Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0267

Original Issue: August 13, 2015

Revision 1: August 04, 2016

ATA System: 5380

SUBJECT: FUSELAGE - Aft Pressure Bulkhead - Replacement of Station 1582 Aft Pressure

Bulkhead

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

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laws.

ECCN: 9E991

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ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 21

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 34

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 38

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . 55

FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION . . . . . . . . . . . . . . . . 60

FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS . . . . . . . . . . . . . 62

FIGURE 4: REMOVAL OF PRESSURE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL . . . . . . . . . . . . . . . . . . . . . 69

FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION . . . . . . . . . . . . . . . . . . . 72

FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL . . . . . . . . . . . . . . . . . . 75

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 78

FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 85

FIGURE 10: AFT PRESSURE BULKHEAD PRESSURE RING FASTENER REMOVAL . . . . . . . . . 87

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
FIGURE 11: AFT PRESSURE BULKHEAD ATTACHMENT TO THE PRESSURE RING AT STA 1582 . 89

FIGURE 12: FORWARD SECTION 48 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 91

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION . . . . . . . . . . . . . . . . . 110

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION . . . . . . . . . . . . . . . . 122

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 134

FIGURE 16: PRESSURE SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS . . 142

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS . . . . . . . . . 146

FIGURE 19: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS . . . . . . . . . . . . . . . 156

FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 158

FIGURE 21: STA 1582 FLOOR BEAM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 165

FIGURE 23: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL . . . . . . . . . . . 170

FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION . . . . . . . . . 173

FIGURE 25: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL . . . . . . . . . . . 177

FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION . . . . . . . . 180

FIGURE 27: PREPARATION OF THE VERTICAL FIN . . . . . . . . . . . . . . . . . . . . . . . . . . 183

FIGURE 28: INSTALLATION OF THE VERTICAL FIN . . . . . . . . . . . . . . . . . . . . . . . . . . 190

APPENDIX A: APU WIRING TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

APPENDIX B: ALIGNMENT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: REPLACEMENT OF THE

STA 1582 AFT PRESSURE BULKHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 205

APPENDIX D: PART DEMAND INTENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Commercial 

Airplanes 767

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 767-53A0267

Original Issue: August 13, 2015

Revision 1: August 04, 2016

ATA System: 5380

SUBJECT: FUSELAGE - Aft Pressure Bulkhead - Replacement of Station 1582 Aft Pressure

Bulkhead

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

None.

REASON FOR REVISION

Revision 1 is sent to replace kit number 015T1812-2 with 015T1907-1, and add five airplanes to the effectivity

that were inadvertently omitted at initial release.

These sections were changed:

1. 1.A. Effectivity, added airplane Variable Numbers VN018, VN092, VN191, VN371, and VN537.

2. 1.K.1 Publications Affected - Publications, included additional publications that are affected by this

service bulletin.

3. 2.A. Material - Price and Availability, updated kit number and Re-Order Lead Time (ROLT) information.

4. 2.C.1 Kits/Parts, replaced kit 015T1812-2 with kit number 015T1907-1.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes,

to show the location of all content changes.

Pages with no vertical lines have no changes.

REVISION HISTORY

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Summary Number: 767-53A0267

Original Issue: August 13, 2015

Revision 1: August 04, 2016

ATA System: 5380

SUBJECT: FUSELAGE - Aft Pressure Bulkhead - Replacement of Station 1582 Aft Pressure

Bulkhead

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin gives instruction for the replacement of the Station (STA) 1582 aft pressure bulkhead due

to Widespread Fatigue Damage (WFD). The WFD analysis of the 767, as required by 14 CFR 26.21(b), has

resulted in the conclusion that the existing MPD Section 9, Airworthiness Limitation Item (ALI) inspection program

is not sufficient to preclude the occurrence of WFD in the aft pressure bulkhead before the Limit of Validity (LOV)

as the airplane ages. If widespread fatigue cracking at aft pressure bulkhead radial web lap splices is not found

and repaired, the cracks can rapidly link up and become large, and can result in possible rapid decompression

and loss of structural integrity.

Boeing has not received any reports of cracks in the aft pressure bulkhead web on line number 176 through

423.

The Aft Pressure Bulkhead has been determined to be structure that is susceptible to Widespread Fatigue

Damage (WFD).

Federal Aviation Administration (FAA) AD 2012-09-08 was released to mandate replacement of the initial

configuration aft pressure bulkhead which was installed on line number 1 through 175 per service bulletin

767-53A0139. Design changes were made to improve the durability of the bulkhead in production at line number

176, and again at line number 424. However, the configuration of aft pressure bulkheads installed on line number

176 through 423, have the same web gage of 0.032 inch as the initial configuration aft pressure bulkhead and

does not provide adequate strength to preclude WFD before the Limit of Validity (LOV).

Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.

Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the inspections

at aft pressure bulkhead web for indications of "oil cans" and previous "oil can" repairs currently required by

Boeing Service Bulletin 767-53A0105 and AD 2004-14-19.

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Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the repeat

inspections at aft pressure bulkhead web lap splices currently required by Boeing Service Bulletin 767-53A0147

and AD 2009-06-19.

Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end the repeat

inspections of web at pressure chord joint currently required by Boeing Service Bulletin 767-53A0087 and AD

2004-05-16.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected Yes Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required Yes

ACTION

Remove equipment for access to the forward and aft sides of the STA 1582 aft pressure bulkhead. Remove the

vertical fin, the tail cone (with the APU installed), the left and right STA 1809.5 center bulkhead, and the horizontal

stabilizer. Disconnect and remove the forward portion of Section 48 (with the aft pressure bulkhead attached)

from Section 46 at STA 1582. Remove the aft pressure bulkhead from Section 48 and install a new aft pressure

bulkhead in accordance with this service bulletin. Attach the modified forward part of Section 48 to Section 46

at STA 1582. Reinstall the horizontal stabilizer and reassemble the STA 1809.5 bulkhead. Reinstall the tail cone

and the vertical fin. Install the equipment that was removed for access to the aft pressure bulkhead. Test disturbed

systems in accordance with this service bulletin.

EFFECTIVITY

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

COMPLIANCE

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.

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-14-19 is related to this service bulletin.

The effective date of AD 2004-14-19 is August 20, 2004.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-06-19 is related to this service bulletin.

The effective date of AD 2009-06-19 is April 28, 2009.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-05-16 is related to this service bulletin.

The effective date of AD 2004-05-16 is April 13, 2004.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

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

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

Operators are encouraged to complete the survey provided in APPENDIX D of this service bulletin to help Boeing

predict the quantity and timing of the Boeing Supplied Kits/Parts.

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 767

Service Bulletin

ALERT

Number: 767-53A0267

Original Issue: August 13, 2015

Revision 1: August 04, 2016

ATA System: 5380

SUBJECT: FUSELAGE - Aft Pressure Bulkhead - Replacement of Station 1582 Aft Pressure

Bulkhead

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D624T001 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is applicable to 767-200 and -300 Airplanes, line numbers 176 - 423 in 3

Groups. The Variable Numbers and Group Information for the applicable airplanes are given below.

GROUP CONFIGURATION DESCRIPTION

1 - Airplane Line numbers 176-401 with Non-Dual bottle fire extinguisher

2 - Airplane Line numbers 186-416 with APC Dual Bottle fire extinguisher

Airplane Line numbers 202-423 which have dedicated Static pressure

inputs

3 -

Airplane Models:

767-200, 767-300

Variable Number Group

VA527 - VA530 1

VA713 - VA719 1

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Variable Number Group

VB325 1

VB326 2

VB327 - VB332 1

VE003 1

VE069 1

VE085 - VE086 1

VE104 1

VE118 1

VE124 - VE126 1

VE143 - VE151 1

VE171 - VE172 1

VF001 - VF002 3

VF041 - VF042 3

VF051 3

VF061 - VF062 3

VF071 - VF072 3

VF091 - VF093 3

VF101 - VF102 3

VF161 2

VK005 - VK011 2

VK021 - VK022 2

VK038 - VK053 2

VK081 - VK099 1

VK131 - VK133 1

VK141 - VK142 1

VL002 - VL006 2

VN001 - VN019 3

VN051 - VN062 3

VN081 - VN092 3

VN111 - VN124 3

VN130 - VN132 3

VN151 - VN158 3

VN163 - VN168 3

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Variable Number Group

VN171 - VN173 3

VN191 - VN193 3

VN211 - VN212 2

VN221 - VN224 2

VN231 - VN234 3

VN241 2

VN251 - VN259 2

VN291 3

VN301 - VN306 2

VN371 - VN372 3

VN376 3

VN381 3

VN471 - VN472 3

VN491 - VN496 3

VN531 - VN532 3

VN536 - VN537 3

VN541 - VN542 3

VN551 3

VN631 - VN633 3

VN651 - VN652 3

VN671 - VN672 2

VN681 - VN683 3

VN731 2

VN751 - VN753 3

2. Spares Affected

None.

B. Concurrent Requirements

None.

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ALERT ALERT
C. Reason

This service bulletin gives instruction for the replacement of the Station (STA) 1582 aft pressure bulkhead

due to Widespread Fatigue Damage (WFD). The WFD analysis of the 767, as required by 14 CFR

26.21(b), has resulted in the conclusion that the existing MPD Section 9, Airworthiness Limitation Item

(ALI) inspection program is not sufficient to preclude the occurrence of WFD in the aft pressure bulkhead

before the Limit of Validity (LOV) as the airplane ages. If widespread fatigue cracking at aft pressure

bulkhead radial web lap splices is not found and repaired, the cracks can rapidly link up and become

large, and can result in possible rapid decompression and loss of structural integrity.

Boeing has not received any reports of cracks in the aft pressure bulkhead web on line number 176

through 423.

The Aft Pressure Bulkhead has been determined to be structure that is susceptible to Widespread

Fatigue Damage (WFD).

Federal Aviation Administration (FAA) AD 2012-09-08 was released to mandate replacement of the

initial configuration aft pressure bulkhead which was installed on line number 1 through 175. Design

changes were made to improve the durability of the bulkhead in production at line number 176, and

again at line number 424. However, the configuration of aft pressure bulkheads installed on line number

176 through 423, have the same web gage of 0.032 inch as the initial configuration aft pressure bulkhead

and does not provide adequate strength to preclude WFD before the Limit of Validity (LOV).

Boeing Service Related Problem (SRP) 767-SRP-53-0469 is related to this service bulletin.

Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the

inspections at aft pressure bulkhead web for indications of "oil cans" and previous "oil can" repairs

currently required by Boeing Service Bulletin 767-53A0105 and AD 2004-14-19.

Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will end the

repeat inspections at aft pressure bulkhead web lap splices currently required by Boeing Service Bulletin

767-53A0147 and AD 2009-06-19.

Accomplishment of the aft pressure bulkhead replacement given in this service bulletin will also end

the repeat inspections of web at pressure chord joint currently required by Boeing Service Bulletin

767-53A0087 and AD 2004-05-16.

D. Description

Remove equipment for access to the forward and aft sides of the STA 1582 aft pressure bulkhead.

Remove the vertical fin, the tail cone (with the APU installed), the left and right STA 1809.5 center

bulkhead, and the horizontal stabilizer. Disconnect and remove the forward portion of Section 48 (with

the aft pressure bulkhead attached) from Section 46 at STA 1582. Remove the aft pressure bulkhead

from Section 48 and install a new aft pressure bulkhead in accordance with this service bulletin. Attach

the modified forward part of Section 48 to Section 46 at STA 1582. Reinstall the horizontal stabilizer

and reassemble the STA 1809.5 bulkhead. Reinstall the tail cone and the vertical fin. Install the

equipment that was removed for access to the aft pressure bulkhead. Test disturbed systems in

accordance with this service bulletin.

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

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ALERT ALERT
Affected Maintenance Zones

Model Zone

165, 166, 251, 252, 253, 254, 311, 312, 313,

314, 315, 316, 321, 322, 323, 324, 325, 326,

331, 332, 333, 334, 335, 336, 337, 338, 341,

342, 343, 344, 345, 346, 347, 348

767-200, 767-300

E. Compliance

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

related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times

given in this service bulletin mandatory.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-14-19 is related to this service

bulletin. The effective date of AD 2004-14-19 is August 20, 2004.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-06-19 is related to this service

bulletin. The effective date of AD 2009-06-19 is April 28, 2009.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-05-16 is related to this service

bulletin. The effective date of AD 2004-05-16 is April 13, 2004.

Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

Table 1: Replacement of the STA 1582 Aft Pressure Bulkhead

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 36 -

months after the

original issue

date of this service bulletin.

Before 60,000

total flight cycles

but no earlier

than 37,500 total flight cycles.

Do PART 2: AFT PRESSURE BULKHEAD REPLACEMENT

All Airplanes

F. Approval

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

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

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

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

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

changes.

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

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

before incorporating this service bulletin.

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ALERT ALERT
The Manager of the FAA Seattle Aircraft Certification Office approves the modification defined in this

service bulletin as an alternative method of compliance to the requirements of paragraph (b), (c) and

(d) of AD 2004-14-19. All provisions of AD 2004-14-19 that are not specifically referenced in the above

statement remain fully applicable and must be complied with.

In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the modification

defined in this service bulletin as an alternative method of compliance to the requirements of paragraph

(f) of AD 2009-06-19. All provisions of AD 2009-06-19 that are not specifically referenced in the above

statement remain fully applicable and must be complied with.

In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the modification

defined in this service bulletin as an alternative method of compliance to the requirements of paragraph

(a) and (b) of AD 2004-05-16. All provisions of AD 2004-05-16 that are not specifically referenced in

the above statement remain fully applicable and must be complied with.

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

AFT PRESSURE BULKHEAD REPLACEMENT

Task Number of Persons Task Hours Elapsed Hours

Prepare the new 2 6.00 3.00

bulkhead (Paragraph

3.B., Part 1)

Get Access (Para- 6 228.00 38.00

graph 3.B., Part 2,

through Step 21)

Remove the vertical 6 216.00 36.00

fin (Paragraph 3.B.,

Part 2, Step 22)

Remove the horizon- 6 201.00 33.50

tal stabilizer (Paragraph 3.B., Part 2,

Step 35)

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ALERT ALERT
AFT PRESSURE BULKHEAD REPLACEMENT

Task Number of Persons Task Hours Elapsed Hours

Remove the forward 6 90.00 15.00

part of Section 48

(Paragraph 3.B., Part

2, Step 32 through

Step 34)

Remove the aft pres- 4 13.00 3.25

sure bulkhead from

the forward part of

Section 48 (Paragraph 3.B., Part 2,

Step 35)

Install the new aft 4 13.00 3.25

pressure bulkhead in

the forward part of

Section 48 (Paragraph 3.B., Part 2,

Step 36)

Install the forward 6 90.00 15.00

part of Section 48

(Paragraph 3.B., Part

2, Step

Install the horizontal 6 123.00 20.50

stabilizer (Paragraph

3.B., Part 2, Steps 39

through 44)

Install the tail cone 6 81.00 13.50

(Paragraph 3.B., Part

2, Steps 45 through

49)

Install the vertical fin 6 216.00 36.00

(Paragraph 3.B., Part

2, Step 50

Restore Access 6 237.00 39.50

(Paragraph 3.B., Part

2, Step 51 through

Step 69)

Test disturbed sys- 3 27.00 9.00

tems (Paragraph

3.B., Part 3)

TOTAL FOR EACH AIRPLANE 1541.00 265.50

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ALERT ALERT
H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

767-200 +62.0 +98084.0

767-300 +62.0 +106268.0

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Boeing Service Bulletin 767-25A0300, 767-53A0078, 767-53A0085, 767-53A0087,

767-53A0105, 767-53A0131, 767-53A0139, 767-53A0147

b. Boeing Service Letter 767-SL-00-014, 767-SL-51-008-B, 767-SL-51-036

c. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2003-10-11, 2003-13-03,

2004-05-16, 2004-14-19, 2005-11-02, 2009-06-19, 2011-14-02, 2012-09-08

d. Service Bulletin Index D624T001

e. Standard Overhaul Practices Manual (SOPM) 20-10-02, 20-30-03, 20-41-01, 20-41-02,

20-50-01, 20-50-19

f. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19

g. 767 Aircraft Maintenance Manual (AMM) 05-51-24, 07-11-03, 12-15-01, 12-15-02, 20-10-03,

20-10-04, 20-10-09, 22-10-00, 22-21-00, 23-11-00, 23-41-00, 24-22-00, 25-21-01, 25-21-05,

25-22-01, 25-22-02, 25-22-10, 25-25-01, 25-25-04, 25-27-02, 25-31-04, 25-41-04, 25-52-03,

25-55-01, 27-21-00, 27-21-11, 27-21-13, 27-23-00, 27-28-00, 27-31-00, 27-31-01, 27-31-02,

27-32-00, 27-41-00, 27-41-10, 27-48-00, 27-58-01, 28-25-05, 29-11-00, 31-31-00, 31-51-04,

32-00-20, 33-31-00, 33-45-00, 34-11-01, 36-11-01, 38-11-01, 38-32-11, 38-32-51, 51-24-09,

53-01-01, 53-66-02, 55-10-01, 55-10-02, 55-17-51, 55-36-02

h. 767 Aircraft Recovery Document (ARD)

i. 767-200 Structural Repair Manual (SRM) 51-20-01, 51-50-02

j. 767-300 Structural Repair Manual (SRM) 51-20-01, 51-50-02

2. Data Supplied with this Service Bulletin:

a. Drawings:

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ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

100T3480 Section 48/72 Integration 1 J -

PSDL C -

100T3481 Shim Details - Section 48/72 1 - -

Corrosion Inhibiting Compound Installation 1 C -

- Fuselage

140T6000

Mechanical Equipment Forward 48 Section 1 A -

Stand

2ME148T0200PBR

2 A -

2ME148T0600PBR Mechanical Equipment Aft 48 Section Stand 1 A -

2 A -

Mechanical Equipment Strongback, Pres- 1 - -

sure Bulkhead Transportation and Installation

2ME148T2610PBR

2 A -

3 A -

4 A -

5 A -

Miscellaneous Tool Torque Multiplier and 1 - -

Adapter, Vertical Fin

2MIT100T3480PBR

2 A -

3 A -

4 - -

5 - -

6 - -

Overhead Mechanical Equipment Vertical 1 A -

Fin Assembly Sling

2OHME100T3480PBR

Mechanical Equip Sling and Strongback 1 - -

Fwd 48 Section Pressure Bulkhead

3ME140T0140PBR

2 - -

3 - -

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ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

624T0020 Aft Pressure Bulkhead Parts Removal 1 - -

10 A -

11 - -

12 A -

13 A -

14 A -

15 A -

16 A -

17 A -

2 - -

3 - -

4 - -

5 - -

6 A -

7 A -

8 B -

9 A -

Mechanical Equipment Vertical Fin Lift Fit- 1 B -

tings

ME100T3480PBR

Mechanical Equipment Forward 48 Section 1 - -

Handling Fitting

ME148T0200PBR

Mechanical Equipment Aft 48 Section Han- 1 A -

dling Fitting

ME148T0600PBR

Mechanical Equipment Strongback Pressure 1 - -

Bulkhead Removal

ME148T2610PBR

2 A -

3 A -

5 A -

Mechanical Equipment Vert Fin Stand Floor 1 A -

Mounted

ME170T0100PBR

2 A -

Mechanical Equipment Floor Mounted Stand 1 A -

Horizontal Stabilizer

ME180T0000PBR

Mechanical Equipment Lift Fittings Front 1 - -

and Rear Spar Horizontal Stabilizer

ME182T0000PBR

Misc Tool Alignment Pins Vertical Fin Body 1 - -

Join

MIT100T3480PBR

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ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

Overhead Mech Equip Pressure Dome Sling 1 - -

Fwd 48 Section

OHME148T2610PBR

2 - -

Overhead Mech Equip Horizontal Stabilizer 1 - -

Complete

OHME180T0100PBR

2 - -

Portable Mechanical Equipment Forward 1 - -

48 Section Internal Scaffolding

PME148T0010PBR

2 - -

3 - -

4 - -

5 - -

6 - -

Protective Equipment Pressure Bulkhead 1 - -

Cover

PRE148T2610PBR

Shipping Mech Equip Ground Transporta- 1 - -

tion Aft Pressure Bulkhead

SME148T2610PBR

2 - -

3 - -

4 - -

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

Drawing Number Title

100T3480 Section 48/72 Integration

140T0140 Monocoque Integration - Section 46/48

140T0540 Floor System Integration Section 46 - 48

140T4800 Seal Application Section 48 Integration

146T5500 Stanchion Installation - Sect 46

146T5604 Support Instl - Galley Tie Down Fittings, Sect 46

148T0006 Fastener Instl Bulkhead Splice STA 1809.5

148T0007 Fastener Instl

148T0008 Fastener Instl - STA 1809.5 Splice, Sect 48

148T1150 Frame Instl - Pivot Bulkhead

Bulkhead End Item - Center, Horiz Stab Pivot, STA

1809.5

148T2740

233T9112 Seal Instl - Pitot/Static Tubing Pressure Dome

255T4821 Pressure Seal Instl - Pressure Dome STA 1582.0

272T4831 Retainer Instl - Pressure Seal, Hydraulic Tubing

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ALERT ALERT
Drawing Number Title

Tubing Instl - APU Fuel Feed, Body Sections 45, 46

and 48

346T0003

140T6000 Corrosion Inhibiting Compound Installation - Fuselage

100T3481 Shim Details - Section 48/72

NOTE: 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:

Publication Chapter-Section

767 Illustrated Parts Catalog 28-25, 29-11, 34-11, 53-80

2. Damage Tolerance Based Structural Inspections:

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

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

Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

L. Interchangeability and Intermixability of Parts

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

M. Software Accomplishment Summary

Not affected.

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

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

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

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

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

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

2. Fax to (206) 662-7145

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

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

Unit Price as of

the original issue

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name

Top Kit - STA 1582 Aft Pressure Bulkhead 550 $86,435.00

Replacement

015T1907-1

691T0103-1 Aft Pressure Bulkhead 450 $578,050.00

Operators are encouraged to complete the survey provided in APPENDIX D of this service bulletin to

help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

B. Industry Support Information

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

C. Parts Necessary for Each Airplane

1. Kits/Parts

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

NOTE: One top kit, one aft bulkhead assembly and the items shown in Paragraph 2.C.2., Parts

and Materials Supplied by the Operator, are necessary for each airplane. The Top Kit is

divided into Figure kits for each installation figure shown in the table below.

Kit 691T0103

Part Number Quantity

691T0103-1 1

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ALERT ALERT
Figure Kit

Top Kit 1 6 11 12 13 14

015T1907-1 1 1 1 1 1 1

Figure Kit

Top Kit 15 16 17 22 24 26

015T1907-1 1 1 1 1 1 1

Figure Kit

Top Kit 28

015T1907-1 1

ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

1 6 11 12 13 14

Qty

140T0140-5 . . . 2 . . WASHER (a)

140T0142U1 . . . 1 . . CLIP (b)

(140T0142-1 optional)

140T0142U2 . . . 1 . . CLIP (b)

(140T0142-2 optional)

140T0169-7 . . . 2 . . FITTING ASSY -

140T0345-1 1 . . . . . COVER PLATE -

SEAL BLOCK AS- -

SY

140T0345-3 1 . . . . .

148T0012-2 . . . . 2 2 FILLER -

148T0012-3 . . . . 2 2 FILLER -

148T0012-4 . . . . 1 1 SHIM -

148T0012-5 . . . . 1 1 SHIM -

148T0012-11 . . . . 1 1 FILLER -

148T0012-18 . . . . . 2 SHIM -

148T0012-19 . . . . 2 . SHIM -

148T0015-1 . . . . 2 2 SPLICE-STRAP -

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

1 6 11 12 13 14

Qty

SEAL BLOCK AS- -

SY

148T2629-2 1 . . . . .

