# rostraCommercial Airplane v 

## Group 

# Service Bulletin

Number: 737-53-1116 

## RevisionTransmittal Sheet Date: July 21, 1988 Revision 2: September30, 1993 ATA System: 5331

SUBJECT: FUSELAGE

- FORWARD GALLEY DOORWAY UPPER CORNERS

- INSPECTION, 

### REPAIR, AND PREVENTIVE MODIFICATION
Thisrevision includesall pagesofthe service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work isnecessaryon airplanes modified as given in the initial release or Revision 1ofthis service bulletin. No morework isnecessary onairplanesthat have cracks repaired asgiven inthe initial releaseor Revision 1 of this bulletin, provided they are within the repairable crack area specified inthis revision. Contact Boeing for repair instructionsifcracks havebeen repaired that are outsidethe repairable area specified in Revision2 ofthisbulletin. SUMMARY This revision issent to provide alist of reference service bulletins applicable to 737 door corner and hinge 

# S cutouts. Also, this revision provides information on the crack length and location that is repairable with the repair given inthisbulletin. Paragraph l.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph forchanges. Vertical linesare put on the left edge of each page, except inParagraph l.A., Effectivity, toshow the location of important changes. Pageswith arevision number anddate, but noverticallines, have no important changes. REVISION HISTORY Initial Release: July21, 1988 Revision 1: September 7,1989 Revision2: 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 of75,000flight 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 isrecommended 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 inthe 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 ofthisservicebulletin. were eight cracksreported at the upper aftcorner on three airplanes, and nine cracks inthe skin at the Ifnocracksale found repeatthe inspection at 4,500 forward corner on five airplanes. The airplanes had flightcycle intervals until the preventive modification accumulated from 29,000to 47,300flight hours,and isaccomplished. from 40,500to60,800 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 inthe skin, skin doubler, or Ao~licabili Man-hours (Hours) bearstrap doubler in the upper corners of the forward galleydoorway. 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 isaccomplished. Ifcracks are found, install the repair doublers and | MATERIAL INFORMATION triplersoverthe cracked areas per thisbulletin. COMPLIANCE Boeing suppliedkits 

## 3See Paragraph I.G., Material Price andAvailability. 

### 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: July21. 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 servicebulletin isfor 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) PY191

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 TANZANIA (TNZ) 

# 0 PY611-PY612 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 PY162 ANSETT AIRLINES OFAUSTRALIA (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-PQ012 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) PM171 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 PL712 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 21/88 737-53-1116 REV 2: Sep 30/93 4

## BOEING SERVICE BULLETIN 737-53-1116

DRAGONAIR (DRG) PK357 PK872 DUKE FARMS (DFI) PP991 EG 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 GPAGROUP LTD. (GUI) PK252 PK355

Jul21/88 737-53-1116 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) PH712-PH713 PM016-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-PJ106 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 POLYTECHNOLOGIES, INC. (PTI) PP728-PP729 POLYNESIAN AIRLINES (PLY) PP947 REPUBLIC OF NIGER (NIR) PY166 ROYAL AIR MAROC (RAM) PK271-PK274 PY671-PY672

Jul 2
- Sep 3737-53-1116 REV 2: Sep 30/93 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 PY131 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 TUNISAIR (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 3-11 REV 2: Sep30/93 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 PK819-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 PY611-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 galleydoorwaywill detect cracking that could result in pressurization difficulties. Repair of cracks or accomplishment of preventive modification on uncracked structure is terminating actionfor inspection per this service bulletin. Six operators have reported cracks inthe upper corners of the forward galleydoorways on atotal of eight airplanes. Three airplanes had a total of eight cracks inthe upper aft corner,with crack lengths of up to 2 inches inthe skin, and a 2 inch long crack inthe bearstrap doubler on one airplane. Five airplanes had atotal of nine cracksfrom 0.1 inch to 1.5 inches inlength in the upper forward corner skin. The airplanes had accumulated from 29.000 to 47,300flight hours, and from 40,500to 60,800flight 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 instalation. The installation change eliminatesone fastenerand moves onefastener to make the repaircompatible 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 hingecutouts. Also,the crack location and limits that can be repaired with instructionsin thisbulletin are defined inthis revision. The foreyard galley door upper forward corner modification, installed per thisservice bulletin, overlaps 

