Commercial

Airplane

Group

737

Service Bulletin

Number: 737-53-1163 Summary Date: December 21, 1993

ATA System: 5313

SUBJECT: FUSELAGE - FORWARD ENTRY DOORWAY SKIN CUTOUT - UPPER FORWARD AND

UPPER AFT CORNERS - INSPECTION, MODIFICATION, AND REPAIR

BACKGROUND

Seventeen operators have found cracks in the upper

corners of the forward entry door skin cutout. The

airplanes had collected from 33,150 to 76,242 flight

cycles.

The cause of the cracks isfatigue fromcabin

pressure. Continued operation with cracks in the

doorway upper corners can result in cabin

pressurization problems and unscheduled downtime

for repairs.

Installation of doublers as given in this service

bulletin can prevent cracks at the doorway upper

corners.

ACTION

Do a close visual inspection and a low and high

frequency eddy current inspection for cracks at the

forward entry doorway upper corners.

If no cracks are found, repeat the inspection until the

preventive change is done.

If a crack is found, install the applicable repair kit.

COMPLIANCE

Do the inspections before the airplane has flown

27,000 flight cycles. If there are no cracks, do the

inspection every 4500 flight cycles until the

preventive change is done. If the airplane has flown

more than 27,000 flight cycles, do the inspections

before the airplane has flown 4500 more flight

cycles.

EFFECTIVITY

All 737 airplanes, Line Numbers 1 through 1922

divided into 2 groups

MANPOWER

Task

Total

Man-hours

Elapsed Time

(Hours)

Inspection 3 3

Preventive Change 44 44

Repair 60 60

MATERIAL INFORMATION

Boeing Supplied Kits

Refer to Paragraph I.G., Material - Price and

Availability.

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207 Summary Page 1 of 2
BOEING SERVICE BULLETIN 737-53-1163

FORWARD ENTRY DOOR

CORNER CRACKS

TYPICAL UPPER

FWD

C60078

Dec 21/93

Summary Page 2 of 2
Commercial

Airplane

Group

737

Service Bulletin

Number: 737-53-1163

Date: December 21, 1993

ATA System: 5313

SUBJECT: FUSELAGE - FORWARD ENTRY DOORWAY SKIN CUTOUT - UPPER FORWARD AND

UPPER AFT CORNERS - INSPECTION, MODIFICATION, AND REPAIR

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.

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AER LINGUS (ARL)

1 PG255 PG573 PK029 PK641-PK642 PP951-PP952 PW591-PW594

2 PY281 PY322-PY323

AERO CONTROLS, INC (AEO)

1 PG629

AERO COSTA RICA (AOR)

1 PK872-PK873

AEROLINEAS ARGENTINAS (ARG)

1 PH705-PH708 PH741-PH743 PK102-PK103

2 PY007

AERON AVIATION (AAV)

1 PJ072

AIR ALGERIE (ALG)

1 PK361 PK631 PK633-PK634 PL717-PL725

2 PY051-PY053

AIR ATLANTA ICELANDIC (AID)

1 PJ104

2 PY002 PY381

AIR BERLIN GMBH (BER)

1 PW032 PW517

AIR CALEDONIE INTERNATIONAL (NCI)

1 PP918

AIR CHINA (BEJ)

1 PM281-PM283 PP521-PP522

Dec 21/93 737-53-1163

Page 1 of 23
BOEING SERVICE BULLETIN 737-53-1163

AIR COLUMBUS (COB)

1 PP904 PP907

AIR EUROPA (ARE)

1 PM382 PP501-PP502 PP831 PP835 PP840 PP846

AIR FRANCE (AFA)

1 PL502-PL503 PN101-PN117 PP902 PP910-PP912 PT211

AIR GABON S.A. (GBN)

2 PY191

AIR GUINEE (GNE)

2 PY651

AIR HOLLAND CHARTER B.V. (HOL)

1 PP504

AIR MADAGASCAR (MAD)

1 PG375 PL793

AIR MALTA (MLT)

1 PL621-PL626

AIR NAMIBIA (NAM)

1 PN492

AIR NAURU (NAU)

1 PK356 PK581

2 PY286

AIR NEW ZEALAND, LTD. (ANZ)

1 PJ009 PK211 PK213-PK214 PK216-PK220 PM181

2 PY741

AIR NIPPON CO., LTD. (ANK)

1 PG582

AIR ONE AB SWEDEN (AOW)

1 PJ003

AIR TANZANIA (TNZ)

2 PY611-PY612

AIR TOULOUSE INTERNATIONAL (TOL)

1 PL716

AIR UK (LEISURE) (UKL)

1 PW001 PW014 PW017 PW051

AIR ZAIRE (ZAI)

2 PY111 PY113

AIR ZIMBABWE (ZMB)

1 PN431-PN433

ALASKA AIRLINES (ASA)

2 PY112 PY134-PY135 PY270 PY461-PY463

Dec 21/93 737-53-1163

2
BOEING SERVICE BULLETIN 737-53-1163

ALL NIPPON AIRWAYS CO. LTD. (ANA)

1 PG584-PG586 PK711-PK716

ALOHA (ALO)

