Service Bulletin ALERT Number: 767-53A0267 Original Issue: August 13, 2015 Revision 1: August 04, 2016 ATA System: 5380

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

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ECCN: 9E991

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Original Issue: August 13, 2015 Revision 1: August 04, 2016 767-53A0267 1 of 206 2.0 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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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

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

Original Issue: August 13, 2015 Revision 1: August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 206 Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0267 Revision Transmittal Sheet 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

Original Issue: August 13, 2015 Revision 1: August 04, 2016

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Original Issue: August 13, 2015 Revision 1: August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 206 Commercial Airplanes 767 Service Bulletin ALERT Number: 767-53A0267 Summary 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.

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 AD Related Yes Paragraph 1.E., Compliance and Paragraph 1.F., Approval 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 Air- plane Flight Manual) Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts Operator Supplied Parts/Material Yes Paragraph 2.C.2., Parts and Materials Supplied by the Operator Special Tooling Required Yes Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin

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.

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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Original Issue: August 13, 2015 Revision 1: August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 206 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

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

3 - Airplane Line numbers 202-423 which have dedicated Static pressure inputs

Airplane Models:

767-200, 767-300

Variable Number Group VA527 - VA530 1 VA713 - VA719 1

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

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.

C. Reason

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.

D. Description

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

Affected Maintenance Zones Model Zone 767-200, 767-300 165, 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

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

Condition Action Compliance Time (Whichever Repeat Interval Occurs Later) (Not to Exceed) All Airplanes Do PART 2: AFT PRES- Before 60,000 Within 36 - SURE BULKHEAD RE- total flight cycles months after the PLACEMENT but no earlier original issue than 37,500 to- date of this ser- tal flight cycles. vice 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.

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 (Para- graph 3.B., Part 2, Step 35)

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 (Para- graph 3.B., Part 2, Step 35) Install the new aft 4 13.00 3.25 pressure bulkhead in the forward part of Section 48 (Para- graph 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

H. Weight and Balance Changes

Change in Weight Change in Moment Airplane (Pounds) (Pound-Inches) 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:

Drawing No Title Sheet DCN/REV ADCN 100T3480 Section 48/72 Integration 1 J - PSDL C - 100T3481 Shim Details - Section 48/72 1 - - 140T6000 Corrosion Inhibiting Compound Installation 1 C - - Fuselage 2ME148T0200PBR Mechanical Equipment Forward 48 Section 1 A - Stand 2 A - 2ME148T0600PBR Mechanical Equipment Aft 48 Section Stand 1 A - 2 A - 2ME148T2610PBR Mechanical Equipment Strongback, Pres- 1 - - sure Bulkhead Transportation and Installa- 2 A - tion 3 A - 4 A - 5 A - 2MIT100T3480PBR Miscellaneous Tool Torque Multiplier and 1 - - Adapter, Vertical Fin 2 A - 3 A - 4 - - 5 - - 6 - - 2OHME100T3480PBR Overhead Mechanical Equipment Vertical 1 A - Fin Assembly Sling 3ME140T0140PBR Mechanical Equip Sling and Strongback 1 - - Fwd 48 Section Pressure Bulkhead 2 - - 3 - -

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 - ME100T3480PBR Mechanical Equipment Vertical Fin Lift Fit- 1 B - tings ME148T0200PBR Mechanical Equipment Forward 48 Section 1 - - Handling Fitting ME148T0600PBR Mechanical Equipment Aft 48 Section Han- 1 A - dling Fitting ME148T2610PBR Mechanical Equipment Strongback Pressure 1 - - Bulkhead Removal 2 A - 3 A - 5 A - ME170T0100PBR Mechanical Equipment Vert Fin Stand Floor 1 A - Mounted 2 A - ME180T0000PBR Mechanical Equipment Floor Mounted Stand 1 A - Horizontal Stabilizer ME182T0000PBR Mechanical Equipment Lift Fittings Front 1 - - and Rear Spar Horizontal Stabilizer MIT100T3480PBR Misc Tool Alignment Pins Vertical Fin Body 1 - - Join

Drawing No Title Sheet DCN/REV ADCN OHME148T2610PBR Overhead Mech Equip Pressure Dome Sling 1 - - Fwd 48 Section 2 - - OHME180T0100PBR Overhead Mech Equip Horizontal Stabilizer 1 - - Complete 2 - - PME148T0010PBR Portable Mechanical Equipment Forward 1 - - 48 Section Internal Scaffolding 2 - - 3 - - 4 - - 5 - - 6 - - PRE148T2610PBR Protective Equipment Pressure Bulkhead 1 - - Cover SME148T2610PBR Shipping Mech Equip Ground Transporta- 1 - - tion Aft Pressure Bulkhead 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 148T2740 Bulkhead End Item - Center, Horiz Stab Pivot, STA 1809.5 233T9112 Seal Instl - Pitot/Static Tubing Pressure Dome 255T4821 Pressure Seal Instl - Pressure Dome STA 1582.0 272T4831 Retainer Instl - Pressure Seal, Hydraulic Tubing

Drawing Number Title 346T0003 Tubing Instl - APU Fuel Feed, Body Sections 45, 46 and 48 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.

