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Revision 3: July 16, 2009 737-53A1210

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 267

ALERT ALERT

Commercial

Airplanes 737

ALERT ALERT

Service Bulletin

Number: 737-53A1210

Original Issue: December 14, 2000

Revision 3: July 16, 2009

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Fuselage Skin Chem-Mill Line Crack Inspection and Repair

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2000 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Unpublished Work - All Rights Reserved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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, 

MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or 

its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document 

or otherwise.
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ALERT ALERT

BLANK PAGE
 Table of Contents

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ALERT ALERT

Table of Contents

Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 79

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 80

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 80

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 81

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 84

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 2 . . . . . . . . . . . . . . . . . . . . . . 105

FIGURE 2: THIS FIGURE WAS DELETED AT REVISION 2 . . . . . . . . . . . . . . . . . . . . . . 106

FIGURE 3: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

107

FIGURE 4: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

112

FIGURE 5: CROWN AREA SKIN INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

FIGURE 6: CROWN AREA SKIN INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

FIGURE 7: CROWN AREA SKIN INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

FIGURE 8: THIS FIGURE WAS DELETED AT REVISION 2 . . . . . . . . . . . . . . . . . . . . . . 126

FIGURE 9: THIS FIGURE WAS DELETED AT REVISION 2 . . . . . . . . . . . . . . . . . . . . . . 127
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FIGURE 10: PREVENTIVE MODIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

FIGURE 11: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41 . . . . . . . 135

FIGURE 12: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41 . . . . . . . 138

FIGURE 13: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41 . . . . . . . 141

FIGURE 14: SKIN INSPECTIONS IN THE LOWER LOBE AREA . . . . . . . . . . . . . . . . . . . 144

FIGURE 15: SKIN INSPECTIONS IN THE LOWER LOBE AREA . . . . . . . . . . . . . . . . . . . 147

FIGURE 16: THIS FIGURE WAS DELETED AT REVISION 2 . . . . . . . . . . . . . . . . . . . . . 150

FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT . . . . . . . . . . . . . . . . . . . . . 151

FIGURE 18: INSPECTION OF THE TIME-LIMITED SKIN REPAIR AT A LAP JOINT. . . . . . . . . 157

FIGURE 19: THIS FIGURE WAS DELETED AT REVISION 2 . . . . . . . . . . . . . . . . . . . . . 160

FIGURE 20: THIS FIGURE WAS DELETED AT REVISION 2 . . . . . . . . . . . . . . . . . . . . . 161

FIGURE 21: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-19R TO

24R AND S-4L TO S-4R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

FIGURE 22: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-24R TO

S-24 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

FIGURE 23: TEAR STRAP ATTACHMENT TO SKIN INSPECTION . . . . . . . . . . . . . . . . . 166

FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR . . . . . . . . . . . . . 168

FIGURE 25: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN 175

FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540,

STRINGER 14 - STRINGER 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14

- STRINGER 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

FIGURE 28: SECTION 41 - SKIN INSPECTION - STRINGER-18R AND STRINGER-19R BETWEEN STA

303 AND STA 320 AND STRINGER- 15R BETWEEN STA 344 AND STA 352 . . . . 196

FIGURE 29: SKIN INSPECTIONS IN THE LOWER LOBE AREA . . . . . . . . . . . . . . . . . . . 198

FIGURE 30: TYPICAL INTERNAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

FIGURE 31: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 490 AND STA 500, STRINGER 17L

204

FIGURE 32: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 727 AND STA 1016 . . . . . 206

FIGURE 33: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 360 AND STA 540 AND STA 727

AND STA 1016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540. . . 212

FIGURE 35: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 727 AND 1016. . . . . 218

FIGURE 36: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540. . . . . . . . . . 222

FIGURE 37: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540. . . . . . . . . . 224

FIGURE 38: TIME LIMITED REPAIR - CHEM-MILL CRACKS - NOT LOCATED AT LAP JOINTS . . 226

FIGURE 39: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN 230

FIGURE 40: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN 234

FIGURE 41: SKIN INSPECTIONS IN THE LOWER LOBE AREA . . . . . . . . . . . . . . . . . . . 238

FIGURE 42: FUSELAGE WINDOW BELT AREA INSPECTION . . . . . . . . . . . . . . . . . . . . 241

FIGURE 43: FUSELAGE WINDOW BELT AREA INSPECTION . . . . . . . . . . . . . . . . . . . . 244

FIGURE 44: FUSELAGE WINDOW BELT AREA INSPECTION . . . . . . . . . . . . . . . . . . . . 248

FIGURE 45: CROWN AREA SKIN INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 251

FIGURE 46: CROWN AREA SKIN INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 254

FIGURE 47: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN 257

FIGURE 48: POST REPAIR INSPECTION - SKIN CHEM-MILL CRACK REPAIR AT STRINGER 12 261

FIGURE 49: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN 263
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APPENDIX A: COST BENEFIT ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
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BLANK PAGE
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ALERT ALERT

Commercial

Airplanes 737

ALERT ALERT

Service Bulletin

Number: 737-53A1210 Revision Transmittal Sheet

Original Issue: December 14, 2000

Revision 3: July 16, 2009

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Fuselage Skin Chem-Mill Line Crack Inspection and Repair

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes inspected as shown in Revision 2 of this service bulletin.

More work is necessary on airplanes inspected as shown in the original issue or revision 1 of this service 

bulletin. Additional areas have been identified to be inspected for vertical and horizontal chem-mill line cracks. 

Inspection areas are clearly identified to facilitate compliance.

Airplanes PM551-PM557, PM559-PM563, PW037-PW050, PW052-PW054, PW094, PW106, PW156-PW157, 

PW261, PW265-PW268, PW281, PW293, PW296, PW504, PW519-PW520, PW526, PW536-PW545, PW556, 

PW564, PW575-PW576, PW595-PW596, PW616, PW633-PW634, PW662, PW681-PW683, PW701-PW702, 

PW711-PW717, PW741-PW742, PW761, PW771 are added to Group 16 of this service bulletin effectivity.

REASON FOR REVISION

This revision is sent to add 737-400 airplanes to this service bulletin effectivity that were incorrectly removed in 

revision 2 of this service bulletin.

Changes to this service bulletin include: -

— Paragraph 1.A., Effectivity: Airplanes PM551-PM557, PM559-PM563, PW037-PW050, PW052-PW054, 

PW094, PW106, PW156-PW157, PW261, PW265-PW268, PW281, PW293, PW296, PW504, PW519-

PW520, PW526, PW536-PW545, PW556, PW564, PW575-PW576, PW595-PW596, PW616, PW633-

PW634, PW662, PW681-PW683, PW701-PW702, PW711-PW717, PW741-PW742, PW761, PW771 are 

added to the Group 16 effectivity. 

— Summary Compliance: FAA Airworthiness Directive is added.

— Paragraph 1.E.,Compliance: FAA Airworthiness Directive is added. Compliance information and SRM 

reference is updated. Damage tolerance based structural inspection statement is moved to Paragraph 1.K. 

Publications Affected.

— Paragraph 1.F., Approval: Approval information is updated.

— Paragraph 1.G., Manpower: Manpower tables for Group 6, Group 7 and Group 8 is updated.

— Paragraph 1.H.,Weight and Balance Changes: Weight and balance information is updated.

— Paragraph 1.J., References, 1. Existing Data: FAA Airworthiness Directive is added and SRM reference is 

updated.
 

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ALERT ALERT

— Paragraph 2.C.2. Parts and Material Supplied by the Operator: Brackets are added to the ends of fastener 

part numbers.

— Paragraph 3.B., Work Instructions, 1 Part 1, 5 Part 5 and 6 Part 6: SRM reference is updated.

— Paragraph 3.B., Work Instructions, 6 Part 6 a.,(1),(a),4),{d}: A note is added to clarify staggered fasteners 

locations common to the time limited repair.

— FIGURE 17 and FIGURE 18: The fastener pattern has been changed to stagger fasteners common to the 

tear strap.

— FIGURE 24: Brackets are added to the ends of fastener part numbers and SRM reference is updated.

— FIGURE 35: A new inspection area is added.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity 

paragraph for changes.

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

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: December 14, 2000

Revision 1: October 25, 2001

Revision 2: March 3, 2009

Revision 3: July 16, 2009
Original Issue: December 14, 2000

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ALERT ALERT

Commercial

Airplanes 737

ALERT ALERT

Service Bulletin

Number: 737-53A1210 Summary

Original Issue: December 14, 2000

Revision 3: July 16, 2009

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Fuselage Skin Chem-Mill Line Crack Inspection and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN 

PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS

None

BACKGROUND

Accomplishment of the inspections, modifications and repairs given in this service bulletin will ensure that 

fuselage skin cracks at chem-mill lines are found and repaired. This action is necessary to find and fix fatigue 

cracking of the skin panels which could result in sudden fracture and failure of the skin panels of the fuselage, 

and consequent rapid decompression of the airplane.

Operators have reported horizontal cracks along the edges of the chem-milled pockets in the skin at S-12 in the 

bay forward of body station STA 520 and just above the S-4, S-10, and S-14 lap joints. Operators have reported 

37 horizontal chem-mill line cracks of the fuselage crown skin at non-lap-joint areas. Skin inspection maps as 

given in this service bulletin present areas that need to be inspected for crown chem-mill line cracks. Fuselage 

skin cracks at tear strap attachments to the fuselage skin have also been reported by some operators. The 

chem-mill cracks were up to 8 inches long, and on at least 4 of the airplanes multiple adjacent bays were found 

to be cracked along the same stringer. These airplanes had flown 23,425 to 64,420 flight-cycles.

Operators have reported numerous horizontal skin cracks along the edges of the chem-milled pockets in the 

skin below S-14, and section 41. The cracks were up to 7.25 inches long. These airplanes had flown 22,786 - 

80,113 flight-cycles. 

Operators have also reported 13 circumferential cracks along the vertical chem-mill steps of the fuselage skin 

next to the STA 360, STA 727 and STA 908 Butt-Joints. The most critical situation was four in-line cracks in 

multiple adjacent bays on the aft side of the STA 908 butt joint from S-3R to S-7R. Crack lengths varied from 

0.75 inch to 4 inches. These airplanes had flown 45,100 flight cycles (65,200 flight hours) to 67,400 flight cycles 

(70,800 flight hours).
 

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Analysis by Boeing indicates that these cracks are caused by fatigue due to tension stresses plus local bending 

stresses at the edge of chem-milled pockets or bonded skin doublers. Boeing did a cost benefit analysis on the 

changes given in this service bulletin. Refer to Appendix A for the analysis.

Boeing Service Related Problem (SRP) 737-SRP-53-0281 is related to this service bulletin.

ACTION

On all affected airplanes, do a detailed inspection and eddy current inspection of the fuselage skin for cracks at 

S-12 in the bay forward of STA 520, just above the S-4, S-10, and S-14 lap joints from STA 360 to STA 1016, 

at S-15 between STA 360 and STA 540, aft of STA 727 and other locations of known cracking identified in this 

service bulletin. Skin inspection maps as given in this service bulletin indicate additional areas that need to be 

inspected for possible signs of chem-mill line cracks at the fuselage crown. 

On all affected airplanes, do a High Frequency Eddy current (HFEC) Sliding Probe inspection of the tear strap 

attachments to the fuselage skin for signs of cracks at the locations as given in this service bulletin.

On all affected airplanes, do detailed inspection of the crown area skins from S-10L to S-10R between STA 360 

and STA 1016 for indications of horizontal chem-mill line cracks.

