Number: 737-53-1061

Date: May 28, 1982

Revision 4: July 16, 1992

ATA System: 5311

SUBJECT: FUSELAGE - OVERWING FRAME INSPECTION, MODIFICATION AND REPAIR - BODY

STATION 559 THROUGH 639

This revision includes all pages of the service bulletin.

SUMMARY

This revision is sent to identify a new stub beam lower chord for Body Station 597, new stub beam repairs for

Body Stations 578 and 597, and new frame outer chord repairs for Body Stations 616 and 639. Inspections

have been clarified to include all of portions of the frames below Stringer S-16 and all of the stub beams at

Body Stations 559, 578, 597, 616 and 639. Inspection interval has been reduced to 4,500 flight cycles. Post

modification inspections of the circumferential frames at Body Stations 616 and 639 have been added.

Illustrations have been clarified. Inspections have been added for airplanes that were changed as given in

other releases of this service bulletin at Body Station 597 and have not installed radius fillers. An inspection

for Group 4 airplanes that have modified a circumferential frame at Body Station 597 has been added.

Typical crack locations have been added to illustrations. Service history has been updated. Shimming

instructions have been added to eliminate gaps that may exist between stub beams and body frames. Kit

history and kit procurement information has been clarified. Additional access information has been added. A

flight safety addendum has been added. Flight control cable disconnection and rigging instructions have been

added. Maintenance manual references have been added. The retrofit flow chart has been updated and

expanded.

Paragraph I.A., Effectivity, shows changes of airplane operators. Each operator should examine the

Effectivity paragraph for changes.

More work is necessary on airplanes that have installed stub beam lower chords with 1/4 inch diameter

fasteners at Body Station 597 as given by Revisions 1,2 or 3 of this service bulletin. More work is necessary

on airplanes that have changed shear ties as given in Revision 1,2 or 3 of this service bulletin.

The information contained in Notice of Status Changes 737-53-1061 NSC3, NSC4 and NSC5 have been

incorporated In this revision.

Vertical lines are put on the left edge of each page, except in Paragraph I.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: May 28, 1982

Revision 1: December 16, 1983

Revision 2: April 18, 1986

Revision 3: June 15,1989

Revision 4: July 16, 1992
Number:

Date:

Revision 4:

ATA System:

737-53-1061

May 28, 1982

July 16, 1992

5311

SUBJECT: FUSELAGE - OVERWING FRAME INSPECTION, MODIFICATION AND REPAIR - BODY

STATION 559 THROUGH 639

BACKGROUND

Based on a structural review of the 737 airplane,

incorporation of the modification per this service

bulletin is recommended on aging airplanes.

Thirty-six operators have reported 197 cracks in the

overwing body frames and stub beams between

Body Stations 559 through 639 on 115 airplanes.

There were cracks in shear ties, webs, inboard and

outboard chords of the body station frames. There

were cracks in the webs, attach angles, upper and

lower chords of the stub beams. There were 100

reports of cracks at Body Station 639 with 12

reports of severed body frame webs, 12 reports of

severed body frame inboard chords, and 4 reports

of severed body frame outboard chords. There

were 70 reports of cracks at Body Station 597 with

a 12 inch crack reported in the stub beam web and

a 5 inch crack reported in the stub beam lower

chord. The airplanes had accumulated between

9,400 to 74,900 flight cycles and 8,000 to 65,600

flight hours.

Two operators have reported 15 sheared fasteners

in the overwing body frames and stub beams

between Body Stations 559 through 639 on 6

airplanes.

Periodic inspection of the body frame and overwing

stub beam structure at Body Stations 559 through

639 per this service bulletin will detect cracks at an

early stage of propagation. The installation of the

preventive modification will reduce the possibility of

fatigue cracks. Undetected fatigue cracks could

lead to damage in adjacent structure and may

result in extensive repairs.

ACTION (PRR 32974, 32974-R, 33419 and

33421-R)

On airplanes subject to the 737 Aging Airplane

Structural Modification Program, accomplish

modification at the thresholds given in the

compliance section of this service bulletin.

Remove seats, carpets, side panels and floor

panels to get access to overwing stub beams and

body frames between Body Stations 559 through

639.

Do a detailed visual inspection of circumferential

frames from Stringer S-16 down to the top of the

center wing fuel cell. Do a detailed visual

inspection of the stub beam at Body Stations 559,

578, 597, 616 and 639. Do inspections at the

thresholds given in the compliance section of this

service bulletin. If no cracks or damaged fasteners

are found , repeat inspection at the thresholds

given in the compliance section of this service

bulletin until the preventive modification is done. If

cracks or damaged fasteners are found within the

limits given in this service bulletin, then repair per

this bulletin.

For Airplane Groups 1 through 3, accomplish an

eddy current inspection of the Body Station 639

frame inboard chord fastener hole at Stringer S-16.

If no cracks are found, repeat eddy current

inspection at the thresholds given in the compliance

section of this service bulletin until the preventive

modification is accomplished. If cracks are found

within the limits given in this service bulletin, repair

per this bulletin.

The preventive modification for Airplane Groups 1

through 3 is as follows: reinforce body frame inner

chords and flanges, replace stub beam lower

chords, replace stub beam upper chords, replace

stub beam attach angles to the BBL 45.5 floor

beam, and reinforce the stub beam web at Body

Stations 597, 616 and 639. Disconnect, connect rig

and functional test some flight control cable

systems when replacing stub beam webs. Entry

into the center wing fuel tank will be necessary

when replacing stub beam lower chords at Body

Stations 559, 578 and 597.

The preventive modification for Airplane Group 4 is

as follows: Reinforce body frame inner chords and
flanges at Body Stations 559, 578 and 597.

Replace stub beam lower chords at Body Stations

559, 578 and 597. Replace stub beam upper

chords at Body Station 597. Replace stub beam

attach angles to the BBL 45.5 floor beam.

Disconnect, connect, rig and functional test some

flight control cable systems when replacing stub

beam webs. Entry into the center wing fuel tank will

be necessary when replacing stub beam lower

chords at Body Stations 559, 578 and 597.

If cracks or damaged fasteners are found and

cracked component can be replaced by the

preventive modification, accomplish the

modification on the affected frame. If cracks are

within limits of this service bulletin, then repair

those cracks as given in this service bulletin. Do

post modification inspections at Body Stations 616

and 639 frames.

COMPLIANCE

Refer to Paragraph I.D in Service Bulletin

EFFECTIVITY

Airplane Line Numbers 1 - 848 divided into 4

groups

MANPOWER

Refer to Paragraph F in Service Bulletin

MATERIAL INFORMATION

Refer to Paragraph G in Service Bulletin

Jul 16/92

REV. 4: Jul 16/92 Summary Page 2 of 2
Number:

Date:

Revision 4:

ATA System:

737-53-1061

May 28, 1982

July 16, 1992

5311

SUBJECT: FUSELAGE - OVERWING FRAME INSPECTION, MODIFICATION AND REPAIR - BODY

STATION 559 THROUGH 639

I. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-19567, Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

An equivalent change is on subsequent production airplanes. Refer to PRRs 32974, 32974-R,

33419 and 33421-R for data about this change.

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

CUSTOMER

GROUP VARIABLE NUMBER

AER LINGUS (ARL)

1 PG254-PG255 PG573

2 PK029 PK614

4 PY281 PY321-PY323

PG575

PK641 -PK642

AEROLINEAS ARGENTINAS (ARG)

1 PH705-PH708 PH741-PH743

2 PK102-PK103

4 PY007-PY008

AIR ALGERIE (ALG)

2 PL717-PL725

4 PY051-PY053

AIR FRANCE (AFA)

2 PL502-PL503

AIR GABON S.A. (GBN)

4 PY191

AIR GUINEE (GNE)

4 PY651

AIR LANKA, LTD. (LNK)

1 PH701 PL802

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

Page 1 of 53
LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (CONTINUED)

CUSTOMER

GROUP VARIABLE NUMBER

AIR MADAGASCAR (MAD)

1 PG375

2 PL793

AIR NAURU (NAU)

2 PK356 PK581

4 PY286

AIR NEW ZEALAND, LTD. (ANZ)

2 PK047 PK211

AIR NIPPON CO., LTD. (ANK)

1 PG582

AIR TANZANIA (TNZ)

4 PY611-PY612

AIR ZAIRE (ZAI)

4 PY111 PY113

PK213-PK214

AIRCRAFT SUPPORT GROUP (ASG)

4 PY342 PY344

ALASKA AIRLINES (ASA)

4 PY112 PY134-PY135 PY270 PY461-PY462

ALL NIPPON AIRWAYS CO. LTD. (ANA)

1 PG578-PG581 PG583-PG586

2 PK711-PK716

ALOHA (ALO)

1 PG046 PG629 PG705

2 PK286-PK287 PK305-PK306 PK691-PK695

4 PY001 PY005 PY231 PY242

AMERICA WEST AIRLINES, INC. (AMW)

1 PC004 PG036 PL801

2 PK082 PK283 PK625-PK626 PL081

AMERICAN AIRLINES, INC. (AAL)

1 PG271-PG276 PG351 PG403

ANGOLA AIRLINES (ANG)

2 PK661

4 PY162

ANSETT WORLDWIDE AVIATION SERVICES (AWW)

1 PA001 PA003-PA004

ARAMCO SERVICES CO. (ARM)

2 PL151

4 PY241 PY243-PY244

ATLANTA ICELANDIC (AID)

4 PY002 PY381

Jul 16/92

REV. 4: Jul 16/92

PY451

PL551-PL559

737-53-1061

2
LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (CONTINUED)

CUSTOMER

GROUP VARIABLE NUMBER

AVENSA (AVN)

2 PK042-PK043

AVIATECA (AVT)

