 3 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB STRIP [Group 2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 4 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Summary**  **Number: 767-25A0505** Original Issue: January 14, 2011 ATA System: 2550 **SUBJECT:** EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water Incursion Change THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** This service bulletin and a kit of parts provides retrofit instructions to improve water drainage in the lower lobe. Water coming through the floor panels can accumulate up to 12 gallons in this location and typical aircraft movement may not remove all the water. There is a potential for water to enter the electronic equipment bay. Installation of parts assist in water drainage and will prevent water from getting into the electronic equipment bay. If parts are not installed possible water damage could occur to electronic equipment which could result in an electrical short and potential loss of several functions essential for safe flight. Boeing Service Related Problem (SRP) 767-SRP-25-0290 is related to this service bulletin. **ACTION (PRR F06004-1RS)** Install 2 drains, dam and new support structure. **EFFECTIVITY** 767-300 and 767-200 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. **COMPLIANCE** Boeing recommends that operator accomplish the instructions provided in this bulletin within 24 months after the Original Issue date on this service bulletin. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 5 of 60**INDUSTRY SUPPORT INFORMATION Group 1:**  Boeing warranty remedies are available for airplanes in warranty as of November 5, 2009. Please refer to Paragraph 2.B., Industry Support Information. **Group 2:** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **MANPOWER Group 1:**  **Elapsed Hours Total Task Hours**  **Airplanes** 8.50 16.00 767-300BCF **Group 2: Elapsed Hours**  **Total Task Hours Airplanes**  8.50 16.00 767-200SF
**MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 6 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 767 Service Bulletin **ALERT Number: 767-25A0505**  Original Issue: January 14, 2011 ATA System: 2550 **SUBJECT:** EQUIPMENT / FURNISHINGS - Cargo Compartment - Forward Lower Lobe Water Incursion Change THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR F06004-1RS for data about this change.
**DESCRIPTION CONFIGURATION**  **GROUP** 767-300BCF for VN191-VN195

- 1 767-200SF for VA511

- 2

Airplane Models: 767-200, 767-300 **Group Variable Number**  2 VA511 1 VN191 - VN195 2. Spares Affected None. **B. Concurrent Requirements** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 7 of 60**C. Reason** This service bulletin and a kit of parts provides retrofit instructions to improve water drainage in the lower lobe. Water coming through the floor panels can accumulate up to 12 gallons in this location and typical aircraft movement may not remove all the water. There is a potential for water to enter the electronic equipment bay. Installation of parts assist in water drainage and will prevent water from getting into the electronic equipment bay. If parts are not installed possible water damage could occur to electronic equipment which could result in an electrical short and potential loss of several functions essential for safe flight. Boeing Service Related Problem (SRP) 767-SRP-25-0290 is related to this service bulletin. **D. Description** Installs 2 drains, dam and new support structure. The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 119, 121, 122 767-300 **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 119, 121, 122 767-200 **E. Compliance** Boeing recommends that operator accomplish the instructions provided in this bulletin within 24 months after the Original Issue date on this service bulletin. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved for all airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 8 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT G. Manpower**  The table below shows an estimate of the task hours necessary to do this change for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **Group 1: Elapsed Hours**  **Task Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 1.50 3.00 2 Figure 1 0.50 1.00 2 Figure 2 1.50 3.00 2 Figure 3 1.25 2.50 2 Figure 4 1.25 2.50 2 Figure 5 1.50 3.00 2 Figure 6 0.50 0.50 1 Close Access 8.50 16.00 TOTAL FOR EACH AIRPLANE **Group 2: Elapsed Hours**  **Task Hours Number of Persons**  **Task** 0.50 0.50 1 Open Access 1.50 3.00 2 Figure 7 0.50 1.00 2 Figure 2 1.50 3.00 2 Figure 3 1.25 2.50 2 Figure 4 1.25 2.50 2 Figure 5 1.50 3.00 2 Figure 8 0.50 0.50 1 Close Access 8.50 16.00 TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 9 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT H. Weight and Balance Changes**  **Group 1: Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane**  +408.0 +2.6 767-300BCF **Group 2: Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane**  +902.0 +3.5 767-200SF
**I. Electrical Load Data** Not changed. **J. References** 1. Existing Data a. Engineering Change Memo PRR F06004-1RS b. Boeing Service Related Problem (SRP) 767-SRP-25-0290 c. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-50-01, 20-50-19 d. 767 Aircraft Maintenance Manual (AMM) 25-52-02 e. 767-200SF Structural Repair Manual (SRM) 51-40-02 f. 767-300BCF Structural Repair Manual (SRM) 51, 51, 51-40-02, 51-40-08 2. Data supplied with this Service Bulletin None. 3. Installation Drawings Used in the Preparation of this Service Bulletin
**Title Drawing Number**  SUPP0RT INSTALLATION - END LINING, STA 355, 453T1104 LINING INSTL - CEILING, FWD LWR CARGO COMPT, MOD 657T4640 SUPPORT INSTL - CEILING, FWD LWR CARGO COMPT, MOD 657T4641 LINING INSTL - CEILING, LWR CARGO COMPT, MOD 845T3108 SUPPORT INSTL - CEILING, LWR CARGO COMPT (MOD) 845T3109 STA 355 ENDWALL ASSY - REWORK INSTL 845T3154

