Commercial 

Airplanes 737

Service Bulletin

Number: 737-57A1271

Original Issue: September 11, 2003

Revision 3: February 13, 2012

ATA System: 5752

SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard

Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

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persons from specific countries. The controller of this data has the individual responsibility to abide by all export

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ECCN: 9E991

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Copyright © 2003 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more

information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

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4.0
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BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 30

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 31

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 33

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FIGURE 1: INSPECTION - TRACK WEBS AND FLANGES . . . . . . . . . . . . . . . . . . . . . . . 42

FIGURE 2: INSPECTION - WITH TRACK-TO-WING ATTACHMENT ASSEMBLED . . . . . . . . . . 44

FIGURE 3: INSPECTION - WITH TRACK-TO-WING ATTACHMENT DISASSEMBLED . . . . . . . . 46

FIGURE 4: REPLACEMENT - ANTI-FRET STRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

FIGURE 5: REPLACEMENT - TAPERED SHIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

FIGURE 6: TRACK REPAIRS AND BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 52

FIGURE 7: ALIGNMENT - TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

FIGURE 8: INSTALLATION - NEW SPARES TRACK - GROUP 1 AIRPLANES - 737-100/200 . . . . 63

FIGURE 9: INSTALLATION - NEW SPARES TRACK - GROUP 3 AIRPLANES - 737-300/400/500 . . 68

FIGURE 10: SHOP AID - PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

FIGURE 11: TRACK OVERHAUL - SUPPLEMENTAL INSTRUCTIONS TO OHM 57-53-15 . . . . . . 73

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BOEING SERVICE BULLETIN 737-57A1271

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

Revision Transmittal Sheet Number: 737-57A1271

Original Issue: September 11, 2003

Revision 3: February 13, 2012

ATA System: 5752

SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard

Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on the airplane(s) changed in accordance with Revision 2 of this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 78-13-07, AD 90-06-02, AD 2000-25-07 & AD

2002-05-07 are related to this service bulletin.

REASON FOR REVISION

This revision is sent to incorporate Information Notice 737-57A1271 IN 02. This Information Notice informed

operators that sheet 2 of 3 in Figure 1 should be ignored. References to the related AD's were added and

additional notes were added to section 3.A. General Information.

These sections were changed:

1. Figure 1 was revised to remove the graphic on sheet 2 of 3.

2. 3.A. General Information, additional notes were added.

3. 1.F. Approval, updated to the current statement.

The data given in Information Notice 737-57A1271 IN 02 is included in this revision.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: September 11, 2003

Revision 1: July 30, 2008

Revision 2: January 17, 2011

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BOEING SERVICE BULLETIN 737-57A1271
Commercial 

Airplanes 737

Service Bulletin

Summary Number: 737-57A1271

Original Issue: September 11, 2003

Revision 3: February 13, 2012

ATA System: 5752

SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard

Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin gives the instructions to inspect, repair, overhaul, and replace the flap track at Wing Buttock

Line (WBL) 254.

Since 1989, Boeing has more than thirty reports of cracks in the flap track at WBL 254. Cracks were found in

the area of the rear spar attachment, in the track webs, and in the upper and lower flanges at the aft end of the

track. The cracks in the area of the rear spar attachment were found at the edge of the hole for the outboard

bolt, or at the outer edge of the flange adjacent to the outboard bolt. The cracks in the upper and lower flanges

were 0.1 to 1.5 inches in length, and the cracks in the aft end of the webs were 0.75 to 7.0 inches in length. In

one incident the aft end of a track had cracks through the two lower flanges, through the two webs, and through

the fail-safe spacer. The two upper flanges were all that kept the aft end attached to the remaining part of the

track. Also, a track was found with cracks through the two upper and two lower flanges, and through the two

webs. The fail-safe spacer was all that kept the aft end of this track attached. This track also had a piece broken

out in the curved area of the upper outboard flange.

Some of the reports also show that tracks were found loose and had corrosion in the area of the rear spar

attachment. These tracks that were found loose also had damaged, or missing, anti-fret strips and tapered

shims. Initially, the loose tracks were thought to be caused by a weak bond of, or compression damage to, the

phenolic anti-fret strip installed in the joint between the track and rear spar. But, subsequent reports showed

that the sequence and procedures used during track installation could also be a cause of loose tracks. During

installation, when full torque is applied to the forward attach bolt, it can cause the track to move laterally at the

rear spar joint. If the track moves laterally at the rear spar joint during the installation procedures, it can put a

side load on the inboard aft attach bolt. Then, when the inboard aft attach bolt is tightened to the specified torque

value, some of the torque can be absorbed by friction. Subsequently, because of the friction, the torque applied

to the bolt is not sufficient to hold the track tight against the rear spar structure.

Continued operation with a cracked and/or loose attachment at the rear spar could cause the track to break. A

result of a broken track could be the loss of the outboard trailing edge flap, and may preclude continued safe

flight and landing of the airplane.

The new spares track assemblies have increased upper flange thickness in the attachment area that mates with

the wing rear spar, and improved coatings and processes for corrosion protection. The new track for the

737-100/200 also has an improved fail-safe configuration at the forward end that makes it comparable to the

737-300/400/500 track assembly.

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The inspections given in this service bulletin will find the conditions that make repair or replacement of the flap

track necessary. The repairs, scheduled overhauls, correct alignment during installation, and regularly scheduled

maintenance will keep tracks in a serviceable condition. There is no terminating action for this service bulletin.

This service bulletin replaces Service Bulletins 737-57A1082, 737-57A1249, and 737-57A1265.

Boeing Service Related Problem (SRP) 737-SRP-57-0131 is related to this service bulletin.

ACTION (PRR 35005-238RS)

Do an initial inspection of the track webs, track flanges, and the track-to-wing attachment at WBL 254. Look for

stop-drill repairs and cracks in the track webs. Look for stop-drill repairs, cracks, nicks, corrosion pits, galling,

and other signs of damage on the track flanges. Look for corrosion, loose bolts, and a damaged or a missing

anti-fret strip and/or tapered shim at the track-to-wing attachment.

Remove a track from service if it has a stop-drill repair. If possible, make repairs to the edges of the track flange,

but replace the track if cracks are found in the webs.

Disassemble the track-to-wing joint and do more inspections if signs of corrosion, loose bolts, or a damaged or

missing anti-fret strip or tapered shim are found. If necessary make and install a new anti-fret strip, and/or tapered

shim, and remove corrosion and make repairs to the track. Do the procedures to correctly align the track during

assembly of the track-to-wing joint. If the track cannot be repaired, install a serviceable flap track assembly.

During installation of a serviceable flap assembly, do the procedures to correctly align the track during installation.

Do the repeat inspections and schedule the initial, and repeat overhaul, of a flap track at the times given in

Paragraph 1.E., Compliance.

Flap track assemblies with short fail-safe bars, part number 65-46428-31 and 65-46428-33 must be removed

from service during inspection or repair.

EFFECTIVITY

All 737-100, -200, -200C, -300, -400, and -500 airplanes line numbers 1 through 3132.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive AD 78-13-07, AD 90-06-02, AD 2000-25-07 & AD

2002-05-07 are related to this service bulletin.

Refer to Paragraph 1.E., Compliance, for the repeat inspection and overhaul thresholds.

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection, and/or repair procedures, given in this service

bulletin.

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BOEING SERVICE BULLETIN 737-57A1271
MANPOWER

Airplanes Total Task Hours Elapsed Hours

All 82 23

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 737-57A1271

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

Number: 737-57A1271

Original Issue: September 11, 2003

Revision 3: February 13, 2012

ATA System: 5752

SUBJECT: WINGS - Trailing Edge And Trailing Edge Devices - Trailing Edge Flaps - Outboard

Flap, Inboard Track Inspection/Overhaul/Replacement at WBL 254

1. 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.

GROUP CONFIGURATION DESCRIPTION

737-100/-200/-200C, airplanes with flap track assemblies 65-46428-()

or 65C35380-(). Inspection, overhaul and replacement instructions

given are applicable to Group 1 airplanes

1 -

737-200/-200C, airplanes with flap track assemblies 65-67158-() or

65C35380-(). If necessary, these tracks can be replaced with

65-67158-6.

2 -

737-300/400/500 airplanes with 65-46428-(), 65C35616-(),

65C35387-(), 65C34812-() or 65C35380-() flap track assemblies.

The inspection, overhaul, and replacement instructions given in this

service bulletin are applicable to Group 3 airplanes.

3 -

Airplane Models:

737-100, 737-200, 737-200C, 737-300, 737-400, 737-500

Variable Number Group

PA001 - PA022 1

PA099 1

PA231 - PA232 1

PC001 - PC005 2

PG001 - PG075 1

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Variable Number Group

PG199 1

PG201 - PG230 1

PG251 - PG255 1

PG271 - PG279 1

PG301 - PG314 1

PG331 - PG332 1

PG351 - PG356 1

PG375 1

PG401 - PG403 1

PG431 - PG442 1

PG471 - PG475 1

PG501 - PG505 1

PG571 - PG586 1

PG621 - PG630 1

PG651 - PG652 1

PG701 - PG705 1

PH001 1

PH011 - PH013 1

PH021 - PH024 1

PH701 - PH715 1

PH731 - PH732 1

PH741 - PH743 1

PJ001 - PJ002 2

PJ003 - PJ009 1

PJ031 - PJ032 2

PJ071 - PJ072 2

PJ101 - PJ104 2

PJ105 - PJ119 1

PJ201 - PJ219 1

PJ301 - PJ302 3

PJ551 - PJ561 3

PJ601 - PJ615 3

PJ811 3

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PJ816 - PJ817 3

PK026 - PK029 1

PK041 - PK053 1

PK061 - PK070 1

PK081 - PK082 1

PK091 - PK099 1

PK101 - PK103 1

PK111 - PK120 1

PK141 - PK146 1

PK201 - PK204 1

PK211 - PK223 1

PK231 - PK241 1

PK251 - PK258 1

PK271 - PK274 1

PK281 - PK289 1

PK291 1

PK301 - PK318 1

PK341 1

PK351 - PK361 1

PK391 1

PK431 - PK433 1

PK451 - PK452 1

PK461 - PK469 1

PK495 1

PK501 - PK504 1

PK511 - PK515 1

PK519 1

PK521 - PK528 1

PK541 - PK565 1

PK581 1

PK591 - PK599 1

PK601 - PK617 1

PK621 - PK637 1

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PK641 - PK642 1

PK661 - PK666 1

PK671 - PK681 1

PK691 - PK697 1

PK711 - PK716 1

PK731 - PK765 1

PK771 - PK779 1

PK801 - PK804 1

PK819 - PK827 1

PK830 1

PK861 - PK863 1

PK871 - PK874 1

PK881 - PK884 1

PK901 - PK938 1

PK971 - PK974 1

PL001 - PL028 1

PL061 1

PL081 1

PL101 - PL113 1

PL151 1

PL171 - PL172 1

PL201 - PL203 1

PL221 1

PL401 - PL417 1

PL421 1

PL441 1

PL451 - PL456 1

PL471 1

PL491 1

PL501 - PL506 1

PL551 - PL562 1

PL581 1

PL601 - PL603 1

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PL611 1

PL621 - PL626 1

PL631 - PL632 1

PL711 - PL712 1

PL716 - PL747 1

PL756 1

PL758 1

PL761 - PL770 1

PL781 - PL788 1

PL793 1

PL801 - PL803 2

PM001 - PM006 1

PM016 - PM017 1

PM021 - PM023 1

PM051 - PM066 1

PM101 - PM119 1

PM141 - PM142 1

PM171 1

PM181 1

PM251 - PM255 1

PM281 - PM283 1

PM381 - PM399 3

PM401 - PM417 3

PM541 - PM564 3

PN001 - PN002 1

PN021 - PN043 1

PN081 - PN086 1

PN101 - PN117 1

PN131 - PN163 1

PN401 - PN420 1

PN431 - PN433 1

PN451 - PN456 1

PN471 - PN474 1

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PN481 1

PN491 - PN493 1

PN501 - PN502 1

PN511 - PN512 1

PN521 1

PP001 - PP054 3

PP101 - PP169 3

PP181 - PP199 3

PP201 - PP205 3

PP221 3

PP231 - PP243 3

PP281 - PP286 3

PP301 - PP305 3

PP351 - PP353 3

PP376 - PP384 3

PP391 - PP393 3

PP401 - PP440 3

PP471 - PP475 3

PP501 - PP522 3

PP631 - PP634 3

PP651 - PP652 3

PP671 - PP699 3

PP701 - PP733 3

PP771 - PP779 3

PP801 - PP808 3

PP821 - PP827 3

PP831 - PP848 3

PP851 - PP852 3

PP861 - PP877 3

PP891 - PP899 3

PP901 - PP936 3

PP946 - PP948 3

PP951 - PP952 3

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PP961 - PP967 3

PP981 - PP991 3

PP993 3

PQ001 - PQ016 3

PQ026 - PQ041 3

PQ051 - PQ092 3

PQ101 - PQ199 3

PQ201 - PQ202 3

PQ221 - PQ237 3

PQ241 - PQ243 3

PQ251 - PQ267 3

PQ281 - PQ299 3

PQ301 - PQ307 3

PQ331 - PQ332 3

PQ341 - PQ348 3

PQ361 - PQ373 3

PQ391 - PQ395 3

PQ401 - PQ418 3

PQ421 3

PQ431 - PQ438 3

PQ447 - PQ448 3

PQ451 3

PQ454 3

PQ471 - PQ475 3

PQ479 - PQ481 3

PQ486 - PQ487 3

PQ491 - PQ493 3

PQ771 - PQ772 3

PQ791 - PQ793 3

PQ801 - PQ805 3

PQ931 - PQ935 3

PQ951 3

PQ971 - PQ997 3

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PR001 - PR017 3

PR021 - PR034 3

PR041 - PR045 3

PR061 - PR072 3

PR077 - PR082 3

PR091 - PR092 3

PR096 3

PR101 3

PR121 - PR122 3

PR131 - PR132 3

PR141 - PR143 3

PR161 - PR172 3

PR181 3

PS601 - PS631 3

PS636 - PS638 3

PS641 - PS644 3

PS651 - PS657 3

PS666 - PS669 3

PS691 - PS692 3

PS701 - PS706 3

PS751 - PS799 3

PS811 3

PS836 - PS837 3

PS841 - PS846 3

PS851 - PS852 3

PS856 3

PS861 - PS863 3

PS866 - PS868 3

PS871 - PS874 3

PS896 - PS897 3

PS901 - PS941 3

PS956 - PS957 3

PS961 - PS963 3

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PS971 - PS978 3

PT001 - PT015 3

PT021 - PT031 3

PT041 - PT064 3

PT101 - PT105 3

PT121 - PT138 3

PT146 - PT148 3

PT161 - PT170 3

PT181 - PT188 3

PT211 - PT220 3

PT295 3

PT301 - PT309 3

PT331 - PT360 3

PT381 - PT399 3

PT401 - PT438 3

PT501 - PT517 3

PT561 - PT565 3

PT581 - PT586 3

PT611 - PT621 3

PT641 - PT644 3

PT651 - PT656 3

PT671 - PT672 3

PT681 - PT685 3

PT701 - PT703 3

PT716 - PT717 3

PT721 - PT725 3

PT801 - PT834 3

PT851 - PT854 3

PT871 - PT886 3

PT901 - PT930 3

PT971 - PT973 3

PT981 - PT985 3

PT996 3

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PU001 - PU025 3

PU301 3

PU311 - PU313 3

PV001 - PV055 3

PV201 - PV209 3

PV226 - PV229 3

PV231 - PV237 3

PV271 - PV272 3

PV281 - PV287 3

PV296 3

PV301 - PV302 3

PV351 3

PV356 - PV357 3

PW001 - PW054 3

PW061 - PW068 3

PW072 3

PW086 - PW088 3

PW091 - PW094 3

PW101 - PW102 3

PW106 3

PW111 - PW120 3

PW156 - PW157 3

PW161 - PW171 3

PW201 - PW252 3

PW261 - PW268 3

PW271 - PW276 3

PW278 3

PW281 - PW293 3

PW296 3

PW301 - PW327 3

PW401 - PW408 3

PW411 - PW418 3

PW421 - PW424 3

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PW431 - PW435 3

PW441 - PW450 3

PW461 - PW467 3

PW501 - PW504 3

PW511 - PW522 3

PW524 - PW550 3

PW556 - PW557 3

PW561 - PW564 3

PW571 - PW576 3

PW591 - PW596 3

PW611 - PW622 3

PW631 - PW637 3

PW661 - PW662 3

PW681 - PW683 3

PW701 - PW702 3

PW711 - PW717 3

PW741 - PW742 3

PW761 3

PW771 3

PW831 3

PW851 - PW856 3

PX071 1

PX701 1

PY001 - PY006 2

PY007 - PY008 1

PY021 - PY022 1

PY031 1

PY036 - PY037 1

PY046 - PY048 1

PY051 - PY053 1

PY056 - PY057 1

PY101 - PY103 1

PY111 - PY113 1

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BOEING SERVICE BULLETIN 737-57A1271
Variable Number Group

PY131 - PY135 1

PY141 - PY143 1

PY151 - PY154 1

PY156 - PY157 1

PY161 - PY162 1

PY166 1

PY191 1

PY201 1

PY221 - PY222 1

PY231 1

PY241 - PY244 1

PY270 - PY275 1

PY281 1

PY286 1

PY301 - PY304 2

PY321 - PY323 2

PY341 - PY346 2

PY361 - PY362 2

PY381 1

PY401 1

PY409 - PY411 1

PY421 - PY422 1

PY441 1

PY451 1

PY461 - PY463 1

PY591 - PY595 1

PY611 - PY612 1

PY621 1

PY631 1

PY651 1

PY671 - PY672 1

PY721 1

PY741 1

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BOEING SERVICE BULLETIN 737-57A1271
2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for

the recommended use.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives the instructions to inspect, repair, overhaul, and replace the flap track at

Wing Buttock Line (WBL) 254.

Since 1989, Boeing has more than thirty reports of cracks in the flap track at WBL 254. Cracks were

found in the area of the rear spar attachment, in the track webs, and in the upper and lower flanges at

the aft end of the track. The cracks in the area of the spar attachment were found at the edge of the

hole for the outboard bolt, or between the center bolt hole and the outboard bolt hole, or at the outer

edge of the flange adjacent to the outboard bolt. The cracks in the upper and lower flanges were 0.1

to 1.5 inches in length, and the cracks in the aft end of the webs were 0.75 to 7.0 inches in length. In

one incident the aft end of a track had cracks through the two lower flanges, through the two webs,

and through the fail-safe spacer. The two upper flanges were all that kept the aft end attached to the

remaining part of the track. Also, a track was found with cracks through the two upper and two lower

flanges, and through the two webs. The fail-safe spacer was all that kept the aft end of this track

attached. This track also had a piece broken out in the curved area of the upper outboard flange.

Some of the reports also show that tracks were found loose and had corrosion in the area of the rear

spar attachment. These tracks that were found loose also had damaged, or missing, anti-fret strips

and tapered shims. Initially, the loose tracks were thought to be caused by a weak bond of, or

compression damage to, the phenolic anti-fret strip installed in the joint between the track and rear

spar. But, subsequent reports showed that the sequence and procedures used during track installation

could also be a cause of loose tracks. During installation, when full torque is applied to the forward

attach bolt, it can cause the track to move laterally at the rear spar joint. If the track moves laterally at

the rear spar joint during the installation procedures, it can put a side load on the inboard aft attach

bolt. Then, when the inboard aft attach bolt is tightened to the specified torque value, some of the

torque can be absorbed by friction. Subsequently, because of the friction, the torque applied to the bolt

is not sufficient to hold the track tight against the rear spar structure.

Continued operation with a cracked and/or loose attachment at the rear spar could cause the track to

break. A result of a broken track could be the loss of the outboard trailing edge flap, and may preclude

continued safe flight and landing of the airplane.

The new spares track assemblies have increased upper flange thickness in the attachment area that

mates with the wing rear spar, and improved coatings and processes for corrosion protection. The new

track for the 737-100/200 also has an improved fail-safe configuration at the forward end that makes

it comparable to the 737-300/400/500 track assembly.

The inspections given in this service bulletin will find the conditions that make repair or replacement

of the flap track necessary. The repairs, scheduled overhauls, correct alignment during installation,

and regularly scheduled maintenance will keep tracks in a serviceable condition. There is no terminating

action for this service bulletin.

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BOEING SERVICE BULLETIN 737-57A1271
This service bulletin replaces Service Bulletins 737-57A1082, 737-57A1249, and 737-57A1265.

Boeing Service Related Problem (SRP) 737-SRP-57-0131 is related to this service bulletin.

Revision 01 is sent to include the data given in Information Notice 737-57A1271 IN 01 and make these

changes:

– The two notes that read "Some small cracks in the web, that start in the fastener holes, can be

repaired with the overhaul instructions given in 737 OHM 57-53-15" are removed from the work

instructions. Also, this statement is not added to the Action and Description paragraphs as stated

in Information Notice 737-57A1271 IN 01.

– Three notes are added to Paragraph 1.E., Compliance. The notes give more data about the

overhaul of the flap tracks as related to the initial and repeat inspections.

– A statement that shows the relationship between this service bulletin, Service Bulletin 737-57A1082,

AD 90-06-02, and Boeing Document D6-38505 is added to Paragraph 1.F., Approval.

– Figure 7, Note (d), List Item 3 is corrected to read "inboard attach hole" and a caution is added

before List Item 3 to make sure that the inner diameter of the steel bushing is not increased at the

inboard attach bolt.