272T4825-9 . . . 1 . . BRACKET ASSY- -

40345 (678782 . 1 . . . . SEAL -

optional)

412T3106-406 . . . 2 . . FITTING ASSY -

412T3106-408 . . . 1 . . fitting assy -

BOLT, PROTRUD- (a)

ING HD

BACB30MY10K10X . . . . 8 8

BOLT TITANIUM (a)

O/S

BACB30MY10K3X . . . . 10 10

BOLT, PROTRUD- (a)

ING HD

BACB30MY10K5X . . . . 5 5

BOLT, PROTRUD- (a)

ING HD

BACB30MY10K6X . . . . 1 1

BOLT, PROTRUD- (a)

ING HD

BACB30MY10K7X . . . . 11 11

BOLT, PROTRUD- (a)

ING HD

BACB30MY10K8X . . . . 14 14

BOLT, PROTRUD- (a)

ING HD

BACB30MY12K10X . . . . 4 4

BOLT, PROTRUD- (a)

ING HD

BACB30MY12K6X . . . . 2 2

BOLT, PROTRUD- (a)

ING HD

BACB30MY12K7X . . . . 4 4

BOLT, PROTRUD- (a)

ING HD

BACB30MY12K8X . . . . 4 4

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K10X . . . . 7 7

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K11X . . . . 3 3

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K12X . . . . 4 4

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

1 6 11 12 13 14

Qty

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K5X . . . . 35 35

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K6X . . . . 1 1

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K7X . . . . 65 65

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K8X . . . . 3 3

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K9X . . . . 1 1

BACB30NM4K14 16 . . . . . BOLT, HEX HEAD (a)

BOLT, 100 DEG (a)

HEX DR

BACB30NW8K13X . . . . 4 4

BOLT, 100 DEG (a)

HEX DR

BACB30NW8K5X . . . . 2 2

BOLT, 100 DEG (a)

HEX DR

BACB30NW8K7X . . . . 2 2

BOLT, 100 DEG (a)

HEX DR

BACB30NW8K8X . . . . 4 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K11X . . . . 4 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K12X . . . . 4 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K8X . . . . 2 2

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K9X . . . . 2 2

BOLT, PROTRUD- (a)

ING HD

BACB30NX12K12X . . . . 4 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX6K10X . . . 2 . .

BOLT, PROTRUD- (a)

ING HD

BACB30NX6K4X . . . 20 . .

BOLT, PROTRUD- (a)

ING HD

BACB30NX6K5X . . . 2 . .

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

1 6 11 12 13 14

Qty

BOLT, 12 PT (a)

HEAD

BACB30US5K16 . . . 26 . .

BOLT, 12 PT (a)

HEAD

BACB30US5K17 . . . 58 . .

BOLT, 12 PT (a)

HEAD

BACB30US5K18 . . . 40 . .

BOLT, 12 PT (a)

HEAD

BACB30US5K19 . . . 24 . .

BOLT, 12 PT (a)

HEAD

BACB30US5K21 . . . 10 . .

BOLT, 12 PT (a)

HEAD

BACB30US5K25 . . . 6 . .

BOLT, 12 PT (a)

HEAD

BACB30US6K31 . . . 4 . .

BOLT, 12 PT (a)

HEAD

BACB30US6K33 . . . 40 . .

BOLT, 12 PT (a)

HEAD

BACB30US6K34 . . . 32 . .

BOLT, 12 PT (a)

HEAD

BACB30US6K35 . . . 8 . .

BOLT, 12 PT (a)

HEAD

BACB30US6K36 . . . 8 . .

BOLT, 12 PT (a)

HEAD

BACB30US7K35 . . . 20 . .

BOLT, 12 PT (a)

HEAD

BACB30US7K39 . . . 12 . .

BOLT, 12 PT (a)

HEAD

BACB30US7K40 . . . 16 . .

BOLT, 12 PT (a)

HEAD

BACB30US8K42 . . . 16 . .

BACC30BH10 . . . . 14 14 COLLAR (a)

BACC30BH12 . . . . 4 4 COLLAR (a)

BACC30BH6 . . . 24 . . COLLAR (a)

BACC30M10 . . . . 49 49 COLLAR (a)

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

1 6 11 12 13 14

Qty

BACC30M12 . . . . 14 14 COLLAR (a)

BACC30M8 . . . . 145 145 COLLAR (a)

BACN10HR5CD . . . 156 . . NUT (a)

SELF-LOCKING (a)

NUT

BACN10HR6CD . . . 92 . .

BACN10HR7CD . . . 44 . . NUT (a)

BACN10HR8CD . . . 16 . . NUT (a)

BACN11AG3 15 . . . . . NUT, SELF-LOCK (a)

RIVET, UNIVER- (a)

SAL HD

BACR15BB5A7C 50 . . . . .

RIVET, UNIVER- (a)

SAL HD

BACR15BB6A8C 5 . . . . .

BACR15FT6KE7C 8 . . . . . RIVET (a)

BACR15FV7KE7 . . . . 5 5 RIVET (a)

BACR15FV7KE8 . . . . 1 1 RIVET (a)

BACS12HN3-7 15 . . . . . BOLT (a)

SHIM, LAMINAT- -

ED

BACS40R011B012F . . . 2 . .

BACS40R011B027F . . . . 2 2 SHIM,LAMINATED -

SHIM, LAMINAT- -

ED

BACS40R012B027F . . . . 2 2

SHIM, LAMINAT- -

ED

BACS40R016B098F . . . . 1 1

SHIM, LAMINAT- -

ED

BACS40R027C030F . . . . 1 1

BACW10BP5CD . . . 156 . . CSK WASHER (a)

BACW10BP5DP . . . 154 . . WASHER-PLAIN (a)

BACW10BP6CD . . . 92 . . WASHER, PLAIN (a)

BACW10BP6DP . . . 92 . . WASHER (a)

BACW10BP7CD . . . 44 . . WASHER (a)

BACW10BP7DP . . . 44 . . WASHER (a)

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

1 6 11 12 13 14

Qty

BACW10BP8CD . . . 16 . . WASHER (a)

BACW10BP8DP . . . 16 . . WASHER (a)

NAS1149D0316J . 8 . . . . WASHER (a)

NAS1149D0332J 30 . . . . . WASHER (a)

NAS1149D0363J 5 . . . . . WASHER, FLAT (a)

NAS1399D6A10 . . 31 . . . RIVET, BLIND (a)

(NAS1399D6AB10

optional)

SPACERS FOR -

RIVETS

NAS42DD3-44FC 1 . . . . .

SPACERS FOR -

RIVETS

NAS42DD3-48FC 1 . . . . .

SPACERS FOR -

RIVETS

NAS42DD3-64FC 1 . . . . .

(a) 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.

(b) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify

these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts

are changed to the 'dash' configuration when installed as given in the Accomplishment Instructions of this

service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Boeing Service

Letter 767-SL-00-014 for more information.

ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

15 16 17 22 24 26

Qty

148T2746-1 2 . . . . . washer (a)

148T2746-2 2 . . . . . filler -

233T9110-566 . . 1 . . . TUBE ASSY -

233T9110-665 . . 1 . . . TUBE ASSEMBLY -

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

15 16 17 22 24 26

Qty

PLATER RETAIN- -

ER

233T9113-4 . . 2 . . .

270T0004-1101 . 3 . . . . SEAL -

270T0004-1102 . 1 . . . . SEAL -

272T4830-1 . 1 . . . . RETAINER- -

272T4830-2 . 1 . . . . RETAINER ASSY- -

69B41314-6 . . 1 . . . SEAL- -

BACB30LM3-3 . . 24 . . . BOLT (a)

BOLT, 12 PT (a)

HEAD

BACB30LT5-12 10 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30LT7-12 8 . . . . .

BOLT, PROTRUD- (a)

ING HD

BACB30MY8K4X . . . 12 . .

BOLT, 100 DEG (a)

HEX DR

BACB30NW8K8X . . . . 6 6

BACB30NX10K10 44 . . . . . HEX DRIVE BOLT (a)

BACB30NX10K7 54 . . . . . BOLT (a)

BACB30NX14K16 8 . . . . . BOLT (a)

BOLT, PROTRUD- (a)

ING HD

BACB30NX6K4X . . . 3 . .

BACB30NX6K5 8 . . . . . BOLT (a)

BOLT, PROTRUD- (a)

ING HD

BACB30NX6K6X . . . 5 . .

BACB30NX8K5 8 . . . . . HI LOK (a)

BOLT, PROTRUD- (a)

ING HD

BACB30NX8K5X . . . 22 . .

BOLT, PROTRUD- (a)

ING HD

BACB30NX8K6X . . . 6 . .

BACB30NX8K7 76 . . . . . BOLT, HEX DRIVE (a)

BOLT, PROTRUD- (a)

ING HD

BACB30NX8K7X . . . 14 . .

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

15 16 17 22 24 26

Qty

BOLT, 12 PT (a)

HEAD

BACB30US12K37 4 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30US12K40 4 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30US7K24 22 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30US7K26 2 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30US7K27 4 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30US7K28 32 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30US8K30 2 . . . . .

BOLT, 12 PT (a)

HEAD

BACB30US8K31 4 . . . . .

BOLT, 100 DEG (a)

HEAD

BACB30VF3K5 . . . . 10 10

BACB30VF3K7 . . . . 3 3 BOLT (a)

BACC10DK6 . . 10 . . . CLAMP, LOOP -

BACC30BH10 107 . . . . . COLLAR (a)

COLLAR, (a)

PRELOAD

BACC30BH14 8 . . . . .

BACC30BH6 8 . . . . . COLLAR (a)

BACC30BH8 84 . . 42 . . COLLAR (a)

BACC30M6 . . . 8 . . COLLAR (a)

BACC30M8 . . . 12 6 6 COLLAR (a)

SELF-LOCKING (a)

NUT

BACN10HR12CD 8 . . . . .

BACN10HR7CD 60 . . . . . NUT (a)

BACN10HR8CD 4 . . . . . NUT (a)

BACN10JC3CD . 18 . . . . NUT (a)

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

15 16 17 22 24 26

Qty

SELF-LOCKING (a)

NUT

BACN10JC5CD 10 . . . . .

SELF-LOCKING (a)

NUT

BACN10JC7CD 8 . . . . .

RIVET, UNIVER- (a)

SAL HD

BACR15FT5KE9C . . . . 2 2

BACR15FV6KE7 . . . . 5 5 RIVET (a)

BACR15FV6KE8 . . . . 1 1 RIVET (a)

BACS12HN3-9 . 24 . . . . BOLT (a)

SHIM, LAMINAT- -

ED

BACS40R040C095F . . . 2 . .

BACW10BP12CD 8 . . . . . WASHER, PLAIN (a)

BACW10BP12DP 8 . . . . . WASHER, PLAIN (a)

BACW10BP5CD 10 . . . . . CSK WASHER (a)

BACW10BP5DP 12 . . . . . WASHER-PLAIN (a)

BACW10BP7CD 68 . . . . . WASHER (a)

BACW10BP7DP 68 . . . . . WASHER (a)

BACW10BP8DP 4 . . . . . WASHER (a)

NAS1149D0316J . 24 . . . . WASHER (a)

(a) 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.

ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

28

Qty

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K10X 6

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K12X 6

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

28

Qty

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K13X 2

BOLT, PROTRUD- (a)

ING HD

BACB30NX10K15X 2

BOLT, PROTRUD- (a)

ING HD

BACB30NX12K11X 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX12K14X 10

BOLT TIANIUM (a)

O/S

BACB30NX12K15X 58

BACB30NX12K9X 14 BOLT, HEX DRIVE (a)

BOLT, PROTRUD- (a)

ING HD

BACB30NX16K11X 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX6K19X 8

BOLT, PROTRUD- (a)

ING HD

BACB30NX6K6X 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX8K16X 4

BOLT, PROTRUD- (a)

ING HD

BACB30NX8K5X 28

BOLT, PROTRUD- (a)

ING HD

BACB30NX8K9X 6

BOLT, 12 PT (a)

HEAD

BACB30US16K47 4

BOLT, 12 PT (a)

HEAD

BACB30US16K48 4

BOLT, 12 PT (a)

HEAD

BACB30US16K50 2

BOLT, 12 PT (a)

HEAD

BACB30US16K51 2

BOLT, 12 PT (a)

HEAD

BACB30US18K52 4

BACC30BH10 16 COLLAR (a)

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ALERT ALERT
ALL

KIT 015T1907-1

Notes

Existing Part

Name Number

Figure

New Part Number

28

Qty

BACC30BH12 86 COLLAR (a)

BACC30BH6 12 COLLAR (a)

BACC30BH8 38 COLLAR (a)

BACC30X16 4 COLLAR (a)

BACN11B16CS 12 BARREL NUT (a)

BACN11B18CS 4 BARREL NUT (a)

BACW10BP16CD 12 WASHER, PLAIN (a)

BACW10BP18CD 4 WASHER, PLAIN (a)

NAS1149E1632P 16 WASHER (a)

(a) 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.

2. Parts and Materials Supplied by the Operator

The following parts or materials are necessary to do the change in this service bulletin. Parts and

materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine

operator part and material supply to make sure all necessary parts and materials are available.

Part Number/Specifica- Qty Name Notes

tion

A 1 Plate -

B 1 Plate -

BACB30NM4K4 8 Bolt -

BACB30NX6K5 120 Bolt -

BACB30NX6K8 18 Bolt -

BACC30BH6SW 138 Collar -

BACB30LM3-3 8 Bolt -

BMS 5-25 2 Oz Epoxy Adhesive -

BMS 5-95 2 Oz Sealant -

BMS 5-125 Type II 2 Oz Sealant -

BMS 5-142 2 Oz Sealant -

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ALERT ALERT
Part Number/Specifica- Qty Name Notes

tion

BMS 3-27 2 Oz Sealant -

BMS 3-38 2 Oz Sealant -

BMS 10-11 2 Oz Primer -

C 6 Angle -

D 2 Angle -

E 2 Angle -

F 2 Plate -

G 2 Angle -

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

Boeing can supply the tool(s) shown in Paragraph 2.F., Special Tooling Necessary to do this Service

Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of

the service bulletin by e-mail to ServiceBulletinRentalLoanTools@boeing.com. The tool(s) are subject

to the terms and conditions of the Boeing standard purchase order acknowledgement. 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 Boeing Part Page

2. Fax to (425) 965-8237

Rental Data:

Daily Price as of

the Original Issue

date of this service bulletin (US

Dollars)

Tool Kit Number Name

Forward 48 Section Internal $550.00

Scaffolding

PME148T0010PBR

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Rental Data:

Daily Price as of

the Original Issue

date of this service bulletin (US

Dollars)

Tool Kit Number Name

PRE148T2610PBR Pressure Bulkhead Cover $224.00

MIT100T3480PBR Vertical Fin Alignment Pins $200.00

ME170T0100PBR Vertical Fin Floor Stand $260.00

OHME148T2610PBR Pressure Dome Sling $420.00

2OHME100T3480PBR Vertical Fin Lift Sling $260.00

ME100T3480PBR Vertical Fin Lift Fittings $380.00

ME182T0000PBR Horizontal Stabilizer Lift Fittings $200.00

OHME180T0100PBR Horizontal Stabilizer Lift Sling $380.00

Forward 48 Section Sling and $260.00

Strongback

3ME140T0140PBR

Vertical Fin Torque Multiplier $550.00

and Adapter

2MIT100T3480PBR

Aft 48 Section Lift Sling and At- $400.00

tach Fittings

ME148T0600PBR

Pressure Bulkhead Removal (a)

Strongback

ME148T2610PBR

ME180T0000PBR Horizontal Stabilizer Floor Stand $240.00

2ME148T0600PBR Aft 48 Section Stand $380.00

Forward 48 Section Attach Fit- $420.00

tings

ME148T0200PBR

2ME148T0200PBR Forward 48 Section Stand $440.00

Pressure Bulkhead Transporta- $400.00

tion Removal Strongback

2ME148T2610PBR

Pressure Bulkhead Ground $460.00

Transportation Fixture

2SME148T2610PBR

A $150.00 handling is added to all tool rentals

(a) Rental price data for this tool was not available at the time this service

bulletin was issued.

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Purchase Data:

Unit Price as of

the Original Issue

date of this Service Bulletin (US

Dollars)

Tool Kit Number Name

Forward 48 Section internal $192,263.00

Scaffolding

PME148T0010PBR

PRE148T2610PBR Pressure Bulkhead Cover $24,471.00

MIT100T3480PBR Vertical Fin Alignments Pins $12,818.00

ME170T0100PBR Vertical Fin Floor Stand $27,104.00

OHME148T2610PBR Pressure Dome Sling $82,322.00

2OHME100T3480PBR Vertical Fin Lift Sling $28,371.00

ME100T3480PBR Vertical Fin Lift Sling $60,331.00

ME182T0000PBR Horizontal Stabilizer Lift Fittings $12,819.00

OHME180T0100PBR Horizontal Stabilizer Lift Sling $64,089.00

Forward 48 Section Sling and $28,680.00

Strongback

3ME140T0140PBR

Vertical Fin Torque Multiplier $192,263.00

and Adapter

2MIT100T3480PBR

Aft 48 Section Lift Sling and At- $74,129.00

tach Fittings

ME148T0600PBR

2ME148T0600PBR Aft 48 Section Stand $62,077.00

Forward 48 Section Attach fit- $81,929.00

tings

ME148T0200PBR

2ME148T0200PBR Forward 48 Section Stand $94,649.00

ME180T0000PBR Horizontal Stabilizer Floor Stand $21,600.00

Pressure Bulkhead Transporta- $72,810.00

tion

2ME148T2610PBR

Pressure Dome Removal (a)

Strongback

ME148T2610PBR

Pressure Bulkhead Ground $105,508.00

Transportation Fixture

2SME148T2610PBR

(a) Purchase price data for this tool was not available at the time this service bulletin was

issued.

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

To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability.

Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be

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

Tool Kit Number Name

Forward 48 Section Internal

Scaffolding

PME148T0010PBR

PRE148T2610PBR Pressure Bulkhead Cover

MIT100T3480PBR Vertical Fin Alignment Pins

ME170T0100PBR Vertical Fin Floor Stand

OHME148T2610PBR Pressure Dome Sling

Pressure Dome Removal

Strongback

ME148T2610PBR

2OHME100T3480PBR Vertical Fin Lift Sling

ME100T3480PBR Vertical Fin Lift Fittings

ME182T0000PBR Horizontal Stabilizer Lift Fittings

OHME180T0100PBR Horizontal Stabilizer Lift Sling

Forward 48 Section Sling and

Strongback

3ME140T0140PBR

Vertical Fin Torque Multiplier and

Adapter

2MIT100T3480PBR

Aft 48 Section Lift Sling and Attach FittingsME148T0600PBR

ME180T0000PBR Horizontal Stabilizer Floor Stand

2ME148T0600PBR Aft 48 Section Stand

Forward 48 Section Attach FittingsME148T0200PBR

2ME148T0200PBR Forward 48 Section Stand

Pressure Bulkhead Transportation2ME148T2610PBR

Pressure Bulkhead Ground

Transportation Fixture

2SME148T2610PBR

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ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

definition of the acronyms.

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

3. 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 and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 767 Structural Repair Manual,

Chapter 51.

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

SRM Chapter 51.

5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

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

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

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

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate

full threaded fasteners (screws) needed for installation in this service bulletin.

7. 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.

8. Boeing Service Letter 767-SL-51-036, 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.

9. Refer to Appendix C for logic diagrams. Logic diagrams are provided as an aid only.

Information contained in Paragraph 1.E., Compliance is the primary source for

compliance times. Information in Paragraph 3.B., Work Instructions is the primary

source for tasks required for compliance.

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
10. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

11. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

12. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

13. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

14. When more than one OPTION is given for a CONDITION, do only one of the OPTION

numbers. When more than one ACTION is given for a CONDITION number or an

OPTION number, do all of the ACTION numbers for that CONDITION number or

OPTION number.

15. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

16. Use of colors in Figures is based on guidance from the ATA e-Business Program

(ATA) iSpec 2200.

17. Some steps in the Work Instructions are labeled as Required for Compliance (RC).

If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps

labeled as RC, including sub-steps under an RC step and any figures identified in

an RC step, must be done to comply with the AD. An Alternative Method of

Compliance (AMOC) is required for any deviations to RC steps, including sub-steps

and identified figures. Steps not labeled as RC may be deviated from using accepted

methods in accordance with the operator's maintenance or inspection program without

obtaining approval of an AMOC. This is provided that the RC steps, including

sub-steps and identified figures, can still be done as specified, and the airplane can

be put back in an airworthy condition.

B. WORK INSTRUCTIONS

1. Do PART 1: BULKHEAD PREPARATION

2. Do PART 2: AFT PRESSURE BULKHEAD REPLACEMENT

3. Do PART 3: SYSTEM TESTS

4. Put the airplane back to a serviceable condition

PART 1: BULKHEAD PREPARATION

1. Prepare the new aft pressure bulkhead assembly in accordance with FIGURE 1.

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
2. Group 2:

Do additional preparation of the new aft pressure bulkhead assembly in accordance with FIGURE

2.

PART 2: AFT PRESSURE BULKHEAD REPLACEMENT

1. Supply airplane electrical power. Refer to 767 AMM 24-22-00 as an accepted procedure.

2. Pressurize the center hydraulic system. Refer to 767 AMM 29-11-00 as an accepted procedure.

3. Use the STAB TRIM levers or switches to move the horizontal stabilizer to the neutral position (2

units of trim on the position indicator).

4. Remove the pressure from the center, right, and left hydraulic systems. Refer to 767 AMM 29-11-00

as an accepted procedure.

5. Set the C, R, and L STAB TRIM switches on the P10 Panel to the CUTOUT position and attach

DO-NOT-OPERATE tags.

6. On the P61 right side panel, put these switches in the OFF position and attach DO-NOT-OPERATE

tags:

S2 RIGHT TAIL HD SHUT OFF VALVE SWITCH

S4 CENTER TAIL HD SHUT OFF VALVE SWITCH

S6 LEFT TAIL HD SHUT OFF VALVE SWITCH

7. Open the following circuit breakers and attach DO-NOT-CLOSE tags:

a. On the P11 Overhead Circuit Breaker Panel:

(1) For the APU Fuel System:

11B36, APU START

11D34, FUEL DC PUMP PWR

11D35, FUEL DC PUMP CONT

11M25, FUEL PUMPS L FWD R AFT

(2) For the horizontal stabilizer ballscrew and pivot pins:

11A36, ALT STAB TRIM (if installed)

11C12, STAB TRIM SHUTOFF L

11C13, STAB TRIM SHUTOFF CENTER

11H17, FLT CONT SHUTOFF TAIL LEFT

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11H18, FLT CONT SHUTOFF TAIL CENTER

11H27, FLT CONT SHUTOFF TAIL RIGHT

11D29, ENG HYD PUMP L SUPPLY

11D30, ENG HYD. PUMP R SUPPLY

11L25, HYD ELEC PUMP L

11L16, HYD ELEC PUMP R

11L15, ELEC HYD PUMP C

111L18, HYD SYS C PRESS

11D31, AIR HYD PUMP

b. On the P6 Main Power Distribution Panel:

6E3, APU FUEL VALVES

8. Remove airplane electrical power. Refer to 767 AMM 24-22-00 as an accepted procedure.

9. Support and jack the airplane indoors as follows:

a. Install nose and main landing gear down locks. Refer to 767 AMM 32-00-20 as an accepted

procedure.

b. Deflate the nose gear and pump oil into the nose gear. Simultaneously deflate both main

gears and pump oil into the main gears. When the oil flow is free of nitrogen bubbles close

the valves. Pump additional oil into both the nose and main landing gear oleos to achieve one

inch of chrome showing. Refer to 767 AMM 12-15-01 and 767 AMM 12-15-02 as accepted

procedures.

c. Partially support the airplane with nose and main landing gear/axial jacks at all five axle

jackpoints. Refer to 767 AMM 07-11-03 as an accepted procedure. Apply a 10,000 - 12,000

pound load at each axial jack location. Install wheel chocks and chains at each main landing

gear.