1 PG201

AVIATION SALES CO., INC. (ASC)

1 PG331 PG401-PG402 PG436

AVIOGENEX AIR TRANSPORT (AVG)

2 PL501 PL506

BAHAMASAIR (BAH)

2 PK351 PK353 PL061

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

1 PJ031 PJ072

2 PJ004-PJ009 PK882

BRITANNIA AIRWAYS, INC. (BRI)

1 PJ101 PJ103-PJ106

2 PJ108 PJ110-PJ111 PJ113-PJ118

BRITISH AIRWAYS (BAB)

2 PK731-PK749 PK771-PK777 PK779

CAMEROON AIRLINES (CAM)

4 PY046-PY047

CANADIAN AIRLINES INTERNATIONAL LTD. (CDI)

1 PG651-PG652

2 PK026-PK028 PK221 PK358

PK881 PK884 PL401-PL411

4 PY151-PY154 PY303-PY304 PY421

PG572

PK215

PG574 PJ102

PL716

PK819

PK671-PK675 PK677-PK678 PK822

PL761-PL762 PL764-PL770

PY441

CARNIVAL AIR (CVL)

1 PG302 PG305 PG312 PL712

CASINO EXPRESS (CIN)

1 PG279

CAYMAN AIRWAYS (CAY)

2 PK222 PK561

CONTINENTAL AIRLINES, INC. (CAL)

1 PA006-PA014 PA016-PA020 PG056 PG064 PG199 PG225

PG229 PG432-PG433 PG441-PG442 PG501-PG505 PG621-PG628 PG630

PG704 PL001

COPA COMPANIA PANAMENA DE AVIATION S.A. (COP)

1 PC001

2 PJ107 PJ112

4 PY341

CRUZEIRO DO SUL (CRU)

2 PK141-PK146

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

3
LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (CONTINUED)

CUSTOMER

GROUP VARIABLE NUMBER

DAN AIR (DAN)

2 PK820 PL421

DELTA AIR LINES, INC. (DAL)

2 PK611 PK613

DRAGONAIR (DRG)

2 PK357 PK871-PKE

E G AND G (EGN)

1 PG037 PG208

2 PL763

EGYPTAIR (EGP)

2 PK252 PK254-PK2

EURALAIR (ERA)

1 PG026 PG028-PG(

4 PY004 PY006

PK615 PK623-PK624

873

PG210

!55

PG215

PK257-PK258

329

EUROPE AERO SERVICE (EUR)

2 PK203 PK359 PK612

FAR EASTERN AIR TRANSPORT (FAT)

1 PA002 PA005 PG055

2 PK562

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

1 PA231 PC002 PG034

FRENCH POSTAL OFFICE (FPO)

4 PY101 PY302

GB AIRWAYS (GBA)

2 PK282 PL171

GOVERNMENT OF BRAZIL (BRZ)

2 PK068-PK069

GOVERNMENT OF MEXICO (MXG)

1 PC005 PG223

GOVERNMENT OF SHARJAH (SHJ)

2 PL581

GULF AIR (GUL)

2 PK461-PK468 PK616 PK824

HAPAG LLOYD (HAP)

2 PL504-PL505

HEAVYLIFT AIRCRAFT ENGINEERING (HVL)

2 PJ109

INDIAN AIRLINES (IND)

1 PH709 PH711-PH713

2 PH021-PH022 PH024 PK231-PK233

4 PY631

PG226 PG228 PG230

PG213

3 PK235-PK240 PM001-PM002

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

4

PG431
LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (CONTINUED)

CUSTOMER

GROUP VARIABLE NUMBER

INTERNATIONAL AIR LEASES (IAL)

1 PG043 PG047-PG048 PG251 PG253

IRAN ISLAMIC REPUBLIC AIRLINE (IRN)

1 PH731

2 PK391

4 PY021-PY022

IRAQI AIRWAYS (IRQ)

4 PY141-PY142

ITALJET S.R.L. (ITJ)

2 PK432

JET AVIATION (JTA)

2 PL441

KENYA AIRWAYS (KEN)

2 PK253 PK256

LADECO (LDE)

2 PK212 PK830

LAN-CHILE S.A. (LAN)

2 PK360 PK825

LINA CONGO (LNA)

4 PY411

LINHAS AEREAS DE MOCAMBIQUE (LAM)

1 PH703

4 PY031

LUFTHANSA GERMAN AIRLINES (DLH)

2 PK901-PK932

4 PY345-PY346

LUXAIR (LUX)

2 PK451-PK452

MALAYSIAN AIRLINES SYSTEM BERHAD (MAS)

2 PK051 PL736-PL738 PL740-PL745

4 PY201

MALEV HUNGARIAN AIRLINES (HGA)

2 PK284-PK285

MARKAIR, INC. (ALK)

1 PG216 PG218-PG219

MIDWAY AIRLINES, INC. (MID)

2 PK622 PK628-PK629

NASA (NAS)

1 PA099

NIGERIA AIRWAYS, LTD. (NIA)

2 PL781-PL782

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

5
LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (CONTINUED)

CUSTOMER

GROUP VARIABLE NUMBER

NORDAM (NOP)

2 PK352

NWT AIR (NTA)

4 PY132-PY133

OLYMPIC AIRWAYS (OLY)

2 PK301-PK304 PK307-PK310 PM021-PM023

P. T. AIRFAST (PTF)

1 PG204 PG278

PAN AFRICAN EXPRESS (PFX)

1 PG211

PAN AMERICAN WORLD AIRWAYS, INC. (PAA)

1 PG020-PG021

PETROLAIR SYSTEMS S. A. (PTS)

2 PL471

PLUNA (PLU)

2 PL201-PL203

POLARIS LEASING CO. (PLS)

1 PG202 PG205 PG207 PG220-PG222 PG438 PG577

4 PX701

PRIVATE FLIGHT DIRECTORATE (ABU DHABI) (ABD)

2 PK495

REPUBLIC OF NIGER (NIR)

4 PY166

ROYAL AIR MAROC (RAM)

2 PK271-PK273 PK826

SABA AIRLINES S. A. (SBA)

1 PG209 PG212

SABENA BELGIAN WORLD AIRLINES (SAB)

2 PK041 PK044-PK046 PK048-PK050 PK052-PK053 PK431 PK433

4 PY272-PY275

SAUDI ARABIAN AIRLINES CORP. (SVA)

2 PK311-PK317 PL726-PL735

4 PY036-PY037

SAUDI ROYAL FLEET (SRF)

2 PK318

SERVICIOS AEREOS RUTAS ORIENTE, (SARO) (SEV)

1 PA015 PA021-PA022

SIERRA PACIFIC AIRLINES (SRP)

1 PC003 PG203 PG217

2 PK627

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 6
LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (CONTINUED)

CUSTOMER

GROUP VARIABLE NUMBER

SOLOMON AIRLINES, LTD. (SOI)

2 PK823

SOUTH AFRICAN AIRWAYS (SAA)

1 PG353-PG356

2 PL101-PL110

SOUTHWEST AIRLINES CO. (SWA)

2 PK091-PK099 PK541-PK559 PK621

SOUTHWEST-SWAL (SWL)

2 PK521 PK523-PK524

SUDAN (SUD)

4 PY156-PY157

SULTANAIR (SLR)

1 PJ001 PJ032 PL803

2 PK563

T A PORTUGUESES (TAP)

2 PK971 PK973 PL451-PL452

3 PK974

TACA INTERNATIONAL AIRLINES, INC. (TAC)

1 PG059 PG352

2 PK223

4 PY131

TAN SAHSA HONDURAS AIRLINES (SAH)

1 PJ071 PL711

2 PK081 PL758

THAI AIRWAYS INTERNATIONAL, INC. (TII)

2 PK511 PK514

TIME AIR SWEDEN AB (TIS)

1 PJ002-PJ003

TRANS EUROPEAN AIRWAYS (TEA)

2 PK281

TRANSAVIA AIRLINES (TAV)

1 PG074

2 PK501-PK503 PK821

4 PY102-PY103

TRANSPORT AERIEN TRANSREGLONAL (TTR)

4 PY003 PY301 PY361-PY362

TUNIS AIR (TUN)

2 PK861-PK863

4 PY621

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

7
LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (CONTINUED)

CUSTOMER

GROUP VARIABLE NUMBER

UNITED AIR LINES, INC. (UAL)

1 PG001-PG004 PG006-PG019 PG022-PG025 PG027

PG038-PG040 PG044-PG045 PG051-PG054 PG057

PG075

2 PK201-PK202 PL002-PL022

UNITED STATES AIR FORCE (USF)

1 PJ201-PJ219

PG030 PG032-PG033

PG060-PG063 PG065-PG072

USAIR, INC. (USA)

1 PG041-PG042

PG313-PG314

2 PK288-PK289

PG073

PG474

PK591 -PK599

PG206

PG576

PK601-PK609

PG301

PK883

PG303-PG304 PG306-PG311

PM101

VARIG AIRLINES (VAR)

2 PK111-PK116 PK118-PK120 PL453-PL454

VASP (VSP)

1 PG435

2 PH011-PH013

4 PX071

PG437

PK061-PK062

PY222

PG439-PG440 PG471-PG473

PK065-PK067 PK241 PK354-PK355 PL756

VENEZUELA - GOVERNMENT OF (VNZ)

2 PK070

VISCOUNT AIR SERVICE INC. (VAS)

1 PG224

WHIRLPOOL FINANCIAL CORP (ZZW)

1 PG214

WIEN AIRLINES (WIE)

4 PY343 PY401

XIAMEN AIRLINES CO. LTD. (XIA)

2 PK874

YEMEN AIRWAYS (YEM)

2 PK341

ZAMBIA AIRWAYS (ZAM)