1 PG046 PK286-PK287 PK691-PK695 PK697 PP825-PP826

2 PY001 PY231 PY242 PY451

ALYEMDA DEM. YEMEN AIRLINES (ALY)

2 PY409-PY410

AMERICA WEST AIRLINES, INC. (AMW)

1 PC004 PG036 PK283 PK565 PK696 PL081

PL172 PL551-PL562 PL801 PP181-PP187 PP189 PP194-PP199

PP891-PP899 PP901 PP903 PP931-PP934 PS666-PS668

AMIRI FLIGHT (ABD)

1 PK495

ANGOLA AIRLINES (ANG)

1 PK661 PK664-PK666

2 PY162

ANSETT AIRLINES OF AUSTRALIA (ANS)

1 PP908-PP909 PP914 PQ026-PQ041

ANSETT WORLDWIDE AVIATION SERVICES (AWW)

1 PA001

ARAMCO ASSOCIATED CO. (ARM)

1 PL151 PL456

2 PY241 PY243-PY244

ARCO (ATR)

1 PN452-PN453

ARKIA ISRAELI AIRLINES, LTD (ARK)

1 PG575

ASEAN AVIATION (L) INC. (ASJ)

1 PG578-PG581 PG583

ASIANA AIRLINES (AAR)

1 PT212-PT213 PW005 PW007-PW009 PW011 PW013 PW018-PW020

PW025

ATASCO USA, INC. (ATJ)

1 PL762

AVENSA (AVN)

1 PK042-PK043 PM383

AVIATECA (AVT)

1 PG201 PL737 PL740-PL741 PP352 PP379 PP384

PP948

2 PY201

AVIATION SALES CO., INC. (ASC)

1 PG331 PG401

Dec 21/93 737-53-1163

3
BOEING SERVICE BULLETIN 737-53-1163

AVIOGENEX AIR TRANSPORT (AVG)

1 PL501 PL506 PN501-PN502

BAVARIA (BAV)

1 PL455

BOURAQ INDONESIA AIRLINES (PTB)

1 PJ001 PL742-PL744 PL803

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

1 PJ007-PJ008 PK882 PN455 PT021-PT023 PW571-PW573

BRITANNIA AIRWAYS, INC. (BRI)

1 PJ101 PJ108 PJ110-PJ111 PJ113-PJ115 PJ117-PJ119 PK801-PK804

BRITISH AIRWAYS (BAB)

1 PK731-PK765 PK771-PK777 PK779 PP353 PW091-PW093 PW111-PW112

PW115 PW117

BRITISH MIDLAND (BMA)

1 PP915-PP916 PP923-PP924 PQ281 PT295 PW004 PW006

PW501

CALDWELL AIRCRAFT TRADING CO. (CAS)

1 PG402

CAMEROON AIRLINES (CAM)

1 PM171

2 PY046-PY047

CANADIAN AIRLINES INTERNATIONAL LTD. (CDI)

1 PK028 PK358 PK671-PK675 PK677-PK681 PK822 PK881

PK884 PL401-PL417 PL764-PL770 PM141-PM142

2 PY151-PY154 PY303-PY304 PY421-PY422 PY441

CARNIVAL AIR (CVL)

1 PG302 PG305 PG312 PL712 PW061

CASINO EXPRESS (CIN)

1 PG279 PG436

CAYMAN AIRWAYS (CAY)

1 PK222 PK561

CHIA (CHS)

1 PW026 PW030 PW034-PW035

CHINA AIR LINES, INC. (CHI)

1 PN472-PN474

CHINA SOUTHERN AIRLINES (GUN)

1 PK636-PK637 PM251-PM254 PN405

CHINA SOUTHWEST AIRLINES (XIN)

1 PP631-PP634

COMAIR (CML)

1 PG354 PG356

Dec 21/93 737-53-1163

4
BOEING SERVICE BULLETIN 737-53-1163

CONTINENTAL AIRLINES, INC. (CAL)

1 PA006-PA009 PA011-PA014 PA016-PA020 PG056 PG064 PG199

PG225 PG433 PG501-PG505 PG621-PG625 PG627-PG628 PG630

PG704 PL001 PP671-PP699 PP701-PP726 PP730 PP732-PP733

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

1 PC001 PJ107 PJ112 PK617 PL745

2 PY341

CORSE AIR INTERNATIONAL (COR)

1 PW661

CROATIA AIRLINES (CRH)

1 PK904 PK906-PK907 PK928 PK932

DAMANIA AIRWAYS LTD. (DAI)

1 PL451-PL452

DELTA AIR LINES, INC. (DAL)

1 PK611 PK613 PK623-PK624 PK632 PL221 PL611

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

DEUTSCHE BA (DBA)

1 PP508 PP510

DUKE FARMS (DFI)

1 PP991

E G AND G (EGN)

1 PG037 PG208 PG210 PG215 PG431 PL763

EAST WEST AIRLINES (INDIA) (BOM)

1 PK615-PK616 PK819 PK824 PL171 PL758

EDRESS, SHIEKH M. (SME)