NOTE: Parking brake can remain set.

d. Mechanically lock all five axle jacks.

10. Disassemble and remove (or shift forward) equipment from the aft part of the passenger

compartment for access to the Aft Pressure Bulkhead joint at STA 1582. This includes:

a. Passenger seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

b. Partitions. Refer to 767 AMM 25-25-04 as an accepted procedure.

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c. Aft Galley Complex A1, A4, or A1-A3. Refer to 767 AMM 25-31-04 as an accepted procedure.

d. Lavatories. Refer to 767 AMM 25-41-04 as an accepted procedure.

e. Sidewall Panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

f. Ceiling panels. Refer to 767 AMM 25-22-01, 767 AMM 25-22-02, and/or 767 AMM 25-22-10

as accepted procedures.

g. Sidewall and Ceiling Insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

h. Doorway/Galley Floor Covering. Refer to 767 AMM 25-27-02 as an accepted procedure.

i. Floor Panels. Refer to 767 AMM 53-01-01 as an accepted procedure.

11. Disassemble and remove (or shift forward) equipment from the aft end of the bulk cargo

compartment for access to the Aft Pressure Bulkhead joint at STA 1582. This includes:

a. Bulk Cargo Compartment Aft Lining. Refer to 767 AMM 25-55-01 as an accepted procedure.

b. Bulk Cargo Compartment Sidewall Lining, for access to the pitot-static tubes on the left side

from the aft pressure bulkhead to the bulk cargo door aft frame at STA 1461. Refer to 767

AMM 25-55-01 as an accepted procedure.

c. Potable Water Tanks. Refer to 767 AMM 38-11-01 as an accepted procedure.

d. Vacuum Lavatory Waste Tanks. Refer to 767 AMM 38-32-11 as an accepted procedure.

e. Sidewall Insulation, which includes insulation blankets and capstrips from the sidewall, ceiling,

and aft pressure bulkhead. Refer to 767 AMM 25-52-03 as an accepted procedure.

NOTE: Boeing Service Bulletin 767-25A0300, "Equipment/Furnishings - Insulation - Aft

Bulkhead to Floor Insulation Blankets Modification", which is mandated by FAA AD

2003-13-03, requires replacement of aft pressure bulkhead insulation blankets.

12. Disconnect the elevator (E1A/E1B/E2A/E2B), stabilizer trim (ST1A/ST1B/ ST2A/ST2B) and rudder

(RA/RB) control cables. Refer to 767 AMM 20-10-03 as an accepted procedure.

a. Install cable clamps.

b. Disconnect the cables at any turnbuckle aft of the aft pressure bulkhead.

c. Remove and salvage any air seals where the cable penetrates the aft pressure bulkhead.

d. Move and coil the cable ends forward and aft of the aft pressure bulkhead.

13. Remove and salvage the control cable air seals and fasteners for the elevator (E1A/E1B/E2A/E2B),

stabilizer trim (ST1A/ST1B/ ST2A/ST2B) and rudder (RA/RB) control cables. Refer to 767 AMM

20-10-04 as an accepted procedure. The salvaged air seals will be installed on the new aft pressure

bulkhead assembly when the control cables are reinstalled.

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14. Disconnect and remove auxiliary pitot tubes and seals in accordance with FIGURE 3.

15. Disconnect and remove auxiliary static system tubes (if installed) and hydraulic lines as follows.

a. Group 3:

Disconnect the auxiliary static system (AS1 and AS2) tubes at the junctions between STA

1605.5 and STA 1629, between stringers S-31L and S-32L. Cap the open ends of all tubes.

Refer to 767 AMM 20-10-09 as an accepted procedure.

b. Disconnect and cap the hydraulic lines at or near STA 1809.

c. Disconnect and cap the hydraulic lines forward of the aft pressure bulkhead.

d. Remove and discard the pressure seals at the aft pressure bulkhead in accordance with

FIGURE 4.

e. Remove hydraulic lines between the aft pressure bulkhead and STA 1809.

f. Group 3:

Move the auxiliary static system (AS1 and AS2) tubes forward of STA 1582.

16. Disconnect the electrical connectors from the altitude pressure switches. Refer to 767 AMM

38-32-51 as an accepted procedure.

17. Disconnect electrical systems, including:

a. Lights

b. APU Power

c. High Frequency Communications

d. Stall Warning Systems

e. Interphone

f. Autopilot

g. Yaw Damper

h. Rudder Trim Actuator

i. Rudder Ratio Changer

j. Rudder and Elevator Shutoff Valves

k. Rudder Position Indicator

l. Stabilizer Trim Control System

m. Flap/Stabilizer Position Module

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n. Flight Recorder Systems

o. APU Fire Detection System

18. Disassemble and remove and keep all seal components where wires penetrate the aft pressure

bulkhead. Move all loose wires forward or aft, as necessary.

19. Disconnect and remove the APU Air Supply Duct. Refer to 767 AMM 36-11-01 as an accepted

procedure.

20. Disconnect the APU fuel line at the aft pressure bulkhead as follows:

a. In the aft end of the bulk cargo compartment, disconnect the shroud and APU fuel line at the

aft pressure bulkhead fitting. Salvage all bolts, nuts, and washers. Refer to the task "Remove

the APU Fuel Line and Shroud Between the Center Compartment of the Auxiliary Fuel Tank

and the Pressure Bulkhead for the Aft Cargo Compartment" in 767 AMM 28-25-05 as an

accepted procedure.

b. Remove the APU fuel line between the aft pressure bulkhead the APU firewall. Refer to the

task "Remove the APU Fuel Line and Shroud Between the Pressure Bulkhead for the Aft

Cargo Compartment and the APU Firewall Bulkhead" in 767 AMM 28-25-05 as an accepted

procedure.

c. Remove and keep the APU fuel line bulkhead fitting in accordance with FIGURE 5.

d. Install the APU fuel line bulkhead fitting on the new aft pressure bulkhead in accordance with

FIGURE 6.

21. Remove the Dorsal Fin. Refer to 767 AMM 53-66-02 as an accepted procedure.

CAUTION: SLOWLY LIFT AND REMOVE LARGE STRUCTURAL COMPONENTS TO PREVENT

DAMAGE TO THE AIRPLANE OR TO PERSONS.

22. Remove the Vertical Fin. A vertical fin removal procedure is shown in 767 ARD 2-60-2. (This

procedure has similarities that can be used as a guideline):

a. Install internal scaffolding PME148T0010PBR inside Section 48.

b. Attach vertical fin lift fittings ME100T3480PBR to the vertical fin.

c. Attach vertical fin lift sling 2OHME100T3480PBR to the vertical fin and apply 1,000 pounds

upward prelift tension to the sling.

d. Disconnect the fin-to-body link at the leading edge of the fin. Remove the 16 tension bolts

and 156 lock bolts that attach the vertical fin to the aft body. Use torque tool 2MIT100T3480PBR

as necessary when removing the tension bolts. Record the locations and quantity of all shims

removed at the time of the fin removal. Store the service ready shims for reuse. Lift the vertical

fin off the body. A vertical fin removal procedure is shown in 767 ARD 2-60-2 for airplane

recovery purposes.

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e. Without a rotating fixture, the vertical fin must be stored in an upright position. Use fin stand

ME170T0100PBR or create a tool to act as a base to support the vertical fin by attaching to

the four corner tension bolt locations. The vertical fin should be stored indoors.

NOTE: All H-11 hardware should have been replaced at fin to body joint per Boeing Service

Bulletin 767-53A0085 and FAA AD 2003-10-11 by July 1, 2006.

CAUTION: THE TRAP LOCKING DEVICES MUST BE REMOVED FROM THE HORIZONTAL

STABILIZER PIVOTS ON BOTH THE LEFT AND RIGHT SIDES TO DO THE PIN

ROTATION CHECK

23. Support the horizontal stabilizer with 767 SRM Horizontal Stabilizer supplementary supports in

accordance with 767-200 SRM 51-50-02 and 767-300 SRM 51-50-02 Detail IV on the left and right

sides. The four jacks should be loaded until the horizontal stabilizer pivot fittings begin to move

vertically relative to the airplane Section 48 structure (767 AMM 55-17-51) and check that the outer

pin can be rotated freely.

NOTE: The sum of all four jacks loads should not exceed 5,000 pounds. The center of gravity

of the Horizontal Stabilizer is aft of the pivot fitting pins. The jacks at the rear spar will

support greater percentage of load than jacks at the front spar. The corresponding left

side and right side jacks should be uniformly loaded.

24. Remove the horizontal stabilizer-to-body seals. Refer to 767 AMM 55-10-01 as an accepted

procedure.

25. Remove the horizontal stabilizer-to-body blade seals. Refer to 767 AMM 55-10-02 as an accepted

procedure.

26. Remove horizontal stabilizer fairing skin panels in accordance with FIGURE 23 and FIGURE 25.

CAUTION: INSUFFICIENT OR EXCESSIVE LIFT FORCE CAN RESULT IN STRUCTURAL DAMAGE

AND A SAFETY HAZARD.

27. Do one of the options that follow:

a. Option 1: REMOVAL OF ALL ELEVATORS

(1) Remove all the elevators installed on the horizontal stabilizer. Refer to 767 AMM 27-31-01

and 767 AMM 27-31-02 as an accepted procedure.

NOTE: If the elevators are not removed, it will require installation of forward lower tool

fittings on the tail cone after it is removed and prior to storing the structure on

the stand.

(2) Remove the rudder-to-body seal. Refer to 767 AMM 55-36-02 as an accepted procedure.

(3) Install lift fittings ME148T0600PBR-1/-2/-3/-4/-5 and sling ME148T0600PBR-12.

(4) Break the fay seal between the tail cone and STA 1809.5

(5) Support the tail cone between STA 1809 and STA 1952 with lift fittings and sling

ME148T0600PBR.

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NOTE: The APU will remain in place.

(6) Remove the fasteners that attach the tail cone to the STA 1809 bulkhead in accordance

with FIGURE 7.

(7) Slowly lift the tail cone aft and up to clear the upper STA 1809.5 bulkhead structure and

airplane.

NOTE: Make sure not to damage the STA 1809.5 bulkhead structure, HSTAB or airplane.

(8) Locate and store the tail cone on stand 2ME148T0600PBR.

b. Option 2: NON REMOVAL OF ELEVATORS

(1) Remove the rudder-to-body seal. Refer to 767 AMM 55-36-02 as an accepted procedure.

(2) Install lift fittings ME148T0600PBR-1/-2/-5 and sling ME148T0600PBR-12.

NOTE: Do not install lift fittings ME148T0600PBR-3/-4 at this time.

(3) Install protective foam pads between the tail cone and HSTAB/inboard elevators.

(4) Break the fay seal between the tail cone and STA 1809.5.

(5) Support the tail cone between STA 1809 and STA 1952 with lift fittings and sling

ME148T0600PBR. The APU will remain in place. Remove the fasteners that attach the

tail cone to the STA 1809 bulkhead in accordance with FIGURE 7.

(6) Prepare the tail cone between and lift fittings ME148T0600PBR-3/-4 for installation.

NOTE: Do not install the lift fittings at this time. The lift fittings will be installed after the

tail cone is removed from the airplane and before storing on stand.

(7) Slowly lift the tail cone vertically up to clear the lower section of STA 1809.5 bulkhead

structure, HSTAB and elevators and slowly move aft to clear the upper section of STA

1809.5 bulkhead structure HSTAB and elevators.

NOTE: Make sure not to damage the STA 1809.5 bulkhead structure, HSTAB, elevators

or airplane.

(8) Install lift fittings ME148T0600PBR-3/-4.

(9) Locate and store the tail cone on stand 2ME148T0600PBR.

28. Attach horizontal stabilizer lift fittings ME182T0000PBR and lift sling OHME180T0100PBR to the

horizontal stabilizer and make the sling cable assembly tight.

29. Disconnect the stabilizer trim ballscrew from the horizontal stabilizer center section. Refer to 767

AMM 27-41-10 as an accepted procedure.

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30. Do not remove the horizontal stabilizer pivot pins. Make sure the horizontal stabilizer sling cable

assembly is still tight. With the horizontal stabilizer vertically balanced as described in Step 23 and

Step 28, complete the disassembly of the STA 1809.5 bulkhead in accordance with FIGURE 8 to

allow the horizontal stabilizer to be removed. The left and right STA 1809.5 center bulkhead

assemblies will remain attached to the horizontal stabilizer at the pivot pins. Make sure there is

no load on the hinge pins as the center of gravity is subject to change.

NOTE: Secure the jackscrew in order to prevent it swinging whilst carrying out access, inspection,

repair or replacement.

CAUTION: THE LEFT AND RIGHT STA 1809.5 BULKHEAD OUTER CHORDS WILL NO LONGER

BE CONNECTED TO THE SURROUNDING STRUCTURE AFTER COMPLETION OF

THE FASTENER REMOVALS GIVEN IN FIGURES 7 AND 8. TO PREVENT DAMAGE

TO THE OUTER CHORDS, USE CARE TO REMOVE THE OUTER CHORDS WHILE

THE HORIZONTAL STABILIZER (WITH THE STA 1809.5 CENTER BULKHEAD

ASSEMBLIES ATTACHED) IS REMOVED.

31. Use the horizontal stabilizer lift sling to vertically lift the horizontal stabilizer a small amount to

unload the 767 SRM Horizontal Stabilizer supplementary supports, then remove the supplementary

supports. Remove the left and right STA 1809.5 bulkhead outer chords, which are trapped between

the STA 1809.5 center bulkhead assemblies and the forward part of section 48 that remains. Move

the horizontal stabilizer aft until it is clear of the STA 1809.5 bulkhead. Set the horizontal stabilizer

down on a storage fixture similar to ME180T0000PBR.

32. Make and install temporary STA 1809.5 bulkhead stabilizing tools in accordance with FIGURE 18.

CAUTION: INSUFFICIENT OR EXCESSIVE LIFT FORCE CAN RESULT IN STRUCTURAL DAMAGE

AND A SAFETY HAZARD.

LEAVING THE PME148T0010PBR INTERNAL SCAFFOLDING INSIDE THE FORWARD

PART OF SECTION 48 DURING THE OVERHEAD REMOVAL PROCESS RESULTS

IN A FORWARD SHIFT IN THE CENTER OF GRAVITY OF THE FORWARD PART OF

SECTION 48 THAT MAY CAUSE SEPARATION DIFFICULTIES.

33. RC - Support the forward part of Section 48 (STA 1582 to STA 1809) with lift fittings and sling

3ME140T0140PBR and handling fittings ME148T0200PBR. Remove fasteners, clips, and fittings

in accordance with FIGURE 9. Detach the STA 1582 floor beam in accordance with FIGURE 20.

Remove the forward part of Section 48 (the aft pressure bulkhead will remain attached to the

forward part of Section 48 at this time). Remove and store the forward part of Section 48 (which

includes the aft pressure bulkhead) on stand 2ME148T0200PBR.

WARNING: UNTIL THE STA 1582 FLOOR BEAM TEMPORARY SUPPORTS ARE INSTALLED, DO

NOT PLACE EXCESSIVE WEIGHT ON THE MAIN DECK FLOOR STRUCTURE AFT

OF STA 1562. THE MAIN DECK FLOOR AFT OF STA 1562 IS NOT SUPPORTED. DO

THIS TO PREVENT INJURY TO PERSONNEL AND DAMAGE TO THE FLOOR

STRUCTURE.

WARNING: INSTALL APPROPRIATE SAFETY BARRICADES OR SIMILAR TO BLOCK THE END

OF THE MAIN DECK FLOOR AFT OF STA 1582. DO THIS TO PREVENT INJURY TO

PERSONNEL.

34. Install temporary supports for the STA 1582 floor beam in accordance with FIGURE 22. Prior to

installation of the supports, make sure that the floor grid is level, and not deflected down or up.

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35. RC - Attach removal strongback ME148T2610PBR and lifting fixture OHME148T2610PBR to the

existing aft pressure bulkhead in the forward part of Section 48. Remove the rivets that attach the

aft pressure bulkhead to the Section 48 pressure ring in accordance with FIGURE 10. Remove

the old aft pressure bulkhead from the forward part of Section 48.

NOTE: Some rivets will need to be removed just prior to installation of the strongback due to the

rivet location being hidden under the strongback attach location.

36. RC - Attach lifting fixture OHME148T2610PBR to installation strongback 2ME148T2610PBR (this

strongback is shipped already attached to the new aft pressure bulkhead) and lift the new bulkhead

into position in the forward part of Section 48. Install fasteners to attach the new aft pressure

bulkhead to the Section 48 (STA 1582) pressure ring in accordance with FIGURE 11. Remove

the aft pressure bulkhead lifting fixture.

37. Install protective equipment PRE148T2610PBR on the new dome.

WARNING: WITH THE STA 1582 FLOOR BEAM TEMPORARY SUPPORTS REMOVED, DO NOT

PLACE EXCESSIVE WEIGHT ON THE MAIN DECK FLOOR STRUCTURE AFT OF

STA 1562. THE MAIN DECK FLOOR AFT OF STA 1562 IS NOT SUPPORTED. DO

THIS TO PREVENT INJURY TO PERSONNEL AND DAMAGE TO THE FLOOR

STRUCTURE.

CAUTION: JUST PRIOR TO FINAL POSITIONING OF THE FORWARD PART OF SECTION 48,

REMOVE THE STA 1582 FLOOR BEAM TEMPORARY SUPPORTS. DO THIS TO

PREVENT DAMAGE TO THE NEW AFT PRESSURE BULKHEAD FROM THE FLOOR

BEAM SUPPORT FASTENERS.

38. RC - Lift the forward part of Section 48 (STA 1582 to STA 1809, including the new aft pressure

bulkhead) into position from the storage stand with lift fittings and sling 3ME140T0140PBR and

handling fittings ME148T0200PBR. Install fasteners in accordance with FIGURE 12 to attach the

new aft pressure bulkhead and the forward part of Section 48 to Section 46 at STA 1582. Attach

the STA 1582 floorbeam in accordance with FIGURE 22. Remove the sling, handling fittings, and

lift fittings.

39. Remove the temporary STA 1809.5 bulkhead stabilizing tools in accordance with FIGURE 20.

40. RC - Lift the horizontal stabilizer (with the left and right STA 1809.5 center bulkheads attached at

the hinge pins) from the storage fixture and move it near its final position using the lift sling and

lift fittings. Before moving the horizontal stabilizer into its final position, position the previously

removed left and right STA 1809.5 bulkhead outer chords between the forward part of Section 48

and the STA 1809.5 center bulkhead assemblies. The final position is set by alignment of the left

and right center bulkhead fastener patterns.

41. Support the horizontal stabilizer with 767 SRM Horizontal Stabilizer supplementary supports in

accordance with 767-200 SRM 51-50-02 and 767-300 SRM 51-50-02 Detail IV on the left and right

sides. The four jacks should be loaded until the supports have taken the load off the horizontal

stabilizer lift sling. Do not yet remove the horizontal stabilizer lift sling or lift fittings.

NOTE: The sum of all four jacks loads should not exceed 5,000 pounds. The center of gravity

of the Horizontal Stabilizer is aft of the pivot fitting pins. The jacks at the rear spar will

support greater percentage of load than jacks at the front spar. The corresponding left

side and right side jacks should be uniformly loaded.

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42. RC - Attach the left and right STA 1809.5 center bulkheads in accordance with FIGURE 13 and

FIGURE 14. Use care to prevent excessive loading of the stabilizer hinge joints.

43. Connect the stabilizer trim ballscrew to the horizontal stabilizer center section. Refer to 767 AMM

27-41-10 as an accepted procedure.

44. Remove the horizontal stabilizer lift sling and lift fittings. Reinstall the production fasteners at the

lift fitting attach points.

45. Lift the tail cone into position with the sling and lift fittings. Install the fasteners in accordance with

FIGURE 15, to attach the tail cone to the STA 1809 bulkhead. Remove the sling and lift fittings.

NOTE: Accomplishment of Part 3 Step 41 (horizontal stabilizer support), Step 42 (align and attach

STA 1809.5 center bulkheads), Step 43 (stabilizer trim ballscrew attachment), Step 44

(removal of lift sling and fittings), and Step 45 (attach tail cone) should return the horizontal

stabilizer to the position initially given in Step 23.

46. The horizontal stabilizer is now supported by suitable means, with trap lock devices removed.

Check that the right and left horizontal stabilizer pivot pins can be rotated freely with an applied

torque of 400 in-lb or less. If necessary, remove and reinstall both the left and right pivot pins.

Refer to 767 AMM 55-17-51 as an accepted procedure.

47. Install horizontal stabilizer fairing skin panels in accordance with FIGURE 24 and FIGURE 26.

48. Install the horizontal stabilizer-to-body seals. Refer to 767 AMM 55-10-01 as an accepted procedure.

49. Install the horizontal stabilizer-to-body blade seals. Refer to 767 AMM 55-10-02 as an accepted

procedure.

50. Prepare the Vertical Fin in accordance with FIGURE 27.

51. Install the Vertical Fin in accordance with FIGURE 28.

52. Inspect the fin-to-body joints. If there is no sealant, apply sealant in accordance with Boeing Drawing

140T4800. Do not plug drain holes.

53. Finish the fastener heads, damaged paint, bare areas and all fillet seals in the interior of the fin in

accordance with SOPM 20-41-02.

54. Apply corrosion inhibiting compound in the interior of the fin with BMS 3-23 in accordance with

Boeing Drawing 140T6000. Refer to 767-200 SRM 51-20-01 and 767-300 SRM 51-20-01 for

additional help.

55. Connect the fin-to-body link at the leading edge of the fin.

56. Remove the internal scaffolding PME148T0010PBR from inside Section 48.

57. Remove the vertical fin lift fittings and sling.

58. Finish all bare aluminum with chemical film treatment and two coats of BMS 10-11, Type I primer.

Apply corrosion inhibiting compound to both the forward and aft sides of the aft pressure bulkhead.

Refer to 767 AMM 51-24-09 as an accepted procedure.

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59. Install the Dorsal Fin. Refer to 767 AMM 53-66-02 as an accepted procedure.

60. Install the APU fuel line between the aft pressure bulkhead the APU firewall. Refer to the task

"Install the APU Fuel Line and Shroud Between the Pressure Bulkhead for the Aft Cargo

Compartment and the APU Firewall Bulkhead" in 767 AMM 28-25-05 as an accepted procedure.

61. In the aft end of the bulk cargo compartment, attach the APU fuel line and shroud to the aft pressure

bulkhead fitting. Refer to the task "Install the APU Fuel Line and Shroud Between the Center

Compartment of the Auxiliary Fuel Tank and the Pressure Bulkhead for the Aft Cargo Compartment"

in 767 AMM 28-25-05 as an accepted procedure.

62. Install the APU Air Supply Duct. Refer to 767 AMM 36-11-01 as an accepted procedure.

63. Connect electrical systems, including:

a. Lights

b. APU Power

c. High Frequency Communications

d. Stall Warning Systems

e. Interphone

f. Autopilot

g. Yaw Damper

h. Rudder Trim Actuator

i. Rudder Ratio Changer

j. Rudder and Elevator Shutoff Valves

k. Rudder Position Indicator

l. Stabilizer Trim Control System

m. Flap/Stabilizer Position Module

n. Flight Recorder Systems

o. APU Fire Detection System

64. Install salvaged pressure seals where wires penetrate the aft pressure bulkhead.

65. Connect the electrical connectors for the altitude pressure switches. Refer to 767 AMM 38-32-51

as an accepted procedure.

