### Commercial **Airplanes** 

# 777 Service Bulletin **SPECIAL ATTENTION Number: 777-25-0482**  Original Issue: February 24, 2011 ATA System: 2521 **SUBJECT:** EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel - Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support Structure Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 1 of 59 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 2 of 59 **BOEING SERVICE BULLETIN 777-25-0482**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1. Existing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2. Data supplied with this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 14 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 21 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 23 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL. . . . . . . . . . 28 FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION. . . . . . . 31 FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 1]. . . . . . . . . 38 FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 2]. . . . . . . . . 41 FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL. . . . . . . . . 44 FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION. . . . . . . 47 FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 1]. . . . . . . . . 54 FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 2]. . . . . . . . . 57

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 3 of 59 **BOEING SERVICE BULLETIN 777-25-0482**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 4 of 59 **BOEING SERVICE BULLETIN 777-25-0482**

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### Commercial **Airplanes** 

# 777 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 777-25-0482** Original Issue: February 24, 2011 ATA System: 2521 **SUBJECT:** EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel - Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support Structure BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** This service bulletin provides instructions and a kit of parts to strengthen the structure which supports the forward lowered ceiling panels for some 777 model airplanes. If you do not do this service bulletin and a 9G forward load condition occurs, the forward lowered ceiling panels and support structure could become dislodged and injure personnel or interfere with emergency evacuation. The possibility of a 9G forward load when landing is small. No operator has reported dislodged ceiling panels from such a load. The support structure was found to be under strength during the design review of a new section 41 lowered ceiling configuration. Only airplanes incorporating the Overhead Space Utilization (OSU) option would have under strength structure. The OSU option includes overhead stowage boxes in the ceiling inboard of left and right door 1. The under strength area supports lowered ceiling panels immediately aft of these overhead stowage boxes. This service bulletin provides for increasing strength by installing thicker structure and an additional load path on each side. Boeing Service Related Problem (SRP) 777-SRP-25-0289 is related to this service bulletin. This SRP is described in Fleet Team Digest Article 777 FTD 25-09010. **ACTION (PRR 62224)** Expose the support structure for the lowered ceiling panels in section 41. Disconnect a tie rod and remove two C-channels and related brackets from both left and right side ceiling panel support structure. Install new support channel assemblies composed of C-channels having thicker cross sections. The new assemblies also include fittings for attaching two tie rods in place of fittings for attaching one tie rod. Add a new load path on each side by adding new fittings to the rails above the changed structure and adding new tie rods between the fittings on new support structure and the new fittings on the rails above. Reconnect the existing tie rods. Forward interior cabin equipment must be removed for access to remove lowered ceiling panels.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 5 of 59**EFFECTIVITY** 777-200, -200LR and -300ER airplanes incorporating Overhead Space Utilization (OSU) option. 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. Boeing recommends that the changes given in this service bulletin be done within 5 years after the original issue date of this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of January 16, 2008. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  10.00 (a) 18.50 (a) All (a) Manpower estimates for access and restoring access are not included in this manpower estimate.
**MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 6 of 59 **BOEING SERVICE BULLETIN 777-25-0482**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 7 of 59 **BOEING SERVICE BULLETIN 777-25-0482**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 8 of 59 **BOEING SERVICE BULLETIN 777-25-0482**

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### Commercial **Airplanes** 

# 777 Service Bulletin **SPECIAL ATTENTION Number: 777-25-0482**  Original Issue: February 24, 2011 ATA System: 2521 **SUBJECT:** EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel - Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support Structure BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 62224 for data about this change.
**DESCRIPTION CONFIGURATION**  **GROUP** 777-200 and 777-300ER Airplanes with Overhead Space Utilization (OSU) Option and line number from 423 through 494. - 1
777-200, 777-200LR, and 777-300ER Airplanes with Overhead Space Utilization (OSU) Option and line number from 497 through 751. - 2

Airplane Models: 777-200, 777-200LR, 777-300ER **Group Variable Number**  2 WC221 - WC222 1 WC301 - WC306 2 WC307 - WC308 1 WC381 - WC388 2 WC389 - WC395

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 9 of 59**Group Variable Number**  2 WC486 - WC493 2 WC506 - WC508 2 WC531 - WC536 2 WC546 - WC548 2 WC556 2 WC566 - WC567 2 WD001 - WD002 2 WD011 - WD015 2 WD031 - WD036 2 WD066 - WD067 1 WD501 - WD502 2 WD503 - WD510 1 WD521 - WD526 2 WD527 - WD539 2 WD546 - WD552 1 WD561 2 WD562 - WD573 2 WD581 - WD591 2 WD606 - WD609 2 WD621 - WD632 2 WD651 - WD661 2 WD671 - WD675 2 WD741 - WD750 2 WD761 - WD770 2 WD786 - WD788 2 WD796 - WD804 2 WD826 - WD830 2 WD871 - WD875 2 WD911 - WD912 2 WD936 - WD939 2 WD966