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 10 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 11 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 12 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kit is subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 **REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR REORDER LEAD TIME (ROLT) AND THE LATEST PRICE INFORMATION**  **Unit Price as of the original issue date of this Service**  **Bulletin (US Dollars) QTY**  **Name Kit Number** 

$27,077.00 1 767-300BCF Water Management Retrofit Kit 880T0026-1 $26,844.00 1 767-200SF Water Management Retrofit Kit 880T0026-2
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing Part Page 2. Fax to (206) 662-7145 **B. Industry Support Information Group 1:**  Boeing warranty remedies are available for 767 airplanes in warranty as of November 5, 2009. For task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. The kit for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kit to Boeing Spares. Please refer to this service bulletin number and reference the airplane variable number in your purchase order. **Group 2:** Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 13 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT C. Parts Necessary For Each Airplane**  1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **NOTE:**One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. **Group 1:**
**Kit 880T0026-1 Notes**  **Existing Part Number Name**  **QTY New Part Number**  767-300BCF Water Management Retrofit Kit - 880T0026-1
845T3108-11 CEILING LINER 1 845T3108-21 845T3108-12 CEILING LINER 1 845T3108-22 845T3108-13 CEILING LINER 1 845T3108-23 845T3108-12 CEILING LINER 1 845T3108-32 845T3109-29 SUPPORT ASSY 1 845T3109-41 657T1137-1 SUPPORT ASSY 1 845T3109-42 Or IDR-767-25-0406-0065-5 Or IDR-767-25-0420-0010-5 Or IDR-767-25-0424-0017-5 Or IDR-767-25-0433-0002-5 SUPPORT 4 845T3109-47 TUBE 1 845T3109-48 TUBE 1 845T3109-49 SUPPORT ASSY 1 845T3109-51 SPUD ASSY 2 845T3109-52 CLOSURE BLOCK DETAIL 1 845T3109-53 CLOSURE BLOCK DETAIL 1 845T3109-58 845T3109-25 LEFT SUPPORT ASSY 1 845T3109-61 SUPPORT ASSY 1 845T3109-62 845T3109-25 RIGHT SUPPORT ASSY 1 845T3109-64 SUPPORT ASSY 1 845T3109-70 SUPPORT ASSY 1 845T3109-71

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 14 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT Group 1:** 
**Kit 880T0026-1 Notes**  **Existing Part Number Name**  **QTY New Part Number**  453T1541-1 SUPPORT ASSY 1 845T3109-73 SUPPORT ASSY 1 845T3109-75 SUPPORT ASSY 2 845T3154-14 453T1602-6 SUPPORT ASSY 1 845T3154-15 453T1602-7 SUPPORT ASSY 1 845T3154-16 453T1602-8 SUPPORT ASSY 1 845T3154-17 (a) BOLT, PAN HD, CROSS 10 BACB30NT3K2 (a) BOLT, PROTRUDING HD 4 BACB30VT5HK3 (a) BOLT 20 BACB30VT6K5 (a) CLAMP, LOOP 12 BACC10D616A (a) CLAMP, LOOP 6 BACC10DK16 (a) CLAMP, HOSE 4 BACC10JB022C040 (a) NUT 7 BACN10JC3CD (a) NUT 14 BACN10YR08CM (a) NUT 16 BACN10YR3CM (a) NUT 4 BACN10ZV08 (a) NUT 20 BACN10ZV3 (a) RIVET, UNIVERSAL HEAD 12 BACR15BB4D5C (a) RIVET 20 BACR15BB5D5C (a) RIVET, UNIVERSAL HD 10 BACR15BB5D6C (a) SCREW, 100 DEG HEAD 36 BACS12ER3K6 (a) SCREW 4 BACS12FA08K15 (a) SCREW, WASHER HEAD 4 BACS12FA08K22 (a) FAIRING SCREWS 10 BACS12FA3K10 (a) SCREW, WASHER HEAD 50 BACS12FA3K14 (a) SCREW, WASHER HEAD 212 BACS12FA3K8 (a) SCREW 6 BACS12GU3K10 (a) SCREW 4 BACS12GX08A16 (a) SCREW 4 BACS12GX08A22 (a) SCREW 11 BACS12GX3A8 (a) SCREW 10 BACS12HJ3K6