2 PK291

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

8
LISTING BY VARIABLE NUMBER

GROUP 1

PA001-PA022

PG201 -PG230

PG375

PG621-PG630

PJ001-PJ003

PL711-PL712

PA099

PG251 -PG255

PG401-PG403

PG651 -PG652

PJ031-PJ032

PL801-PL803

PA231 -PA232

PG271-PG279

PG431-PG442

PG701-PG705

PJ071-PJ072

PC001-PC005

PG301 -PG314

PG471 -PG475

PH701-PH715

PJ101-PJ106

PG001-PG075

PG331-PG332

PG501 -PG505

PH731-PH732

PJ201-PJ219

PG199

PG351 -PG356

PG571-PG586

PH741-PH743

PL001

GROUP 2

PH001

PK041 -PK053

PK141-PK146

PK271-PK273

PK391

PK511-PK514

PK601 -PK609

PK691-PK695

PK861 -PK863

PL061

PL401-PL411

PL501-PL506

PL761-PL770

PH011-PH013

PK061 -PK070

PK201 -PK204

PK281-PK289

PK431-PK433

PK521 -PK524

PK611-PK616

PK711-PK716

PK871 -PK874

PL081

PL421

PL551-PL559

PL781-PL782

PH021-PH024

PK081-PK082

PK211-PK215

PK291

PK451 -PK452

PK541 -PK559

PK621-PK629

PK731-PK749

PK881-PK884

PL101-PL110

PL441

PL581

PL793

PJ004-PJ009

PK091-PK099

PK221 -PK223

PK301-PK318

PK461 -PK469

PK561 -PK563

PK641 -PK642

PK771-PK779

PK901 -PK932

PL151

PL451-PL454

PL716-PL745

PM001-PM002

PJ107-PJ118

PK101-PK103

PK231 -PK241

PK341

PK495

PK581

PK661 -PK662

PK819-PK826

PK971-PK973

PL171

PL471

PL756

PM021-PM023

PK026-PK029

PK111-PK120

PK251-PK258

PK351 -PK360

PK501 -PK503

PK591-PK599

PK671 -PK678

PK830

PL002-PL022

PL201-PL203

PL491

PL758

PM101

GROUP 3

PK974

GROUP 4

PX071

PY046-PY048

PY151-PY154

PY221 -PY222

PY301-PY304

PY411

PY621

PX701

PY051-PY053

PY156-PY157

PY231

PY321-PY323

PY421

PY631

PY001-PY008

PY101-PY103

PY161-PY162

PY241-PY244

PY341-PY346

PY441

PY651

PY021-PY022

PY111-PY113

PY166

PY270-PY275

PY361-PY362

PY451

PY031

PY131-PY135

PY191

PY281

PY381

PY461 -PY462

PY036-PY037

PY141-PY143

PY201

PY286

PY401

PY611-PY612

2. Spares

None

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

9
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 structures 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.

Periodic inspection of the body frame and overwing stub beam structure at Body Stations 559 through 639 per this service bulletin will detect cracks at an early stage of propagation. The installation of the

preventive modification will reduce the possibility of fatigue cracks. Undetected fatigue cracks could

lead to damage in adjacent structure and may result in extensive repairs.

Thirty-six operators have reported 197 cracks in the overwing body frames and stub beams between

Body Stations 559 through 639 on 115 airplanes. Body frames had cracks in shear ties, webs, inboard

and outboard chords. Stub beams had cracks in webs, attach angles, upper and lower chords. There

were 100 reports of cracks at Body Station 639 with 12 reports of severed body frame webs, 12 reports of severed body frame inboard chords, and 4 reports of severed body frame outboard chords. There

were 70 reports of cracks at Body Station 597 with a 12 inch crack reported in the stub beam web and a

5 inch crack reported in the stub beam lower chord. The airplanes had accumulated 9,400 to 74,900

flight cycles and 8,000 to 65,600 flight hours.

Two operators have reported 15 sheared fasteners in the overwing body frames and stub beams

between Body Stations 559 through 639 on 6 airplanes.

Revision 1 of this bulletin provided superseding modification and repair kits with new improved lower

chords. The detailed visual inspection was expanded to include the attachment fasteners at the Body Station 597 stub beam frame lower chord to BBL 70.85 rib upper chord interface. The modification

provided larger attach fasteners at Body Station 597.

As a result of operator experience, Revision 2 was issued to add a special eddy current inspection for

cracks in the Body Station 639 inboard chord and to provide operators with revised repair drawings indicating trim requirements for repair angle installation and correct repair angle part numbers. Also, a

repair was added for cracks in the frame inboard chord and web at Body Station 597, 616 and 639 on

both sides of Groups 1, 2 and 3 airplanes.

Revision 3 was issued to provide the recommendations of the 737 Structures Working Group. As a

result of operator experience Revision 3 was issued to provide operators with revised modification and

repair drawings. New kit and supplemental kit information was provided.

Revision 4 is issued to identify a new stub beam lower chord for Body Station 597 and new stub beam

repairs for Body Stations 578 and 597, and new frame outer chord repairs for Body Stations 616 and

639. Inspection interval has been reduced to 4,500 flight cycles. Inspections have been clarified to

include all of portions of the frames below Stringer S-16 and all of the stub beams at Body Stations 559,

578, 597, 616 and 639. Post modification inspections at Body Stations 616 and 639 have been added.

Illustrations have been clarified. Typical cracks have been added to illustrations. Shimming instructions have been added to eliminate gaps that may exist between stub beams and body frames.

Service history has been updated. Kit history and kit procurement information have been clarified.

Additional access information has been added. A flight safety addendum has been added. Flight control cable disconnection and rigging instructions have been added for the preventive modification.

Maintenance Manual References have been added. On Group 4 airplanes, the requirement to replace the upper chord at Body Station 578 during preventive modification has been removed. The intent of

Notice of Status Change 737-53-1061NSC4 has been incorporated. The retrofit flow chart has been

updated and expanded.

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 10
A structural reassessment of the 737 airplane has been conducted under the requirements of Federal

Aviation Administration (FAA) Advisory Circular 91-56 in accordance with Federal Aviation Regulation

(FAR) 25.571, as amended in 1978, to ensure safe operation of 737 airplanes throughout their

operational life. Based on a structural reassessment of the 737 airplane, it has been determined that

the structure affected by this service bulletin is structurally significant and should be inspected in

accordance with the flight safety inspection program in the addendum to this service bulletin.

C. Description

On airplanes subject to the 737 Aging Airplane Structural Modification Program, accomplish

modification at the thresholds given in the compliance section of this service bulletin.

Remove seats, carpets, side panels and floor panels to get access to overwing stub beams and body

frames between Body Stations 559 through 639.

Do a detailed visual inspection of circumferential frames from Stringer S-16 down to the top of the

center wing fuel cell. Do a detailed visual inspection of the stub beam at Body Stations 559, 578, 597,

616 and 639. Do inspections at the thresholds given in the compliance section of this service bulletin. If

no cracks or damaged fasteners are found, repeat inspection at the thresholds given in the compliance

section of this service bulletin until the preventive modification is done. If cracks or damaged fasteners

are found within the limits given in this service bulletin, then repair per this bulletin.

Accomplish post modification detailed visual inspections of the circumferential frames at Body Station

616 and 639 at the times given in the compliance section.

On airplanes in Groups 1 through 3, accomplish an eddy current inspection of the Body Station 639

frame inboard chord fastener hole at Stringer S-16. If no cracks are found, repeat eddy current

inspection at the thresholds given in the compliance section of this service bulletin until the preventive

modification is accomplished. If cracks are found, repair per this bulletin.

The preventive modification for Airplane Groups 1 through 3 is as follows: reinforce body frame inner

chords and flanges, replace stub beam lower chords, replace stub beam upper chords, replace stub

beam attach angles to the BBL 45.5 floor beam, and reinforce the stub beam web at Body Stations 597,

616 and 639. Disconnect, connect rig and functional test some flight control cable systems when

replacing stub beam webs. Entry into the center wing fuel tank will be necessary when replacing stub

beam lower chords at Body Stations 559, 578 and 597.

The preventive modification for Airplane Group 4 is as follows: Reinforce body frame inner chords and

flanges at Body Stations 559, 578 and 597. Replace stub beam lower chords at Body Stations 559,

578 and 597. Replace stub beam upper chords at Body Station 597. Replace stub beam attach angles

to the BBL 45.5 floor beam. Disconnect, connect, rig and functional test some flight control cable

systems when replacing stub beam webs. Entry into the center wing fuel tank will be necessary when

replacing stub beam lower chords at Body Stations 559, 578 and 597.

On airplanes that have had the circumferential frames at Body Station 597 modified, visually inspect

frame at Body Station 597 at the intervals given in the compliance section until radius fillers are

installed.

If cracks or damaged fasteners are found and cracked component can be replaced by the preventive

modification, accomplish the modification on the affected frame. If cracks are within limits of this

service bulletin, then repair those cracks as given in this service bulletin.

On Group 4 airplanes that have modified a circumferential frame at Body Station 578 with kit

65C22320-186, make sure the upper chord was not replaced.

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 11
Airplanes have been divided into 4 groups. Airplane Groups 1 through 3 represent passenger airplanes that reinforce or replace the stub beams and body frames at Body Station 559, 578, 597, 616 and 639

at and below Stringer S-16. Airplane Groups 1 through 3 have different body frame repairs below

Stringer S-16 at Body Station 597. Airplane Group 4 represents cargo airplanes that reinforce or

replace the stub beams and the body frames at Body Station 559, 578, 597, 616 and 639 at and below

Stringer S-16.

On airplanes that have installed stub beam lower chords with 1/4 inch diameter fasteners at Body Station 597 as given by Revisions 1, 2 or 3 of this service bulletin, do an inspection for short edge margin on the stub beam lower chord and replace as necessary.