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 10 of 59 **BOEING SERVICE BULLETIN 777-25-0482**2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** This service bulletin provides instructions and a kit of parts to strengthen the structure which supports the forward lowered ceiling panels for some 777 model airplanes. If you do not do this service bulletin and a 9G forward load condition occurs, the forward lowered ceiling panels and support structure could become dislodged and injure personnel or interfere with emergency evacuation. The possibility of a 9G forward load when landing is small. No operator has reported dislodged ceiling panels from such a load. The support structure was found to be under strength during the design review of a new section 41 lowered ceiling configuration. Only airplanes incorporating the Overhead Space Utilization (OSU) option would have under strength structure. The OSU option includes overhead stowage boxes in the ceiling inboard of left and right door 1. The under strength area supports lowered ceiling panels immediately aft of these overhead stowage boxes. This service bulletin provides for increasing strength by installing thicker structure and an additional load path on each side. Boeing Service Related Problem (SRP) 777-SRP-25-0289 is related to this service bulletin. This SRP is described in Fleet Team Digest Article 777-FTD-25-09010. **D. Description** Expose the support structure for the lowered ceiling panels in section 41. Disconnect a tie rod and remove two C-channels and related brackets from both left and right side ceiling panel support structure. Install new support channel assemblies composed of C-channels having thicker cross sections. The new assemblies also include fittings for attaching two tie rods in place of fittings for attaching one tie rod. Add a new load path on each side by adding new fittings to the rails above the changed structure and adding new tie rods between the fittings on new support structure and the new fittings on the rails above. Reconnect the existing tie rods. Forward interior cabin equipment must be removed for access to remove lowered ceiling panels. Airplanes are divided into two groups because of a difference in the width of the new tie rod fitting and the lattice rail to which the fitting is attached. The work is the same for both groups. The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 221, 222, 223, 224 777-200, 777-300ER

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 11 of 59 **BOEING SERVICE BULLETIN 777-25-0482 Group 2:** 
**Affected Maintenance Zones Zone**  **Model** 221, 222, 223, 224 777-200, 777-200LR, 777- 300ER **E. 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. Boeing recommends that the changes given in this service bulletin be done within 5 years after the original issue date of this service bulletin. **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. **G. Manpower** The table below shows an estimate of the task hours necessary to do this change for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **Group 1: Elapsed Hours**  **Task Hours Number of Persons**  **Task** (a) (a) (a) Open Access 1.25 2.50 2 Figure 1 3.00 6.00 2 Figure 2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 12 of 59 **BOEING SERVICE BULLETIN 777-25-0482 Group 1:**  **Elapsed Hours Task Hours**  **Number of Persons Task**  0.75 0.75 1 Figure 3 1.25 2.50 2 Figure 5 3.00 6.00 2 Figure 6 0.75 0.75 1 Figure 7 (a) (a) (a) Close Access 10.00 (a) 18.50 (a) TOTAL FOR EACH AIRPLANE (a) Manpower estimates for access and restoring access are not included in this manpower estimate. **Group 2: Elapsed Hours**  **Task Hours Number of Persons**  **Task** (a) (a) (a) Open Access 1.25 2.50 2 Figure 1 3.00 6.00 2 Figure 2 0.75 0.75 1 Figure 4 1.25 2.50 2 Figure 5 3.00 6.00 2 Figure 6 0.75 0.75 1 Figure 8 (a) (a) (a) Close Access 10.00 (a) 18.50 (a) TOTAL FOR EACH AIRPLANE (a) Manpower estimates for access and restoring access are not included in this manpower estimate. **H. Weight and Balance Changes Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane**  +2053.3 +5.3 777-200 +940.2 +5.3 777-300
**I. Electrical Load Data** Not changed.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 13 of 59 **BOEING SERVICE BULLETIN 777-25-0482 J. References**  1. Existing Data a. Engineering Change Memo PRR 62224 b. 777-200 Structural Repair Manual (SRM) 51-20-01, 51-20-10, 51-40-02, 51-40-03, 51-40-04, 51-40-08 c. 777-300 Structural Repair Manual (SRM) 51-20-01, 51-20-10, 51-40-02, 51-40-03, 51-40-04, 51-40-08 d. Boeing Document D-590 e. Boeing Drawing 012W6100 f. Service Related Problem (SRP) 777-SRP-25-0289 g. Fleet Team Digest Article (FTD) 777 FTD 25-09010 2. Data supplied with this Service Bulletin None. 3. Installation Drawings Used in the Preparation of this Service Bulletin
**Title Drawing Number**  TIE ROD INSTL-LOWERED CEILING 413W1200 SUPPORT STRUCTURE INSTL - LOWERED CEILING, DOOR 1 413W1201 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: **Chapter-Section**