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 15 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT Group 1:** 
**Kit 880T0026-1 Notes**  **Existing Part Number Name**  **QTY New Part Number**  (a) STRAP 4 BACS38K1 (a) SHIM,LAMINATED 6 BACS40R008D010F (a) SHIM,LAMINATED 8 BACS40R008D012F (a) WASHER 10 BACW10P136AL (a) WASHER, PLAIN 10 BACW10P151AL (a) WASHER, PLAIN 4 BACW10P183AL (a) WASHER 13 NAS1149D0332J (a) There are more parts than are necessary. **Group 2:**
**Kit 880T0026-2 Notes**  **Existing Part Number Name**  **QTY New Part Number**  767-200SF Water Management Retrofit Kit - 880T0026-2
657T4640-7 CEILING LINER 1 657T4640-41 657T4640-32 CEILING LINER 1 657T4640-42 657T4640-29 CEILING LINER 1 657T4640-43 657T4640-32 CEILING LINER 1 657T4640-44 SUPPORT ASSY 1 845T3109-41 657T1137-4 SUPPORT ASSY 1 845T3109-42 SUPPORT 4 845T3109-47 TUBE 1 845T3109-48 TUBE 1 845T3109-49 SUPPORT ASSY 1 845T3109-51 SPUD ASSY 2 845T3109-52 CLOSURE BLOCK DETAIL 1 845T3109-53 CLOSURE BLOCK DETAIL 1 845T3109-58 845T3109-25 LEFT SUPPORT ASSY 1 845T3109-61 657T4661-12 SUPPORT ASSY 1 845T3109-62 657T4661-13 RIGHT SUPPORT ASSY 1 845T3109-64 SUPPORT ASSY 1 845T3109-70

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 16 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT Group 2:** 
**Kit 880T0026-2 Notes**  **Existing Part Number Name**  **QTY New Part Number**  SUPPORT ASSY 1 845T3109-71 453T1541-1 SUPPORT ASSY 1 845T3109-73 SUPPORT ASSY 1 845T3109-75 SUPPORT ASSY 2 845T3154-14 453T1602-6 SUPPORT ASSY 1 845T3154-15 453T1602-7 SUPPORT ASSY 1 845T3154-16 453T1602-8 SUPPORT ASSY 1 845T3154-17 (a) BOLT, PAN HD, CROSS 10 BACB30NT3K2 (a) BOLT, PROTRUDING HD 4 BACB30VT5HK3 (a) BOLT 20 BACB30VT6K5 (a) CLAMP, LOOP 12 BACC10D616A (a) CLAMP, LOOP 6 BACC10DK16 (a) CLAMP, HOSE 4 BACC10JB022C040 (a) NUT 7 BACN10JC3CD (a) NUT 14 BACN10YR08CM (a) NUT 16 BACN10YR3CM (a) NUT 4 BACN10ZV08 (a) NUT 20 BACN10ZV3 (a) RIVET, UNIVERSAL HEAD 12 BACR15BB4D5C (a) RIVET 20 BACR15BB5D5C (a) RIVET, UNIVERSAL HD 10 BACR15BB5D6C (a) SCREW, 100 DEG HEAD 36 BACS12ER3K6 (a) SCREW 4 BACS12FA08K15 (a) SCREW, WASHER HEAD 4 BACS12FA08K22 (a) FAIRING SCREWS 10 BACS12FA3K10 (a) SCREW, WASHER HEAD 50 BACS12FA3K14 (a) SCREW, WASHER HEAD 212 BACS12FA3K8 (a) SCREW 6 BACS12GU3K10 (a) SCREW 4 BACS12GX08A16 (a) SCREW 4 BACS12GX08A22 (a) SCREW 11 BACS12GX3A8

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 17 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT Group 2:** 
**Kit 880T0026-2 Notes**  **Existing Part Number Name**  **QTY New Part Number**  (a) SCREW 10 BACS12HJ3K6 (a) STRAP 4 BACS38K1 (a) SHIM,LAMINATED 6 BACS40R008D010F (a) SHIM,LAMINATED 8 BACS40R008D012F (a) WASHER 10 BACW10P136AL (a) WASHER, PLAIN 10 BACW10P151AL (a) WASHER, PLAIN 4 BACW10P183AL (a) WASHER 13 NAS1149D0332J (a) There are more parts than are necessary.