– Figure 9, Note (b) is moved to the part number column of Step 9 and the note is changed to add

Track Assembly 65C35616-5. Note (d) is added to Step 9 to give part usage data.

– Figure 11, added an upper limit for the thermal spray coating dimensions. Added additional coating

information to view E-E, and added a new detail view "C". Note (c) is added to Step 2 to show

thermal spray coating requirements.

Revision 02 is sent to make to following changes:

– 1.A. Effectivity:

- Added reference to 65C35380-( ) and 65-67158-6 part numbers in the group configuration

description.

– 1.D. Description:

- Added reference to 65C35380-( ) and 65-67158-6 part numbers in the group configuration

description.

- Added Maintenance zone table.

– 1.E. Compliance:

- Added statement to remove flap track assemblies with short failsafe bars from service.

– 1.K. Publications Affected:

- Added damage tolerance statement.

– 2.C. Parts Necessary For Each Airplane:

- Revised note (c) for spare parts availability.

– 3.B. Work Instructions:

- Clarified the inspection steps.

– Figure 3 and 7:

- Clarified notes.

– Figure 8:

- Corrected fastener grip length for step 11.

Revision 3 is sent to incorporate Information Notice 737-57A1271 IN 02. This Information Notice

informed operators that sheet 2 of 3 in Figure 1, in revision 2 of this service bulletin should be ignored.

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BOEING SERVICE BULLETIN 737-57A1271
D. Description

Do an initial inspection of the track webs, track flanges, and the track-to-wing attachment at WBL 254.

Look for stop-drill repairs and cracks in the track webs. Look for stop-drill repairs, cracks, nicks, corrosion

pits, galling, and other signs of damage on the track flanges. Look for corrosion, loose bolts, and a

damaged or a missing anti-fret strip and/or tapered shim at the track-to-wing attachment.

Remove a track from service if it has a stop-drill repair. If possible, make repairs to the edges of the

track flange, but replace the track if cracks are found in the webs.

Disassemble the track-to-wing joint and do more inspections if signs of corrosion, loose bolts, or a

damaged or missing anti-fret strip or tapered shim are found. If necessary make and install a new

anti-fret strip, and/or tapered shim, and remove corrosion and make repairs to the track. Do the

procedures to correctly align the track during assembly of the track-to-wing joint. If the track cannot be

repaired, install a serviceable flap track assembly. During installation of a serviceable flap assembly,

do the procedures to correctly align the track during installation.

Do the repeat inspections and schedule the initial, and repeat overhaul, of a flap track at the times

given in Paragraph 1.E., Compliance.

Flap track assemblies with short fail-safe bars, part number 65-46428-31 and 65-46428-33, must be

removed from service if damage is found during an inspection or repair. If damage is not found, these

flap tracks with short fail-safe bars must be removed from service at the initial overhaul.

NOTE: It will be necessary to keep records of the flap tracks because they can be moved from one

airplane to another.

NOTE: The steel flap track and the aluminum spacer block are a machined set. During initial assembly,

the aluminum spacers are machined to fit the machined slot in the steel tracks. Thus, each

assembly must be kept together, as a machined set, during the overhaul procedures.

The airplane effectivity is divided in three groups as follows:

• Group 1 are 737-100/200 airplanes with 65-46428-() or 65C35380-( ) Flap Track Assemblies. The

inspection, overhaul, and replacement instructions given in this service bulletin are applicable to

Group 1 airplanes.

• Group 2 are 737-200 airplanes with 65-67158-() or 65C35380-( ) Flap Track Assemblies. The

inspection and overhaul instructions given in this service bulletin are applicable to Group 2 airplanes.

If necessary, these tracks can be replaced with part number 65-67158-6.

• Group 3 are 737-300/400/500 airplanes with 65-46428-(), 65C35616-(), 65C35387-(), 65C34812-()

or 65C35380-( ) Flap Track Assemblies. The inspection, overhaul, and replacement instructions

given in this service bulletin are applicable to Group 3 airplanes.

Revision 1 - no more work is necessary on airplanes changed as shown in initial release of this service

bulletin.

Revision 2 - No more work is necessary on airplanes changed in accordance with the original issue or

Revision 1 of this service bulletin.

Revision 3 - No more work is necessary on airplanes changed in accordance with Revision 2 of this

service bulletin.

The work in this service bulletin is done in the maintenance zone(s) given below.

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BOEING SERVICE BULLETIN 737-57A1271
Group 1-2:

Affected Maintenance Zones

Model Zone

737-100, 737-200, 737-200C 3-7, 4-7

Group 3:

Affected Maintenance Zones

Model Zone

737-300, 737-400, 737-500 307, 407

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Federal Aviation Administration Airworthiness Directive (AD) 78-13-07, Amendment 39-3253; AD

2000-25-07, Amendment 39-1204; AD 2002-05-07, Amendment 39-12675; and AD 90-06-02,

Amendment 39-6489 are related to this service bulletin.

Boeing recommends the inspection and overhaul of the flap track installed at Left WBL 254, and Right

WBL 254, as follows.

• Initial Inspection.

Perform the initial inspection of the flap track, using the instructions in this service bulletin, prior

to the later of the times specified below:

• 15,000 flight cycles or 8 years since new or overhauled, whichever occurs first, or

• 180 days after the issue date on this service bulletin

• Within 24 months of the last inspection performed in accordance with Part I of the

Accomplishment Instructions of Boeing Service Bulletin 737-57A1249, Revision 1, including

Appendix A, dated June 1, 2000.

NOTE: Overhaul of a flap track, with the overhaul instructions given in this service bulletin, can satisfy

the initial inspection. Flap track assemblies with short failsafe bars, part number 65-46428-31

and 65-46428-33 must be removed from service during inspection or repair.

NOTE: Tracks overhauled to satisfy the initial inspection must be scheduled for the repeat inspections

and repeat overhauls.

• Initial Overhaul.

Do an initial overhaul of the flap track, using the instructions in this service bulletin, within 10,000

flight cycles or 4 years, whichever occurs first, of the Initial Inspection.

• Repeat Inspections.

Perform repeat inspections of the flap track within 10,000 flight cycles or 4 years, whichever occurs

first, of the overhaul using the instructions in this service bulletin.

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BOEING SERVICE BULLETIN 737-57A1271
NOTE: Overhaul of a flap track, with the overhaul instructions given in this service bulletin, can satisfy

a repeat inspection.

• Repeat Overhauls.

Repeat the overhaul of the flap track, using the instructions in this service bulletin, at intervals not

to exceed 20,000 flight cycles or 8 years, whichever occurs first.

F. Approval

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

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft

Certification Office approves these actions:

1. Performance of all requirements defined in "WORK INSTRUCTIONS, INSPECTION - TRACK

WEB AND FLANGES" constitutes, for the inboard track only, an alternative method of compliance

to the inspection intervals, methods and repair required by paragraphs A, B, C, and D of

Airworthiness Directive 78-13-07. All other provisions of Airworthiness Directive 78-13-07, not

specifically referenced in this statement, remain fully effective and must be complied with. The

requirements for the outboard track defined by Airworthiness Directive 78-13-07, remain in effect

and are not affected by the alternative method of compliance statement, described above.

2. Performance of detail visual inspection and requirements defined in "WORK INSTRUCTIONS,

INSPECTION - TRACK WEB AND FLANGES" constitutes an alternative method of compliance

to the inspection methods and corrective action required by paragraphs (a) and (b) of Airworthiness

Directive 2000-25-07. All other provisions of Airworthiness Directive 2000-25-07, not specifically

referenced in this statement, remain fully effective and must be complied with.

3. Performance of inspections defined in "WORK INSTRUCTIONS, INSPECTION - WITH

TRACK-TO-WING ATTACHMENT ASSEMBLED" constitutes an alternative method of compliance

to the inspection methods required by paragraphs (a)(1), (a)(2) and (d) of Airworthiness Directive

2002-05-07. All other provisions of Airworthiness Directive 2002-05-07, not specifically referenced

in this statement, remain fully effective and must be complied with.

4. Performance of actions defined in "WORK INSTRUCTIONS, INSPECTION - WITH

TRACK-TO-WING ATTACHMENT DISASSEMBLED" constitutes an alternative method of

compliance to the rework required by paragraph (c) of Airworthiness Directive 2002-05-07. all other

provisions of Airworthiness Directive 2002-05-07, not specifically referenced in this statement,

remain fully effective and must be complied with.

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BOEING SERVICE BULLETIN 737-57A1271
5. The Manager of the FAA Seattle Aircraft Certification office approves the overhaul of the outboard

flap inboard track per the Accomplishment Instructions in Service Bulletin 737-57A1271, Revision

3, as an Alternative Method of Compliance to the modification requirements of Paragraph A of AD

90-06-02 for SB 737-57A1082 only. All provisions of AD 90-06-02 not specifically referenced in

the above statement, including the modification threshold, remain fully applicable and must be

complied with.

G. Manpower

The table below shows an estimate of the task-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

task-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.

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 6 24.0 (a) 4.0

Inspect 2 6.0 3.0

Repair (b) (b) (b)

Replace 4 16.0 8.0

Close Access 6 30.0 (a) 5.0

Test 2 6.0 3.0

TOTAL FOR EACH AIRPLANE 82.0 23.0

The estimate shows the man hours necessary for the access procedures

to do the inspection with the track-to-wing attachment disassembled.

(a)

(b) No estimate given for the repair procedures.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

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BOEING SERVICE BULLETIN 737-57A1271
J. References

1. Existing Data:

a. Engineering Change Memo PRR 35005-238RS

b. Service Related Problem (SRP) 737-SRP-57-0131

c. 737-100/200 Maintenance Manual (AMM) Subject 12-20-0, 27-51-72, 27-51-111, 27-51-121,

27-51-151, 27-51-281

d. 737-300/400/500 Maintenance Manual (AMM) Subject 27-51-49. 27-51-52

e. 737 Nondestructive Test (NDT) Manual 737, Part 4, Subject 57-50-01

f. 737 Nondestructive Test (NDT) Manual 737, Part 6, Subject 57-50-01

g. 737 Nondestructive Test (NDT) Manual 737, Part 6, Subject 57-50-06

h. 737 Nondestructive Test (NDT) Manual 737, Part 6, Subject 51-00-00, Figure 19.

i. 737 Nondestructive Test (NDT) Manual 737, Part 6, Subject 51-00-00, Figure 24.

j. Overhaul Manual 57-53-15

k. 737 Structural Repair Manual (SRM) Chapter 51

l. Boeing Standard Overhaul Practices Manual (BSOPM) 20-10-01, 20-10-03. 20-30-02, 20-42-05,

20-43-03

m. Boeing Service Bulletin 737-57A1082

n. Boeing Service Bulletin 737-57-1203

o. Boeing Service Bulletin 737-57A1249

p. Boeing Service Bulletin 737-57A1265

q. FAA Airworthiness Directive 78-13-07, Amendment 39-3253

r. FAA Airworthiness Directive 90-06-02, Amendment 39-6489

s. FAA Airworthiness Directive 2000-25-07, Amendment 39-12041

t. FAA Airworthiness Directive 2002-05-07, Amendment 39-12675

u. Boeing Document D6-38505

v. Boeing Parts Standards Document D-590

w. Boeing Drawing 65-88700

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BOEING SERVICE BULLETIN 737-57A1271
2. Data supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

65-46429 Flap Track Installation - Inbd And Outbd Flap

65-46428 Track Assy - Outboard Flap

65C34812 Track Assy - Outboard Flap

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

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability

information.