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 [email protected] FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Kit Number Name ROLT as of the Unit Price as of original issue the original issue date of this Ser- date of this Ser- vice Bulletin (Cal- vice Bulletin (US endar Days) Dollars) 015T1907-1 Top Kit - STA 1582 Aft Pressure Bulkhead 550 $86,435.00 Replacement 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

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 Figure 1 6 11 12 13 14 Existing Part New Part Number Qty Name Number Notes 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 - 140T0345-3 1 . . . . . SEAL BLOCK AS- - SY 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 -

ALL

KIT 015T1907-1 Figure 1 6 11 12 13 14 Existing Part New Part Number Qty Name Number Notes 148T2629-2 1 . . . . . SEAL BLOCK AS- - SY 272T4825-9 . . . 1 . . BRACKET ASSY- - 40345 (678782 . 1 . . . . SEAL - optional) 412T3106-406 . . . 2 . . FITTING ASSY - 412T3106-408 . . . 1 . . fitting assy - BACB30MY10K10X . . . . 8 8 BOLT, PROTRUD- (a) ING HD BACB30MY10K3X . . . . 10 10 BOLT TITANIUM (a) O/S 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 BOLT, PROTRUD- (a) ING HD

ALL

KIT 015T1907-1 Figure 1 6 11 12 13 14 Existing Part New Part Number Qty Name Number Notes 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 BOLT, PROTRUD- (a) ING HD BACB30NM4K14 16 . . . . . BOLT, HEX HEAD (a) 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, 100 DEG (a) HEX DR 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 . . BOLT, PROTRUD- (a) ING HD

ALL

KIT 015T1907-1 Figure 1 6 11 12 13 14 Existing Part New Part Number Qty Name Number Notes 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 . . BOLT, 12 PT (a) HEAD BACC30BH10 . . . . 14 14 COLLAR (a) BACC30BH12 . . . . 4 4 COLLAR (a) BACC30BH6 . . . 24 . . COLLAR (a) BACC30M10 . . . . 49 49 COLLAR (a)

ALL

KIT 015T1907-1 Figure 1 6 11 12 13 14 Existing Part New Part Number Qty Name Number Notes BACC30M12 . . . . 14 14 COLLAR (a) BACC30M8 . . . . 145 145 COLLAR (a) BACN10HR5CD . . . 156 . . NUT (a) BACN10HR6CD . . . 92 . . SELF-LOCKING (a) NUT BACN10HR7CD . . . 44 . . NUT (a) BACN10HR8CD . . . 16 . . NUT (a) BACN11AG3 15 . . . . . NUT, SELF-LOCK (a) BACR15BB5A7C 50 . . . . . RIVET, UNIVER- (a) SAL HD BACR15BB6A8C 5 . . . . . RIVET, UNIVER- (a) SAL HD BACR15FT6KE7C 8 . . . . . RIVET (a) BACR15FV7KE7 . . . . 5 5 RIVET (a) BACR15FV7KE8 . . . . 1 1 RIVET (a) BACS12HN3-7 15 . . . . . BOLT (a) BACS40R011B012F . . . 2 . . SHIM, LAMINAT- - ED BACS40R011B027F . . . . 2 2 SHIM,LAMINATED - BACS40R012B027F . . . . 2 2 SHIM, LAMINAT- - ED BACS40R016B098F . . . . 1 1 SHIM, LAMINAT- - ED BACS40R027C030F . . . . 1 1 SHIM, LAMINAT- - ED 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)

ALL

KIT 015T1907-1 Figure 1 6 11 12 13 14 Existing Part New Part Number Qty Name Number Notes 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) NAS42DD3-44FC 1 . . . . . SPACERS FOR - RIVETS NAS42DD3-48FC 1 . . . . . SPACERS FOR - RIVETS NAS42DD3-64FC 1 . . . . . SPACERS FOR - RIVETS (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 Figure 15 16 17 22 24 26 Existing Part New Part Number Qty Name Number Notes 148T2746-1 2 . . . . . washer (a) 148T2746-2 2 . . . . . filler - 233T9110-566 . . 1 . . . TUBE ASSY - 233T9110-665 . . 1 . . . TUBE ASSEMBLY -

ALL

KIT 015T1907-1 Figure 15 16 17 22 24 26 Existing Part New Part Number Qty Name Number Notes 233T9113-4 . . 2 . . . PLATER RETAIN- - ER 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) BACB30LT5-12 10 . . . . . BOLT, 12 PT (a) HEAD BACB30LT7-12 8 . . . . . BOLT, 12 PT (a) HEAD BACB30MY8K4X . . . 12 . . BOLT, PROTRUD- (a) ING HD BACB30NW8K8X . . . . 6 6 BOLT, 100 DEG (a) HEX DR BACB30NX10K10 44 . . . . . HEX DRIVE BOLT (a) BACB30NX10K7 54 . . . . . BOLT (a) BACB30NX14K16 8 . . . . . BOLT (a) BACB30NX6K4X . . . 3 . . BOLT, PROTRUD- (a) ING HD BACB30NX6K5 8 . . . . . BOLT (a) BACB30NX6K6X . . . 5 . . BOLT, PROTRUD- (a) ING HD BACB30NX8K5 8 . . . . . HI LOK (a) BACB30NX8K5X . . . 22 . . BOLT, PROTRUD- (a) ING HD BACB30NX8K6X . . . 6 . . BOLT, PROTRUD- (a) ING HD BACB30NX8K7 76 . . . . . BOLT, HEX DRIVE (a) BACB30NX8K7X . . . 14 . . BOLT, PROTRUD- (a) ING HD

ALL

KIT 015T1907-1 Figure 15 16 17 22 24 26 Existing Part New Part Number Qty Name Number Notes 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, 12 PT (a) HEAD BACB30VF3K5 . . . . 10 10 BOLT, 100 DEG (a) HEAD BACB30VF3K7 . . . . 3 3 BOLT (a) BACC10DK6 . . 10 . . . CLAMP, LOOP - BACC30BH10 107 . . . . . COLLAR (a) BACC30BH14 8 . . . . . COLLAR, (a) PRELOAD BACC30BH6 8 . . . . . COLLAR (a) BACC30BH8 84 . . 42 . . COLLAR (a) BACC30M6 . . . 8 . . COLLAR (a) BACC30M8 . . . 12 6 6 COLLAR (a) BACN10HR12CD 8 . . . . . SELF-LOCKING (a) NUT BACN10HR7CD 60 . . . . . NUT (a) BACN10HR8CD 4 . . . . . NUT (a) BACN10JC3CD . 18 . . . . NUT (a)

