Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Number: 757-54-0049

Original Issue: July 16, 2007

Revision 1: September 23, 2009

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification

- Rolls Royce RB211-535E Engines

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2007 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Unpublished Work - All Rights Reserved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

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7.0
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BOEING SERVICE BULLETIN 757-54-0049

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 20

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 26

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

[Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

[Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM [Group 1,

Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM [Group 1,

Configuration 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Revision 1: September 23, 2009 757-54-0049

3 of 77

BOEING SERVICE BULLETIN 757-54-0049
FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . 53

FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . 56

FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION [Group 1, Configuration

1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

FIGURE 13: ENGINE NUMBER 1 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . 71

FIGURE 14: ENGINE NUMBER 2 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION [Group 1, Configuration 1] . . . . . . . . . . . . . . . . . . 74

APPENDIX A: AFT HINGE FITTING FASTENER STACKUP . . . . . . . . . . . . . . . . . . . . . . . . 77

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BOEING SERVICE BULLETIN 757-54-0049
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 757-54-0049

Original Issue: July 16, 2007

Revision 1: September 23, 2009

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification

- Rolls Royce RB211-535E Engines

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes changed as shown in the original issue of this service bulletin. Washer

stackup should be inspected for the correct installation sequence. If the installation is found to be incorrect, the

nut(s) and bolt(s) must be removed and the washers reinstalled.

Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2008-13-20, is related to this service

bulletin.

REASON FOR REVISION

This revision is sent to change the Work Instructions for Part III - Preventive Modification, and the associated

figures, to allow the option of doing the Part III - Preventive Modification on just the hinges that are damaged,

and allow continued repeat inspections on the hinges that are undamaged. This revision also corrects the names

of the different washers (special washer, countersunk washer, plain washer) used in Figure 11 and Figure 12.

This revision is also sent to add an inspection for airplanes, that did the original issue, to inspect the fastener

stackup securing the aft hinge fittings to the strut.

Changes to this service bulletin include:

— Paragraph 1.E., Compliance - Footnote and Damage Tolerance note added.

— Paragraph 3.B., Work Instructions, Part III-Preventive Modification - Added steps 4, 5. Added Caution note

to step 3.

— Figures 1-12 were modified to include a footnote adding flexibility in inspecting and modifying the hinges.

— Figures 13 and 14 were modified to include a note stating that quantities could be halved if only one hinge

is removed/installed on either strut.

— The fastener tables in Figures 11 and 12 were modified to correct the names of washers and to add words

that clarify the washer orientation.

— Added note to Figures 5, 6, 9 and 10, to clarify that you remove one bolt at a time, replace it with a new

bolt, and then go to the next bolt.

— Added a second configuration for those airplanes that have completed the original issue of this service

bulletin, to inspect for washer stackup in Figures 11 and 12. Added Appendix A to show correct fastener

stackup.

— Added flexibility to install a new aft hinge fitting if heat damage is found after trimming.

— Added ammonium persulfate in addition to Nital to use for inspecting for heat damage.

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— Replaced BMS 3-24 grease with BMS 3-33 grease.

— Changed torque reference from SOPM 20-50-01 to BAC5009.

— Added the word "interim" to the title for Figures 13 and 14 and removed the torque specifications in the

footnotes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: July 16, 2007

Revision 1: September 23, 2009

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BOEING SERVICE BULLETIN 757-54-0049
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Summary Number: 757-54-0049

Original Issue: July 16, 2007

Revision 1: September 23, 2009

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification

- Rolls Royce RB211-535E Engines

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

You cannot make the changes given in this service bulletin unless the changes given in Service Bulletin

757-54-0015 R3 are made prior to or concurrent with this service bulletin. The 757-54-0015 service bulletin

replaced an older aft hinge fitting and attachment bolts with the current part numbers on airplanes line numbers

through 241. The changes given in Service Bulletin 757-54-0015 were made on airplanes after line number 241,

before delivery.

BACKGROUND

This service bulletin gives instructions to do a detailed inspection and preventive modification on the thrust

reverser aft hinge fittings, and hinge fitting attachment bolts. Attachment bolts have been reported to fail at the

thrust reverser aft hinge fittings. The hinge has integral fail-safe features, but loss of the entire four bolt pattern

constitutes complete loss of the load path. Loss of the load path could result in the departure of the thrust reverser

from the airplane which could result in damage to the airplane and hazards to persons or property on the ground.

Boeing has received 13 reports of 14 separate incidents of bolt failure at the thrust reverser aft hinge fittings.

All of the reported incidents occurred on airplanes with Rolls Royce RB211-535E engines. Of the 14 incidents

there were 9 hinges with 1 out of 4 bolts failed, 2 hinges with 2 out of 4 bolts failed, and 3 hinges with 3 out of

4 bolts failed.

The possible causes of the bolt failure can be attributed to high operational loads, contact loads caused by

possible interference between the thrust reverser hinge and the hinge beam, and the 4 attachment bolts are

installed with washers that can ride the radius of the hinge fitting spotface.

As a part of a service bulletin validation program, this change was completed on airplane NT744 by Service

Bulletin 757-54-0049 Validation Copy 01 before the initial release of this service bulletin. The change completed

on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 is equivalent to the initial release of this

service bulletin.

Boeing Service Related Problem (SRP) 757-SRP-54-0098 is related to this service bulletin.

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Revision 1: September 23, 2009 757-54-0049

7 of 77
ACTION (PRR 54530-267RS)

Inspections:

Get Access to the thrust reverser aft hinge fittings. Do a detailed inspection of the aft hinge fittings and the eight

attachment bolts for signs of damage. If any damage to the aft hinge fitting and/or attachment bolts is found,

the damage must be corrected before further flight and the preventive modification must be scheduled. For

Group 1, Configuration 2 airplanes, do a detailed inspection of washer stackup. If the stackup is incorrect, the

washers must be removed and reinstalled.

Preventive Modification:

Operators may do the preventive modification. After the preventive modification is accomplished it is no longer

necessary to do the repeat inspections shown in this service bulletin. Get Access to the thrust reverser aft hinge

fittings. Remove the thrust reverser C-ducts. Trim the aft hinge fitting lugs to clear possible contact with the

hinge beam. Remove the four attachment bolts on each aft hinge fitting, high frequency eddy current (HFEC)

inspect the fastener holes and replace with new and improved bolts, washers and nuts. Refit thrust reversers

and return airplane to a serviceable condition.

The related 757-300 bulletin is Service Bulletin 757-54-0050.

EFFECTIVITY

757-200/ 200CB/ 200PF airplanes with Rolls Royce RB211-535E engines. Refer to Paragraph 1.A.1.

COMPLIANCE

Refer to Service Bulletin Paragraph 1.E for compliance.

Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2008-13-20 is related to this service

bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of October 17, 2003. Please refer to

Paragraph 2.B., Industry Support Information.

MANPOWER

Refer to Service Bulletin Paragraph 1.G Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN 757-54-0049
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BOEING SERVICE BULLETIN 757-54-0049
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BOEING SERVICE BULLETIN 757-54-0049

BLANK PAGE
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Number: 757-54-0049

Original Issue: July 16, 2007

Revision 1: September 23, 2009

ATA System: 5451

SUBJECT: NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Aft Hinge Fitting Modification

- Rolls Royce RB211-535E Engines

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below. Refer to PRR 54530-267RS for data about

this change.

GROUP CONFIGURATION DESCRIPTION

757-200/ 200CB/ 200PF Airplanes, with Rolls Royce RB211-535E

engines.

1 -

Airplanes that have not been modified in accordance with the original

issue of this service bulletin.

1

Airplanes that have been modified in accordance with the original

issue of this service bulletin.

