rostraCommercial

Airplane v

Group Service Bulletin

Number: 737-53-1116 Revision Transmittal Sheet Date: July 21, 1988

Revision 2: September 30, 1993

ATA System: 5331

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes modified as given in the initial release or Revision 1 of this service

bulletin.

No more work is necessary on airplanes that have cracks repaired as given in the initial release or Revision 1

of this bulletin, provided they are within the repairable crack area specified in this revision. Contact Boeing for repair instructions if cracks have been repaired that are outside the repairable area specified in Revision 2

of this bulletin.

SUMMARY

S This revision is sent to provide a list of reference service bulletins applicable to 737 door corner and hinge cutouts. Also, this revision provides information on the crack length and location that is repairable with the

repair given in this bulletin.

Paragraph l.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

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

of important changes.

Pages with a revision number and date, but no vertical lines, have no important changes.

REVISION HISTORY

Initial Release: July 21, 1988

Revision 1: September 7, 1989

Revision 2: September 30, 1993

BOEING GOMMlEROIAAIRPIAlE GROUP P.t BOX 3707 SEA IrE, WASHINGTON 98124-2207
sA N - n O Commercial

Airplane 7

Group Service Bulletin

Number: 737-531116 Summary Date: July 21, 1988

Revision 2: September 30, 1993

ATA System: 5331

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION

BACKGROUND Accomplishment Instructions at or before the

accumulation of 75,000 flight cycles. Based on a structural review of the 737 airplane, incorporation of the modification per this service | Do the inspections prior to reaching 35,000 flight bulletin is recommended on aging airplanes. cycles. On airplanes with 35,000 or more flight cycles, do the inspections at the first available Six operators have found seventeen cracks in the opportunity, recommended at the next maintenance skin and doublers at the upper corners of the j interval, not to exceed 4,500 flight cycles after forward galley doorway on eight airplanes. There j receipt of this service bulletin.

were eight cracks report ed at the upper aft corner on

three airplanes, and nine cracks in the skin at the If no cracks ale found repeat the inspection at 4,500 forward corner on five airplanes. The airplanes had flight cycle intervals until the preventive modification accumulated from 29,000 to 47,300 flight hours, and is accomplished. from 40,500 to 60,800 flight cycles.

Cause of the cracking is attributed to fatigue from EFFECTIVITY

pressurization cycles, and it not corrected could result in cabin pressurization difficulties, and 737 airplanes, Line Number 1-1560, less unscheduled downtime for repairs. PJ201 -PJ21 9

ACTION MANPOWER

Accomplish high and low frequency eddy current Total Elapsed Time inspections for cracks in the skin, skin doubler, or Ao~licabili Man-hours (Hours) bearstrap doubler in the upper corners of the forward galley doorway. Inspection 5 2.5

Preventive

If no cracks are found, accomplish the preventive Modification 0.7 0.7 modification, or repeat the inspection until the Repair - per corner 14 14 preventive modification is accomplished.

If cracks are found, install the repair doublers and | MATERIAL INFORMATION triplers over the cracked areas per this bulletin.

COMPLIANCE Boeing supplied kits

3See Paragraph I.G., Material Price and Availability. As recommended by the 737 Aging Fleet Structures

Working Group, accomplish the modification per the

BOEING GOMMERGIAI.AIRPLUkJE GROUP PO. BOX 3707 SEATTLE. WASHINGION 98124-22C7 Summary Page 1 of 2
BOEING SERVICE BULLETIN 737-53-1116

+ L 1 ++ ++ + + + \

++ +

+ +CRACKS

~ +± (TYPICAL)

I+++

AFT CORNER SHOWN

FORWARD CORNER SIMILAR

Jui 21/88

REV 2: Sep 30/93 Summary Page 2 of 2
AssAFAKyW Commercial

Airplane

Group Service Bulletin

Number: 737-53-1116

Date: July 21. 1988

Revision 2: September 30, 1993

ATA System: 5331

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION,

REPAIR, AND PREVENTIVE MODIFICATION

i. PLANNING INFORMATION

A. Eflectivlty

1. Airplanes

Refer to Service Bulletin Index Document D16-19567, Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AER LINGUS (ARL)

PG255 PG573 PK029 PK641-PK642 PP951-PP952 PY281

PY322-PY323

AEROLINEAS ARGENTINAS (ARG)

PH705-PH708 PH741-PH743 PK102-PK103 PY007

AERON AVIATION (AAV)

PJ072

AIR ALGERIE (ALG)

PK361 PK631 PK633-PK634 PL717-PL725 PY051-PY053

AIR ATLANTA ICELANDIC (AID)

PJ104 PK614 PL027 PY002 PY381

AIR CHINA (BEJ)

PM281-PM2S3 PPS21-PP522

AIR COLUMBUS (COB)

PP904 PP907

AIR EUROPA (ARE)

PP501-PP502 PP827 PP831 PP833-PP835 PP840 PP846

AIR FRANCE (AFA)

PL52-PL503 PN101-PN117 PP902 PP910

AIR GABON S.A. (GBN)

PY1 91

Jul 21/88 737-53-1116

REV 2: Sep 30/93 Page1 of 23
BOEING SERVICE BULLETIN 737-53-1116

AIR GUINEE (GNE)

PY651

AIR HOLLAND CHARTER B.V. (HOI) PP504

AIR LANKA, LTD. (LNK)

PH701

AIR MADAGASCAR (MAD)

PG375 PL793

AIR MALTA (MLT)

PLG21 -PL626

AIR NAMIBIA (NAM) PN492

AIR NAURU (NAU) PK356 PK581 PY286

AIR NEW ZEALAND, LTD. (ANZ) PJ009 PK211 PK213-PK214 PK216-PK220 PM18, PY741

AIR NIPPON CO., LTD. (ANK) PG582

AIR SWEDEN (TIS)

