94-17-03 BOEING: Amendment 39-8998. Docket 92-NM-237-AD. \n\n\tApplicability: Model 767 series airplanes equipped with Rolls-Royce RB211-524 series engines, certificated in any category.\n \n\tCompliance: Required as indicated, unless accomplished previously. \n\n\tTo ensure the integrity of the fail safe features of the thrust reverser system, accomplish the following: \n\n\t(a)\tWithin 30 days after October 15, 1991 (the effective date of AD 91-22-02, Amendment 39-8062), perform the inspections, adjustments, and functional checks described in Boeing Service Bulletin 767-78-0048, dated August 15, 1991, or Revision 1, dated March 26, 1992. Perform those actions in accordance with procedures described in the service bulletin. After the effective date of this AD, those actions shall be accomplished only in accordance with Revision 1 of the service bulletin. Accomplishment of the actions required by this paragraph terminates the actions required by paragraph (a) of AD 91-22-02, amendment 39-8062. \n\n\t\t(1)\tExcept as provided by paragraph (a)(2) of this AD, repeat all inspections and functional checks in accordance with the service bulletin at intervals not to exceed 3,000 flight hours. \n\n\t\t(2)\tRepeat the functional check of the grounding wire for the thrust reverser Selector Sequence Valve (SSV) in accordance with the service bulletin at intervals not to exceed 1,500 flight hours, and whenever maintenance action is taken that would disturb the SSV grounding circuit. \n\n\t(b)\tIf any of the inspections and/or functional checks required by paragraph (a) of this AD cannot be successfully performed, or if those inspections and/or functional checks result in findings that are unacceptable in accordance with Boeing Service Bulletin 767-78-0048, dated August 15, 1991, or Revision 1, dated March 26, 1992, accomplish paragraphs (b)(1) and (b)(2) of this AD. After the effective date of this AD, the actions required by paragraph (b)(2) of this AD shall be accomplished onlyin accordance with Boeing Service Bulletin 767-78-0048, Revision 1, dated March 26, 1992. \n\n\t\t(1)\tPrior to further flight, deactivate the associated thrust reverser in accordance with Section 78-31-1 of Boeing Document D630T002, "Boeing 767 Dispatch Deviation Guide," Revision 11, dated March 15, 1993. No more than one thrust reverser on any airplane may be deactivated under the provisions of this paragraph. \n\n\t\t(2)\tWithin 10 days after deactivation of any thrust reverser in accordance with this paragraph, the thrust reverser must be repaired in accordance with Boeing Service Bulletin 767- 78-0048, dated August 15, 1991, or Revision 1, dated March 26, 1992. Additionally, the inspections and/or functional checks required by paragraph (a) of this AD must be successfully accomplished; once this is accomplished, the thrust reverser must then be reactivated. \n\n\t(c)\tWithin 3 years after the effective date of this AD, install a second locking gearbox system on the left- and right-handengine thrust reversers, in accordance with Boeing Service Bulletin 767-78-0059, Revision 2, dated June 10, 1993; or Revision 3, dated January 20, 1994. \n\n\tNOTE 1: Revisions 2 and 3 of Boeing Service Bulletin 767-78-0059 reference Rolls-Royce Service Bulletins RB.211-71-9608, RB.211-71-9600, and RB.211-71-9601, and Eldec Service Bulletin 8-651-32-01 as additional sources of service information for accomplishment of the locking gearbox installation. However, the Boeing service bulletins do not specify the appropriate revision levels for those Rolls-Royce and Eldec service bulletins. The appropriate revision levels for the Rolls-Royce and Eldec service bulletins to be used in conjunction with Boeing Service Bulletin 767-78-0059 are as follows: Rolls-Royce Service Bulletin RB.211-71-9608, Revision 1, dated October 2, 1992; Rolls-Royce Service Bulletin RB.211-71-9600, Revision 4, dated February 11, 1994; Rolls-Royce Service Bulletin RB.211-71-9601, Revision 1, dated October 2, 1992;and Eldec Service Bulletin 8-651-32-01, dated January 31, 1992. \n\n\t(d)\tWithin 3,000 flight hours