2

Airplane Models:

757-200, 757-200CB, 757-200PF

Variable Number Group

NA002 - NA028 1

NA194 - NA199 1

NA237 - NA239 1

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11 of 77
Variable Number Group

NA301 - NA305 1

NA341 - NA352 1

NA392 - 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 - NB228 1

NB230 1

NB236 1

NB239 1

NB261 - NB267 1

NB291 - NB299 1

NB301 - NB302 1

NB311 1

NB321 - NB331 1

NB421 - NB438 1

NB446 1

NB451 - NB454 1

NB501 - NB523 1

NB561 1

NB571 1

NB581 - NB583 1

NC058 - NC062 1

NC936 - NC950 1

NC971 - NC974 1

ND001 - ND007 1

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12 of 77

BOEING SERVICE BULLETIN 757-54-0049
Variable Number Group

ND011 - ND059 1

ND111 - ND113 1

ND161 - ND199 1

ND201 - ND203 1

ND221 - ND225 1

ND241 - ND248 1

ND301 - ND322 1

ND401 1

ND891 1

ND895 1

NJ001 - NJ004 1

NJ031 - NJ032 1

NN001 - NN002 1

NN051 - NN052 1

NS601 - NS616 1

NT001 - NT009 1

NT201 - NT202 1

NT231 - NT234 1

NT237 - NT240 1

NT242 1

NT245 - NT248 1

NT281 - NT289 1

NT381 - NT386 1

NT401 - NT409 1

NT411 - NT412 1

NT426 - NT427 1

NT431 - NT432 1

NT436 - NT438 1

NT446 1

NT731 - NT769 1

NT861 - NT862 1

NT901 - NT916 1

NT971 - NT985 1

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BOEING SERVICE BULLETIN 757-54-0049
2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for

the recommended use.

B. Concurrent Requirements

You cannot make the changes given in this service bulletin unless the changes given in Service Bulletin

757-54-0015 R3 are made prior to or concurrent with this service bulletin. The 757-54-0015 service

bulletin replaced an older aft hinge fitting and attachment bolts with the current part numbers on airplanes

line numbers through 241. The changes given in Service Bulletin 757-54-0015 were made on airplanes

after line number 241, before delivery.

C. Reason

This service bulletin gives instructions to do a detailed inspection and preventive modification on the

thrust reverser aft hinge fittings, and hinge fitting attachment bolts. Attachment bolts have been reported

to fail at the thrust reverser aft hinge fittings. The hinge has integral fail-safe features, but loss of the

entire four bolt pattern constitutes complete loss of the load path. Loss of the load path could result in

the departure of the thrust reverser from the airplane which could result in damage to the airplane and

hazards to persons or property on the ground.

Boeing has received 13 reports of 14 separate incidents of bolt failure at the thrust reverser aft hinge

fittings. All of the reported incidents occurred on airplanes with Rolls Royce RB211-535E engines. Of

the 14 incidents there were 9 hinges with 1 out of 4 bolts failed, 2 hinges with 2 out of 4 bolts failed,

and 3 hinges with 3 out of 4 bolts failed.

The possible causes of the bolt failure can be attributed to high operational loads, contact loads caused

by possible interference between the thrust reverser hinge and the hinge beam, and the 4 attachment

bolts are installed with washers that can ride the radius of the hinge fitting spotface.

As a part of a service bulletin validation program, this change was completed on airplane NT744 by

Service Bulletin 757-54-0049 Validation Copy 01 before the initial release of this service bulletin. The

change completed on airplane NT744 by Service Bulletin 757-54-0049 Validation Copy 01 is equivalent

to the initial release of this service bulletin.

Revision 1: This revision is sent to change the Work Instructions for Part III - Preventive Modification,

and the associated figures, to allow the option of doing the Part III - Preventive Modification on just the

hinges that are damaged, and allow continued repeat inspections on the hinges that are undamaged.

This revision also corrects the names of the different washers (special washer, countersunk washer,

plain washer) used in Figure 11 and Figure 12.

Changes to this service bulletin include:

— Paragraph 1.E., Compliance - Footnote and Damage Tolerance note added.

— Paragraph 3.B., Work Instructions, Part III-Preventive Modification - Added steps 4, 5. Added

Caution note to step 3.

— Figures 1-12 were modified to include a footnote adding flexibility in inspecting and modifying the

hinges.

— Figures 13 and 14 were modified to include a flag note stating that quantities could be halved if

only one hinge is removed/installed on either strut.

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1: September 23, 2009 757-54-0049

14 of 77

BOEING SERVICE BULLETIN 757-54-0049
— The Fastener Tables in Figures 11 and 12 were modified to correct the names of washers and to

add words that clarify the washer orientation.

— Added note to Figures 5, 6, 9 and 10, to clarify that you remove one bolt at a time, replace it with

a new bolt, and then go to the next bolt.

— Added a second configuration for those airplanes that have completed the original issue of this

service bulletin, to inspect for washer stackup in Figures 11 and 12. Added Appendix A to show

correct fastener stackup.

— Added flexibility to install a new aft hinge fitting if heat damage is found after trimming.

— Added ammonium persulfate in addition to Nital to use for inspecting for heat damage.

— Replaced BMS 3-24 grease with BMS 3-33 grease.

— Changed torque reference from SOPM 20-50-01 to BAC5009.

— Changed Figures 13 and 14 to interim installation of existing fittings and removed torque

specifications in footnotes.

Boeing Service Related Problem (SRP) 757-SRP-54-0098 is related to this service bulletin.

D. Description

Inspections:

Get Access to the thrust reverser aft hinge fittings. Do a detailed inspection of the aft hinge fittings and

the eight attachment bolts for signs of damage. If any damage to the aft hinge fitting and/or attachment

bolts is found, the damage must be corrected before further flight and the preventive modification must

be scheduled. For Group 1, Configuration 2 airplanes, do a detailed inspection of washer stackup. If

the stackup is incorrect, the washers must be removed and reinstalled.

Preventive Modification:

Operators may do the preventive modification. After the preventive modification is accomplished it is

no longer necessary to do the repeat inspections shown in this service bulletin. Get Access to the thrust

reverser aft hinge fittings. Remove the thrust reverser C-ducts. Trim the aft hinge fitting lugs to clear

possible contact with the hinge beam. Remove the four attachment bolts on each aft hinge fitting, high

frequency eddy current (HFEC) inspect the fastener holes and replace with new and improved bolts,

washers and nuts. Refit thrust reversers and return airplane to a serviceable condition.

The related 757-300 bulletin is Service Bulletin 757-54-0050.

Revision 1: More work is necessary on airplanes changed as shown in the original issue of this service

bulletin. Washer stackup should be inspected for the correct installation sequence. If the installation is

found to be incorrect, the nut(s) and bolt(s) must be removed and the washers reinstalled.

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

Affected Maintenance Zones

Model Zone

757-200, 757-200CB, 757- 415, 416, 425, 426, 431, 441

200PF

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BOEING SERVICE BULLETIN 757-54-0049
E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2008-13-20 is related to this

service bulletin.

Table 1(Group 1, Configuration 1): Inspection of the two thrust reverser aft hinge fittings and eight fitting

attach bolts on each engine for contact and damage

Repeat

Interval

(Not

to Exceed)

Compliance

Time

Condition Action

3000

Flight

Cycles

(a)

Within 3000

Flight Cycles after the original

issue date of

this service bulletin

Do a Detailed Inspection of the two thrust reverser aft hinge

fittings and eight fitting attach bolts on each engine as

given in Accomplishment Instruction 3.B.,Part II

Group 1, Configuration

1 Airplanes

Before Further -

Flight

Replace the aft hinge fitting and do Preventive Modification

as given in Accomplishment Instruction 3.B., Part III (c)

Cracked or broken aft

hinge fitting

Before Further -

Flight

Apply surface finish as given in Accomplishment Instruction 3.B., Part IIAft hinge fitting shows Option 1

contact damage less

than 0.005 inch depth Within 3000 -

Flight Cycles after surface finish

is applied

Do Preventive Modification as given in

Accomplishment Instruction 3.B., Part

III (c)

Before Further -

Flight

Do Preventive Modification as given in

Accomplishment Instruction 3.B., Part

III (c)

Option 2

Before Further -

Flight

Do Preventive Modification as given in Accomplishment

Instruction 3.B., Part III (c)

Aft hinge fitting shows

contact damage greater

than or equal to 0.005

inch depth

Before Further -

Flight

Do Preventive Modification as given in

Accomplishment Instruction 3.B., Part

III (c)

Damaged attach bolt Option 1

Before Further -

Flight

Do a High Frequency Eddy Current

(HFEC) Inspection of the attach bolt hole

as given in Accomplishment Instruction

3.B., Part II

Option 2

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Table 1(Group 1, Configuration 1): Inspection of the two thrust reverser aft hinge fittings and eight fitting

attach bolts on each engine for contact and damage

Repeat

Interval

(Not

to Exceed)

Compliance

Time

Condition Action

Before Further -

Flight

Replace bolt as given in Accomplishment Instruction 3.B.,

Part II

No crack was found in

attach bolt hole as a result of HFEC inspection Within 3000 -

Flight Cycles after bolt replacement

Do Preventive Modification as given in Accomplishment

Instruction 3.B., Part III (c)

Before Further -

Flight

Do Preventive Modification as given in Accomplishment

Instruction 3.B., Part III(c)

A crack was found in

attach bolt hole as a result of HFEC inspection

Before Further -

Flight

If any crack is found in aft hinge fitting, install new aft hinge

fitting or contact Boeing for repair instructions and repair

as given in Accomplishment Instruction 3.B., Part III

0.4688 inch nominal

lower fastener hole with

crack

OR OR

If any crack is found in the strut, contact Boeing for repair

instructions and do the repair.