PJ003

AIR 

PY61 

TANZANIA 

1-PY612

(TNZ) 0

AIR TOULOUSE INTERNATIONAL (TOL) PL716

AIR ZAIRE (ZAI)

PY11. PY113

AIR ZIMBABWE (ZMB) PN431 -PN433

ALASKA AIRLINES (ASA)

PY112 PY134-PY135 PY270 PY461-PY463

ALL NIPPON AIRWAYS CO. LTD. (ANA) PG584-PG586 PK711-PK716

ALOHA (ALO)

PG0046 PK286-PK287 PK305 PK691-PK695 PK697 PP825-PP826 PYC0l PY231 PY242 PY451

ALYEMDA DEM. YEMEN AIRLINES (ALY) PY409-PY410

Jul 21/88 737-53-1116 REV 2: Sep 30/93 2
BOEING SERVICE BULLETIN 737-53-1116

AMERICA WEST AIRLINES, INC. (AMW) PC004 PG036 PK283 PK565 PK696 PLO81

PL172 PL551-PL562 PL801 PP181-PP187 PP189 PP891-PP899

PP901 PP903 PP931-PP934

AMIRI FLIGHT (ABD)

PK495

ANGOLA AIRLINES (ANG)

PK661 PK664-PK666 PY1 62

ANSETT AIRLINES OF AUSTRALIA (ANS)

PQ026-PQo37

ANSETT WORLDWIDE AVIATION SERVICES (AWW)

PA001

ARAMCO ASSOCIATED CO. (ARM)

PLi51 PL456 PY241 PY243-PY244

ARKIA ISRAELI AIRLINES, LTD (ARK)

PG575

ASEAN AVIATION (L) INC. (ASJ)

PG578-PG581 PG583

ATASCO USA. INC. (ATJ)

PL762

AUSTRALIAN AIRLINES LIMITED (AUS) PQ001-PQ01 2

AVENSA (AVN)

PK042-PK043

AVIATECA (AVT)

PG201 PL737 PL740-PL741 PP352 PP379 PP384

PP948 PY201

AVIATION SALES CO., INC. (ASC)

PG331 PG401

AVIOGENEX AIR TRANSPORT (AVG)

PL501 PL506 PN501-PN502

BAVARIA (BAV)

PL455

BOURAQ INDONESIA AIRLINES (PTB) PJOO1 PL742-PL744 PL803

BRAATHENS S.A.F.E. (BRT)

PJ007-PJOO8 PK882 PN452-PN453 PN455

BRITANNIA AIRWAYS, INC. (BRI)

PJ1O1 PJ103 PJ108 PJ1I0-PJ111 PJ113-Pj115 PJ117-PJ119

PK801-PK804

Jul 21/88 737-53-1116

REV 2: Sep 30/93 3
BOEING SERVICE BULLETIN 737-53-1116

BRITISH AIRWAYS (BAB)

PK731-PK765 PK771-PK777 PK779 PK820 PP353

BRITISH MIDLAND (BMA)

PP908-PP909

CALDWELL AIRCRAFT TRADING CO. (CAS)

PG402

CAMEROON AIRLINES (CAM)

PM1 71 PY046-PY047

CANADIAN AIRLINES INTERNATIONAL LTD. (CDI) PG651-PG652 PK027-PK028 PK358 PK671-PK675 PK677-PK681 PK822

PK8S1 PK884 PL401-PL417 PL764-PL770 PM141-PM142 PY151-PY154

PY303-PY304 PY421-PY422 PY441

CARNIVAL AIR (CVL)

P0302 PG305 PG312 PK622 PL71 2

CASINO EXPRESS (CIN)

PG279 PG436

CAYMAN AIRWAYS (CAY)

PK222 PK561

CHINA A!R LINES, INC. (CHI) PN472

CHINA SOUTHERN AIRLINES (GUN) PK636-PK637 PM251-PM254 PN405

CHINA SOUTHWEST AIRLINES (XIN)

PP631 -PP634

CHINA XINHUA AIRLINES (XIH)

PY401 PY594-PY595

CONTINENTAL AIRLINES, INC. (CAL) PA006-PA009 PA011-PA014 PA016-PA020 PG056 PG064 PG199

PG225 PG229 PG432-PG433 PG441 PG501-PG505 PG621-PG625

PG627-PG628 PG630 PG704 PL001 PP67t-PP699 PP701-PP726

PP730 PP732-PP733

COPA COMPANIA PANAMENA DE AVIATION S.A. (COP) PCoo1 PJ107 PJ112 PK617 PY341

CROATIA AIRLINES (CRH)

PK904 PK906-PK907 PK928 PK932

DAMANIA AIRWAYS LTD. (DAI) PK354 PL451-PL452

DELTA AIR LINES, INC. (DAL)

PK611 PK61 3 PK623-PK624 PK632 PL221 PL61 1

PN131-PN163 PN401-PN404 PN407-PN420 PP231-PP243

Jul 21/88 737-53-111 6 REV 2: Sep 30/93 4
BOEING SERVICE BULLETIN 737-53-1116

DRAGONAIR (DRG)

PK357 PK872

DUKE FARMS (DFI)

PP991

E G AND G (EGN)

PG037 PG208 PG210 PG215 PG431 PL763

EAST WEST AIRLINES (INDIA) (BOM)

PK61S-PK616 PK819 PK824 PL171 PL758

EDRESS, SHIEKH M. (SME)

PL505

EGYPTAIR (EGP)

PK254-PK255 PK257-PK258

EL AL ISRAEL AIRLINES, LTD. (ELA)

PL631-PL632

EURALAIR (ERA)

PG026 PG028-PG029 PY004 PY006

EUROPE AERO SERVICE (EUR)

PK203 PK215 PK282 PK359 PK564 PK61 2

FAR EASTERN AIR TRANSPORT (FAT)