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

NOTES:

1. Inspection and maintenance alternatives are shown in a diagram in Section III.,

ACCOMPLISHMENT INSTRUCTIONS.

2. If the damaged area is more than the specified limits, write to Boeing for repair instructions. To

help Boeing send a reply, give the limits and location of the damage. When possible, send

sketches and photographs. If the damage includes corrosion, send data on the length, width, and

largest depth of clean up.

SEND TO: BOEING COMMERCIAL AIRPLANE GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT

3. A retrofit flow diagram is provided in the Accomplishment Instructions.

4. The last page of this service bulletin is an evaluation form. Please use this form to tell us what

you think of the quality of this service bulletin.

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

12
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.

Within 3,000 flight cycles of release of Revision 4 of this bulletin on airplanes that have accumulated

15,000 or more flight cycles, accomplish a detailed visual inspection of circumferential frame from

Stringer S-16 down to the top of the center wing fuel cell and of the stub beams at Body Stations 559,

578, 597, 616 and 639. If no cracks or damaged fasteners are found, repeat inspection at intervals not

more than 4,500 flight cycles until the preventive modification is done per Part II of the accomplishment

instructions.

Within 24,000 flight cycles after the repair or preventive modification is done, do a detailed visual

inspection of the Body Stations 616 and 639 frame webs, inner chords and outer chords near Stringer

S-16. If no cracks are found, then repeat inspections at regular maintenance intervals of not more than

4,500 flight cycles.

On Group 1 - 3 airplanes, at the next scheduled maintenance period when access to Body Station 639

Frame is available, accomplish the special inspection of the frame inboard chord fastener hole at

Stringer S-16 at intervals of 15,000 flight cycles. Repair any cracks found before further flight. If no

cracks are found, repeat eddy current inspections at 15,000 flight cycle intervals until the Part II

preventive modification is accomplished.

On airplanes that have changed circumferential frame at Body Station 597 as given by original issue of

this service bulletin, Revisions 1, 2 or 3 of this service bulletin, visually inspect the frames for cracks

every 4,500 flight cycles. Do these inspections until radius fillers are installed as given by Revision 4 of

this service bulletin.

Within 3,000 flight cycles of release of Revision 4 of this service bulletin, do an inspection for short edge

margin on the stub beam lower chord on airplanes that have installed stub beam lower chords with 1/4

inch diameter fasteners at Body Station 597 as given by Revision 1, 2 or 3 of this service bulletin.

This service bulletin describes a flight safety inspection program, in the addendum to this service

bulletin, that is the minimum necessary to ensure the structural integrity of the stub beams and

circumferential frames between Body Stations 616 and 639.

E. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The repairs and

changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR)

and are FAA approved.

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 13
F. Manpower

The data below shows an estimate of the man-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

man-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 examine the work

- Time to cure the materials

- Time to make the parts

- Time to find the tools.

Man-Hour Estimate Per Airplane (Repeat Inspection)

Task

Access

Inspection

Number of Persons

4

4

Restoration and 4

Operational

Check

TOTAL FOR

Man-Hour Estimate Per Airplane (Modification)

Man-Hours

12

4

16

32

Elapsed Time (Hours)

3

1

4

8

Task

Access

Inspection

Modification

(Groups 1 - 3)

Modification

(Group 4)

Restoration

Cable Rigging

and

Operational

Checks

Number of Persons

4

4

4

4

4

4

Man-Hours Elapsed Time (Hours)

32

6

288

116

32

16

8

1.5

72

29

8

8

TOTAL FOR AIRPLANEGROUPS 1 - 3

TOTAL FOR AIRPLANEGROUP 4

374 97.5

202 54.5

NOTE: Man-hours to accomplish repairs will vary depending on type and extent of the repair.

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 14
G. Material - Price and Availability

Boeing can supply the kits shown in Paragraph II.A., Parts Necessary For Each Airplane, as shown

below.

Kit Number

65C22320-1

65C22320-161

65C22320-162

65C22320-163

65C22320-164

65C22320-165

65C22320-166

65C22320-167

65C22320-168

65C22320-169

65C22320-171

65C22320-172

65C22320-173

65C22320-174

65C22320-175

65C22320-176

65C22320-179

65C22320-180

65C22320-181

65C22320-182

65C22320-183

65C22320-184

65C22320-185

Name

Subkit

Subkit

Subkit

Subkit

Subkit

Subkit

Subkit

Top Kit

Top kit

Supplemental Subkit

Supplemental Subkit

Supplemental Subkit

Supplemental Subkit

Supplemental Subkit

Supplemental Subkit

Supplemental Subkit

Supplemental Subkit

Supplemental Subkit

Subkit

Subkit

Subkit

Subkit

Subkit

Unit Pnce

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

$3,717.00

$166.00

$1,311.00

$188.00

$5.00

$161.00

$161.00

$681.00

$546.00

$6,287.00

$6,398.00

Inactive for future procurement

Inactive for future procurement

$2,841.00

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

15
Kit Number

65C22320-186

65C22320-187

65C22320-188

65C22320-2

65C22320-201

65C22320-202

65C22320-203

65C22320-204

65C22320-207

65C22320-208

65C22320-3

65C22320-4

65C22320-5

65C22320-6

65C22320-7

65C22320-75

65C22320-76

65C22320-8

65C25211-1

65C25211-101

65C25211-102

65C25211-105

65C25211-106

65C25211-11

65C25211-111

Name

Subkit

Top Kit

Top Kit

Subkit

Top Kit

Top Kit

Subkit

Subkit

Supplemental Subkit

Subkit

Subkit

Subkit

Subkit

Subkit

Subkit

Top Kit

Top Kit

Subkit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Unit Price

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

$20,570.00

$6,558.00

$4,691.00

$3,166.00

$932.00

$1,627.00

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

$1,739.00

Inactive for future procurement

Inactive for future procurement

$2,196.00

$573.00

$520.00

$520.00

$199.00

$194.00

Inactive for future procurement

$709.00

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

16
Kit Number

65C25211-112

65C25211-115

65C25211-116

65C25211-119

65C25211-12

65C25211-120

65C25211-121

65C25211-122

65C25211-123

65C25211-124

65C25211-125

65C25211-126

65C25211-129

65C25211-130

65C25211-133

65C25211-134

65C25211-137

65C25211-138

65C25211-141

65C25211-142

65C25211-143

65C25211-144

65C25211-145

65C25211-146

65C25211-147

Name

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Supplemental Repair Kit

Supplemental Repair Kit

Repair Kit

Repair Kit

Supplemental Repair Kit

Supplemental Repair Kit

Repair Kit

Repair Kit

Supplemental Repair Kit

Supplemental Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Unit Price

$709.00

$237.00

$237.00

$873.00

Inactive for future procurement

$873.00

$686.00

$686.00

$1,032.00

$665.00

$520.00

$520.00

$172.00

$172.00

$665.00

$665.00

$266.00

$266.00

$243.00

$192.00

$372.00

$372.00

$249.00

$208.00

$411.00

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

17
Kit Number

65C25211-148

65C25211-2

65C25211-21

65C25211-22

65C25211-31

65C25211-32

65C25211-41

65C25211-42

65C25211-51

65C25211-52

65C25211-61

65C25211-62

65C25211-65

65C25211-66

65C25211-71

65C25211-72

65C25211-75

65C25211-76

65C25211-81

65C25211-82

65C25211-85

65C25211-86

65C25211-91

65C25211-92

65C25211-95

Name

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Unit Pnce

$411.00

$473.00

$324.00

$324.00

Inactive for future procurement

$295.00

Inactive for future procurement

$686.00

$265.00

$265.00

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

Inactive for future procurement

$137.00

$137.00

$211.00

$211.00

$537.00

$537.00

$194.00

$194.00

$493.00

$493.00

$207.00

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

18
Kit Number

65C25211-96

65C25211-97

65C25211-98

65C31658-1

65C31658-2

65C31658-3

65C31658-4

65C31658-5

65C31658-6

65C31658-27

65C31658-28

Date: July 16, 1992

Name

Repair Kit

Repair Kit

Repair Doubler

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

Repair Kit

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

The prices are applicable from May 1, 1992 through September 17,1992. After this date new price data

is applicable. Prices are in United States Dollars. Terms: Net 30 days.

Send purchase orders and letters about the supply data to the Director of Spares and refer to this

service bulletin number.

H. Special Tools - Price and Availability

None

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

19

Unit Pnce

$207.00

$442.00

$124.00

$1,737.00

$1,791.00

$1,614.00

$1,635.00

$1,399.00

$1,399.00

$1,395.00

$1,386.00
I. Weight and Balance

Change in Weight Change in Moment

Applicability (Pounds) (Pound-Inches)

65C22320-181 +15 +9,585

65C22320-182 +15 +9,240

65C22320-185 +7 +4,046

65C22320-203 +18 +10,746

65C22320-204 +12 +7,164

65C22320-208 +6 +3,468

65C22320-7 +5 +2,795

65C22320-8 +5 +2,795

Weight and Balance change for repair will vary depending on extent of repairs.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 32974-R, 32974, 33421-R and 33419

b. 737 Maintenance Manual Subjects 27-09-111, 27-51-0, 27-62-0, 28-10-00, 28-11-0, 28-11-31,

28-21-00, 28-23-0, 32-31-41 and 53-10-3

c. 737 Structural Repair Manual Subjects 51-30-2 and 51-50-1

d. 737 Structural Item Interim Advisories 737-56 and 737-119

e. Boeing Standard Overhaul Practices Manual Subject 20-60-04

f. Boeing Document D6-38505 "Aging Airplane Service Bulletin Structural Modification Program -

Model 737-100/-200/-200C"

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

20
2. Data supplied with this service bulletin:

a. Drawings:

Drawing Number

65C22320

Sheet DCN ADCN

PL L 19

Title

Frame Installation Overwing, Body

Station 559 to 639, Top Kit

1 B 9

2 B W1

3 B 2

4 A 2

8 A 2

9

10 A 1

11 2

PL E 9 Repair Installation - Overwing Stub

Frames

1 B 4

2 A 2

3

4

PL A 3 Frame Installation - Web and Chord

Repair (Top Kit)

1 A 2

2 A 

3

4

Boeing Process Specifications referred to on drawings are not given in this service bulletin since

these procedures are frequently used as standard shop practices.