66. Install the hydraulic lines that were removed earlier that pass through the aft pressure bulkhead.

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ALERT ALERT
67. Group 3:

Install the auxiliary static system tubes that were removed earlier that pass through the aft pressure

bulkhead.

68. Install pressure seals at the aft pressure bulkhead in accordance with FIGURE 16.

69. Install auxiliary pitot tubes and seals in accordance with FIGURE 17.

70. Reconnect the stabilizer trim (ST1A/ST1B/ ST2A/ST2B), elevator (E1A/E1B/E2A/E2B), and rudder

(RA/RB) control cables. Refer to 767 AMM 20-10-03 as an accepted procedure.

a. Connect the cable ends (coiled forward and aft of the aft pressure bulkhead) through the aft

pressure bulkhead at the appropriate turnbuckle.

b. Install new or salvaged air seals and fasteners where cables penetrate the aft pressure

bulkhead. Refer to 767 AMM 20-10-04 as an accepted procedure.

c. Remove cable clamps.

71. Adjust the Stabilizer Trim System. Refer to 767 AMM 27-41-00 as an accepted procedure.

72. Adjust the Elevator System. Refer to 767 AMM 27-31-00 as an accepted procedure.

73. Adjust the Rudder System. Refer to 767 AMM 27-21-00 as an accepted procedure.

74. Install equipment in the aft end of the bulk cargo compartment that was removed for access. This

includes:

a. Potable Water Tanks. Refer to 767 AMM 38-11-01 as an accepted procedure.

b. Vacuum Lavatory Waste Tanks. Refer to 767 AMM 38-32-11 as an accepted procedure.

c. Sidewall Insulation. Refer to 767 AMM 25-52-03 as an accepted procedure.

d. Bulk Cargo Compartment Aft Lining. Refer to 767 AMM 25-55-01 as an accepted procedure.

e. Bulk Cargo Compartment Sidewall Lining, for access to the pitot-static tubes on the left side

from the aft pressure bulkhead to the bulk cargo door aft frame at STA 1461. Refer to 767

AMM 25-55-01 as an accepted procedure.

75. Install equipment in the aft part of the passenger compartment that was removed for access. This

includes:

a. Floor Panels. Refer to 767 AMM 53-01-01 as an accepted procedure.

b. Doorway/Galley Floor Covering. Refer to 767 AMM 25-27-02 as an accepted procedure.

c. Sidewall and Ceiling Insulation. Refer to 767 AMM 25-21-05 as an accepted procedure.

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ALERT ALERT
d. Ceiling panels. Refer to 767 AMM 25-22-01, 767 AMM 25-22-02, and/or 767 AMM 25-22-10

as accepted procedures.

e. Sidewall Panels. Refer to 767 AMM 25-21-01 as an accepted procedure.

f. Aft Galley Complex A1, A4, or A1-A3. Refer to 767 AMM 25-31-04 as an accepted procedure.

g. Lavatories. Refer to 767 AMM 25-41-04 as an accepted procedure.

h. Partitions. Refer to 767 AMM 25-25-04 as an accepted procedure.

i. Passenger seats. Refer to 767 AMM 25-25-01 as an accepted procedure.

76. Dejack the airplane. Service the nose and main landing gears and put them in serviceable condition.

PART 3: SYSTEM TESTS

1. Bleed the hydraulic system. Refer to 767 AMM 29-11-00 as an accepted procedure. Do a leak

check of the hydraulic lines that were removed and reinstalled. Refer to 767 AMM 20-10-09 as an

accepted procedure.

2. Do a leak test of the new pitot-static tubes. Refer to 767 AMM 34-11-01 as an accepted procedure.

3. Do a test of the Autopilot. Refer to the task "AFDS Operational Test" in 767 AMM 22-10-00 as an

accepted procedure.

4. Do a test of the Yaw Damper System. Refer to the task "Operational Test - Yaw Damper System"

in 767 AMM 22-21-00 an accepted procedure.

5. Test the left and right High Frequency Communications Systems. Refer to the task "Operational

Test - HF Communication System" in 767 AMM 23-11-00 as an accepted procedure.

6. Do a test of the Interphone system. Refer to the task "Operational Test - Service Interphone

System" in 767 AMM 23-41-00 as an accepted procedure.

7. Do a test of the Stick Nudger. Refer to steps 2.A., 2.B., 2.C., 2.D., 2.G., and 2.H. in the task

"Operational Test - Stall Warning System" in 767 AMM 27-32-00 as an accepted procedure.

8. Test the Horizontal Stabilizer Trim Control System. Refer to the task "Operational Test" in 767

AMM 27-41-00 as an accepted procedure.

9. Test the Stabilizer Trim System. Refer to the "Manual-Mechanical Stabilizer Trim Control Operational

Test", the "Lever Force Test" and the "Horizontal Stabilizer Trim Control System Operational Test"

in 767 AMM 27-41-00 as an accepted procedure.

10. Test the Elevator System. Refer to the task "System Test - Elevator Controls" in 767 AMM 27-31-00

as an accepted procedure. It is acceptable to not perform the "Elevator Position Indication Test",

the "Elevator Power Control Actuators Test", the "Elevator Feel System Test", the "Stick Nudger

Test", and the "Elevator Autopilot Servo Rods Test" tasks within the Systems Test.

11. Do an operational test of the Elevator Control System. Refer to the task "Operational Test - Elevator

Control System" in 767 AMM 27-31-00 as an accepted procedure.

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ALERT ALERT
12. Test the Rudder System. Refer to the task "System Test - Rudder and Rudder Trim Control" in

767 AMM 27-21-00. It is acceptable to not perform the "Test Rudder Pedal Adjustment Mechanism

Travel", the "Test Captain's Rudder Pedal Travel", the "Test First Officer's Pedal Travel", the "Test

Single Hydraulic System and PCA", the "Test Rudder Ratio-Changer System", the "Test Rudder

Ration Flight Deck Annunciation", the "Test the Left RRCM", the "Test the Right RRCM", and the

"Rudder Trim Authority and Rate Test" tasks within the System Test.

13. Test the Rudder Trim Actuator. Refer to the task "Rudder Trim Actuator - Test" in 767 AMM

27-21-11 as an accepted procedure.

14. Test the Rudder Ratio Changer. Refer to the task "Rudder Ratio Changer Mechanism - Test" in

767 AMM 27-21-13 as an accepted procedure.

15. Test the Rudder and Elevator Shutoff Valves. Refer to the task "Rudder and Elevator Shutoff

Valves - System Test" in 767 AMM 27-23-00 as an accepted procedure.

16. Test the Rudder Position Indicator. Refer to the task "Rudder Position Indication - Operational

Test" in 767 AMM 27-28-00 as an accepted procedure.

17. Test the Position Indicating System. Refer to the task "Operational Test - Position Indicating

System" in 767 AMM 27-48-00 as an accepted procedure.

18. Test the Flap/Stabilizer Position Module. Refer to the task "Test for the FSPM" in 767 AMM 27-58-01

as an accepted procedure.

19. Test the Takeoff Configuration Warning Card Module. Refer to steps 4.A., 4.B., 4.C., 4.I., and

4.J.in the task "Warning Electronics Unit (WEU) Card Module Test" in 767 AMM 31-51-04 as an

accepted procedure.

20. Test the Flight Data Recorder. Refer to the task "Flight Data Recorder Operational Test" in 767

AMM 31-31-00 as an accepted procedure.

21. Test the service lights. Refer to the task "Service Lights - Operational Test" in 767 AMM 33-31-00

as an accepted procedure.

22. Test the logo lights. Refer to the task "Logo Lights - Operational Test" in 767 AMM 33-45-00 as

an accepted procedure.

23. Test the altitude pressure switches. Refer to 767 AMM 38-32-51 as an accepted procedure.

24. Test the APU wiring in accordance with APPENDIX A.

25. Do a cabin pressure leakage test. Refer to 767 AMM 05-51-24 as an accepted procedure.

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ALERT ALERT
FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION

(SHEET 2 OF 5)

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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 new aft pressure bulkhead.

Step Task Name Identification Qty More Data

1 Remove Fastener - 4 -

1.19 - 1.21 inch diameter, normal to

the bulkhead surface. 125 microinch

or better surface finish.

Drill / Ream Hole - 4

Break sharp edges

and apply chemical

film treatment and

two coats of BMS10-

11, Type I primer to

the bare edges of

the holes.

Apply Finish - -

2 Locate SEAL BLOCK ASSY 148T2629-2 - -

Drill / Ream Rivet Hole - 21 -

FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION

(SHEET 3 OF 5)

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ALERT ALERT
Step Task Name Identification Qty More Data

Apply a pressure

faying surface seal

to the entire mating

surface of the seal

block assembly.

3 Apply Sealant BMS 5-95 -

Install (New) SEAL BLOCK ASSY 148T2629-2 1 -

RIVET, UNIVERSAL BACR15BB5A7C 21 -

HD

Install (New)

4 Remove Fastener - 4 -

Locate SEAL BLOCK ASSY 140T0345-3 - -

Drill / Ream Rivet Hole - 22 -

Apply a pressure

faying surface seal

to the entire mating

surface of the seal

block assembly.

5 Apply Sealant BMS 5-95 -

Install (New) SEAL BLOCK ASSY 140T0345-3 1 -

RIVET, UNIVERSAL BACR15BB5A7C 18 -

HD

6 Install (New)

RIVET, UNIVERSAL BACR15BB5A7C 4 -

HD

7 Install (New)

Optional, if oversize

rivets are necessary.

RIVET, UNIVERSAL BACR15BB6A8C 4

HD

Install (New)

Apply a pressure

faying surface seal

to the entire mating

surface of the coverplate and pressure

pan.

8 Apply Sealant BMS 5-95 -

Install (New) COVER PLATE 140T0345-1 1 -

9 Install (New) BOLT BACS12HN3-7 14 -

Install (New) WASHER NAS1149D0332J 14 Under screw head.

Install (New) WASHER NAS1149D0332J 14 Under nut.

Install (New) NUT, SELF-LOCK BACN11AG3 14 -

Fillet seal all screw

heads, nuts, and

washers.

10 Apply Sealant BMS 5-95 -

The parts shown in the table below are provided as extra parts for this figure.

FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION

(SHEET 4 OF 5)

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ALERT ALERT
Name Identification Qty More Data

BOLT, HEX HEAD BACB30NM4K14 16

NUT, SELF-LOCK BACN11AG3 1

RIVET, UNIVERSAL BACR15BB5A7C 7

HD

RIVET, UNIVERSAL BACR15BB6A8C 1

HD

RIVET BACR15FT6KE7C 8

BOLT BACS12HN3-7 1

WASHER NAS1149D0332J 2

WASHER, FLAT NAS1149D0363J 5

SPACERS FOR RIV- NAS42DD3-44FC 1

ETS

SPACERS FOR RIV- NAS42DD3-48FC 1

ETS

SPACERS FOR RIV- NAS42DD3-64FC 1

ETS

FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION

(SHEET 5 OF 5)

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ALERT ALERT
FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

Step Task Name Identification Qty More Data

0.530 - 0.539 inch

diameter, normal to

the doubler. 125 microinch or better

surface finish.

1 Drill / Ream Hole - 1

Break sharp edges

and apply chemical

film treatment and

two coats of BMS

10-11, Type I primer

to the bare edges of

the holes.

Apply Finish - -

FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS

(SHEET 2 OF 4)

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ALERT ALERT
FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS

(SHEET 3 OF 4)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

From pressure dome

seal retainer plates.

1 Remove Screw - 4

At approximately

STA 1480 and aft of

STA 1605. Cap

open ends of tubes.

Refer to 767 AMM

20-10-09 as an accepted procedure.

2 Disconnect Tube Assy 233T9110-513 -

At approximately

STA 1502 and aft of

STA 1605. Cap

open ends of tubes.

Refer to 767 AMM

20-10-09 as an accepted procedure.

3 Disconnect Tube Assy 233T9110-614 -

4 Remove Tube Assy 233T9110-513 1 (a)

Remove Tube Assy 233T9110-614 1 (a)

Remove Retainer Plate 233T9113-1 1 -

Remove Retainer Plate 233T9113-2 1 -

Remove Seal 69B41314-1 2 -

(a) Disconnect tube assy from existing clamps, but keep existing clamp hardware for tube reinstallation.

FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 4: REMOVAL OF PRESSURE SEALS

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 4: REMOVAL OF PRESSURE SEALS

(SHEET 2 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

1 Remove Screw - 6 -

Remove Washer - 6 -

2 Remove Screw - 16 -

Remove Nut - 16 -

Remove Washer - 16 -

3 Remove Retainer - 1 -

4 Remove Pressure Seal - 3 -

5 Remove Pressure Seal - 1 -

6 Remove Retainer - 1 -

FIGURE 4: REMOVAL OF PRESSURE SEALS

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL

(SHEET 2 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

1 Remove Bolt - 8 -

Remove Washer - 8 -

2 Remove Bulkhead Fitting 60B92409-13 1 -

3 Remove Seal - 1 -

FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION

(SHEET 1 OF 3)

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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.

FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Step Task Name Identification Qty More Data

40345 (678782 option- 1 -

al)

1 Install (New) SEAL

2 Install (Kept) Bulkhead Fitting 60B92409-13 1 -

3 Install (New) Bolt BACB30NM4K4 8 -

Install (New) WASHER NAS1149D0316J 8 -

FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL

(SHEET 1 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers as applicable shown in the circle symbols in the figure

or related drawing sheet(s) shown in the figure. The QTY numbers shown below are the number of parts

necessary for each airplane.

REQUIREMENTS:

1. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0078,

"Fuselage - Section 48 - Body station 1809.5 Bulkhead Outer Chord Inspection, Repair, and

Modification." An Alternative Method of Compliance (AMOC) to the requirements of the applicable

Airworthiness Directive may have been granted for configurations different than those shown in Boeing

Service Bulletin 767-53A0078. These fastener locations must be maintained to the requirements of

AD 2005-11-02 or to an approved AMOC to that AD. When fasteners are removed from these locations,

document the fastener/nut/collar diameter, grip and type removed and the existing fastener hole

diameter. Use care to not damage the fastener hole when removing fasteners. Do not clean the bores

of these fastener holes with brass bottle brushed. Do an open-hole High Frequency Eddy Current

(HFEC) inspection at all parts in the stack-up at these locations. Verify that there are no surface defects

(such as rifling, gouging, nicks, burrs, or excessive surface roughness) in the bores of these fastener

holes, other than that normally produced during a typical reaming operation. If any defect is found,

contact The Boeing Company for repair instructions and do the repair. Verify that washers or fillet relief

exists to accommodate the fasteners head-to-shank fillet radius. When fasteners are installed, use the

same type and size fasteners that were removed earlier.

2. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0131,

"Fuselage - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord,

Horizontal and Vertical Inner Chord, and External Skin - Inspection." An Alternative Method of

Compliance (AMOC) to the requirements of the applicable Airworthiness Directive may have been

granted for configurations different than those shown in Boeing Service Bulletin 767-53A0131. These

fastener locations must be maintained to the requirements of FAA AD 2011-14-02 or to an approved

AMOC to that AD. When fasteners are removed from these locations, document the fasteners/nut/collar

diameter, grip and type removed and the existing fastener hole diameter. Use care to not damage the

fastener hole when removing fasteners. Do not clean the bored of these fastener holes with brass bottle

brushes. Do an open-hole High Frequency Eddy Current (HFEC) inspection at all parts in the stack-up

at these locations. Verify that there are no surface defects (such as rifling, gouging, nicks, burrs, or

excessive surface roughness) in the bores of these fastener holes, other than that normally produced

during a typical reaming operation. If any defect is found, contact The Boeing Company for repair

instructions and do the repair. Verify that washers or fillet relief exists to accommodate the fasteners

head-to-shank fillet radius. When fasteners are installed, use the same type and size fasteners that

were removed earlier. However, Boeing recommends that H-11 steel bolts be replaced with Inconel

bolts. Refer to Boeing Service Letter 767-SL-51-008-B.

Step Task Name Identification Qty More Data

1 Remove Fastener - 288 -

Remove Shim - - (a)

(a) Remove and keep any shims or fillers that are found common to the affected fastener locations. Note

shim or filler locations before removal to ensure they are reinstalled in the proper locations.

FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL

(SHEET 2 OF 3)

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ALERT ALERT
The flag note numbers shown below agree with the numbers shown in the flag symbols in this figure or the

related drawing sheet.

FLAG NOTE NUMBER MORE DATA

1 These fastener locations are also affected by Boeing Service Bulletin 767-53A0078.

2 These fastener locations are also affected by Boeing Service Bulletin 767-53A0131.

3 Note the shim size removed, and keep if correctly fitted and free of damage.

FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL

(SHEET 1 OF 7)

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ALERT ALERT
FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL

(SHEET 2 OF 7)

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FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL

(SHEET 3 OF 7)

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FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL

(SHEET 4 OF 7)

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ALERT ALERT
FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL

(SHEET 5 OF 7)

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BOEING SERVICE BULLETIN 767-53A0267

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.

REQUIREMENTS:

1. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0078,

"Fuselage - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and

Modification." An Alternative Method of Compliance (AMOC) to the requirements of the applicable

Airworthiness Directive may have been granted for configurations different than those shown in

767-53A0078. These fastener locations must be maintained to the requirements of FAA AD 2005-11-02

or to an approved AMOC to that AD. When fasteners are removed from the locations, document the

fastener/nut/collar diameter, grip and type removed and the existing fastener hole diameter. Use care

to not damage the fastener hole when removing fastener hole when removing fasteners. Do not clean

the bores of these fastener holes with brass bottle brushed. Do an open-hole High Frequency Eddy

Current (HFEC) inspection at all parts in the stack-up at these locations. Verify that there are no surface

defects (such as rifling, gouging, nicks, burrs, or excessive surface roughness) in the bores of these

fastener holes, other than that normally produced during a typical reaming operation. If any defect is

found, contact The Boeing Company for repair instructions and do the repair. Verify that washers or

fillet relief exists to accommodate the fasteners head-to-shank fillet radius. When fasteners are installed,

use the same type and size fasteners that were removed earlier.

2. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0131,

"Fuselage - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord,

Horizontal and Vertical Inner Chord, and External Skin - Inspection." An Alternative Method of

Compliance (AMOC) to the requirements of the applicable Airworthiness Directive may have been

granted for configurations different that those shown in 767-53A0131. These fastener locations must

be maintained the requirements of FAA AD 2011-14-02 or to an approved AMOC to that AD. When

fasteners are removed from these locations, document the fastener/nut/collar diameter, grip and type

removed and the existing fastener hole diameter. Use care to not damage the fastener hole when

removing fasteners. Do not clean the bores of these fastener holes with brass bottle brushes. Do an

open-hole High Frequency Eddy Current (HFEC) inspection at all parts in the stack-up at these locations.

Verify that there are no surface defects (such as rifling, gouging, nicks, burrs, or excessive surface

roughness) in the bores of these fastener holes, other than that normally produced during a typical

reaming operation. If any defect is found, contact The Boeing Company for repair instructions and do

the repair. Verify that washers or fillet relief exists to accommodate the fasteners head-to-shank fillet

radius. When fasteners are installed, use the same type and size fasteners that were removed earlier.

However, Boeing recommends that H-11 steel bolts be replaced with Inconel bolts. Refer to Boeing

Service Letter 767-SL-51-008-B

Step Task Name Identification Qty More Data

1 Remove Fastener - 428 -

2 Remove / Keep Filler - 8 If installed

3 Remove Filler - 12 -

4 Remove Splice Strap - 4 -

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL

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ALERT ALERT
Step Task Name Identification Qty More Data

5 Remove Shim - 12 -

The horizontal stabilizer pivot fittings will

remain attached to

the center bulkhead

assy.

6 Remove / Keep Center Bulkhead Assy - 2

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NOTE NUMBER MORE DATA

1 These fastener locations are also affected by Boeing Service Bulletin 767-53A0078.

2 These fastener locations are also affected by Boeing Service Bulletin 767-53A0131.

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL

(SHEET 7 OF 7)

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ALERT ALERT
FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers as applicable shown in the circle symbols in the figure

or related drawing sheet(s) shown in the figure. The QTY numbers shown below are the number of parts

necessary for each airplane.

CAUTION: TO PREVENT DAMAGE, PRIOR TO REMOVAL OF THE FORWARD PART OF SECTION 48

MAKE SURE THAT THE STA 1582 FLOOR BEAM HAS BEEN DETACHED IN ACCORDANCE

WITH FIGURE 21. AFTER THE FLOOR BEAM HAS BEEN DETACHED, THE EXISTING FLOOR

STRUCTURE MUST BE SUPPORTED. REFER TO FIGURE 22 AS AN ACCEPTED PROCEDURE.

Step Task Name Identification Qty More Data

1 Remove Nut - 308 -

Remove Bolt - 308 -

Remove Washer - 616 -

2 Remove Fastener - 18 -

Waste tank tie rod

attach fittings

Remove Fitting - 2

Ceiling support fittings3 Remove Fitting - 3

4 Remove Fastener - 6 -

Remove Clip - 2 -

Remove Shim - 2 -

FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 10: AFT PRESSURE BULKHEAD PRESSURE RING FASTENER REMOVAL

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers as applicable shown in the circle symbols in the figure

or related drawing sheet(s) shown in the figure. The QTY numbers shown below are the number of parts

necessary for each airplane.

Step Task Name Identification Qty More Data

1 Remove Blind Rivet - 31 -

Remove Pressure Bulkhead - 1 -

FIGURE 10: AFT PRESSURE BULKHEAD PRESSURE RING FASTENER REMOVAL

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ALERT ALERT
FIGURE 11: AFT PRESSURE BULKHEAD ATTACHMENT TO THE PRESSURE RING AT STA 1582

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers as applicable shown in the circle symbols in the figure

or related drawing sheet(s) shown in the figure. The QTY numbers shown below are the number of parts

necessary for each airplane.

NOTE: In order to align the new aft pressure bulkhead with the STA 1582 pressure ring, Boeing recommends

that a series of fastener holes around the circumference of the joint (for example, bolt location numbers

16, 31, 41, 51, 76, 89, 114, 129, and 147 left and right) be selected as indexing points. At these indexing

points, use locating pins such as those shown in Appendix B to assist in aligning the joint. Install

temporary bushings in the full size holes in the Section 48 pressure ring.

Step Task Name Identification Qty More Data

1 Install (New) Aft Bulkhead Assembly 691T0103-1 1 -

Drill / Ream Fastener Hole - 31 -

NAS1399D6A10 31 -

(NAS1399D6AB10 optional)

Install (New) RIVET, BLIND

(a) Apply BMS 5-95 faying surface sealant to all mating surfaces of the aft pressure bulkhead failsafe chord

and the pressure ring. Ensure that all fasteners listed in this figure and in Figure 12 are installed before

the maximum squeeze-out life of the sealant has been reached.

FIGURE 11: AFT PRESSURE BULKHEAD ATTACHMENT TO THE PRESSURE RING AT STA 1582

(SHEET 2 OF 2)

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FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 1 OF 19)

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ALERT ALERT
The step numbers shown below agree with the numbers as applicable shown in the circle symbols in the figure

or related drawing sheet(s) shown in the figure. The QTY numbers shown below are the number of parts

necessary for each airplane.