PA002 PA005 PG055 PG226 PG228 PG230

PK562 PN481

FAUCETT (COMPANIA DE AVIATION S.A. (FCT)

PC002 PGC34 PG213 PK241 PL711

FORTUNE AVIATION (FOR)

PK432

FRENCH POSTAL OFFICE (FPO)

PY101-PY103 PY302 PY342 PY344

GATARI AIR SERVICE (GRI)

PL441

GERMANIA FLUGGESELLSCHAFT MBH (GER)

PP503 PQ231-P0233

GOVERNMENT OF BRAZIL (BRZ)

PK068-PK069

GOVERNMENT OF MEXICO (MXG)

PC005 PG223

GOVERNMENT OF SHARJAH (SHJ)

PL581

GPA GROUP LTD. (GUI)

PK252 PK355

Jul 21/88 737-53-1116

REV 2: Sep 30/93 5
BOEING SERVICE BULLETIN 737-53-1116

GULF AIR (GUL) PK461-PK464 PK466-PK468

HAPAG LLOYD (HAP) PL504

HEAVYLIFT AIRCRAFT ENGINEERING (HVL) PJ109

INDIAN AIR FORCE (IDF) PH71 2-PH71 3 PM01 6-PM01 7

INDIAN AIRLINES (IND) PHO21 PHO24 PH709 PH711 PK231 -PK233 PK235-PK240 PM0O1-PMOOS PY631

INDONESIAN AIR FORCE (IDO) PL601-PL603

INTEGRATED RESOURCES (INH) PG271 PG273 PG629 PJ006 PY005

INTER EUROPEAN AIRWAYS (IER) PP841 -PP842

INTERAMERICA S.A. DE C.V. (INJ) PL7S1

INTERNATIONAL AIR LEASES (IAL) PG043 PG047-PG048 PG253 A

INTERNATIONAL AIRLINE SUPPORT GROUP (ASG)

INTERNATIONAL LEASE FINANCE (ILF) PL745

INTERNATIONAL PACIFIC TRADING CO. (IPT) PG224 PG572 PG574 PJ102

IRAN AIR (IRN)

PH731 PK391 PY021-PY022

IRAQI AIRWAYS (IRQ)

PY141-PY142

JAPAN TRANSOCEAN AIR CO., LTD. (SWL) PK521 PK523-PK527 PN451 PN454 PN456

JET EXPRESS ,JXP)

PK221

JUGOSLOVENSKI AEROTRANSPORT (JAT) PP771 -PP779

KENYA AIRWAYS (KEN) PK253 PK256

Jul 21/88 REV 2: Sep 30193 7374-1116
BOEING SERVICE BULLETIN 737-53-1116

KLM ROYAL DUTCH AIRLINES (KLM) PP861 -PP870

KOREAN AIR FORCE (KAF)

PP221

LACSA (LAC)

PK871

LADECO (LDE)

PJ005 PK212 PK281 PK826 PK830 PL802 PP946

LAN-CHILE S.A. (LAN)

PK360 PK825 PL025 PL028

LAPA (LAZ)

PG365 PK047 PK051

LAUDA AIR LUFTFAHRT AG (LAL) PPS51 -PP852

LIBERTY AIRLINE, LTD. (LIR)

PJ004

LINA CONGO (LNA)

PY411

LINHAS AEREAS DE MOCAMBIQUE (LAM) PH703 PY031

LITHUANIAN AIRLINES (LIJ)

PK563

LUFTHANSA GERMAN AIRLINES (DLH) PK901-PK903 PK905 PK911-PK927 PK929-PK931 PK933-PK938 PQ051-PQO65 P0086-P0090 PY345-PY346

MALAYSIAN AIRLINES SYSTEM BERHAD (MAS) PL746-PL747

MALEV HUNGARIAN AIRLINES (HGA) PK284-PK285 PK827

MANDALAAIRLINES (MND)

PL421 PNO01-PNO02

MARKAIR, INC. (ALK)

PN493 PP301 PP305 PY056-PY057 PY592-PY593

MODILUFT (MOU)

PK90S-PK91 0

MONARCH AIRLINES, LTD. (MON) PP821 PP823-PP824 PP832

MONTELY II (MOY)

PJ031

Jul 21/88

REV 2: Sep 30/93 737-53-1116
BOEING SERVICE BULLETIN 737-53-1116

MORRIS AIR (MOR) PP162 PP164-PP165 PP169 PP191-PP192 PP201-PP205 PP302-PP304 PP351 PP378 PP381-PP382 PP727

NASA (NAS)

PA099

NATIONAL AIRLINES (NAW)

PJ105-PJ1 06

NICA (NICARAGUENCE DE AVIACION) (NIC) PK823

NIGERIA AIRWAYS, LTD. (NIA) PL781-PL782 PL784-PL788

NORDIC EAST (NOE;

PJ002

NWT AIR (NTA)

PX701 PY132-PY133

OLYMPIC AIRWAYS (OLY)

PK301-PK304 PK307-PK310 PM021-PM023

P. T. AIRFAST (PTF) PG204 PG278 PY343

PAKISTAN INTERNATIONAL AIRLINES CORP. (PIA) PP281 -PP286

PETROLAIR SYSTEMS S. A. (PTS) PL471

PHILIPPiNE AIRLINES, INC. (PAL)

PP935-PP936

PLUNA (PLU)

PL201 -PI203

POLARIS AIRCRAFT LEASING CORP. (PLS) PG202 PG205 PG207 PG211 PG216 PG21S-PG219 PG272 PK026 PK306 PK465 PK873-PK874 PL061

POLY TECHNOLOGIES, INC. (PTI) PP728-PP729

POLYNESIAN AIRLINES (PLY)

PP947

REPUBLIC OF NIGER (NIR) PY1 66

ROYAL AIR MAROC (RAM)