ALL

KIT 015T1907-1 Figure 15 16 17 22 24 26 Existing Part New Part Number Qty Name Number Notes BACN10JC5CD 10 . . . . . SELF-LOCKING (a) NUT BACN10JC7CD 8 . . . . . SELF-LOCKING (a) NUT BACR15FT5KE9C . . . . 2 2 RIVET, UNIVER- (a) SAL HD BACR15FV6KE7 . . . . 5 5 RIVET (a) BACR15FV6KE8 . . . . 1 1 RIVET (a) BACS12HN3-9 . 24 . . . . BOLT (a) BACS40R040C095F . . . 2 . . SHIM, LAMINAT- - ED 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 Figure 28 Existing Part New Part Number Qty Name Number Notes BACB30NX10K10X 6 BOLT, PROTRUD- (a) ING HD BACB30NX10K12X 6 BOLT, PROTRUD- (a) ING HD

ALL

KIT 015T1907-1 Figure 28 Existing Part New Part Number Qty Name Number Notes BACB30NX10K13X 2 BOLT, PROTRUD- (a) ING HD BACB30NX10K15X 2 BOLT, PROTRUD- (a) ING HD BACB30NX12K11X 4 BOLT, PROTRUD- (a) ING HD BACB30NX12K14X 10 BOLT, PROTRUD- (a) ING HD BACB30NX12K15X 58 BOLT TIANIUM (a) O/S BACB30NX12K9X 14 BOLT, HEX DRIVE (a) 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, PROTRUD- (a) ING HD 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 BOLT, 12 PT (a) HEAD BACC30BH10 16 COLLAR (a)

ALL

KIT 015T1907-1 Figure 28 Existing Part New Part Number Qty Name Number Notes 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 -

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 [email protected]. 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:

Tool Kit Number Name Daily Price as of the Original Issue date of this service bulletin (US Dollars) PME148T0010PBR Forward 48 Section Internal $550.00 Scaffolding

Rental Data:

Tool Kit Number Name Daily Price as of the Original Issue date of this service bulletin (US Dollars) 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 3ME140T0140PBR Forward 48 Section Sling and $260.00 Strongback 2MIT100T3480PBR Vertical Fin Torque Multiplier $550.00 and Adapter ME148T0600PBR Aft 48 Section Lift Sling and At- $400.00 tach Fittings ME148T2610PBR Pressure Bulkhead Removal (a) Strongback ME180T0000PBR Horizontal Stabilizer Floor Stand $240.00 2ME148T0600PBR Aft 48 Section Stand $380.00 ME148T0200PBR Forward 48 Section Attach Fit- $420.00 tings 2ME148T0200PBR Forward 48 Section Stand $440.00 2ME148T2610PBR Pressure Bulkhead Transporta- $400.00 tion Removal Strongback 2SME148T2610PBR Pressure Bulkhead Ground $460.00 Transportation Fixture 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.

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPON- DER AT [email protected] FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFOR- MATION

Purchase Data: Tool Kit Number Name Unit Price as of the Original Issue date of this Ser- vice Bulletin (US Dollars) PME148T0010PBR Forward 48 Section internal $192,263.00 Scaffolding 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 3ME140T0140PBR Forward 48 Section Sling and $28,680.00 Strongback 2MIT100T3480PBR Vertical Fin Torque Multiplier $192,263.00 and Adapter ME148T0600PBR Aft 48 Section Lift Sling and At- $74,129.00 tach Fittings 2ME148T0600PBR Aft 48 Section Stand $62,077.00 ME148T0200PBR Forward 48 Section Attach fit- $81,929.00 tings 2ME148T0200PBR Forward 48 Section Stand $94,649.00 ME180T0000PBR Horizontal Stabilizer Floor Stand $21,600.00 2ME148T2610PBR Pressure Bulkhead Transporta- $72,810.00 tion ME148T2610PBR Pressure Dome Removal (a) Strongback 2SME148T2610PBR Pressure Bulkhead Ground $105,508.00 Transportation Fixture (a) Purchase price data for this tool was not available at the time this service bulletin was issued.

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 PME148T0010PBR Forward 48 Section Internal Scaffolding PRE148T2610PBR Pressure Bulkhead Cover MIT100T3480PBR Vertical Fin Alignment Pins ME170T0100PBR Vertical Fin Floor Stand OHME148T2610PBR Pressure Dome Sling ME148T2610PBR Pressure Dome Removal Strongback 2OHME100T3480PBR Vertical Fin Lift Sling ME100T3480PBR Vertical Fin Lift Fittings ME182T0000PBR Horizontal Stabilizer Lift Fittings OHME180T0100PBR Horizontal Stabilizer Lift Sling 3ME140T0140PBR Forward 48 Section Sling and Strongback 2MIT100T3480PBR Vertical Fin Torque Multiplier and Adapter ME148T0600PBR Aft 48 Section Lift Sling and At- tach Fittings ME180T0000PBR Horizontal Stabilizer Floor Stand 2ME148T0600PBR Aft 48 Section Stand ME148T0200PBR Forward 48 Section Attach Fit- tings 2ME148T0200PBR Forward 48 Section Stand 2ME148T2610PBR Pressure Bulkhead Transporta- tion 2SME148T2610PBR Pressure Bulkhead Ground Transportation Fixture

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.

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.

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

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 1 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 2 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 206 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 new aft pressure bulkhead.