**Publication** 53-13 777 Illustrated Parts Catalog 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 14 of 59 **BOEING SERVICE BULLETIN 777-25-0482 L. Interchangeability and Intermixability of Parts**  Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 15 of 59 **BOEING SERVICE BULLETIN 777-25-0482**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 16 of 59 **BOEING SERVICE BULLETIN 777-25-0482**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Refer to 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 **Group 1: Unit Price as of**  **the original issue date of this Ser**  **vice Bulletin (US Dollars)**  **ROLT as of the original issue**  **date date of this Service Bulletin**  **(Calendar Days) Name**  **Kit Number**

$13,329.00 514 TOP KIT - REWORK OF OSU TYPE SECTION 41 LOWERED CEILING SUPPORT STRUCTURE, GROUP 1 005W3441-1

**Group 2: Unit Price as of**  **the original issue date of this Ser**  **vice Bulletin (US Dollars)**  **ROLT as of the original issue**  **date date of this Service Bulletin**  **(Calendar Days) Name**  **Kit Number**

$13,329.00 514 TOP KIT - REWORK OF OSU TYPE SECTION 41 LOWERED CEILING SUPPORT STRUCTURE, GROUP 2 005W3441-2

**B. Industry Support Information** Boeing warranty remedies are available for 777 airplanes in warranty as of January 16, 2008. For task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. **C. Parts Necessary For Each Airplane** 1. Kits/Parts To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 17 of 59 **BOEING SERVICE BULLETIN 777-25-0482 NOTE:** One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. The Top Kit is divided into Figure kits for each installation figure shown in the table below. **Figure Kit 8**  **7 6**  **4 3**  **2 Top Kit** 

- 1 1
- 1 1 005W3441-1 1
- 1 1
- 1 005W3441-2 **Group 1:**
**KIT 005W3441-1**

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

**New Part Number 7**  **6 3**  **2 QTY**  (a),(b) 413W1221-105B AND 413W1221- 113B AND 413W1221-35B AND 413W1221-7 SUPPORTSTRUCTURE ASSY - LOWERED CEILING, SECT 41 1 413W1210-105B

(a),(b) 413W1221-106B AND 413W1221- 113B AND 413W1221-35 AND 413W1221-7 SUPPORTSTRUCTURE ASSY - LOWERED CEILING, SECT 41 1 413W1210-106B

(a),(b) 413W1221-55B GUSSET 2 2 413W1221-246B (a),(b) 413W1221-31B GUSSET 1 1 413W1221-269B (a),(b) 413W1221-33B GUSSET 1 1 413W1221-270B (a),(b) 413W1221-35B ANGLE 1 1 413W1221-271B (a),(b) 413W1221-60B CORNER BRACK- ET 1 1 413W1221-272B (a),(b) 413W1221-60B CORNER BRACK- ET 1 1 413W1221-273B
MISCELLANEOUS - MACHINE PART 1 1 422W2165-111
TIE ROD ASSY 1 1 777081-178 BUSHING 2 2 BACB28AK04-024 BUSHING 1 1 BACB28AK04-038 (c) BOLT 2 2 BACB30NR4K15 (c) BOLT, HEX HEAD 1 1 BACB30NR4K17

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 18 of 59 **BOEING SERVICE BULLETIN 777-25-0482 Group 1:** 
**KIT 005W3441-1**

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

**New Part Number 7**  **6 3**  **2 QTY**  (c) BOLT, PROTRUD- ING HD 8 8 BACB30NX5HK3 (c) BOLT 4 4 BACB30VF3K6 (c) BOLT, 100 DEG HEX DR 12 12 BACB30YP5K4 COLLAR, PRELOAD 10 10 BACC30BH5 COLLAR, SHEAR 12 12 BACC30BL5 NUT 3 3 BACN10YR4CD (c) RIVET 5 5 BACR15BB4D6C (c) RIVET, UNIVER- SAL HD 13 12 BACR15FT5D6C (c) RIVET, UNIVER- SAL HD 10 10 BACR15FT5D7C (c) RIVET 5 5 BACR15GF4D6 SHIM, LAMINATED 1 1 BACS40R009D024F
WASHER 3 3 BACW10BP4CD WASHER 3 3 BACW10BP4DP (a) Discard the existing part. (b) You cannot use the existing part to replace the new or changed part. (c) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 19 of 59 **BOEING SERVICE BULLETIN 777-25-0482 Group 2:** 
**KIT 005W3441-2**