PK271-PK274 PY671-PY672

REV Jul 2 2: - Sep Sep 30/93 3737-53-1116 8
BOEING SERVICE BULLETIN 737-53-1116

SABENA S.A. (SAB) PK041 PK044-PK04S PK048-PK050 PK052-PK053 PK431 PK433

PP961-PP965 PY272-PY275

SAHSA (SERVICIO AEREO DE HONDURASS.A.) (SAH)

PJ032 PJ071 PL736

SAUDI ARABIAN AIRLINES CORP. (SVA) PK311 -PK317 PL726-PL735 PY036-PY037

SAUDI ROYAL FLEET (SRF)

PK318

SERVICIOS AEREOS RUTAS ORIENTE, (SARO) (SEV)

PA015 PA021-PA022 PK351 PK353

SIERRA PACIFIC AIRLINES (SRP)

P0003 PG217 PG577 PK627

SOUTH AFRICAN AIRWAYS (SM)

PG353-PG354 PG356 PL101-PL113

SOUTHWEST AIRLINES CO. (SWA)

PK082 PK091-PK099 PK541-PK560 PK621 PK628-PK630 PM051-PM066

PP101-PP135 PP161 PP163 PP166-PP163 PP380 PP731

PP822

SUDAN (SUD)

PY156-PY157

SULTANAIR (SLR) PG251 PP188 PP190

T A PORTUGUESES (TAP)

PK971 PK973-PK974 PN081-PN086 PY721

TACA INTERNATIONAL AIRLINES, INC. (TAO)

PG059 PG352 PK223 PN491 PY1 31

TAESA (TES)

PK625-PK626

TAT EUROPEAN AIRLINES (TTR)

PY003 PY301 PY321 PY361 -PY362

TEA BASEL (TEB)

PP838

THAI AIR FORCE (TAF)

PK519

THAI AIRWAYS INTERNATIONAL, INC. (Tll)

PK511 PK514-PK515

TRANSAERO (TRX)

PK451 -PK452

Jul 21/88 737-53-11 i6

REV 2: Sep 30/93 9
BOEING SERVICE BULLETIN 737-53-1115

TRANSAVIA AIRLINES (TAV) PG074 PK501-PK504 PK821 PP501-PP804

TRANSBRASIL AIRLINES INC. (TBL) PP836-PP637 PP847-PP848 PQ241-P0242

TRANSTAR (AFM)

PG274 PG276 PG403

TRITON AIRLINES INC. (TTN) PK352

TUNIS AIR (TUN)

PK861-PK863 PY621

UNITED AIR LINES, INC. (UAL) PGO01-PGO04 PGOOG-PGO13 PGO15-PGO19 PG022-PG025 PG027 PG030 PG032-PG033 PG038-PGO40 PG045 PG051-PG054 PG057 PG060-PG063 PGO65-PG072 PG075 PK201-PK202 PLO02-PLO23 PQ101-PQ123

USAIR, INC. (USA) PGO41-PG042 PG073 PG206 PG301 PG303-PG304 PG306-PG311 PG313-PG314 PG474 PG576 PK288-PK289 PK591-PK599 PK601-PK610 PK883 PM1 01-PM1 19 PNO21 -PN043 PP001-PP010 PP012-PP045 PP376-PP377 PP383 PP401 -PP436 PP471-PP475 PV001-PV004

VARIG AIRLINES (VAR) PK111-PK116 PK118-PK120 PK141-PKI46 PL453-PL454 PP839 PP905-PP906 PP981 -PP982

VARSA (VAB)

PG351

VASP (VSP)

P0435 PG437 PG439-PG440 PG4711-PG473 PHOl1-PHO13 PK061-PK062 PK0S5-PK067 PL7S6 PX071

VENEZUELA - GOVERNMENT OF (VNZ) PK070

VISCOUNT AIR SERVICE INC. (VAS) PG203 PG209 PG212 PG220-PG222

VIVA AIR (VIV)

PP391 -PP392

WHIRLPOOL FINANCIAL CORP 'ZZW) PG214

XIAMEN AIRLINES CO. LTD. (XIA) PK635 PM255

YEMEN AIRWAYS (YEM) PK341

YUNNAN PROVINCIAL IMPORT & EXPORT CORP. (YUN) PP651 -PP652

JUl 211688 

REV 3-11 2: Sep 30/93 73-3101
BOEING SERVICE BULLETIN 737-53-1116

ZAMBIA AIRWAYS (ZAM)