On all affected airplanes, do a detailed inspection of the lower lobe skins for cracks from S-14L to S-14R, 

between STA 360 and STA 1016 and in Section 41 as given in this service bulletin. Skin inspection maps as 

given in this service bulletin indicate additional areas that need to be inspected for possible signs of chem-mill 

line cracks at the fuselage lower lobe and section 41.

Also, on all affected airplanes do a detailed inspection and eddy current inspections of the fuselage crown skin 

(from S-10L to S-10R) for vertical cracks just forward and aft of STA 360, STA 500C, STA 540, STA 727, STA 

727G, and STA 908, as applicable depending on the model, along the chem-mill lines as provided in this Service 

Bulletin.

If any crack is found, repair as given in this service bulletin, or contact Boeing for repair instructions and install 

the repair.

EFFECTIVITY

737-200, -200C, -300, -400, and -500 series airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of 

affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive 2004-18-06 and 98-11-04 R1 are related to this 

service bulletin.

See Service Bulletin Paragraph 1.E. for compliance information.

INDUSTRY SUPPORT INFORMATION

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

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.
 

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MATERIAL INFORMATION

Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

DO DETAILED INSPECTIONS OF THE LOWER

LOBE SKINS BELOW S-14 FROM STA 360 TO STA

1016 AND SECTION 41 FOR CRACKS. ALSO DO

DETAILED INSPECTIONS OF THE UPPER LOBE SKINS

ABOVE S-10 BETWEEN STA 360 AND STA 1016. IF

ANY CRACK IS FOUND, REPAIR AS GIVEN IN THIS

SERVICE BULLETIN, OR CONTACT BOEING FOR

REPAIR INSTRUCTIONS AND INSTALL THE REPAIR.

DO DETAILED INSPECTION AND EDDY CURRENT INSPECTION FOR

CRACKS JUST ABOVE S-4, S-10 AND S-14 BETWEEN STA 360 TO

STA 1016 AND ALONG THE CHEM-MILL LINES AT S-12, BETWEEN

STA 500D TO STA 520 FOR 737-300, STA 482B TO 520 FOR

737-500, AND STA 500E TO 520 FOR 737-400. ALSO IN THE

CROWN BETWEEN S-10L AND S-10R, AND AT S-15 BETWEEN STA 360

AND STA 540 AND AFT OF STA 727. IF ANY CRACK IS FOUND,

REPAIR AS GIVEN IN THIS SERVICE BULLETIN, OR CONTACT

BOEING FOR REPAIR INSTRUCTIONS AND INSTALL THE REPAIR.

ADDITIONAL INSPECTION MAPS ARE GIVEN IN THE SERVICE

BULLETIN.

S-4L

S-10L

S-14L

S-15L

STA

360

STA

540

STA

727

STA

908

STA

1016

STA

259.5

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

737-400 SHOWN,

OTHER MODELS ARE SIMILAR

V21666
 

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S-10R

STA

360

STA

540

STA

727

STA

908

STA

500C

STA

727G

737-400 SHOWN

OTHER MODELS ARE

SIMILAR

DO EDDY CURRENT INSPECTIONS OF THE FUSELAGE SKIN FOR VERTICAL

CRACKS ALONG THE CHEM-MILL LINES AT THE BUTT JOINT AND OTHER

LOCATIONS GIVEN IN THIS SERVICE BULLETIN. IF ANY CRACK IS

FOUND, REPAIR AS GIVEN IN THIS SERVICE BULLETIN, OR CONTACT

BOEING FOR REPAIR INSTRUCTIONS AND INSTALL THE REPAIR.

1522051
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ALERT ALERT

Commercial

Airplanes 737

ALERT ALERT

Service Bulletin

Number: 737-53A1210

Original Issue: December 14, 2000

Revision 3: July 16, 2009

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Fuselage Skin Chem-Mill Line Crack Inspection and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN 

PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE 

BULLETIN TO THE NEW OWNER.

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.

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - 737-200C Airplanes line numbers 294 through 

1113.

2 - 737-200 Airplanes line numbers 292 through 

1426 with a different Section 41 solid / bonded 

skin configuration to Group 13.

3 - 737-300 Airplanes line numbers 1001 through 

1446 with a different Section 41 solid / bonded 

skin configuration to Groups 6, 9, 10, 14 and 15.

4 - 737-400 Airplanes line numbers 1487 through 

1922 with a different Section 41 solid / bonded 

skin configuration to Groups 7, 11 and 16.

5 - 737-500 Airplanes line numbers 1718 through 

1921 with a different Section 41 solid / bonded 

skin configuration to Groups 8, 12 and 17 

excluding airplane variable numbers PU001-

PU007.
 

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ALERT ALERT

6 - 737-300 Airplanes line numbers 2554 through 

2565 that do not require inspections for 

horizontal chem-mill cracks in the crown area 

between STA 360 and STA 1016.

7 - 737-400 Airplanes line numbers 2560 through 

2564 that do not require inspections for 

horizontal chem-mill cracks in the crown area 

between STA 360 and STA 1016.

8 - 737-500 Airplane line number 2553 that does 

not require inspections for horizontal chem-mill 

cracks in the crown area between STA 360 and 

STA 1016.

9 - 737-300 Airplanes line numbers 1955 through 

2495 with a different Section 41 solid / bonded 

skin configuration to Groups 3 and 14 and 

differences in areas in which inspections can be 

terminated by SB 737-53A1177. Excluding 

PP151-PP160 and PS751-PS756.

10 - 737-300 Airplanes line numbers 2497 through 

2550 with a different Section 41 solid / bonded 

skin configuration to Groups 3 and 14 and 

differences in areas in which inspections can be 

terminated by SB 737-53A1177. Excluding 

PS757-PS762.

11 - 737-400 Airplanes line numbers 2501 through 

2551 with a different Section 41 solid / bonded 

skin configuration to Group 4 and differences in 

areas in which inspections can be terminated by 

SB 737-53A1177.

12 - 737-500 Airplanes line numbers 2498 through 

2552 with a different Section 41 solid / bonded 

skin configuration to Group 5 and differences in 

areas in which inspections can be terminated by 

SB 737-53A1177.

13 - 737-200 Airplanes line numbers 1453 through 

1585 with a different Section 41 solid / bonded 

skin configuration to Group 2.

14 - 737-300 Airplanes line numbers 1447 through 

1920 with a different Section 41 solid / bonded 

skin configuration to Groups 3, 6, 9, 10, and 15. 

Excluding PP127-PP148.

15 - 737-300 Airplanes line numbers 1924 through 

1953 with a different Section 41 solid / bonded 

skin configuration to Groups 3 and 14 and 

differences in areas in which inspections can be 

terminated by SB 737-53A1177. Excluding 

PP149-PP150.

GROUP CONFIGURATION DESCRIPTION
 

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ALERT ALERT

Airplane models:

737-200 737-200C 737-300 737-400

737-500

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

A.P.S. TRADING SERV S.R.L (PSV)

2 PL019

AAM (VMA)

14 PQ192

9 PQ237

AAR AIRCRAFT SALES & LEASING (AFD)

14 PQ116

AEGEAN AIRLINES S.A. (CRM)

16 PW046 PW053 PW157 PW261

PW564

4 PW002

9 PS608

AERGO CAPITAL LIMITED (CLJ)

2 PK909 PK912 PK922

16 - 737-400 Airplanes line numbers 1931 through 

2496 with a different Section 41 solid / bonded 

skin configuration to Group 4 and differences in 

areas in which inspections can be terminated by 

SB 737-53A1177.

17 - 737-500 Airplanes line numbers 1923 through 

2494 with a different Section 41 solid / bonded 

skin configuration to Group 5 and differences in 

areas in which inspections can be terminated by 

SB 737-53A1177. Excluding PU008-PU025.

18 - 737-300 Airplane Variable Numbers PP149-

PP160 and PS751-PS762 - Airplanes with no 

chem-milled skin panels in certain areas of the 

crown.

19 - 737-500 Airplane Variable Numbers PU001-

PU007 - Airplanes with no chem-milled skin 

panels in certain areas of the crown.

20 - 737-500 Airplane Variable Numbers PU008-

PU025 - Airplanes with no chem-milled skin 

panels in certain areas of the crown.

21 - 737-300 Airplane Variable Numbers PP127-

PP148 - Airplanes with no chem-milled skin 

panels in certain areas of the crown.

GROUP CONFIGURATION DESCRIPTION
 

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ALERT ALERT

AERO CONTRACTORS OF NIGERIA (NCC)

14 PQ194 PQ196

16 PV041

17 PT396 PT401 PT420–PT421 PT430–PT431

PT433

4 PV031

AERO NORTH INTERNATIONAL (NIN)

17 PT125

AEROFLOT - CARGO (CGB)

3 PP825–PP826

AEROFLOT-DON (DAU)

17 PT507–PT508 PT701–PT703

AEROFLOT-NORD (CJS)

12 PT028

17 PT009 PT027 PT050–PT051 PT054

PT056–PT057 PT147–PT148 PT183–PT184

5 PT021–PT022 PT182 PT295

AEROGAL/GALAPAGOS AIRLINES (ERG)

14 PQ226 PQ243

2 PK715 PK827 PL102 PL110

PL171 PL624–PL625 PN030 PN405

3 PP946

AEROLINEA PRINCIPAL (APW)

2 PK775

AEROLINEAS ARGENTINAS (ARG)

12 PT304–PT306

17 PT042 PT044–PT045 PT047 PT102

PT220 PT303 PT509–PT510

2 PG584–PG585 PK102–PK103 PK735–PK737 PK740

PK747 PK750–PK751 PK755 PK757

PK761 PK765 PN104 PN110–PN115

PN117

5 PT023 PT101 PT212 PT214

AEROLINEAS AUSTRAL CHILE S.A. (LUT)

2 PK745 PL405 PM141–PM142 PN103

AEROSERVICE (SRI)

2 PL742–PL743

AEROSUCRE (SUS)

1 PY201 PY451

AEROSUR (REO)

2 PK495 PK594 PK713–PK714 PK716
 

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ALERT ALERT

AEROSVIT (UKA)

14 PP924 PQ284 PQ286

16 PW039 PW265 PW268 PW595–PW596

17 PT614–PT615

2 PK564

4 PW591–PW592

AEROTECNIC, LLC (TCQ)

2 PM054

AEROVISTA GULF EXPRESS (GXP)

1 PY621

2 PK861–PK862

AIR ALGERIE (ALG)

1 PY051 PY053

2 PK633–PK634 PL722 PL724

AIR AUSTRAL (AUX)

17 PT215

AIR CANADA (ACN)

2 PK679–PK680

AIR CARRIER ACCESSORY SERVICE (RCY)

2 PN085

AIR CHINA (BEJ)

9 PQ361 PQ363–PQ364

AIR CHINA INNER MONGOLIAN (IML)

9 PQ365–PQ366 PS614–PS616

AIR CHINA SOUTHWEST BRANCH (XIN)

3 PP632–PP633

6 PQ408

9 PQ402–PQ406

AIR CHINA TIANJIN BRANCH (TJA)

9 PQ367–PQ369

AIR CORRIDOR (KRD)

2 PK468 PK749

AIR DOMINICANA (DMA)

3 PP894

AIR GUINEE (GNE)

1 PY651

AIR INDIA (IND)

1 PY631

2 PK237–PK240 PM001–PM006
 

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ALERT ALERT

AIR INUIT (AIU)