1 PL505

EGYPTAIR (EGP)

1 PK254-PK255 PK257-PK258

EL AL ISRAEL AIRLINES, LTD. (ELA)

1 PL631-PL632

ETHIOPIAN AIRLINES, CORP. (ETH)

1 PN512

EURALAIR (ERA)

1 PG026 PG028-PG029 PT146

2 PY004 PY006

EUROPE AERO SERVICE (EUR)

1 PK203 PK215 PK282 PK359 PK564 PK612

PQ228-PQ229 PT214

EUROPEAN AIRLINES (EUF)

1 PQ227

Dec 21/93 737-53-1163

5
BOEING SERVICE BULLETIN 737-53-1163

FAR EASTERN AIR TRANSPORT (FAT)

1 PA002 PA005 PG055 PG226 PG228 PG230

PK562 PN481

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

1 PC002 PG034 PG213 PK241 PL711

FORTUNE AVIATION (FOR)

1 PK432

FRENCH POSTAL OFFICE (FPO)

1 PS641-PS642

2 PY101-PY103 PY302 PY342 PY344

GARUDA INDONESIAN AIRWAYS (GIA)

1 PQ282-PQ286

GATARI AIR SERVICE (GRI)

1 PL441

GERMANIA FLUGGESELLSCHAFT MBH (GER)

1 PP503 PP506-PP507 PQ231-PQ236

GOVERNMENT OF BRAZIL (BRZ)

1 PK068-PK069

GOVERNMENT OF MEXICO (MXG)

1 PC005 PG223 PP919

GOVERNMENT OF SHARJAH (SHJ)

1 PL581

GPA GROUP LTD. (GUI)

1 PK252 PK354-PK355 PK614 PL027 PP827 PP833-PP834

GULF AIR (GUL)

1 PK461-PK464 PK466-PK468

HAPAG LLOYD (HAP)

1 PL504 PT101 PW511-PW516 PW518

HEAVYLIFT AIRCRAFT ENGINEERING (HVL)

1 PJ109

ICELANDAIR (ICE)

1 PW561-PW563

INDIAN AIR FORCE (IDF)

1 PH712-PH713 PM016-PM017

INDIAN AIRLINES (IND)

1 PH021 PH024 PH709 PH711 PK231-PK233 PK235-PK240

PM001-PM006

2 PY631

INDONESIAN AIR FORCE (IDO)

1 PL601-PL603

Dec 21/93 737-53-1163

6
BOEING SERVICE BULLETIN 737-53-1163

INTEGRATED RESOURCES (INH)

1 PG271 PG273 PJ006

INTER EUROPEAN AIRWAYS (IER)

1 PP841-PP842 PP922 PW116

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

1 PL761

INTERNATIONAL AIR LEASES (IAL)

1 PG043 PG047-PG048 PG253

INTERNATIONAL AIRLINE SUPPORT GROUP (ASG)

1 PG021

INTERNATIONAL LEASE FINANCE (ILF)

1 PL746

INTERNATIONAL PACIFIC TRADING CO. (IPT)

1 PG224 PG572 PG574 PJ102

IRAN AIR (IRN)

1 PH731 PK391

2 PY021-PY022

IRAQI AIRWAYS (IRQ)

2 PY141-PY142

ISTANBUL AIRLINES (IST)

1 PW002 PW022 PW024 PW028 PW036

JAPAN TRANSOCEAN AIR CO., LTD. (SWL)

1 PK521 PK523-PK528 PN451 PN454 PN456

JET AIRWAYS (INDIA) PVT. LTD. (JPL)

1 PP920-PP921

JETALL HOLDING CORPORATION (JEL)

2 PY005

JUGOSLOVENSKI AEROTRANSPORT (JAT)

1 PP771-PP779

KENYA AIRWAYS (KEN)

1 PK253 PK256

KLM ROYAL DUTCH AIRLINES (KLM)

1 PP861-PP873 PW611-PW615

KOREAN AIR FORCE (KAF)

1 PP221

LACSA (LAC)

1 PK357 PK871

LADECO (LDE)

1 PJ005 PK212 PK281 PK826 PK830 PL802

PP946

Dec 21/93 737-53-1163

7
BOEING SERVICE BULLETIN 737-53-1163

LAN-CHILE S.A. (LAN)

1 PK360 PK825 PL025 PL028

LAPA (LAZ)

1 PG355 PK047 PK051

LAUDA AIR LUFTFAHRT AG (LAL)

1 PP851-PP852

LIBERTY AIRLINE, LTD. (LIR)

1 PJ004

LINA CONGO (LNA)

2 PY411

LINHAS AEREAS DE MOCAMBIQUE (LAM)

1 PH703

2 PY031

LITHUANIAN AIRLINES (LIJ)

1 PK563

LUFTHANSA GERMAN AIRLINES (DLH)

1 PK901-PK903 PK905 PK911-PK927 PK929-PK931 PK933-PK938 PQ051-PQ073

PQ086-PQ092

2 PY345-PY346

MAERSK AIR (MRS)

1 PP505 PT121 PT123

MALAYSIAN AIRLINES SYSTEM BERHAD (MAS)