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BOEING SERVICE BULLETIN 737-57A1271
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary For Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

NOTE: Quantity is for the replacement of one flap track.

Part Number / QTY Name Existing Part Number Notes

Specification

65-46428-36 1 Flap Track Assy (Group 1 Airplanes) (a) (b)

- - Flap Track Assy (Group 2 Airplanes) 65-67158-2, or -3, or -6 (c)

65C34812-8 1 Flap Track Assy (Group 3 Airplanes) (d) (e)

66-23210-1 1 Sleeve 66-23210-6 (j)

BACB30LE7HK26 1 Bolt - (h) (j)

BACB30LE8HK32 1 Bolt - (i) (j)

BACB30LE8HK31 1 Bolt - (i) (j)

BACB30LT7DU27 1 Bolt - (j)

BACB30LT7DU17 1 Bolt - (j)

BACN10HR7CD 1 Nut - (j)

BACN10JD107 1 Nut - (j)

BACW10BN7SC 1 Washer - (j)

BACW10BP7C 1 Washer - (j)

BACW10BP7CD 1 Washer - (j)

BACW10BP7P 1 Washer - (j)

BACW10DN8 1 Washer, Torque-Indicating - (k)

NAS577B8A 1 Barrel Nut - (j)

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BOEING SERVICE BULLETIN 737-57A1271
Part Number / QTY Name Existing Part Number Notes

Specification

NAS578-8A 1 Retainer - (j)

NAS1149F0716P - Washer - (j)

NAS1149F0732P - Washer - (j)

NAS1149F0763P - Washer - (j)

NAS1149F0816P - Washer - (i) (j)

NAS1149F0832P - Washer - (i) (j)

NASM20995C32 - Lockwire -

MS24665-285 1 Cotter Pin -

BMS 5-95 1 pt Sealant -

BMS 10-11, Type I 8 oz Primer -

Refer to BSOPM

20-43-03

Type 2, Class A 8 oz Chemical Conversion Coating -

MIL-C-11796, 8 oz Corrosion Preventive Compound -

Class 3

BMS 10-67, Type - Thermal Spray Powder - (l)

1, Class 2 or 4

Loctite 262 or MIL- - Retaining Compound - (l)

S-46163, Type II,

Grade O

Locquic Primer N - Adhesion Promoter - (l)

7649

65-46428-2, or -3, or -5, or -7, or -9, or -11, or -15, or -17, or -19, or -21, or -23, or -25, or-27, or -33,

or -35.

(a)

You can use the existing part 65-46428-2, or -3, or -5, or -7, or -9, or -11, or -15, or -17, or -19, or -21,

or -23, or -25, or-27, or -35, overhauled with the instructions in this service bulletin to replace the new

or changed part.

(b)

You cannot use the existing part 65-46428-33 to replace the new or changed part. Boeing recommends

that you remove the 65-46428-33 from service as given in Service Bulletin 737-57-1203.

If you use the existing part 65-46428-2, or -3, or -5, or -7, or -9, or -11, or -15, or -17, or -19, or -21, or

-23, or -25, or-27, or -35, you reduce the effect of the change given in this service bulletin. The existing

track assembly does not have the fail safe capability of the new spares track assembly.

The new spare flap track assembly for Group 2 airplanes is 65-67158-6. See 737-100/-200 AMM 27-

51-151 for removal and installation of these flap track assemblies.

(c)

(d) 65-46428-31, or 65C35387-4, or 65C35616-5, or 65C34812-3, or -4, or -6

You can use the existing part 65C35616-5, or 65C35387-4, or 65C34812-3, or -4, or -6, overhauled

with the instructions in this service bulletin to replace the new or changed part.

(e)

You cannot use the existing part 65-46428-31 to replace the new or changed part. Boeing recommends

that you remove the 65-46428-31 from service as given in Service Bulletin 737-57-1203.

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(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners.

It is possible, because of shim thickness, that a bolt one grip length shorter or longer can be necessary

for installation of the new spares track assembly. One Washer NAS1149F0716P, or NAS1149F0732,

can be used to adjust the grip length of the bolt. See Figures 8 and 9.

(h)

It is possible, because of shim thickness, that a bolt one grip length shorter or longer can be necessary

for installation of the new spares track assembly. One Washer NAS1149F0816P, or NAS1149F0832P,

can be used to adjust the grip length of the bolt. See Figures 8 and 9.

(i)

If installed on the configuration of your airplane: The removed part can be serviceable and satisfactory

for installation of the new spares flap track assembly. See Figures 8 and 9.

(j)

A new torque-indicating washer is necessary if the wing-to-track attachment is disassembled during

the inspection procedures, and for the track alignment and installation procedures given in Figures 7,

8, and 9.

(k)

The retaining compound and adhesion promoter are necessary for the overhaul of a flap track. The

application of the thermal spray powder (Tungsten-Carbide-Cobalt) is optional during the overhaul

procedures, unless the track had Tungsten-Carbide-Cobalt applied during manufacture. Tracks that

had Tungsten-Carbide-Cobalt applied during manufacture, must also have the compound applied

during the overhaul procedures. See Figure 11.

(l)

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

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

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BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

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

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, 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

– Hole dimensions for standard solid rivets are in Structural Repair Manual 737

(SRM) 51

– Torque limits to tighten nuts and bolts are in 737 SRM 51

4. Use the approved fastener and process material substitutions in accordance with

737 SRM 51. Alternate fasteners are listed in 737 SRM 51.

5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

6. If the length of any fastener specified in this service bulletin does not meet the

installation standards in 737 SRM 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards in 737

SRM 51 may be used. In addition, washers may be installed for fastener grip length

in accordance with SRM Chapter 51.

7. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate access procedures may be required.

8. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

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9. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

10. Boeing Service Letter 737-SL-51-042, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

11. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

12. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

13. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

The removed part can be discarded if a new or serviceable part is installed.

14. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

15. Some Boeing parts are supplied in a temporary configuration. Those parts are

identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is

permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'

(dash) part number. Boeing Drawing 005W0900 contains more data.

B. WORK INSTRUCTIONS

INSPECTION - GROUP 1 AND GROUP 2 AIRPLANES - 737-100/200/200C

1. Remove the forward fairing from Flap Track Position 2 (Position 7 opposite).

NOTE: Position 2 is equivalent to Left WBL 254 and Position 7 is equivalent to Right WBL 254.

2. Refer to 737-100/200 AMM 27-51-121 and remove the center and aft fairings from Position 2

(Position 7 opposite).

NOTE: When you disconnect the push rod from the aft flap, install a support to sufficiently hold

the aft flap in a stable position during the inspection procedures. During the inspection

procedures it will be necessary to extend and retract the flaps to get access to all areas

of the flap track.

3. INSPECTION - TRACK WEBS AND FLANGES.

Do a visual and eddy current inspection of the flap track web and flanges as shown in Figure 1.

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a. If damage is found in the web or on the upper and/or lower flanges of the track:

(1) Make repairs as given in 737 OHM 57-53-15.

(2) If the damage cannot be repaired as given in OHM 57-53-15: Replace the flap track with

a serviceable flap track. Do not stop-drill cracks in the flanges of the track. Go to Step 5

for instructions for removal and installation.

b. If an existing stop-drill repair is found on the upper and/or lower flanges of the track:

(1) Replace the flap track with a serviceable flap track. Do not stop-drill cracks in the flanges.

Go to Step 5 for instructions for removal and installation.

c. If the web has an existing stop-drill repair:

(1) Replace the flap track with a serviceable flap track. Do not stop-drill cracks in the web.

Go to Step 5 for instructions for removal and installation.

d. If you do not find damage in the flanges and/or the web, or you made repairs as given in 737

OHM 57-53-15, continue with the detail visual, ultrasonic, and eddy current inspections given

in Step 4, below.

e. If a flap track assembly with a short failsafe bar, part number 65-46428-31 or 65-46428-33,

is found, it must be removed from service during inspection or repair.

4. INSPECTION - WITH TRACK-TO-WING ATTACHMENT ASSEMBLED.

Using Figure 2, do a detail visual inspection, ultrasonic inspection, and an eddy current inspection

in the area where the flap track is attached to the wing rear spar.

a. If the track is loose at the attachment to the wing rear spar: Do the inspection with the

track-to-wing attachment disassembled as shown in Step 5, below.

b. If there are signs of damage, or corrosion, to the tapered shim and/or anti-fret strip: Do the

inspection with the track-to-wing attachment disassembled as shown in Step 5, below.

c. If the ultrasonic or eddy current inspection shows an indication of a crack: Do the inspection

with the track-to-wing attachment disassembled as shown in Step 5, below.

d. If no signs of cracks, damage, corrosion, or a loose track are found: Schedule the overhaul

of the flap track at the flight cycle or in-service time given in Paragraph 1. E., Compliance

5. INSPECTION - WITH TRACK-TO-WING ATTACHMENT DISASSEMBLED.

a. Refer to 737-100/200 AMM 27-51-72 and remove the trailing edge flaps.

b. Refer to 737-100/200 AMM 27-51-281 and remove the flap transmission.

c. Refer to 737-100/200 AMM 27-51-111 and remove the fore-flap sequencing carriage from

the track.

d. Remove the bolts, lower the aft end of the track, and do the inspections given in Figure 3.

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(1) If the anti-fret strip is discarded during the inspection: Make and install a new anti-fret

strip as shown in Figure 4. Make the shop aid, shown in Figure 10, to get a satisfactory

installation of the new anti-fret strip.

(2) If the tapered shim is discarded during the inspection: Make and install a new tapered

shim as shown in Figure 5. Make the shop aid, shown in Figure 10, to get a satisfactory

installation of the new tapered shim.

(3) If the steel bushing is discarded during the inspection: Make and install a new bushing

as shown in Figure 6.

(4) If corrosion is found on the mating surface, and/or in the bolt holes: Remove the corrosion

as given in Figure 6.

(5) If corrosion is found during the inspection along the outboard edge of the track flange

adjacent to the outboard bolt: Make repairs as shown in the rework tables of Figure 6.

If damage is too large and cannot be removed within the limits of the rework tables:

Replace the flap track with a serviceable flap track.