PK291 PL026

IDENTIFICATION BY VARIABLE NUMBER

PA301-PA022 PA099 PA231-PA232 PCOO1-PCO05 PGO0i-PGO75 PG199

PG201-PG230 PG251-PG255 PG271-PG279 PG301-PG314 PG331 -PG332 PG351 -PG356

PG375 PG401-PG403 PG431-PG442 PG471-PG475 PG501-PG50S PG571-PG586

PG621-PG630 PG651-PG652 PG-/01-PG705 PH001 PHO11-PHO13 PHO21-PH024

PH701-PH715 PH731-PH732 PH741-PH743 PJ001-PJ009 PJ031-PJ032 PJ071-PJ072

PJ101-PJ119 PK026-PK029 PK041-PK053 PK061-PK070 PK081-PK082 PK091-PKOS9

PK101-PK103 PK111-PK120 PK141-PK146 PK201-PK204 PK21 1-PK223 PK231 -PK241

PK251-PK258 PK271-PK274 PK281-PK289 PK291 PK301-PK318 PK341

PK351-PK361 PK391 PK431-PK433 PK451-PK452 PK461-PK469 PK495

PK601 -PK504 PK511-PK515 PK519 PK521 -PK527 PK541-PK565 PK581

PK591 -PK599 PK601-PK617 PK621-PK637 PK641 -PK642 PK661-PK666 PK671-PK681

PK691 -PK697 PK711 -PK716 PK731-PK76S PK771 -PK779 PK801 -PK804 PK81 9-PK827

PK830 PK861-PK863 PK871-PK874 PK881-PK884 PK901-PK938 PK971-PK974

PLO01-PL028 PL061 PL081 PL101-PL113 P1151 PL171-PL172

PL201-PL203 PL221 PL401-PL417 PL421 PL441 PL451-PL456

PL471 PL491 PL501-PL506 PL551-PL562 PL581 PL601-PL603

PL611 PL621-PL626 PL631-PL632 P711-PL712 PL716-PL747 PL756

PL758 PL761-PL770 PL781-PL788 PU793 PL801-PL803 PM001-PM006

PM016-PM017 PM021-PM023 PMO51-PM066 PM101-PM119 PM141-PM142 PM171

PM181 PM251-PM255 PM281-PM283 PNO01-PNO02 PNO21 -PN043 PNO8I-PNO86

PN101-PN117 PN131-PN163 PN401-PN420 PN431-PN433 PN451-PN456 PN471-PN472

PN481 PN491-PN493 PN501-PN502 PN511 PP001-PP045 PP101-PP135

PP161-PP169 PP181-PP192 PP201-PP205 PP221 PP231-PP243 PP281-PP286

PP301-PP305 PP351-PP353 PP37S6-PP384 PP391 -PP392 PP401-PP436 PP471-PP475

rPP501-PP504 PP521-PP522 PP631-PP634 PP651-PP652 PP671-PP699 PP701-PP733

PP771-PP779 PP801-PP804 PP821-PP827 PP831-PP842 PP846PP848 PP851-PP852

PP861-PP870 PP891-PP899 PP901-PP910 PP931-PP936 PP946-PP948 PP951-PP952

PP961-PP965 PP981-PP982 PP99 PQ001-PQ012 PQ026-PQ037 PQ051-PQ065

PQ086-PQO90 PQ101-PQ123 PQ231-PQ233 PQ241-PQ242 PV001-PV004 PX071

PX701 PYOO1-PY008 PY021-PY022 PY031 PY036-PY037 PY046-PY048

PY051-PY053 PY056-PY057 PY101-PY103 PY111-PY113 PY131-PY135 PY141-PY143

PY151-PY154 PY156-PY157 PY161-PY162 PY166 PY191 PY201

PY221 -PY222 PY231 PY241 -PY244 PY270-PY275 PY281 PY286

PY301-PY3C4 PY321-PY323 PY341-PY346 PY361-PY362 PY381 PY401

PY409-PY411 PY421-PY422 PY441 PY451 PY461-PY463 PY591-PY595

PY61 1-PY612 PY621 PY631 PY651 PY671-PY672 PY721

PY741

2. Spares

None

Jul 21/88 737-5311116

REV 2: Sep 30193 11
BOEING SERVICE BULLETIN 737-53-1116

B. Reason

As a result of the FAA-sponsored Aging Fleet Conference, a 737 Structures Working Group with Airline and Boeing members and FAA observers was formed to review structural service bulletin modifications and recommend selected bulletins for incorporation on aging airplanes. This service bulletin modification has been recommended for incorporation on aging 737 airplanes.

Inspection of the upper corners of the forward galley doorway will detect cracking that could result in pressurization difficulties. Repair of cracks or accomplishment of preventive modification on uncracked structure is terminating action for inspection per this service bulletin.

Six operators have reported cracks in the upper corners of the forward galley doorways on a total of eight airplanes. Three airplanes had a total of eight cracks in the upper aft corner, with crack lengths of up to 2 inches in the skin, and a 2 inch long crack in the bearstrap doubler on one airplane. Five airplanes had a total of nine cracks from 0.1 inch to 1.5 inches in length in the upper forward corner skin.

The airplanes had accumulated from 29.000 to 47,300 flight hours, and from 40,500 to 60,800 flight cycles.

Revision 1 of this bulletin was issued to provide the recommendations of the Aging Fleet 737 Structures Working Group and to change the forward galley doorway upper forward corner repair doubler instal ation. The installation change eliminates one fastener and moves one fastener to make the repair compatible with the Service Bulletin 737-53-1074 modification.

Revision 2 is sent to provide a list of reference service bulletins applicable to 737 door corners and hinge cutouts. Also, the crack location and limits that can be repaired with instructionsin this bulletin are defined in this revision.

The 

the preventive 

foreyard galley 

modification 

door upper 

for 

forward 

the upper 

corner 

hinge 

modification, 

cutout installed 

installed per this service bulletin, overlaps a

therefore, it is suggested that prior or concurrent 

per Service Bulletin 737-53-1074, W

incorporation of the preventive modification per service bulletin 737-53-1074 be accomplished prior to the repair per this bulletin. Airplanes repaired per the original issue or Revision 1 of this bulletin do not require additional work per this revision, provided the cracks are within the repairable crack area specified in Revision 2.

There are four other service bulletins for 737-100 and 737-200 door cutout cracks. Table I shows the service bulletins and the areas they cover.

TABLE I - SERVICE BULLETINS FOR DOOR CUTOUT CRACKING

DOORWAY Upper UpperAft Lower Lower Aft Upper Lower

Forward Corner Forward Corner Hinge Hinge Corner Corner Cutout Cutout

Forward Entry 737-53-1163 737-53-1083 (a)

Forward Galley 737-53-1 11 6

Aft Galley 737-53-1149 737-53-1074

(a) Service Bulletin 737-53-1083 is for tne lower sill

Jul 21/88 

REV 737-53-1116 2: Sep 30/93 12
BOEING SERVICE BULLETIN 737-53-1116

C. Description

Accomplish high and low frequency eddy current inspections of the area around fasteners in the upper corners of the forward galley doorway to determine if there are cracks in the skin, skin doubler, or bearstrap doubler.

If no cracks are found, accomplish the preventive modification per this bulletin, or repeat the inspection until the preventive modification is accomplished.