1 PY243

AIR ITALY (RIT)

14 PP393

3 PP903

AIR MADAGASCAR (MAD)

14 PP852

AIR MALAWI (AML)

17 PT397

9 PS602

AIR NAMIBIA (NAM)

17 PT503–PT504

AIR NIPPON (ANK)

12 PT060 PT063

17 PT053

8 PT064

AIR NORTH YUKON'S AIRLINE (AND)

1 PY592

2 PK596 PK599

AIR ONE (ADH)

14 PQ228–PQ229

16 PV232–PV234 PV236–PV237 PW041 PW043

PW052 PW054

2 PK432 PK933 PK938

AIR PHILIPPINES (PHP)

2 PK099 PK542 PN021 PN025

PN029 PN031 PN038 PN417–PN418

AIR SLOVAKIA (SLO)

2 PK936

3 PP851 PP866 PP868–PP869

AIR TANZANIA (TNZ)

2 PN413

AIR ZIMBABWE (ZMB)

2 PN431–PN433

AIRASIA BERHAD (ASW)

14 PM385 PQ184 PQ332

3 PP002 PP021 PP407–PP409 PP471

9 PM397

AIRBALTIC CORPORATION (BCB)

17 PT005 PT161–PT163 PT424–PT425 PT428–PT429
 

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ALERT ALERT

AIRCOMPANY TATARSTAN (TTQ)

17 PT170

AIRCRAFT MAINTENANCE CORP. (AMF)

2 PK254

AIRFAST INDONESIA (PTF)

2 PN481

AIRLINE CAPITAL LEASING, INC. (VTI)

2 PJ009

AIRTRAN AIRWAYS (CQT)

2 PK697

AIRWORK NZ (ANX)

1 PY741

14 PP039–PP040 PQ242

3 PP028

ALASKA AIRLINES (ASA)

11 PW241–PW242

16 PJ301–PJ302 PW231–PW240

4 PW116

7 PW245

ALOHA AIR CARGO (HLH)

1 PY131 PY463 PY593–PY594 PY721

ALTER BAIL AVIATION (ABH)

2 PK215 PK359

AMERICAN FALCON AIR (FAK)

2 PL026

AMERISTAR AIR CARGO (CGG)

2 PK221 PK560 PM051

APOLLO AVIATION GROUP LLC (APV)

3 PP234 PP419 PP421 PP905

PP981–PP982

ARIK AIR (AKD)

14 PQ154 PQ161

ASIA AIRLINES (YDO)

1 PY135

2 PL020

ASIANA AIRLINES (AAR)

7 PW283
 

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ALERT ALERT

ASTRAEUS, LTD. (AUA)

9 PP929 PS605

ATLANT-SOYUZ (AYZ)

14 PP967

3 PP233 PP239

ATLANTIC AIRLINES (LNL)

2 PK673 PL008 PL622–PL623

ATLANTIC AIRLINES LTD (YDG)

14 PQ119

ATLAS BLUE (ABT)

16 PW633–PW634

17 PT581

4 PW631–PW632

AURELA (URE)

14 PQ233

9 PQ307

AURORA AVIATION (AGX)

14 PP199 PQ141–PQ142 PS666–PS667

15 PQ287

3 PP420

AUTOMATIC LLC (AUM)

2 PK759–PK760 PK764

AVE.COM (PHX)

2 PK213 PK823 PK826 PM252

3 PP892

AVIACSA AEROEXO (AEJ)

14 PP425

2 PK211 PK216–PK219 PK598 PK609

PK625–PK626 PM101–PM102 PM104–PM107 PM114–PM119

PM181 PN401–PN404

3 PP422–PP423

AVIOGENEX (AVG)

2 PN501

AVIOR (AWD)

2 PK549 PK591 PM052 PM058

PN133–PN134 PN137 PN139 PN144

PN147–PN148 PN153 PN159

AVSTAR (VSV)

2 PK355 PL111
 

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ALERT ALERT

AWAS (AWW)

14 PP911–PP912

17 PT216

5 PT213

6 PQ473

BABCOCK & BROWN A/C MANAGEMENT (BBB)

3 PP848

BAHAMASAIR (BAH)

2 PL501 PL506

BASIC CAPITAL MANAGEMENT (BCM)

2 PN455

BATAVIA AIR (BTV)

11 PV203

14 PP917 PP921

16 PW156 PW575

2 PJ107 PJ112 PK252 PK283–PK284

PK305 PK360 PK514–PK515 PK563

PK617 PK622 PK635 PK711–PK712

PK825 PL413

3 PP003–PP004 PP006 PP008 PP017–PP020

PP406

4 PW005 PW015 PW020 PW032

9 PS631

BAVARIA (BAV)

14 PP984

BAYU INDONESIA AIR (BAY)

2 PK561

BCI AIRCRAFT LEASING (BLI)

1 PY112 PY134 PY462

2 PN131 PN136 PN138 PN142–PN143

3 PP231–PP232 PP237–PP238 PP679 PP682

BELAVIA (ITU)

10 PQ472

BELLVIEW AIRLINES (BEB)

2 PK203 PK612 PK872 PL028

BLUE AIR (BTR)

14 PQ160

16 PW741

3 PQ026

BLUE DART AVIATION (BDA)

13 PN521

2 PK231–PK232 PL451 PM281
 

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ALERT ALERT

BLUE PANORAMA AIRLINES (BPA)

16 PW519

4 PW518

7 PW284

BLUEBIRD CARGO (BLS)

14 PM383

4 PW001

9 PQ342–PQ344

BMI BRITISH MIDLAND (BMA)

17 PT186–PT187

9 PQ292

BOA (BOV)

14 PQ304

9 PS604

BOEING CAPITAL CORPORATION (ZMF)

3 PP162

9 PQ792

BOURAQ AIRLINES (PTB)

2 PK501 PK913 PK918–PK920 PK931

BRANSON AIR (PTY) LTD (BSL)

2 PK874 PL025

BRITISH AIRWAYS (BAB)

11 PW324–PW327

14 PP841–PP842 PQ283 PQ305

16 PW301–PW302 PW305–PW308 PW312 PW314–PW315

PW317–PW323

9 PM399

BRUSSELS AIRLINES (EBA)

4 PW013 PW571–PW572

9 PS656

BULGARIA AIR (BLD)

12 PT437

14 PQ087 PQ190 PQ331

17 PT427

3 PP503 PQ086

5 PT211

9 PQ262

BURAQ AIR (BQA)

2 PL723 PL725
 

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ALERT ALERT

C.I.T. LEASING CORPORATION (TCI)

14 PQ231

3 PP836

4 PW562

CANADIAN NORTH (ANP)

1 PY152–PY154 PY422 PY441

2 PK681 PL415 PN132 PN492

CAPITAL AIRCRAFT (CPT)

2 PK464

CAPITAL AIRWAYS LLC (CPY)

3 PP404

CARDIG AIR (CGD)

3 PP241–PP242

CARGO AIR (CGE)

3 PP410

CASBAH AG AVIATION DIVISION (BHV)

2 PL581

CAYMAN AIRWAYS (CAY)

1 PY244

2 PK753

9 PQ293 PQ481

CELTIC CAPITAL (IAQ)

2 PN411

CENTRALWINGS (CLW)

16 PW106 PW267

CHANCHANGI AIRLINES (CGI)

2 PL412 PL416–PL417 PN083–PN084 PN086

9 PQ362 PQ401

CHILEAN AIR FORCE (CHF)

3 PQ053

CHINA EASTERN AIRLINES (CEA)

9 PQ263 PQ411–PQ412

CHINA EASTERN AIRLINES WUHAN (WUH)

9 PQ492

CHINA POSTAL AIRLINES (YIH)

10 PQ471

9 PM407–PM409 PQ295–PQ296 PQ493
 

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ALERT ALERT

CHINA SOUTHERN AIRLINES (GUN)

10 PM542 PQ407 PQ479–PQ480

12 PT061–PT062

14 PQ252–PQ255

6 PM543–PM544 PM547

9 PM412 PM541

CHINA UNITED AIRLINES (CUL)

14 PP728–PP729

9 PS609–PS610

CHINA XINHUA AIRLINES (XIH)

10 PQ804–PQ805

6 PM546

9 PQ264

CHINA XINJIANG AIRLINES (XIJ)

6 PM545

CIRRUS ME S.A.L (CMU)

2 PM103

CITYLINE HUNGARY LTD. (CTZ)

1 PY101

COMAIR LIMITED (CML)

14 PP915 PP923

16 PW118 PW215–PW216 PW303 PW310–PW311

PW556

2 PK734 PK738 PK744 PK748

PK754 PK758

3 PQ001 PQ003–PQ006 PQ008 PQ010

4 PW111–PW112 PW115

CONOCOPHILLIPS ALASKA, INC. (ATR)

2 PN452–PN453

CONTINENTAL AIRLINES (CAL)

14 PP721–PP726 PP730 PP732–PP733

3 PP671–PP675 PP678 PP680–PP681 PP683

PP688–PP699 PP701 PP703–PP710 PP712–PP720

CONVIASA S.A. (VSS)

14 PP198 PQ117 PS668

2 PL005 PL010 PN154–PN155

CORENDON AIRLINES (HVA)

16 PM557

7 PW282
 

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ALERT ALERT

CSA (CSA)

16 PW304 PW309

17 PT617–PT621

4 PW517

CSC TRANSPORT (CTC)

4 PW007

DAIMLERCHRYSLER AVIATION (DCY)

3 PP119–PP120

DBA (DBA)

9 PP511 PP515 PS655

DELMUN AVIATION SERVICES (DLM)

2 PK318

DELTA AIR LINES (DAL)

2 PN149 PN161 PN415

3 PP240 PP243

DELTA CONNECTION (DTC)

1 PY272

DNIPROAVIA (DNE)

14 PP510

17 PT041

4 PW031

DOLPHIN AIR (FDN)

1 PY241

2 PL151

DONGHAI AIRLINES (JWC)

3 PP651–PP652

9 PM396 PM405

EASTOK AVIA (ETK)

13 PN493

14 PP034 PP440

2 PK632 PN407–PN408 PN410 PN416

4 PV023 PW011

EDREES AVIATION (SME)

2 PL505

EG&G TECHNICAL SERVICES (EGN)

2 PJ205 PJ207–PJ210 PL763

EGYPTAIR (EGP)

17 PT561 PT563–PT565
 

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ALERT ALERT

ESEN AIR LTD. (ESN)

2 PK317 PL729

ESTAFETA (EST)

1 PY275

14 PQ224–PQ225

3 PP833 PP846

ESTELAR (ESQ)

13 PL626

EUROPE AIRPOST (EUE)

14 PP392 PP951–PP952 PS641–PS642

15 PP925

3 PP832 PP947

9 PQ421 PQ771 PS607 PS643–PS644

EUROPEAN AVIATION AIR CHARTER (EUL)

1 PY273

2 PK041 PK044 PK046 PK048–PK049

PN001

3 PP965

EUROPEAN CAPITAL HOLDINGS (ECC)

2 PJ006 PK524–PK525 PK641–PK642

EXECUTIVE JET AIRCRAFT COMPANY (EXF)

2 PL441

EXPORT RESTRICTED AIRPLANES (YWV)

1 PY022 PY141–PY142

2 PJ003 PK214 PK391 PL758

9 PQ288–PQ289

EXPRESSAIR (PTX)

2 PK304 PM022

FAA (FAA)

2 PL768

FEDERATIVE REPUBLIC OF BRAZIL (BRZ)