1 PL747 PW027 PW031 PW033 PW062-PW063

MALEV HUNGARIAN AIRLINES (HGA)

1 PK284-PK285 PK827

MANDALA AIRLINES (MND)

1 PL421 PN001-PN002

MARKAIR, INC. (ALK)

1 PN493 PP301 PP305 PQ226 PW113-PW114 PW502

2 PY056-PY057 PY592-PY595

MODILUFT (MOU)

1 PK908-PK910

MONARCH AIRLINES, LTD. (MON)

1 PM381 PP821 PP823-PP824 PP832 PP913

MONTELY II (MOY)

1 PJ031

MORRIS AIR (MOR)

1 PP162 PP164-PP165 PP169 PP188 PP190-PP192 PP201-PP205

PP302-PP304 PP351 PP378 PP381-PP382 PP727

NASA (NAS)

1 PA099

Dec 21/93 737-53-1163

8
BOEING SERVICE BULLETIN 737-53-1163

NATIONAL AIRLINES (NAW)

1 PJ105-PJ106

NICA (NICARAGUENCE DE AVIACION) (NIC)

1 PK823

NIGERIA AIRWAYS, LTD. (NIA)

1 PL781-PL782 PL784-PL788

NORDIC EAST (NOE)

1 PJ002

NWT AIR (NTA)

2 PX701 PY132-PY133

OLYMPIC AIRWAYS (OLY)

1 PK301-PK304 PK307-PK310 PM021-PM023

P. T. AIRFAST (PTF)

1 PG204 PG278

2 PY343

PAKISTAN INTERNATIONAL AIRLINES CORP. (PIA)

1 PP281-PP286

PEGASUS AIRLINES (PGS)

1 PW029

PETROLAIR SYSTEMS S. A. (PTS)

1 PL471

PHILIPPINE AIRLINES, INC. (PAL)

1 PM384-PM385 PM387-PM388 PM390-PM391 PP935-PP936

PLM TRANSPORTATION EQUIPMENT CORP. (PLI)

1 PK820

PLUNA (PLU)

1 PL201-PL203

POLARIS AIRCRAFT LEASING CORP. (PLS)

1 PG202 PG205 PG207 PG211 PG218-PG219 PG272

PG274 PG276 PG651-PG652 PJ103 PK026-PK027 PK221

PK305 PK465 PK874 PL061

POLY TECHNOLOGIES, INC. (PTI)

1 PP728-PP729

POLYNESIAN AIRLINES (PLY)

1 PP947

PRESIDENTIAL AIR (PRB)

1 PG432

QANTAS AIRWAYS, LTD. (QAN)

1 PQ001-PQ016 PW531-PW535

Dec 21/93 737-53-1163

9
BOEING SERVICE BULLETIN 737-53-1163

REPUBLIC OF NIGER (NIR)

2 PY166

ROYAL AIR MAROC (RAM)

1 PK271-PK274 PW631-PW632

2 PY671-PY672

SABENA S.A. (SAB)

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

PP961-PP967 PW010 PW503

2 PY272-PY275

SAHSA (SERVICIO AEREO DE HONDURAS,S.A.) (SAH)

1 PJ032 PJ071 PL736

SAUDI ARABIAN AIRLINES CORP. (SVA)

1 PK311-PK317 PL726-PL735

2 PY036-PY037

SAUDI ROYAL FLEET (SRF)

1 PK318

SCANDINAVIAN AIRLINES SYSTEM (SAS)

1 PT181-PT182

SERVICIOS AEREOS RUTAS ORIENTE, (SARO) (SEV)

1 PA015 PA021-PA022 PK351 PK353

SIERRA PACIFIC AIRLINES (SRP)

1 PC003 PG577 PK627

SILKAIR (SLK)

1 PM392 PP509

SINGAPORE AIRLINES, LTD (SIA)

1 PQ222

SOUTH AFRICAN AIRWAYS (SAA)

1 PG353 PL101-PL113

SOUTHWEST AIRLINES CO. (SWA)

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

PP101-PP148 PP161 PP163 PP166-PP168 PP193 PP380

PP731 PP822 PU001-PU007

SUDAN (SUD)

2 PY156-PY157

SULTANAIR (SLR)

1 PG251

SUNEXPRESS AIR (SNS)

1 PM389

T A PORTUGUESES (TAP)

1 PK971 PK973-PK974 PN081-PN086 PP984-PP986 PQ301-PQ305

2 PY721

Dec 21/93 737-53-1163

10
BOEING SERVICE BULLETIN 737-53-1163

TACA INTERNATIONAL AIRLINES, INC. (TAC)

1 PG059 PG352 PK223 PN491 PQ331-PQ332

2 PY131

TAESA (TES)

1 PK625-PK626

TAT EUROPEAN AIRLINES (TTR)

2 PY003 PY301 PY321 PY361-PY362

TEA BASEL (TEB)

1 PP838 PP845 PQ224-PQ225

THAI AIR FORCE (TAF)

1 PK519

THAI AIRWAYS INTERNATIONAL, INC. (TII)