2. Parts and Materials Supplied by the Operator
**Notes Name**  **QTY Part Number /**  **Specification** (a) (b) TAPE - SEALING 1 Roll 657T4640-101 Equivalent to BMS 5-146, Class 1, Type I, Grade A. (a) (c) TAPE - DOUBLEBACK 1 Roll 657T4640-102 Equivalent to BMS 5-133, Class 1, Type IV. (d) Sealant 1 Quart Pro-Seal 870 BMS 5-95, Class B. (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Can be procured from 3M Company, 1425 Stokke Parkway, Menomonie, WI 54751. (c) Can be procured from Orcon Corporation, 1570 Atlantic Street, Union City, CA 94587–3299 (d) Can be procured from PRC-DeSoto International, Incorporated, Post Office Box 1800, Sylmar, CA 91342-3728
3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 18 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT D. Parts Necessary to Change Spares**  None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 19 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 20 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:**KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:**1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are in 767-300BCF SRM 51 Structural Repair Manual (SRM) 51 – Torque limits to tighten nuts and bolts are in 767-300BCF SRM 51. 5. Use the approved fastener and process material substitutions in accordance with 767-300BCF SRM 51. Alternate fasteners are listed in 767-300BCF SRM 51 and Boeing Drawing 012W6100. 6. If the length of any fastener specified in this service bulletin does not meet the installation standards in 767-300BCF SRM 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in 767-300BCF SRM 51 may be used. 7. Fay surface seal the lower surface of z-support bracket assy and the upper surface of drain fitting using BMS 5-95. Within the sealant's application time, apply sealant to upper surface of the fitting. Apply sealant to the surface with sufficient thickness required to fill the assembled faying surfaces and to give continuous and visible squeeze-out at the faying surface joints. Refer to SOPM 20-50-19 as an accepted procedure. 8. Apply BMS 5-95, Class "C" sealant to fasteners using method 2. Extruded sealant shall be continuous to indicate adequate sealing. Do not remove sealant from fastener threads prior to nut installation. Apply Class "B" sealant fillet around fastener after installation. Apply sealant so as to form a visually uniform coating which completely covers the fastener. Application to be completed within application time of sealant. Refer to SOPM 20-50-19 as an accepted procedure.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 21 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**9. Proper routing for right side hose into the bilge shall be determined by mock-up. Extra length of tubing was provided by design. Trim the excess as required when proper routing is accomplished. If required, usage of two extra plastic straps BACS38K1 is acceptable. 10. Proper routing for left side hose shall be determined by mock-up. The supports brackets shall be installed to the cargo bulkhead approximately 16 inches apart, with a tolerance of +/- 2.50 inches. Horizontal adjustment of about 0.6 inches is permitted by support bracket design. Extra length of tubing was provided by design - trim the excess as required when proper routing is accomplished. If required, usage of extra two plastic straps BACS38K1 is acceptable. 11. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS Group 1:**  1. Gain access to forward side of cargo bulkhead through door 119AL. 2. Gain access to aft side of cargo bulkhead through the forward cargo door. 3. Remove ceiling liners and structure in accordance with FIGURE 1. 4. Install cargo bulkhead support in accordance with FIGURE 2. 5. Install right side ceiling supports in accordance with FIGURE 3. 6. Install left side ceiling supports and install support (secondary dam) at station 368 in accordance with FIGURE 4. 7. Install drain tubing in accordance with FIGURE 5. 8. Install ceiling panels in accordance with FIGURE 6. 9. Put the airplane back to a serviceable condition. **Group 2:** 1. Gain access to forward side of cargo bulkhead through door 119AL. 2. Gain access to aft side of cargo bulkhead through the forward cargo door. 3. Remove ceiling liners and structure in accordance with FIGURE 7. 4. Install cargo bulkhead support in accordance with FIGURE 2. 5. Install right side ceiling supports in accordance with FIGURE 3.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 22 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**6. Install left side ceiling supports and install support (secondary dam) at station 368 in accordance with FIGURE 4. 7. Install drain tubing in accordance with FIGURE 5. 8. Install ceiling panels in accordance with FIGURE 8. 9. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 23 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND STRUCTURE**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 24 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND**  **STRUCTURE (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 25 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND**  **STRUCTURE (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 26 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) 1 845T3108-11 CEILING LINER Remove 1 (a) (b) 1 845T3108-12 CEILING LINER Remove 2 (a) (b) 1 845T3108-13 CEILING LINER Remove 3 (c) For VN191 2 IDR-767-25-0406-0087- 3 SUPPORT BRACKET Remove 4 (c) For VN192 2 IDR-767-25-0420-0081- 3 SUPPORT BRACKET Remove (c) For VN193 2 IDR-767-25-0424-0065- 3 SUPPORT BRACKET Remove (c) For VN194 2 IDR-767-25-0433-0044- 3 SUPPORT BRACKET Remove (c) For VN195 2 657T4664-1 SUPPORT BRACKET Remove For VN191 1 IDR-767-25-0406-0065- 5 STABILIZATION STRAP ASSY Remove 5
For VN192 1 IDR-767-25-0420-0010- 5 STABILIZATION STRAP ASSY Remove
For VN193 1 IDR-767-25-0424-0017- 5 STABILIZATION STRAP ASSY Remove
For VN194 1 IDR-767-25-0433-0002- 5 STABILIZATION STRAP ASSY Remove
For VN195. 1 657T1137-4 STABILIZATION STRAP ASSY Remove