2 PK068–PK069

FIRST AIR (BRS)

1 PY133 PY281 PY410 PY421

2 PK358 PL407

FLAIR AIRLINES (FLR)

16 PW662

4 PW503

FLANA (FLQ)

1 PY270
 

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ALERT ALERT

FLYING CARPET (FYC)

2 PM064 PN140

FLYLAL CHARTERS (LCT)

14 PQ189

FRESH AIR LTD. (FRR)

2 PN024 PN035

FUTURA (FUA)

14 PP430 PP432

16 PW047–PW048 PW101 PW266

3 PP899

4 PV032 PW561

GA TELESIS, LLC (GTG)

2 PK233 PK235 PK739

GARUDA INDONESIA (GIA)

10 PQ487

11 PW461–PW467

14 PP508 PQ285

16 PV271 PW067 PW119 PW712

9 PM404 PP514 PS653

GARY AIRCRAFT (GRH)

2 PL745

GE AVIATION MATERIALS (GML)

3 PP001

GECAS (GEF)

14 PP840

2 PK026–PK027 PK256 PK466–PK467

3 PP235–PP236

4 PW009 PW012 PW018–PW019 PW021

9 PM398 PM410–PM411

GENERIC CUSTOMER/SUPPLIER (XXX)

1 PY411 PY611

14 PP046 PP431 PP436–PP438 PP936

15 PQ199

17 PT382–PT383 PT385

2 PH743 PJ005 PJ110–PJ111 PK029

PK112 PK144 PK253 PK274

PK286 PK503 PK519 PK801

PK803–PK804 PK821 PK934 PL004

PL009 PL012 PL014–PL016 PL023

PL107 PL112 PL740–PL741 PL793

PM253

3 PP031 PP161
 

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ALERT ALERT

GEORGIAN AIRWAYS (GEI)

14 PP044

17 PT611

5 PT181

GERMANIA (GER)

14 PP507 PP838 PQ152 PQ234–PQ235

3 PP961

9 PQ230

GLOBAL AIR (YCH)

2 PJ004 PK145 PK548 PK595

PL013

GOL AIRLINES (GOT)

14 PP922 PQ120 PQ143–PQ145 PQ158

PQ162–PQ163 PQ191 PQ193 PQ195

PQ227 PQ303

15 PP988

9 PP989–PP990

HAINAN AIRLINES (HNA)

14 PQ088–PQ091 PQ156–PQ157

4 PW093

9 PS611 PS613

HAMBURG INTERNATIONAL (HAU)

3 PP904

HOLA AIRLINES (HLB)

4 PW006

IAI (IAI)

2 PK692

ICARO (IKA)

1 PY461

2 PK742 PK771

IDM CAS (IDN)

2 PK552

ILFC (ILF)

14 PQ302

17 PT169

9 PQ491

INDIAN AIR FORCE (IDF)

2 PM016–PM017

INTAL AIR (IRT)

1 PY242 PY274

2 PK312
 

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ALERT ALERT

INTERAIR (ITI)

1 PY046–PY047

2 PK546 PK610 PL108 PL113

INTERLINK AIRLINES (ILK)

2 PK743 PK904 PK907 PL103

IRAQI AIRWAYS (IRQ)

14 PQ198

JANCO AIRCRAFT AND ENGINES (JNC)

2 PM282–PM283

JAPAN TRANSOCEAN AIR (SWL)

16 PW520 PW681–PW683

4 PW515–PW516

JAT YUGOSLAV AIRLINES (JAT)

14 PP778–PP779 PQ241

3 PP771–PP777

4 PV024

JATAYU AIR (JAJ)

2 PJ117 PK257 PK511

JET LITE (JPQ)

16 PW064 PW066

9 PQ306

JET MIDWEST (JMI)

2 PK558 PM057 PM060 PM066

JET TIME (JME)

14 PM384 PM391

3 PP504 PP897

JET2.COM LTD (CEX)

14 PP908–PP909 PP913–PP914 PQ038–PQ039

3 PQ027 PQ030–PQ037 PQ051–PQ052 PQ054–PQ055

PQ058–PQ059

JET4YOU.COM (JFU)

4 PW511 PW661

JETAIRFLY (TLB)

17 PT103

JETCONNECT LIMITED (JCL)

14 PQ013–PQ016

16 PW540 PW542–PW543

3 PQ012
 

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ALERT ALERT

JETLEASE (JLI)

1 PY595

JETRAN INTERNATIONAL, LTD. (JTI)

2 PK593

JETSCAPE LEASING (IAN)

4 PW008

JETSTAR PACIFIC AIRLINES (PAH)

16 PW102 PW316

JORDAN AVIATION (JOR)

14 PQ123–PQ124 PQ187

17 PT671

3 PP896

4 PW502

JSC "AIRCOMPANY SCAT" (DVW)

17 PT426 PT435

JSC STARLINE.KZ (MZK)

2 PK911 PL556

KARTHAGO AIRLINES (KAG)

14 PQ180

9 PP926 PP928 PP930

KARTIKA AIRLINES (KRK)

2 PK309–PK310

KD AVIA (JSK)

14 PP196 PP426 PP429 PP837

PP843–PP844 PP916 PQ232

3 PP016 PP305 PP383 PP418

PP424 PP475 PP801 PP867

PP870

9 PS652

KLM - ROYAL DUTCH AIRLINES (KLM)

14 PP871–PP873

16 PW616–PW619

3 PP861 PP863–PP864

4 PW014 PW017 PW611–PW615

9 PP874–PP875

LAC (CQC)

1 PY113

LAM (LAM)

2 PL455–PL456 PN451 PN454
 

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ALERT ALERT

LAN AIRLINES (LAN)

2 PK431 PK914

LAPA ARGENTINA (LAZ)

2 PK051

LAS VEGAS SANDS, CORP. (LVS)

14 PP506 PQ236

LIBYAN AIRLINES (LAA)

2 PK361

LINEAS AEREAS AZTECA (AZX)

14 PP983 PP986

LION AIR (MLI)

16 PW037–PW038 PW042

3 PP181–PP182

4 PW016 PW022–PW023 PW025 PW029

PW501

LJH AVIATION MANAGEMENT (WAT)

2 PL006

LLC GLOBUS (LLG)

16 PW526

LOBAYE AIRWAYS (LBY)

2 PN409

LOCALEASE (LLA)

2 PK282

LOCKHEED MARTIN (LMA)

3 PQ057

LOT POLISH AIRLINES (LOT)

11 PV283

16 PV281–PV282 PW065

17 PT651–PT655

LUFTHANSA GERMAN AIRLINES (DLH)

14 PQ062–PQ073 PQ092

17 PT331–PT360

3 PQ060–PQ061

9 PQ074–PQ085 PS701–PS703

LUXAIR (LUX)

17 PT672

MACEDONIAN AIRLINES, MACEDONIA (MCC)

17 PT612–PT613
 

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ALERT ALERT

MACQUARIE AIR FINANCE (ZGT)

16 PW504

3 PP022 PP962

MAGELLAN AIRCRAFT SERVICES (MAP)

14 PQ113

MAGNICHARTERS (MAM)

14 PQ168

2 PK143 PL454 PL554 PL558

3 PP405 PQ028

MALAYSIA AIRLINES (MAS)

11 PJ551 PW224–PW230

16 PW044 PW201–PW214 PW217–PW223

7 PJ552

MANDALA AIRLINES (MND)

2 PK255 PK636 PL027 PL421

PL744 PN002

4 PW004 PW010

MANGAL AIRLINES (MGG)

2 PL785

MARANATHA LEASING CORPORATION (MNT)

2 PK201–PK202 PL011

MAX AVIA (MXY)

2 PK222 PK315 PK671 PK830

PL732

MERPATI NUSANTARA AIRLINES (PNM)

14 PP043 PP434–PP435 PQ281

2 PK354 PK614–PK615 PK623–PK624 PK819

PK917 PK929–PK930 PL409

3 PP898

4 PW091

MEXICO'S PRESIDENTIAL AIRCRAFT (MXG)

14 PP919 PQ155

MIDAMERICAN AEROSPACE, LTD (MML)

1 PY231

2 PL557

MIRAGE AVIATION LTD (MLE)

3 PP991

MISTRAL AIR (MSX)

14 PQ222

9 PQ341 PS638
 

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ALERT ALERT

MNG AIRLINES (MHK)

4 PW512 PW514 PW593

NAT AVIATION U.S.A. (NTV)

2 PK258 PK551 PK557 PK732

NATIONAL CITY (NTJ)

2 PL471

NATIONWIDE AIRLINES (NWR)

2 PJ007–PJ008 PK357 PK741 PK871

PK906 PK928 PK932 PL631–PL632

PN107 PN109

NEW AXIS AIRWAYS (NXA)

14 PQ301

4 PW033

NEWJET (NES)

2 PL172 PL562

NICON AIRWAYS LTD. (EAV)

2 PL453 PN032

NOK AIR (OWL)

16 PM553 PW045

NOLINOR AVIATION (NLO)

1 PY671–PY672

NORDESTE (NDT)

14 PP987

NORTHERN AIR CARGO (NAC)

2 PN150–PN152

NORTHSTAR PRESIDIO MANAGEMENT (INH)

2 PK094–PK095

NORWEGIAN AIR SHUTTLE AS (NSB)

14 PM381 PM389 PP805–PP808 PP918

PP985

9 PM401–PM402 PQ791 PQ793 PS601

PS654

NOVA AIR (PDM)

2 PL007 PL406 PN412 PN414

OKAY AIRWAYS COMPANY LIMITED (OKY)

3 PP631 PP634

9 PQ290
 

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ALERT ALERT

OLYMPIC AIRLINES (OLY)

16 PV201–PV202 PV231 PW068 PW072

PW711 PW713–PW717 PW771

4 PW063

9 PS657

OLYMPIC AIRWAY SERVICES (OLS)

4 PW062

ONE SOURCE AEROSPACE (OSA)

2 PK043

ORENBURG AIRLINES (ORG)

17 PT010 PT301–PT302

4 PW028 PW036

ORIX AVIATION SYSTEMS (OXA)

5 PT121

OUR AIRLINE (NAU)

3 PP831 PP902

OZJET AIRLINES (OZJ)

2 PK045 PK050 PK052–PK053

PACE AIRLINES (PIE)

2 PL001 PL502–PL503 PN102 PN116

3 PP835

PACIFIC PEARL AIRWAYS (PPA)

2 PN146

PACIFIC SKY AVIATION INC. (SEF)

17 PT219

PAKISTAN INT'L AIRLINES (PIA)

3 PP281–PP286

9 PS612

PAMIR AIRWAYS (PMY)

2 PN135

PEGASUS AIRLINES (PGS)

4 PW030

PERUVIAN AIR FORCE (PRF)

2 PN082

PERUVIAN AIR LINE S.A. (PVU)

2 PK802

PHILIPPINE AIRLINES (PAL)

9 PQ803
 

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ALERT ALERT

PHUKET AIRLINES (PHK)

2 PN037 PN039

PLATINUM AIRWAYS (PLW)

14 PP189

PLUNA (PLU)

2 PL201–PL203

PRECISIONAIR (PCR)

15 PM395

PT. INDONESIA AIRASIA (WAA)

14 PM388 PM390

9 PP516–PP517

PT. TOP AIR (PTZ)

13 PK528

2 PK937

Q AVIATION (QAV)

14 PQ132

2 PK288 PK603–PK604

QANTAS (QAN)