1 PK511 PK514-PK515 PW161-PW162

THE CIT GROUP/CAPITAL FINANCE CO. (TCI)

1 PK622

TRANS EUROPEAN AIRWAYS ITALIA S.P.A. (TEI)

1 PQ221 PQ223

TRANSAERO (TRX)

1 PK451-PK452

TRANSAVIA AIRLINES (TAV)

1 PG074 PK501-PK504 PK821 PP801-PP808

TRANSBRASIL AIRLINES INC. (TBL)

1 PP836-PP837 PP843-PP844 PP847-PP848 PQ241-PQ243 PW016 PW021

PW023

TRANSMED (TRZ)

1 PW012 PW015

TRANSTAR (AFM)

1 PG403

TRITON AIRLINES INC. (TTN)

1 PK352

TUNIS AIR (TUN)

1 PK861-PK863

2 PY621

UNITED AIR LINES, INC. (UAL)

1 PG001-PG004 PG006-PG013 PG015-PG019 PG022-PG025 PG027 PG030

PG032-PG033 PG038-PG040 PG045 PG051-PG054 PG057 PG060-PG063

PG065-PG072 PG075 PK201-PK202 PL002-PL023 PQ101-PQ198

UNITED STATES AIR FORCE (USF)

1 PJ201-PJ219

Dec 21/93 737-53-1163

11
BOEING SERVICE BULLETIN 737-53-1163

USAIR, INC. (USA)

1 PG041-PG042 PG073 PG206 PG301 PG303-PG304 PG306-PG311

PG313-PG314 PG474 PG576 PK288-PK289 PK591-PK599 PK601-PK610

PK883 PM101-PM119 PN021-PN043 PP001-PP010 PP012-PP054 PP376-PP377

PP383 PP401-PP440 PP471-PP475 PV001-PV010 PV012-PV040

VARIG AIRLINES (VAR)

1 PK111-PK116 PK118-PK120 PK141-PK146 PL453-PL454 PP839 PP905-PP906

PP917 PP981-PP982 PP987 PQ251-PQ255

VARSA (VAB)

1 PG351

VASP (VSP)

1 PG435 PG437 PG439-PG440 PG471-PG473 PH011-PH013 PK061-PK062

PK065-PK067 PL756

2 PX071

VENEZUELA - GOVERNMENT OF (VNZ)

1 PK070

VISCOUNT AIR SERVICE INC. (VAS)

1 PG203 PG209 PG212 PG216-PG217 PG220-PG222 PK306

VIVA AIR (VIV)

1 PP391-PP393 PP983

WHIRLPOOL FINANCIAL CORP (ZZW)

1 PG214

WIEN AIRLINES (WIE)

2 PY401

XIAMEN AIRLINES CO. LTD. (XIA)

1 PK635 PM255 PN521

YEMEN AIRWAYS (YEM)

1 PK341

YUNNAN PROVINCIAL IMPORT & EXPORT CORP. (YUN)

1 PP651-PP652

ZAMBIA AIRWAYS (ZAM)