Step Task Name Identification Qty More Data 1 Remove Fastener - 4 - Drill / Ream Hole - 4 1.19 - 1.21 inch diameter, normal to the bulkhead surface. 125 microinch or better surface finish. Apply Finish - - Break sharp edges and apply chemical film treatment and two coats of BMS10- 11, Type I primer to the bare edges of the holes. 2 Locate SEAL BLOCK ASSY 148T2629-2 - - Drill / Ream Rivet Hole - 21 -

FIGURE 1: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 3 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Step Task Name Identification Qty More Data 3 Apply Sealant BMS 5-95 - Apply a pressure faying surface seal to the entire mating surface of the seal block assembly. Install (New) SEAL BLOCK ASSY 148T2629-2 1 - Install (New) RIVET, UNIVERSAL BACR15BB5A7C 21 - HD 4 Remove Fastener - 4 - Locate SEAL BLOCK ASSY 140T0345-3 - - Drill / Ream Rivet Hole - 22 - 5 Apply Sealant BMS 5-95 - Apply a pressure faying surface seal to the entire mating surface of the seal block assembly. Install (New) SEAL BLOCK ASSY 140T0345-3 1 - 6 Install (New) RIVET, UNIVERSAL BACR15BB5A7C 18 - HD 7 Install (New) RIVET, UNIVERSAL BACR15BB5A7C 4 - HD Install (New) RIVET, UNIVERSAL BACR15BB6A8C 4 Optional, if oversize HD rivets are necessary. 8 Apply Sealant BMS 5-95 - Apply a pressure faying surface seal to the entire mating surface of the cover- plate and pressure pan. 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 - 10 Apply Sealant BMS 5-95 - Fillet seal all screw heads, nuts, and washers.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 1 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 206 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 1 Drill / Ream Hole - 1 0.530 - 0.539 inch diameter, normal to the doubler. 125 microinch or better surface finish. Apply Finish - - 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.

FIGURE 2: AFT PRESSURE BULKHEAD ASSEMBLY PREPARATION (SHEET 2 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS (SHEET 1 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 62 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS (SHEET 2 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 3: REMOVAL OF AUXILIARY PITOT SYSTEM TUBES AND SEALS (SHEET 3 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 206 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.

Step Task Name Identification Qty More Data 1 Remove Screw - 4 From pressure dome seal retainer plates. 2 Disconnect Tube Assy 233T9110-513 - 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. 3 Disconnect Tube Assy 233T9110-614 - 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. 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 4: REMOVAL OF PRESSURE SEALS (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 4: REMOVAL OF PRESSURE SEALS (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 67 of 206 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.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 68 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 69 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 5: APU FUEL LINE BULKHEAD FITTING REMOVAL (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 70 of 206 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.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 71 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 72 of 206 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.

FIGURE 6: APU FUEL LINE BULKHEAD FITTING INSTALLATION (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 73 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Step Task Name Identification Qty More Data 1 Install (New) SEAL 40345 (678782 option- 1 - al) 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 74 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 7: AFT SECTION 48 (TAIL CONE) FASTENER REMOVAL (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 75 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 76 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 77 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL (SHEET 1 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 78 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL (SHEET 2 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 79 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL (SHEET 3 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 80 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL (SHEET 4 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 81 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 8: STA 1809.5 CENTER BULKHEAD REMOVAL (SHEET 5 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 82 of 206 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 (SHEET 6 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 83 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Step Task Name Identification Qty More Data 5 Remove Shim - 12 - 6 Remove / Keep Center Bulkhead Assy - 2 The horizontal stabilizer pivot fittings will remain attached to the center bulkhead assy.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 84 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL (SHEET 1 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 85 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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 - Remove Fitting - 2 Waste tank tie rod attach fittings 3 Remove Fitting - 3 Ceiling support fittings 4 Remove Fastener - 6 - Remove Clip - 2 - Remove Shim - 2 -

FIGURE 9: FORWARD SECTION 48 PARTS REMOVAL (SHEET 2 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 86 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 10: AFT PRESSURE BULKHEAD PRESSURE RING FASTENER REMOVAL (SHEET 1 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 87 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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 (SHEET 2 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 88 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 11: AFT PRESSURE BULKHEAD ATTACHMENT TO THE PRESSURE RING AT STA 1582 (SHEET 1 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 89 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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 - Install (New) RIVET, BLIND NAS1399D6A10 31 - (NAS1399D6AB10 optional) (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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 90 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 12: FORWARD SECTION 48 INSTALLATION (SHEET 1 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 91 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 92 of 206 BOEING SERVICE BULLETIN 767-53A0267 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 1 Install (New) CLIP 140T0142U1 1 - (140T0142-1 optional) 2 Install (New) CLIP 140T0142U2 1 - (140T0142-2 optional) 3 Install (New) FITTING ASSY 140T0169-7 2 - Install (New) SHIM, LAMINATED BACS40R011B012F 2 Maximum gap 0.010 inch. Remove 0.003 inch laminations as required. Install shims with BMS 10- 11, Type I primer after delamination. 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 93 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Step Task Name Identification Qty More Data 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 Refer to Tables 1 - 12 for specific locations (a) Install (New) CSK WASHER BACW10BP5CD 154 under bolt head Install (New) WASHER-PLAIN BACW10BP5DP 154 under nut Install (New) NUT BACN10HR5CD 154 - 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 Refer to Tables 1 - 12 for specific locations (a) (b) 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 94 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Step Task Name Identification Qty More Data 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 Refer to Tables 1 - 12 for specific locations (a) (b) Install (New) WASHER BACW10BP7CD 44 under bolt head Install (New) WASHER BACW10BP7DP 44 under nut Install (New) NUT BACN10HR7CD 44 - 9 Install (New) BOLT, 12 PT HEAD BACB30US8K42 16 Refer to Tables 1 - 12 for specific locations (a) (b) Install (New) WASHER BACW10BP8CD 16 under bolt head Install (New) WASHER BACW10BP8DP 16 under nut Install (New) NUT BACN10HR8CD 16 - 10 Install (New) BOLT, 12 PT HEAD BACB30US5K25 2 Bolt numbers 046L and 046R (a) 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

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 001 BACB30US5K18 0.312 - 0.316 - 002 L BACB30US5K18 0.312 - 0.316 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION (SHEET 5 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 95 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 1 - BOLT IDENTIFICATION AND INSTALLATION - S-1L TO S-5L

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 96 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 2 - BOLT IDENTIFICATION AND INSTALLATION - S-6L TO S-11L

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 97 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 3 - BOLT IDENTIFICATION AND INSTALLATION - S-12L TO S-16L