(6) If damage is found with the eddy current inspection of the outboard hole: Remove the

damage as given in the eddy current inspection procedures, but make sure the hole

remains in the limits given in Figure 6.

If damage is too large and cannot be removed during rework in accordance with Figure

6: Replace the flap track with a serviceable flap track.

e. Align and install the track as shown in Figure 7.

f. Refer to 737-100/200 AMM 27-51-111 and install the fore-flap sequencing carriage.

g. Refer to 737-100/200 AMM 27-51-281 and install the flap transmission.

h. Refer to 737-100/200 AMM 27-51-72 and install the trailing edge flaps.

6. Refer to 737-100/200 AMM 12-20-0 and lubricate the flap track.

7. Refer to 737-100/200 AMM 27-51-121 and install the center and aft fairings at Position 2 (Position

7 opposite).

8. Install the forward fairing at Position 2 (Position 7 opposite).

9. Put the airplane back to a serviceable condition.

INSPECTION - GROUP 3 AIRPLANES - 737-300/400/500

1. Remove the forward fairing from Flap Track Position 2 (Position 7 opposite).

2. Refer to 737-300/400/500 AMM 27-51-52 and remove the center and aft fairing from Flap Track

Position 2 (Position 7 opposite).

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NOTE: When you disconnect the push rod from the aft flap, install a support to sufficiently hold

the aft flap in a stable position during the inspection procedures. During the inspection

procedures it will be necessary to extend and retract the flaps to get access to all areas

of the flap track.

3. INSPECTION - TRACK WEBS AND FLANGES.

Do a visual and eddy current inspection of the flap track web and flanges as shown in Figure 1.

a. If damage is found in the web or on the upper and/or lower flanges of the track:

(1) Make repairs as given in 737 OHM 57-53-15.

(2) If the damage cannot be repaired as given in OHM 57-53-15: Replace the flap track with

a serviceable flap track. Do not stop-drill cracks in the flanges of the track. Go to Step 5

for instructions for removal and installation.

b. If an existing stop-drill repair is found on the upper and/or lower flanges of the track:

(1) Replace the flap track with a serviceable flap track. Do not stop-drill cracks in the flanges.

Go to Step 5 for instructions for removal and installation.

c. If the web has an existing stop-drill repair:

(1) Replace the flap track with a serviceable flap track. Do not stop-drill cracks in the web.

Go to Step 5 for instructions for removal and installation.

d. If you do not find damage in the flanges and/or the web, or you made repairs as given in 737

OHM 57-53-15: Continue with the detail visual, ultrasonic, and eddy current inspections given

in Step 4, below.

e. If a flap track assembly with a short failsafe bar, part number 65-46428-31 or 65-46428-33,

is found, it must be removed from service during inspection or repair.

4. INSPECTION - WITH TRACK-TO-WING ATTACHMENT ASSEMBLED.

Using Figure 2, do a detail visual inspection, and an ultrasonic and eddy current inspection in the

area where the flap track is attached to the wing rear spar.

a. If the track is loose at the attachment to the wing rear spar: Do the inspection with the

track-to-wing attachment disassembled as shown in Step 5, below.

b. If there are signs of damage, or corrosion, to the tapered shim and/or anti-fret strip: Do the

inspection with the track-to-wing attachment disassembled as shown in Step 5, below.

c. If the ultrasonic or eddy current inspection shows an indication of a crack: Do the inspection

with the track-to-wing attachment disassembled as shown in Step 5, below.

d. If no signs of cracks, damage, corrosion, or a loose track are found: Schedule the overhaul

of the flap track at the flight cycle or in-service time given in Paragraph 1. E., Compliance.

e. If a flap track assembly with a short failsafe bar, part number 65-46428-31 or 65-46428-33,

is found, it must be removed from service during inspection or repair.

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BOEING SERVICE BULLETIN 737-57A1271
5. INSPECTION - WITH TRACK-TO-WING ATTACHMENT DISASSEMBLED.

a. Refer to 737-300/400/500 AMM 27-51-34 and remove the trailing edge flaps.

b. Refer to 737-300/400/500 AMM 27-51-71 and remove the flap transmission.

c. Refer to 737-300/400/500 AMM 27-51-47 and remove the fore-flap sequencing carriage from

the track.

d. Remove the bolts, lower the aft end of the track, and do the inspections given in Figure 3.

(1) If the anti-fret strip is discarded during the inspection: Make and install a new anti-fret

strip as shown in Figure 4. Make the shop aid, shown in Figure 10, to get a satisfactory

installation of the new anti-fret strip.

(2) If the tapered shim is discarded during the inspection: Make and install a new tapered

shim as shown in Figure 5. Make the shop aid, shown in Figure 10, to get a satisfactory

installation of the new tapered shim.

(3) If the steel bushing is discarded during the inspection: Make and install a new bushing

as shown in Figure 6.

(4) If corrosion is found on the mating surface, and/or in the bolt holes: Remove the corrosion

as given in Figure 6.

(5) If corrosion is found during the inspection along the outboard edge of the track flange

adjacent to the outboard bolt: Make repairs as shown in the rework tables of Figure 6.

If damage is too large and cannot be removed within the limits of the rework tables:

Replace the flap track with a serviceable flap track.

(6) If damage is found with the eddy current inspection of the outboard hole: Remove the

damage as given in the eddy current inspection procedures, but make sure the hole

remains in the limits given in Figure 6.

If damage is too large and cannot be removed during the rework in accordance with

Figure 6: Replace the flap track with a serviceable flap track.

e. Align and install the track as shown in Figure 7.

f. Refer to 737-300/400/500 AMM 27-51-47 and install the fore-flap sequencing carriage.

g. Refer to 737-300/400/500 AMM 27-51-71 and install the flap transmission.

h. Refer to 737-300/400/500 AMM 27-51-34 and install the trailing edge flaps.

6. Refer to 737-300/400/500 AMM 12-20-0 and lubricate the flap track.

7. Refer to 737-300/400/500 AMM 27-51-52 and install the center and aft fairings at Position 2

(Position 7 opposite).

8. Install the forward fairing at Position 2 (Position 7 opposite).

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BOEING SERVICE BULLETIN 737-57A1271
9. Put the airplane back to a serviceable condition.

OVERHAUL - GROUPS 1, 2, AND 3, AIRPLANES - 737-100/200/200C/300/400/500

1. At the flight cycle or in- service time given in Paragraph 1. E.,Compliance:

Refer to 737-100/200 AMM 27-51-151 and remove the flap track from the wing at Position 2

(Position 7 opposite).

Refer to 737-300/400/500 AMM 27-51-49 and remove the flap track from the wing at Position 2

(Position 7 opposite).

2. Do an overhaul of the flap track as given in 737 OHM 57-53-15 and Figure 11.

3. Install an overhauled flap track at Position 2 (Position 7 opposite) as given in 737-100/200 AMM

27-51-151. Align the flap track during installation as shown in Figure 7.

Install an overhauled flap track at Position 2 (Position 7 opposite) as given in 737-300/400/500

AMM 27-51-49. Align the flap track during installation as shown in Figure 7.

4. Schedule the repeat inspections and the repeat overhaul of the flap track at the flight cycles or

times given in Paragraph 1. E., Compliance.

5. Put the airplane back to a serviceable condition.

REPLACEMENT - GROUP 1 AIRPLANES

1. Refer to 737-100/200 AMM 27-51-151 and remove the flap track assembly. During removal, discard

the parts shown in Figure 8.

2. Refer to 737-100/200 AMM 27-51-151 and install the new track assembly. During installation, do

the alignment procedures given in Figure 7 and install the parts shown in Figure 8.

3. Put the airplane back to a serviceable condition.

REPLACEMENT - GROUP 2 AIRPLANES

1. Replace the track assembly with an identical spares track assembly.

REPLACEMENT - GROUP 3 AIRPLANES - 737-300/400/500

1. Refer to 737-300/400/500 AMM 27-51-49 and remove the flap track assembly. During removal,

discard the parts shown in Figure 9.

2. Refer to 737-300/400/500 AMM 27-51-49 and install the new spares track assembly. During

installation, do the alignment procedures given in Figure 7 and install the parts shown in Figure

9.

3. Put the airplane back to a serviceable condition.

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 1: INSPECTION - TRACK WEBS AND FLANGES

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
WARNING: MAKE SURE THAT PERSONS AND EQUIPMENT ARE CLEAR OF ALL CONTROL SURFACES

BEFORE YOU SUPPLY HYDRAULIC POWER. CONTROL SURFACES CAN MOVE QUICKLY

WHEN YOU SUPPLY HYDRAULIC POWER. THIS CAN CAUSE INJURY TO PERSONS AND

DAMAGE TO EQUIPMENT.

WARNING: MAKE SURE THAT PERSONS AND EQUIPMENT ARE CLEAR OF THE LEADING EDGE AND

TRAILING EDGE FLAPS AND FLAP DRIVE MECHANISMS BEFORE YOU MOVE THE FLAP

CONTROL HANDLE. AN ACCIDENTAL FLAP MOVEMENT CAN CAUSE INJURY TO PERSONS

OR DAMAGE TO EQUIPMENT.

STEP TASK NAME PART NUMBER QTY NOTES

1 Supply Hydraulic Power - - (a)

Extend/Retract Flaps - -

Remove Hydraulic Power - -

2 Clean Flap Track - 1 (b)

3 Inspect Track Flanges - - (c)

4 Inspect Track Webs - - (d)

5 Do Eddy Current Inspection - - (e)

Refer to 737-100/200 AMM 27-51-0 and supply hydraulic power. Group 3: Refer to 737-300/400/500

AMM 27-51-00 and supply hydraulic power. As necessary, extend and retract the flaps during the inspection procedures to get access to all areas of the flap track.

(a)

Warning: MAKE SURE TO REMOVE HYDRAULIC POWER BEFORE PERSONS GO INTO THE INSPECTION AREA. AN ACCIDENTAL FLAP MOVEMENT CAN CAUSE INJURY TO PERSONS OR

DAMAGE TO EQUIPMENT.

Remove loose paint, sealant, corrosion inhibiting compounds, dirt and grease from the flanges and

webs of the track. Removal of the finish is not necessary, unless signs of cracks or corrosion are found

during the subsequent inspections.

(b)

Caution: DO NOT PRESSURE WASH THE FLAP TRACK. WATER OR SOLVENTS UNDER HIGH

PRESSURE CAN GET UNDER THE FASTENER HEADS AND BETWEEN THE WEBS AND SPACER

BAR. A RESULT CAN BE UNWANTED CORROSION AND CRACKS.

Do a detailed visual inspection along the full length of the upper and lower flanges of the flap track.

Look for stop-drill repairs, cracks, nicks, corrosion pits, galling, pieces broken off, or other signs of

damage. Give special attention to the edges of the flanges. Reject a track that shows these signs of

damage, or has existing stop-drill repairs.