1 PK291 PL026

Dec 21/93 737-53-1163

12
BOEING SERVICE BULLETIN 737-53-1163

IDENTIFICATION BY VARIABLE NUMBER

GROUP 1

PA001-PA022 PA099 PA231-PA232 PC001-PC005 PG001-PG075 PG199

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

PG375 PG401-PG403 PG431-PG442 PG471-PG475 PG501-PG505 PG571-PG586

PG621-PG630 PG651-PG652 PG701-PG705 PH001 PH011-PH013 PH021-PH024

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

PJ101-PJ119 PJ201-PJ219 PK026-PK029 PK041-PK053 PK061-PK070 PK081-PK082

PK091-PK099 PK101-PK103 PK111-PK120 PK141-PK146 PK201-PK204 PK211-PK223

PK231-PK241 PK251-PK258 PK271-PK274 PK281-PK289 PK291 PK301-PK318

PK341 PK351-PK361 PK391 PK431-PK433 PK451-PK452 PK461-PK469

PK495 PK501-PK504 PK511-PK515 PK519 PK521-PK528 PK541-PK565

PK581 PK591-PK599 PK601-PK617 PK621-PK637 PK641-PK642 PK661-PK666

PK671-PK681 PK691-PK697 PK711-PK716 PK731-PK765 PK771-PK779 PK801-PK804

PK819-PK827 PK830 PK861-PK863 PK871-PK874 PK881-PK884 PK901-PK938

PK971-PK974 PL001-PL028 PL061 PL081 PL101-PL113 PL151

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 PL711-PL712 PL716-PL747

PL756 PL758 PL761-PL770 PL781-PL788 PL793 PL801-PL803

PM001-PM006 PM016-PM017 PM021-PM023 PM051-PM066 PM101-PM119 PM141-PM142

PM171 PM181 PM251-PM255 PM281-PM283 PM381-PM392 PN001-PN002

PN021-PN043 PN081-PN086 PN101-PN117 PN131-PN163 PN401-PN420 PN431-PN433

PN451-PN456 PN471-PN474 PN481 PN491-PN493 PN501-PN502 PN511-PN512

PN521 PP001-PP054 PP101-PP148 PP161-PP169 PP181-PP199 PP201-PP205

PP221 PP231-PP243 PP281-PP286 PP301-PP305 PP351-PP353 PP376-PP384

PP391-PP393 PP401-PP440 PP471-PP475 PP501-PP510 PP521-PP522 PP631-PP634

PP651-PP652 PP671-PP699 PP701-PP733 PP771-PP779 PP801-PP808 PP821-PP827

PP831-PP848 PP851-PP852 PP861-PP873 PP891-PP899 PP901-PP924 PP931-PP936

PP946-PP948 PP951-PP952 PP961-PP967 PP981-PP987 PP991 PP993

PQ001-PQ016 PQ026-PQ041 PQ051-PQ073 PQ086-PQ092 PQ101-PQ198 PQ221-PQ229

PQ231-PQ236 PQ241-PQ243 PQ251-PQ255 PQ281-PQ286 PQ301-PQ305 PQ331-PQ332

PS641-PS642 PS666-PS668 PT021-PT023 PT101 PT121-PT123 PT146

PT181-PT182 PT211-PT214 PT295 PU001-PU007 PV001-PV040 PW001-PW036

PW051 PW061-PW063 PW091-PW093 PW111-PW117 PW161-PW162 PW501-PW503

PW511-PW518 PW531-PW535 PW561-PW563 PW571-PW573 PW591-PW594 PW611-PW615

PW631-PW632 PW661

GROUP 2

PX071 PX701 PY001-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-PY304 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

Dec 21/93 737-53-1163

13
BOEING SERVICE BULLETIN 737-53-1163

B. Reason

Seventeen operators have found cracks in the upper corners of the skin at the forward entry doorway.

The airplanes had collected from 33,150 to 76,242 flight cycles.

The cause of the cracks is fatigue from cabin pressure loads. Continued operation with cracks in the

doorway upper corners can result in cabin pressurization problems and unscheduled downtime for

repairs.

Installation of doublers as given in this service bulletin can prevent cracks at the doorway corners.

There are four other service bulletins for 737 door cutout cracks. Table I shows the service bulletins

and the areas they cover.

TABLE I - SERVICE BULLETINS FOR DOOR CUTOUT CRACKING

DOORWAY Upper

Forward

Corner

Upper Aft

Corner

Lower

Forward

Corner

Lower Aft

Corner

Upper

Hinge

Cutout

Lower

Hinge

Cutout

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

Forward Galley 737-53-1116

Aft Entry 737-53-1149737-53-1074

Aft Galley

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

C. Description

On Group 1 and 2 airplanes, do a close visual inspection and a high and low frequency eddy current

inspection for cracks at the upper corners of the forward entry door.

If you find no cracks and you don't do the preventive change, then you must make repeat inspections

as shown in section II.D., Compliance. If you do a preventive change or a repair, then no more

inspections are necessary. The preventive changes are shown in Section III., Accomplishment

Instructions.

If you find cracks, then you must do a repair. Stop drill the crack as given in 737 SRM 51-10-1 or

737-300/400/500 SRM 51-10-02 and install the repair kit given in section III., Accomplishment

Instructions.

The airplane effectivity is divided into two groups. Group 2 airplanes have a main cargo door

immediately aft of the forward entry door. Group 1 airplanes do not have a main cargo door.

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

of the quality of this service bulletin.

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

NOTES:

1. The changes specified in the service bulletins shown in Table I can be made before or during

the changes specified in this service bulletin.

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

Give the size and location of the damage. When possible, send sketches and photographs. If

the damage includes corrosion, send data on the length, width, and depth of clean up.

SEND TO: BOEING COMMERCIAL AIRPLANE GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT

D. Compliance

Do the inspections before the airplane has flown 27,000 flight cycles. If there are no cracks, do the

inspection every 4500 flight cycles until the preventive change is done. If the airplane has flown more

than 27,000 flight cycles, do the inspections before the airplane has flown 4500 more flight cycles.

E. Approval

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

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

are FAA approved. The service bulletin and the FAA approval were based on the airplane in its

original Boeing delivery configuration or as modified by other FAA approved Boeing changes and do

not apply to airplanes on which other configuration changes have been made.

F. Manpower

The following table shows an estimate of the man-hours necessary to do this service bulletin for each

doorway. 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.

Task Number of

Persons Man-Hours Elapsed Time(Hours)

Inspection 1 3 3

Preventive Change 1 44 44

Repair 1 60 60

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

G. Material - Price and Availability

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

below. Kit availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date

Boeing gets the purchase order.