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

21

65C252111

65C31658
3. Installation Drawings:

Drawing

65-46536

65-46537

65-46538

65-46539

65-46540

Title

Frame Installation Body Station 559

Frame Installation Body Station 578

Frame Installation Body Station 597

Frame Installation - Emergency

Escape Hatch Body Station 616

Frame Installation - Emergency

Escape Hatch, Body Station 639

These drawings were used to prepare this service bulletin. They are not necessary to make the

changes specified. They are not supplied with this service bulletin. They may not be applicable to

all airplane configurations or operators.

K. Publications Changed

Publication Chapter-Section

737 Structural Repair Manual

737 Illustrated Parts Catalog

53-10

53-10

L. Electrical Load Data

None

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

22
II. MATERIAL INFORMATION

A. Parts Necessary For Each Airplane

1. To get the kits shown below, refer to Paragraph I.G., Material - Price and Availability.

NOTE: The top kits are divided into subkits. Top kits and operator supplied materials specified in

Paragraph II.A.2., Parts and Materials Supplied by the Operator, are necessary for each

airplane.

Preventive Modification Kits for Overwing Frames from Body Station 559 to 639

-2011-2021-207

Quantity Part Number Groups Name 3ody

.65C22320-201

35C22320-181

35C22320-182

65C22320-185

.65C22320-203

.65C22320-7

.65C22320-202

1 . 65C22320-204

1 . 65C22320-208

1 .65C22320-8

- 35C22320-207

Affected

1 through 3

1 through 3

1 through 3

1 through 3

1 through 3

1 through 3

4

4

4

4

1 through 4

Top Kit

Sub Kit - Stub Beam

Replacement

Sub Kit - Stub Beam

Replacement

Sub Kit - Stub Beam Upper and

Lower Chord Replacement

Sub Kit - Stub Beam and Frame

Change

Sub Kit - Stub Beam Lower

Chord Replacement

Top Kit

Sub Kit - Stub Beam and Frame

Change

Sub Kit - Stub Beam Lower

Chord Replacement

Sub Kit - Stub Beam Lower

Chord Replacement

Supplemental Kit- Stub Beam

Lower Chord Replacement

Stations

Affected

559 - 639

639

616

578

597

559

559 - 597

597

578

559

597

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

23

1

1

1

1

1
PREVENTIVE MODIFICATION KIT HISTORY

Inactive Kit Number

65C22320-75

65C22320-167

65C22320-187

None

65C22320-5

65C22320-165

65C22320-3

65C22320-163

65C22320-183

65C22320-2

65C22320-162

65C22320-1

65C22320-161

65C22320-76

65C22320-168

65C22320-188

None

65C22320-6

65C22320-166

65C22320-186

65C22320-4

65C22320-164

65C22320-184

Supplemental Kit

Number

65C22320-169

65C22320-172

65C22320-207

None

None

65C22320-175

None

65C22320-173

65C22320-207

None

65C22320-180

None

65C22320-179

65C22320-170

65C22320-171

65C22320-207

None

None

65C22320-176

None

None

65C22320-174

65C22320-207

Replacing Kit Number

65C22320-167 (Top Kit)

65C22320-187 (Top Kit)

65C22320-201 * (Top Kit)

65C22320-7*(a)

65C22320-165

65C22320-185*

65C22320-163

65C22320-183

65C22320-203*

65C22320-162

65C22320-182*

65C22320-161

65C22320-181*

65C22320-168 (Top Kit)

65C22320-188 (Top Kit)

65C22320-202* (Top Kit)

65C22320-8*(a)

65C22320-166

65C22320-186

65C22320-208*(b)

65C22320-164

65C22320-184

65C22320-204*

(a) -7 and -8 Kits are original kits that do not replace any kits.

(b) -208 Kit does not contain the upper chords in the -186 kit because the existing T section is a

better installation.