The notes below assume that the intermediate fastener holes (the fastener holes between the stringer locations)

will be drilled and reamed to their final hole sizes after the forward Section 48 has been positioned against the

STA 1582 frame segments. As an alternative, before the forward Section 48 is positioned, install temporary

fasteners at the stringer fastener locations to ensure that the aft pressure bulkhead and pressure ring are

adequately clamped together. Use pull reamers to make the intermediate fastener holes the size specified in

this figure using the Section 48 pressure ring as a template and guide. Feed the reamers from the aft side of

the bulkhead and attach it to a drill motor on the forward side of the bulkhead. Ensure that adequate clamping

force exists to make sure that chips or burrs do not break out between the parts. The rivets that attach the aft

pressure bulkhead to Section 48 do not alone provide adequate clamping force to ensure that chips and burrs

do not form between the parts.

NOTE:

1. In the new aft pressure bulkhead, all of the intermediate fastener holes (the fastener holes between

stringer end fitting locations) are 1/16 inch diameter undersize.

2. Apply BMS 5-95 faying surface sealant to all mating surfaces of the aft pressure bulkhead pressure

chord and the STA 1582 frame segment.

3. In order to align the forward part of Section 48 (with the new aft pressure bulkhead installed) with the

STA 1582 forward chord, Boeing recommends that a series of fastener holes around the circumference

of the joint (for example, bolt location numbers 16, 31, 41, 51, 76, 89, 114,129, and 147 left and right)

be selected as indexing points. At these indexing points, use locating pins such as those shown in

Appendix B to assist in aligning the joint. Install temporary bushings in undersize holes, if necessary.

4. Fasteners at stringer locations should be installed wet with BMS 5-95 sealant. Sealant should be applied

under the bolt head, in the hole, under the nut, and on the bolt threads. Sealant squeeze out to be

continuous from above the base of the fastener head and nut, covering the washer to the structure.

Sealant squeeze out can be supplemented with the application of a brush coat of BMS 5-95 sealant.

5. Apply the initial pull up torque to the fasteners at stringer locations. Torque values and application

sequence are shown in Table 13.

6. Clamp the new aft pressure bulkhead to Section 48 at the stringer bolt locations. After the aft pressure

bulkhead is clamped into position, the intermediate fastener locations (the fasteners between the

stringer locations) in the new aft pressure bulkhead pressure chord and failsafe chord must be drilled

and reamed to the specified final hole size through the holes that exist in the STA 1582 forward chord

and the Section 48 pressure ring.

7. Fasteners between stringer locations should be installed wet with BMS 5-95 sealant. Sealant should

be applied under the bolt head and under the nut. Sealant squeeze out to be continuous from above

the base of the fastener head and nut, covering the washer to the structure. Sealant squeeze out can

be supplemented with the application of a brush coat of BMS 5-95 sealant.

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 2 OF 19)

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ALERT ALERT
8. For sealants with squeeze-out life longer than 48 hours, reapply torque values as given in note (a) and

Table 14, except start to do the torque reapplication not sooner than 60 minutes after the initial torque

application as given in note (b) and Table 13 to bolt numbers 153 and 154 left and right (S-39L and

S-39R). For initial torque application (note (b) and Table 13) and torque reapplication (note (a) and

Table 14), maintain the sequences given in notes (a) and (b), Table 13, and Table 14, and ensure that

torque is reapplied to each bolt not sooner than 60 minutes after the initial application of torque to that

bolt.

9. After installation of the Section 48 forward section, fill the gap between Section 46 and Section 48 at

STA 1582 with BMS 5-95 sealant. Also apply BMS 5-125 Type II levelling compound as necessary

forward of any lower Section 48 drains to ensure free flow of water.

Step Task Name Identification Qty More Data

140T0142U1 1 -

(140T0142-1 optional)

1 Install (New) CLIP

140T0142U2 1 -

(140T0142-2 optional)

2 Install (New) CLIP

3 Install (New) FITTING ASSY 140T0169-7 2 -

Maximum gap 0.010

inch. Remove 0.003

inch laminations as

required. Install

shims with BMS 10-

11, Type I primer after delamination.

Install (New) SHIM, LAMINATED BACS40R011B012F 2

4 Install (New) FITTING ASSY 412T3106-406 2 -

5 Install (New) fitting assy 412T3106-408 1 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 3 OF 19)

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ALERT ALERT
Step Task Name Identification Qty More Data

Refer to Tables 1 -

12 for specific locations (a)

6 Install (New) BOLT, 12 PT HEAD BACB30US5K16 23

Refer to Tables 1 -

12 for specific locations (a)

Install (New) BOLT, 12 PT HEAD BACB30US5K17 56

Refer to Tables 1 -

12 for specific locations (a)

Install (New) BOLT, 12 PT HEAD BACB30US5K18 39

Refer to Tables 1 -

12 for specific locations (a)

Install (New) BOLT, 12 PT HEAD BACB30US5K19 24

Refer to Tables 1 -

12 for specific locations (a)

Install (New) BOLT, 12 PT HEAD BACB30US5K21 10

Refer to Tables 1 -

12 for specific locations (a)

Install (New) BOLT, 12 PT HEAD BACB30US5K25 2

Install (New) CSK WASHER BACW10BP5CD 154 under bolt head

Install (New) WASHER-PLAIN BACW10BP5DP 154 under nut

Install (New) NUT BACN10HR5CD 154 -

Refer to Tables 1 -

12 for specific locations (a) (b)

7 Install (New) BOLT, 12 PT HEAD BACB30US6K31 4

Refer to Tables 1 -

12 for specific locations (a) (b)

Install (New) BOLT, 12 PT HEAD BACB30US6K33 40

Refer to Tables 1 -

12 for specific locations (a) (b)

Install (New) BOLT, 12 PT HEAD BACB30US6K34 32

Refer to Tables 1 -

12 for specific locations (a) (b)

Install (New) BOLT, 12 PT HEAD BACB30US6K35 8

Refer to Tables 1 -

12 for specific locations (a) (b)

Install (New) BOLT, 12 PT HEAD BACB30US6K36 8

Install (New) WASHER, PLAIN BACW10BP6CD 92 under bolt head

Install (New) WASHER BACW10BP6DP 92 under nut

Install (New) SELF-LOCKING NUT BACN10HR6CD 92 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 4 OF 19)

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Step Task Name Identification Qty More Data

Refer to Tables 1 -

12 for specific locations (a) (b)

8 Install (New) BOLT, 12 PT HEAD BACB30US7K35 16

Refer to Tables 1 -

12 for specific locations (a) (b)

Install (New) BOLT, 12 PT HEAD BACB30US7K39 12

Refer to Tables 1 -

12 for specific locations (a) (b)

Install (New) BOLT, 12 PT HEAD BACB30US7K40 16

Install (New) WASHER BACW10BP7CD 44 under bolt head

Install (New) WASHER BACW10BP7DP 44 under nut

Install (New) NUT BACN10HR7CD 44 -

Refer to Tables 1 -

12 for specific locations (a) (b)

9 Install (New) BOLT, 12 PT HEAD BACB30US8K42 16

Install (New) WASHER BACW10BP8CD 16 under bolt head

Install (New) WASHER BACW10BP8DP 16 under nut

Install (New) NUT BACN10HR8CD 16 -

Bolt numbers 046L

and 046R (a)

10 Install (New) BOLT, 12 PT HEAD BACB30US5K25 2

Install (New) WASHER 140T0140-5 2 under bolt head

Install (New) CSK WASHER BACW10BP5CD 2 under nut

Install (New) NUT BACN10HR5CD 2 -

(a) After the initial pull-up sequence of steps has been completed, apply the final torque values given in Table

14 to these fasteners in the sequence that follows: Begin with bolt numbers 155 L and 155 R, and apply

the appropriate Table 14 torque values simultaneously to both fasteners. After bolt numbers 155 L and

155 R have been torqued to the proper values, proceed to the next bolt on each side, in descending bolt

number order, and apply the appropriate Table 14 torque values simultaneously to each pair of fasteners.

Continue to follow this sequence until all of these fasteners have been torqued to the appropriate Table

14 torque value.

(b) Follow the initial pull-up sequence given in Table 13 when installing these fasteners.

TABLE 1 - BOLT IDENTIFICATION AND INSTALLATION - S-1L TO S-5L

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

001 BACB30US5K18 0.312 - 0.316 -

002 L BACB30US5K18 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 5 OF 19)

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TABLE 1 - BOLT IDENTIFICATION AND INSTALLATION - S-1L TO S-5L

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

1L 003 L BACB30US8K42 0.546 - 0.561 -

004 L BACB30US8K42 0.546 - 0.561 -

005 L BACB30US5K18 0.312 - 0.316 -

006 L BACB30US5K18 0.312 - 0.316 -

007 L BACB30US5K18 0.312 - 0.316 -

2L 008 L BACB30US8K42 0.546 - 0.561 -

009 L BACB30US8K42 0.546 - 0.561 -

010 L BACB30US5K21 0.312 - 0.316 -

011 L BACB30US5K21 0.312 - 0.316 -

012 L BACB30US5K18 0.312 - 0.316 -

3L 013 L BACB30US8K42 0.546 - 0.561 -

014 L BACB30US8K42 0.546 - 0.561 -

015 L BACB30US5K18 0.312 - 0.316 -

016 L BACB30US5K18 0.312 - 0.316 -

017 L BACB30US5K18 0.312 - 0.316 -

4L 018 L BACB30US8K42 0.546 - 0.561 -

019 L BACB30US8K42 0.546 - 0.561 -

020 L BACB30US5K18 0.312 - 0.316 -

021 L BACB30US5K21 0.312 - 0.316 -

022 L BACB30US5K21 0.312 - 0.316 -

5L 023 L BACB30US7K39 0.484 - 0.499 -

024 L BACB30US7K39 0.484 - 0.499 -

025 L BACB30US5K21 0.312 - 0.316 -

026 L BACB30US5K21 0.312 - 0.316 -

027 L BACB30US5K18 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 6 OF 19)

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TABLE 2 - BOLT IDENTIFICATION AND INSTALLATION - S-6L TO S-11L

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

6L 028 L BACB30US7K39 0.484 - 0.499 -

029 L BACB30US7K39 0.484 - 0.499 -

030 L BACB30US5K18 0.312 - 0.316 -

031 L BACB30US5K18 0.312 - 0.316 -

032 L BACB30US5K18 0.312 - 0.316 -

7L 033 L BACB30US7K39 0.484 - 0.499 -

034 L BACB30US7K39 0.484 - 0.499 -

035 L BACB30US5K18 0.312 - 0.316 -

036 L BACB30US5K19 0.312 - 0.316 -

037 L BACB30US5K19 0.312 - 0.316 -

8L 038 L BACB30US7K40 0.484 - 0.499 -

039 L BACB30US7K40 0.484 - 0.499 -

040 L BACB30US5K19 0.312 - 0.316 -

041 L BACB30US5K19 0.312 - 0.316 -

042 L BACB30US5K19 0.312 - 0.316 -

9L 043 L BACB30US7K40 0.484 - 0.499 -

044 L BACB30US7K40 0.484 - 0.499 -

045 L BACB30US5K25 0.312 - 0.316 -

046 L See step table, Step 10 0.312 - 0.316 -

047 L BACB30US5K19 0.312 - 0.316 -

10L 048 L BACB30US7K40 0.484 - 0.499 -

049 L BACB30US7K40 0.484 - 0.499 -

050 L BACB30US5K19 0.312 - 0.316 -

051 L BACB30US5K19 0.312 - 0.316 -

052 L BACB30US5K19 0.312 - 0.316 -

11L 053 L BACB30US7K40 0.484 - 0.499 -

054 L BACB30US7K40 0.484 - 0.499 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 7 OF 19)

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TABLE 3 - BOLT IDENTIFICATION AND INSTALLATION - S-12L TO S-16L

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

055 L BACB30US5K19 0.312 - 0.316 -

056 L BACB30US5K19 0.312 - 0.316 -

057 L BACB30US5K19 0.312 - 0.316 -

12L 058 L BACB30US6K36 0.421 - 0.436 -

059 L BACB30US6K36 0.421 - 0.436 -

060 L BACB30US5K18 0.312 - 0.316 -

061 L BACB30US5K18 0.312 - 0.316 -

062 L BACB30US5K18 0.312 - 0.316 -

13L 063 L BACB30US6K35 0.421 - 0.436 -

064 L BACB30US6K35 0.421 - 0.436 -

065 L BACB30US5K17 0.312 - 0.316 -

066 L BACB30US5K17 0.312 - 0.316 -

067 L BACB30US5K17 0.312 - 0.316 -

14L 068 L BACB30US6K34 0.421 - 0.436 -

069 L BACB30US6K34 0.421 - 0.436 -

070 L BACB30US5K17 0.312 - 0.316 -

071 L BACB30US5K17 0.312 - 0.316 -

072 L BACB30US5K17 0.312 - 0.316 -

15L 073 L BACB30US6K34 0.421 - 0.436 -

074 L BACB30US6K34 0.421 - 0.436 -

075 L BACB30US5K17 0.312 - 0.316 -

076 L BACB30US5K17 0.312 - 0.316 -

077 L BACB30US5K17 0.312 - 0.316 -

16L 078 L BACB30US6K36 0.421 - 0.436 -

079 L BACB30US6K36 0.421 - 0.436 -

080 L BACB30US5K17 0.312 - 0.316 -

081 L BACB30US5K17 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 4 - BOLT IDENTIFICATION AND INSTALLATION - S-17L TO S-23L

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

17L 082 L BACB30US6K34 0.421 - 0.436 -

083 L BACB30US6K34 0.421 - 0.436 -

084 L BACB30US5K17 0.312 - 0.316 -

085 L BACB30US5K17 0.312 - 0.316 -

18L 086 L BACB30US6K34 0.421 - 0.436 -

087 L BACB30US6K34 0.421 - 0.436 -

088 L BACB30US5K17 0.312 - 0.316 -

089 L BACB30US5K17 0.312 - 0.316 -

19L 090 L BACB30US6K34 0.421 - 0.436 -

091 L BACB30US6K34 0.421 - 0.436 -

092 L BACB30US5K17 0.312 - 0.316 -

093 L BACB30US5K17 0.312 - 0.316 -

20L 094 L BACB30US6K35 0.421 - 0.436 -

095 L BACB30US6K35 0.421 - 0.436 -

096 L BACB30US5K17 0.312 - 0.316 -

097 L BACB30US5K17 0.312 - 0.316 -

098 L BACB30US5K17 0.312 - 0.316 -

099 L BACB30US5K17 0.312 - 0.316 -

22L 100 L BACB30US6K34 0.421 - 0.436 -

101 L BACB30US6K34 0.421 - 0.436 -

102 L BACB30US5K17 0.312 - 0.316 -

103 L BACB30US5K17 0.312 - 0.316 -

23L 104 L BACB30US6K33 0.421 - 0.436 -

105 L BACB30US6K33 0.421 - 0.436 -

106 L BACB30US5K17 0.312 - 0.316 -

107 L BACB30US5K17 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 5 - BOLT IDENTIFICATION AND INSTALLATION - S-24L TO S-32L

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

24L 108 L BACB30US6K34 0.421 - 0.436 -

109 L BACB30US6K34 0.421 - 0.436 -

110 L BACB30US5K17 0.312 - 0.316 -

111 L BACB30US5K17 0.312 - 0.316 -

25L 112 L BACB30US6K34 0.421 - 0.436 -

113 L BACB30US6K34 0.421 - 0.436 -

114 L BACB30US5K16 0.312 - 0.316 -

26L 115 L BACB30US6K33 0.421 - 0.436 -

116 L BACB30US6K33 0.421 - 0.436 -

117 L BACB30US5K16 0.312 - 0.316 -

27L 118 L BACB30US6K33 0.421 - 0.436 -

119 L BACB30US6K33 0.421 - 0.436 -

120 L BACB30US5K16 0.312 - 0.316 -

28L 121 L BACB30US6K33 0.421 - 0.436 -

122 L BACB30US6K33 0.421 - 0.436 -

123 L BACB30US5K16 0.312 - 0.316 -

29L 124 L BACB30US6K33 0.421 - 0.436 -

125 L BACB30US6K33 0.421 - 0.436 -

126 L BACB30US5K16 0.312 - 0.316 -

30L 127 L BACB30US7K35 0.484 - 0.499 -

128 L BACB30US7K35 0.484 - 0.499 -

129 L BACB30US5K17 0.312 - 0.316 -

31L 130 L BACB30US6K33 0.421 - 0.436 -

131 L BACB30US6K33 0.421 - 0.436 -

132 L BACB30US5K16 0.312 - 0.316 -

32L 133 L BACB30US6K33 0.421 - 0.436 -

134 L BACB30US6K33 0.421 - 0.436 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 6 - BOLT IDENTIFICATION AND INSTALLATION - S-33L TO S-39L

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

135 L BACB30US5K16 0.312 - 0.316 -

33L 136 L BACB30US6K33 0.421 - 0.436 -

137 L BACB30US6K33 0.421 - 0.436 -

138 L BACB30US5K18 0.312 - 0.316 -

34L 139 L BACB30US6K33 0.421 - 0.436 -

140 L BACB30US6K33 0.421 - 0.436 -

141 L BACB30US5K16 0.312 - 0.316 -

35L 142 L BACB30US7K35 0.484 - 0.499 -

143 L BACB30US7K35 0.484 - 0.499 -

144 L BACB30US5K16 0.312 - 0.316 -

36L 145 L BACB30US6K33 0.421 - 0.436 -

146 L BACB30US6K33 0.421 - 0.436 -

147 L BACB30US5K16 0.312 - 0.316 -

37L 148 L BACB30US7K35 0.484 - 0.499 -

149 L BACB30US7K35 0.484 - 0.499 -

38L 150 L BACB30US7K35 0.484 - 0.499 -

151 L BACB30US7K35 0.484 - 0.499 -

152 L BACB30US5K16 0.312 - 0.316 -

39L 153 L BACB30US6K31 0.421 - 0.436 -

154 L BACB30US6K31 0.421 - 0.436 -

155 BACB30US5K16 0.312 - 0.316 -

TABLE 7 - BOLT IDENTIFICATION AND INSTALLATION - S-1R TO S-5R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

002 R BACB30US5K18 0.312 - 0.316 -

1R 003 R BACB30US8K42 0.546 - 0.561 -

004 R BACB30US8K42 0.546 - 0.561 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 7 - BOLT IDENTIFICATION AND INSTALLATION - S-1R TO S-5R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

005 R BACB30US5K18 0.312 - 0.316 -

006 R BACB30US5K18 0.312 - 0.316 -

007 R BACB30US5K18 0.312 - 0.316 -

2R 008 R BACB30US8K42 0.546 - 0.561 -

009 R BACB30US8K42 0.546 - 0.561 -

010 R BACB30US5K18 0.312 - 0.316 -

011 R BACB30US5K18 0.312 - 0.316 -

012 R BACB30US5K18 0.312 - 0.316 -

3R 013 R BACB30US8K42 0.546 - 0.561 -

014 R BACB30US8K42 0.546 - 0.561 -

015 R BACB30US5K18 0.312 - 0.316 -

016 R BACB30US5K18 0.312 - 0.316 -

017 R BACB30US5K18 0.312 - 0.316 -

4R 018 R BACB30US8K42 0.546 - 0.561 -

019 R BACB30US8K42 0.546 - 0.561 -

020 R BACB30US5K18 0.312 - 0.316 -

021 R BACB30US5K21 0.312 - 0.316 -

022 R BACB30US5K21 0.312 - 0.316 -

5R 023 R BACB30US7K39 0.484 - 0.499 -

024 R BACB30US7K39 0.484 - 0.499 -

025 R BACB30US5K21 0.312 - 0.316 -

026 R BACB30US5K21 0.312 - 0.316 -

027 R BACB30US5K18 0.312 - 0.316 -

TABLE 8 - BOLT IDENTIFICATION AND INSTALLATION - S-6R TO S-11R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

6R 028 R BACB30US7K39 0.484 - 0.499 -

029 R BACB30US7K39 0.484 - 0.499 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 8 - BOLT IDENTIFICATION AND INSTALLATION - S-6R TO S-11R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

030 R BACB30US5K18 0.312 - 0.316 -

031 R BACB30US5K18 0.312 - 0.316 -

032 R BACB30US5K18 0.312 - 0.316 -

7R 033 R BACB30US7K39 0.484 - 0.499 -

034 R BACB30US7K39 0.484 - 0.499 -

035 R BACB30US5K18 0.312 - 0.316 -

036 R BACB30US5K19 0.312 - 0.316 -

037 R BACB30US5K19 0.312 - 0.316 -

8R 038 R BACB30US7K40 0.484 - 0.499 -

039 R BACB30US7K40 0.484 - 0.499 -

040 R BACB30US5K19 0.312 - 0.316 -

041 R BACB30US5K19 0.312 - 0.316 -

042 R BACB30US5K19 0.312 - 0.316 -

9R 043 R BACB30US7K40 0.484 - 0.499 -

044 R BACB30US7K40 0.484 - 0.499 -

045 R BACB30US5K25 0.312 - 0.316 -

046 R See step table, Step 10 0.312 - 0.316 -

047 R BACB30US5K19 0.312 - 0.316 -

10R 048 R BACB30US7K40 0.484 - 0.499 -

049 R BACB30US7K40 0.484 - 0.499 -

050 R BACB30US5K19 0.312 - 0.316 -

051 R BACB30US5K19 0.312 - 0.316 -

052 R BACB30US5K19 0.312 - 0.316 -

11R 053 R BACB30US7K40 0.484 - 0.499 -

054 R BACB30US7K40 0.484 - 0.499 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 9 - BOLT IDENTIFICATION AND INSTALLATION - S-12R TO S-16R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

055 R BACB30US5K19 0.312 - 0.316 -

056 R BACB30US5K19 0.312 - 0.316 -

057 R BACB30US5K19 0.312 - 0.316 -

12R 058 R BACB30US6K36 0.421 - 0.436 -

059 R BACB30US6K36 0.421 - 0.436 -

060 R BACB30US5K18 0.312 - 0.316 -

061 R BACB30US5K18 0.312 - 0.316 -

062 R BACB30US5K18 0.312 - 0.316 -

13R 063 R BACB30US6K35 0.421 - 0.436 -

064 R BACB30US6K35 0.421 - 0.436 -

065 R BACB30US5K17 0.312 - 0.316 -

066 R BACB30US5K17 0.312 - 0.316 -

067 R BACB30US5K17 0.312 - 0.316 -

14R 068 R BACB30US6K34 0.421 - 0.436 -

069 R BACB30US6K34 0.421 - 0.436 -

070 R BACB30US5K17 0.312 - 0.316 -

071 R BACB30US5K17 0.312 - 0.316 -

072 R BACB30US5K17 0.312 - 0.316 -

15R 073 R BACB30US6K34 0.421 - 0.436 -

074 R BACB30US6K34 0.421 - 0.436 -

075 R BACB30US5K17 0.312 - 0.316 -

076 R BACB30US5K17 0.312 - 0.316 -

077 R BACB30US5K17 0.312 - 0.316 -

16R 078 R BACB30US6K36 0.421 - 0.436 -

079 R BACB30US6K36 0.421 - 0.436 -

080 R BACB30US5K17 0.312 - 0.316 -

081 R BACB30US5K17 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 14 OF 19)

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TABLE 10 - BOLT IDENTIFICATION AND INSTALLATION - S-17R TO S-23R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