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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 (SHEET 8 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 98 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 4 - BOLT IDENTIFICATION AND INSTALLATION - S-17L TO S-23L

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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 (SHEET 9 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 99 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 5 - BOLT IDENTIFICATION AND INSTALLATION - S-24L TO S-32L

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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 (SHEET 10 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 100 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 6 - BOLT IDENTIFICATION AND INSTALLATION - S-33L TO S-39L

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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 (SHEET 11 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 101 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 7 - BOLT IDENTIFICATION AND INSTALLATION - S-1R TO S-5R

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 6R 028 R BACB30US7K39 0.484 - 0.499 - 029 R BACB30US7K39 0.484 - 0.499 -

FIGURE 12: FORWARD SECTION 48 INSTALLATION (SHEET 12 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 102 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 8 - BOLT IDENTIFICATION AND INSTALLATION - S-6R TO S-11R

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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 (SHEET 13 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 103 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 9 - BOLT IDENTIFICATION AND INSTALLATION - S-12R TO S-16R

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 104 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 10 - BOLT IDENTIFICATION AND INSTALLATION - S-17R TO S-23R

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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 (SHEET 15 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 105 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 11 - BOLT IDENTIFICATION AND INSTALLATION - S-24R TO S-32R

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 106 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 12 - BOLT IDENTIFICATION AND INSTALLATION - S-33R TO S-39R

STRINGER BOLT IDENTIFICATION HOLE DIA MORE DATA NUMBER 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)

STEP BOLT NUMBER STRINGER TORQUE (INCH- POUNDS) 1 28 L, 29 L, 100 R, 101 R 6L and 22R 410 - 450, simultaneously 2 28 R, 29 R, 100 L, 101 L 6R and 22L 410 - 450, simultaneously 3 154 L through 033 L and 154R 39L through 7L and 39R through 7R 410 - 450 (a) (b) through 033 R, at stringer locations only.

FIGURE 12: FORWARD SECTION 48 INSTALLATION (SHEET 17 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 107 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

TABLE 13 - INITIAL PULL-UP SEQUENCE AND TORQUE VALUES (STRINGER LOCATIONS ONLY)

STEP BOLT NUMBER STRINGER TORQUE (INCH- POUNDS) 4 024 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. (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

BOLT PART NUMBER TORQUE APPLIED TO BOLT TORQUE APPLIED TO NUT (INCH- HEAD (INCH-POUNDS) POUNDS) 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 (SHEET 18 OF 19) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 108 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data A BOLT, PROTRUDING BACB30NX6K4X 20 0.200-0.203 - HD COLLAR BACC30BH6 20 - - B BOLT, PROTRUDING BACB30NX6K5X 2 0.200-0.203 - HD COLLAR BACC30BH6 2 - - C BOLT, PROTRUDING BACB30NX6K10X 2 0.200-0.203 - HD 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 109 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 1 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 110 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 2 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 111 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 3 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 112 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 4 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 113 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 5 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 114 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 6 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 115 of 206 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 116 of 206 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) 13 Install (New) Fastener - 214 See Fastener Data Table for part numbers and final hole diameters. (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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 117 of 206 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 A BOLT, PROTRUDING BACB30MY8K5X 35 0.263-0.266 - HD COLLAR BACC30M8 35 - - B BOLT, PROTRUDING BACB30MY8K6X 1 0.263-0.266 - HD COLLAR BACC30M8 1 - - C BOLT, PROTRUDING BACB30MY8K7X 65 0.263-0.266 (b) HD COLLAR BACC30M8 65 - (b) D BOLT, PROTRUDING BACB30MY8K8X 3 0.263-0.266 - HD COLLAR BACC30M8 3 - - E BOLT, PROTRUDING BACB30MY8K9X 1 0.263-0.266 - HD COLLAR BACC30M8 1 - - F BOLT, PROTRUDING BACB30MY8K10X 7 0.263-0.266 - HD COLLAR BACC30M8 7 - - G BOLT, PROTRUDING BACB30MY8K11X 3 0.263-0.266 - HD COLLAR BACC30M8 3 - H BOLT, PROTRUDING BACB30MY8K12X 4 0.263-0.266 - HD COLLAR BACC30M8 4 - - I BOLT TITANIUM O/S BACB30MY10K3X 10 0.325-0.328 - COLLAR BACC30M10 10 - - J BOLT, PROTRUDING BACB30MY10K5X 5 0.325-0.328 - HD COLLAR BACC30M10 5 - - K BOLT, PROTRUDING BACB30MY10K6X 1 0.325-0.328 - HD COLLAR BACC30M10 1 - -

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 9 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 118 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data L BOLT, PROTRUDING BACB30MY10K7X 11 0.325-0.328 - HD COLLAR BACC30M10 11 - - M BOLT, PROTRUDING BACB30MY10K8X 14 0.325-0.328 - HD COLLAR BACC30M10 14 - - N BOLT, PROTRUDING BACB30MY10K10X 8 0.325-0.328 - HD COLLAR BACC30M10 8 - - O BOLT, PROTRUDING BACB30MY12K6X 2 0.388-0.391 - HD COLLAR BACC30M12 2 - - P BOLT, PROTRUDING BACB30MY12K7X 4 0.388-0.391 - HD COLLAR BACC30M12 4 - - Q BOLT, PROTRUDING BACB30MY12K8X 4 0.388-0.391 (b) HD COLLAR BACC30M12 4 - (b) R BOLT, PROTRUDING BACB30MY12K10X 4 0.388-0.391 (b) HD COLLAR BACC30M12 4 - (b) S BOLT, PROTRUDING BACB30NX10K8X 2 0.325-0.328 - HD COLLAR BACC30BH10 2 - - T BOLT, PROTRUDING BACB30NX10K9X 2 0.325-0.328 - HD COLLAR BACC30BH10 2 - - U BOLT, PROTRUDING BACB30NX10K11X 4 0.325-0.328 (b) HD COLLAR BACC30BH10 4 - (b) V BOLT, PROTRUDING BACB30NX10K12X 4 0.325-0.328 (b) HD COLLAR BACC30BH10 4 - (b)