1 845T3109-25 SUPPORT ASSY Remove 6 1 845T3109-29 SUPPORT ASSY Remove 7 1 453T1602-6 SUPPORT Remove 8 1 453T1602-7 SUPPORT Remove 9 1 453T1602-8 SUPPORT Remove 10 (a) Refer to 767 AMM 25-52-02 as an accepted procedure. (b) Panel can be used as a template to layout cut-outs in the new panels. (c) Plug any open holes left by removing the support brackets with AD rivet. Refer to 767-300BCF SRM 51- 40-02 as an accepted procedure.

**FIGURE 1: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND STRUCTURE**  **(SHEET 4 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 27 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT**  **ASSEMBLIES (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 28 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT**  **ASSEMBLIES (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 29 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  1 845T3154-15 SUPPORT ASSY Install (New) 1 1 845T3154-16 SUPPORT ASSY Install (New) 2 1 845T3154-17 SUPPORT ASSY Install (New) 3 2 845T3154-14 SUPPORT ASSY Install (New) 4 (a) 8 BACS12ER3K6 SCREW, 100 DEG HEAD Install (New) 5

8 BACS12ER3K6 SCREW, 100 DEG HEAD Install (New) 6 (a) 2 BACS12ER3K6 SCREW, 100 DEG HEAD Install (New) 7 (a) 1 BACS12ER3K6 SCREW, 100 DEG HEAD Install (New) 8 (a) 2 BACS12ER3K6 SCREW, 100 DEG HEAD Install (New) 9 (a) 6 BACS12ER3K6 SCREW, 100 DEG HEAD Install (New) 10 (a) Drill 0.2180 - 0.2290 diameter hole from hole in existing structure. Countersink 0.2610 - 0.2710 X 100 degree (near side). Refer to 767-300BCF SRM 51-40-08 as an accepted procedure.

**FIGURE 2: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CARGO BULKHEAD SUPPORT ASSEMBLIES**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 30 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING**  **SUPPORTS (SHEET 1 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 31 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING**  **SUPPORTS (SHEET 2 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 32 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING**  **SUPPORTS (SHEET 3 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 33 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING**  **SUPPORTS (SHEET 4 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 34 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING**  **SUPPORTS (SHEET 5 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 35 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  1 453T1541-1 SUPPORT ASSY Remove 1 Gap to be 0.1500 +/- 0.0100 between Support Assemblies. 1 845T3109-42 SUPPORT ASSY Install (New) 2
Fay seal mating surfaces of cargo bulkhead support assembly with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure. Gap to be 0.1500 +/- 0.0100 between Support Assemblies. 1 845T3109-62 SUPPORT ASSY Install (New) 3

(a) 2 BACB30NT3K2 BOLT, PAN HD, CROSS Install (New) 4 (b) 1 845T3109-51 SUPPORT ASSY Install (New) 5 Drill 0.1610 / 0.1640 diameter holes frompilot holes in Support Assy. 2 BACB30VT5HK3 BOLT, PROTRUDING HD Install (New)

2 BACN10ZV08 NUT Install (New) 2 BACW10P183AL WASHER, PLAIN Install (New) 1 845T3109-64 RIGHT SUPPORT AS- SY Install (New) 6 (c) 2 BACS40R008D012F SHIM,LAMINATED Install (New) (a) 2 BACB30NT3K2 BOLT, PAN HD, CROSS Install (New) Drill holes from pilotholes in Support Assy. 4 BACR15BB5D6C RIVET, UNIVERSAL HD Install (New)

**FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING SUPPORTS**  **(SHEET 6 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 36 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 845T3109-73 SUPPORT ASSY Install (New) 7 Drill from holes in existing structure. 2 BACR15BB5D5C RIVET Install (New)

1 BACB30VT6K5 BOLT Install (New) Install under head of bolt. 1 BACW10P151AL WASHER, PLAIN Install (New) (d) 1 BACN10ZV3 NUT Install (New) 4 BACB30VT6K5 BOLT Install (New) 8 Install under head of bolt. 4 BACW10P151AL WASHER, PLAIN Install (New) (d) 4 BACN10ZV3 NUT Install (New) Install in accordancewith Accomplishment Instructions, General Information Note 7 and 8. 1 845T3109-52 SPUD ASSY Install (New) 9