Unit Price

ROLT Until

Kit Number Name (weeks) Mar 13/94

65C36941-1 Kit - Preventive Change 25 $ 1948.00

65C36941-5 Kit - Repair 25 $ 1563.00

65C36941-7 Kit - Repair 25 $ 2120.00

65C36941-13 Kit - Preventive Change 25 $ 1697.00

65C36941-15 Kit - Repair 25 $ 1978.00

65C36941-17 Kit - Repair 25 $ 2360.00

The kits are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. After the Unit Price date, new price (and ROLT ) 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

I. Weight and Balance

Applicability

Change in

Weight

(Pounds) Change in Moment (Pound-Inches)

Group Kit 737-100 737-200 737-300 737-400 737-500

1 65C36941-1 +3.9 +1279.2 +1138.8 +967.2 +686.4 +1177.8

65C36941-5 +5.8 +1902.4 +1693.6 +1438.4 +1020.8 +1751.6

65C36941-7 +10.1 +3312.8 +2949.2 +2504.8 +1777.6 +3050.2

2 65C36941-13 +5.6 - +1635.2 - - -

65C36941-15 +7.6 - +2219.2 - - -

65C36941-17 +10.6 - +3095.2 - - -

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

J. References

1. Existing Data:

a. 737 Maintenance Manual Subject 25-21-331.

b. 737-300/400/500 Maintenance Manual Subject 25-21-31

c. 737 Structural Repair Manual Subject 51-10-1, 51-30-8

d. 737-300/400/500 Structural Repair Manual Subject 51-10-02, 51-40-08

e. 737 Nondestructive Test Manual, Part 6, Subject 51-00-00

f. Boeing Standard Overhaul Practices Manual section 20-50-11, 20-50-12

g. Boeing Service Bulletins:

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

Modification, and Repair"

737-53-1083 "Fuselage - Forward Entry Door Cutout Structure at Lower Sill - Inspection,

Modification, and Repair"

737-53-1116 "Fuselage - Forward Galley Doorway Upper Corners - Inspection, Repair,

and Modification"

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

Inspection, Repair and Modification"

2. Data supplied with this service bulletin:

a. Drawings:

Drawing Number Sheet DCN ADCN Title

65C36941 PL - 1,2 Repair and Preventive Modification,

1-- Upper Forward Entry Doorway - Kit

2--

3. Installation Drawings:

None

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

these procedures are frequently used as standard shop practices.

K. Publications Changed

None

L. Electrical Load Data

None

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

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.

Airplane

Group Application Kit Number

1 Preventive Change 65C36941-1

1 Repair for Cracks in the Skin and Doubler, but not the Strap 65C36941-5

1 Repair for Cracks in the Skin, the Doubler, and the Strap 65C36941-7

2 Preventive Change 65C36941-13

2 Repair for Cracks in the Skin and Doubler, but not the Strap 65C36941-15

2 Repair for Cracks in the Skin, the Doubler, and the Strap 65C36941-17

2. Parts and Materials Supplied by the Operator:

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

Quantity Part Number (Specification) Name

As Required BMS 5-95, Class B-1/2, -2, or -4 (a) Sealant

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

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. But, it is

possible that maintenance and overhaul tools in the manuals shown in Paragraph I.J., References,

can be necessary. Examine operator tool supply to make sure all necessary tools are available.

D. Existing Parts Accountability

None

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

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

- All linear dimensions are in inches

- Tolerance on linear dimensions other than rivet and bolt edge margin is plus or minus 0.03 inch

- Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

- Angular tolerance is plus or minus 2 degrees

- Fastener hole dimensions are in 737 Structural Repair Manual Chapter 51

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

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

4. Refer to 737 Structural Repair Manual (SRM) Section 51-30-8 or 737-300/400/500 SRM Section

51-40-08 for countersink instructions and instructions on how to install countersink repair washers.

5. Refer to the Standard Overhaul Practices manual 20-50-11 for application of aerodynamic

smoother.

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

PART I - INSPECTION

A. Get access to the passenger cabin side of the forward entry doorway upper corners by removing the

sidewall lining panels. Refer to 737 Maintenance Manual (MM) Subject 25-21-331 or

737-300/400/500 MM Subject 25-21-31.

B. Do a close visual inspection and a low and high frequency eddy current inspection for cracks in the

skin, doubler and strap at the doorway upper corners as shown in Figure 1.

C. If no cracks are found at the doorway upper corners, repeat the inspection at the times shown in the

compliance section. Repeat the inspections until the preventive change is done as given in Part II.

D. If cracks are found at the doorway upper corners, do the repair as given in Part III.

NOTE: The repair given in Part III is applicable only to cracks that are found in the areas specified on

drawing 65C36941, which is supplied with this service bulletin. If the crack is not in the area

specified in drawing 65C36941, tell The Boeing Company.

E. Return the airplane to normal.

F. A Preventive change or repair is the last procedure necessary to complete this service bulletin.

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

PART II - PREVENTIVE CHANGE

A. Get access to the passenger cabin side of the forward entry doorway upper corners by removing the

sidewall lining panels. Refer to 737 Maintenance Manual (MM) Subject 25-21-331 or

737-300/400/500 MM Subject 25-21-31.

B. Remove the existing bolts and rivets as shown on the applicable kit drawing. For group 1 airplanes

use kit drawing 65C36941-1, for group 2 airplanes use kit drawing 65C36941-13.

C. Position the external doubler supplied in the preventive change kit.

D. Through the existing fastener holes, backdrill the fastener holes in the external doubler as shown on

the applicable kit drawing.