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 10 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 119 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data W BOLT, PROTRUDING BACB30NX12K12X 4 0.388-0.391 (b) HD COLLAR BACC30BH12 4 - (b) X RIVET BACR15FV7KE7 5 - - Y RIVET BACR15FV7KE8 1 - - Z BOLT, 100 DEG HEX BACB30NW8K5X 2 0.263-0.266 - DR COLLAR BACC30M8 2 - - AA BOLT, 100 DEG HEX BACB30NW8K7X 2 0.263-0.266 (a) DR COLLAR BACC30M8 2 - (a) AB BOLT, 100 DEG HEX BACB30NW8K8X 4 0.263-0.266 (a) DR COLLAR BACC30M8 4 - (a) AC BOLT, 100 DEG HEX BACB30NW8K13X 4 0.263-0.266 (a) DR 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 120 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FLAG NOTE MORE DATA 1 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". 2 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".

FIGURE 13: LEFT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 12 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 121 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 1 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 122 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 2 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 123 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 3 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 124 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 4 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 125 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 5 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 126 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 6 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 127 of 206 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.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 128 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 129 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data A BOLT, PROTRUDING BACB30MY8K5X 35 0.263-0.266 - HD COLLAR BACC30M8 35 - - B BOLT, PROTRUDING BACB30MY8K6X 1 0.263-0.266 - HD COLLAR BACC30M8 1 - - C BOLT, PROTRUDING BACB30MY8K7X 65 0.263-0.266 (b) HD COLLAR BACC30M8 65 - (b) D BOLT, PROTRUDING BACB30MY8K8X 3 0.263-0.266 - HD COLLAR BACC30M8 3 - - E BOLT, PROTRUDING BACB30MY8K9X 1 0.263-0.266 - HD COLLAR BACC30M8 1 - - F BOLT, PROTRUDING BACB30MY8K10X 7 0.263-0.266 - HD COLLAR BACC30M8 7 - - G BOLT, PROTRUDING BACB30MY8K11X 3 0.263-0.266 - HD COLLAR BACC30M8 3 - - H BOLT, PROTRUDING BACB30MY8K12X 4 0.263-0.266 - HD COLLAR BACC30M8 4 - - I BOLT TITANIUM O/S BACB30MY10K3X 10 0.325-0.328 - COLLAR BACC30M10 10 - - J BOLT, PROTRUDING BACB30MY10K5X 5 0.325-0.328 - HD COLLAR BACC30M10 5 - - K BOLT, PROTRUDING BACB30MY10K6X 1 0.325-0.328 - HD COLLAR BACC30M10 1 - - L BOLT, PROTRUDING BACB30MY10K7X 11 0.325-0.328 - HD COLLAR BACC30M10 11 - -

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 9 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 130 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data M BOLT, PROTRUDING BACB30MY10K8X 14 0.325-0.328 - HD COLLAR BACC30M10 14 - - N BOLT, PROTRUDING BACB30MY10K10X 8 0.325-0.328 - HD COLLAR BACC30M10 8 - - O BOLT, PROTRUDING BACB30MY12K6X 2 0.388-0.391 - HD COLLAR BACC30M12 2 - - P BOLT, PROTRUDING BACB30MY12K7X 4 0.388-0.391 - HD COLLAR BACC30M12 4 - - Q BOLT, PROTRUDING BACB30MY12K8X 4 0.388-0.391 (b) HD COLLAR BACC30M12 4 - (b) R BOLT, PROTRUDING BACB30MY12K10X 4 0.388-0.391 (b) HD COLLAR BACC30M12 4 - (b) S BOLT, PROTRUDING BACB30NX10K8X 2 0.325-0.328 - HD COLLAR BACC30BH10 2 - - T BOLT, PROTRUDING BACB30NX10K9X 2 0.325-0.328 - HD COLLAR BACC30BH10 2 - - U BOLT, PROTRUDING BACB30NX10K11X 4 0.325-0.328 (b) HD COLLAR BACC30BH10 4 - (b) V BOLT, PROTRUDING BACB30NX10K12X 4 0.325-0.328 (b) HD COLLAR BACC30BH10 4 - (b) W BOLT, PROTRUDING BACB30NX12K12X 4 0.388-0.391 (b) HD 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 131 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data Z BOLT, 100 DEG HEX BACB30NW8K5X 2 0.263-0.266 - DR COLLAR BACC30M8 2 - - AA BOLT, 100 DEG HEX BACB30NW8K7X 2 0.263-0.266 (a) DR COLLAR BACC30M8 2 - (a) AB BOLT, 100 DEG HEX BACB30NW8K8X 4 0.263-0.266 (a) DR COLLAR BACC30M8 4 - (a) AC BOLT, 100 DEG HEX BACB30NW8K13X 4 0.263-0.266 (a) DR 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.

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 11 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 132 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FLAG NOTE MORE DATA 2 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".

FIGURE 14: RIGHT STA 1809.5 CENTER BULKHEAD INSTALLATION (SHEET 12 OF 12) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 133 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION (SHEET 1 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 134 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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 1 Install (New) Fastener - 288 Refer to the fastener data table.

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION (SHEET 2 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 135 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 136 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 137 of 206 BOEING SERVICE BULLETIN 767-53A0267 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 Com- pany 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.

FIGURE 15: AFT SECTION 48 (TAIL CONE) INSTALLATION (SHEET 5 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 138 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 16: PRESSURE SEAL INSTALLATION (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 139 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 16: PRESSURE SEAL INSTALLATION (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 140 of 206 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.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 141 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS (SHEET 1 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 142 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS (SHEET 2 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 143 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 17: INSTALLATION OF AUXILIARY PITOT SYSTEM TUBES AND PRESSURE SEALS (SHEET 3 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 144 of 206 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.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 145 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 1 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 146 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 2 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 147 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 3 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 148 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 4 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 149 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 5 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 150 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 6 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 151 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 7 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 152 of 206 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.