Install in accordancewith Accomplishment Instructions, General Information Note 7 and 8. 4 BACS12HJ3K6 SCREW Install (New)

Install in accordancewith Accomplishment Instructions, General Information Note 7 and 8. 4 BACN10YR3CM NUT Install (New)

(e) (f) 1 845T3109-58 CLOSURE BLOCK DETAIL Install (New) 10 (f) 1 845T3109-70 SUPPORT ASSY Install (New) 11 4 BACS12FA3K8 SCREW, WASHER HEAD Install (New) 12 (g) 1 BACS12FA08K15 SCREW Install (New) 13 Install in accordancewith Accomplishment Instructions, General Information Note 8. 1 BACN10YR08CM NUT Install (New)

**FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING SUPPORTS**  **(SHEET 7 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 37 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (g) 1 BACS12FA08K22 SCREW, WASHER HEAD Install (New) 14

1 BACN10YR08CM NUT Install (New) (g) (h) 1 BACS12GX08A16 SCREW Install (New) 15 1 BACN10YR08CM NUT Install (New) (g) (h) 1 BACS12GX08A22 SCREW Install (New) 16 1 BACN10YR08CM NUT Install (New) (i) 1 BACS12GX3A8 SCREW Install (New) 17 (j)

- PRO-SEAL 870 SEALANT Apply 18 (a) Leave a 0.005-0.010 clearance between bolt head and support structure. (b) Locate support assy Fwd/Aft, by mock-up. A good location shall perfectly nest the two small structuralsupports and shall clear all other structural parts and adjacent fasteners. If needed, it is acceptable to locally trim this support assy, along the edge, without compromising the edge margins. Trim area shall not be more than 0.1 inch from the part trimline and shall not exceed 0.5 inches in length. (c) Strip .003 laminations if and as required. Install shims wet and finish cut edges with BMS 10-11, type 1 yellow primer. Refer to SOPM 20-41-02 as an accepted procedure. (d) Torque nut to 20-25 In-Lbs. Refer to SOPM 20-50-01 as an accepted procedure. (e) The aft face of cargo bulkhead support assembly and the aft face of closure block detail need to be flush. (f) Fay seal all mating surfaces with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure. (g) Drill hole through mating parts from hole in 845T3109-58 to 0.1920 - 0.2030 diameter. (h) Countersink near side 0.332 - 0.319 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted procedure. (i) Countersink near side 0.385 - 0.371 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted procedure. (j) Fillet seal all visible edges and gap seal all gaps with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure.

**FIGURE 3: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL RIGHT SIDE CEILING SUPPORTS**  **(SHEET 8 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 38 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS**  **AND INSTALL SUPPORT AT STATION 368 (SHEET 1 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 39 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS**  **AND INSTALL SUPPORT AT STATION 368 (SHEET 2 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 40 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS**  **AND INSTALL SUPPORT AT STATION 368 (SHEET 3 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 41 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS**  **AND INSTALL SUPPORT AT STATION 368 (SHEET 4 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 42 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS**  **AND INSTALL SUPPORT AT STATION 368 (SHEET 5 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 43 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Gap to be 0.1500 +/- 0.0100 between Support Assemblies. 1 845T3109-41 SUPPORT ASSY Install (New) 1

1 845T3109-61 LEFT SUPPORT ASSY Install (New) 2 (a) 2 BACS40R008D012F SHIM,LAMINATED Install (New) (b) 2 BACB30NT3K2 BOLT, PAN HD, CROSS Install (New) Drill holes from pilotholes in Support Assy. 4 BACR15BB5D6C RIVET, UNIVERSAL HD Install (New)

**FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS AND INSTALL SUPPORT AT STATION 368**  **(SHEET 6 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 44 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 BACB30VT6K5 BOLT Install (New) 3 Install under head of bolt. 1 BACW10P136AL WASHER Install (New) (c) 1 BACN10ZV3 NUT Install (New) Install in accordancewith Accomplishment Instructions, General Information Note 7 and 8. 1 845T3109-52 SPUD ASSY Install (New) 4

Install in accordancewith Accomplishment Instructions, General Information Note 7 and 8. 4 BACS12HJ3K6 SCREW Install (New)

Install in accordancewith Accomplishment Instructions, General Information Note 7 and 8. 4 BACN10YR3CM NUT Install (New)

(d) (e) 1 845T3109-53 CLOSURE BLOCK DETAIL Install (New) 5 (e) 1 845T3109-71 SUPPORT ASSY Install (New) 6 4 BACS12FA3K8 SCREW, WASHER HEAD Install (New) 7 (f) 1 BACS12FA08K15 SCREW Install (New) 8 Install in accordancewith Accomplishment Instructions, General Information Note 8. 1 BACN10YR08CM NUT Install (New) (f) 1 BACS12FA08K22 SCREW, WASHER HEAD Install (New) 9