after accomplishing the modification required by paragraph (c) of this AD, or within 1,000 flight hours after the effective date of this AD, whichever occurs later; and thereafter at intervals not to exceed 3,000 flight hours; perform operational checks of the number 2 and number 3 gearbox locks and of the air motor brake in accordance with Appendix 1 (including Figure 1) of this AD. \n\n\t(e)\tAccomplishment of the modification and periodic operational checks required by paragraphs (c) and (d) of this AD constitutes terminating action for the inspections, adjustments, and functional checks required by paragraph (a) of this AD. \n\n\t(f)\tAn alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA, Transport Airplane Directorate. Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Seattle ACO. \n\n\tNOTE 2: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Seattle ACO. \n\n\t(g)\tSpecial flight permits may be issued in accordance with sections 21.197 and 21.199 of the Federal Aviation Regulations (FAR) (14 CFR 21.197 and 21.199) to operate the airplane to a location where the requirements of this AD can be accomplished. \n\n\t(h)\tCertain actions shall be done in accordance with Boeing Service Bulletin 767-78-0048, Revision 1, dated March 26, 1992; and Boeing Service Bulletin 767-78-0059, Revision 2, dated June 10, 1993, or Boeing Service Bulletin 767-78-0059, Revision 3, dated January 20, 1994. The incorporation by reference of these documents was approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Certain other actions shall be done in accordance with Boeing Service Bulletin 767-78-0048, dated August 15, 1991. The incorporation by reference of that document was approved previously by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51 as of October 15, 1991 (56 FR 51638). Copies may be obtained from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington 98124-2207. Copies may be inspected at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC. \n\n\t(i)\tThis amendment becomes effective on September 14, 1994. \n\n\nFIGURE 1\n\n\n\n\t\t\t\t\tAPPENDIX 1\n\n1.\tGearbox Lock and Air Motor Brake Test \n\n\tA.\tGeneral \n\t\t(1)\tTo do the test of the gearbox locks and air motor brake, you must do the steps that follow: \n\t\t\t(a)\tDo the deactivation procedure of the thrust reverser system. \n\t\t\t(b)\tDo the test of the air motor brake. \n\t\t\t(c)\tDo the test of the gearbox locks. \n\t\t\t(d)\tDo the activation procedure of the thrust reverser system. \n\tB.\tEquipment \n\t\t(1)\tCP30784 - INA Access Platform, Rolls-Royce \n\t\t(2)\tCP30769 - Protection Pads, Rolls-Royce \n\t\t(3)\tCP30785 - Access Stools, Rolls-Royce \n\t\t(4)\tUT1293/1 - Load Tool, Rolls-Royce (2 required) \n\tC.\tProcedure (Fig. 1). \n\n\tWARNING:\tDO THE DEACTIVATION PROCEDURE OF THE THRUST \n\tREVERSER SYSTEM, WHICH MUST INCLUDE THE INSTALLATION OF LOCK \tBARS (OR BLOCKERS), TO PREVENT THE ACCIDENTAL OPERATION OF THE THRUST REVERSER. THE ACCIDENTAL OPERATION OF THE THRUST \tREVERSER COULD CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. \n\n\t\t(1)\tDo the deactivation procedure of the thrust reverser in the forward thrust position for ground maintenance.\n \n\t\t(2)\tUse a 0.25 inch (6.4 mm) square drive to turn the manual lock release screw to release the No. 2 and No. 3 gearbox locks. \n\n\t\tNOTE: It is not always easy to turn the manual lock release screws. This is because of a preload in the systems. To release the preload, lightly turn the manual cycle and lockout shaft in the stow direction. \n\n\t\t\t(a)\tMake sure the lock indicators are extended at gearboxes No. 2 and No. 3. \n\n\t\t(3)\tDo a test of the air motor brake: \n\t\t\t(a)\tIF YOU USE THE LOAD TOOLS; \n\t\t\t\tTry to move the translating cowl in the extend direction as follows: \n\t\t\t\t1)\tRemove the lock bars that you installed in the deactivation procedure. \n\t\t\t\t2)\tInstall the load tools through the cutouts and into the No. 2 and No. 3 gearboxes. \n\t\t\t\t3)\tAttach the torque wrenches to the load tools. \n\t\t\t\t4)\tTry to move the translating cowl in the extend direction. \n\t\t\t(b)\tIF YOU DO NOT USE THE LOAD TOOLS; \n\t\t\t\tTry to move the translating cowl in the extend direction as \n\t\t\t\tfollows: \n\t\t\t\t1)\tRemove the lock bars that you installed in the \n\t\t\t\t\tdeactivation procedure. \n\t\t\t\t2)\tPut the 0.25 inch (6.4 mm) square drive extensions into the manual cycle and lockout shaft at the No. 2 andNo. 