Step Task Name Identification Qty More Data 1 Make Plate A 1 From 6061-T6 aluminum alloy sheet, 0.125 inch thick. 2 Make Plate B 1 From 6061-T6 aluminum alloy sheet, 0.125 inch thick. 3 Make Angle C 6 From 6061-T6 aluminum angle or ex- trusion, 0.1875 inch thick. 4 Make Angle D 2 From 6061-T6 aluminum angle or ex- trusion, 0.1875 inch thick. 5 Make Angle E 2 From 6061-T6 aluminum angle or ex- trusion, 0.1875 inch thick. 6 Install (New) Plate A 1 - Install (New) Angle C 3 - Install (New) Angle D 1 - Install (New) Angle E 1 - Identify Left STA 1809.5 Bulk- - - Mark the aft side of head Tool the tool and place orientation arrows on the aft side of the tool. Identify Left STA 1809.5 Bulk- - 1 Mark the tool as the head Tool left 1809.5 bulkhead stabilization tool.

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 8 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 153 of 206 BOEING SERVICE BULLETIN 767-53A0267 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 - Identify Right STA 1809.5 Bulk- - 1 Mark the tool as the head Tool right 1809.5 bulkhead stabilization tool. Identify Right STA 1809.5 Bulk- - - Mark the aft side of head Tool the tool and place orientation arrows on the aft side of the tool. 8 Attach Left STA 1809.5 Bulk- - 1 Attach the tool to the head Tool upper and lower STA 1809.5 bulkhead using temporary fasteners. Install (New) Temporary Fastener - 8 - 9 Attach Right STA 1809.5 Bulk- - 1 Attach the tool to the head Tool upper and lower STA 1809.5 bulkhead using temporary fasteners. Install (New) Temporary Fastener - 8 -

FIGURE 18: MAKE AND INSTALL STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 9 OF 10) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 154 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 155 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 19: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 1 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 156 of 206 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.

Step Task Name Identification Qty More Data 1 Remove Temporary Fastener - 8 - Remove Left STA 1809.5 Bulk- - 1 - head Tool 2 Remove Temporary Fastener - 8 - Remove Right STA 1809.5 Bulk- - 1 - head Tool

FIGURE 19: REMOVE STA 1809.5 BULKHEAD STABILIZATION TOOLS (SHEET 2 OF 2) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 157 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT (SHEET 1 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 158 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT (SHEET 2 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 159 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 20: STA 1582 FLOOR BEAM DETACHMENT (SHEET 3 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 160 of 206 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.

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 161 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 21: STA 1582 FLOOR BEAM SUPPORT (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 162 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 21: STA 1582 FLOOR BEAM SUPPORT (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 163 of 206 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.

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 1 Make Plate F 2 From 6061-T6 aluminum, 0.5 inch thick. 2 Make Angle G 2 From 6061-T6 aluminum, at least 0.5 inch thick. Each flange should be at least 4 inches wide and 4 inches deep. 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 164 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT (SHEET 1 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 165 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT (SHEET 2 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 166 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT (SHEET 3 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 167 of 206 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.

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.

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT (SHEET 4 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 168 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data A BOLT, PROTRUDING BACB30NX8K5X 22 0.263-0.266 - HD COLLAR BACC30BH8 22 - - B BOLT, PROTRUDING BACB30NX8K6X 6 0.263-0.266 - HD COLLAR BACC30BH8 6 - - C BOLT, PROTRUDING BACB30NX8K7X 14 0.263-0.266 - HD COLLAR BACC30BH8 14 - - D BOLT, PROTRUDING BACB30NX6K4X 3 0.200-0.203 - HD COLLAR BACC30M6 3 - - E BOLT, PROTRUDING BACB30NX6K6X 5 0.200-0.203 - HD COLLAR BACC30M6 5 - - F BOLT, PROTRUDING BACB30MY8K4X 12 0.263-0.266 - HD COLLAR BACC30M8 12 - -

FIGURE 22: STA 1582 FLOOR BEAM ATTACHMENT (SHEET 5 OF 5) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 169 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 23: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 170 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 23: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 171 of 206 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 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 172 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION (SHEET 1 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 173 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION (SHEET 2 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 174 of 206 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 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.

FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION (SHEET 3 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 175 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data E BOLT, 100 DEG HEAD BACB30VF3K5 10 - Apply 18 - 25 in-lbs of torque. F BOLT BACB30VF3K7 3 - Apply 18 - 25 in-lbs of torque.

FIGURE 24: LEFT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION (SHEET 4 OF 4) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 176 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 25: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 177 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 25: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN REMOVAL (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 178 of 206 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 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 179 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION (SHEET 1 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 180 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION (SHEET 2 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 181 of 206 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 this figure.

NOTE: Install fasteners wet with BMS 5-95 sealant.

Code Name Identification Qty Hole Dia More Data A BOLT, 100 DEG HEX BACB30NW8K8X 6 0.263-0.266 - DR COLLAR BACC30M8 6 - - B RIVET, UNIVERSAL BACR15FT5KE9C 2 - - HD C RIVET BACR15FV6KE7 5 - - D RIVET BACR15FV6KE8 1 - - E BOLT, 100 DEG HEAD BACB30VF3K5 10 - Apply 18 - 25 in-lbs of torque. F BOLT BACB30VF3K7 3 - Apply 18 - 25 in-lbs of torque.

FIGURE 26: RIGHT SIDE HORIZONTAL STABILIZER FAIRING SKIN INSTALLATION (SHEET 3 OF 3) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 182 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 27: PREPARATION OF THE VERTICAL FIN (SHEET 1 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 183 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 27: PREPARATION OF THE VERTICAL FIN (SHEET 2 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 184 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 27: PREPARATION OF THE VERTICAL FIN (SHEET 3 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 185 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 27: PREPARATION OF THE VERTICAL FIN (SHEET 4 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 186 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 27: PREPARATION OF THE VERTICAL FIN (SHEET 5 OF 7) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 187 of 206 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 this figure.