E. Drill the new fastener holes at the locations shown on the applicable kit drawing.

F. In the countersunk fastener holes that are covered by the external doubler, install the repair washers

wet with sealant (refer to BMS 5-95).

G. Assemble external doubler to fuselage skin with sealant (refer to BMS 5-95).

H. Install the new fasteners as shown on the applicable kit drawing.

NOTE: The fastener grip lengths shown on the drawing picture sheet are for the repair. The

preventive change kits contain the correct fasteners for the preventive change doublers.

I. Trim the external doublers flush with the existing door opening.

J. Apply aerodynamic smoother to the edge of the external doublers except at the door cutout. Taper

the aerodynamic smoother from the doubler edge to the fuselage skin.

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

PART III - REPAIR

NOTE: The repair given in this bulletin can only be used to repair a crack within the limits shown on the

drawing supplied with this bulletin. On group 1 airplanes, see drawing 65C36941, Sheet 1, View

B3. On group 2 airplanes, see drawing 65C36941, Sheet 2, View B3. Only cracks up to 2.5

inches in length and within the crack zone shown on the drawing can be repaired as given in this

bulletin. See Flagnote 3 on the drawing. Contact Boeing for a repair if cracks exceed these

limits.

A. Get access to the passenger cabin side of the forward entry doorway upper corners by removing the

sidewall lining panels. Reference 737 Maintenance Manual (MM) Subject 25-21-331 or

737-300/400/500 MM Subject 25-21-31.

B. Stop drill the crack as given in 737 SRM 51-10-1 or 737-300/400/500 SRM 51-10-02.

C. At the doorwayupper corners, remove the existing bolts and rivets as shown on the applicable kit

drawing. See Section II, Material Information, for the applicable kit drawing.

D. Position the external doubler and tripler supplied in the repair kit.

E. Through the existing fastener holes, backdrill the fastener holes in the external doubler and tripler as

given on the applicable kit drawing.

F. Drill the new fastener holes at the locations shown on the applicable kit drawing.

G. In the countersunk fastener holes that are covered by the external doubler, install the repair washers

wet with sealant (refer to BMS 5-95).

H. Assemble the external doubler and tripler to the fuselage skin with sealant (refer to BMS 5-95).

I. Install the new fasteners as shown on the applicable kit drawing.

NOTE: The fastener grip lengths shown on the drawing are for the repair of cracks through the skin,

the doubler, and the strap. The other kit, the kit for the repair of cracks through the skin and

doubler only, contains the correct fasteners for that repair.

J. Trim the external doublers flush with the existing door opening.

K. Apply aerodynamic smoother to the edge of the external doublers except at the door cutout. Taper

the aerodynamic smoother from the doubler edge to the fuselage skin.

Dec 21/93 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

1 2 3 4

FORWARD ENTRY DOOR

DOOR STRAP

BODY SKIN

FWD

C60117

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

figure.

STEP TASK NAME PROCEDURE REFERENCES NOTES

1 Inspect Skin High frequency

eddy current

NDT Part 6,

51-00-00, Figure 4

Do the inspection on the

outer surface. (a) (b)

2 Inspect Skin, doubler,

and door strap

Close visual _ Do the inspection on the

inner surface. (a) (b)

3 Inspect Doubler and

strap

Low frequency

eddy current

NDT Part 6,

51-00-00, Figure 8

Do the inspection from

the outside. (a) (b)

4 Inspect Skin Visual - Do the inspection from

the outside. (a) (b)

(a) On group 1 airplanes, inspect an area that would be covered by the largest doubler

shown on drawing 65C36941, Sheet 1, View B3.

FIGURE 1. INSPECTION

Dec 21/93 SHEET 1 OF 2 737-53-1163

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BOEING SERVICE BULLETIN 737-53-1163

(Continued)

(b) On group 2 airplanes, inspect an area that would be covered by the largest doubler

shown on drawing 65C36941, Sheet 2, View B3.

FIGURE 1. INSPECTION

Dec 21/93 SHEET 2 OF 2 737-53-1163

23

Commercial

Airplane

Group

737

Service Bulletin

Number: 737-53-1163 Evaluation Form

Date: December 21, 1993

ATA System: 5313

Prepared By: Steve Richmond

SUBJECT: FUSELAGE - FORWARD ENTRY DOORWAY SKIN CUTOUT - UPPER FORWARD AND

UPPER AFT CORNERS - INSPECTION, MODIFICATION, AND REPAIR

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

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

items:

- Did this service bulletin meet your estimate of quality?

- How easy is this service bulletin to understand?

- Are the Planning Information, Material Information and Accomplishment Instructions satisfactory?

- Will you do this service bulletin fully? If not, please tell us why.

- Is the Manpower estimate satisfactory?

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

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

Please give us this data:

OPERATOR: TODAY'S DATE:

PREPARED BY: TITLE:

ORGANIZATION: TELEX CODE:

TELEPHONE NUMBER:

COMMENTS:

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

form.

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

directly to this address:

R.G. Kelsey, Manager

Service Bulletin Engineering

Boeing Commercial Airplane Group

P.O. Box 3707, Mail Stop 2L-02

Seattle, WA 98124-2207

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207