# a the preventive modification for the upper hinge cutout installed per Service Bulletin 737-53-1074, 

## W therefore, it is suggested that prior or concurrent 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 1of this bulletin do not require additional work per this revision, provided thecracks arewithin the repairable crack area specified in Revision 2. There are four other service bulletins for 737-100 and 737-200 door cutout cracks. Table Ishows the service bulletinsand the areasthey cover. TABLE I
- SERVICE BULLETINS FOR DOOR CUTOUT CRACKING 

### DOORWAY Upper UpperAft Lower LowerAft Upper Lower Forward Corner Forward Corner Hinge Hinge Corner Corner Cutout Cutout Forward Entry 737-53-1163 737-53-1083 (a) Forward Galley 737-53-1 116 Aft

Galley 737-53-1149 737-53-1074 (a)Service Bulletin 737-53-1083 isfortne lowersill

Jul 21/88 737-53-1116 REV 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 ofthe forward galley doorwaytodetermine ifthere are cracksinthe skin, skin doubler, orbearstrap doubler. If no cracks are found, accomplish the preventive modification per this bulletin, or repeat the inspection until thepreventive modification isaccomplished. Ifcracks are found, stop drill the crack ends, and install the repair doublers and triplers over the crackedareas perthis bulletin. NOTES: 1. Prioror 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. Thisservice bulletin islisted inBoeing Document D6-38505. An evaluation form is attached to this service bulletin. Please use this form to tell us what you thinkofthequality ofthis service bulletin. D.Compliance Based on a structural review of the 737 airplane, it isrecommended that the modification per the Accomplishment Instructions of this service bulletin be accomplished prior to, or upon accumulation of 75,000flight cycles. Do the inspections priorto accumulating35,000 flightcycles. On airplaneswith 35,000or moreflight cycles, do the inspections at the first available opportunity, recommended at the next maintenance interval, notto exceed 4,500 flightcyclesafter receipt of thisservice bulletin. Ifno cracksare found, repeatthe inspectionsat 4,500flight cycle intervals untilthe preventive modification isdone. E.Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified inthis service bulletin complywith the applicable Federal Aviation Regulations (FAR) and are FM approved. The service bulletin and the FAA approval were based on the airplane inits original Boeing delivery configuration or as modified by other FAA approved Boeing changes and do not applytoairplanesonwhich otherconfiguration changeshave been made.

Jul 21/88 7373531116 

### REV 2: Sep30/93 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 requiredto accomplish this crack repairper doorway corner. The following breakdown of manpower requirements is suggested as a guideto assist operators in planning and accomplishing thisrepair. 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 asnecessary 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 - Priceand Availability 

### Boeing can supplythekits shown inParagraph lI.A.1 as shown below. Kit availability isshown inthe Reorder Lead Time (ROLT). This revision does not show Boeing price datafor kitsshown below.
Kit Number Description ROLT 65C33800-12 Kit
- Repair 18 weeks 65C33800-13 Kit
- Repair 15weeks 65C33800-14 Kit
- Repair 22 weeks 65C33800-15 Kit
- Repair 22 weeks 65C33800-16 Kit
- Gutter 22weeks The kits are subject to the terms and conditions of Boeing's standard purchase order acknowledgment. Address purchase orders and correspondence pertaining to thisquotation to Director of Spares, and refer tothis servicebulletin number. The following kit identified in Paragraph il.A.1 may be furnished or fabricatedfrom operators existing stock or purchased directly from industry sources. Kit availability is shown inthe Reorder Lead Time (ROLT). This revision does not show Boeing pricedata forthe kit shown below.
Kit Number Description ROLT 65C33-01-1 Kit
- Preventive Modification 22weeks The kit issubject to theterms and conditions of Boeing's standard purchaseorder acknowledgment. Address purchase orders and correspondence pertaining to this quotation to Director of Spares, and referto thisservice bulletin number.

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

## BOEING SERVICE BULLETIN 737-53-1116

H.Special Tools
- PriceandAvailability All required coldwork toolsand sleeves for accomplishment ofthis service bulletin may be selected from appropriate tables inStructural Repair Manual and procuredfrom industry sources, as required. Two sourcesthat provide coldwork tools, aswell as engineering and Service, is FatigueTechnology, Inc., and West Coast Industries, Inc. Also available from both companies isa kit of coidwork tooling specificallytailored tothe requirements of thisservicebulletin. ReferTo: FTI Kit Number: FTI-737-53-1116-1 FatigueTechnology, Inc. P.O. BoxC-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. 14900Whitman Avenue North Seattle,WA 98133-6532 Phone Number (206) 365-7513 Fax (206) 365-7483 1.Weightand Balance Change inWeight Change inMoment AoDlicabilit (Piounds) _Pound-Inches_ 737-100 (a) +9.2 +2,825 737-200 (a) +9.2 +3,494 737-300 (a) +9.2 +2,089 (a)Approximateweight and balance information based on incorporation of 65C33800-12, -13 and -16 kits (worst case) on an airplane. Actual weight and balance tobe determined by operator based on extentof kit incorporation. NOTE: incorporation of Preventive Modification kit65C33801-1 has noeffect on airplaneweight and balance.