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

24

Body

Station

559-639

559-639

559-639

559

578

578

597

597

597

616

616

639

639

559-597

559-597

559-597

559

578

578

578

597

597

597

Airplane

Groups

Affected

1-3

1-3

1-3

1-3

1-3

1-3

1-3

1-3

1-3

1-3

1-3

1-3

1-3

4

4

4

4

4

4

4

4

4

4

* Active Kit
OVERWING STUB FRAME REPAIR KITS FROM BODY STATION 559 TO 639

Kit Number

65C25211-101

65C25211-102

65C25211-105

65C25211-106

65C25211-111

65C25211-112

65C25211-115

65C25211-116

65C25211-141

65C25211-142

65C25211-143

65C25211-144

65C25211-81

65C25211-82

65C25211-85

65C25211-86

65C25211-91

65C25211-92

65C25211-95

65C25211-96

65C25211-125

65C25211-126

65C25211-129

Side Descntpion of Change

L Repair Kit - Lower Chord

R Repair Kit - Lower Chord

L Repair Kit - Frame Attach Angle

R Repair Kit - Frame Attach Angle

L Repair Kit - Lower Chord

R Repair Kit - Lower Chord

L Repair Kit - Frame Attach Angle

R Repair Kit - Frame Attach Angle

L Repair Kit- Stub Beam Web Cracks near

Inner Chord

R Repair Kit - Stub Beam Web Cracks near

Inner Chord

L Repair Kit - Stub Beam Inboard Web Crack

R Repair Kit - Stub Beam Inboard Web Crack

L Repair Kit - Lower Chord

R Repair Kit - Lower Chord

L Repair Kit - Frame Attach Angle

R Repair Kit - Frame Attach Angle

L Repair Kit - Lower Chord

R Repair Kit - Lower Chord

L Repair Kit - Frame Attach Angle

R Repair Kit - Frame Attach Angle

L Repair Kit - Shear Tie

R Repair Kit - Shear Tie

L Supplemental Repair Kit - Shear Tie

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

25

Airplane

Groups

Affected

1 through 3

1 through 3

1 through 3

1 through 3

4

4

4

4

1 through 3

1 through 3

Body

Station

559

559

559

559

559

559

559

559

578

578

578

578

578

578

578

578

578

578

578

578

597

597

597

1

1

1

1

1

1

4

4

4

4

1

1

1

through 3

through 3

through 3

through 3

through 3

through 3

through 3

through 3

through 3
OVERWING STUB FRAME REPAIR KITS FROM BODY STATION 559 TO 639

65C25211-130

65C25211-133

65C25211-134

65C25211-137

65C25211-138

65C25211-145

65C25211-146

65C25211-147

65C25211-148

65C25211-71

65C25211-72

65C25211-75

65C25211-76

65C25211-121

65C25211-122

65C25211-124

65C25211-32

65C25211-51

65C25211-52

65C25211-97

65C25211-1

65C25211-119

65C25211-120

R Supplemental Repair Kit - Shear Tie

L Repair Kit - Shear Tie

R Repair Kit - Shear Tie

L Supplemental Repair Kit - Shear Tie

R Supplemental Repair Kit - Shear Tie

L Repair Kit - Stub Beam Web Cracks near

Inner Chord

R Repair Kit - Stub Beam Web Cracks near

Inner Chord

L Repair Kit - Stub Beam Inboard Web Crack

R Repair Kit - Stub Beam Inboard Web Crack

L Repair Kit - Frame Attach Angle

R Repair Kit - Frame Attach Angle

L Repair Kit - Frame Attach Angle

R Repair Kit - Frame Attach Angle

L Repair Kit - Stub Beam Outboard Web

R Repair Kit - Stub Beam Outboard Web

L + R Supplemental Repair Kit - Outboard Stub

Beam Web

R Repair Kit - Stub Beam Inboard Web

L Repair Kit - Frame Web near Stringer S-16

R Repair Kit - Frame Web near Stringer S-16

L Repair Kit - Stub Beam Inboard Web

L Repair Kit - Stub Beam Inboard Web

L Repair Kit - Stub Beam Outboard Web

R Repair Kit - Stub Beam Outboard Web

Jul 16/92

REV. 4: Jul 16/92

1 through 3

4

4

4

4

1 through 3

1 through 3

1 through 3

1 through 3

1 through 3

1 through 3

4

4

1 through 4

1 through 4

1 through 4

1 through 4

1 through 4

1 through 4

1 through 4

1 through 4

1 through 4

1 through 4

597

597

597

597

597

597

597

597

597

597

597

597

597

616

616

616

616

616

616

616

639

639

639

737-53-1061

26
OVERWING STUB FRAME REPAIR

639 65C25211-123 L+R

639 65C25211-2 R

639 65C25211-21 L

639 65C25211-22 R

KITS FROM BODY STATION 559 TO 639

Supplemental Repair Kit - Outboard Stub

Beam Web

Repair Kit- Inboard Stub Beam Web

Repair Kit - Upper Web below Stringer

S-16

Repair Kit - Upper Web below Stringer

S-16

OVERWING STUB FRAME REPAIR KIT HISTORY

Body Inactive Kit Number

Station

597 65C25211-61

597 65C25211-62

597 65C25211-65

597 65C25211-66

616 65C25211-31

616 65C25211-41

616 65C25211-42

639 65C25211-11

639 65C25211-12

Supplemental Kit

Number

65C25211-129

65C25211-130

65C25211-137

65C25211-138

65C25211-98

65C25211-124

65C25211-124

65C25211-123

65C25211-123

Replacing Kit

Number

65C25211-125

65C25211-126

65C25211-133

65C25211-134

65C25211-97

65C25211-121

65C25211-122

65C25211-119

65C25211-120

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

27

1 through 4

1 through 4

1 through 4

1 through 4

Airplane

Group

Affected

1 through 3

1 through 3

4

4

1 through 4

1 through 4

1 through 4

1 through 4

1 through 4
OVERWING FRAME INSTALLATION REPAIR KITS FROM BODY STATION 559 TO 639 - WEB AND

Side Descritpion of Change Airplane

Groups

Affected

65C31658-27

65C31658-28

65C31658-39

65C31658-40

65C31658-5

65C31658-6

65C31658-3

65C31658-4

65C31658-53

65C31658-54

65C31658-75

65C31658-76

65C31658-1

65C31658-2

65C31658-51

65C31658-52

65C31658-55

65C31658-56

L Top Kit - Web Repair

R Top Kit -Web Repair

L Top Kit - Web Repair

R Top Kit - Web Repair

L Top Kit - Web Repair

R Top Kit - Web Repair

L Top Kit - Web and Inboard Chord Repair

R Top Kit - Web and Inboard Chord Repair

L Top Kit - Outer Chord Repair

R Top Kit - Outer Chord Repair

L Top Kit - Web, Inboard Chord and Outboard Chord

Repair

R Top Kit - Web, Inboard Chord and Outboard Chord

Repair

L Top Kit - Web and Inboard Chord Repair

R Top Kit - Web and Inboard Chord Repair

L Top Kit - Outer Chord Repair

R Top Kit - Outer Chord Repair

L Top Kit - Inner and Outer Chord and Web Repair

R Top Kit - Inner and Outer Chord and Web Repair

Jul 16/92

REV. 4: Jul 16/92

2

2

3

3

1

1

1 through 3

1 through 3

1 through 3

1 through 3

4

4

1 through 3

1 through 3

1 through 3

1 through 3

4

4

737-53-1061

28

CHORD

Body

Station

Kit Number

597

597

597

597

597

597

616

616

616

616

616

616

639

639

639

639

639

639
2. Parts and Materials Supplied by the Operator:

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

Part Number (Specification)

BMS 5-81

BMS 5-95-1/2, -2 or -4 (b)

BACS40R

7075-T6

Name

Secondary Fuel Barrier

Sealant

Sealant

Shim

Aluminum Stock for Radius

Fillers

(a) 1 quart should be the maximum quantity of sealant necessary when secondary fuel barrier

needs to be repaired.

(b) See Boeing Standard Practices Overhaul Manual Subjects 20-50-12 and 20-60-04

(c) There are ten possible shim locations they may or may not need shims depending on whether or

not gaps exist.

B. Parts Necessary to Change Spares

None

C. Special Tools and Equipment

No special tools or equipment are necessary to do the change in this service bulletin. Maintenance and

overhaul tools in manuals shown in Paragraph I.J., References, may be necessary. Examine operator

tool supply to make sure all necessary tools are available.

D. Existing Parts Accountability

None

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 29

Quantity

1 Quart (a)

1 Quart

(c)

1/8 x 3/4 x 8

in
BLANK PAGE

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

30
III. 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 figures give the recommended sequence of steps.

2. The work instructions are divided into five parts as follows:

Part I - Inspection

Part II - Preventive Modification

Part III - Repair

Part IV - Special Inspection

Part V - Retrofit Flow Diagram

3. As recommended by the 737 Aging Fleet Structures Working Group, accomplish the Preventive

Modification per Part II, except Paragraphs G and H, of the Accomplishment Instructions of this

service bulletin prior to or upon accumulation of 75,000 flight cycles. Paragraphs G and H were not

included in 737 Aging Fleet Document D6-38505 Revision F because they address problems found

after the 737 Structures Working Group reviewed this service bulletin.

4. 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

- 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.

5. Flow charts that represent these accomplishment instructions follow these accomplishment

instructions.

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

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

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

31
Part I- Inspection

A. Remove seats, carpet, floor panels and side wall panels as required to gain access to the overwing stub

beams and portions of the body frames at Body Stations 559, 578, 597, 616 and 639.

B. Accomplish a detailed visual inspection for cracks and damaged fasteners of overwing stub beams and

body frames per Figure 1.

C. On airplanes that have installed stub beam lower chords with 1/4 inch diameter fasteners at Body

Station 597 as given by Revisions 1, 2 or 3 of this service bulletin, do an inspection of the stub beam

lower chord for short edge margin as given in Figure 1. If edge margin is less than 1.5D, do an

inspection for cracks as given in Figure 1 or replace lower chord as given in Paragraph H of Part II of

these Accomplishment Instructions at times given in the compliance section. Refer to 737 Structural

Repair Manual Subject 51-30-2 for more information on removal and installation of fasteners.

D. On airplanes that have changed either circumferential frame at Body Station 597 as given by Revision

1, 2 or 3 of this service bulletin, visually inspect the frames for cracks. Do this inspection at the intervals

given in the compliance section until radius fillers are installed as given in Paragraph G of Part II of

these accomplishment instructions.

E. If no cracks or damaged fasteners are found, repeat inspections as given in the compliance section of

this service bulletin or accomplish Part II Preventive Modification.

F. If cracks or damaged fasteners are found within limits given in Figure 2, accomplish repair per Part III -

Repair.

G. On airplanes that have had the repair or preventive modification on the frames at Body Station 616 and

639, do a detailed visual inspection of the Body Stations 616 and 639 frame webs, inner chords and

outer chords near Stringer S-16. If no cracks are found, then repeat inspections. Do these inspections

at times given in the compliance section of this service bulletin.

H. On Group 4 airplanes that have modified a circumferential frame at Body Station 578 with kit

65C22320-186, make sure the upper chord was not replaced.

I. If the upper chord was replaced on Group 4 airplanes at Body Station 578 with kit 65C22320-186,

contact Boeing for instructions.

J. Reinstall components removed in Step A. Return airplane to normal.

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

32
Part II - Preventive Modification

NOTES: 1. The following instructions supplement information contained on Drawing 65C22320. Unless

otherwise noted, all references are to that drawing.

2. Entry into the center fuel cell is not necessary if only the stub beams at Body Stations 616 or

639 are being preventively modified.

A. Defuel airplane (Ref. 737 Maintenance Manual Subject 28-23-00).

B. Purge center wing fuel cells, if installed (Ref. 737 Maintenance Manual Subject 28-10-00).

C. Remove center wing access panels and fuel cells, if installed, to gain access to overwing stub beam

attachments in number 1 and 2 fuel cell cavities (Ref. 737 Maintenance Manual Subject 28-11-31).

D. Disconnect flight control cables to replace stub beam webs. Refer to 737 Maintenance Manual

Subjects 27-09-111 and 27-62-0 for more information to disconnect speedbrake cables SBA and SBB

that go into spoiler mixer quad on the left side of the airplane. Refer to 737 Maintenance Manual

Subjects 27-09-111 and 32-31-41 for more information to disconnect landing gear valve cables LGVA

and LGVB on the left side of the airplane. Refer to 737 Maintenance Manual Subjects 27-09-111 and

27-51-0 for more information to disconnect wing flap cables WFA and WFB.

E. On Groups 1,2, and 3 airplanes, modify overwing stub beams at Body Stations 559, 578, 597, 616 and

639 per Drawing 65C22320 using kits 65C22320-7, -185, -203, -182 and -181.

NOTES:

1. When replacing 4 attach fasteners common to the plus chord and the stub beam lower

chord at the Body Station 597, maintain a minimum edge margin of 1.5D.

2. It will be necessary to scrape sealant away from the outboard end of the stub beam

lower chord to get clearance to remove the lower chord. The lower chord is replaced

during preventive modification of the stub beams at Body Stations 559, 578, and 597.

3. Repair any secondary fuel barrier sealant removed or damaged during installation of any

stub beams parts (Ref. 737 Maintenance Manual 28-11-0).

4. Shim any gaps more than 0.01 inch that exist between the frame and the stub beam to

reduce pull down stresses. Gaps may occur after installation of the stub beam to floor

beam fasteners and before installation of the frame to stub beam fasteners. Take

measurements in the following four areas for all 5 overwing frames on each side of the

airplane: upper inboard chord area, upper outboard chord area, lower inboard chord

area, and lower outboard chord area. Shims that are more than 0.05 inch thick should

pick up a second row of fasteners. Gaps between the frame web and the stub beam

must have a shim installed that fills the complete frame to stub beam joint. Install single

and double tapered shims (Ref BACS40R or equivalent) with a faying surface seal (Ref.

BMS 5-95). If any gaps are more than 0.2 inch contact Boeing for instructions.

5. If 1.5D edge margin can not be maintained during installation of -39 or -40 shear ties in

kit 65C22320-203, then trim the shear tie flange to clear the existing rivets. Maintain

10:1 ratio when trimming flange. Install two rivets MS20470D6 in the partially trimmed

flange. Maintain 1.5D edge margin. Install rivets in line with other rivets in crease beam

outer chord. Maintain 3D minimum fastener spacing along crease beam outer chord.

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 33
F. On Group 4 airplanes, modify overwing stub beams at Body Stations 559, 578, and 597 per drawing

using kits 65C22320-8, -208 and -204.

NOTES:

1. When replacing attach fasteners for the lower chord of the stub beam at Body Station

597, maintain a minimum edge margin of 1.5D.

2. It will be necessary to scrape sealant away from the outboard end of the stub beam

lower chord to get clearance to remove the lower chord.