Step Task Name Identification Qty More Data 1 Apply Corrosion Inhibiting BMS 3-38 (BMS 3-27 - (a) (e) Compound OPTIONAL) 2 Locate Alignment Pins - - (b) 3 Install (Temporary) Bolt - 4 Install with the fastener head against the body bulkhead surface (f) 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, squeeze- out 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 188 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 189 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 1 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 190 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 2 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 191 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 3 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 192 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 4 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 193 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 5 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 194 of 206 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 this figure.

Step Task Name Identification Qty More Data 1 Inspect Fin Terminal Fittings - - (a) 2 Apply Sealant BMS 5-95 - (b) 3 Install (New) Bolt - 8 1000-1100 in-lbs torque. This is an initial torque (c) Install (New) Barrel Nut - 8 - 4 Inspect Shear Fastener Loca- - - (d) tions 5 Ream Fastener Hole - - (e) Deburr Fastener Hole - - - 6 Install (New) Shear Fastener - 16 (f) 7 Torque Bolt - - See Fastener code table for torque values. 8 Remove Bolt - 4 These are the temporary bolts installed in Figure 27. Remove Barrel Nut - 4 - 9 Inspect Fin Terminal Fittings - - (a) 10 Apply Sealant BMS 5-95 - (b) 11 Install (New) Bolt - 8 See fastener code table for torque values. (c) Install (New) Barrel Nut - 8 - 12 Inspect Shear Fastener Loca- - - (d) tions 13 Ream Fastener Hole - - (e) (h) Deburr Fastener Hole - - - 14 Install (New) Fastener - 148 Install sequentially, in both directions, starting at tension bolt locations. See fastener code table. (f) (i) 15 Remove Temporary Fastener - 8 -

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 6 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 195 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

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. Pre- coat 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.

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 7 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 196 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data A BOLT, PROTRUDING BACB30NX6K6X 4 0.200-0.203 - HD COLLAR BACC30BH6 4 - - B BOLT, PROTRUDING BACB30NX6K19X 8 0.200-0.203 - HD COLLAR BACC30BH6 8 - - C BOLT, PROTRUDING BACB30NX8K5X 28 0.263-0.266 - HD COLLAR BACC30BH8 28 - - D BOLT, PROTRUDING BACB30NX8K9X 6 0.263-0.266 - HD COLLAR BACC30BH8 6 - - E BOLT, PROTRUDING BACB30NX8K16X 4 0.263-0.266 - HD COLLAR BACC30BH8 4 - - F BOLT, PROTRUDING BACB30NX10K10X 6 0.325-0.328 - HD COLLAR BACC30BH10 6 - - G BOLT, PROTRUDING BACB30NX10K12X 6 0.325-0.328 - HD COLLAR BACC30BH10 6 - - H BOLT, PROTRUDING BACB30NX10K13X 2 0.325-0.328 - HD COLLAR BACC30BH10 2 - - I BOLT, PROTRUDING BACB30NX10K15X 2 0.325-0.328 - HD COLLAR BACC30BH10 2 - - J BOLT, HEX DRIVE BACB30NX12K9X 14 0.388-0.391 - COLLAR BACC30BH12 14 - - K BOLT, PROTRUDING BACB30NX12K11X 4 0.388-0.391 - HD COLLAR BACC30BH12 4 - - L BOLT, PROTRUDING BACB30NX12K14X 10 0.388-0.391 - HD COLLAR BACC30BH12 10 - -

FIGURE 28: INSTALLATION OF THE VERTICAL FIN (SHEET 8 OF 9) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 197 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

Code Name Identification Qty Hole Dia More Data M BOLT TIANIUM O/S BACB30NX12K15X 58 0.388-0.391 - COLLAR BACC30BH12 58 - - N BOLT, PROTRUDING BACB30NX16K11X 4 0.513-0.516 - HD COLLAR BACC30X16 4 - - O BOLT, 12 PT HEAD BACB30US16K47 4 - 7,800 - 8,800 in-lbs torque (a) WASHER, PLAIN BACW10BP16CD 4 - - WASHER NAS1149E1632P 4 - - BARREL NUT BACN11B16CS 4 - - P BOLT, 12 PT HEAD BACB30US16K48 4 - 7,800 - 8,800 in-lbs torque (a) WASHER, PLAIN BACW10BP16CD 4 - - WASHER NAS1149E1632P 4 - - BARREL NUT BACN11B16CS 4 - - Q BOLT, 12 PT HEAD BACB30US16K50 2 - 7,800 - 8,800 in-lbs torque (a) WASHER, PLAIN BACW10BP16CD 2 - - WASHER NAS1149E1632P 2 - - BARREL NUT BACN11B16CS 2 - - R BOLT, 12 PT HEAD BACB30US16K51 2 - 7,800 - 8,800 in-lbs torque (a) WASHER, PLAIN BACW10BP16CD 2 - - WASHER NAS1149E1632P 2 - - BARREL NUT BACN11B16CS 2 - - S BOLT, 12 PT HEAD BACB30US18K52 4 - 10,450 - 11,500 in-lbs torque (a) 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 198 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 199 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 200 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 201 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 202 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 203 of 206 BOEING SERVICE BULLETIN 767-53A0267 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) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 204 of 206 BOEING SERVICE BULLETIN 767-53A0267 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 (SHEET 1 OF 1) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 205 of 206 BOEING SERVICE BULLETIN 767-53A0267 ALERT ALERT

APPENDIX D: PART DEMAND INTENT (SHEET 1 OF 1) Original Issue: August 13, 2015 Revision 1 August 04, 2016 Export Controlled ECCN: 9E991 - BOEING 767-53A0267 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 206 of 206