0.5312 inch nominal

upper fastener hole

with crack

Before Further -

Flight

Install new aft hinge fitting as given in Accomplishment

Instruction 3.B., Part III.

Aft hinge fitting is found

to have heat damage

after trimming. OR

Contact Boeing for repair instructions and do the repair.

(a) Accomplishment of the Preventive Modification on a hinge as given in Accomplishment Instruction 3.B.,

Part III terminates the requirement to do repeat inspections on that hinge.

(b) Not Used

(c) Preventive Modification is required for hinges with damage and is optional for hinges without damage.

Repeat inspections are required on all unmodified hinges until the Preventive Modification, as given in Accomplishment Instruction 3.B, Part III, is accomplished.

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BOEING SERVICE BULLETIN 757-54-0049
Table 2 (Group 1, Configuration 2): DETAILED INSPECTION OF FASTENER STACKUP ON AFT

HINGE FITTINGS FOR AIRPLANES THAT HAVE BEEN MODIFIED IN ACCORDANCE WITH THE

ORIGINAL ISSUE OF THIS SERVICE BULLETIN

Repeat Interval (Not

to Exceed)

Condition Action Compliance Time

Within 3000 flight cy- -

cles after the Revision

1 date of this Service

Bulletin.

Do a one-time detailed

inspection of fastener

stackup as given in Accomplishment Instruction 3.B., Part IV.

Group 1, Configuration

2 airplanes

Reinstall washers cor- Before Further Flight -

rectly as given in Accomplishment Instruction 3.B., Part IV.

Washers found to be

installed incorrectly after doing one-time detailed inspection.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft

Certification Office approves the inspection methods and modifications with the corresponding

compliance times specified in Tables 1 and 2 under paragraph 1.E., "Compliance," of Service Bulletin

757-54-0049, Revision 1, as an AMOC to the inspection methods and modifications with the

corresponding compliance times specified in paragraph 1.E., "Compliance," of Service Bulletin

757-54-0049, dated July 16, 2007 as required by paragraphs (f) and (h) of AD 2008-13-20. All provisions

of AD 2008-13-20 that are not specifically referenced in the preceding sentence remain fully applicable

and must be complied with.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this 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 examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

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BOEING SERVICE BULLETIN 757-54-0049
Group 1 Configuration 1 - INSPECTION MANHOURS:

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 2.0 1.0

Figure 1 2 1.0 0.5

Figure 2 2 1.0 0.5

Close Access 2 2.0 1.0

TOTAL FOR EACH AIRPLANE 6.0 3.0

Group 1 Configuration 1 - MODIFICATION MANHOURS:

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 10.5 5.25

Figure 3 2 8.0 4.0

Figure 4 2 8.0 4.0

Figure 5 2 5.0 2.5

Figure 6 2 5.0 2.5

Figure 7 2 1.0 0.5

Figure 8 2 1.0 0.5

Figure 9 2 5.0 2.5

Figure 10 2 5.0 2.5

Figure 11 2 1.0 0.5

Figure 12 2 1.0 0.5

Close Access 2 10.5 5.25

TOTAL FOR EACH AIRPLANE 61 30.5

NOTE: The total man-hours is dependant on the method of modification. The total man-hours shown

are for modification of the aft hinge fitting on the airplane.

Group 1, Configuration 2 - DETAILED INSPECTION (of Fastener Stackup) MANHOURS:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 2 2.0 1.0

Inspect 2 2.0 1.0

Close Access 2 2.0 1.0

TOTAL FOR EACH AIRPLANE 6.0 3.0

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BOEING SERVICE BULLETIN 757-54-0049
H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR-54530-267RS.

b. 757 Aircraft Maintenance Manual (AMM) 24-41-01, 29-11-25, 71-00-02, 78-31-00, 78-31-10,

78-31-20.

c. 757 Non-destructive Testing (NDT) Manual, Part 6, 51-00-16, Part 6, 51-00-17.

d. Boeing Drawing 65-88700.

e. Boeing Tooling Drawing MIT012N8549-2.

f. Service Bulletin 757-54-0015 "NACELLES/PYLONS - NACELLE STRUT - THRUST

REVERSER HINGE FITTING REPLACEMENT".

g. Service Bulletin 757-54-0050 "NACELLES/PYLONS - Nacelle Strut - Thrust Reverser Hinge

Fitting Modification - Rolls Royce RB211-535E Engines".

h. Standard Overhaul Practices Manual (SOPM) 20-10-01, 20-10-02, 20-10-03, 20-30-03,

20-42-10, 20-44-01, 20-50-01, 20-50-10, 20-50-19

i. Boeing Service Letter 757-SL-51-022

j. Federal Aviation Administration (FAA) Airworthiness Directive 2008-13-20

2. Data supplied with this Service Bulletin:

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

Miscelaneous Tool - Hinge Assembly 1 - -

Aligning Tool

MIT012N8549-2

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

None.

K. Publications Affected

1. Publications:

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BOEING SERVICE BULLETIN 757-54-0049
Publication Chapter-Section

757 Illustrated Parts Catalog 54-51

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

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability

information.

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BOEING SERVICE BULLETIN 757-54-0049

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, and Paragraph

2.D., Parts Necessary to Change Spares, as shown below. If there is a limit to the quantity (QTY) of

available kits, a supply sequence is given by Spares. More kits become available as shown in the

Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

Unit Price thru

Oct/31/06

ROLT

(Weeks)

Kit Number Name Date QTY

TOP KIT-THRUST RE- 08/25/05 10 30 $5,276

VERSER HINGE MODIFICATION RB211-535E

012N5108-1

TOP KIT-THRUST RE- 09/01/05 10 30 $5,276

VERSER HINGE MODIFICATION RB211-535E

012N5108-1

TOP KIT-THRUST RE- 09/09/05 10 30 $5,276

VERSER HINGE MODIFICATION RB211-535E

012N5108-1

TOP KIT-THRUST RE- 09/16/05 10 30 $5,276

VERSER HINGE MODIFICATION RB211-535E

012N5108-1

TOP KIT-THRUST RE- 09/23/05 10 30 $5,276

VERSER HINGE MODIFICATION RB211-535E

012N5108-1

TOP KIT-THRUST RE- 09/30/05 10 30 $5,276

VERSER HINGE MODIFICATION RB211-535E

012N5108-1

The kits/parts are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United

States dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of the methods that

follow:

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

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle,

Washington 98124-2207 USA

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BOEING SERVICE BULLETIN 757-54-0049
B. Industry Support Information

Boeing warranty remedies are available for 757 airplanes in warranty as of October 17, 2003. For the

initial inspection labor hour reimbursement for airplanes in warranty as of that date, send a claim to

Boeing Warranty. Please note that subsequent inspections, as outlined in the MPD (Maintenance

Planning Document), do not qualify for Boeing warranty remedies. If the condition described in this

service bulletin is found during the initial, or MPD directed inspection, please note that the kits for

airplanes in warranty as of October 17, 2003, will be supplied at no charge. Send a purchase order for

the kits to Boeing Spares, and a warranty claim for labor hours to Boeing Commercial Airplanes Group

- Warranty & Product Assurance Contracts. Please refer to this service bulletin number and reference

the airplane variable numbers in your purchase order and any labor hour claim.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

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.