11 PW546 PW557

16 PW536–PW539 PW541 PW544–PW545

3 PQ002 PQ007 PQ009 PQ011

4 PW531–PW535

QUIKJET (QKJ)

14 PQ221 PQ223

REGIONALCARGO (RGC)

1 PY057

REPEX AIRLINES (REX)

1 PY102–PY103

REPUBLIC OF INDONESIA (IDO)

2 PL601–PL603

REPUBLIC OF KOREA AIR FORCE (KAF)

3 PP221

REPUBLIC OF NIGER (NIR)

1 PY166

REPUBLIC OF VENEZUELA (VNZ)

2 PK070

REPUBLICAIR (RPB)

2 PL553 PL555
 

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ALERT ALERT

RICO (RLA)

2 PK120

ROSSIYA RUSSIAN AIRLINES (STG)

17 PT164–PT168

ROYAL AIR MAROC (RAM)

17 PT582–PT584

2 PK271–PK272

ROYAL KHMER AIRLINES (KHM)

2 PN163

RUTACA AIRLINES (ZRU)

2 PK281 PK611 PK613 PK901

PK903 PK915–PK916 PM062

RUTAS AEREAS VENEZOLANAS S.A. (RTV)

2 PK822 PL402 PL414 PN145

PN157

RYAN INTERNATIONAL AIRLINES (RYN)

14 PQ197

2 PK543 PK606

RYM AIRLINES (RYM)

2 PL017–PL018

S7 AIRLINES (SBR)

16 PM556 PW094

17 PT381 PT388–PT389 PT501–PT502 PT505–PT506

4 PW051

SAFAIR (SFA)

2 PK731 PK746 PK824 PK974

PL061

SAFAIR OPERATIONS (SFZ)

2 PK820

SAFI AIRWAYS (FFI)

3 PP521–PP522

SAMA AIRLINES (AWM)

14 PP509

15 PM393–PM394

9 PS606 PS651

SAS NORWAY (BRT)

16 PW574 PW576

17 PT002–PT004 PT006–PT008 PT011 PT024–PT025

4 PW573
 

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ALERT ALERT

SAT AIRLINES (SKH)

2 PL221 PN158

SAUDI ARABIAN AIRLINES (SVA)

1 PY036

2 PK316 PL727–PL728 PL730–PL731 PL733

SEAGLE AIR (SGQ)

3 PP964

SHAHEEN INTERNATIONAL (SHK)

2 PK602 PK608 PL003 PL551

PL561 PN036

SHANTOU AIRLINES (SHT)

9 PM415–PM417

SHENZHEN AIRLINES (SHZ)

9 PQ486 PS691–PS692

SIERRA PACIFIC AIRLINES (SRP)

2 PK627 PL621

SILVER AIR (SARL) (SVT)

14 PP935

2 PK313–PK314 PL726 PL734

3 PP865

SILVER SKY (SLZ)

2 PN419

SKY AIRLINES (SYC)

11 PW278

16 PV235 PW281 PW293 PW296

SKY EXPRESS (SXR)

17 PT058 PT124 PT217–PT218 PT616

3 PQ056

5 PT123 PT146

9 PQ258–PQ259

SKY HOLDING COMPANY (PSH)

2 PK752 PL401 PL403 PN491

3 PP802

SKY KING (SKN)

2 PK351–PK353 PK696 PL002 PN156

PN162
 

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ALERT ALERT

SKY SERVICE (SSV)

2 PK526–PK527 PK628–PK629 PK772 PK881

PK884 PK902 PK908 PK910

PK923 PK927 PK971 PK973

PL736

SKYEUROPE (SKP)

12 PT438

17 PT434

SKYNET ASIA AIRWAYS (SNU)

16 PM555

4 PW026

SLOK AIR (SRO)

2 PM108–PM113

SOUTH AFRICAN AIRWAYS (SAA)

2 PL104–PL106

9 PM413–PM414

SOUTHERN WINDS (SOW)

2 PK047 PK616

SOUTHWEST AIRLINES (SWA)

14 PP169 PP188 PP190–PP193 PP205

PP353 PP727 PP731

18 PP149–PP160 PS751–PS762

19 PU001–PU007

2 PM065

20 PU008–PU025

21 PP127–PP148

3 PP101–PP118 PP121–PP126 PP163–PP168 PP202–PP204

PP301–PP304 PP351 PP376–PP380 PP382

PP402–PP403 PP501–PP502 PP803–PP804 PP821–PP824

PP827

SPACE WORLD AIRLINE/SWA (WIN)

2 PL021–PL022

SRIWIJAYA AIR (SJA)

14 PP910

2 PJ114 PK302–PK303 PK307–PK308 PK777

PM021 PM254 PN023 PN026–PN027

PN040 PN042–PN043

4 PW034–PW035 PW061

9 PP927

STA SUPPLIES PTE. LTD. (SSP)

14 PQ040–PQ041

STAR (EQA)

13 PN512
 

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ALERT ALERT

STAR AIR (SGY)

2 PN033

STAR UP S.A. (SRU)

2 PJ115 PK921 PL611

STEWART INDUSTRIES INT'L (SDT)

13 PN473

2 PK905 PK926 PK935 PM251

SUNDOWNER OKLAHOMA CITY LLC (SDO)

16 PW313

SWIFT AIR (SWF)

14 PM392

3 PP352 PP847 PP862 PP948

SWIFT AIR LLC (SFW)

16 PV042–PV043

4 PW563

TAAG (ANGOLA AIRLINES) (ANG)

1 PY162

2 PK661 PK664–PK666

TACA INTERNATIONAL AIRLINES (TAC)

2 PL737 PN420

TAF LINHAS AEREAS (TFL)

2 PL404 PN160

TAILWIND AIRLINES (TWK)

11 PW243–PW244

TAROM - ROMANIAN AIR TRANSPORT (TRM)

10 PQ931–PQ932

TEEBAH AIRLINES (EBH)

2 PK601 PK605 PN028

THAI AIRASIA (THA)

3 PP411–PP412 PP676–PP677 PP684 PP686–PP687

THAI AIRWAYS INTERNATIONAL (TII)

16 PW164–PW167

4 PW161–PW162 PW594

THE MOURITZEN FAMILY TRUST (MRZ)

1 PY191

THE PEGASUS AVIATION COMPANY (PEG)

2 PK285
 

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ALERT ALERT

TITAN AIRWAYS (TIU)

14 PM387 PP505

9 PS636–PS637

TNT AIRWAYS (TNB)

14 PP391 PP433 PP845

3 PP384 PP413–PP414 PP472 PP474

PP702 PP711

TRAFIC (TFI)

1 PY056

TRANS AIR CONGO (TSC)

2 PK562 PK763

TRANSAERO AIRLINES (TRX)

14 PP966

16 PW040 PW120

17 PT046 PT049 PT052 PT104–PT105

2 PK451 PK773 PK779

3 PP963

4 PW024 PW113–PW114

TRANSMILE AIR SERVICES (TML)

1 PY151

13 PN474

2 PN472

TRAVEL SERVICE (TSF)

12 PT436

17 PT432

TRIGANA AIR (TGN)

2 PL504

TRITON AVIATION SERVICES (TIA)

2 PK677 PL408 PL410–PL411 PL770

PN101 PN105–PN106 PN108

TUIFLY (HAP)

4 PW513

TUNISAIR (TUN)

17 PT641–PT642

TURKISH AIRLINES (THY)

16 PM552 PM559–PM560 PM562–PM564 PW049–PW050

TURKMENISTAN AIRLINES (TUE)

9 PQ265 PQ801–PQ802

UETAAM (MXA)

2 PN041
 

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ALERT ALERT

UKRAINE INTERNATIONAL AIRLINES (UKR)

14 PM382 PQ251

16 PM551 PM554 PM561 PW701–PW702

PW742

17 PT043 PT048 PT055 PT059

PT511–PT512

UNITED AIR LINES (UAL)

14 PQ111–PQ112 PQ114–PQ115 PQ118 PQ121–PQ122

PQ125–PQ131 PQ133–PQ140 PQ146–PQ151 PQ164–PQ167

PQ169–PQ179 PQ181–PQ183 PQ185–PQ186

15 PQ201–PQ202

17 PT384 PT386–PT387 PT390–PT395 PT398–PT399

PT402–PT419 PT422–PT423

3 PQ101–PQ110

UNIVERSAL ASSET MANAGEMENT (UAM)

2 PM056 PM059 PM061

UNKNOWN CUSTOMER (UNZ)

17 PT185

2 PK111 PK114 PK118–PK119 PK675

US AIR FORCE (USF)

2 PJ202 PJ206 PJ211 PJ213–PJ219

US AIRWAYS (USA)

14 PP032 PP036–PP038 PP047–PP054 PP185–PP187

PP194–PP195 PP197 PP428 PP439

16 PV044–PV055

2 PL081 PL560

3 PP005 PP007 PP014–PP015 PP024–PP027

PP029–PP030 PP183–PP184 PP401 PP417

PP834 PP891 PP893 PP895

PP901 PP931–PP934

4 PV001–PV010 PV012–PV022 PV025–PV030 PV033–PV040

9 PS669

UT FINANCE CORPORATION (ZZJ)

14 PQ153

VASP AIRLINES (VSP)

2 PK581

9 PP512

VIKING AIRLINES (VAI)

9 PQ291

VISION AIR (VIL)

2 PK863

3 PP685
 

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ALERT ALERT

VIVA AEROBUS (VIV)

14 PP041 PP427

3 PP009–PP010 PP013 PP023 PP473

VOLVO AERO SERVICES (AGD)

3 PP381

WEBJET LINHAS AEREAS LTDA. (WJL)

14 PP839 PP906–PP907 PQ159 PQ188

15 PQ256–PQ257

9 PQ260–PQ261 PQ266–PQ267 PS603

WELLS FARGO (FSB)

9 PP513

WEST DOVER LLC (WDR)

3 PP415

WESTAIR CARGO AIRLINES (WCO)

1 PY037

WESTSTAR AVIATION (WSE)

2 PK565

WILMINGTON TRUST COMPANY (WBT)

14 PP035 PP042 PP045

WINGS OF LEBANON S.A.L. (WGL)

2 PN141

XSTRATA CANADA CORPORATION (NAD)

1 PY612

XTRA AIRWAYS (CIN)

16 PW761

4 PW117

ZAMBIAN AIRWAYS (MBA)

2 PK220 PL109

ZASA (CZA)