1 BACN10YR08CM NUT Install (New) (f) (g) 1 BACS12GX08A16 SCREW Install (New) 10 1 BACN10YR08CM NUT Install (New) (f) (g) 1 BACS12GX08A22 SCREW Install (New) 11 1 BACN10YR08CM NUT Install (New) (h) 1 BACS12GX3A8 SCREW Install (New) 12

**FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS AND INSTALL SUPPORT AT STATION 368**  **(SHEET 7 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 45 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (i)

- 845T3109 SEAL Apply 13 1 845T3109-75 SUPPORT ASSY Install (New) 14 Install near side. 4 BACR15BB5D5C RIVET Install (New) 15 (a) Strip .003 laminations if and as required. Install shims wet and finish cut edges with BMS 10-11, type 1 yellow primer. Refer to SOPM 20-41-02 as an accepted procedure. (b) Leave a 0.005-0.010 clearance between bolt head and support structure. (c) Torque nut to 20-25 In-Lbs. Refer to SOPM 20-50-01 as an accepted procedure. (d) The aft face of cargo bulkhead support assembly and the aft face of closure block detail need to be flush. (e) Fay seal all mating surfaces with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure. (e) Drill hole through mating parts from hole in 845T3109-58 to 0.1920 - 0.2030 diameter. (e) Countersink near side 0.332 - 0.319 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted procedure. (h) Countersink near side 0.385 - 0.371 X 100 degree. Refer to 767-300BCF SRM 51-40-08 as an accepted procedure. (i) Fillet seal all visible edges and gap seal all gaps with BMS 5-95. Refer to SOPM 20-50-19 as an accepted procedure.

**FIGURE 4: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL LEFT SIDE CEILING SUPPORTS AND INSTALL SUPPORT AT STATION 368**  **(SHEET 8 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 46 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 47 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 48 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 49 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  1 845T3109-48 TUBE Install (New) 1 1 BACC10JB022C040 CLAMP, HOSE Install (New) 2 Remove existing clamps. 5 BACC10D616A CLAMP, LOOP Install (New) 3

5 BACS12GX3A8 SCREW Install (New) 5 NAS1149D0332J WASHER Install (New) 5 BACN10JC3CD NUT Install (New) Route tube in accordance with Accomplishment Instructions, General Information Note 9. 1 845T3109-48 TUBE Route 4

1 BACS38K1 STRAP Install (New) 1 845T3109-49 TUBE Install (New) 5 1 BACC10JB022C040 CLAMP, HOSE Install (New) 6 Install brackets inaccordance with Accomplishment Instructions, General Information Note 10. 4 845T3109-47 SUPPORT Install (New) 7

8 BACR15BB4D5C RIVET, UNIVERSAL HEAD Install (New)

4 BACC10DK16 CLAMP, LOOP Install (New) 8 4 BACS12GU3K10 SCREW Install (New) 4 NAS1149D0332J WASHER Install (New) 4 BACN10YR3CM NUT Install (New) Route tube in accordance with Accomplishment Instructions, General Information Note 10. 1 845T3109-49 TUBE Route 9

1 BACS38K1 STRAP Route

**FIGURE 5: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL DRAIN TUBING (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 50 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 51 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Drill 0.1920 - 0.1980 diameter holes from holes in existing structure. 1 845T3109-51 SUPPORT ASSY Drill 1

Refer to 767 AMM25-52-02 as an accepted procedure. 1 845T3108-21 CEILING LINER Install (New) 2
(d) (a) (b) 51 BACS12FA3K8 SCREW, WASHER HEAD Install (New)

- 657T4640-101 TAPE - SEALING Install (New) Refer to 767 AMM25-52-02 as an accepted procedure. 1 845T3108-32 CEILING LINER Install (New) 3
(c) (d)

- 657T4640-101 TAPE - SEALING Install (New) Refer to 767 AMM25-52-02 as an accepted procedure. 1 845T3108-22 CEILING LINER Install (New) 4
(d) (a) (b) 58 BACS12FA3K8 SCREW, WASHER HEAD Install (New)

- 657T4640-101 TAPE - SEALING Install (New) 2 BACS12FA3K10 FAIRING SCREWS Install (New) 5 Refer to 767 AMM25-52-02 as an accepted procedure. 1 845T3108-23 CEILING LINER Install (New) 6
(c) (d) (a) (b) 33 BACS12FA3K8 SCREW, WASHER HEAD Install (New) All locations except those designated for a different fastener.