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

Kit 012N5108

Existing Part Notes

Number

New Part Number QTY Name

-1

TOP KIT- THRUST REVERSER HINGE -

MODIFICATION RB211-535E

012N5108-1 -

012N5108-2 8 WASHER- SPECIAL - (b)(d)

012N5108-3 8 WASHER- SPECIAL - (b)(d)

012N5108-4 8 WASHER- SPECIAL - (b)(d)

012N5108-5 8 WASHER- SPECIAL - (b)(d)

BACB30US7K15X 8 BOLT, 12 PT HEAD BACB30LE7U( ) (a)(b)(c)(d)(e)

BACB30LE7U( ) (a)(b)(c)(d)(e)

BACB30LE7U( )X

BACB30LE7U( )Y

BACB30US7K15Y 8 BOLT, 12 PT HEAD

BACB30US8K19X 8 BOLT, 12 PT HEAD BACB30LE8U19 (a)(b)(c)(d)(e)

BACB30LE8U19 (a)(b)(c)(d)(e)

BACB30LE8U19X

BACB30LE8U19Y

BACB30US8K19Y 8 BOLT, 12 PT HEAD

BACN10HR7CS 8 SELF-LOCKING NUT BACN10HR7CS (a)(c)

BACN10HR8CS 8 NUT BACN10HR8CS (a)(c)

BACW10BP71APU 8 WASHER, PLAIN BACW10BP7APU (a)(b)(c)

BACW10BP72APU 8 WASHER, PLAIN BACW10BP7APU (a)(b)(c)

BACW10BP81ACU 8 WASHER, PLAIN BACW10BP8APU (a)(b)(c)

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BOEING SERVICE BULLETIN 757-54-0049
Kit 012N5108

Existing Part Notes

Number

New Part Number QTY Name

-1

BACW10BP82ACU 8 WASHER, PLAIN BACW10BP8APU (a)(b)(c)

(a) Discard the existing part.

(b) This part is not used in production.

(c) You cannot use the existing part to replace the new or changed part.

(d) There are more parts than are necessary.

(e) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer

than indicated. Also, if any fasteners part numbers listed are not available or have been superseded,

substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700,

are used to determine the part numbers used as substitutes.

2. Parts and Materials Supplied by the Operator:

Part Number / Specification QTY Name Notes

Type 51 4 Ounces De-Soto Hi-Temperature Primer (a)

BMS3-33 4 Ounces Grease (b)

311N5148-1 - Hinge Fitting (c)

(a) Refer to the Boeing Standard Overhaul Practices Manual SOPM 20-44-01 or 757 Structural Repair

Manual, Chapter 51, for material sources.

(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(c) Hinge Fitting quantity depends on the number of fittings that need to be replaced.

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the

number of parts changed on each airplane.

Existing Part Number QTY Name New Part Number Notes

311N5148-1 4 Hinge Fitting (b) (a) (c)

(a) Make the change given in this service bulletin.

(b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change

given in this service bulletin was made.

(c) You cannot use the existing part to replace the modified part. If you use the existing part to replace

the modified part you will cancel the effect of the change given in this service bulletin.

4. Parts Removed and Not Replaced:

None.

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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.

However, MIT012N8549-2 may be necessary if the aft hinge fitting is being replaced.

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BOEING SERVICE BULLETIN 757-54-0049
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

– Torque limits to tighten nuts and bolts are in 757 SRM, Chapter 51

5. Use the approved fastener and process material substitutions as given in 757 SRM,

Chapter 51. Alternate fasteners are listed in 757 SRM Chapter 51 and Boeing Drawing

65-88700.

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

installation standards in SRM Chapter 51, then a fastener of the same specification,

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

SRM Chapter 51 may be used.

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.

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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 "as

given in" 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. Refer to Appendix A for Aft Hinge Fitting Fastener Stackup.

B. WORK INSTRUCTIONS

PART I - ACCESS

1. Remove electrical power and electrically ground airplane. Refer to 757 AMM 24-41-01 as an

accepted procedure.

2. Install thrust reverser lock out pins. Refer to 757 AMM 78-31-00 as an accepted procedure.

3. Open thrust reverser C-Ducts. Refer to 757 AMM 78-31-00 as an accepted procedure.

4. Install thrust reverser actuator hold open locks, tool number B71009. Refer to 757 AMM 71-00-02

as an accepted procedure.

PART II - INSPECTION (Group 1, Configuration 1)

1. Do a Detailed Inspection on the number 1 engine thrust reverser aft hinge fittings and attach bolts

as given in Figure 1.

a. If the aft hinge fitting is cracked or broken, do PART III - Preventive modification and install a

new 311N5148-1 fitting.

NOTE: The new aft hinge fitting can be positioned using tool MIT012N8549-2. See Service

Bulletin 757-54-0015 for more information on how to use the tool.

b. If no damage to aft hinge fittings and attach bolts is found, do one of the following:

(1) Do PART V - Close Access, and do repeat inspections as given in Paragraph 1.E.

Compliance until the preventive modification is accomplished.

(2) Do PART III - Preventive Modification.

c. If contact damage to the base metal of the thrust reverser aft hinge fittings is less than 0.005

inch deep, do one of the following options:

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(1) Option 1: Reapply surface finish, Type 51 Primer, as given in SOPM 20-44-01, and do

Part III - Preventive Modification as given in Paragraph 1.E Compliance.

(2) Option 2: Do PART III - Preventive Modification.

d. If contact damage to the base metal of the thrust reverser aft hinge fittings is found to be equal

to or more than 0.005 inches deep, do PART III - Preventive Modification.

e. If damage to an attach bolt is found, do one of the following options:

(1) Option 1: Do PART III - Preventive Modification.

(2) Option 2: Remove the damaged attach bolt and HFEC inspect the attach bolt hole as

given in 757 NDT, Part 6, 51-00-17 and 757 NDT, Part 6, 51-00-16.

(a) If no crack exists install new attach bolt (either existing BACB30LE or new

BACB30US) and do PART III - Preventive Modification as given in Paragraph 1.E

Compliance.

(b) If a crack is found do PART III - Preventive Modification.

2. Do a Detailed Inspection on the number 2 engine thrust reverser aft hinge fittings and attach bolts

as given in Figure 2.

a. If the aft hinge fitting is cracked or broken, do PART III - Preventive modification and install a

new 311N5148-1 fitting.

NOTE: The new aft hinge fitting can be positioned using tool MIT012N8549-2. See Service

Bulletin 757-54-0015 for more information on how to use the tool.

b. If no damage to aft hinge fittings and attach bolts is found, do one of the following:

(1) Do PART V - Close Access, and do repeat inspections as given in Paragraph 1.E.

Compliance until the preventive modification is accomplished.

(2) Do PART III - Preventive Modification.

c. If contact damage to the base metal of the thrust reverser aft hinge fittings is less than 0.005

inch deep, do one of the following options:

(1) Option 1: Reapply surface finish, Type 51 Primer, as given in SOPM 20-44-01, and do

Part III - Preventive Modification as given in Paragraph 1.E Compliance.

(2) Option 2: Do PART III - Preventive Modification.

d. If contact damage to the base metal of the thrust reverser aft hinge fittings is found to be equal

to or more than 0.005 inches deep, do PART III - Preventive Modification.

e. If damage to an attach bolt is found, do one of the following options:

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BOEING SERVICE BULLETIN 757-54-0049
(1) Option 1: Do PART III - Preventive Modification.

(2) Option 2: Remove the damaged attach bolt and HFEC inspect the attach bolt hole as

given in 757 NDT, Part 6, 51-00-17 and 757 NDT, Part 6, 51-00-16.

(a) If no crack exists install new attach bolt (either existing BACB30LE or new

BACB30US) and do PART III - Preventive Modification as given in Paragraph 1.E

Compliance.

(b) If a crack is found do PART III - Preventive Modification.