(c)

Do a detailed visual inspection along the full length of the track webs. Look for stop-drill repairs, cracks,

or other signs of damage. During the inspection, give special attention to the area adjacent to the fastener countersinks in the webs.

(d)

Reject tracks that have existing stop-drill repairs, and/or cracks in the web. No repair instructions are

given in this service bulletin for web cracks.

Do the eddy current inspection given in 737 NDT Part 6, 57-50-06. Reject a track that shows indications

of cracks.

(e)

FIGURE 1: INSPECTION - TRACK WEBS AND FLANGES

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 2: INSPECTION - WITH TRACK-TO-WING ATTACHMENT ASSEMBLED

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

Remove sealant sufficiently to get a clear view of

the outer edges of the tapered shim and anti-fret

strip.

1 Remove Sealant - -

2 Inspect Tapered Shim - - (a)

Anti-Fret Strip - -

3 Inspect Track Attachment - - (b)

4 Inspect Track Attachment - - (c)

5 Inspect Track Attachment - - (d)

6 Apply Sealant BMS 5-95 - (e)

Do a detailed visual inspection of the tapered shim and anti-fret strip. Look for signs of movement between the components. Look to make sure the anti-fret strip is installed. Look for corrosion.(a)

Do a detailed visual inspection of the area where the track is attached to the wing rear spar. Use

manual force, up to 150 pounds, and try to move the track from the installed position. Look for signs

of movement, cracks, and corrosion.

(b)

Do the eddy current inspection given in 737 NDT Part 6, 57-50-01. Do this inspection to find cracks in

the outboard edge of the track adjacent to the outboard attach bolt.

(c)

Do the ultrasonic inspection given in 737 NDT Part 4, 57-50-01. Do this inspection to find cracks in

the inner edge of the track adjacent to the outboard attach bolt.

(d)

Apply around the outer edges of the tapered shim and anti-fret strip. Do not apply the sealant at this

time if disassembly of the track-to-wing attachment is made necessary as given in the Paragraph 3.B.,

Work Instructions.

(e)

FIGURE 2: INSPECTION - WITH TRACK-TO-WING ATTACHMENT ASSEMBLED

(SHEET 2 OF 2)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 3: INSPECTION - WITH TRACK-TO-WING ATTACHMENT DISASSEMBLED

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Cotter Pin - 1

Loosen Nut - 1

2 Remove/Keep Bolt - 1

Washer - 2

Nut - 1

3 Remove/Keep Bolt - 1

4 Remove/Discard Washer - 1

Put a support below the

track to hold it in position

during the inspection procedures.

5 Lower Track - 1

6 Inspect Anti-Fret Strip - 1 (a)

7 Inspect Tapered Shim - 1 (b)

8 Inspect Track Attachment - 1 (c)

9 Inspect Bushing - 1 (d)

10 Inspect Track Flange - 1 (e)

11 Inspect Hole - 2 (f)

Do a detailed visual inspection of the anti-fret strip. Look for signs that show the strip is loose or damaged. Discard a strip if it is made from phenolic material, or if it is loose, or if it is damaged.(a)

Do a detailed visual inspection of the tapered shim. Discard a shim if it is damaged or shows signs of

corrosion. Discard a shim if it is less than 1.70 inches wide as measured normal to the aft edge of the

shim. Discard a shim if it is made from laminated material.

(b)

Do a detailed visual inspection of the track in the area where it mates against the wing skin. Look for

corrosion on the surface and corrosion in the bolt holes. Rework/overhaul a track if it shows signs of

corrosion.

(c)

If corrosion is found in the area where the track mates against the wing skin, do a detailed visual inspection of the bushing. Discard a bushing if there are signs of corrosion between the outer wall and

track.

(d)

Refer to 737 NDT Part 6, 51-00-00, Figure 24 and do an eddy current inspection on the upper surface

of the track flange adjacent to the inboard and outboard bolt holes. Set the eddy current instrument

frequency setting to 50 KHz to prevent false crack indications caused by scratches in the cadmium

plating. Repair or replace a track that shows an indication of a crack.

(e)

As an alternative to the eddy current inspection, you can do a magnetic particle inspection as given in

BSOPM 20-20-01.

Refer to 737 NDT Part 6, 51-00-00, Figure 19 and do an eddy current inspection of the inboard and

outboard bolt holes. Repair or replace a track that shows an indication of a crack. As an alternative to

the eddy current inspection, you can do a magnetic particle inspection as given in BSOPM 20-20-01.

(f)

FIGURE 3: INSPECTION - WITH TRACK-TO-WING ATTACHMENT DISASSEMBLED

(SHEET 2 OF 2)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 4: REPLACEMENT - ANTI-FRET STRIP

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Anti-Fret Strip 69-50772-( ) 1 (a)

Measure Thickness - -

2 Make Anti-Fret Strip - 1 (b)

Apply to all surfaces. Refer to BSOPM 20-43-03.Chemical Conversion Type 2, Class A -

Coating

Apply

Primer BMS 10-11, Type I - one layer to all surfaces.

3 Clean Surface - - (c)

Apply to all bare aluminum. Refer to BSOPM

20-43-03.

Chemical Conversion Type 2, Class A -

Coating

Apply

Primer BMS 10-11, Type I - Two layers.

To mating surface of new

anti-fret strip.

4 Apply Sealant BMS 5-95 -

Install Anti-Fret Strip - 1

5 Install Pressure Plate - 1

6 Install Temporary Fasteners - 2

7 Apply Torque - - (d)

8 Remove Temporary Fasteners - 2

Pressure Plate - 1

Apply a bead around the

edges of the strip.

9 Apply Sealant BMS 5-95 -

Remove the damaged anti-fret strip and measure the thickness. The new replacement strip must have

the same thickness as the removed strip.

(a)

(b) Make from 7075-T6 Aluminum Alloy Sheet, AMS-QQ-A-250/12.

Clean and remove all signs of enamel paint from the wing lower surface in the wing-to-track attachment

area. Refer to BSOPM 20-30-02.

(c)

Apply 360-420 inch-pound. Give the sealant sufficient time to cure before you continue with the subsequent step.(d)

FIGURE 4: REPLACEMENT - ANTI-FRET STRIP

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 5: REPLACEMENT - TAPERED SHIM

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

65-46429-( ), 69- 1 (a)

50772-( ) or 69-

77633

1 Remove Tapered Shim

Measure Thickness - -

2 Make Tapered Shim - 1 (b)

Apply to all surfaces. Refer to BSOP 20-43-03.Chemical Conversion Type 2, Class A -

Coating

Apply

Primer BMS 10-11, Type I - one layer to all surfaces.

3 Clean Surface - - (c)

Primer BMS 10-11, Type I - Two layers.

To mating surface of new

tapered shim.

4 Apply Sealant BMS 5-95 -

Install Tapered Shim - 1

5 Install Pressure Plate - 1

6 Install Temporary Fasteners - 2

Self-Aligning Washer - 2 (e)

7 Apply Torque - - 360-420 inch-pound.

8 Apply Torque - - (d)

9 Remove Temporary Fasteners - 2

Pressure Plate - 1

Apply a bead around the

edges of the shim.

10 Apply Sealant BMS 5-95 -

Remove the rejected shim and measure the thickness. The new replacement shim must have the

same thickness as the removed shim, unless corrosion was removed from the upper surface of the

track. If corrosion was removed from the track, increase the thickness of the new shim to adjust for

the change in the thickness of the track. If you do not know the correct thickness of the new shim, refer

to 737-100/200 AMM 27-51-151 for Group 1 and Group 2 Airplanes, and 737-300/400/500 AMM 27-

51-49 for Group 3 Airplanes.

(a)

Make from 2024-T351 Aluminum Alloy Plate, or Sheet, AMS-QQ-A-250/12. The thickness at all points

along the aft edge of the shim must not be less than 0.03 inches.

(b)

Clean and remove all signs of enamel paint from the mating surface of the track. Refer to BSOPM 20-

30-02.

(c)

Apply 400-460 inch-pounds. Give the sealant sufficient time to cure before you continue with the subsequent step.(d)

The two holes are not perpendicular to the surfaces of the tapered shim. To get a satisfactory pressure

during the torque procedure, use self-aligning washers.

(e)

FIGURE 5: REPLACEMENT - TAPERED SHIM

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 6: TRACK REPAIRS AND BUSHING REPLACEMENT

(SHEET 1 OF 5)

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FIGURE 6: TRACK REPAIRS AND BUSHING REPLACEMENT

(SHEET 2 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
Rework Table 1 - Flap Track 65-46427-4

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.235 0.380 0.235 0.380 4.270 0.5835 0.6855 0.5835

Rework Table 2 - Flap Tracks 65-46427-5/-7/-11/-13/-17/-21/-23/-25/-27/-29/-31/-44/-46 & 65C35380-2

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.195 0.340 0.195 0.340 4.270 0.5835 0.6855 0.5835

Rework Table 3 - Flap Tracks 65-67156-2/-12/-14

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.208 0.348 0.208 0.348 4.270 0.5835 0.6855 0.5835

Rework Table 4 - Flap Tracks 65-46427-35/-39

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

Do Not Rework - Remove from service if damaged

Rework Table 5 - Flap Tracks 65C34809-2 & 65C35387-2 & 65C35616-3

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.195 0.340 0.195 0.340 4.270 0.5835 0.6855 0.5835

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 6: TRACK REPAIRS AND BUSHING REPLACEMENT

(SHEET 3 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Corrosion - - (a)

2 Measure Repair Area - - (b)

3 Remove Bushing 69-37234-( ) 1 (c)

4 Inspect Hole - 1 (d)

Increase Diameter - -

Measure Diameter - -

Shot peen the holes as given in BSOPM

20-10-03, Intensity.012A, Coverage 2.0.

Shot peen Hole - 1

Apply cadmium-titanium alloy plating to

the holes as given in BSOPM 20-42-02.

Apply Plating - -

5 Inspect Hole - 2 (e)

Increase Diameter - -

Measure Diameter - -

Shot peen the holes as given in BSOPM

20-10-03, Intensity.012A, Coverage 2.0.

Shot peen Hole - 2

Apply cadmium-titanium alloy plating to

the holes as given in BSOPM 20-42-02.

Apply Plating - -

Shot peen all surfaces of the repair area

as given in BSOPM 20-10-03, Intensity.012A, Coverage 2.0.

6 Shot peen Repair Area - -

Apply cadmium-titanium alloy plating to

all surfaces of the repair area as given

in BSOPM 20-42-02.

7 Apply Plating - -

8 Make Repair Bushing - 1 (f)

Apply Plating - -

9 Apply Sealant BMS 5-95 - Install bushing wet with sealant.

Install Repair Bushing - 1 (g)

If corrosion was found during the inspection, refer to the track repair procedures given in the 737 OHM

57-53-15 and BSOPM 20-10-01, and remove the damaged material from the repair area of the track.

Maintain flatness of the repaired surface.