If cracks are found, stop drill the crack ends, and install the repair doublers and triplers over the cracked areas per this bulletin.

NOTES:

1. Prior or concurrent incorporation of Boeing Sorvice Bulletin 737-53-1074, "Fuselage - Entry and Galley Doorway Skin Cutouts - Inspection and Modification". is suggested on commonly affected airplanes.

2. This service bulletin is listed in Boeing Document D6-38505.

An evaluation form is attached to this service bulletin. Please use this form to tell us what you think of the quality of this service bulletin.

D. Compliance

Based on a structural review of the 737 airplane, it is recommended that the modification per the Accomplishment Instructions of this service bulletin be accomplished prior to, or upon accumulation of 75,000 flight cycles.

Do the inspections prior to accumulating 35,000 flight cycles. On airplanes with 35,000 or more flight cycles, do the inspections at the first available opportunity, recommended at the next maintenance interval, not to exceed 4,500 flight cycles after receipt of this service bulletin. If no cracks are found, repeat the inspections at 4,500 flight cycle intervals until the preventive modification is done.

E. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and are FM approved. The service bulletin and the FAA approval were based on the airplane in its original Boeing delivery configuration or as modified by other FAA approved Boeing changes and do not apply to airplanes on which other configuration changes have been made.

Jul 21/88 7373531116 REV 2: Sep 30/93 13
BOEING SERVICE BULLETIN 737-53-1116

F. Manpower

Approximately 7 man-hours and a crew of 2 are required to accomplish this inspection per airplane, plus approximately an additional 0.7 man-hour and a crew of 1 is required to accomplish this

preventive modification per doorway corner.

Approximately 14 man-hours are required to accomplish this crack repair per doorway corner.

The following breakdown of manpower requirements is suggested as a guide to assist operators in planning and accomplishing this repair. This estimate is for direct labor performed by an experienced

crew. It does not include setup, planning, familiarization, cure time, tool acquisition, or lost time. Factor this estimate as necessary based on your own experience.

i SElapsed Time

Operation Crew Size Man-Hours (Hours)

Access i1 1 1

Crack Repair (maximum) 1 12 12

Restoration I 1 1 1

TOTAL PER DOORWAY CORNER 14 14

G. Material - Price and Availability

Boeing can supply the kits shown in Paragraph lI.A.1 as shown below. Kit availability is shown in the Reorder Lead Time (ROLT). This revision does not show Boeing price data for kits shown below.

Kit Number Description ROLT

65C33800-12 Kit - Repair 18 weeks

65C33800-13 Kit - Repair 15 weeks

65C33800-14 Kit - Repair 22 weeks

65C33800-15 Kit - Repair 22 weeks

65C33800-16 Kit - Gutter 22 weeks

The kits are subject to the terms and conditions of Boeing's standard purchase order acknowledgment.

Address purchase orders and correspondence pertaining to this quotation to Director of Spares, and refer to this service bulletin number.

The following kit identified in Paragraph il.A.1 may be furnished or fabricated from operators existing stock or purchased directly from industry sources. Kit availability is shown in the Reorder Lead Time

(ROLT). This revision does not show Boeing price data for the kit shown below.

Kit Number Description ROLT

65C33-01-1 Kit - Preventive Modification 22 weeks

The kit is subject to the terms and conditions of Boeing's standard purchase order acknowledgment.

Address purchase orders and correspondence pertaining to this quotation to Director of Spares, and

refer to this service bulletin number.

Jul 21/88 737-53-1116 REV 2: Sep 30/93 14
BOEING SERVICE BULLETIN 737-53-1116

H. Special Tools - Price and Availability

All required coldwork tools and sleeves for accomplishment of this service bulletin may be selected

from appropriate tables in Structural Repair Manual and procured from industry sources, as required.

Two sources that provide coldwork tools, as well as engineering and Service, is Fatigue Technology, Inc., and West Coast Industries, Inc. Also available from both companies is a kit of coidwork tooling specifically tailored to the requirements of this service bulletin.

Refer To:

FTI Kit Number: FTI-737-53-1116-1

Fatigue Technology, Inc.

P.O. Box C-88388

Seattle, WA 98188

Phone Number (206) 246-2010

Fax (206) 244-9886

Refer To:

WCI Kit Number: WCI-737-53-1116

West Coast Indlustriesinc.

14900 Whitman Avenue North

Seattle, WA 98133-6532

Phone Number (206) 365-7513

Fax (206) 365-7483

1. Weight and Balance

Change in Weight Change in Moment

AoDlicabilit (Piounds) _Pound-Inches_

737-1 00 (a) +9.2 +2,825

737-200 (a) +9.2 +3,494

737-300 (a) +9.2 +2,089

(a) Approximate weight and balance information based on incorporation of 65C33800-12, -13 and -16

kits (worst case) on an airplane. Actual weight and balance to be determined by operator based on

extent of kit incorporation.

NOTE: incorporation of Preventive Modification kit 65C33801-1 has no effect on airplane weight and

balance.

Jul 21/88 737-53-1116

REV 2: Sep 30193 15
BOEING SERVICE BULLETIN 737-53-1116

.J. References

1. Existing Data:

a. 737 Structural Repair Manual Subjects 51-10-1, 51-30-9

b. 737 Nondestructive Test Manual Part 6, Subjects 51-00-00, 53-10-42

c. Boeing Service Bulletins:

737-53-1074 "Fuselage - Entry and Galley Doorway Skin Cutouts - Inspection and Modification"

737-53-1083 "Fusel&.ge - Forward Entry Doorway Structure At Lower Sill - Inspection, Modification and Repair'

737-53-1 149 "Fuselage - Aft Galley and Aft Entry Doorway, Upper Corner Skin Cutout Inspection, Repair and Modification"

737-53-1163 "Fuselage - Forward Entry Doorway Skin Cutout - Upper Forward and Upper Aft Corners - Inspection, Modification and Repair "

d. Boeing Document DG6-38505, "Aging Airplane Service Bulletin Structural Modification Program -

Model 737-1 001A200/-200C"-

2. Data supplied with the original issue and Revision 1 of this service bulletin:

Drawings:

DrawigNme Sheet DCN ADCN Title 65C33800 PL A- Skin and Stringer Installation - Repair (Top Kit) 65C33800 1 C3. Process Data:

Boeing Process Specifications that are listed on the drawings supplied in support of this service bulletin are not detailed in this service bulletin since they are common practices which can be accomplished in accordance with operator's normal procedures.