PART III - PREVENTIVE MODIFICATION (Group 1, Configuration 1)

1. Remove hydraulic power and depressurize hydraulic systems. Refer to 757 AMM 29-11-25 as an

accepted procedure.

2. Remove the C-Duct hinged access door. Refer to 757 AMM 78-31-10 as an accepted procedure.

CAUTION: THE THRUST REVERSER C-DUCTS SHOULD BE REMOVED. IF THE THRUST

REVERSER C-DUCTS ARE NOT REMOVED AND YOU DO THE PREVENTIVE

MODIFICATION, THEN HYDROGEN EMBRITTLEMENT CAN OCCUR AFTER THE

PLATING IS APPLIED TO THE AFT HINGES.

3. Remove thrust reverser C-Ducts. Refer to 757 AMM 78-31-20 as an accepted procedure.

4. Aft Hinge Fittings that are damaged and/or have damaged bolts, must do one of the options below.

Any fittings that are undamaged with undamaged bolts, and are not being re-worked per the options

below, must continue to be inspected at the times shown in Paragraph 1.E Compliance, until steps

4 and 5 are accomplished.

NOTE: Option 2 below applies to NEW and EXISTING fittings. The aft hinge fitting can be

positioned during installation using tool MIT012N8549-2. MIT012N8549-2 is used in

Service Bulletin 757-54-0015. Step 5 of this part may be performed prior to or concurrently

with step 4 of this part.

a. Option 1:

(1) Trim the thrust reverser aft hinge fittings on the number 1 engine as given in Figure 3.

(2) Trim the thrust reverser aft hinge fittings on the number 2 engine as given in Figure 4.

b. Option 2:

(1) Remove the thrust reverser aft hinge fittings on the number 1 engine as given in Figure

13.

(2) Trim the thrust reverser aft hinge fittings on the number 1 engine as given in Figure 3.

(3) Install the thrust reverser aft hinge fittings on the number 1 engine as given in Figure 13.

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BOEING SERVICE BULLETIN 757-54-0049
(4) Remove the thrust reverser aft hinge fittings on the number 2 engine as given in Figure

14.

(5) Trim the thrust reverser aft hinge fittings on the number 2 engine as given in Figure 4.

(6) Install the thrust reverser aft hinge fittings on the number 2 engine as given in Figure 14.

5. A trimmed fitting must have larger bolts, new washers, and new nuts installed. Do the steps below

which apply to a trimmed fitting.

a. Oversize and High Frequency Eddy Current (HFEC) Inspect the thrust reverser aft hinge fitting

lower fastener holes on the number 1 engine as given in Figure 5.

(1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.4688

inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions

and repair the fitting.

(2) If any crack is found in the strut structure and the fastener hole size is already 0.4688

inch nominal, then contact Boeing for repair instructions and do the repair.

b. Oversize and HFEC Inspect the thrust reverser aft hinge fitting lower fastener holes on the

number 2 engine as given in Figure 6.

(1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.4688

inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions

and repair the fitting.

(2) If any crack is found in the strut structure and the fastener hole size is already 0.4688

inch nominal, then contact Boeing for repair instructions and do the repair.

c. Install the lower fasteners in the thrust reverser aft hinge fitting on the number 1 engine as

given in Figure 7.

d. Install the lower fasteners in the thrust reverser aft hinge fitting on the number 2 engine as

given in Figure 8.

e. Oversize and HFEC Inspect the thrust reverser aft hinge fitting upper fastener holes on the

number 1 engine as given in Figure 9.

(1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.5312

inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions

and repair the fitting.

(2) If any crack is found in the strut structure and the fastener hole size is already 0.5312

inch nominal, then contact Boeing for repair instructions and do the repair.

f. Oversize and HFEC Inspect the thrust reverser aft hinge fitting upper fastener holes on the

number 2 engine as given in Figure 10.

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BOEING SERVICE BULLETIN 757-54-0049
(1) If any crack is found in the aft hinge fitting and the fastener hole size is already 0.5312

inch nominal, then install a new aft hinge fitting or contact Boeing for repair instructions

and repair the fitting.

(2) If any crack is found in the strut structure and the fastener hole size is already 0.5312

inch nominal, then contact Boeing for repair instructions and do the repair.

g. Install the upper fasteners in the thrust reverser aft hinge fitting on the number 1 engine as

given in Figure 11.

h. Install the upper fasteners in the thrust reverser aft hinge fitting on the number 2 engine as

given in Figure 12.

6. Install thrust reverser C-Ducts. Refer to 757 AMM 78-31-20 as an accepted procedure.

7. Install the C-Duct hinged access door. Refer to 757 AMM 78-31-10 as an accepted procedure.

PART IV - ONE-TIME DETAILED INSPECTION FOR AIRPLANES THAT HAVE DONE THE ORIGINAL

ISSUE OF THIS SERVICE BULLETIN (Group 1, Configuration 2)

1. Do a One-Time Detailed Inspection of the washers installed under the nuts and bolts that are

installed in FIGURE 11 and FIGURE 12 to secure the aft hinge fittings to the structure. The

countersunk washer must be installed under the head of the bolt with the countersink towards the

bolt head and the special washer must be installed under the nut with the tapered side toward the

aft hinge fitting. See Appendix A.

2. If the washers are not installed correctly, then remove the nut and bolt and reinstall the hardware

as given in FIGURE 11 and FIGURE 12.

PART V - CLOSE ACCESS

1. Remove thrust reverser actuator hold open lock tool number B71009. Refer to 757 AMM 71-00-02

as an accepted procedure.

2. Close and lock thrust reversers. Refer to 757 AMM 78-31-00 as an accepted procedure.

3. Remove thrust reverser lock out pins. Refer to 757 AMM 78-31-00 as an accepted procedure.

4. Return Airplane to a serviceable condition.

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BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
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 engine.

FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME PROCEDURE MORE DATA (d)

1 Inspect Bolts Detailed Inspection (a) (b)

2 Inspect Aft Hinge Fitting Detailed Inspection (c)

3 Inspect Bolts Detailed Inspection (a) (b)

4 Inspect Aft Hinge Fitting Detailed Inspection (c)

(a) Inspect the bolts for damage. Look for loose, fretting or broken bolts.

(b) Removal of the bolts is not required for this inspection.

(c) Inspect the aft hinge fitting for signs of contact and any broken or cracked fitting.

(d) If only one hinge is being inspected, it is OK to skip the steps that don't apply.

FIGURE 1: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
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 engine.

FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME PROCEDURE MORE DATA (d)

1 Inspect Bolts Detailed Inspection (a) (b)

2 Inspect Aft Hinge Fitting Detailed Inspection (c)

3 Inspect Bolts Detailed Inspection (a) (b)

4 Inspect Aft Hinge Fitting Detailed Inspection (c)

(a) Inspect the bolts for damage. Look for loose, fretting or broken bolts.

(b) Removal of the bolts is not required for this inspection.

(c) Inspect the aft hinge fitting for signs of contact and any broken or cracked fitting.

(d) If only one hinge is being inspected, it is OK to skip the steps that don't apply.

FIGURE 2: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - DETAILED INSPECTION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
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 engine.

FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA (h)

Thrust Reverser 1 (a)

Aft Hinge Fitting

1 Clean

2 Identify Trim Locations 3 (b)

Refer to SOPM 20-10-01

and SOPM 20-10-02 as

an accepted procedure.

(e) (f) (c)

Thrust Reverser 3

Aft Hinge Fitting

Lug

3 Hand Blend

Thrust Reverser 3 (g)

Aft Hinge Fitting

4 Deburr

Thrust Reverser 3 (d)

Aft Hinge Fitting

5 Inspect

Refer to SOPM 20-10-03

as an accepted procedure. Intensity 0.014A,

coverage 2.0

Shot Peen or Flap

Peen

6 Do

Refer to SOPM 20-42-10

an accepted procedure.

Cadmium Plate to a

thickness 0.0003 - 0.0005

inch.

7 Apply Cadmium Plate

Refer to SOPM 20-44-01

as an accepted procedure.

8 Apply Primer Type 51 1 Coat

Thrust Reverser 1 (a)

Aft Hinge Fitting

9 Clean

10 Identify Trim Locations 3 (b)

Refer to SOPM 20-10-01

and SOPM 20-10-02 as

an accepted procedure.