3. Repair any secondary fuel barrier sealant removed or damaged during installation of any

stub beams parts (Ref. 737 Maintenance Manual Subject 28-11-0).

4. Shim any gaps more than 0.01 inch that exist between the frame and the stub beam to

reduce pull down stresses. Gaps may occur after installation of the stub beam to floor

beam fasteners and before installation of the frame to stub beam fasteners. Take

measurements in the following four areas on each side of the airplane: upper inboard

chord area, upper outboard chord area, lower inboard chord area, and lower outboard

chord area. Shims that are more than 0.05 inch thick should pick up a second row of

fasteners. Gaps between the frame web and the stub beam must have a shim installed

that fills the complete frame to stub beam joint. Install single and double tapered shims

(Ref BACS40R or equivalent) with a faying surface seal (Ref. BMS 5-95). If any gaps

are more than 0.2 inch contact Boeing for instructions.

5. During installation of kit 65C22320-204, if the -45 or -46 shear ties can not be installed

because of interference with existing rivets in the plus chord flange, then trim the shear

tie flange to clear the existing rivets. Maintain 10:1 ratio when trimming flange. Install

two rivets MS20470D6 in the partially trimmed flange. Maintain 1.5D edge margin.

Install rivets in line with other rivets in crease beam outer chord. Maintain 3D minimum

fastener spacing along crease beam outer chord.

G. On Group 1 through 4 airplanes, install radius fillers as given in Figure 4 during modification of frame at

Body Station 597.

H. On any Group 1 through 4 airplanes with a short edge margin in the stub beam lower chord at Body

Station 597, replace those lower chords per drawing using kits 65C22320-207.

NOTES:

1. When replacing attach fasteners for the lower chord of the stub beam at Body Station

597, maintain a minimum edge margin of 1.5D.

2. It will be necessary to scrape sealant away from the outboard end of the stub beam

lower chord to get clearance to remove the lower chord.

3. Repair any secondary fuel barrier sealant removed or damaged during installation of any

stub beams parts (Ref. 737 Maintenance Manual Subject 28-11-0).

4. Shim any gaps more than 0.01 inch that exist between the frame and the stub beam to

reduce pull down stresses. Gaps may occur after installation of the stub beam to floor

beam fasteners and before installation of the frame to stub beam fasteners. Take

measurements in the lower inboard and outboard chord areas on each side of the

airplane. Shims that are more than 0.05 inch thick should pick up a second row of

fasteners. Gaps between the frame web and the stub beam must have a shim installed

that fills the complete frame to stub beam joint. Install single and double tapered shims

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

34
(Ref BACS40R or equivalent) with a faying surface seal (Ref. BMS 5-95). If any gaps

are more than 0.2 inch contact Boeing for instructions.

I. Clean center wing fuel tank, reinstall fuel cells removed for access and close fuel tank (Ref. 737

Maintenance Manual Subject 28-11-31).

J. Refuel airplane and check for fuel leaks (Ref. Maintenance Manual Subjects 28-21-0 and 28-11-0).

K. Connect and rig flight control cables that were disconnected for stub beam web replacement. Refer to

737 Maintenance Manual Subjects 27-09-111 and 27-62-0 for more information to connect speedbrake

cables SBA and SBB that go into spoiler mixer quad on the left side of the airplane. Refer to 737

Maintenance Manual Subjects 27-09-111 and 32-31-41 for more information to connect landing gear

valve cables LGVA and LGVB on the left side of the airplane. Refer to 737 Maintenance Manual

Subjects 27-09-111 and 27-51-0 for more information to connect wing flap cables WFA and WFB.

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

35
Part III - Repair

NOTES:

1. If removal of fasteners that attach the lower chord of the stub beam frames to the top of the

center fuel cell becomes necessary, then gain access for entry into center fuel cell as given in

Part II of these accomplishment instructions.

2. If removal of web is necessary, then disconnect flight control cables. Disconnect flight control

cables to replace stub beam webs. Refer to 737 Maintenance Manual Subjects 27-09-111 and

27-62-0 for more information to disconnect speedbrake cables SBA and SBB that go into

spoiler mixer quad on the left side of the airplane. Refer to 737 Maintenance Manual Subjects 27-09-111 and 32-31-41 for more information to disconnect landing gear valve cables LGVA

and LGVB on the left side of the airplane. Refer to 737 Maintenance Manual Subjects 27-09-111 and 27-51-0 for more information to disconnect wing flap cables WFA and WFB.

3. Repair any secondary fuel barrier sealant removed or damaged during installation of any stub

beams parts (Ref. 737 Maintenance Manual Subject 28-11-0).

4. If access must be gained for replacement of the lower portion of frames at Body Station 616 or

639, Stringer S-16 may be cut midway between body station frames while taking care not to

damage the skin. Refer to 737 Structural Repair Manual Subject 53-10-3 Figure 1 Detail II for

more information on splicing the stringer. Use stringer splice material 69-78188-17 to restore

strnger to normal.

A. If cracked component can be replaced by installation of the appropriate preventive modification kit,

accomplish Part II Preventive Modification for the affected frame.

B. If cracked part is covered in and is within the repair limits of Figure 2, accomplish applicable repair per Repair Drawing 65C25211 or 65C31658.

C. If cracked components can not be replaced or repaired per Step A or Step B, then contact Boeing for

repair instructions.

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

36
Part IV - Special Inspection

A. If not already accomplished, remove seats, carpet, floor and side panels as required to gain access to

Body Station 639 Frame on both sides of the airplane.

B. Eddy-current inspect inboard chord of frame at Body Station 639 per Figure 3 for cracks propagating

from the inboard fastener hole at Stringer 16.

C. If cracks are found, repair per Part III - Repair.

D. If no cracks are found, repeat inspection at the threshold given in the compliance section of this service

bulletin until Body Station 639 frame is preventively modified per Part II - Preventive Modification.

E. Reinstall floor panels, side panels, carpets and seats that were removed for access and restore airplane

to normal.

Jul 16/92 737-53-1061

REV. 4: Jul 16/92 37
AIRPLANES THAT HAVE NOT BEEN REPAIRED OR PREVENTIVELY MODIFIED

AS GIVEN IN SERVICE BULLETIN 737-53-1061 REVISION

AIRPLANES WITH

LESS THAN 15,000

FLIGHT CYCLES

UPON ACCUMULATION

OF 15,000 FLIGHT

CYCLES

AIRPLANES WITH

15,000 FLIGHT

CYCLES OR MORE

WITHIN 3,000

FLIGHT CYCLES

AT A REGULAR SCHEDULED MAINTENANCE PERIOD:

(A) VISULLY INSPECT FRAMES AT BS 559, 578, 597, 616 AND

639 PER PART I INSPECTION, GROUPS 1-4 AIRPLANES

(B) EDDY-CURRENT INSPECT BS 639 FRAME AT S-16 PER PART IV

SPECIAL INSPECTION, GROUPS 1-3 AIRPLANES ONLY

REINSPECT EVERY 15,000 FLIGHT CYCLES

NO CRACKS OR

DAMAGED FASTENERS

REINSPECT EVERY 4,500

FLIGHT CYCLES UNTIL

PREVENTIVE MODIFICATION

IS DONE

MODIFY EACH UNREPAIRED

FRAME OR PART OF FRAME

NOT REPAIRED PER PART

II PREVENTIVE MODIFICATION

CRACK OR DAMAGED

FASTENER FOUND

REPLACE CRACKED PART PER PART II

PREVENTIVE MODIFICATION OR REPAIR

CRACKED PART PER PART III REPAIR

FOR EACH FRAME

OR PART OF FRAME

NOT REPLACED OR

REPAIRED

FOR EACH FRAME

OR PART OF FRAME

REPLACED OR

REPAIRED

AT BODY STATIONS 559, 578 AND 597 NO FURTHER ACTION PER THIS BULLETIN

AT BODY STATIONS 616 AND 639 CONTINUE TO DO POST MODIFICATION

INSPECTIONS AT TIMES GIVEN IN COMPLIANCE SECTION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

38

)
AIRPLANE MODIFIED OR REPAIRED AS GIVEN BY THE ORIGINAL ISSUE,

REVISION 1, REVISION 2 OR REVISION 3 OF SERVICE BULLETIN 737-53-1061

AIRPLANES THAT HAVE HAD

STA 597 CIRCUMFERENTIAL

FRAME MODIFIED

AIRPLANES THAT HAVE HAD

STA 616 OR 639 CIRCUMFERENTIAL

FRAMES MODIFIED

VISUALLY INSPECT CIRCUMFERENTIAL

FRAME AT STATION 597 EVERY

4,500 FLIGHT CYCLES UNTIL

RADIUS FILLERS ARE INSTALLED

INSPECT STUB BEAM LOWER

CHORD AT STATION 597

FOR SHORT EDGE MARGIN

WITHIN 3,000 FLIGHT CYCLES

DO POST MODIFICATION VISUAL INSPECTIONS

WITHIN 24,000 FLIGHT CYCLES

AND THEN EVERY 4,500 FLIGHT CYCLES

EDGE MARGIN IS LESS

THAN 1.5D, CONTINUE

TO INSPECT EVERY 4 500

FLIGHT CYCLES OR REPLACE

STUB BEAM LOWER CHORD

EDGE MARGIN IS

MORE THAN 1.5D

NO MORE ACTION IS NECESSARY

AIRPLANE PARTS NOT MODIFIED OR REPAIRED SHOULD BE INSPECTED

OR MODIFIED AS GIVEN IN THE PREVIOUS FLOW CHART FOR

AIRPLANES THAT HAVE NOT BEEN REPAIRED OR MODIFIED

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

39
Illustration Table of Contents

Title Page

Figure 1. Inspection 39

Figure 2. Repair Limits 43

Figure 3. Special Inspection 46

Figure 4. Radius Filler Fabrication and Installation 49

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

40
FIGURE 1. INSPECTION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

41
FIGURE 1. INSPECTION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

42
FIGURE 1. INSPECTION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

43
FIGURE 1. INSPECTION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

44
Figure 2. Repair Limits

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

45
Figure 2. Repair Limits

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

46
Figure 2. Repair Limits

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

47
Figure 2. Repair Limits

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

48
Figure 3. Special Inspection

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

49
Figure 3. Special Inspection

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

50
FIGURE 4. RADIUS FILLER FABRICATION AND INSTALLATION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

51
FIGURE 4. RADIUS FILLER FABRICATION AND INSTALLATION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

52
FIGURE 4. RADIUS FILLER FABRICATION AND INSTALLATION

Jul 16/92

REV. 4: Jul 16/92

737-53-1061

53
ADDENDUM

FLIGHT SAFETY SECTION

INSPECTION TO ENSURE STRUCTURAL INTEGRITY OF AIRFRAME

Table I is a summary of inspections specified in Accomplishment Instructions, Part I - Flight Safety

Inspection Program, that are recommended for the detection of cracks prior to their reaching critical

lengths. Failure to detect cracks prior to their reaching critical length may result in failure of the escape

hatch door frames at Body Station 616 and 639 resulting in progressive failure of adjacent structure.