2 PL735

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

PG584–PG586 2

PH001 2

PH011–PH013 2

PH021–PH024 2

PH743 2
 

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ALERT ALERT

PJ003–PJ009 2

PJ105–PJ119 2

PJ201–PJ219 2

PJ301–PJ302 16

PJ551 11

PJ552 7

PK026–PK029 2

PK041–PK053 2

PK061–PK070 2

PK081–PK082 2

PK091–PK099 2

PK101–PK103 2

PK111–PK120 2

PK141–PK146 2

PK201–PK204 2

PK211–PK223 2

PK231–PK241 2

PK251–PK258 2

PK271–PK274 2

PK281–PK289 2

PK291 2

PK301–PK318 2

PK341 2

PK351–PK361 2

PK391 2

PK431–PK433 2

PK451–PK452 2

PK461–PK469 2

PK495 2

PK501–PK504 2

PK511–PK515 2

PK519 2

PK521–PK527 2

PK528 13

PK541–PK565 2

PK581 2

PK591–PK599 2

PK601–PK617 2

PK621–PK637 2

Variable Group
 

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ALERT ALERT

PK641–PK642 2

PK661–PK666 2

PK671–PK681 2

PK691–PK697 2

PK711–PK716 2

PK731–PK765 2

PK771–PK779 2

PK801–PK804 2

PK819–PK827 2

PK830 2

PK861–PK863 2

PK871–PK874 2

PK881–PK884 2

PK901–PK938 2

PK971–PK974 2

PL001–PL028 2

PL061 2

PL081 2

PL101–PL113 2

PL151 2

PL171–PL172 2

PL201–PL203 2

PL221 2

PL401–PL417 2

PL421 2

PL441 2

PL451–PL456 2

PL471 2

PL491 2

PL501–PL506 2

PL551–PL562 2

PL581 2

PL601–PL603 2

PL611 2

PL621–PL625 2

PL626 13

PL631–PL632 2

PL717–PL746 2

PL747 13

Variable Group
 

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ALERT ALERT

PL756 2

PL758 2

PL761–PL770 2

PL781–PL788 2

PL793 2

PM001–PM006 2

PM016–PM017 2

PM021–PM023 2

PM051–PM066 2

PM101–PM119 2

PM141–PM142 2

PM171 2

PM181 2

PM251–PM255 2

PM281–PM283 2

PM381–PM392 14

PM393–PM395 15

PM396–PM399 9

PM401–PM417 9

PM541 9

PM542 10

PM543–PM547 6

PM551–PM564 16

PN001–PN002 2

PN021–PN043 2

PN081–PN086 2

PN101–PN117 2

PN131–PN163 2

PN401–PN420 2

PN431–PN433 2

PN451–PN456 2

PN471–PN472 2

PN473–PN474 13

PN481 2

PN491–PN492 2

PN493 13

PN501 2

PN502 13

PN511–PN512 13

Variable Group
 

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ALERT ALERT

PN521 13

PP001–PP031 3

PP032–PP054 14

PP101–PP126 3

PP127–PP148 21

PP149–PP160 18

PP161–PP168 3

PP169 14

PP181–PP184 3

PP185–PP199 14

PP201–PP204 3

PP205 14

PP221 3

PP231–PP243 3

PP281–PP286 3

PP301–PP305 3

PP351–PP352 3

PP353 14

PP376–PP384 3

PP391–PP393 14

PP401–PP424 3

PP425–PP440 14

PP471–PP475 3

PP501–PP504 3

PP505–PP510 14

PP511–PP517 9

PP521–PP522 3

PP631–PP634 3

PP651–PP652 3

PP671–PP699 3

PP701–PP720 3

PP721–PP733 14

PP771–PP777 3

PP778–PP779 14

PP801–PP804 3

PP805–PP808 14

PP821–PP827 3

PP831–PP836 3

PP837–PP845 14

Variable Group
 

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ALERT ALERT

PP846–PP848 3

PP851 3

PP852 14

PP861–PP870 3

PP871–PP873 14

PP874–PP875 9

PP891–PP899 3

PP901–PP905 3

PP906–PP924 14

PP925 15

PP926–PP930 9

PP931–PP934 3

PP935–PP936 14

PP946–PP948 3

PP951–PP952 14

PP961–PP965 3

PP966–PP967 14

PP981–PP982 3

PP983–PP987 14

PP988 15

PP989–PP990 9

PP991 3

PP993 14

PQ001–PQ012 3

PQ013–PQ016 14

PQ026–PQ037 3

PQ038–PQ041 14

PQ051–PQ061 3

PQ062–PQ073 14

PQ074–PQ085 9

PQ086 3

PQ087–PQ092 14

PQ101–PQ110 3

PQ111–PQ198 14

PQ199 15

PQ201–PQ202 15

PQ221–PQ229 14

PQ230 9

PQ231–PQ236 14

Variable Group
 

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ALERT ALERT

PQ237 9

PQ241–PQ243 14

PQ251–PQ255 14

PQ256–PQ257 15

PQ258–PQ267 9

PQ281–PQ286 14

PQ287 15

PQ288–PQ296 9

PQ301–PQ305 14

PQ306–PQ307 9

PQ331–PQ332 14

PQ341–PQ344 9

PQ361–PQ369 9

PQ401–PQ406 9

PQ407 10

PQ408 6

PQ411–PQ413 9

PQ421 9

PQ471–PQ472 10

PQ473 6

PQ479–PQ480 10

PQ481 9

PQ486 9

PQ487 10

PQ491–PQ493 9

PQ771 9

PQ791–PQ793 9

PQ801–PQ803 9

PQ804–PQ805 10

PQ931–PQ932 10

PS601–PS616 9

PS631 9

PS636–PS638 9

PS641–PS642 14

PS643–PS644 9

PS651–PS657 9

PS666–PS668 14

PS669 9

PS691–PS692 9

Variable Group
 

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ALERT ALERT

PS701–PS703 9

PS751–PS762 18

PT001–PT011 17

PT021–PT023 5

PT024–PT027 17

PT028 12

PT041–PT059 17

PT060–PT063 12

PT064 8

PT101 5

PT102–PT105 17

PT121–PT123 5

PT124–PT125 17

PT146 5

PT147–PT148 17

PT161–PT170 17

PT181–PT182 5

PT183–PT187 17

PT211–PT214 5

PT215–PT220 17

PT295 5

PT301–PT303 17

PT304–PT306 12

PT331–PT360 17

PT381–PT399 17

PT401–PT435 17

PT436–PT438 12

PT501–PT512 17

PT561–PT565 17

PT581–PT584 17

PT611–PT621 17

PT641–PT642 17

PT651–PT655 17

PT671–PT672 17

PT701–PT703 17

PU001–PU007 19

PU008–PU025 20

PV001–PV040 4

PV041–PV055 16

Variable Group
 

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ALERT ALERT

PV201–PV202 16

PV203 11

PV231–PV237 16

PV271–PV272 16

PV281–PV282 16

PV283 11

PW001–PW036 4

PW037–PW050 16

PW051 4

PW052–PW054 16

PW061–PW063 4

PW064–PW068 16

PW072 16

PW091–PW093 4

PW094 16

PW101–PW102 16

PW106 16

PW111–PW117 4

PW118–PW120 16

PW156–PW157 16

PW161–PW162 4

PW163–PW167 16

PW201–PW223 16

PW224–PW230 11

PW231–PW240 16

PW241–PW244 11

PW245 7

PW261 16

PW265–PW268 16

PW278 11

PW281 16

PW282–PW284 7

PW293 16

PW296 16

PW301–PW323 16

PW324–PW327 11

PW461–PW467 11

PW501–PW503 4

PW504 16

Variable Group
 

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ALERT ALERT

PW511–PW518 4

PW519–PW520 16

PW526 16

PW531–PW535 4

PW536–PW545 16

PW546 11

PW556 16

PW557 11

PW561–PW563 4

PW564 16

PW571–PW573 4

PW574–PW576 16

PW591–PW594 4

PW595–PW596 16

PW611–PW615 4

PW616–PW620 16

PW631–PW632 4

PW633–PW634 16

PW661 4

PW662 16

PW681–PW683 16

PW701–PW702 16

PW711–PW717 16

PW741–PW742 16

PW761 16

PW771 16

PY022 1

PY036–PY037 1

PY046–PY048 1

PY051–PY053 1

PY056–PY057 1

PY101–PY103 1

PY111–PY113 1

PY131–PY135 1

PY141–PY143 1

PY151–PY154 1

PY156–PY157 1

PY161–PY162 1

PY166 1

Variable Group
 

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ALERT ALERT

2. Spares Affected

None.

PY191 1

PY201 1

PY221–PY222 1

PY231 1

PY241–PY244 1

PY270–PY275 1

PY281 1

PY286 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

Variable Group
 

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ALERT ALERT

B. Concurrent Requirements

None

C. Reason

Accomplishment of the inspections, modifications and repairs given in this service bulletin will ensure 

that fuselage skin cracks at chem-mill lines are found and repaired. This action is necessary to find 

and fix fatigue cracking of the skin panels which could result in sudden fracture and failure of the skin 

panels of the fuselage, and consequent rapid decompression of the airplane.

Operators have reported horizontal cracks along the edges of the chem-milled pockets in the skin at 

S-12 in the bay forward of body station STA 520 and just above the S-4, S-10, and S-14 lap joints. 

Operators have reported 37 horizontal chem-mill line cracks of the fuselage crown skin at non-lap-joint 

areas. Skin inspection maps as given in this service bulletin present areas that need to be inspected 

for crown chem-mill line cracks. Fuselage skin cracks at tear strap attachments to the fuselage skin 

have also been reported by some operators. The chem-mill cracks were up to 8 inches long, and on 

at least 4 of the airplanes multiple adjacent bays were found to be cracked along the same stringer. 

These airplanes had flown 23,425 to 64,420 flight-cycles.

Operators have reported numerous horizontal skin cracks along the edges of the chem-milled pockets 

in the skin below S-14, and section 41. The cracks were up to 7.25 inches long. These airplanes had 

flown 22,786 - 80,113 flight-cycles.

Operators have also reported 13 circumferential cracks along the vertical chem-mill steps of the 

fuselage skin next to the STA 360, STA 727 and STA 908 Butt-Joints. The most critical situation was 

four in-line cracks in multiple adjacent bays on the aft side of the STA 908 butt joint from S-3R to S7R. Crack lengths varied from 0.75 inch to 4 inches. These airplanes had flown 45,100 flight cycles 

(65,200 flight hours) to 67,400 flight cycles (70,800 flight hours).

Analysis by Boeing indicates that these cracks are caused by fatigue due to tension stresses plus local 

bending stresses at the edge of chem-milled pockets or bonded skin doublers. Boeing did a cost 

benefit analysis on the changes given in this service bulletin. Refer to Appendix A for the analysis.

Boeing Service Related Problem (SRP) 737-SRP-53-0281 is related to this service bulletin.

Revision 1 was sent to:

— Clarify in the Summary, Reason and Description sections that cracks were reported at stringer 

12.

— Move S-12 data from the second table to the first table in the Reason section.

— Add the Preventive Modification to the Manpower table.

— Add Cost Benefit Analysis and Weight and Balance information.

— Add SRM 53-30-03; NDT 53-30-09; SIIA 737-242 and installation drawings to the Reference 

section.

— Revise the Figures referenced in Parts and Materials Supplied by Operator and added the 

material required to perform the Preventive Modification.

— Delete the Group 7 inspection requirements from the Part 1 Work Instructions.

— Add reference to AMM for fairing removal in Part 3 Lower Lobe Area Skin Inspection.

— Add Part 6 Preventive Modification requirements for Groups 3, 5, 6, and 8 to the Work 

Instructions.

— Add Preventive Modification to Figure 1 and changed the reference of Fig. 3-10 to Fig. 3-9.

— Add the reference of 737-300 to Figure 5, 737-400 to Figures 6 and 14, and 737-500 to Figures 

7 and 15.
 

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ALERT ALERT

— Delete the inspection requirements at S-4 and S-10 locations in Figure 8 on Group 6 airplanes.

— Delete the original Figure 9, which was the inspection of group 7 airplanes.

— Revise the old Figure 10 to the new Figure 9 and deleted the inspection of S-4 and S-10 

locations.

— Add the Figure 10 Preventive Modification.

— Revise 53-00-00 to 51-00-00 in Figure 16 notes c, e, f, g and Figure 20 notes a, c, and d.Boeing 

did a cost benefit analysis on the changes given in this service bulletin. Refer to Appendix A for 

the analysis.