3 gearboxes. \n\t\t\t\t\ta)\tAttach the standard drive tools. \n\t\t\t\t3)\tTry to move the translating cowl in the extend direction. \n\t\t\t(c)\tIf the translating cowl moves, replace the air motor and shutoff valve. \n\t\t(4)\tDo a test of the gear box locks: \n\n\t\tNOTE:\tThe steps that follow are for the No. 3 gearbox. Then, do these steps again for the No. 2 gearbox. \n\t\t\t(a)\tInstall the lock bars in the manual cycle and lockout shafts at the No. 2 and No. 3 gearboxes. \n\t\t\t(b)\tInstall the INA access platform in the exhaust mixer duct. \n\t\t\t(c)\tInstall the protection pads and the access stools. \n\t\t\t(d)\tRelease the air motor brake: \n\t\t\t\t1)\tOpen the air motor access and pressure relief panel. \n\t\t\t\t2)\tPull the air motor brake release handle forward and \t\t\t\t\tturn it counterclockwise to lock the handle in its position. \n\t\t\t(e)\tTurn the manual lock release screw clockwise to engage the \t\t\t\tNo. 3 gearbox lock. \n\t\t\t\t1)\tMake sure that the lock indicator is retracted (under \t\t\t\t\tthe surface) at gearbox No. 3. \n\t\t\t(f)\tMake sure No. 2 gearbox lock is released. \n\t\t\t\t1)\tMake sure the lock indicator is extended at gearbox \t\t\t\t\tNo. 2. \n\t\t\t(g)\tIF YOU USE THE LOAD TOOLS; \n\t\t\t\t\tDo a check of the lock dogs as follows: \n\t\t\t\t1)\tRemove the lock bars from the No. 2 and No. 3 \t\t\t\t\t\tgearboxes. \n\t\t\t\t2)\tInstall the load tool through the cutout and into the No. \t\t\t\t\t3 gearbox. \n\t\t\t\t3)\tAttach the torque wrench to the load tool. \n\n\n\tCAUTION:\tDO NOT APPLY A TORQUE LOAD OF MORE THAN 30 \n\tPOUND-INCHES (3.4 NEWTON-METERS) TO THE MANUAL CYCLE AND LOCK OUT SHAFT. A LARGER \tTORQUE LOAD CAN CAUSE DAMAGE TO THE MECHANISM. \n\n\t\t\t\t4)\tApply a torque counterclockwise through the manual \n\t\t\t\t\twind position of the No. 3 gearbox. \n\t\t\t\t\ta)\tIf the translating cowl does not move, the lock \t\t\t\t\t\tbar touched one of the two lock dogs. \n\t\t\t\t\tb)\tIf the translating cowl moved, lock the thrust \n\t\t\t\t\t\treverser until the No. 3 gearbox is replaced. \n\t\t\t\t5)\tTurn the manual lock release screw \t\t\t\t\t\t\tcounterclockwise to release the gearbox lock. \n\t\t\t\t\ta)\tMake sure that the indication rod comes out \t\t\t\t\t\tof the No. 3 gearbox. \n\t\t\t\t6)\tTurn the manual cycle and lockout shaft \n\t\t\t\t\tcounterclockwise a 1/4 of a turn. \n\t\t\t\t7)\tTurn the manual lock release screw clockwise to \n\t\t\t\t\tengage the No. 3 gearbox lock. \n\t\t\t\t\ta)\tMake sure that the indication rod is fully \n\t\t\t\t\t\tretracted (under the surface). \n\n\n\tCAUTION:\tDO NOT APPLY A TORQUE LOAD OF MORE THAN 30 \n\tPOUND-INCHES (3.4 NEWTON-METERS) TO THE MANUAL CYCLE AND LOCKOUT SHAFT. A GREATER \tTORQUE LOAD CAN CAUSE DAMAGE TO THE MECHANISM. \n\n\t\t\t\t8)\tApply a torque counterclockwise through the manual \n\t\t\t\t\twind position of the No. 3 gearbox. \n\t\t\t\t\ta)\tIf the manual cycle and lockout shaft can not be turned more than \t\t\t\t\t\t\tapproximately 1/4 turn, the second lock dog is serviceable. \n\t\t\t\t\tb)\tIf the manual cycle and lockout shaft can be \n\t\t\t\t\t\tturned more than approximately 1/4 turn, the \n\t\t\t\t\t\tsecond lock dog is unserviceable. Lock thethrust reverser until the No. 3 gearbox is \n\t\t\t\t\t\treplaced. \n\n\t\t\t\t\tNOTE:\tThe two lock dogs are found 1/2 turn apart when you use the manual cycle and lockout shaft. If necessary, do the check again to make sure that the lock dogs are serviceable.