K. Publications Changed

None

L. Electrical Load Data

None

ul 21/88737-53-1116

2: Sep30/9316
BOEING SERVICE BULLETIN 737-53-1118

. 11. MATERIAL INFORMATION

A. Parts Necessary For Each Airplane

The following is provided to aid in kit selection.

Usar Kit

Preventive Modification

Forward and aft corners 65C33801-1

Repair - Forward Corner

Skin and bearstrap cracks 65C33800-12

Skin or bearstrap crack 65033800-14

Repair - Aft Corner

Skin and bearstrap cracks 65C33800-13

Skin or bearstrap crack 65C33800-15

Rain Gutter Replacement 65C33800-16

(Required with Repair)

1. The kits may be obtained as noted in Paragraph l.G.

NOTE: One or more kits and operator furnished materials listed in Paragraph II.A.2 are required to modify or repair each airplane.

Charge in Weight Change in Moment , Acolicability (Pounds) (Pound-Inches)

737-100 (a) +9.2 +2,825

737-200 (a) +9.2 +3,494

737-300 (a) +9.2 +2,089

(a) Kit contains excess parts not required for installation. Discard excess parts or return them to

operators spare stack.

737-53-1074 "Fuselage - Entry and Galley Doorway Skin Cutouts - Inspection and

Modification"

737-53-1083 "Fuselage - Forward Entry Doorway Structure At Lower Sill - Inspection, Modification and Repair"

737-53-1149 "Fuselage -Aft Galley and Aft Entry Docrway, Upper Corner Skin Cutout

Inspection, Repair and Modification"

737-53-1163 "Fuselage - Forward Entry Doorway Skin Cutout - Upper Forward and Upper Aft Corners - Inspection, Modification and Repair"

(a) Kit fasteners may be furnished from operator's existing stocks

Jul 21/88 737-53-1116

REV 2: Sep 30/93 17
BOEING SERVICE BULLETIN 737-53-1116

2. The following materials are to be furnished by the operator.

Quantity 3M-jfimtoi Nomenclature

As Required BMS 5-95, Type I, Class B-1/2, Sealant

-2 or -4 (a)

As Required BMS 10-11, Type I (a) Primer

As Required BMS 10-11, Type II Enamel - Color to Match

Airplane

(a) See Boeing Standard Practices Overhaul Manual Subject 20-50-12.

B. Parts Necessary to Change Spares

None

C. Special Tools and Equipment

Coldworking tools are required during accomplishment of the preventive modification per this service bulletin. See Paragraph l.G. 'or details.

D. Existing Parts Accountability

None

Jul 21/88 737-53-1116 REV 2: Sep 30/93 18
BOEING SERVICE BULLETIN 737-53-1116

.| 111. ACCOMPLISHMENT INSTRUCTIONS

NOTES:

1. The paragraphs identified with letters give the general work instructions and the necessary tests.

The instructions identified with numbers on the figure(s) give the recommended sequence of steps.

2. As recommended by the 737 Aging Fleet Structures Working Group, accomplish the modification

per his service bulletin, Figure 3 of the Accomplishment Instructions prior to, or upon the

accumulation of 75,000 flight cycles.

3. Unless specified differently, these dimensions and tolerances are used:

- All linear dimensions are in inches - Tolerance on linear dimensions other than rivet and bolt edge margin 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 - The hole dimensions for standard solid rivets are found in 737 Structural Repair Manual Chapter 51

- The torque limits to tighten nuts and bolts are found in 737 Structural Repair Manual Chapter 51.

4. Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners.

b. Obey all warnings and cautions in the specified manual sections.

A. Open the forward galley door for access to interior surface of door cutout to accomplish inspection and rework of doorway upper corners.

B. Accomplish an eddy current inspection of the skin, bonded skin doubler, and bearstrap tripler in each

upper corner of the doorway per Figure 1.

C. if cracked doorway corners are found, repair per Figure 2.

D. If no cracks are found, accomplish preventive modification per Figure 3. As an option, reinstall reveal

fittings and rivets and repeat inspection of upper doorway corners until the preventive modification is

accomplished.

NOTE: Delayed implementation of the preventive modification may cause oversizing requirements beyond the preventive modification kit range. The fastener holes may be oversized one time

only (Maximum hole size allowed before cold working is 0.238 inch)

E. Refinish the rework area around doorway as required, and restore airplane to operational configuration.

Jul 21/88 737-53-1116

REV 2: Sep 30/93 19
BOEING SERVICE BULLETIN 737-53-1116

S TA 3t2

332. 131

+ --- i

-;¢2C'Lr at-d

(,, TYPCA (8 PLACES) Sa

TYPICAL- A. 4-, +f ,1 

:, *1 (7 PLACES) I

STICL(TYPICAL)

E<> FWD

The instruction numbers shown below agree with the numbers shown inside the circle symbols in the figure.

CAUTION: WHEN DRILLING OUT EXISTING FASTENERS, DO NOT USE DRILL BIT SIZE ANY

LARGER THAN EXISTING FASTENER DIAMETER.

1 Carefully drill out existing fasteners in shaded areas.

2 Remove magnesium reveal corner fittings 65-53594-1 (or -501) and 65-53595-1 (or -501) from bearstrap doubler and retain for later use. Clean off any sealant residue from exposed area of bearstrap doubler.