Revision 2 was sent to tell operators of modified inspection thresholds, modified inspection intervals, 

new inspection areas and to remove inspections from areas that have solid skins. Also additional NDT 

inspection methods have been added.

Changes in Revision 2 of this service bulletin include: -

— Subject: The title is changed to include "chem-mill line crack".

— Background and Reason: Have been updated to include new data. 

— Action and Description: Have been updated to include new inspection locations and inspection 

methods.

— Effectivity: Have been split into new groups.

— Compliance Section: Updated the Compliance information.

— Approval: Have been updated to include AD requirements.

— Manpower: Have been updated to include new inspection areas.

— Weight and Balance: Have been updated to remove Figure 16 and Figure 20 skin repairs.

— References: Have been updated.

— Work instructions: Have been updated to included new inspection areas, remove and add new 

skin repairs.

— FIGURE 1 and FIGURE 2: Logic diagrams have been deleted.

— FIGURE 3, FIGURE 4, FIGURE 5, FIGURE 6, FIGURE 7 and FIGURE 10: Have been updated 

to add new inspections.

— FIGURE 8, FIGURE 9, FIGURE 16, FIGURE 19 and FIGURE 20: Have been deleted.

— FIGURE 11, FIGURE 12, FIGURE 13, FIGURE 14 and FIGURE 15: Have been updated to 

remove inspection areas.

— FIGURE 21 AND FIGURE 22: Adds NDT inspections between STA 259.5 and STA 360.

— FIGURE 23: Adds NDT inspection of the tear straps.

— FIGURE 24: Adds a skin repair for chem-mill line cracks at stringer 12.

— FIGURE 25: Adds a vertical crack inspections at STA 312, STA 360, STA 460, STA 500C, STA 

540, STA 727, STA 727G and STA 908.

— FIGURE 26: Adds a skin inspection on the left side between STA 360 and STA 540.

— FIGURE 27: Adds a skin inspection on the right side between STA 360 and STA 540.

— FIGURE 28: Adds a skin inspection on the right side between STA 303 and STA 320 and 

between STA 344 and STA 352.

— FIGURE 29: Adds skin inspections to the lower lobe area.

— FIGURE 30: Adds a typical internal skin inspection.

— FIGURE 31: Adds a skin inspection on the left side between STA 490 and STA 500.

— FIGURE 32: Adds a skin inspection on the left side between STA 727 and STA 1016.

— FIGURE 33: Adds a skin inspection on the left side between STA 360 and STA 540 and between 

STA 727 and STA 1016.

— FIGURE 34: Adds skin inspections on the left and right side between STA 360 and STA 540.

— FIGURE 35: Adds skin inspections on the left and right side between STA 727 and STA 1016.

— FIGURE 36 and FIGURE 37: Adds a skin inspection on the left side between STA 360 and STA 

540.

— FIGURE 38: Adds a time limited skin repair for chem-mill cracks not located at lap joints.
 

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ALERT ALERT

— FIGURE 39: Adds a vertical crack inspections at STA 312, STA 360, STA 460, STA 500C, STA 

540, STA 727 and STA 908.

— FIGURE 40: Adds a vertical crack inspections at STA 312, STA 360, STA 460, STA 540, STA 

727 and STA 908.

— FIGURE 41: Provides skin inspections for the lower lobe area.

— FIGURES 42, 43 and 44: Provide window belt inspections previously in Figures 5, 6 and 7 

respectively.

— FIGURE 45: Provides crown area skin inspections for Groups 18 and 21.

— FIGURE 46: Provides crown area skin inspections for Groups 19 and 20.

— FIGURE 47: Provides inspection for vertical cracks at chem-mill lines of fuselage skin for Groups 

18 through 21.

— FIGURE 48: Provides post repair inspection for the skin chem-mill crack repair at stringer 12.

— FIGURE 49: Adds a vertical crack inspections at STA 312, STA 360, STA 460, STA 500C, STA 

540, STA 727 and STA 908.

Revision 3 is sent to add 737-400 airplanes to this service bulletin effectivity that were incorrectly 

removed in revision 2 of this service bulletin.

Changes in Revision 3 of this service bulletin include: -

— Paragraph 1.A., Effectivity: Airplanes PM551-PM557, PM559-PM563, PW037-PW050, PW052-

PW054, PW094, PW106, PW156-PW157, PW261, PW265-PW268, PW281, PW293, PW296, 

PW504, PW519-PW520, PW526, PW536-PW545, PW556, PW564, PW575-PW576, PW595-

PW596, PW616, PW633-PW634, PW662, PW681-PW683, PW701-PW702, PW711-PW717, 

PW741-PW742, PW761, PW771 are added to the Group 16 effectivity. 

— Summary Compliance: FAA Airworthiness Directive is added.

— Paragraph 1.E.,Compliance: FAA Airworthiness Directive is added. Compliance information and 

SRM reference is updated. Damage tolerance based structural inspection statement is moved to 

Paragraph 1.K. Publications Affected.

— Paragraph 1.F., Approval: Approval information is updated.

— Paragraph 1.G., Manpower: Manpower tables for Group 6, Group 7 and Group 8 is updated.

— Paragraph 1.H.,Weight and Balance Changes: Weight and balance information is updated.

— Paragraph 1.J., References, 1. Existing Data: FAA Airworthiness Directive is added and SRM 

reference is updated.

— Paragraph 2.C.2. Parts and Material Supplied by the Operator: Brackets are added to the ends 

of fastener part numbers.

— Paragraph 3.B., Work Instructions, 1 Part 1, 5 Part 5 and 6 Part 6: SRM reference is updated.

— Paragraph 3.B., Work Instructions, 6 Part 6 a.,(1),(a),4),{d}: A note is added to clarify staggered 

fasteners locations common to the time limited repair.

— FIGURE 17 and FIGURE 18: The fastener pattern has been changed to stagger fasteners 

common to the tear strap.

— FIGURE 24: Brackets are added to the ends of fastener part numbers and SRM reference is 

updated.

— FIGURE 35: A new inspection area is added.
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

D. Description

On all affected airplanes, do a detailed inspection and eddy current inspection of the fuselage skin for 

cracks at S-12 in the bay forward of STA 520, just above the S-4, S-10, and S-14 lap joints from STA 

360 to STA 1016, at S-15 between STA 360 and STA 540, aft of STA 727 and other locations of known 

cracking identified in this service bulletin. Skin inspection maps as given in this service bulletin indicate 

additional areas that need to be inspected for possible signs of chem-mill line cracks at the fuselage 

crown. 

On all affected airplanes, do a High Frequency Eddy current (HFEC) Sliding Probe inspection of the 

tear strap attachments to the fuselage skin for signs of cracks at the locations as given in this service 

bulletin.

On all affected airplanes, do detailed inspection of the crown area skins from S-10L to S-10R between 

STA 360 and STA 1016 for indications of horizontal chem-mill line cracks.

On all affected airplanes, do a detailed inspection of the lower lobe skins for cracks from S-14L to 

S-14R, between STA 360 and STA 1016 and in Section 41 as given in this service bulletin. Skin 

inspection maps as given in this service bulletin indicate additional areas that need to be inspected for 

possible signs of chem-mill line cracks at the fuselage lower lobe and section 41.

Also, on all affected airplanes do a detailed inspection and eddy current inspections of the fuselage 

crown skin (from S-10L to S-10R) for vertical cracks just forward and aft of STA 360, STA 500C, STA 

540, STA 727, STA 727G, and STA 908, as applicable depending on the model, along the chem-mill 

lines as provided in this Service Bulletin.

If any crack is found, repair as given in this service bulletin, or contact Boeing for repair instructions 

and install the repair.

Revision 2 - More work is necessary on airplanes inspected as given in revision 1, or original issue of 

this service bulletin. Additional areas have been identified to be inspected for vertical and horizontal 

chem-mill line cracks. Inspection areas are clearly identified to facilitate compliance.

Revision 3 - No more work is necessary on airplanes inspected as shown in Revision 2 of this service 

bulletin.
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directives 2004-18-06 and 98-11-04 R1 are 

related to this service bulletin.

Accomplishment of Boeing service bulletin (SB) 737-53A1177 Revision 2, 3, 4, 5 or 6 terminates 

inspections under the repair area only.

On all airplanes: Accomplishment of SB 737-53A1177 does not terminate inspection requirements 

above S-10 lap joints on the left and right side from STA 540 to STA 727. 

Group 1-5, 9-21: Table 1 - Skin Inspection Requirements - Fuselage Crown Area And Other Areas Of Known

Cracks - Horizontal Chem-Mill Line and Skin Cracks at the Tear Strap Tabs

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)

Areas previously 

inspected as given in 

the original issue or 

revision 1 of this 

service bulletin. 

Do external detailed 

inspection and eddy current 

inspection for any crack as 

given in Accomplishment 

Instruction 3.B.1. Part 1 - 

Crown Area Skin 

Inspection.(c) (f)

Within 4,500 flight cycles from the 

accomplishment of the last 

inspection as given in the original 

issue or revision 1 of this service 

bulletin.

4,500 Flight 

Cycles.(a)(b)

Areas that have not 

been inspected as 

given in the original 

issue or revision 1 of 

this service bulletin.

Do external detailed 

inspection and eddy current 

inspection for any crack as 

given in Accomplishment 

Instruction 3.B.1. Part 1 - 

Crown Area Skin 

Inspection.(c) (f)

Before 35,000 total airplane flight 

cycles.

4,500 Flight 

Cycles.(b)

Any crack found in the 

fuselage skin.

Do the repair as given in 

Accomplishment Instruction 

3.B.5. Part 5 - Permanent 

Repair. (d) (e)

or 

Do the repair as given in 

Accomplishment Instruction 

3.B.6. Part 6 - Time Limited 

Repair.(d)

Before further flight. -

Time Limited Repair is 

installed and is located 

at lap splice.

Do an external detailed 

inspection of the repaired 

area for any cracks and 

loose, missing or damaged 

fasteners as given in 

Accomplishment Instruction 

3.B.6.a.(1).(a).3).

Within 3,000 flight cycles from the 

time the repair was installed.

3,000 flight 

cycles. (e)
 

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ALERT ALERT

Time Limited Repair is 

installed and is not 

located at lap splice.

Do an external detailed 

inspection of the repaired 

area for any cracks and 

loose, missing or damaged 

fasteners as given in 

Accomplishment Instruction 

3.B.6.a.(2).(c).

Within 3,000 flight cycles from the 

time the repair was installed.

3,000 flight 

cycles. (e)

Damaged or loose 

fasteners found.

Replace any damaged or 

loose fasteners.

Before further flight. -

Crack found at a Time 

Limited Repair.

Contact Boeing for repair 

instructions and install the 

repair.

Before further flight. -

Time Limited Repair is 

installed and is located 

at lap splice.

Install permanent repair as 

given in Accomplishment 

Instruction 3.B.6.a.(1).(a).4).

(g)

Within 6,000 

flight cycles 

from the time 

the repair was 

installed.

Within 1,000 flight 

cycles from the 

date of revision 3 

of this service 

bulletin.

-

Time Limited Repair is 

installed and is not 

located at lap splice.

Install permanent repair as 

given in Accomplishment 

Instruction 3.B.6.a.(2).(d).

(g)

Within 6,000 

flight cycles 

from the time 

the repair was 

installed.

Within 1,000 flight 

cycles from the 

date of revision 3 

of this service 

bulletin.

-

(a) Areas that have been inspected according to the previous releases of this service bulletin need to have 

repeat inspections according to the requirements of this table.