(a)

Measure the width (W) of the track in the repair area. Measure the thickness (T) of the track in the repair

area at the four locations shown. Do not include the thickness of the tapered shim.

(b)

If the width and thickness are in the limits shown in the tables: Continue with the inspection of the

bushing.

-

- If the width and thickness are not in the limits shown in the tables: Write to Boeing for repair instructions.

FIGURE 6: TRACK REPAIRS AND BUSHING REPLACEMENT

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
(c) Refer to BSOPM 20-50-03 and remove the bushing if it was rejected during the inspection.

Note: It can be necessary to remove the tapered shim before you remove the bushing. To remove the

tapered shim use a heat gun to make the sealant soft, and then use steel lockwire to cut the sealant

between the lower surface of the shim and the track. Find and record the thickness of the tapered shim

before removal. To find the shim thickness do one of these procedures:

— Measure the shim thickness before removal.

— Refer to the thickness that is recorded on the decal bonded to the wing rear spar adjacent to the

flap track.

— Use the procedure given in 737-100/200 AMM 27-51-151 for Group 1 and Group 2 Airplanes and

737-300/400/500 AMM 27-51-49 for Group 3 Airplanes.

Note: The anti-fret strip must be installed if you use the AMM procedure to find the shim thickness.

(d) Do a detailed visual inspection of the hole. Look for signs of corrosion.

If corrosion is found: Increase the hole diameter, as given in BSOPM 20-10-01, to remove corrosion.

Make and install a repair bushing. Hole diameter, before bushing installation, must remain in the limits

shown in the tables.

-

(e) Do a detailed visual inspection of the d1 and d3 holes. Look for signs of corrosion.

— If corrosion is found: Increase the hole diameters as given in BSOPM 20-10-01 to remove the corrosion. Hole diameters must remain in the limits shown in the rework tables.

Make the bushing from 15-5PH or 17-4PH 180-200 ksi Steel Bar, AMS 5643, as shown in the 737 OHM

57-53-15. Use the dimensions shown in this service bulletin illustration. The outer diameter (OD) must

be 0.0015 - 0.0017 inches larger than the diameter of the hole. Apply cadmium plating to all surfaces

of the bushing as given in BSOPM 20-42-05, Finish Code F-15.02.

(f)

Refer to BSOPM 20-50-03 and install the bushing with the shrink fit procedure. Make sure the bushing

does not protrude above the upper surface of the track, within 0.000/ -0.003 inches.

(g)

FIGURE 6: TRACK REPAIRS AND BUSHING REPLACEMENT

(SHEET 5 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 7: ALIGNMENT - TRACK INSTALLATION

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 7: ALIGNMENT - TRACK INSTALLATION

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN 737-57A1271
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 7: ALIGNMENT - TRACK INSTALLATION

(SHEET 3 OF 6)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

1 Make Alignment Pin - 1 (a)

Install Alignment Pin - 1

2 Lift/Align/Hold Flap Track - 1 (b)

Apply to the shank and

threads of the bolt.

3 Apply Compound MIL-C-11796, Class 3 -

BACB30LE7HU( ) or 1 (c)

BACB30LE7HK( )

Install Bolt

BACW10AK-C7 or 1 (c) Under bolt head.

BACW10BN7SC

Washer

NAS1149F0716P or 1 or 2 (c) Under nut.

AN960-716L

Washer

BACN10HR7C or 1 (c)

BACN10HR7CD or

BACN10B7L

Nut

Temporarily tighten the

nut to 40-60 pound-inch.

4 Apply Torque - -

Temporarily tighten the

nut to 270-300 poundinch.

5 Apply Torque - -

Temporarily tighten the

nut to 360-420 poundinch.

6 Apply Torque - -

7 Inspect Alignment Pin - - (d)

8 Remove Alignment Pin - 1

Decrease the torque to

40-60 pound-inch.

9 Loosen Nut - 1

Decrease the torque to

40-60 pound-inch.

10 Loosen Nut - 1

NAS577-8A or 1 (c)

NAS577B8A

11 Install Barrel Nut

Retainer NAS578-8A 1

Apply Compound MIL-C-11796, Class 3 -

BACB30LE8H( ) or 1 (c)

BACB30LE8HU( ) or

BACB30LE8HK( )

Install Bolt

Washer - Torque-In- BACW10DN8 1 (e)

dicating

FIGURE 7: ALIGNMENT - TRACK INSTALLATION

(SHEET 4 OF 6)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

Temporarily tighten the

bolt to 40-60 pound-inch

Apply Torque - -

Tighten nut to 270 - 300

pound-inch.

12 Apply Torque - -

Install Cotter Pin MS24665-285 1 (f)

Tighten nut to 360 - 420

pound-inch. (h)

13 Apply Torque - -

Cation: DURING THE INSTALLATION OF THE INBOARD ATTACH BOLT, MAKE SURE THAT THE

SHANK OF THE BOLT DOES NOT TOUCH AGAINST THE THREADS OF THE BARREL NUT. IF THE

SHANK OF THE BOLT TOUCHES THE THREADS OF THE BARREL NUT, THE FLAP TRACK WILL NOT

BE HELD WITH SUFFICIENT FORCE TO PREVENT MOVEMENT DURING FLIGHT. MOVEMENT

DURING FLIGHT CAN DAMAGE THE TRACK, ATTACH BOLTS, AND MATING STRUCTURE.

14 Apply Torque - - (g)

Refer to BSOPM 20-50-

02.

MS20995C32, or -

MS20995N32, or

MS20995F41

15 Install Lockwire

Apply a bead around the

heads of the bolts.

16 Apply Sealant BMS 5-95 -

Apply a bead around the

edges of the tapered shim

and anti-fret strip.

17 Apply Sealant BMS 5-95 -

(a) Make from steel. Diameter 0.4990 inch (+0.0005 to -0.0000). Length as necessary to extend through track.

Lift the track up until it engages the alignment pin and touches firmly against the wing skin. Hold the track

in position until the bolt is installed.

(b)

Use the components that were removed from your airplane to do the installation of a track that was disassembled for inspection, or for the installation of a repaired or overhauled track.(c)

Use the components shown in Figure 8 for the installation of a New Spares Track Assembly 65-46428-36.

Use the components shown in Figure 9 for the installation of a New Spares Track Assembly 65C34812-8.

Apply a light force and try to turn the pin in the hole and move the pin up and down in the hole. Look for

easy movement of the pin. If the pin moves easily the track is aligned correctly. If the pin does not move

easily, do the steps below:

(d)

1. Decrease the torque on the forward attach bolt to 40-60 pound-inch

2. Remove the outboard attach bolt and lower the aft end of the track down to a support.

Caution: DO NOT INCREASE THE INNER DIAMETER OF THE STEEL BUSHING AT THE INBOARD

ATTACH BOLT. A RESULT OF AN INCREASED DIAMETER AT THIS LOCATION CAN BE A LOOSE

TRACK. A LOOSE TRACK CAN MOVE DURING FLIGHT AND DAMAGE THE TRACK, ATTACH BOLTS,

AND MATING STRUCTURE.

FIGURE 7: ALIGNMENT - TRACK INSTALLATION

(SHEET 5 OF 6)

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BOEING SERVICE BULLETIN 737-57A1271
Increase the inner diameter of the aluminum bushing in the inboard attach hole in the wing skin and

aft track support fitting to 0.5015 inch maximum.

3.

Apply a chemical conversion coating to the inner surface of the bushing as given in BSOPM 20-43-

03.

4.

5. Install the 0.4990 (+0.0005 to -0.0000) diameter alignment pin in the inboard hole.

6. Lift the track up until it engages the alignment pin and touches against the wing skin.

7. Install the outboard attach bolt and apply a torque of 40-60 inch-pound to the nut.

8. Remove the alignment pin.

9. Apply a 270-300 pound-inch torque on the nut of the forward attach bolt.

10. Apply a 360-420 pound-inch torque on the nut of the outboard attach bolt.

Install the alignment pin in the inboard attach hole. If the pin moves easily the track is aligned correctly.

If the pin does not move easily, do these steps, 1 through 11, again, or write to Boeing for instructions.

11.

Install a new torque-indicating washer. Make sure to put the special countersink washer, that is a component

of the new torque-indicating washer, against the bolt head.

(e)

(f) If there is a castellated nut on the forward attach bolt, install a cotter pin.

Tighten the bolt until the torque-indicating washer does not turn. Maximum torque permitted is 1,300 poundinch. Make sure one full thread on the bolt extends through the nut.(g)

If the outer ring of the torque-indicating washer continues to turn at 950 pound-inch, or more, of torque; it

is possible that the track installation has one or more of these conditions:

The shank of the bolt is too long and bottoms out against the nut. If the bolt shank is too long, install

one or two Washers BACW10AKP8 under the torque-indicating washer.

-

- There is too much sealant in the bolt hole. Remove the bolt and remove the unwanted sealant.

- The track is not aligned correctly. Do the alignment procedures again, or contact Boeing for instructions.

Make sure that the bolt protrudes from the nut by a minimum of one thread and that the nut does not bottom

out on the thread run-out. If a bottoming out condition exists, add an extra washer under the nut or bolt

head. Additionally, the bolt length may be adjusted two grip lengths longer or shorter.

(h)

FIGURE 7: ALIGNMENT - TRACK INSTALLATION

(SHEET 6 OF 6)

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 8: INSTALLATION - NEW SPARES TRACK - GROUP 1 AIRPLANES - 737-100/200

(SHEET 1 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 8: INSTALLATION - NEW SPARES TRACK - GROUP 1 AIRPLANES - 737-100/200

(SHEET 2 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

NOTE: Refer to 737 AMM 27-51-151 for track removal and installation procedures.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/Discard Cotter Pin MS24665-285 1 (a)

Remove/Discard Nut BACN10HR7C 1 (a)

Nut AN310-7 1 (a)

Remove/Keep Nut BACN10JD107 1 (a)

Washer MS20002-7 1

Washer MS20002-C7 1

Remove/Discard Bolt BACB30LM7DU17 1 (a)

Bolt BACB30NM7DK( ) 1 (a)

Sleeve 66-23210-6 1 (a)

Remove/Keep Sleeve 66-23210-1 1 (a)

2 Remove/Discard Nut BACN10B7L 1 (a)

Nut BACN10HR7C 1 (a)

Remove/Keep Nut BACN10HR7CD 1 (a)

3 Remove/Keep Washer AN960-716L 1

4 Remove/Discard Washer BACW10AK-C7 1

5 Remove/Discard Bolt BACB30LE7HU( ) 1

6 Remove/Discard Bolt BACB30LE8HU( ) 1

7 Remove/Discard Washer BACW10AK-C8 1 (a)

Remove/Discard Washer BACW10DN8 1 (a)

8 Remove/Discard Barrel Nut NAS577-8A 1

Remove/Keep Retainer NAS578-8A 1

9 Remove Flap Track Assy 65-46428-( ) 1 (b)

Caution: MAKE SURE TO ALIGN THE NEW TRACK CORRECTLY DURING INSTALLATION. AN INCORRECTLY ALIGNED TRACK CAN MOVE DURING FLIGHT. MOVEMENT DURING FLIGHT CAN DAMAGE

THE TRACK, ATTACH BOLTS, AND MATING STRUCTURE.