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

**New Part Number 8**  **6 4**  **2 QTY**  (a), (b) 413W1221-105B AND 413W1221- 113B AND 413W1221-35 AND 413W1221-7 SUPPORTSTRUCTURE ASSY - LOWERED CEILING, SECT 41 1 413W1210-105B

(a), (b) 413W1221-106B AND 413W1221- 113B AND 413W1221-35 AND 413W1221-7 SUPPORTSTRUCTURE ASSY - LOWERED CEILING, SECT 41 1 413W1210-106B

(a), (b) 413W1221-55B GUSSET 2 2 413W1221-246B (a), (b) 413W1221-31B GUSSET 1 1 413W1221-269B (a), (b) 413W1221-33B GUSSET 1 1 413W1221-270B (a), (b) 413W1221-35B ANGLE 1 1 413W1221-271B (a), (b) 413W1221-60B CORNER BRACK- ET 1 1 413W1221-272B (a), (b) CORNER BRACK- ET 1 1 413W1221-273B
MISCELLANEOUS - MACHINE PART 1 1 422W2165-108
TIE ROD ASSY 1 1 777081-178 BUSHING 2 2 BACB28AK04-024 BUSHING 1 1 BACB28AK04-038 (c) BOLT 2 2 BACB30NR4K15 (c) BOLT, HEX HEAD 1 1 BACB30NR4K17 (c) BOLT, PROTRUD- ING HD 8 8 BACB30NX5HK3 (c) BOLT 4 4 BACB30VF3K6 (c) BOLT, 100 DEG HEX DR 12 12 BACB30YP5K4 (c) COLLAR, PRELOAD 10 10 BACC30BH5 COLLAR, SHEAR 12 12 BACC30BL5 NUT 3 3 BACN10YR4CD

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 20 of 59 **BOEING SERVICE BULLETIN 777-25-0482 Group 2:** 
**KIT 005W3441-2**

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

**New Part Number 8**  **6 4**  **2 QTY**  (c) RIVET 5 5 BACR15BB4D6C (c) RIVET, UNIVER- SAL HD 13 12 BACR15FT5D6C (c) RIVET, UNIVER- SAL HD 10 10 BACR15FT5D7C (c) RIVET 5 5 BACR15GF4D6 SHIM, LAMINATED 1 1 BACS40R009D024F
WASHER 3 3 BACW10BP4CD WASHER 3 3 BACW10BP4DP (a) Discard the existing part. (b) You cannot use the existing part to replace the new or changed part. (c) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. 2. Parts and Materials Supplied by the Operator
**Notes Name**  **QTY Part Number /**  **Specification** (a) Primer 2 oz BMS 10-11, Type I (a) Paint 2 oz BMS 10-83, Type III Enamel, Boeing Color 8328 (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced **NOTE:**Parts below are not replaced individually but are replaced by a part of an assembly as explained in the Notes column.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 21 of 59 **BOEING SERVICE BULLETIN 777-25-0482 Notes**  **QTY Name**  **Existing Part Number** 413W1221- 245B (a) 1 Member 413W1221-105B
413W1221- 267B (a) , (b) 2 Member 413W1221-113B
413W1221-33 (a) , (b) , 413W1221-270 (c) , (d) 4 Gusset 413W1221-33

413W1221-35 (a) , (b) , 413W1221-271 (c) , (d) 4 Angle 413W1221-35

413W1221-269 (a) , (b) 2 Fitting Assy 413W1224-7
413W1221-269 (a) , (d) 2 Gusset 413W1221-31
413W1221-246 (c) , (d) 4 Gusset 413W1221-55 qty (2) 413W1221-273 and qty (2) 413W1221-272 (c) , (d) 4 Angle 413W1221-60