3 Inspect exposed area of skin (outside) and bearstrap doubler (inside) for cracks around each removed fastener location (Ref. 737 Nondestructive Test Manual (NDT) 06-37239, Part 6, Subject 51-00-00, Figure 4). Depending on inspection results, take appropriate action per Accomplishment Instructions.

A Inspect skin doubler (underneath skin) for cracks around each removed fastener location (Ref. 737 NDT Manual D6-37239, Part 6, Subject 5310-42). Depending on inspection results, take appropriate action per Accomplishment Instructions.

FIGURE 1. FORWARD GALLEY DOORWAY UPPER CORNER INSPECTION

Jul 21/88 737-53-1116

REV 2: Sep 30/93 

20
BOEING SERVICE BULLETIN 737-53-1116

a|

WST STA STA

33.131 2 291 .5

S-6 t T

S-8 - 56

t ~~~TYPltAL CRACK ---- )

SEE DETAIL I FOR

5-9 CRACK REPAIR LIMITS

ZYFWD

STA

STA 312

332.1

I~ LCA

- - -- -- - - - - -- -- -r j--- --

f-- ' \/L1 I4. FINSPECTION ,,,^ AREA .

(TYPICAL)

DETAIL I

CRACK REPAIR LIMITS

0

FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

Jul 1/88737-53-1 116

REV2: Sep30/93 73 i21
BOEING SERVICE BULLETIN 737-53-1116

The instruction numbers shown below agree with the numbers shown inside the circle symbols in the figure.

NOTE: This repair can only be used if cracks are within the area indicated by the shaded area of Detail S . Contact Boeing for a repair if cracks are not within the area indicated.

1 Remove existing rain gutter.

2 Stop drill end of crack (Ref. 737 Structural Repair Manual Subject 51-10-1). Typical cracks are shown. Only cracks 2.5 inches long or less, within the shaded area shown in Detail I can be repaired

as given in this figure 2.

j 3 If skin assembly or bearstrap doubler (but not both) is cracked, install repair strap and doubler per drawing 65C33800 using kit 65C33800-14.

4 If both skin assembly and bearstrap doubler are cracked, install repair strap, doubler, and tripler per drawing 65C33800 using kit 65033800-12.

5 If skin assembly or bearstrap doubler (but not both) is cracked, install repair strap and doubler per drawing 85C33800 using kit 65C33800-15.

6 If both skin assembly and bearstrap doubler are cracked, install repair strap, doubler, and tripler per drawing 65C33800 using kit 65C33800-13

7 Install new rain gutter and appropriate tiller strips under gutter per drawing 65C33800 using kit 65C33800-16. Trim filler strips as required, depending on which repair kits are installed.

FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

Jul 21/88 737-53-1116 REV 2: Sep 30/93 22
BOEING SERVICE BULLETIN 737-53-1116

-P STA

332.1 @

i~~~~--; t ~ n\

X-- --

SI ||,'A

Ty ICAL

/ g-1 / ( PLACES)

- -- --- I- -- L2 -

+- + m,7PLCES)

,-UPPER FORWARD

tCORNER

AFT SUPPER 

C ORNER >~ FWD

The instruction numbers shown below agree with the numbers shown inside the circ le symbols in the

t figure.

1 Drill out fastener holes to the appropriate starting hole size for 1/4 inch diameter rivets and high interference sleeve cold working rnethod (Ref. 7.37 Structural Repair Manual Subject 514309).

2 Cold work fastener holes in uncracked corners using high interference sleeve method (Ret. 737 Structural Repair Manual Subject 514-0-9).

3 Enlarge fastener holes in reveal fittings to 0.254 - 0.265 inch diameter. Apply sealant (Ref. EIMS 5-95) to faying surface of fitings, and position in place on bearstrap doubler.

4 install indicated fasteners from kit 65C331301 or from operators stock.

|The instructions given below agree wnth 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.

|A install rivet BACR1 5BB8B(-) wet with sealant, with the manufactured head on the outboard side of the

| B Enlarge countersink tar side to 0.425 - 0.431 inch diameter. Install rivet BACR15BB8BI0 wet with sealant and with the manufactured head on the outboard side of the skip. Shave the formed head (far side) as required to be flush with structure.

()Grip length of fastener indicated by number adjacent to fastener symbol.

I--

FIGURE 3. PREVENTIVE MODIFICATION - FORWARD GALLEY DOORWAY

REV 21 Sep 30/93 2 2 
DWAI VOP Commercial

Airplane

Group Service Bulletin

Number: 737-53-1116 Evaluation Form

Date: July 21, 1988

Revision 2: September 30, 1993

ATA System: 5331

Prepared By: Steve Lemon

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION,

REPAIR, AND PREVENTIVE MODIFICATION

Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data

that you give us to improve the quality of our service bulletins. Please include data about these or other

items:

- Did this service bulletin meet your estimate of quality? - How easy is this service bulletin to understand? - Are the Planning Information, Material Information and Accomplishment Instructions satisfactory? - Will You do this service bulletin fully? If not, please tell us why. - is the Manpower estimate satisfactory?

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these

changes, please use a Pubiication Change Request (PCR) form.

Please give us this data:

OPERATOR: TODAYS DATE:

, PREPARED BY: TITLE: -

ORGANIZATION: TELEX CODE:

TELEPHONE NUMBER: --

COMMENTS:

If you have other comments please use the other side. Thank you for the time you used to complete this

form.

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form

directly to this address:

T.J. Taylor, Manager Service Bulletin Engineering Boeing Commercial Airplane Group P.O. Box 3707, Mail Stop 2L-02

Seattle, WA 98124-2207

BOEING COMMERGIALAIRPLANE GROUP P-O. BOX3707 SEATTLE. WASHINGTON 8124-2207