17R 082 R BACB30US6K34 0.421 - 0.436 -

083 R BACB30US6K34 0.421 - 0.436 -

084 R BACB30US5K17 0.312 - 0.316 -

085 R BACB30US5K17 0.312 - 0.316 -

18R 086 R BACB30US6K34 0.421 - 0.436 -

087 R BACB30US6K34 0.421 - 0.436 -

088 R BACB30US5K17 0.312 - 0.316 -

089 R BACB30US5K17 0.312 - 0.316 -

19R 090 R BACB30US6K34 0.421 - 0.436 -

091 R BACB30US6K34 0.421 - 0.436 -

092 R BACB30US5K17 0.312 - 0.316 -

093 R BACB30US5K17 0.312 - 0.316 -

20R 094 R BACB30US6K35 0.421 - 0.436 -

095 R BACB30US6K35 0.421 - 0.436 -

096 R BACB30US5K17 0.312 - 0.316 -

097 R BACB30US5K17 0.312 - 0.316 -

098 R BACB30US5K17 0.312 - 0.316 -

099 R BACB30US5K17 0.312 - 0.316 -

22R 100 R BACB30US6K34 0.421 - 0.436 -

101 R BACB30US6K34 0.421 - 0.436 -

102 R BACB30US5K17 0.312 - 0.316 -

103 R BACB30US5K17 0.312 - 0.316 -

23R 104 R BACB30US6K33 0.421 - 0.436 -

105 R BACB30US6K33 0.421 - 0.436 -

106 R BACB30US5K17 0.312 - 0.316 -

107 R BACB30US5K17 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 11 - BOLT IDENTIFICATION AND INSTALLATION - S-24R TO S-32R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

24R 108 R BACB30US6K34 0.421 - 0.436 -

109 R BACB30US6K34 0.421 - 0.436 -

110 R BACB30US5K17 0.312 - 0.316 -

111 R BACB30US5K17 0.312 - 0.316 -

25R 112 R BACB30US6K34 0.421 - 0.436 -

113 R BACB30US6K34 0.421 - 0.436 -

114 R BACB30US5K16 0.312 - 0.316 -

26R 115 R BACB30US6K33 0.421 - 0.436 -

116 R BACB30US6K33 0.421 - 0.436 -

117 R BACB30US5K16 0.312 - 0.316 -

27R 118 R BACB30US6K33 0.421 - 0.436 -

119 R BACB30US6K33 0.421 - 0.436 -

120 R BACB30US5K16 0.312 - 0.316 -

28R 121 R BACB30US6K33 0.421 - 0.436 -

122 R BACB30US6K33 0.421 - 0.436 -

123 R BACB30US5K16 0.312 - 0.316 -

29R 124 R BACB30US6K33 0.421 - 0.436 -

125 R BACB30US6K33 0.421 - 0.436 -

126 R BACB30US5K16 0.312 - 0.316 -

30R 127 R BACB30US7K35 0.484 - 0.499 -

128 R BACB30US7K35 0.484 - 0.499 -

129 R BACB30US5K17 0.312 - 0.316 -

31R 130 R BACB30US6K33 0.421 - 0.436 -

131 R BACB30US6K33 0.421 - 0.436 -

132 R BACB30US5K16 0.312 - 0.316 -

32R 133 R BACB30US7K35 0.484 - 0.499 -

134 R BACB30US7K35 0.484 - 0.499 -

135 R BACB30US5K16 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 16 OF 19)

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TABLE 12 - BOLT IDENTIFICATION AND INSTALLATION - S-33R TO S-39R

BOLT IDENTIFICATION HOLE DIA MORE DATA

NUMBER

STRINGER

33R 136 R BACB30US6K33 0.421 - 0.436 -

137 R BACB30US6K33 0.421 - 0.436 -

138 R BACB30US5K16 0.312 - 0.316 -

34R 139 R BACB30US6K33 0.421 - 0.436 -

140 R BACB30US6K33 0.421 - 0.436 -

141 R BACB30US5K16 0.312 - 0.316 -

35R 142 R BACB30US6K33 0.421 - 0.436 -

143 R BACB30US6K33 0.421 - 0.436 -

144 R BACB30US5K16 0.312 - 0.316 -

36R 145 R BACB30US6K33 0.421 - 0.436 -

146 R BACB30US6K33 0.421 - 0.436 -

147 R BACB30US5K16 0.312 - 0.316 -

37R 148 R BACB30US7K35 0.484 - 0.499 -

149 R BACB30US7K35 0.484 - 0.499 -

38R 150 R BACB30US7K35 0.484 - 0.499 -

151 R BACB30US7K35 0.484 - 0.499 -

152 R BACB30US5K18 0.312 - 0.316 -

39R 153 R BACB30US6K31 0.421 - 0.436 -

154 R BACB30US6K31 0.421 - 0.436 -

TABLE 13 - INITIAL PULL-UP SEQUENCE AND TORQUE VALUES (STRINGER LOCATIONS ONLY)

TORQUE (INCHPOUNDS)STEP BOLT NUMBER STRINGER

410 - 450, simultaneously1 28 L, 29 L, 100 R, 101 R 6L and 22R

410 - 450, simultaneously2 28 R, 29 R, 100 L, 101 L 6R and 22L

154 L through 033 L and 154R 39L through 7L and 39R through 7R 410 - 450 (a) (b)

through 033 R, at stringer locations

only.

3

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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TABLE 13 - INITIAL PULL-UP SEQUENCE AND TORQUE VALUES (STRINGER LOCATIONS ONLY)

TORQUE (INCHPOUNDS)STEP BOLT NUMBER STRINGER

024 L through 003 L and 024 R 5L through 1L and 5R through 1R 1000 - 1050 (a) (c)

through 003 R, at stringer locations

only.

4

(a) At stringer locations only. Do not apply this torque to the 5/16 inch diameter bolts in between the stringer

locations.

(b) Apply torque simultaneously to matching left and right bolt locations (example: bolt number 154 L and bolt

154 R), in order, beginning with bolt numbers 154 L and 154 R and ending with bolt numbers 033 L and

033 R.

(c) Apply torque simultaneously to matching left and right bolt locations (example: bolt number 024 L and bolt

024 R), in order, beginning with bolt numbers 024 L and 024 R and ending with bolt numbers 003 L and

003 R.

TABLE 14 - FINAL TORQUE VALUES

TORQUE APPLIED TO NUT (INCHPOUNDS)TORQUE APPLIED TO BOLT

HEAD (INCH-POUNDS)

BOLT PART NUMBER

BACB30US5K( ) 225 - 275 180 - 250

BACB30US6K( ) 450 - 550 300 - 500

BACB30US7K( ) 756 - 924 510 - 840

BACB30US8K( ) 1170 - 1430 870 - 1300

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

FIGURE 12: FORWARD SECTION 48 INSTALLATION

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Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30NX6K4X 20 0.200-0.203 -

HD

A

COLLAR BACC30BH6 20 - -

BOLT, PROTRUDING BACB30NX6K5X 2 0.200-0.203 -

HD

B

COLLAR BACC30BH6 2 - -

BOLT, PROTRUDING BACB30NX6K10X 2 0.200-0.203 -

HD

C

COLLAR BACC30BH6 2 - -

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

BRACKET ASSY- 272T4825-9 1 -

BOLT, 12 PT HEAD BACB30US5K16 3 -

BOLT, 12 PT HEAD BACB30US5K17 2 -

BOLT, 12 PT HEAD BACB30US5K18 1 -

BOLT, 12 PT HEAD BACB30US5K25 2 -

BOLT, 12 PT HEAD BACB30US7K35 4 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION

(SHEET 19 OF 19)

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FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 1 OF 12)

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FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 2 OF 12)

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FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 3 OF 12)

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FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 4 OF 12)

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FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 5 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 6 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

NOTE: Many of the affected fastener locations have been cold worked during production. If any of the fastener

locations need to be made larger than specified in this figure, contact The Boeing Company to determine

if additional cold work is necessary and do all additional work that The Boeing Company determines

to be necessary.

REQUIREMENTS:

1. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0078,

"Fuselage - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and

Modification." An Alternative Method of Compliance (AMOC) to the requirements of the applicable

Airworthiness Directive may have been granted for configurations different than those shown in

767-53A0078. These fastener locations must be maintained to the requirements of FAA AD 2005-11-02

or to an approved AMOC to that AD. When fasteners are removed from these locations, document the

fastener/nut/collar diameter, grip and type removed and the existing fastener hole diameter. Use care

to not damage the fastener hole when removing fasteners. Do not clean the bores of these fastener

holes with brass bottle brushes. Do an open-hole High Frequency Eddy Current (HFEC) inspection at

all parts in the stack-up at these locations. Verify that there are no surface defects (such as rifling,

gouging, nicks, burrs, or excessive surface roughness) in the bores of these fastener holes, other than

that normally produced during a typical reaming operation. If any defect is found, contact The Boeing

Company for repair instructions and do the repair. Verify that washers or fillet relief exists to

accommodate the fasteners head-to-shank fillet radius. When fasteners are installed, use the same

type and size fasteners that were removed earlier.

2. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0131,

"Fuselage - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord,

Horizontal and Vertical Inner Chord, and External Skin - Inspection." An Alternative Method of

Compliance (AMOC) to the requirements of the applicable Airworthiness Directive may have been

granted for configurations different than those shown in 767-53A0131. These fastener locations must

be maintained to the requirements of FAA AD 2011-14-02 or to an approved AMOC to that AD. When

fasteners are removed from these locations, document the fastener/nut/collar diameter, grip and type

removed and the existing fastener hole diameter. Use care to not damage the fastener hole when

removing fasteners. Do not clean the bores of these fastener holes with brass bottle brushes. Do an

open-hole High Frequency Eddy Current (HFEC) inspection at all parts in the stack-up at these locations.

Verify that there are no surface defects (such as rifling, gouging, nicks, burrs, or excessive surface

roughness) in the bores of these fastener holes, other than that normally produced during a typical

reaming operation. If any defect is found, contact The Boeing Company for repair instructions and do

the repair. Verify that washers or fillet relief exists to accommodate the fasteners head-to-shank fillet

radius. When fasteners are installed, use the same type and size fasteners that were removed earlier.

However, Boeing recommends that H-11 steel bolts be replaced with Inconel bolts. Refer to Boeing

Service Letter 767-SL-51-008-B

Step Task Name Identification Qty More Data

1 Install (Kept) Center Bulkhead Assy - 1 -

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 7 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Step Task Name Identification Qty More Data

2 Install (Kept) Filler - 4 If removed earlier

3 Install (New) FILLER 148T0012-2 2 -

4 Install (New) FILLER 148T0012-3 2 -

5 Install (New) SHIM 148T0012-4 1 (a) (b)

Bond Epoxy Adhesive BMS 5-25 - -

6 Install (New) SHIM 148T0012-5 1 (a) (b)

Bond Epoxy Adhesive BMS 5-25 - -

7 Install (New) FILLER 148T0012-11 1 -

8 Install (New) SPLICE-STRAP 148T0015-1 2 -

9 Install (New) SHIM,LAMINATED BACS40R011B027F 2 (a)

10 Install (New) SHIM, LAMINATED BACS40R012B027F 2 (a)

11 Install (New) SHIM, LAMINATED BACS40R016B098F 1 (a)

12 Install (New) SHIM, LAMINATED BACS40R027C030F 1 (a)

See Fastener Data

Table for part numbers and final hole

diameters.

13 Install (New) Fastener - 214

(a) Remove 0.003 inch laminations as necessary to achieve maximum allowable pull-up of 0.005 inch. After

adjustment, apply one coat of BMS 10-11 Type I primer.

(b) Bond into position with BMS 5-25, Type II, Grade I epoxy adhesive.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

The QTY numbers shown below are the number of fasteners necessary for this figure.

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 8 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
NOTE: Install all bolts wet with BMS 5-95 sealant.

Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30MY8K5X 35 0.263-0.266 -

HD

A

COLLAR BACC30M8 35 - -

BOLT, PROTRUDING BACB30MY8K6X 1 0.263-0.266 -

HD

B

COLLAR BACC30M8 1 - -

BOLT, PROTRUDING BACB30MY8K7X 65 0.263-0.266 (b)

HD

C

COLLAR BACC30M8 65 - (b)

BOLT, PROTRUDING BACB30MY8K8X 3 0.263-0.266 -

HD

D

COLLAR BACC30M8 3 - -

BOLT, PROTRUDING BACB30MY8K9X 1 0.263-0.266 -

HD

E

COLLAR BACC30M8 1 - -

BOLT, PROTRUDING BACB30MY8K10X 7 0.263-0.266 -

HD

F

COLLAR BACC30M8 7 - -

BOLT, PROTRUDING BACB30MY8K11X 3 0.263-0.266 -

HD

G

COLLAR BACC30M8 3 -

BOLT, PROTRUDING BACB30MY8K12X 4 0.263-0.266 -

HD

H

COLLAR BACC30M8 4 - -

I BOLT TITANIUM O/S BACB30MY10K3X 10 0.325-0.328 -

COLLAR BACC30M10 10 - -

BOLT, PROTRUDING BACB30MY10K5X 5 0.325-0.328 -

HD

J

COLLAR BACC30M10 5 - -

BOLT, PROTRUDING BACB30MY10K6X 1 0.325-0.328 -

HD

K

COLLAR BACC30M10 1 - -

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 9 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30MY10K7X 11 0.325-0.328 -

HD

L

COLLAR BACC30M10 11 - -

BOLT, PROTRUDING BACB30MY10K8X 14 0.325-0.328 -

HD

M

COLLAR BACC30M10 14 - -

BOLT, PROTRUDING BACB30MY10K10X 8 0.325-0.328 -

HD

N

COLLAR BACC30M10 8 - -

BOLT, PROTRUDING BACB30MY12K6X 2 0.388-0.391 -

HD

O

COLLAR BACC30M12 2 - -

BOLT, PROTRUDING BACB30MY12K7X 4 0.388-0.391 -

HD

P

COLLAR BACC30M12 4 - -

BOLT, PROTRUDING BACB30MY12K8X 4 0.388-0.391 (b)

HD

Q

COLLAR BACC30M12 4 - (b)

BOLT, PROTRUDING BACB30MY12K10X 4 0.388-0.391 (b)

HD

R

COLLAR BACC30M12 4 - (b)

BOLT, PROTRUDING BACB30NX10K8X 2 0.325-0.328 -

HD

S

COLLAR BACC30BH10 2 - -

BOLT, PROTRUDING BACB30NX10K9X 2 0.325-0.328 -

HD

T

COLLAR BACC30BH10 2 - -

BOLT, PROTRUDING BACB30NX10K11X 4 0.325-0.328 (b)

HD

U

COLLAR BACC30BH10 4 - (b)

BOLT, PROTRUDING BACB30NX10K12X 4 0.325-0.328 (b)

HD

V

COLLAR BACC30BH10 4 - (b)

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 10 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30NX12K12X 4 0.388-0.391 (b)

HD

W

COLLAR BACC30BH12 4 - (b)

X RIVET BACR15FV7KE7 5 - -

Y RIVET BACR15FV7KE8 1 - -

BOLT, 100 DEG HEX BACB30NW8K5X 2 0.263-0.266 -

DR

Z

COLLAR BACC30M8 2 - -

BOLT, 100 DEG HEX BACB30NW8K7X 2 0.263-0.266 (a)

DR

AA

COLLAR BACC30M8 2 - (a)

BOLT, 100 DEG HEX BACB30NW8K8X 4 0.263-0.266 (a)

DR

AB

COLLAR BACC30M8 4 - (a)

BOLT, 100 DEG HEX BACB30NW8K13X 4 0.263-0.266 (a)

DR

AC

COLLAR BACC30M8 4 - (a)

(a) If the repair or modification given in Service Bulletin 767-53A0078 was previously installed, install new

fasteners of the same type and size specified in Service Bulletin 767-53A0078, FAA AD 2005-11-02 or

approved AMOC instead of the fasteners specified in this table. If any fastener holes have been damaged

and the fasteners specified in 767-53A0078, FAA AD 2005-11-02 or approved AMOC cannot be reinstalled,

Contact The Boeing Company for repair instructions and do the repair.

(b) Some of these fasteners may have been replaced in accordance with Service Bulletin 767-53A0131. If

the repair given in Service Bulletin 767-53A0131 was previously installed, install new fasteners of the

same type and size specified in Service Bulletin 767-53A0131, FAA AD 2011-14-02 or approved AMOC

instead of the fasteners specified in this table. If any fastener holes have been damaged and the fasteners

specified in 767-53A0131, FAA AD 2011-14-02 or approved AMOC cannot be reinstalled, Contact The

Boeing Company for repair instructions and do the repair.

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

SHIM 148T0012-19 2 -

COLLAR BACC30BH10 2 -

COLLAR BACC30M8 14 -

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 11 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
FLAG NOTE MORE DATA

The fasteners in this area may have been replaced with oversize

fasteners as part of the repair or modification in Service Bulletin

767-53A0078, "Fuselage - Section 48 - Body Station 1809.5

Bulkhead Outer Chord Inspection, Repair, and Modification".

1

The fasteners in this area may have been replaced with oversize

fasteners as part of the repair in Boeing Service Bulletin 767-

53A0131, "Fuselage - Section 48 - Main Frame and Skins - STA

1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical

Inner Chord, and External Skin - Inspection".

2

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 12 OF 12)

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ALERT ALERT
FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 1 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 2 OF 12)

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ALERT ALERT
FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 3 OF 12)

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ALERT ALERT
FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 4 OF 12)

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ALERT ALERT
FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 5 OF 12)

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ALERT ALERT
FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 6 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

NOTE: Many of the affected fastener locations have been cold worked during production. If any of the fastener

locations need to be made larger than specified in this figure, contact The Boeing Company to determine

if additional cold work is necessary and do all additional work that The Boeing Company determines

to be necessary.

REQUIREMENTS:

1. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0078,

"Fuselage - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and

Modification." An Alternative Method of Compliance (AMOC) to the requirements of the applicable

Airworthiness Directive may have been granted for configurations different than those shown in

767-53A0078. These fastener locations must be maintained to the requirements of FAA AD 2005-11-02

or to an approved AMOC to that AD. When fasteners are removed from these locations, document the

fastener/nut/collar diameter, grip and type removed and the existing fastener hole diameter. Use care

to not damage the fastener hole when removing fasteners. Do not clean the bores of these fastener

holes with brass bottle brushes. Do an open-hole High Frequency Eddy Current (HFEC) inspection at

all parts in the stack-up at these locations. Verify that there are no surface defects (such as rifling,

gouging, nicks, burrs, or excessive surface roughness) in the bores of these fastener holes, other than

that normally produced during a typical reaming operation. If any defect is found, contact The Boeing

Company for repair instructions and do the repair. Verify that washers or fillet relief exists to

accommodate the fasteners head-to-shank fillet radius. When fasteners are installed, use the same

type and size fasteners that were removed earlier.

2. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0131,

"Fuselage - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord,

Horizontal and Vertical Inner Chord, and External Skin - Inspection." An Alternative Method of

Compliance (AMOC) to the requirements of the applicable Airworthiness Directive may have been

granted for configurations different than those shown in 767-53A0131. These fastener locations must

be maintained to the requirements of FAA AD 2011-14-02 or to an approved AMOC to that AD. When

fasteners are removed from these locations, document the fastener/nut/collar diameter, grip and type

removed and the existing fastener hole diameter. Use care to not damage the fastener hole when

removing fasteners. Do not clean the bores of these fastener holes with brass bottle brushes. Do an

open-hole High Frequency Eddy Current (HFEC) inspection at all parts in the stack-up at these locations.

Verify that there are no surface defects (such as rifling, gouging, nicks, burrs, or excessive surface

roughness) in the bores of these fastener holes, other than that normally produced during a typical

reaming operation. If any defect is found, contact The Boeing Company for repair instructions and do

the repair. Verify that washers or fillet relief exists to accommodate the fasteners head-to-shank fillet

radius. When fasteners are installed, use the same type and size fasteners that were removed earlier.

However, Boeing recommends that H-11 steel bolts be replaced with Inconel bolts. Refer to Boeing

Service Letter 767-SL-51-008-B.

Step Task Name Identification Qty More Data

1 Install (Kept) Center Bulkhead Assy - 1 -

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 7 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Step Task Name Identification Qty More Data

2 Install (Kept) Filler - 4 If removed earlier

3 Install (New) FILLER 148T0012-2 2 -

4 Install (New) FILLER 148T0012-3 2 -

5 Install (New) SHIM 148T0012-4 1 (a) (b)

Bond Epoxy Adhesive BMS 5-25 - -

6 Install (New) SHIM 148T0012-5 1 (a) (b)

Bond Epoxy Adhesive BMS 5-25 - -

7 Install (New) FILLER 148T0012-11 1 -

8 Install (New) SPLICE-STRAP 148T0015-1 2 -

9 Install (New) SHIM,LAMINATED BACS40R011B027F 2 (a)

10 Install (New) SHIM, LAMINATED BACS40R012B027F 2 (a)

11 Install (New) SHIM, LAMINATED BACS40R016B098F 1 (a)

12 Install (New) SHIM, LAMINATED BACS40R027C030F 1 (a)

See Fastener Data

Table for part numbers and final hole

diameters.

13 Install (New) Fastener - 214

(a) Remove 0.003 inch laminations as necessary to achieve maximum allowable pull-up of 0.005 inch. After

adjustment, apply one coat of BMS 10-11 Type I primer.

(b) Bond into position with BMS 5-25, Type II, Grade I epoxy adhesive.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

The QTY numbers shown below are the number of fasteners necessary for this figure.

NOTE: Install all bolts wet with BMS 5-95 sealant.

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 8 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30MY8K5X 35 0.263-0.266 -

HD

A

COLLAR BACC30M8 35 - -

BOLT, PROTRUDING BACB30MY8K6X 1 0.263-0.266 -

HD

B

COLLAR BACC30M8 1 - -

BOLT, PROTRUDING BACB30MY8K7X 65 0.263-0.266 (b)

HD

C

COLLAR BACC30M8 65 - (b)

BOLT, PROTRUDING BACB30MY8K8X 3 0.263-0.266 -

HD

D

COLLAR BACC30M8 3 - -

BOLT, PROTRUDING BACB30MY8K9X 1 0.263-0.266 -

HD

E

COLLAR BACC30M8 1 - -

BOLT, PROTRUDING BACB30MY8K10X 7 0.263-0.266 -

HD

F

COLLAR BACC30M8 7 - -

BOLT, PROTRUDING BACB30MY8K11X 3 0.263-0.266 -

HD

G

COLLAR BACC30M8 3 - -

BOLT, PROTRUDING BACB30MY8K12X 4 0.263-0.266 -

HD

H

COLLAR BACC30M8 4 - -

I BOLT TITANIUM O/S BACB30MY10K3X 10 0.325-0.328 -

COLLAR BACC30M10 10 - -

BOLT, PROTRUDING BACB30MY10K5X 5 0.325-0.328 -

HD

J

COLLAR BACC30M10 5 - -

BOLT, PROTRUDING BACB30MY10K6X 1 0.325-0.328 -

HD

K

COLLAR BACC30M10 1 - -

BOLT, PROTRUDING BACB30MY10K7X 11 0.325-0.328 -

HD

L

COLLAR BACC30M10 11 - -

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 9 OF 12)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30MY10K8X 14 0.325-0.328 -

HD

M

COLLAR BACC30M10 14 - -

BOLT, PROTRUDING BACB30MY10K10X 8 0.325-0.328 -

HD

N

COLLAR BACC30M10 8 - -

BOLT, PROTRUDING BACB30MY12K6X 2 0.388-0.391 -

HD

O

COLLAR BACC30M12 2 - -

BOLT, PROTRUDING BACB30MY12K7X 4 0.388-0.391 -

HD

P

COLLAR BACC30M12 4 - -

BOLT, PROTRUDING BACB30MY12K8X 4 0.388-0.391 (b)

HD

Q

COLLAR BACC30M12 4 - (b)

BOLT, PROTRUDING BACB30MY12K10X 4 0.388-0.391 (b)

HD

R

COLLAR BACC30M12 4 - (b)

BOLT, PROTRUDING BACB30NX10K8X 2 0.325-0.328 -

HD

S

COLLAR BACC30BH10 2 - -

BOLT, PROTRUDING BACB30NX10K9X 2 0.325-0.328 -

HD

T

COLLAR BACC30BH10 2 - -

BOLT, PROTRUDING BACB30NX10K11X 4 0.325-0.328 (b)

HD

U

COLLAR BACC30BH10 4 - (b)

BOLT, PROTRUDING BACB30NX10K12X 4 0.325-0.328 (b)

HD

V

COLLAR BACC30BH10 4 - (b)

BOLT, PROTRUDING BACB30NX12K12X 4 0.388-0.391 (b)

HD

W

COLLAR BACC30BH12 4 - (b)

X RIVET BACR15FV7KE7 5 - -

Y RIVET BACR15FV7KE8 1 - -

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 10 OF 12)

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BOEING SERVICE BULLETIN 767-53A0267

ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, 100 DEG HEX BACB30NW8K5X 2 0.263-0.266 -

DR

Z

COLLAR BACC30M8 2 - -

BOLT, 100 DEG HEX BACB30NW8K7X 2 0.263-0.266 (a)

DR

AA

COLLAR BACC30M8 2 - (a)

BOLT, 100 DEG HEX BACB30NW8K8X 4 0.263-0.266 (a)

DR

AB

COLLAR BACC30M8 4 - (a)

BOLT, 100 DEG HEX BACB30NW8K13X 4 0.263-0.266 (a)

DR

AC

COLLAR BACC30M8 4 - (a)

(a) If the repair or modification given in Service Bulletin 767-53A0078 was previously installed, install new

fasteners of the same type and size specified in Service Bulletin 767-53A0078, FAA AD 2005-11-02 or

approved AMOC instead of the fasteners specified in this table. If any fastener holes have been damaged

and the fasteners specified in 767-53A0078, FAA AD 2005-11-02 or approved AMOC cannot be reinstalled,

Contact The Boeing Company for repair instructions and do the repair.