413W1221- 268B (b) 1 Member 413W1221-106B (a) Part of Support Structure Assy 413W1210-105B (b) Part of Support Structure Assy 413W1210-106B (c) Part in installation of Support Structure Assy 413W1210-105B (d) Part in installation of Support Structure Assy 413W1210-106B **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 22 of 59 **BOEING SERVICE BULLETIN 777-25-0482 F. Special Tooling Necessary to do this Service Bulletin**  No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. Operators may choose to fabricate locating templates. Refer to FIGURE 2, Step 1, and to FIGURE 6, Step 1, for information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 23 of 59 **BOEING SERVICE BULLETIN 777-25-0482**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 24 of 59 **BOEING SERVICE BULLETIN 777-25-0482**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:**KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:**1. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are in 777-200 SRM 51-40-02 or 777-300 SRM 51-40-02. – Finish protection requirements are in 777-200 SRM 51-20-01 or 777-300 SRM 51-20-01 – Torque limits to tighten nuts and bolts are in 777-200 SRM 51-40-04 or 777-300 SRM 51-40-04. 5. Use the approved fastener and process material substitutions in accordance with 777-200 SRM 51-40-02 or 777-300 SRM 51-40-02. Alternate fasteners are listed in 777-200 SRM 51-40-03 or 777-300 SRM 51-40-03 and Boeing Drawing 012W6100. Countersink information is included in 777-200 SRM 51-40-08 or 777-300 SRM 51-40-08.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 25 of 59 **BOEING SERVICE BULLETIN 777-25-0482**6. If the length of any fastener specified in this service bulletin does not meet the installation standards in 777-200 SRM 51-40-02 or 777-300 SRM 51-40-02, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in 777-200 SRM 51-40-02 or 777-300 SRM 51-40-02 may be used. 7. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS** 1. Removals required for access are extensive and vary among airplane configurations. Equipment between door one left and right such as galleys, lavatories, closets, partitions, overhead stowage boxes, vestibules, and lowered ceiling panels may have to be removed. Therefore, access is not specified in this service bulletin. When the support structure for forward lowered ceiling panels is exposed, proceed as follows. 2. Remove specific left side lowered ceiling support structure members in accordance with FIGURE 1. 3. Install new left side lowered ceiling support structure members in accordance with FIGURE 2. 4. Install new left side tie rod attach fitting and tie rods on:

a. **Group 1:** In accordance with FIGURE 3. b. **Group 2:** In accordance with FIGURE 4. 5. Remove specific right side lowered ceiling support structure members in accordance with FIGURE 5. 6. Install new right side lowered ceiling support structure members in accordance with FIGURE 6. 7. Install new right side tie rod attach fitting and tie rods on:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 26 of 59 **BOEING SERVICE BULLETIN 777-25-0482**a. **Group 1:** In accordance with FIGURE 7. b. **Group 2:** In accordance with FIGURE 8. 8. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 27 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 28 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 29 of 59 **BOEING SERVICE BULLETIN 777-25-0482**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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Disconnect at lower end. Leave upper end attached. Rotate tie rod up and out ofwork area and secure it temporarily. 1 777084-181 Tie Rod Disconnect 1

1 BACB30NR4K14 Bolt Remove 2 NAS1149D0432J Washer Remove 1 BACB28Y4C024 Bushing Remove 1 BACN10YR4CD Nut Remove 13 BACR15FT5D*C Rivet Remove 2 2 BACR15GF4D* Rivet Remove 3 4 BACB30NX5HK3 Bolt Remove 4 4 BACC30BH5 Collar Remove Remove the following parts as an assembly: 1
- SUPPORT STRUC- TURE ASSY Remove 5

1 413W1221-105B Member Remove 1 413W1221-113B Member Remove 2 413W1221-33 Gusset Remove 2 413W1221-35 Angle Remove 1 413W1224-7 Fitting Assy Remove 1 413W1221-31 Gusset Remove 2 413W1221-55 Gusset Remove 2 413W1221-60 Angle Remove (a)

- - Structure Inspect 6 (a) Do a general visual inspection of the existing structure in the area of rework. Remove nicks, scratches,gouges and/or minor corrosion, and protect all exposed aluminum in and around the repair areas in accordance with 777-200 SRM 51-20-01 or 777-300 SRM 51-20-01 as applicable.

**FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 30 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION**  **(SHEET 1 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 31 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION**  **(SHEET 2 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 32 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION**  **(SHEET 3 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 33 of 59 **BOEING SERVICE BULLETIN 777-25-0482**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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Use existing ceiling panel as locatingtemplate (or fabricate similar rigid template). Make sure that ceilingpanel can be installed and that tie rods align with new Support StructureAssy before attaching gussets and angles. 1 413W1210-105B SUPPORT STRUC-TURE ASSY - LOWERED CEILING, SECT 41 Install (New) 1

2 413W1221-246B GUSSET Install (New) 2 Use existing holes in rail. Drill new holes in gusset. 4 BACR15FT5D6C RIVET, UNIVERSAL HD Install (New)