Jul21/88 737-53-1116 REV 2: Sep30193 15

### BOEING SERVICE BULLETIN 737-53-1116

.J.References 1. Existing Data: a. 737 Structural Repair Manual Subjects51-10-1, 51-30-9 b. 737 NondestructiveTest Manual Part 6, Subjects51-00-00, 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' 737-53-1149 "Fuselage

- 

### Aft Galley andAft 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 737-1001A200/-200C"- 2. Data suppliedwith the original issue and Revision 1ofthis 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 insupport of this service bulletin are not detailed inthis service bulletin since they are common practices which can be accomplished inaccordance 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 Thefollowing is providedto aid inkit 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. Thekitsmaybe obtainedas noted inParagraph 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 inWeight Change inMoment

, 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

- Entryand 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 Galleyand 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 befurnished from operator's existingstocks

Jul21/88 737-53-1116 REV 2: Sep 30/93 17

## BOEING SERVICE BULLETIN 737-53-1116

2. Thefollowing materials are to befurnished 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 Toolsand 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 identifiedwith numbers on thefigure(s) givethe recommended sequence ofsteps. 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 75,000flight cycles. 3. Unless specifieddifferently, thesedimensions andtolerances are used:

- All lineardimensions are ininches

- 

### Toleranceon linear dimensions otherthan rivetand bolt edge margin isplusor minus0.03 inch

- 

### Tolerance on rivet and boltedge margin isplusor minus0.05 inch

- 

### Angular tolerance isplusor minus2degrees

- 

### The holedimensionsfor standard solid rivetsarefound in737 Structural Repair Manual Chapter

51

- 

### The torque limitstotighten nutsand bolts are found in737 Structural RepairManual Chapter 51. 4. Referto 737 Structural Repair Manual Chapter 51 foralternative fasteners. b. Obey allwarnings and cautions inthespecified manual sections.

A.Open the forward galley door for access to interior surface of door cutout to accomplish inspection and rework ofdoorway uppercorners. B.Accomplish an eddycurrent inspection ofthe skin, bonded skindoubler, and bearstraptripler ineach upper corner of thedoorway per Figure 1. C. ifcracked doorwaycornersarefound, repair per Figure2. D. Ifno cracksare found, accomplish preventivemodification 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 beoversized onetime only (Maximum hole sizeallowed beforecold working is0.238 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

STA 

### 3t2 332.131

+

--- i

-;¢2C'Lr at-d

(,, TYPCA (8 PLACES) Sa A. 4-, +f ,1 TYPICAL-

:, *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 

### bearstrapdoubler. 3 Inspect exposed area ofskin (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

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

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 inthe figure. NOTE: This repair can only be used ifcracks are within thearea indicated bythe shaded area of Detail S

. Contact Boeing for a repairif 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 inDetail Ican be repaired as given inthisfigure2. 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 Ifskin 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 fillerstrips as required, depending on which repair kitsare 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- - -- --- -- L 2

-

+- + 

### m,7PLCES) ,-UPPER FORWARD tCORNER

SUPPER 

### AFT C



### ORNER >~ 

### FWD The instruction numbers shown below agree with the numbers shown inside the circle 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 workingrnethod (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 fayingsurface offitings,and position in place on bearstrap doubler. 4 install indicated fastenersfrom kit 65C331301 orfrom operators stock. |The instructions given below agree wnth the letter shown in the upper left corner of the fastener symbols @in thefigure. A number inthe lower right corner givesthe grip length of thefastener. |A install rivet BACR15BB8B(-) wet with sealant, with the manufactured head on the outboard side ofthe | B Enlarge countersink tar side to 0.425

- 0.431 inch diameter. Install rivet BACR15BB8BI0 wet with sealant andwith the manufactured head on theoutboard side ofthe skip. Shavethe formed head (far side) as required to be flush with structure.

()Griplength offastener indicated by number adjacent tofastener symbol. I--

FIGURE 3. PREVENTIVE MODIFICATION

- FORWARD GALLEY DOORWAY

REV 21Sep 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
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