FIGURE 8: INSTALLATION - NEW SPARES TRACK - GROUP 1 AIRPLANES - 737-100/200

(SHEET 3 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

Refer to Figure 7 for

alignment and torque

procedures during the installation of the new flap

track.

10 Install/Align Flap Track Assy 65-46428-36 1

11 Install Sleeve 66-23210-1 1

Bolt BACB30LT7DU17 1

Washer BACW10BP7C 1

Washer BACW10BP7P 1

Nut BACN10JD107 1

Apply to shank and

threads of bolt

12 Apply Compound MIL-C-11796, Class 3 -

Install Bolt BACB30LE7HK26 1

13 Install Washer BACW10BP7CD 1

14 Install Washer NAS1149F0732P 1 or 2 AN960-716L is optional.

15 Install Nut BACN10HR7CD 1

16 Install Retainer NAS578-8A 1

Barrel Nut NAS577B8A 1

17 Install Washer BACW10DN8 1

Apply to shank and

threads of bolt

18 Apply Compound MIL-C-11796, Class 3 -

Install Bolt BACB30LE8HK31 1

(c) AN960-716L or

AN960-716 optional

NAS1149F0763P or 1

NAS1149F0732P

19 Install Washer

Cotter Pin MS24665-285 1

Refer to BSOPM 20-50-

02.

NASM20995C32, or -

NASM20995N32

20 Install Lockwire

Apply a bead around the

heads of the bolts.

21 Apply Sealant BMS 5-95 -

Apply a bead around the

edges of the tapered shim

and anti-fret strip.

22 Apply Sealant BMS 5-95 -

(a) This part is not installed on all airplanes. Keep or discard the part that is applicable to your airplane.

Remove a 65-46428-2, or -3, or -5, or -7, or -9, or -11, or -15, or -17, or -19, or -21, or -23, or -25, or27, or -33.(b)

FIGURE 8: INSTALLATION - NEW SPARES TRACK - GROUP 1 AIRPLANES - 737-100/200

(SHEET 4 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
If necessary, install one of these washers between the nut and Washer BACW10BP7P to get the correct

alignment of the nut for installation of the cotter pin.

(c)

FIGURE 8: INSTALLATION - NEW SPARES TRACK - GROUP 1 AIRPLANES - 737-100/200

(SHEET 5 OF 5)

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 9: INSTALLATION - NEW SPARES TRACK - GROUP 3 AIRPLANES - 737-300/400/500

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 9: INSTALLATION - NEW SPARES TRACK - GROUP 3 AIRPLANES - 737-300/400/500

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BOEING SERVICE BULLETIN 737-57A1271
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

NOTE: Refer to 737 AMM 27-51-49 for track removal and installation procedures.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/Discard Cotter Pin MS24665-285 1

Remove/Keep Nut BACN10JD107 1

Washer AN960-716L 1 (a)

Washer AN960-716 1 (a)

Bolt BACB30LT7DU27 1

Sleeve 66-23210-1 1

2 Remove/Keep Nut BACN10HR7CD 1

3 Remove/Keep Washer AN960-716L 1

4 Remove/Keep Washer BACW10BN7SC 1 (a)

Remove/Discard Washer BACW10BP7CD 1 (a)

Washer BACW10AK-C7 1 (a)

5 Remove/Discard Bolt BACB30LE7HU( ) 1 (a)

Remove/Keep Bolt BACB30LE7HK26 1 (a)

6 Remove/Discard Bolt BACB30LE8HU( ) 1 (a)

Remove/Keep Bolt BACB30LE8HK31 1 (a)

7 Remove/Discard Washer BACW10DN8 1

8 Remove/Keep Barrel Nut NAS577B8A 1

Retainer NAS578-8A 1

9 Remove Flap Track Assy (b) 1 (d)

Caution: MAKE SURE TO ALIGN THE NEW TRACK CORRECTLY DURING INSTALLATION. AN INCORRECTLY ALIGNED TRACK CAN MOVE DURING FLIGHT. MOVEMENT DURING FLIGHT CAN DAMAGE

THE TRACK, ATTACH BOLTS, AND MATING STRUCTURE.

Refer to Figure 7 for

alignment and torque

procedures during the installation of the new flap

track.

10 Install/Align Flap Track Assy 65C34812-8 1

FIGURE 9: INSTALLATION - NEW SPARES TRACK - GROUP 3 AIRPLANES - 737-300/400/500

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

11 Install Sleeve 66-23210-1 1

Bolt BACB30LT7DU27 1

Washer BACW10BP7C 1

Washer BACW10BP7P 1

Nut BACN10JD107 1

Apply to shank and treads

of bolt

12 Apply Compound MIL-C-11796, Class 3 -

Install Bolt BACB30LE7HK26

13 Install Washer BACW10BN7SC 1

14 Install Washer NAS1149F0732P 1 or 2 AN960-716L is optional.

15 Install Nut BACN10HR7CD 1

16 Install Retainer NAS578-8A 1

Barrel Nut NAS577B8A 1

17 Install Washer BACW10DN8 1

18 Apply Grease MIL-G-23827 -

Install Bolt BACB30LE8HK31 1

(c) AN960-716L or

AN960-716 optional

NAS1149F0716P or 1

NAS1149F0732P

19 Install Washer

Cotter Pin MS24665-285 1

Refer to BSOPM 20-50-

02.

MS20995C32, or -

MS20995N32, or

MS20995F41

20 Install Lockwire

Apply a bead around the

heads of the bolts.

21 Apply Sealant BMS 5-95 -

Apply a bead around the

edges of the tapered shim

and anti-fret strip.

22 Apply Sealant BMS 5-95 -

(a) This part is not installed on all airplanes. Keep or discard the part that is applicable to your airplane.

(b) 65-46428-31, or 65C35387-4, or 65C35616-5, or 65C34812-3, or -4, or -6

If necessary, install one of these washers between the nut and Washer BACW10BP7P to get the correct

alignment of the nut for installation of the cotter pin.

(c)

You can use the existing part 65C35616-5, or 65C35387-4, or 65C34812-3, or -4, or -6, overhauled

with the instructions in this service bulletin to replace the new or changed part.

(d)

You cannot use the existing part 65-46428-31 to replace the new or changed part.

FIGURE 9: INSTALLATION - NEW SPARES TRACK - GROUP 3 AIRPLANES - 737-300/400/500

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BOEING SERVICE BULLETIN 737-57A1271
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1 Make Shop Aid - 2 (a)

(a) Make from any Aluminum Plate, or equivalent material.

FIGURE 10: SHOP AID - PRESSURE PLATE

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 11: TRACK OVERHAUL - SUPPLEMENTAL INSTRUCTIONS TO OHM 57-53-15

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 11: TRACK OVERHAUL - SUPPLEMENTAL INSTRUCTIONS TO OHM 57-53-15

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BOEING SERVICE BULLETIN 737-57A1271
FIGURE 11: TRACK OVERHAUL - SUPPLEMENTAL INSTRUCTIONS TO OHM 57-53-15

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BOEING SERVICE BULLETIN 737-57A1271
Table 1- Flap Track 65-46427-4

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.235 0.380 0.235 0.380 4.270 0.5835 0.6855 0.5835

Table 2 - Flap Tracks 65-46427-5/-7,/-11/-13/-17/-21/-23/-25/-27 -29 -31/-44/-46/ & 65C35380-2

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.195 0.340 0.195 0.340 4.270 0.5835 0.6855 0.5835

Table 3 - Flap Tracks 65-67156-2/-12/-14

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.208 0.348 0.208 0.348 4.270 0.5835 0.6855 0.5835

Table 4 - Flap Tracks 65-46427-35/-39

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

Do Not Rework - Remove from Service

Table 5 - Flap Tracks 65C34809-2 & 65C35387-2 & 65C35616-3

MAXIMUM ALLOWABLE HOLE DIAMETERSMINIMUM ALLOWABLE DIMENSIONS

T1 (a) T2 (a) T3 (a) T4 (a) W d1 d2 d3

0.195 0.340 0.195 0.340 4.270 0.5835 0.6855 0.5835

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

NOTE: During the overhaul of a flap track assembly, as given in OHM 57-53-15, do the three work steps below.

FIGURE 11: TRACK OVERHAUL - SUPPLEMENTAL INSTRUCTIONS TO OHM 57-53-15

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BOEING SERVICE BULLETIN 737-57A1271
STEP TASK NAME PART NUMBER QTY NOTES

Tables 1, 2, - - (a)

3, 4, 5

1 Refer To

(b) (c) Apply the finish as given in

BSOPM 20-10-05, except as noted in

note (c) below and view C in this figure.

Thickness 0.004 - 0.006. Class 2: Cobalt

composition to be a minimum of 15

percent by weight. Class 4: Surface

roughness as shown.

BMS 10-67, Type I, Class 2 -

or Class 4

2 Apply Finish

Apply to bolt threads and tapped hole

at 23 locations. Apply Locquic Primer N

7649 to the threads and tapped hole

before you apply Loctite 262. To apply

MIL-S-46163, refer to BSOPM 20-50-

12.

Loctite 262 or MIL-S-46163, -

Type II, Grade O

Retaining

Compound

3 Apply

Apply the sealant to the countersink and

counterbore.

Sealant BMS 5-95 -

During the OHM 57-53-15 overhaul procedures: Refer to Tables 1 through 5 of this figure for the minimum track thickness, and maximum hole diameter, in the track attachment area. Minimum track

thickness refers to the track thickness after the removal of corrosion during the overhaul procedures.

(a)

Application of this Tungsten Carbide-Cobalt finish is optional, however, fatigue tests and service experience shows that the Tungsten Carbide-Cobalt finish can help prevent corrosion damage. With this

finish applied, roller wear coating failure occurs within the coating itself (cohesive), thereby leaving a

thin (protective) coating remaining on the 4340M surface after failing. This is unlike the current failure

mode with standard finishes, which yields an adhesive failure (primer to 4340M substrate) leaving the

surface unprotected to the corrosive elements.

(b)

Note: Application of this finish is not optional on flap tracks that had Tungsten Carbide-Cobalt applied

during manufacture.

Thermal Spray Coating shall not terminate with a square edge, but shall taper from full to zero thickness

over a minimum length of 0.006 inches. The tapered edge of the coating shall be contained within a

0.080 inch (wide) band as shown. This band shall start at a tangent point of a shoulder, chamfer, undercut, hole, keyway or similar feature of the part being coated.

(c)

FIGURE 11: TRACK OVERHAUL - SUPPLEMENTAL INSTRUCTIONS TO OHM 57-53-15

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BOEING SERVICE BULLETIN 737-57A1271