Use pilot holes in Step 2 gusset. Drill new holes in Step 1 Support Structure Assy. 4 BACR15FT5D7C RIVET, UNIVERSAL HD Install (New) 3

1 413W1221-269B GUSSET Install (New) 4 Use existing holes in rail. Drill new holes in gusset. 3 BACR15FT5D6C RIVET, UNIVERSAL HD Install (New)

Use pilot holes in Step 4 gusset. Drill new holes in Step 1 Support Structure Assy. 2 BACR15FT5D6C RIVET, UNIVERSAL HD Install (New) 5

1
- Ceiling Panel or Tem- plate Remove 6

**FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 4 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 34 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 413W1221-270B GUSSET Install (New) 7 Use shim if required between new gussetand existing rail. Remove 0.003 thicklaminations as necessary. A gap of0.005 max is permitted between rail andgusset before fastener installation. 1 BACS40R009D024F SHIM, LAMINATED Install (New)

Use existing holes in rail. Drill new holes in gusset and shim.Install with countersunk head on ceiling panel side of rail. 2 BACR15GF4D6 RIVET Install (New)

Use pilot holes in Step 7 gusset. Drill new holes in Step 1 Support Structure Assy. Install with countersunk head on ceiling panel side of rail. 2 BACR15GF4D6 RIVET Install (New) 8

1 413W1221-271B ANGLE Install (New) 9 Use existing holes inrail. Drill holes in angle. 4 BACR15FT5D7C RIVET, UNIVERSAL HD Install (New)

Use pilot holes in Step 9 angle. Drillholes in Step 1 Support Structure Assy. 4 BACR15BB4D6C RIVET Install (New) 10

1 413W1221-272B CORNER BRACKET Install (New) 11 Use existing hole in rail. Drill new hole 0.161 - 0.164 in. dia. in bracket. Install with head on bracket side. (a) 1 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New)

Collar on rail side. 1 BACC30BH5 COLLAR, PRELOAD Install (New)

**FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 5 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 35 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Use pilots in Step 11 bracket. Drill holes 0.161 - 0.164 in. dia. in rail. Install with head on bracket side. 3 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New) 12

Collar on rail side. 3 BACC30BH5 COLLAR, PRELOAD Install (New) Use pilots in Step 11 bracket. Drill holes 0.161 - 0.164 in. dia.in rail or Step 1 Support Structure Assy.Install with countersunk head on rail or Support Structure Assy side. 6 BACB30YP5K4 BOLT, 100 DEG HEX DR Install (New) 13

Collar on bracket side. 6 BACC30BL5 COLLAR, SHEAR Install (New)

1 413W1221-273B CORNER BRACKET Install (New) 14 Use existing hole in rail. Drill new hole 0.161 - 0.164 in. dia. in bracket. Install with head on bracket side. (a) 1 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New)

Collar on rail side. 1 BACC30BH5 COLLAR, PRELOAD Install (New) Use pilots in Step 14 bracket. Drill holes 0.161 - 0.164 in. dia. in rail. Install with head on bracket side. 3 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New) 15

Collar on rail side. 3 BACC30BH5 COLLAR, PRELOAD Install (New)

**FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 6 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 36 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Use pilots in Step 14 bracket. Drill holes 0.161 - 0.164 in. dia.in rail or Step 1 Support Structure Assy.Install with countersunk head on rail or Support Structure Assy side. 6 BACB30YP5K4 BOLT, 100 DEG HEX DR Install (New) 16

Collar on bracket side. 6 BACC30BL5 COLLAR, SHEAR Install (New) (a) Remaining open holes are acceptable. The parts shown in the table below are provided as extra parts for this figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  2 BACC30BH5 COLLAR, PRELOAD 1 BACR15BB4D6C RIVET 3 BACR15FT5D6C RIVET, UNIVERSAL HD 2 BACR15FT5D7C RIVET, UNIVERSAL HD 1 BACR15GF4D6 RIVET

**FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 7 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 37 of 59 **BOEING SERVICE BULLETIN 777-25-0482 This Figure applies only to: Group 1.** 

**FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 38 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 39 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 777084-181 Tie Rod Install (Kept) 1 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side 1 BACB28AK04-024 BUSHING Install (New) Far side 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Maximum gap allowed between partand rail before fastener installation is .003 in. Install shimif required in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51- 20-10. 1 422W2165-111 MISCELLANEOUS - MACHINE PART Install (New) 2

Install 2 near side, 2 far side. 4 BACB30VF3K6 BOLT Install (New)