- 657T4640-101 TAPE - SEALING Install (New) (a) (b) 23 BACS12FA3K14 SCREW, WASHER HEAD Install (New) 7 (a) Drill 0.29 - 0.30 diameter hole through liner from center of existing slotted hole in structure. Refer to 767 AMM 25-52-02 as an accepted procedure.

**FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 52 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) Maintain 0.60 inch edge margin for fasteners. (c) Align new ceiling panel with previously removed ceiling panel to layout cut-outs and do cuts. Refer to 767 AMM 25-52-02 as an accepted procedure. (d) Apply tape to cover all joints and seams in ceiling liner and shrouds. At panel edges tape shall extend to seal edge joint. Centerline of tape to coincide approximately with the centerline of lining attaching fasteners. Once installed, tape shall not be reused. Splice in new tape if tape is removed for any reason. Refer to 767 AMM 25-52-02 as an accepted procedure.

**FIGURE 6: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 53 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND STRUCTURE**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 54 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND**  **STRUCTURE (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 55 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND**  **STRUCTURE (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 56 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  1 657T4640-30 RUB STRIP Remove / Keep 1 (a) 1 657T4640-7 CEILING LINER Remove 2 (a) (b) 1 657T4640-29 CEILING LINER Remove 3 (a) (b) 1 657T4640-32 CEILING LINER Remove 4 (c) 3 657T4664-1 SUPPORT BRACKET Remove 5 1 657T1137-4 STABILIZATION STRAP ASSY Remove 6

1 845T3109-25 SUPPORT ASSY Remove 7 1 845T3109-29 SUPPORT ASSY Remove 8 1 453T1602-6 SUPPORT Remove 9 1 453T1602-7 SUPPORT Remove 10 1 453T1602-8 SUPPORT Remove 11 (a) Refer to 767 AMM 25-52-02 as an accepted procedure. (b) Panel can be used as a template to layout cut-outs in the new panels. (c) Plug any open holes left by removing the support brackets with AD rivets. Refer to 767-200SF SRM 51- 40-02 as an accepted procedure.

**FIGURE 7: CARGO COMPARTMENT - FORWARD LOWER LOBE - REMOVE CEILING LINERS AND STRUCTURE**  **(SHEET 4 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 57 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB STRIP**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 58 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Drill 0.1920 - 0.1980 diameter holes from holes in existing structure. 1 845T3109-51 SUPPORT ASSY Drill 1

Refer to 767 AMM25-52-02 as an accepted procedure. 1 657T4640-41 CEILING LINER Install (New) 2
(d) (a) (b) 51 BACS12FA3K8 SCREW, WASHER HEAD Install (New)

- 657T4640-101 TAPE - SEALING Install (New) Refer to 767 AMM25-52-02 as an accepted procedure. 1 657T4640-44 CEILING LINER Install (New) 3
(c) (d)

- 657T4640-101 TAPE - SEALING Install (New) Refer to 767 AMM25-52-02 as an accepted procedure. 1 657T4640-42 CEILING LINER Install (New) 4
(d) (a) (b) 58 BACS12FA3K8 SCREW, WASHER HEAD Install (New)

- 657T4640-101 TAPE - SEALING Install (New) 3 BACS12FA3K10 FAIRING SCREWS Install (New) 5 Refer to 767 AMM25-52-02 as an accepted procedure. 1 657T4640-43 CEILING LINER Install (New) 6
(c) (d) (a) (b) 33 BACS12FA3K8 SCREW, WASHER HEAD Install (New) All locations except those designated for a different fastener.

- 657T4640-101 TAPE - SEALING Install (New) (a) (b) 23 BACS12FA3K14 SCREW, WASHER HEAD Install (New) 7

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

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

**FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB STRIP**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 59 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) Drill 0.29 - 0.30 diameter hole through liner from center of existing slotted hole in structure. Refer to 767 AMM 25-52-02 as an accepted procedure. (b) Maintain 0.60 inch edge margin for fasteners. (c) Align new ceiling panel with previously removed ceiling panel to layout cut-outs and do cuts. Refer to 767 AMM 25-52-02 as an accepted procedure. (d) Apply tape to cover all joints and seams in ceiling liner and shrouds. At panel edges tape shall extend to seal edge joint. Centerline of tape to coincide approximately with the centerline of lining attaching fasteners. Once installed, tape shall not be reused. Splice in new tape if tape is removed for any reason. Refer to 767 AMM 25-52-02 as an accepted procedure. (e) Install doubleback tape between ceiling liner and rub strip along entire periphery of rub strip. Doubleback tape overlap splices allowed.

**FIGURE 8: CARGO COMPARTMENT - FORWARD LOWER LOBE - INSTALL CEILING PANELS AND RUB STRIP**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 14, 2011 767-25A0505 60 of 60 **BOEING SERVICE BULLETIN 767-25A0505 ALERT**  **ALERT**