(e) (f) (c)

Thrust Reverser 3

Aft Hinge Fitting

Lug

11 Hand Blend

Thrust Reverser 3 (g)

Aft Hinge Fitting

12 Deburr

Thrust Reverser 3 (d)

Aft Hinge Fitting

13 Inspect

Refer to SOPM 20-10-03

as an accepted procedure. Intensity 0.014A,

coverage 2.0

Shot Peen or Flap

Peen

14 Do

FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA (h)

Refer to SOPM 20-42-10

as an accepted procedure. Cadmium Plate to

a thickness 0.0003 -

0.0005 inch.

15 Apply Cadmium Plate

Refer to SOPM 20-44-01

as an accepted procedure.

16 Apply Primer Type 51 1 Coat

(a) Clean the hinge. Refer to SOPM 20-30-03 as an accepted procedure.

(b) Mark the trim locations. Refer to SOPM 20-50-10 as an accepted procedure.

(c) Restore the surface finish to 125 micro-inches Ra.

Do a detailed inspection of the trimmed area for signs of heat damage using Nital or Ammonium

Persulfate as given in SOPM 20-10-02. If any damage is found, install a new aft hinge fitting or

contact Boeing for additional repair instructions.

(d)

Boeing recommends the use of a carbide rotary file. The part should be ground in stages,

checking between stages, checking for heating after each stage. The part surface shall remain

cool to the touch.

(e)

Rotary burrs and files in portable hand-held motors may be used if the speed is limited to 500

rpm, maximum. Higher speed settings and/or other tools may be used provided that:

(f)

— The operator shall produce no discoloration.

— The operator shall not cause sparking or release of molten fines.

— The tools shall be applied with pressure and contact time such that no heat damage occurs.

— Verify the higher speed settings and/or other tools by in-process inspection of test samples

or test parts. Refer to SOPM 20-10-02 as an accepted procedure.

(g) Break all sharp edges, the minimum/maximum radius requirement (0.02 - 0.06 radius).

(h) If only one hinge is being trimmed, it is OK to skip the steps that don't apply.

FIGURE 3: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
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 engine.

FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA (h)

Thrust Reverser 1 (a)

Aft Hinge Fitting

1 Clean

2 Identify Trim Locations 3 (b)

Refer to SOPM 20-10-01

and SOPM 20-10-02 as

an accepted procedure.

(e) (f) (c)

Thrust Reverser 3

Aft Hinge Fitting

Lug

3 Hand Blend

Thrust Reverser 3 (g)

Aft Hinge Fitting

4 Deburr

Thrust Reverser 3 (d)

Aft Hinge Fitting

5 Inspect

Refer to SOPM 20-10-03

as an accepted procedure. Intensity 0.014A,

coverage 2.0

Shot Peen or Flap

Peen

6 Do

Refer to SOPM 20-42-10

an accepted procedure.

Cadmium Plate to a

thickness 0.0003 - 0.0005

inch.

7 Apply Cadmium Plate

Refer to SOPM 20-44-01

as an accepted procedure.

8 Apply Primer Type 51 1 Coat

Thrust Reverser 1 (a)

Aft Hinge Fitting

9 Clean

10 Identify Trim Locations 3 (b)

Refer to SOPM 20-10-01

and SOPM 20-10-02 as

an accepted procedure.

(e) (f) (c)

Thrust Reverser 3

Aft Hinge Fitting

Lug

11 Hand Blend

Thrust Reverser 3 (g)

Aft Hinge Fitting

12 Deburr

Thrust Reverser 3 (d)

Aft Hinge Fitting

13 Inspect

Refer to SOPM 20-10-03

as an accepted procedure. Intensity 0.014A,

coverage 2.0

Shot Peen or Flap

Peen

14 Do

FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA (h)

Refer to SOPM 20-42-10

as an accepted procedure. Cadmium Plate to

a thickness 0.0003 -

0.0005 inch.

15 Apply Cadmium Plate

Refer to SOPM 20-44-01

as an accepted procedure.

16 Apply Primer Type 51 1 Coat

(a) Clean the hinge. Refer to SOPM 20-30-03 as an accepted procedure.

(b) Mark the trim locations. Refer to SOPM 20-50-10 as an accepted procedure.

(c) Restore the surface finish to 125 micro-inches Ra.

Do a detailed inspection of the trimmed area for signs of heat damage using Nital or Ammonium

Persulfate as given in SOPM 20-10-02. If any damage is found, install a new aft hinge fitting or

contact Boeing for additional repair instructions.

(d)

Boeing recommends the use of a carbide rotary file. The part should be ground in stages,

checking between stages, checking for heating after each stage. The part surface shall remain

cool to the touch.

(e)

Rotary burrs and files in portable hand-held motors may be used if the speed is limited to 500

rpm, maximum. Higher speed settings and/or other tools may be used provided that:

(f)

— The operator shall produce no discoloration.

— The operator shall not cause sparking or release of molten fines.

— The tools shall be applied with pressure and contact time such that no heat damage occurs.

— Verify the higher speed settings and/or other tools by in-process inspection of test samples

or test parts. Refer to SOPM 20-10-02 as an accepted procedure.

(g) Break all sharp edges, the minimum/maximum radius requirement (0.02 - 0.06 radius).

(h) If only one hinge is being trimmed, it is OK to skip the steps that don't apply.

FIGURE 4: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING - TRIM

(SHEET 4 OF 4)

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BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
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 engine.

STEP TASK NAME IDENTIFICATION QTY MORE DATA (f)

1 Remove Nut BACN10HR7CS 2

Bolt BACB30LE7U( ) 2 (a)(g)

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 2

Washer BACW10BP7APU 2

Oversize the hole to the size

listed in table 1 below. (e)

2 Drill/Ream Fastener Hole 2

As given in 757 NDT, Part 6,

51-00-17 and757 NDT, Part

6, 51-00-16 (b)

High Frequency Eddy 2

Current (HFEC)

3 Inspect Open Hole

4 Remove Nut BACN10HR7CS 2

Bolt BACB30LE7U( ) 2 (a)(g)

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 2

Washer BACW10BP7APU 2

Oversize the hole to the size

listed in table 1 below. (e)

5 Drill/Ream Fastener Hole 2

As given in 757 NDT, Part 6,

51-00-17 and757 NDT, Part

6, 51-00-16 (c)

High Frequency Eddy 2

Current (HFEC)

6 Inspect Open Hole

BACB30LE7U( ) was installed in production. BACB30LE7U( )X and BACB30LE7U( )Y may

have been installed as given in SB 757-54-0015.

(a)

(b) If any crack is found repeat steps 2 and 3.

(c) If any crack is found repeat steps 5 and 6.

(d) Not Used

The hole through the hinge fitting may be up to 0.457 inch diameter from production. This

condition is equivalent to a 0.4526 - 0.4536 inch existing hole diameter.

(e)

(f) If only one hinge is being oversized and inspected, it is OK to skip the steps that don't apply.

(g) Remove one bolt at a time when oversizing and inspecting.

FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
Table 1 Fastener Hole Sizes

Existing Hole Diameter New Hole Diameter

Nominal 0.4526 - 0.4536 inch

0.4526 - 0.4536 inch 0.4683 - 0.4693 inch

0.4683 - 0.4693 inch Do Not Oversize Hole

FIGURE 5: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 1 OF 3)

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50 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 engine.

STEP TASK NAME IDENTIFICATION QTY MORE DATA (f)

1 Remove Nut BACN10HR7CS 2

Bolt BACB30LE7U( ) 2 (a)(g)

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 2

Washer BACW10BP7APU 2

Oversize the hole to the size

listed in table 1 below. (e)

2 Drill/Ream Fastener Hole 2

As given in 757 NDT, Part 6,

51-00-17 and 757 NDT, Part 6,

51-00-16 (b)

High Frequency Eddy 2

Current (HFEC)

3 Inspect Open Hole

4 Remove Nut BACN10HR7CS 2

Bolt BACB30LE7U( ) 2 (a)(g)

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 2

Washer BACW10BP7APU 2

Oversize the hole to the size

listed in table 1 below. (e)

5 Drill/Ream Fastener Hole 2

As given in 757 NDT, Part 6,

51-00-17 and 757 NDT, Part 6,

51-00-16 (c)

High Frequency Eddy 2

Current (HFEC)

6 Inspect Open Hole

BACB30LE7U( ) was installed in production. BACB30LE7U( )X and BACB30LE7U( )Y may

have been installed as given in SB 757-54-0015.