1 777081-178 TIE ROD ASSY Install (New) 3 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-024 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Near side. 1 BACB30NR4K17 BOLT, HEX HEAD Install (New) 4 Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-038 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New)

**FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 40 of 59 **BOEING SERVICE BULLETIN 777-25-0482 This Figure applies only to: Group 2.** 

**FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 41 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 42 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 777084-181 Tie Rod Install (Kept) 1 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side 1 BACB28AK04-024 BUSHING Install (New) Far side 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Maximum gap allowed between partand rail before fastener installation is .003 in. Install shimif required in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51- 20-10. 1 422W2165-108 MISCELLANEOUS - MACHINE PART Install (New) 2

Install 2 near side, 2 far side. 4 BACB30VF3K6 BOLT Install (New)

1 777081-178 TIE ROD ASSY Install (New) 3 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-024 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Near side. 1 BACB30NR4K17 BOLT, HEX HEAD Install (New) 4 Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-038 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New)

**FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 43 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 44 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 45 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Disconnect at lower end. Leave upper end attached. Rotate tie rod up and out ofwork area and secure it temporarily. 1 777084-181 Tie Rod Disconnect 1

1 BACB30NR4K14 Bolt Remove 2 NAS1149D0432J Washer Remove 1 BACB28Y4C024 Bushing Remove 1 BACN10YR4CD Nut Remove 13 BACR15FT5D*C Rivet Remove 2 2 BACR15GF4D* Rivet Remove 3 4 BACB30NX5HK3 Bolt Remove 4 4 BACC30BH5 Collar Remove Remove the following parts as an assembly: 1
- SUPPORT STRUC- TURE ASSY Remove 5

1 413W1221-106B Member Remove 1 413W1221-113B Member Remove 2 413W1221-33 Gusset Remove 2 413W1221-35 Angle Remove 1 413W1224-7 Fitting Assy Remove 1 413W1221-31 Gusset Remove 2 413W1221-55 Gusset Remove 2 413W1221-60 Angle Remove (a)

- - Structure Inspect 6 (a) Do a general visual inspection of the existing structure in the area of rework. Remove nicks, scratches,gouges and/or minor corrosion, and protect all exposed aluminum in and around the repair areas in accordance with 777-200 SRM 51-20-01 or 777-300 SRM 51-20-01 as applicable.

**FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 46 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION**  **(SHEET 1 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 47 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION**  **(SHEET 2 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 48 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION**  **(SHEET 3 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 49 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Use existing ceiling panel as locatingtemplate (or fabricate similar rigid template). Make sure that ceilingpanel can be installed and that tie rods align with new Support StructureAssy before attaching gussets and angles. 1 413W1210-106B SUPPORT STRUC-TURE ASSY - LOWERED CEILING, SECT 41 Install (New) 1

2 413W1221-246B GUSSET Install (New) 2 Use existing holes in rail. Drill new holes in gusset. 4 BACR15FT5D6C RIVET, UNIVERSAL HD Install (New)

Use pilot holes in Step 2 gusset. Drill new holes in Step 1 Support Structure Assy. 4 BACR15FT5D7C RIVET, UNIVERSAL HD Install (New) 3

1 413W1221-269B GUSSET Install (New) 4 Use existing holes in rail. Drill new holes in gusset. 3 BACR15FT5D6C RIVET, UNIVERSAL HD Install (New)

Use pilot holes in Step 4 gusset. Drill new holes in Step 1 Support Structure Assy. 2 BACR15FT5D6C RIVET, UNIVERSAL HD Install (New) 5

No longer required after upper gussets have been installed. 1
- Ceiling Panel or Tem- plate Remove 6

**FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 4 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 50 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 413W1221-270B GUSSET Install (New) 7 Use shim if required between new gussetand existing rail. Remove 0.003 thicklaminations as necessary. A gap of0.005 max is permitted between rail andgusset before fastener installation. 1 BACS40R009D024F SHIM, LAMINATED Install (New)

Use existing holes in rail. Drill new holes in gusset and shim.Install with countersunk head on ceiling panel side of rail. 2 BACR15GF4D6 RIVET Install (New)

Use pilot holes in Step 7 gusset. Drill new holes in Step 1 Support Structure Assy. Install with countersunk head on ceiling panel side of rail. 2 BACR15GF4D6 RIVET Install (New) 8

1 413W1221-271B ANGLE Install (New) 9 Use existing holes inrail. Drill holes in angle. 4 BACR15FT5D7C RIVET, UNIVERSAL HD Install (New)

Use pilot holes in Step 9 angle. Drillholes in Step 1 Support Structure Assy. 4 BACR15BB4D6C RIVET Install (New) 10