Any cracked structure should be repaired or

your cognizant regulatory agency.

Please report any discrepancies to Boeing

described in the addendum.

Airplane Condition

Service Bulletin

Modification or

Repair not

accomplished

Inspection

Detailed

Visual

replaced prior to further flight unless specifically approved by

Customer Support Engineering using the reporting system

TABLE I

Inspection Threshold

(Flight Cycles)

15,000 Flight Cycles

Repeat Inspection

Interval

(Flight Cycles)

4,500 Flight Cycles

NOTE: For airplanes

with more than 15,000

flight cycles at receipt of

this service bulletin, do

the inspection within

3,000 flight cycles.

Service Bulletin

Modification or

Repair

accomplished

Detailed

Visual

24,000 Flight Cycles

after preventive

modification or repair

4,500 Flight Cycles

NOTE: For airplanes

with more than 24,000

flight cycles after

modification or repair at

receipt of this service

bulletin, do the

inspection within 3,000

flight cycles.

Jul 16/92 ADDENDUM

REV. 4: Jul 16/92
Boeing requests that operators use the following Structural Significant Item (SSI) Reporting System to

report any discrepancies that are found in accomplishing a Flight Safety Inspection.

1. Upon recognition of discrepancy, the following information should be telegraphed to Boeing:

Heading: ATTENTION - SSI DISCREPANCY - SERVICE BULLETIN RELATED

- Service Bulletin number

- Airplane serial number on which discrepancy was found

- Identification of structural item found damaged

- Flight cycles and hours on damaged item

- Location and description of damage including direction and size

- When discovered and inspection method used

Send telegram through Boeing Field Service Representative or directly to:

737 Customer Support Engineering

2. An Operator's Follow-Up Report containing all available pertinent data, relative to the structural

discrepancy, shall be sent to Boeing. A summary of the information that should be reported is shown

in the DISCREPANT STRUCTURE REPORT form attached. Operators may use this form or any

suitable alternative which contains the same information.

3. All data and reports dealing with the Flight Safety Inspection Program shall be submitted either

through a Boeing Field Service Representative or directly to:

The Boeing Commercial Airplane Group

P.O. Box 3707

Seattle, Washington 98124

Attn: Director, 707/727/737 Customer Support Engineering

Org. M-7470 Mail Stop 9H-96

4. All reports will be reviewed promptly.

5. The Boeing Company will summarize the results of all reported significant data for distribution

semi-annually to operators and appropriate Airworthiness Authorities.

Jul 16/92 ADDENDUM

REV. 4: Jul 16/92
DISCREPANT STRUCTURE REPORT

1 REPORT DATA

AIRLINE/AGENCY

A TA INDEX

STATION

2 AIRCRAFT DATA

MFG SERIAL NO

MODEL SERIES

FUGHTHOURS

TAIL NO

FLIGHT CYCLES

3 COMPONENT DATA (AS APPLICABLE AND AVAILABLE)

NAME P/N

IPC/DWG REF SRM REF

COMPLETE THE FOLLOWING IF KNOWN AND DIFFERENT FROM SECTION 2

COMPONENT FLIGHT HOURS SINCE NEW

COMPONENT FLIGHT HOURS SINCE NEW

4 REPAIR DATA PLANNED C

S/N

SINCE OVERHAUL

SINCE OVERHAUL

COMPLETED

4A ACTION

4B REFERENCE ASSOCIATED WITH INSPECTION/REPAIR (SPECIFY NO, PAGE. FIGURE, ECT)

SB AD IPC SRM

MPD OTHER (E G SDR, MRR) SIIA

STRUCTURAL SIGNIFICANT ITEM NO. SERIES 50 NO.

5 SERVICE BULLETINS INCORPORATED IN AREA OF DISCREPANCY

SERVICE BULLETIN APPLICABLE SECTION DATE OF

NO OF SERVICE BULLETIN INCORPORATION

TOTAL FLIGHT HOURS AND

CYCLES AT INCORPORATION

HOURS FUGHTS

HOURS FUGHTS

HOURS FUGHTS

6 INSPECTION DATA (COMPLETE KNOWN INFO, CHECK APPROPRIATE ITEMS FOR DISCREPANT STRUCTURE)

CURRENT INSPECTION INTERVALS (FLIGHTS) CORRESPONDING INSPECTION LEVELS

6A WHEN DISCOVERED

SCHEDULED MAINTENANCE

OVERHAUL

UNSCHEDULED

SPECIALDIRECTED (AD, SB. )

SYMPTOM (FUEL/PRESS LEAK )

RELATED FLEET EXPERIENCE

ACCIDENT INVESTIGATION

SSID

SERIES 50

6B INSPECTION LEVEL

WALK- AROUND

GENERAL VISUAL

EXTERNAL SURVEILLANCE

INTERNAL SURVEILLANCE

DETAILED

SPECIAL

6C DETECTION METHOD

VISUAL TAP TEST

MAG VISUAL SOUND

DYE PENETRANT SMELL

ULTRASONIC FEEL

LOW X-RAY

FREQUENCY PRESS LOSS

EDDY CURRENT

HIGH

FREQUENCY

EDDY CURRENT

BORESCOPE

MAGNETIC

PARTICLE

Jul 16/92

REV. 4: Jul 16/92

ADDENDUM

REPORT NO

MONTH DAY YEAR
DESCREPANT STRUCTURE REPORT

7 DISCREPANCY DESCRIPTION:

Attach sketch, photos and text as required to describe defect and specific location When applicable give details of associated

discrepances on the same aircraft, related experience with this discrepancy on any aircraft, and previous modification (s) to the

discrepant structure

7A TYPE OF DISCREPANCY:

BENT

BROKEN

BUCKLED

BURNED

CLOGGED

CONTAMINATED

CORRODED

CRACKED

DEFORMED

DELAMINATED

7B SIZE OF DISCREPANCY:

DENTED

DETACHED

IMPROPERLY

ADJUSTED

LEAK

INCHES, OR

AREA X

CRACK LENGTH INITIALLY DETECTED

FINAL MEASUREMENT (IF DIFFERENT)

7C DISCREPANT PART:

FRAME/BULKHEAD

PRESSURE BULKHEAD

FRAME AROUND OPENING

WINDOW FORGING

KEEL BEAM

FLOOR

WING CENTER SECTION

WING DRY-BAY AREA/COMPT

SPAR

RIB

LANDING GEAR BEAM

FLAP TRACK

FAIRING

LOOSE

MISSING

OUT-OF-TOLERANCE

STUCK

WORN

NRINKLED

CENTIMETERS

DEPTH

DATE

DATE

SKIN

PLATE/PANEL

CHORD

STRINGER NO

BEAM

STRUT/BRACE

LINK/ROD

LONGERON

FITTING

BRACKET/CUP

STOP

FASTENER

JOINT/SPUCE

LUG

WELD

BOND

OPEN HOLE

FASTENER HOLE

CUT-OUT

ACCESS/UGHTENING HOLE

NOTCH/GROOVE

DISCONTINUITY

BASIC MATERIAL

BUSHING

PIN

7D LOCATION OF DISCREPANT PART:

GENERAL LOCATION (E G., BILGE, UNDER GALLEY)

BODY STA NO

WING STA NO

VERT STAB STA

HORIZ STAB STA

NACELLE/PYLON

COMPARTMENT

NOSE LANDING GEAR

MAIN LANDING GEAR

WING LANDING GEAR

BODY LANDING GEAR

DOOR/ACCESS PANEL

RUDDER

ELEVATOR

AILERON

FLAP

SLAT

SPOILER

TAB (ALSO CHECK ABOVE)

INSPECTED BY

INTERIOR

INBOARD

LEFT

FORWARD

UPPER

LEADING EDGE

MIDDLE

SPECIFIC LOCATION

EXTERIOR

OUTBOARD

RIGHT

AFT

LOWER

TRAILING EDGE

SIDE

REPAIRED BY

ORIGINATED BY

Jul 16/92

REV. 4: Jul 16/92

ADDENDUM

DATE

SIDE 2
Number:

Date:

Revision 4:

ATA System:

Prepared By:

737-53-1061

May 28,1982

July 16, 1992

5311

John Bourgeois

SUBJECT: FUSELAGE - OVERWING FRAME INSPECTION, MODIFICATION AND REPAIR - BODY

STATION 559 THROUGH 639

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Seattle, WA 98124-2207