(b) Some of these fasteners may have been replaced in accordance with Service Bulletin 767-53A0131. If

the repair given in Service Bulletin 767-53A0131 was previously installed, install new fasteners of the

same type and size specified in Service Bulletin 767-53A0131, FAA AD 2011-14-02 or approved AMOC

instead of the fasteners specified in this table. If any fastener holes have been damaged and the fasteners

specified in 767-53A0131, FAA AD 2011-14-02 or approved AMOC cannot be reinstalled, Contact The

Boeing Company for repair instructions and do the repair.

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

SHIM 148T0012-18 2 -

COLLAR BACC30BH10 2 -

COLLAR BACC30M8 14 -

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NOTE MORE DATA

The fasteners in this area may have been replaced with oversize

fasteners as part of the repair or modification in Service Bulletin

767-53A0078, "Fuselage - Section 48 - Body Station 1809.5

Bulkhead Outer Chord Inspection, Repair, and Modification".

1

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 11 OF 12)

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ALERT ALERT
FLAG NOTE MORE DATA

The fasteners in this area may have been replaced with oversize

fasteners as part of the repair in Boeing Service Bulletin 767-

53A0131, "Fuselage - Section 48 - Main Frame and Skins - STA

1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical

Inner Chord, and External Skin - Inspection".

2

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION

(SHEET 12 OF 12)

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ALERT ALERT
FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION

(SHEET 1 OF 5)

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ALERT ALERT
The step numbers shown below agree with the numbers as applicable shown in the circle symbols in the figure

or related drawing sheet(s) shown in the figure. The QTY numbers shown below are the number of parts

necessary for each airplane.

REQUIREMENTS:

1. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0078,

"Fuselage - Section 48 - Body Station 1809.5 Bulkhead Outer Chord Inspection, Repair, and

Modification." An Alternative Method of Compliance (AMOC) to the requirements of the applicable

Airworthiness Directive may have been granted for configurations different than those shown in Boeing

Service Bulletin 767-53A0078. These fastener locations must be maintained to the requirements of

FAA AD 2005-11-02 or to an approved AMOC to that AD. When fasteners are removed from these

locations, document the fastener/nut/collar diameter, grip and type removed and the existing fastener

hole diameter. Use care to not damage the fastener hole when removing fasteners. Do not clean the

bores of these fastener holes with brass bottle brushes. Do an open-hole High Frequency Eddy Current

(HFEC) inspection at all parts in the stack-up at these locations. Verify that there are no surface defects

(such as rifling, gouging, nicks, burrs, or excessive surface roughness) in the bores of these fastener

holes, other than that normally produced during a typical reaming operation. If any defect is found,

contact The Boeing Company for repair instructions and do the repair. Verify that washers or fillet relief

exists to accommodate the fasteners head-to-shank fillet radius. When fasteners are installed, use the

same type and size fasteners that were removed earlier.

2. Some of the fastener locations identified in this figure may have been changed from the original delivered

configuration during the inspection, repair, or modification given in Boeing Service Bulletin 767-53A0131,

"Fuselage - Section 48 - Main Frame and Skins - STA 1809.5 Bulkhead - Forward Outer Chord,

Horizontal and Vertical Inner Chord, and External Skin - Inspection." An Alternative Method of

Compliance (AMOC) to the requirements of the applicable Airworthiness Directive may have been

granted for configurations different than those shown in Boeing Service Bulletin 767-53A0131. These

fastener locations must be maintained to the requirements of FAA AD 2011-14-02 or to an approved

AMOC to that AD. When fasteners are removed from these locations, document the fastener/nut/collar

diameter, grip and type removed and the existing fastener hole diameter. Use care to not damage the

fastener hole when removing fasteners. Do not clean the bores of these fastener holes with brass bottle

brushes. Do an open-hole High Frequency Eddy Current (HFEC) inspection at all parts in the stack-up

at these locations. Verify that there are no surface defects (such as rifling, gouging, nicks, burrs, or

excessive surface roughness) in the bores of these fastener holes, other than that normally produced

during a typical reaming operation. If any defect is found, contact The Boeing Company for repair

instructions and do the repair. Verify that washers or fillet relief exists to accommodate the fasteners

head-to-shank fillet radius. When fasteners are installed, use the same type and size fasteners that

were removed earlier. However, Boeing recommends that H-11 steel bolts be replaced with Inconel

bolts. Refer to Boeing Service Letter 767-SL-51-008-B

Step Task Name Identification Qty More Data

Refer to the fastener

data table.

1 Install (New) Fastener - 288

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION

(SHEET 2 OF 5)

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ALERT ALERT
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

A BOLT, 12 PT HEAD BACB30LT5-12 10 0.312-0.316 -

CSK WASHER BACW10BP5CD 10 - under bolt head

WASHER-PLAIN BACW10BP5DP 10 - under nut

SELF-LOCKING NUT BACN10JC5CD 10 - -

B BOLT, 12 PT HEAD BACB30LT7-12 8 0.437-0.442 -

WASHER BACW10BP7CD 8 - under bolt head

WASHER BACW10BP7DP 8 - under nut

SELF-LOCKING NUT BACN10JC7CD 8 - -

C HI LOK BACB30NX8K5 8 0.250-0.254 (a)

COLLAR BACC30BH8 8 - (a)

D BOLT, HEX DRIVE BACB30NX8K7 76 0.250-0.254 (a)

COLLAR BACC30BH8 76 - (a)

E BOLT BACB30NX10K7 54 0.312-0.316 (a)

COLLAR BACC30BH10 54 - (a)

F HEX DRIVE BOLT BACB30NX10K10 44 0.312-0.316 (a) (b)

COLLAR BACC30BH10 44 - (a) (b)

G BOLT, 12 PT HEAD BACB30US12K37 4 0.778-0.797 -

WASHER, PLAIN BACW10BP12CD 4 - under bolt head

WASHER, PLAIN BACW10BP12DP 4 - under nut

SELF-LOCKING NUT BACN10HR12CD 4 - -

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION

(SHEET 3 OF 5)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

H BOLT, 12 PT HEAD BACB30US12K40 4 0.778-0.797 -

WASHER, PLAIN BACW10BP12CD 4 - under bolt head

WASHER, PLAIN BACW10BP12DP 4 - under nut

SELF-LOCKING NUT BACN10HR12CD 4 - -

I BOLT, 12 PT HEAD BACB30US7K24 22 0.467-0.479 -

WASHER BACW10BP7CD 22 - under bolt head

WASHER BACW10BP7DP 22 - under nut

NUT BACN10HR7CD 22 - -

J BOLT, 12 PT HEAD BACB30US7K26 2 0.467-0.479 -

WASHER BACW10BP7CD 2 - under bolt head

WASHER BACW10BP7DP 2 - under nut

NUT BACN10HR7CD 2 - -

K BOLT, 12 PT HEAD BACB30US7K28 32 0.467-0.479 (b)

WASHER BACW10BP7CD 32 - under bolt head (b)

WASHER BACW10BP7DP 32 - under bolt head (b)

NUT BACN10HR7CD 32 - (b)

L BOLT, 12 PT HEAD BACB30US8K31 2 0.500-0.505 -

washer 148T2746-1 2 - under bolt head

WASHER BACW10BP8DP 2 - under nut

NUT BACN10HR8CD 2 - -

M BOLT, 12 PT HEAD BACB30US8K31 2 0.500-0.505 -

filler 148T2746-2 2 - under bolt head

WASHER BACW10BP8DP 2 - under nut

NUT BACN10HR8CD 2 - -

N BOLT BACB30NX6K5 8 - -

COLLAR BACC30BH6 8 - -

O BOLT BACB30NX14K16 8 - -

COLLAR, PRELOAD BACC30BH14 8 - -

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION

(SHEET 4 OF 5)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

P BOLT, 12 PT HEAD BACB30US7K27 4 0.467-0.479 -

WASHER BACW10BP7CD 4 - under bolt head

WASHER BACW10BP7DP 4 - under nut

NUT BACN10HR7CD 4 - -

(a) Flag Note 1 regions only: If the repair or modification given in Boeing Service Bulletin 767-53A0078 was

previously installed, install new fasteners of the same type and size as specified in Boeing Service Bulletin

767-53A0078, FAA AD 2005-11-02 or approved AMOC instead of the fasteners specified in this table. If

any of these fastener holes have been damaged and the fasteners specified in Boeing Service Bulletin

767-53A0078, FAA AD 2005-11-02 or approved AMOC cannot be reinstalled, Contact The Boeing Company for repair instructions and do the repair.

(b) Flag Note 2 regions only: If the repair given in Boeing Service Bulletin 767-53A0131 was previously installed,

install new fasteners of the same type and size as specified in Boeing Service Bulletin 767-53A0131, FAA

AD 2011-14-02 or approved AMOC instead of the fasteners specified in this table. If any of these fastener

holes have been damaged and the fasteners specified in Boeing Service Bulletin 767-53A0131 , FAA AD

2011-14-02 or approved AMOC cannot be reinstalled, Contact The Boeing Company for repair instructions

and do the repair.

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

BOLT, 12 PT HEAD BACB30US8K30 2 -

COLLAR BACC30BH10 9 -

WASHER-PLAIN BACW10BP5DP 2 -

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NOTE MORE DATA

The fasteners in this area may have been replaced with oversize

fasteners as part of the repair or modification in Service Bulletin

767-53A0078, "Fuselage - Section 48 - Body Station 1809.5

Bulkhead Outer Chord Inspection, Repair, and Modification".

1

The fasteners in this area may have been replaced with oversize

fasteners as part of the repair in Boeing Service Bulletin 767-

53A0131, "Fuselage - Section 48 - Main Frame and Skins - STA

1809.5 Bulkhead - Forward Outer Chord, Horizontal and Vertical

Inner Chord, and External Skin - Inspection".

2

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION

(SHEET 5 OF 5)

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ALERT ALERT
FIGURE 16: PRESSURE SEAL INSTALLATION

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 16: PRESSURE SEAL INSTALLATION

(SHEET 2 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

1 Install (New) RETAINER ASSY- 272T4830-2 1

2 Install (New) SEAL 270T0004-1101 3

3 Install (New) SEAL 270T0004-1102 1

4 Install (New) RETAINER- 272T4830-1 1

5 Install (New) BOLT BACS12HN3-9 6

Install (New) WASHER NAS1149D0316J 6

6 Install (New) BOLT BACS12HN3-9 16

Install (New) WASHER NAS1149D0316J 16

Install (New) NUT BACN10JC3CD 16

7 Apply Sealant BMS 5-95 -

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

NUT BACN10JC3CD 2 -

BOLT BACS12HN3-9 2 -

WASHER NAS1149D0316J 2 -

FIGURE 16: PRESSURE SEAL INSTALLATION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS

(SHEET 2 OF 4)

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ALERT ALERT
FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS

(SHEET 3 OF 4)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

1 Install (New) TUBE ASSY 233T9110-566 1

2 Install (New) TUBE ASSEMBLY 233T9110-665 1

3 Install (New) TUBE ASSY 233T9110-566 -

Route TUBE ASSEMBLY 233T9110-665 -

4 Install (New) PLATER RETAINER 233T9113-4 1

5 Install (New) SEAL- 69B41314-6 1

6 Install (New) PLATER RETAINER 233T9113-4 1

7 Install (New) BOLT BACB30LM3-3 8

8 Connect TUBE ASSY 233T9110-566 -

Connect TUBE ASSEMBLY 233T9110-665 -

9 Apply Sealant BMS 5-142 -

The parts shown in the table below are provided as extra parts for this figure.

NAME IDENTIFICATION QTY MORE DATA

BOLT BACB30LM3-3 16 -

CLAMP, LOOP BACC10DK6 10 -

FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 1 OF 10)

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ALERT ALERT
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 2 OF 10)

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ALERT ALERT
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 3 OF 10)

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ALERT ALERT
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 4 OF 10)

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ALERT ALERT
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 5 OF 10)

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ALERT ALERT
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 6 OF 10)

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ALERT ALERT
FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 7 OF 10)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

From 6061-T6 aluminum alloy sheet,

0.125 inch thick.

1 Make Plate A 1

From 6061-T6 aluminum alloy sheet,

0.125 inch thick.

2 Make Plate B 1

From 6061-T6 aluminum angle or extrusion, 0.1875 inch

thick.

3 Make Angle C 6

From 6061-T6 aluminum angle or extrusion, 0.1875 inch

thick.

4 Make Angle D 2

From 6061-T6 aluminum angle or extrusion, 0.1875 inch

thick.

5 Make Angle E 2

6 Install (New) Plate A 1 -

Install (New) Angle C 3 -

Install (New) Angle D 1 -

Install (New) Angle E 1 -

Mark the aft side of

the tool and place

orientation arrows

on the aft side of the

tool.

Left STA 1809.5 Bulk- - -

head Tool

Identify

Mark the tool as the

left 1809.5 bulkhead

stabilization tool.

Left STA 1809.5 Bulk- - 1

head Tool

Identify

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 8 OF 10)

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ALERT ALERT
Step Task Name Identification Qty More Data

7 Install (New) Plate B 1 -

Install (New) Angle C 3 -

Install (New) Angle D 1 -

Install (New) Angle E 1 -

Mark the tool as the

right 1809.5 bulkhead stabilization

tool.

Right STA 1809.5 Bulk- - 1

head Tool

Identify

Mark the aft side of

the tool and place

orientation arrows

on the aft side of the

tool.

Right STA 1809.5 Bulk- - -

head Tool

Identify

Attach the tool to the

upper and lower

STA 1809.5 bulkhead using temporary fasteners.

Left STA 1809.5 Bulk- - 1

head Tool

8 Attach

Install (New) Temporary Fastener - 8 -

Attach the tool to the

upper and lower

STA 1809.5 bulkhead using temporary fasteners.

Right STA 1809.5 Bulk- - 1

head Tool

9 Attach

Install (New) Temporary Fastener - 8 -

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 9 OF 10)

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ALERT ALERT
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

NOTE: The fasteners identified in the table below are for reference only. Any available lock bolt/collar

combination of the specified size is an acceptable substitute.

Code Name Identification Qty Hole Dia More Data

A Bolt BACB30NX6K5 120 - -

Collar BACC30BH6SW 120 - -

B Bolt BACB30NX6K8 18 - -

Collar BACC30BH6SW 18 - -

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 10 OF 10)

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ALERT ALERT
FIGURE 19: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

1 Remove Temporary Fastener - 8 -

Left STA 1809.5 Bulk- - 1 -

head Tool

Remove

2 Remove Temporary Fastener - 8 -

Right STA 1809.5 Bulk- - 1 -

head Tool

Remove

FIGURE 19: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT

(SHEET 1 OF 4)

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FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT

(SHEET 2 OF 4)

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FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT

(SHEET 3 OF 4)

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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.

NOTE: Before removing any fasteners from the floor beams or stanchions, establish the STA 1582 floor beam

Water Line datum. This datum must be established to ensure that when the STA 1582 floor beam is

reattached it has not been deflected up or down, which can alter the aft galley monument shimming/joint

requirements. Several different methods can be used to verify and maintain this datum. Possible

methods include: 1. Optical planizer; 2. Projection of WL datum using multiple floor beams forward of

STA 1582 using a straight edge at a minimum of two locations; 3. Application of witness marks (using

acceptable non-damaging marks that may be removed by cleaning after the floor beam has been

reattached) at the positions of the STA 1582 floor beam upper and lower chords and the inboard and

outboard flanges of the stanchions on the forward surface of the frame segments (attached to the

Section 46 skin panels).

Step Task Name Identification Qty More Data

1 Remove Fastener - 21 -

Remove Shim - 1 If installed.

2 Remove Fastener - 8 -

3 Remove Fastener - 21 -

Remove Shim - 1 If installed.

4 Remove Fastener - 12 -

FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 21: STA 1582 FLOOR BEAM SUPPORT

(SHEET 1 OF 3)

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FIGURE 21: STA 1582 FLOOR BEAM SUPPORT

(SHEET 2 OF 3)

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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.

NOTE: Before installing the supports shown in this figure, make sure that the STA 1582 floor beam is aligned

with the WL datum established prior to floor beam detachment in accordance with FIGURE 20.

Step Task Name Identification Qty More Data

From 6061-T6 aluminum, 0.5 inch

thick.

1 Make Plate F 2

From 6061-T6 aluminum, at least 0.5

inch thick. Each

flange should be at

least 4 inches wide

and 4 inches deep.

2 Make Angle G 2

3 Install (New) Plate F 1 On the left side. (a)

4 Install (New) Angle G 1 On the left side. (b)

5 Install (New) Plate F 1 On the right side. (a)

6 Install (New) Angle G 1 On the right side. (b)

(a) Make 0.312 - 0.316 inch diameter holes to match fastener locations 102, 103, 110, 111, and 117 in the

STA 1582 forward chord. Attach the plate to the STA 1582 forward chord with temporary 5/16 inch diameter fasteners. Make sure that no fastener threads are in bearing common to the STA 1582 frame segments.

(b) Place the vertical flange of the angle against the plate, and the horizontal flange of the angle against the

lower chord of the STA 1582 floor beam and clamp in place. Attach the angle to the plate using a minimum

of four 1/4 inch diameter bolts.

FIGURE 21: STA 1582 FLOOR BEAM SUPPORT

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT

(SHEET 2 OF 5)

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ALERT ALERT
FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT

(SHEET 3 OF 5)

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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.

NOTE: Before attaching the STA 1582 floor beam to the aft pressure bulkhead inner chord, make sure that

the STA 1582 floor beam is aligned with the WL datum established prior to floor beam detachment in

accordance with FIGURE 20.

Step Task Name Identification Qty More Data

1 Install (New) SHIM, LAMINATED BACS40R040C095F 1 If necessary. (a)

Drill / Ream Hole - 21 -

Install (New) Fastener - 21 -

2 Drill / Ream Hole - 8 -

Install (New) Fastener - 8 -

3 Install (New) SHIM, LAMINATED BACS40R040C095F 1 If necessary. (a)

Drill / Ream Hole - 21 -

Install (New) Fastener - 21 -

4 Drill / Ream Hole - 12 -

Install (New) Fastener - 12 -

(a) Remove solid section or laminations as necessary. Maximum gap without a shim is 0.02 inch. Maximum

thickness of the laminated section of the shim is 0.02 inch. Maximum total shim thickness is 0.06 inch.

After thickness adjustment, apply chemical film treatment to bare aluminum surfaces and apply one coat

of BMS 10-11, Type I primer.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT

(SHEET 4 OF 5)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30NX8K5X 22 0.263-0.266 -

HD

A

COLLAR BACC30BH8 22 - -

BOLT, PROTRUDING BACB30NX8K6X 6 0.263-0.266 -

HD

B

COLLAR BACC30BH8 6 - -

BOLT, PROTRUDING BACB30NX8K7X 14 0.263-0.266 -

HD

C

COLLAR BACC30BH8 14 - -

BOLT, PROTRUDING BACB30NX6K4X 3 0.200-0.203 -

HD

D

COLLAR BACC30M6 3 - -

BOLT, PROTRUDING BACB30NX6K6X 5 0.200-0.203 -

HD

E

COLLAR BACC30M6 5 - -

BOLT, PROTRUDING BACB30MY8K4X 12 0.263-0.266 -

HD

F

COLLAR BACC30M8 12 - -

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT

(SHEET 5 OF 5)

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ALERT ALERT
FIGURE 23: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL

(SHEET 1 OF 3)

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FIGURE 23: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL

(SHEET 2 OF 3)

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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 this figure.

Step Task Name Identification Qty More Data

1 Remove Fastener - 8 (a)

Remove / Keep SKIN - CHEM MILLED - 1 -

2 Remove Fastener - 6 (c)

3 Remove Fastener - 13 (b)

4 Remove / Keep SKIN - CHEM MILLED - 1 -

Remove / Keep SKIN - CHEM MILLED - 1 -

(a) Remove fasteners common to the upper aft fairing skin panel and chord.

(b) Remove fasteners common to the lower aft fairing skin panel and cord.

(c) Remove and keep fasteners common to the lower aft fairing skin panels.

FIGURE 23: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION

(SHEET 2 OF 4)

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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 this figure.

NOTE: Install fasteners wet with BMS 5-95 sealant.

Step Task Name Identification Qty More Data

1 Install (Kept) SKIN - CHEM MILLED - 1 -

Install (New) Fastener - 8 (a)

2 Install (Kept) SKIN - CHEM MILLED - 1 -

Install (Kept) SKIN - CHEM MILLED - 1 -

3 Install (New) Fastener - 6 (b)

4 Install (New) Fastener - 13 -

(a) Install fasteners common to the upper aft fairing skin panel and chord.

(b) Install fasteners common to the upper aft fairing skin panel and chord.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

BOLT, 100 DEG HEX BACB30NW8K8X 6 0.263-0.266 -

DR

A

COLLAR BACC30M8 6 - -

RIVET, UNIVERSAL BACR15FT5KE9C 2 - -

HD

B

C RIVET BACR15FV6KE7 5 - -

D RIVET BACR15FV6KE8 1 - -

FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION

(SHEET 3 OF 4)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

Apply 18 - 25 in-lbs of

torque.

E BOLT, 100 DEG HEAD BACB30VF3K5 10 -

Apply 18 - 25 in-lbs of

torque.

F BOLT BACB30VF3K7 3 -

FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 25: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 25: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL

(SHEET 2 OF 3)

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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 this figure.

Step Task Name Identification Qty More Data

1 Remove Fastener - 8 -

Remove / Keep SKIN - CHEM MILLED - 1 (a)

2 Remove Fastener - 6 -

3 Remove Fastener - 13 -

4 Remove / Keep SKIN - CHEM MILLED - 1 (b)

Remove / Keep SKIN - CHEM MILLED - 1 (b)

(a) These are the Upper Aft Fairing Skin.

(b) These fairing skin panels are fastened together. These are the Lower Aft Fairing Skin.

FIGURE 25: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL

(SHEET 3 OF 3)

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FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION

(SHEET 1 OF 3)

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FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION

(SHEET 2 OF 3)

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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 this figure.

NOTE: Install fasteners wet with BMS 5-95 sealant.