\n \n\t\t\t\t9)\tDo the procedure given above for the No. 2 gearbox \n\t\t\t\t\tlock. \n\t\t\t(h)\tIF YOU DO NOT USE THE LOAD TOOLS; \n\t\t\t\t\tDo a check of the lock dogs as follows: \n\t\t\t\t1)\tRemove the lock bars from the No. 2 and No. 3 \n\t\t\t\t\tgearboxes. \n\t\t\t\t2)\tPut the 0.25 inch (6.4 mm) square drive extensions \t\t\t\t\tinto the manual cycle and lockout shaft at the No. 2 and No. 3 gearboxes. \n\t\t\t\t\ta)\tAttach the standard drive tools. \n\n\n\tCAUTION:\tDO NOT APPLY A TORQUE LOAD OF MORE THAN 30 \n\tPOUND-INCHES (3.4 NEWTON-METERS) TO THE MANUAL CYCLE AND LOCKOUT SHAFT. A LARGER \tTORQUE LOAD CAN CAUSE DAMAGE TO THE MECHANISM. \n\n\t\t\t\t3)\tApply a torque counterclockwise through the manual \n\t\t\t\t\twind position of the No. 3 gearbox. \n\t\t\t\t\ta)\tIf the translating cowl does not move, the lock \n\t\t\t\t\t\tbar touched one of the two lock dogs. \n\t\t\t\t\tb)\tIf the translating cowl moved, lock the thrust \n\t\t\t\t\t\treverser until the No. 3 gearbox is replaced. \n\t\t\t\t4)\tTurn the manual lock release screw \t\t\t\t\t\t\tcounterclockwise to release the gearbox lock. \n\t\t\t\t\ta)\tMake sure that the indication rod comes out \t\t\t\t\t\tof the No. 3 gearbox. \n\t\t\t\t5)\tTurn the manual cycle and lockout shaft \t\n\t\t\t\t\tcounterclockwise a 1/4 of a turn. \n\t\t\t\t6)\tTurn the manual lock release screw clockwise to \n\t\t\t\t\tengage the No. 3 gearbox lock. \n\t\t\t\t\ta)\tMake sure that the indication rod is fully \n\t\t\t\t\t\tretracted (under the surface). \n\n\n\tCAUTION:\tDO NOT APPLY A TORQUE LOAD OF MORE THAN 30 \n\tPOUND-INCHES (3.4 NEWTON-METERS) TO THE MANUAL CYCLE AND LOCKOUT SHAFT. A GREATER \tTORQUE LOAD CAN CAUSE DAMAGE TO THE MECHANISM. \n\n\n\t\t\t\t7)\tApply a torque counterclockwise through the manual \t\t\t\t\twind position of the No. 3 gearbox. \n\t\t\t\t\ta)\tIf the manual cycle and lockout shaft can notbe turned more than approximately 1/4 turn, the second lock dog is serviceable. \n\t\t\t\t\tb)\tIf the manual cycle and lockout shaft can be \t\t\t\t\t\tturned more than approximately 1/4 turn, the second lock dog is unserviceable. Lock the \t\t\t\tthrust reverser until the No. 3 gearbox is replaced. \n\n\t\t\t\t\tNOTE:\tThe two lock dogs are found 1/2 turn apart when you use the manual cycle and lockout shaft. If necessary, do the check again to make sure that the lock dogs are serviceable. \n\n\t\t\t\t8)\tDo the procedure given above for the No. 2 gearbox lock. \n\t\t(5)\tInstall the lock bars in the manual cycle and lockout shafts at the No. 2 and No. 3 gearboxes. \n\t\t(6)\tApply the air motor manual brake: \n\t\t\t(a)\tTurn the air motor brake release handle clockwise and then release. \n\t\t\t(b)\tClose the air motor access and pressure relief panel. \n\t\t(7)\tMake sure the No. 2 and No. 3 gearbox locks are released. \n\t\t\t(a)\tMake sure the lock indicator rods are extended at the No. 2 \t\t\t\tand No. 3 gearboxes. \n\t\t(8)IF YOU USE THE LOAD TOOLS; \n\t\t\tTry to move the translating cowl in the extend direction as follows: \n\t\t\t(a)\tRemove the lock bars from the No. 2 and No. 3 gearboxes. \n\t\t\t(b)\tInstall the load tools through the cutouts and into the No. 2 \t\t\t\tand No. 3 gearboxes. \n\t\t\t(c)\tAttach the torque wrenches to the load tools. \n\t\t\t(d)\tTry to move the translating cowl in the extend direction. \n\t\t(9)\tIF YOU DO NOT USE THE LOAD TOOLS; \n\t\t\tTry to move the translating cowl in the extend direction as follows: \n\t\t\t(a)\tRemove the lock bars from the No. 2 and No. 3 gearboxes. \n\t\t\t(b)\tPut the 0.25 inch (6.4 mm) square drive extensions into the \t\t\t\tmanual cycle and lockout shaft at the No. 2 and No. 3 gearboxes. \n\t\t\t\t1)\tAttach the standard drive tools. \n\t\t\t(c)\tTry to move the translating cowl in the extend direction. \n\t\t(10)\tIf the translating cowl moves, do the full test again. \n\t\t\t(a)\tIf the translating sleeve moves again, lock the thrust reverser \t\t\t\tuntil you can replace the two locking gearboxes and the air motor and shutoff valve. \n\t\t(11)\tRemove the access stools and protection pads. \n\t\t(12)\tRemove the INA access platform from the exhaust mixer duct. \n\t\t(13)\tDo the activation procedure of the thrust reverser system. \n\t\t(14)\tDo the functional test of the thrust reverser system.