1 413W1221-272B CORNER BRACKET Install (New) 11 Use existing hole in rail. Drill new hole 0.161 - 0.164 in. dia. in bracket. Install with head on bracket side. (a) 1 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New)

Collar on rail side. 1 BACC30BH5 COLLAR, PRELOAD Install (New)

**FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 5 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 51 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Use pilots in Step 11 bracket. Drill holes 0.161 - 0.164 in. dia. in rail. Install with head on bracket side. 3 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New) 12

Collar on rail side. 3 BACC30BH5 COLLAR, PRELOAD Install (New) Use pilots in Step 11 bracket. Drill holes 0.161 - 0.164 in. dia.in rail or Step 1 Support Structure Assy.Install with countersunk head on rail or Support Structure Assy side. 6 BACB30YP5K4 BOLT, 100 DEG HEX DR Install (New) 13

Collar on bracket side. 6 BACC30BL5 COLLAR, SHEAR Install (New)

1 413W1221-273B CORNER BRACKET Install (New) 14 Use existing hole in rail. Drill new hole 0.161 - 0.164 in. dia. in bracket. Install with head on bracket side. (a) 1 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New)

Collar on rail side. 1 BACC30BH5 COLLAR, PRELOAD Install (New) Use pilots in Step 14 bracket. Drill holes 0.161 - 0.164 in. dia. in rail. Install with head on bracket side. 3 BACB30NX5HK3 BOLT, PROTRUDING HD Install (New) 15

Collar on rail side. 3 BACC30BH5 COLLAR, PRELOAD Install (New)

**FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 6 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 52 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Use pilots in Step 14 bracket. Drill holes 0.161 - 0.164 in. dia.in rail or Step 1 Support Structure Assy.Install with countersunk head on rail or Support Structure Assy side. 6 BACB30YP5K4 BOLT, 100 DEG HEX DR Install (New) 16

Collar on bracket side. 6 BACC30BL5 COLLAR, SHEAR Install (New) (a) Remaining open holes are acceptable. The parts shown in the table below are provided as extra parts for this figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  2 BACC30BH5 COLLAR, PRELOAD 1 BACR15BB4D6C RIVET 4 BACR15FT5D6C RIVET, UNIVERSAL HD 2 BACR15FT5D7C RIVET, UNIVERSAL HD 1 BACR15GF4D6 RIVET

**FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION (SHEET 7 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 53 of 59 **BOEING SERVICE BULLETIN 777-25-0482 This Figure applies only to: Group 1.** 

**FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 54 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 55 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 777084-181 Tie Rod Install (Kept) 1 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side 1 BACB28AK04-024 BUSHING Install (New) Far side 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Maximum gap allowed between partand rail before fastener installation is .003 in. Install shimif required in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51- 20-10. 1 422W2165-111 MISCELLANEOUS - MACHINE PART Install (New) 2

Install 2 near side, 2 far side. 4 BACB30VF3K6 BOLT Install (New)

1 777081-178 TIE ROD ASSY Install (New) 3 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-024 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Near side. 1 BACB30NR4K17 BOLT, HEX HEAD Install (New) 4 Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-038 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New)

**FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 56 of 59 **BOEING SERVICE BULLETIN 777-25-0482 This Figure applies only to: Group 2.** 

**FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 57 of 59 **BOEING SERVICE BULLETIN 777-25-0482 FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION**  **(SHEET 2 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 58 of 59 **BOEING SERVICE BULLETIN 777-25-0482 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 1 777084-181 Tie Rod Install (Kept) 1 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side 1 BACB28AK04-024 BUSHING Install (New) Far side 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Maximum gap allowed between partand rail before fastener installation is .003 in. Install shimif required in accordance with 777-200 SRM 51-20-10 or 777-300 SRM 51- 20-10. 1 422W2165-108 MISCELLANEOUS - MACHINE PART Install (New) 2

Install 2 near side, 2 far side. 4 BACB30VF3K6 BOLT Install (New)

1 777081-178 TIE ROD ASSY Install (New) 3 Near side. 1 BACB30NR4K15 BOLT Install (New) Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-024 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New) Near side. 1 BACB30NR4K17 BOLT, HEX HEAD Install (New) 4 Near side. 1 BACW10BP4CD WASHER Install (New) Near side. 1 BACB28AK04-038 BUSHING Install (New) Far side. 1 BACW10BP4DP WASHER Install (New) Far side. 1 BACN10YR4CD NUT Install (New)

**FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 24, 2011 777-25-0482 59 of 59 **BOEING SERVICE BULLETIN 777-25-0482**