Step Task Name Identification Qty More Data

1 Install (Kept) SKIN - CHEM MILLED - 1 -

Install (New) Fastener - 8 (a)

2 Install (Kept) SKIN - CHEM MILLED - 1 -

Install (Kept) SKIN - CHEM MILLED - 1 -

3 Install (New) Fastener - 6 (b)

4 Install (New) Fastener - 13 -

(a) Install fasteners common to the upper aft fairing skin panel and chord.

(b) Install fasteners common to the lower aft fairing skin panel and chord.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

BOLT, 100 DEG HEX BACB30NW8K8X 6 0.263-0.266 -

DR

A

COLLAR BACC30M8 6 - -

RIVET, UNIVERSAL BACR15FT5KE9C 2 - -

HD

B

C RIVET BACR15FV6KE7 5 - -

D RIVET BACR15FV6KE8 1 - -

Apply 18 - 25 in-lbs of

torque.

E BOLT, 100 DEG HEAD BACB30VF3K5 10 -

Apply 18 - 25 in-lbs of

torque.

F BOLT BACB30VF3K7 3 -

FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 27: PREPARATION OF THE VERTICAL FIN

(SHEET 1 OF 7)

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FIGURE 27: PREPARATION OF THE VERTICAL FIN

(SHEET 2 OF 7)

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ALERT ALERT
FIGURE 27: PREPARATION OF THE VERTICAL FIN

(SHEET 3 OF 7)

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FIGURE 27: PREPARATION OF THE VERTICAL FIN

(SHEET 4 OF 7)

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FIGURE 27: PREPARATION OF THE VERTICAL FIN

(SHEET 5 OF 7)

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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 this figure.

Step Task Name Identification Qty More Data

BMS 3-38 (BMS 3-27 - (a) (e)

OPTIONAL)

Corrosion Inhibiting

Compound

1 Apply

2 Locate Alignment Pins - - (b)

Install with the fastener head against

the body bulkhead

surface (f)

3 Install (Temporary) Bolt - 4

Install (Temporary) Barrel Nut - 4 -

4 Install (Temporary) Fastener - 8 (c)

5 Remove Crane Sling - - (d)

(a) APPLY 0.001-0.005 INCHES OF BMS3-38 TO BASE OF VERTICAL FIN. (SOPM 20-41-01 states: Apply

a thin layer of BMS 3-38 corrosion inhibiting compound to indicated surfaces). During installation, squeezeout of corrosion inhibiting compound is allowed, but not required.

(b) Lower the vertical fin using the alignment pins and L-pins to position the fin and set it on the fuselage.

(c) Install hex head bolts or similar to BACB30NF() or BACB30NM(). Use non self locking compatible nuts.

No shimming required, torque to 50/65 inch-lb.

(d) Remove all vertical tension from the crane sling. Visually review the fin attach angle hole pattern for correct

alignment with the fastener holes in the fin deck of the fuselage. If the holes are aligned correctly, remove

the crane sling. If necessary, restore vertical tension to the crane sling and reposition the vertical fin until

fastener holes are correctly aligned. If this is required, all temporary bolts must be removed before lifting

the fin.

(e) Use shims kept during removal of the vertical fin. If kept shims are no longer serviceable, replace with

new shims.

(f) The purpose of having these bolts installed now is to safely ensure the vertical fin remains in position

during bolt/barrel nut and hi-lok installation process given in Figure 28. The bolts which were removed

during vertical fin removal process can be re-used for this temporary installation. Do not use new bolts

and barrel nuts in the kit for this temporary installation to prevent damage to the new bolts and barrel nuts

prior to installation.

FIGURE 27: PREPARATION OF THE VERTICAL FIN

(SHEET 6 OF 7)

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ALERT ALERT
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

Code Name Identification Qty Hole Dia More Data

A BOLT, 12 PT HEAD - 2 - 1,000 - 1,100 in-lbs torque

WASHER, PLAIN - 2 - -

WASHER - 2 - -

BARREL NUT - 2 - -

B BOLT, 12 PT HEAD - 1 - 1,000 - 1,100 in-lbs torque

WASHER, PLAIN - 1 - -

WASHER - 1 - -

BARREL NUT - 1 - -

C BOLT, 12 PT HEAD - 1 - 1,000 - 1,100 in-lbs torque

WASHER, PLAIN - 1 - -

WASHER - 1 - -

BARREL NUT - 1 - -

FIGURE 27: PREPARATION OF THE VERTICAL FIN

(SHEET 7 OF 7)

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ALERT ALERT
FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 1 OF 9)

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FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 2 OF 9)

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FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 3 OF 9)

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FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 4 OF 9)

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FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 5 OF 9)

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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 this figure.

Step Task Name Identification Qty More Data

1 Inspect Fin Terminal Fittings - - (a)

2 Apply Sealant BMS 5-95 - (b)

1000-1100 in-lbs

torque. This is an

initial torque (c)

3 Install (New) Bolt - 8

Install (New) Barrel Nut - 8 -

Shear Fastener Loca- - - (d)

tions

4 Inspect

5 Ream Fastener Hole - - (e)

Deburr Fastener Hole - - -

6 Install (New) Shear Fastener - 16 (f)

See Fastener code

table for torque values.

7 Torque Bolt - -

These are the temporary bolts installed in

Figure 27.

8 Remove Bolt - 4

Remove Barrel Nut - 4 -

9 Inspect Fin Terminal Fittings - - (a)

10 Apply Sealant BMS 5-95 - (b)

See fastener code

table for torque values. (c)

11 Install (New) Bolt - 8

Install (New) Barrel Nut - 8 -

Shear Fastener Loca- - - (d)

tions

12 Inspect

13 Ream Fastener Hole - - (e) (h)

Deburr Fastener Hole - - -

Install sequentially,

in both directions,

starting at tension

bolt locations. See

fastener code table.

(f) (i)

14 Install (New) Fastener - 148

15 Remove Temporary Fastener - 8 -

FIGURE 28: INSTALLATION OF THE VERTICAL FIN

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Step Task Name Identification Qty More Data

16 Install (New) Fastener - 8 (f) (i)

(a) Determine the gap at fin terminal fittings in accordance with Boeing Drawing 100T3480, sheet 1. Shim

using predrilled shims, with oversized holes in accordance with Boeing Drawing 100T3481 sheet 1. Precoat shims with 0.001-0.005 inches of BMS3-38 (BMS3-27 optional).

(b) Apply sealant to the bolt thread, shanks, under the bolt head, the barrel nut, washer mating surfaces and

to all areas of the barrel nut that contacts vertical fin structure. Refer to SOPM 20-50-19 as an accepted

procedure. Solvent clean all applicable surfaces, prior to application of sealant, to make sure all corrosion

inhibiting compound is removed. Refer to SOPM 20-30-03 as an accepted procedure.

(c) Fastener head must sit against body bulkhead structure. Check for a small bead of sealant around the

bolt head after installation.

(d) Determine the gap at fastener locations. Shim, if required using predrilled shim in accordance with Boeing

Drawing 100T3481 sheet 1, to maintain a maximum gap of 0.008 inches. Pre-coat shims with 0.001-0.005

inches of BMS3-38 (BMS3-27 optional).

(e) Ream to 1/64 inch oversize. Refer to SOPM 20-10-02 as an accepted procedure.

(f) Solvent clean all applicable surfaces prior to application of sealant. Apply sealant to the shear fastener

thread, shanks and under the shear fastener head. Refer to SOPM 20-50-19 as an accepted procedure.

Solvent clean all applicable surfaces, prior to application of sealant, to make sure all corrosion inhibiting

compound is removed. Refer to SOPM 20-30-03 as an accepted procedure.

(g) Apply sealant to the bolt thread, shanks and under the bolt head. Refer to SOPM 20-50-19 as an accepted

procedure.

(h) If any Fastener locations "B" exceeds 1/64 oversize, contact The Boeing Company for repair instructions

and do the repair. Fastener "B" locations are class 1 cold worked.

(i) All H-11 hardware should have been replaced at fin to body joint in accordance with Boeing Service Bulletin

767-53A0085 and AD 2003-10-11 by July 1, 2006.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 7 OF 9)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

BOLT, PROTRUDING BACB30NX6K6X 4 0.200-0.203 -

HD

A

COLLAR BACC30BH6 4 - -

BOLT, PROTRUDING BACB30NX6K19X 8 0.200-0.203 -

HD

B

COLLAR BACC30BH6 8 - -

BOLT, PROTRUDING BACB30NX8K5X 28 0.263-0.266 -

HD

C

COLLAR BACC30BH8 28 - -

BOLT, PROTRUDING BACB30NX8K9X 6 0.263-0.266 -

HD

D

COLLAR BACC30BH8 6 - -

BOLT, PROTRUDING BACB30NX8K16X 4 0.263-0.266 -

HD

E

COLLAR BACC30BH8 4 - -

BOLT, PROTRUDING BACB30NX10K10X 6 0.325-0.328 -

HD

F

COLLAR BACC30BH10 6 - -

BOLT, PROTRUDING BACB30NX10K12X 6 0.325-0.328 -

HD

G

COLLAR BACC30BH10 6 - -

BOLT, PROTRUDING BACB30NX10K13X 2 0.325-0.328 -

HD

H

COLLAR BACC30BH10 2 - -

BOLT, PROTRUDING BACB30NX10K15X 2 0.325-0.328 -

HD

I

COLLAR BACC30BH10 2 - -

J BOLT, HEX DRIVE BACB30NX12K9X 14 0.388-0.391 -

COLLAR BACC30BH12 14 - -

BOLT, PROTRUDING BACB30NX12K11X 4 0.388-0.391 -

HD

K

COLLAR BACC30BH12 4 - -

BOLT, PROTRUDING BACB30NX12K14X 10 0.388-0.391 -

HD

L

COLLAR BACC30BH12 10 - -

FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 8 OF 9)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

M BOLT TIANIUM O/S BACB30NX12K15X 58 0.388-0.391 -

COLLAR BACC30BH12 58 - -

BOLT, PROTRUDING BACB30NX16K11X 4 0.513-0.516 -

HD

N

COLLAR BACC30X16 4 - -

7,800 - 8,800 in-lbs torque

(a)

O BOLT, 12 PT HEAD BACB30US16K47 4 -

WASHER, PLAIN BACW10BP16CD 4 - -

WASHER NAS1149E1632P 4 - -

BARREL NUT BACN11B16CS 4 - -

7,800 - 8,800 in-lbs torque

(a)

P BOLT, 12 PT HEAD BACB30US16K48 4 -

WASHER, PLAIN BACW10BP16CD 4 - -

WASHER NAS1149E1632P 4 - -

BARREL NUT BACN11B16CS 4 - -

7,800 - 8,800 in-lbs torque

(a)

Q BOLT, 12 PT HEAD BACB30US16K50 2 -

WASHER, PLAIN BACW10BP16CD 2 - -

WASHER NAS1149E1632P 2 - -

BARREL NUT BACN11B16CS 2 - -

7,800 - 8,800 in-lbs torque

(a)

R BOLT, 12 PT HEAD BACB30US16K51 2 -

WASHER, PLAIN BACW10BP16CD 2 - -

WASHER NAS1149E1632P 2 - -

BARREL NUT BACN11B16CS 2 - -

10,450 - 11,500 in-lbs

torque (a)

S BOLT, 12 PT HEAD BACB30US18K52 4 -

WASHER, PLAIN BACW10BP18CD 4 - -

WASHER NAS1149E1632P 4 - -

BARREL NUT BACN11B18CS 4 - -

(a) Torque the 12 point bolts using the 2MIT100T3480PBR torque multiplier.

FIGURE 28: INSTALLATION OF THE VERTICAL FIN

(SHEET 9 OF 9)

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ALERT ALERT
CAUTION: ELECTRICAL POWER - POTENTIAL ELECTRICAL POWER HAZARDS EXIST WHEN

PERFORMING THIS TEST. USE APPLICABLE SHOP PROCEDURES AS REQUIRED.

Reference Wiring Diagrams 49-14-11, 49-15-11, 49-41-11, 49-94-11, and 49-94-14.

A Multimeter, such as a Triplett 630A, Fluke 77, or other equivalent model, capable of reading resistance from

1 milliohm to 1,000 ohms is necessary.

A jumper wire is necessary to provide a path to aircraft ground from each of the connector pins that will be tested.

NOTE: The circuit breaker locations that follow are typical. Circuit breaker locations may vary with the airplane

configuration.

1. On the P11-4 Panel, open the circuit breakers that follow and attach DO-NOT-CLOSE tags:

CB Number Location Name

C1391 B35 APU ALTN CONT

C1052 D35 FUEL DC PUMP CONT

C1306 A33 IND LIGHTS 1

C1575 C29 LANDING GEAR POSITION AIR/GND SYS 2 ALT

C1058 D34 FUEL DC PUMP PWR

C0796 B34 APU REMOTE FIRE IND

2. On the P11-5 Panel, open the circuit breaker that follows and attach DO-NOT-CLOSE tags:

CB Number Location Name

C1055 M25 FUEL PUMPS L FWD R AFT

3. On the P11-6 Panel, open the circuit breakers that follow and attach DO-NOT-CLOSE tags:

CB Number Location Name

C1333 S24 PNEUMATIC AIR SUPPLY APU BLEED CONT

C1336 S23 PNEUMATIC AIR SUPPLY APU BLEED PWR

C1273 R28 RIGHT IND LTS 1

C0865 T35 TRU APU START CONTROL (a)

(a) If the airplane is equipped with TRU START.

4. If the airplane is equipped with TRU START, on the P32 Panel, open the circuit breaker that follows

and attach DO-NOT-CLOSE tags:

APPENDIX A: APU WIRING TEST PROCEDURE

(SHEET 1 OF 5)

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ALERT ALERT
CB Number Location Name

C303 R32 TRU APU START

5. If the airplane is equipped with TRU START, on the P49 Panel, open the circuit breaker that follows

and attach DO-NOT-CLOSE tags:

CB Number Location Name

C89 D03 TRU FAN

6. On the E6/P49 Panel, open the circuit breakers that follow and attach DO-NOT-CLOSE tags:

CB Number Location Name

C1383 C02 APU PRIME CONT

C20 C03 APU START

C868 E04 APU BAT CHGR

C869 E03 APU BAT BUS

7. On the P6-1 Panel, open the circuit breakers that follow and attach DO-NOT-CLOSE tags:

CB Number Location Name

C780 G01 FIRE EXT APU 1

C782 G02 FIRE EXT APU 2 (a)

C1063 E03 FUEL VALVES APU

C806 B03 GEN CONT UNIT APU

(a) If the airplane is equipped with dual APU fire bottles.

8. On the P6-4 Panel, open the circuit breaker that follows and attach DO-NOT-CLOSE tags:

CB Number Location Name

C372 G24 L FWD FUEL BOOST PUMP

9. On the P33 Panel, open the circuit breakers that follow and attach DO-NOT-CLOSE tags:

CB Number Location Name

C321 B07 GROUND SERVICE BUS P-6

C302 E05 APU BAT CHGR

10. On the P34 Panel, open the circuit breaker that follows and attach DO-NOT-CLOSE tags:

APPENDIX A: APU WIRING TEST PROCEDURE

(SHEET 2 OF 5)

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ALERT ALERT
CB Number Location Name

C322 M12 APU GND SVCE BUS

11. On the P5 Panel, set the MAIN BATTERY switch (S2) on the M1OO62 module to "OFF".

12. On the P5 Panel, set the APU START switch (S1) on the M1 Module to "OFF".

13. On the P5 Panel, set the APU BLEED AIR switch (S5) on the M15 module to "OFF".

14. On the P8 Panel, set the APU FIRE switch (S39) on the M1O444 module to "OFF".

15. On the P61 Panel, set the APU MAINT switch (S3) on the M1390 module to "NORM".

16. Disconnect the APU Battery, located in the E6 rack in the aft cargo compartment.

17. Remove the APU Controller (ECU) located in the E6 rack in the aft cargo compartment.

18. In the P49 Panel, disconnect connector D6396P.

19. Depending on the oil level indication chosen, disconnect the applicable connector in the P49 Panel:

D4040P (airplanes with APU oil quantity switch indication), or

D6424P (airplanes with APU oil level indication).

20. Disconnect connectors D4024P, D4030P, and D4138P on the APU firewall.

21. Disconnect the D502 connector on the APU Inlet Door Actuator.

22. Do the wiring continuity test as follows:

a. Set the Multimeter in the proper range to read resistance in the range of 0 to 100 Ohms.

b. Verify that the resistance from pin 2 of ECU connector D408C to airplane ground is less than 1

Ohm.

For most of the continuity checks of the wiring, a jumper wire will be placed in the pin of the firewall

connector and the jumper wire will then also be connected to airplane ground.

c. Do wiring checks as given in the table that follows:

Multimeter Probes Jumper Wire Resistance

D408B pin E7 D408C pin 2 D4030J pin 23 airplane ground 10 Ohms or less

D408B pin E6 D408C pin 2 D4030J pin 9 airplane ground 10 Ohms or less

D408B pin B6 D408C pin 2 D4030J pin 27 airplane ground 10 Ohms or less

D408B pin B5 D408C pin 2 D4030J pin 13 airplane ground 10 Ohms or less

APPENDIX A: APU WIRING TEST PROCEDURE

(SHEET 3 OF 5)

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ALERT ALERT
Multimeter Probes Jumper Wire Resistance

D408B pin A11 D408C pin 2 D4030J pin 26 airplane ground 10 Ohms or less

D408B pin A10 D408C pin 2 D4030J pin 12 airplane ground 10 Ohms or less

D408B pin A9 D408C pin 2 D4030J pin 25 airplane ground 10 Ohms or less

D408B pin A8 D408C pin 2 D4030J pin 11 airplane ground 10 Ohms or less

D408B pin A7 D408C pin 2 D4030J pin 24 airplane ground 10 Ohms or less

D408B pin A6 D408C pin 2 D4030J pin 10 airplane ground 10 Ohms or less

D408B pin B10 D408C pin 2 D4030J pin 9 airplane ground 10 Ohms or less

D408B pin G7 D408C pin 2 D4030J pin 8 airplane ground 10 Ohms or less

D408B pin G6 D408C pin 2 D4030J pin 7 airplane ground 10 Ohms or less

D408B pin G9 D408C pin 2 D4030J pin 4 airplane ground 10 Ohms or less

D408B pin G8 D408C pin 2 D4030J pin 3 airplane ground 10 Ohms or less

D408B pin F11 D408C pin 2 D4030J pin 5 airplane ground 10 Ohms or less

D408B pin F8 D408C pin 2 D4030J pin 6 airplane ground 10 Ohms or less

D408B pin F9 D408C pin 2 D4030J pin 14 airplane ground 10 Ohms or less

D408B pin F10 D408C pin 2 D4030J pin 15 airplane ground 10 Ohms or less

D408B pin H11 D408C pin 2 D4030J pin 2 airplane ground 10 Ohms or less

D408B pin H10 D408C pin 2 D4030J pin 1 airplane ground 10 Ohms or less

D408B pin C9 D408C pin 2 D4030J pin 38 airplane ground 10 Ohms or less

D408B pin C8 D408C pin 2 D4030J pin 37 airplane ground 10 Ohms or less

D408B pin B4 D408C pin 2 D4030J pin 17 airplane ground 10 Ohms or less

D408B pin B3 D408C pin 2 D4030J pin 16 airplane ground 10 Ohms or less

D408B pin A4 D408C pin 2 D4030J pin 35 airplane ground 10 Ohms or less

D408B pin A3 D408C pin 2 D4030J pin 18 airplane ground 10 Ohms or less

D408B pin A2 D408C pin 2 D4030J pin 32 airplane ground 10 Ohms or less

D408B pin A1 D408C pin 2 D4030J pin 34 airplane ground 10 Ohms or less

D408B pin J5 D408C pin 2 D4030J pin 6 airplane ground 10 Ohms or less

D408B pin J4 D408C pin 2 D4030J pin 5 airplane ground 10 Ohms or less

D408B pinD11 D408C pin 2 D4030J pin 16 airplane ground 10 Ohms or less

D408B pin F7 D408C pin 2 D4030J pin 8 airplane ground 10 Ohms or less

D408B pin F6 D408C pin 2 D4030J pin 7 airplane ground 10 Ohms or less

D408B pin E5 D408C pin 2 D4030J pin 12 airplane ground 10 Ohms or less

APPENDIX A: APU WIRING TEST PROCEDURE

(SHEET 4 OF 5)

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ALERT ALERT
Multimeter Probes Jumper Wire Resistance

D408B pin E4 D408C pin 2 D4030J pin 11 airplane ground 10 Ohms or less

D408B pin C5 D408C pin 2 D4030J pin 3 airplane ground 10 Ohms or less

D408B pin J8 D408C pin 2 D4030J pin 2 airplane ground 10 Ohms or less

D408B pin J7 D408C pin 2 D4030J pin 1 airplane ground 10 Ohms or less

D408B pin J10 D408C pin 2 D4030J pin 13 airplane ground 10 Ohms or less

D408C pin 6 D408C pin 2 D4030J pin 20 airplane ground 10 Ohms or less

D408C pin 4 D408C pin 2 D4030J pin 19 airplane ground 10 Ohms or less

D4024J pin 17 airplane ground - - 10 Ohms or less

D4024J pin 4 airplane ground - - 10 Ohms or less

D6396P pin 26 airplane ground D502 pin 10 airplane ground 10 Ohms or less

D6396P pin 24 airplane ground D502 pin 1 airplane ground 10 Ohms or less

D6396P pin 21 airplane ground D502 pin 5 airplane ground 10 Ohms or less

D6396P pin 23 airplane ground D502 pin 7 airplane ground 10 Ohms or less

D6396P pin 8 airplane ground D502 pin 24 airplane ground 10 Ohms or less

D6396P pin 27 airplane ground D502 pin 2 airplane ground 10 Ohms or less

D6396P pin 28 airplane ground S506 pin B airplane ground 10 Ohms or less

K117 pin A1 airplane ground D4138J pin A D4138J pin C 10 Ohms or less

K117 pin A1 airplane ground D4138J pin A D4138J pin D 10 Ohms or less

AIRPLANES WITH OIL QUANTITY SWITCH:

Multimeter Probes Jumper Wire Resistance

D4040J pin 12 airplane ground D4024J pin 14 airplane ground 10 Ohms or less

AIRPLANES WITH OIL LEVEL INDICATION:

Multimeter Probes Jumper Wire Resistance

D6424J pin 1 airplane ground D4024J pin 21 airplane ground 10 Ohms or less

D6424J pin 2 airplane ground D4024J pin 22 airplane ground 10 Ohms or less

D6424J pin 3 airplane ground D4024J pin 23 airplane ground 10 Ohms or less

23. Restore all systems to their normal configuration.

APPENDIX A: APU WIRING TEST PROCEDURE

(SHEET 5 OF 5)

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ALERT ALERT
NOTE:

1. Make alignment pins from case-hardened AISI 1144 or equivalent steel.

2. The pin segment of the alignment pin should have a 100 microinch or better surface finish.

The handle should have a 250 microinch or better surface finish. Boeing recommends that

pins have a black oxide penetrant finish or equivalent.

3. The alignment pins are not intended to be used for lifting.

4. These alignment pins are similar to Boeing tools UT-7039-7, UT-7039-38, and UT-7039-39.

APPENDIX B: ALIGNMENT PINS

(SHEET 1 OF 1)

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ALERT ALERT
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary

source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source

for tasks required for compliance.

1. The table below gives the description for the parts and conditions called out in the logic diagrams.

Title Description

PART 2 AFT PRESSURE BULKHEAD REPLACEMENT

APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: REPLACEMENT OF

THE STA 1582 AFT PRESSURE BULKHEAD

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ALERT ALERT
APPENDIX D: PART DEMAND INTENT

(SHEET 1 OF 1)

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ALERT ALERT