(a)

(b) If any crack is found repeat steps 2 and 3.

(c) If any crack is found repeat steps 5 and 6.

(d) Not Used

The hole through the hinge fitting may be up to 0.457 inch diameter from production. This

condition is equivalent to a 0.4526 - 0.4536 inch existing hole diameter.

(e)

(f) If only one hinge is being oversized and inspected, it is OK to skip the steps that don't apply.

(g) Remove one bolt at a time when oversizing and inspecting.

FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
Table 1 Fastener Hole Sizes

Existing Hole Diameter New Hole Diameter

Nominal 0.4526 - 0.4536 inch

0.4526 - 0.4536 inch 0.4683 - 0.4693 inch

0.4683 - 0.4693 inch Do Not Oversize Hole

FIGURE 6: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 1 OF 3)

BOEING PROPRIETARY -

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Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

53 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 engine.

STEP TASK NAME IDENTIFICATION QTY MORE DATA (d)

See fastener table

and Appendix A (a)

(b) (c)

1 Install (New) Fasteners - 2

See fastener table

and Appendix A (a)

(b) (c)

2 Install (New) Fasteners - 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque bolt head. Torque

to 427-453 in-lbs (target 440 in-lbs).

(a)

(b) Apply BMS3-33 grease to the threads.

Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure.(c)

(d) If only one hinge is being worked, it is OK to skip the step that doesn't apply.

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 are used to

determine the part numbers used as substitutes.

FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 2 OF 3)

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Revision 1 September 23, 2009 757-54-0049

54 of 77

BOEING SERVICE BULLETIN 757-54-0049
CODE NAME IDENTIFICATION HOLE DIA MORE DATA

Install special washer under the

head of the bolt with countersink

towards bolt head and install the

plain washer under the nut. See

Appendix A.

A Nut BACN10HR7CS 0.4531 inch

Bolt BACB30US7K15X

Plain Washer BACW10BP71APU

Special 012N5108-2

Washer

Install special washer under the

head of the bolt with countersink

towards bolt head and install the

plain washer under the nut. See

Appendix A.

A Nut BACN10HR7CS 0.4688 inch

Bolt BACB30US7K15Y

Plain Washer BACW10BP72APU

Special 012N5108-4

Washer

FIGURE 7: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 3 OF 3)

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Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

55 of 77

BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 1 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

56 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 engine.

STEP TASK NAME IDENTIFICATION QTY MORE DATA (d)

See fastener table

and Appendix A (a)

(b) (c)

1 Install (New) Fasteners - 2

See fastener table

and Appendix A (a)

(b) (c)

2 Install (New) Fasteners - 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque bolt head. Torque

to 427-453 in-lbs (target 440 in-lbs).

(a)

(b) Apply BMS3-33 grease to the threads.

Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure.(c)

(d) If only one hinge is being worked, it is OK to skip the step that doesn't apply.

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 are used to

determine the part numbers used as substitutes.

FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 2 OF 3)

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Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

57 of 77

BOEING SERVICE BULLETIN 757-54-0049
CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Install special washer under the

head of the bolt with countersink

towards bolt head and install the

plain washer under the nut. See

Appendix A.

A Nut BACN10HR7CS 4 0.4531 inch

Bolt BACB30US7K15X 4

Plain Washer BACW10BP71APU 4

Special 012N5108-2 4

Washer

Install special washer under the

head of the bolt with countersink

towards bolt head and install the

plain washer under the nut. See

Appendix A.

A Nut BACN10HR7CS 4 0.4688 inch

Bolt BACB30US7K15Y 4

Plain Washer BACW10BP72APU 4

Special 012N5108-4 4

Washer

FIGURE 8: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING LOWER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 3 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

58 of 77

BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 1 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

59 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 engine.

STEP TASK NAME IDENTIFICATION QTY MORE DATA (f)

1 Remove Nut BACN10HR8CS 2

Bolt BACB30LE8U19 2 (a)(g)

BACB30LE8U19X

BACB30LE8U19Y

Washer BACW10BP8ACU 2

Washer BACW10BP8APU 2

Oversize the hole to the size

listed in table 1 below. (e)

2 Drill/Ream Fastener Hole - 2

As given in 757 NDT, Part 6,

51-00-17 and757 NDT, Part

6, 51-00-16 (b)

High Frequency Eddy 2

Current (HFEC)

3 Inspect Fastener Holes

4 Remove Nut BACN10HR8CS 2

Bolt BACB30LE8U19 2 (a)(g)

BACB30LE8U19X

BACB30LE8U19Y

Washer BACW10BP8ACU 2

Washer BACW10BP8APU 2

Oversize the hole to the size

listed in table 1 below. (e)

5 Drill/Ream Fastener Hole - 2

As given in 757 NDT, Part 6,

51-00-17 and757 NDT, Part

6, 51-00-16 (c)

High Frequency Eddy 2

Current (HFEC)

6 Inspect Fastener Holes

BACB30LE8U19 was installed in production. BACB30LE8U19X and BACB30LE8U19Y may

have been installed as given in SB 757-54-0015.

(a)

(b) If any crack is found repeat steps 2 and 3.

(c) If any crack is found repeat steps 5 and 6.

(d) Not Used

The hole through the hinge fitting may be up to 0.521 inch diameter from production. This

condition is equivalent to a 0.5151 - 0.5161 inch existing hole diameter.

(e)

(f) If only one hinge is being oversized and inspected, it is OK to skip the steps that don't apply.

(g) Remove one bolt at a time when oversizing and inspecting.

FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 2 OF 3)

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60 of 77

BOEING SERVICE BULLETIN 757-54-0049
Table 1 Fastener Hole Sizes

Existing Hole Diameter New Hole Diameter

Nominal 0.5151 - 0.5161 inch

0.5151 - 0.5161 inch 0.5307 - 0.5317 inch

0.5307 - 0.5317 inch Do Not Oversize Hole

FIGURE 9: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 3 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

61 of 77

BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 1 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

62 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 engine.

STEP TASK NAME IDENTIFICATION QTY MORE DATA (f)

1 Remove Nut BACN10HR8CS 2

Bolt BACB30LE8U19 2 (a)(g)

BACB30LE8U19X

BACB30LE8U19Y

Washers BACW10BP8ACU 2

Washer BACW10BP8APU 2

Oversize the hole to the size

listed in table 1 below. (e)

2 Drill/Ream Fastener Hole - 2

As given in 757 NDT, Part 6,

51-00-17 and 757 NDT, Part

6, 51-00-16 (b)

High Frequency Eddy 2

Current (HFEC)

3 Inspect Fastener Holes

4 Remove Nut BACN10HR8CS 2

Bolt BACB30LE8U19 2 (a)(g)

BACB30LE8U19X

BACB30LE8U19Y

Washers BACW10BP8ACU 2

Washer BACW10BP8APU 2

Oversize the hole to the size

listed in table 1 below. (e)

5 Drill/Ream Fastener Hole - 2

As given in 757 NDT, Part 6,

51-00-17 and757 NDT, Part 6,

51-00-16 (c)

High Frequency Eddy 2

Current (HFEC)

6 Inspect Fastener Holes

BACB30LE8U19 was installed in production. BACB30LE8U19X and BACB30LE8U19Y may

have been installed as given in SB 757-54-0015.

(a)

(b) If any crack is found repeat steps 2 and 3.

(c) If any crack is found repeat steps 5 and 6.

(d) Not Used

The hole through the hinge fitting may be up to 0.521 inch diameter from production. This

condition is equivalent to a 0.5151 - 0.5161 inch existing hole diameter.

(e)

(f) If only one hinge is being oversized and inspected, it is OK to skip steps that don't apply.

(g) Remove one bolt at a time when oversizing and inspecting.

FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 2 OF 3)

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Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

63 of 77

BOEING SERVICE BULLETIN 757-54-0049
Table 1 Fastener Hole Sizes

Existing Hole Diameter New Hole Diameter

Nominal 0.5151 - 0.5161 inch

0.5151 - 0.5161 inch 0.5307 - 0.5317 inch

0.5307 - 0.5317 inch Do Not Oversize Hole

FIGURE 10: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- OVERSIZE AND HIGH FREQUENCY EDDY CURRENT INSPECTION

(SHEET 3 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

64 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 engine.

FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 1 OF 3)

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Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

65 of 77

BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA (d)

See fastener table

and Appendix A (a)

(b) (c)

1 Install (New) Fasteners - 2

See fastener table

and Appendix A (a)

(b) (c)

2 Install (New) Fasteners - 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque nut. Torque to

558 - 592 in-lbs (target 575 in-lbs).

(a)

(b) Apply BMS3-33 grease to the threads.

Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure.(c)

(d) If only one hinge is being worked, it is OK to skip the step that doesn't apply.

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 are used to

determine the part numbers used as substitutes.

FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 2 OF 3)

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Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

66 of 77

BOEING SERVICE BULLETIN 757-54-0049
CODE NAME IDENTIFICATION HOLE DIA MORE DATA

Install countersunk washer under

the head of the bolt with countersink

towards bolt head and install the

special washer under the nut with

the tapered side toward the aft hinge

fitting. See Appendix A.

B Nut BACN10HR8CS 0.5156 inch

Bolt BACB30US8K19X

Countersunk BACW10BP81ACU

Washer

Special 012N5108-3

Washer

Install countersunk washer under

the head of the bolt with countersink

towards bolt head and install the

special washer under the nut with

the tapered side toward the aft hinge

fitting. See Appendix A.

B Nut BACN10HR8CS 0.5312 inch

Bolt BACB30US8K19Y

Countersunk BACW10BP82ACU

Washer

Special 012N5108-5

Washer

FIGURE 11: ENGINE NUMBER 1 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 3 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

67 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 engine.

FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 1 OF 3)

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Revision 1 September 23, 2009 757-54-0049

68 of 77

BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA (d)

See fastener table

and Appendix A (a)

(b) (c)

1 Install (New) Fasteners - 2

See fastener table

and Appendix A (a)

(b) (c)

2 Install (New) Fasteners - 2

Torque the fasteners. Refer to BAC5009 as an accepted procedure. Torque nut. Torque to

558 - 592 in-lbs (target 575 in-lbs).

(a)

(b) Apply BMS3-33 grease to the threads.

Apply type 51 high temperature primer to bolt shank only. Refer to SOPM 20-44-01 as an accepted procedure.(c)

(d) If only one hinge is being worked, it is OK to skip the step that doesn't apply.

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 are used to

determine the part numbers used as substitutes.

FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 2 OF 3)

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Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

69 of 77

BOEING SERVICE BULLETIN 757-54-0049
CODE NAME IDENTIFICATION HOLE DIA MORE DATA

Install countersunk washer under

the head of the bolt with countersink towards bolt head and install

the special washer under the nut

with the tapered side toward the aft

hinge fitting. See Appendix A.

B Nut BACN10HR8CS 0.5156 inch

Bolt BACB30US8K19X

Countersunk BACW10BP81ACU

Washer

Special 012N5108-3

Washer

Install countersunk washer under

the head of the bolt with countersink towards bolt head and install

the special washer under the nut

with the tapered side toward the aft

hinge fitting. See Appendix A.

B Nut BACN10HR8CS 0.5312 inch

Bolt BACB30US8K19Y

Countersunk BACW10BP82ACU

Washer

Special 012N5108-5

Washer

FIGURE 12: ENGINE NUMBER 2 - THRUST REVERSER AFT HINGE FITTING UPPER FASTENER HOLES

- FASTENER INSTALLATION

(SHEET 3 OF 3)

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70 of 77

BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 13: ENGINE NUMBER 1 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION

(SHEET 1 OF 3)

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71 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 to remove/install both hinge fittings on the number 1

strut. If only one hinge is being removed/installed on the number 1 strut, then the quantities shown should be

halved.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

REMOVAL

1 Remove/Keep Nut BACN10HR7CS 4 (b)

Bolt BACB30LE7U( ) 4

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 4

Washer BACW10BP7APU 4

FIGURE 13: ENGINE NUMBER 1 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA

2 Remove/Keep Nut BACN10HR8CS 4 (b)

Bolt BACB30LE8U19 4

BACB30LE8U19X

BACB30LE8U19Y

Washer BACW10BP8ACU 4

Washer BACW10BP8APU 4

Thrust Reverser 311N5148-1 2

Aft Hinge Fitting

3 Remove/Keep

4 Remove Sealant BMS 5-26 -

INSTALLATION

Fay surface seal. Refer

to SOPM 20-50-19 as an

accepted procedure.

5 Apply Sealant BMS 5-45 -

Thrust Reverser 311N5148-1 2

Aft Hinge Fitting

6 Install

7 Install Nut BACN10HR8CS 4 (a)

Bolt BACB30LE8U19 4

BACB30LE8U19X

BACB30LE8U19Y

Washer BACW10BP8ACU 4

Washer BACW10BP8APU 4

8 Install Nut BACN10HR7CS 4 (a)

Bolt BACB30LE7U( ) 4

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 4

Washer BACW10BP7APU 4

(a) Tighten the fasteners to secure the fittings in place.

(b) If existing hardware is undamaged, you can reuse it.

FIGURE 13: ENGINE NUMBER 1 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION

(SHEET 3 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

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73 of 77

BOEING SERVICE BULLETIN 757-54-0049
This Figure applies only to: Group 1, Configuration 1.

FIGURE 14: ENGINE NUMBER 2 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION

(SHEET 1 OF 3)

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: July 16, 2007

Revision 1 September 23, 2009 757-54-0049

74 of 77

BOEING SERVICE BULLETIN 757-54-0049
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 to remove/install both hinge fittings on the number 2

strut. If only one hinge is being removed/installed on the number 2 strut, then the quantities shown should be

halved.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

REMOVAL

1 Remove/Keep Nut BACN10HR7CS 4 (b)

Bolt BACB30LE7U( ) 4

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 4

Washer BACW10BP7APU 4

FIGURE 14: ENGINE NUMBER 2 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION

(SHEET 2 OF 3)

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75 of 77

BOEING SERVICE BULLETIN 757-54-0049
STEP TASK NAME IDENTIFICATION QTY MORE DATA

2 Remove/Keep Nut BACN10HR8CS 4 (b)

Bolt BACB30LE8U19 4

BACB30LE8U19X

BACB30LE8U19Y

Washer BACW10BP8ACU 4

Washer BACW10BP8APU 4

Thrust Reverser 311N5148-1 2

Aft Hinge Fitting

3 Remove/Keep

4 Remove Sealant BMS 5-26 -

INSTALLATION

Fay surface seal. Refer

to SOPM 20-50-19 as an

accepted procedure.

5 Apply Sealant BMS 5-45 -

Thrust Reverser 311N5148-1 2

Aft Hinge Fitting

6 Install

7 Install Nut BACN10HR8CS 4 (a)

Bolt BACB30LE8U19 4

BACB30LE8U19X

BACB30LE8U19Y

Washer BACW10BP8ACU 4

Washer BACW10BP8APU 4

8 Install Nut BACN10HR7CS 4 (a)

Bolt BACB30LE7U( ) 4

BACB30LE7U( )X

BACB30LE7U( )Y

Washer BACW10BP7ACU 4

Washer BACW10BP7APU 4

(a) Tighten the fasteners to secure the fittings in place.

(b) If existing hardware is undamaged, you can reuse it.

FIGURE 14: ENGINE NUMBER 2 -RE-USEDTHRUST REVERSER AFT HINGE FITTING - REMOVAL

ANDINTERIMINSTALLATION

(SHEET 3 OF 3)

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76 of 77

BOEING SERVICE BULLETIN 757-54-0049
APPENDIX A: AFT HINGE FITTING FASTENER STACKUP

(SHEET 1 OF 1)

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77 of 77

BOEING SERVICE BULLETIN 757-54-0049