(b) For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R it is optional to do general 

visual inspections at 1,000 flight cycle intervals in lieu of the detailed inspections.

(c) It is not required to inspect the chem-mill steps under existing external repair doublers provided either:

1. The installed repair was approved by the FAA or by a Boeing company authorized representative who 

was authorized by the FAA to make such findings, and the installed repair extends a minimum of three 

rows of fasteners on each side of the chem-mill line, Or

2. The doubler extends a minimum of 2 rows beyond the chem-mill step and was accomplished in 

accordance with Figure 42 or 48 of 737-100/200 SRM 53-30-3, or Repair 30 or 31 of 737-300 SRM 

53-00-01, 737-400 SRM 53-00-01 or 737-500 SRM 53-00-01. Inspections are not required directly under 

the repair doubler. Do the inspections required in areas adjacent to the doubler.

If the repair does not meet the above conditions, then inspect the chem-mill step internally in the area 

covered by the doubler as given in 737 NDT, Part 6, 53-30-20. 

(d) If the repair given in Accomplishment Instructions, PART 5 or PART 6 are not applicable, contact Boeing 

for repair instructions and install repair before further flight.

Group 1-5, 9-21: Table 1 - Skin Inspection Requirements - Fuselage Crown Area And Other Areas Of Known

Cracks - Horizontal Chem-Mill Line and Skin Cracks at the Tear Strap Tabs

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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ALERT ALERT

(e) Accomplishment of the Part 5 - Permanent Repair is terminating action for repeat inspections under the 

repair area only.

(f) It is not required to inspect the skin at the tear strap tabs under existing external repair doublers provided 

either:

1. The installed repair was approved by the FAA or by a Boeing company authorized representative who 

was authorized by the FAA to make such findings, and the installed repair extends a minimum of three 

rows of fasteners above and below tear strap tab fasteners that require inspection, Or

2. The doubler extends a minimum of 2 rows above and below the tear strap tab fasteners that require 

inspection, and the repair was accomplished in accordance with Figure 48 of 737-100/200 SRM 53-30-3, 

or Repair 31 of 737-300 SRM 53-00-01, 737-400 SRM 53-00-01 or 737-500 SRM 53-00-01. Inspections 

are not required directly under the repair doubler. Do the inspections required in areas adjacent to the 

doubler.

If the repair does not meet the above conditions, then inspect the skin under the repair doubler at tear 

strap tab using LFEC as given in 737 NDT, Part 6, 53-30-00 Figure 5.

(g) Accomplishment of the permanent repair is terminating action for repeat inspections under the repair area 

only.

Group 3, 9-10, 14-15, 18, 21: Table 2 - Skin Inspection Requirements - Fuselage Window Belt Area Between

STA 500D to STA 520 and Stringer S-10 to S-14 - Horizontal Chem-Mill Line Cracks

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)

Areas previously 

inspected as given in 

the original issue or 

revision 1 of this service 

bulletin. 

Do external detailed 

inspection and eddy 

current inspection as 

given in Accomplishment 

Instruction 3.B.2.a.

(a) (c)

Within 4,500 flight cycles from the 

accomplishment of the last 

inspection given in the original issue 

or revision 1 of this service bulletin.

4,500 Flight 

Cycles.

Areas that have not 

been inspected as 

given in the original 

issue or revision 1 of 

this service bulletin. 

Do external detailed 

inspection and eddy 

current inspection as 

given in Accomplishment 

Instruction 3.B.2.a.

(a) (c)

Before 25,000 

total airplane 

flight cycles.

Within 4,500 flight 

cycles from the 

date of revision 3 

of this service 

bulletin

4,500 Flight 

Cycles.

Any crack found in the 

fuselage skin.

Do the repair as given in 

Accomplishment 

Instruction 3.B.8. Part 8 - 

Skin Chem-Mill Line 

Crack At Stringer 12 - 

Repair Instructions.

(b) (c)

Before further flight. -

Group 1-5, 9-21: Table 1 - Skin Inspection Requirements - Fuselage Crown Area And Other Areas Of Known

Cracks - Horizontal Chem-Mill Line and Skin Cracks at the Tear Strap Tabs

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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ALERT ALERT

(a) It is not required to inspect areas under existing external repair doublers provided the installed repair was 

approved by the FAA or by a Boeing company authorized representative who was authorized by the FAA to 

make such findings, and the installed repair extends a minimum of three rows of fasteners on each side of the 

chem-mill line.

1. If the repair does not meet the above conditions, then inspect the chem-mill step internally in the area 

covered by the doubler as given in 737 NDT, Part 6, 53-30-20. 

(b) If the repair given in Accomplishment Instructions, PART 8 is not applicable, contact Boeing for repair 

instructions and install repair before further flight.

(c) Accomplishment of the preventive modification as given in Part 7 or the repair as given in Part 8 terminates the inspection requirements for the chem-mill steps common to stringer 12 only. All other chem-mill 

inspections in this area must continue.

Group 4, 11, 16: Table 3 - Skin Inspection Requirements - Fuselage Window Belt Area Between STA 500E to

STA 500F and STA 500G to STA 520 and Stringer S-10 to S-14 - Horizontal Chem-Mill Line Cracks

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)

All Airplanes Do external detailed 

inspection and eddy 

current inspection as 

given in Accomplishment 

Instruction 3.B.2.b.

(a)

Before 25,000 

total airplane 

flight cycles.

Within 4,500 

flight cycles from 

the date of 

revision 3 of this 

service bulletin

4,500 Flight 

Cycles.

Any crack found in the 

fuselage skin.

Contact Boeing for repair 

instructions and install 

repair.

Before further flight. -

(a) It is not required to inspect areas under existing external repair doublers provided he installed repair was 

approved by the FAA or by a Boeing company authorized representative who was authorized by the FAA to 

make such findings, and the installed repair extends a minimum of three rows of fasteners on each side of 

the chem-mill line.

1. If the repair does not meet the above conditions, then inspect the chem-mill step internally in the area 

covered by the doubler as given in 737 NDT, Part 6, 53-30-20. 

Group 3, 9-10, 14-15, 18, 21: Table 2 - Skin Inspection Requirements - Fuselage Window Belt Area Between

STA 500D to STA 520 and Stringer S-10 to S-14 - Horizontal Chem-Mill Line Cracks

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Group 5, 12, 17, 19-20: Table 4 - Skin Inspection Requirements - Fuselage Window Belt Area Between STA

482B to STA 520 and Stringer S-10 to S-14 - Horizontal Chem-Mill Line Cracks

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)

Areas previously 

inspected as given in 

the original issue or 

revision 1 of this 

service bulletin. 

Do external detailed 

inspection and eddy 

current inspection as 

given in Accomplishment 

Instruction 3.B.2.c.

(a)

Within 4,500 flight cycles from the 

accomplishment of the last inspection 

given in the original issue or revision 

1 of this service bulletin.

4,500 Flight 

Cycles.

Areas that have not 

been inspected as 

given in the original 

issue or revision 1 of 

this service bulletin.

Do external detailed 

inspection and eddy 

current inspection as 

given in Accomplishment 

Instruction 3.B.2.c

(a)

Before 25,000 

total airplane flight 

cycles.

Within 4,500 flight 

cycles from the 

date of revision 3 

of this service 

bulletin.

4,500 Flight 

Cycles.

Any crack found in the 

fuselage skin.

Do the repair as given in 

Accomplishment 

Instruction 3.B.8. Part 8 - 

Skin Chem-Mill Line 

Crack At Stringer 12 - 

Repair Instructions.

(b) (c)

Before further flight. -

(a) It is not required to inspect areas under existing external repair doublers provided the installed repair was 

approved by the FAA or by a Boeing company authorized representative who was authorized by the FAA to 

make such findings, and the installed repair extends a minimum of three rows of fasteners on each side of 

the chem-mill line.

1. If the repair does not meet the above conditions, then inspect the chem-mill step internally in the area 

covered by the doubler as given in 737 NDT, Part 6, 53-30-20. 

(b) If the repair given in Accomplishment Instructions, PART 8 is not applicable, contact Boeing for repair 

instructions and install repair before further flight.

(c) Accomplishment of Part 8 repair terminates the inspection requirements for the chem-mill steps common 

to the stringer 12 only. All other chem-mill inspections in this area must continue.
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Group 1-5, 9-21: Table 5 - Skin Inspection Requirements - Vertical Chem-Mill Line Cracks - Fuselage Butt

Joints in the Crown Area And Other Areas Of Known Cracks

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)

All airplanes. Do external detailed 

inspection and eddy current 

inspection for any crack as 

given in Accomplishment 

Instruction 3.B.3. Part 3 

Vertical Crack Inspection.

(a)

Before 55,000 

total airplane 

flight cycles or 

55,000 total 

airplane flight 

hours 

whichever 

occurs first.

Within 4,500 

flight cycles or 

4,500 flight 

hours 

whichever 

occurs first from 

the date of 

revision 3 of 

this service 

bulletin.

4,500 Flight 

Cycles or 4,500 

flight hours 

whichever occurs 

first.

Any crack found in the 

fuselage skin.

Do the repair as given in as 

given in Accomplishment 

Instruction 3.B.5.Part 5 - 

Permanent Repair.

(b) (c)

Before further flight. -

(a) It is not required to inspect areas under existing external repair doublers provided either:

1. The installed repair was approved by the FAA or by a Boeing company authorized representative who 

was authorized by the FAA to make such findings, and the installed repair extends a minimum of three 

rows of fasteners on each side of the chem-mill line Or

2. The doubler extends a minimum of 2 rows beyond the chem-mill step and was accomplished in 

accordance with 737-100/200 SRM 53-30-3 Figure 48, or Repair 31 of 737-300 SRM 53-00-01, 737-400 

SRM 53-00-01 or 737-500 SRM 53-00-01. Do the inspections required in areas adjacent to the doubler.

 If the repair does not meet the above conditions, then inspect the chem-mill step internally in the area 

covered by the doubler as given in 737 NDT, Part 6, 53-30-20. 

(b) If the repairs given in Accomplishment Instructions, PART 5 are not applicable, contact Boeing for repair 

instructions and install repair before further flight.

(c) Accomplishment of the Part 5 - Permanent Repair is terminating action for repeat inspections under the 

repair area only.
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Group 1-21: Table 6 - Skin Inspection Requirements - Fuselage Lower Lobe Area and Section 41 - Horizontal

Chem-Mill Line Cracks

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)

Areas that require 

detailed 

inspections as 

given in this 

service bulletin.

Do external detailed inspection 

for any crack as given in 

Accomplishment Instruction 

3.B.4. Part 4 - Lower Lobe 

Area and section 41 Skin 

Inspection. (b)

Before 35,000 

total airplane 

flight cycles.

Within 4,500 flight 

cycles from the 

date of revision 3 

of this service 

bulletin, or

Within 9,000 flight 

cycles from the 

accomplishment 

of the detailed 

inspections given 

in the original 

issue or revision 1 

of this Service 

Bulletin.

4,500 Flight 

Cycles. (a) (e)

Areas that require 

detailed and eddy 

current 

inspections as 

given in this 

service bulletin.

Do external detailed inspection 

and eddy current inspection for 

any crack as given in 

Accomplishment Instruction 

3.B.4. Part 4 - Lower Lobe 

Area and section 41 Skin 

Inspection. (b)

Before 35,000 

total airplane 

flight cycles.

Within 4,500 flight 

cycles from the 

date of revision 3 

of this service 

bulletin.

4,500 Flight 

Cycles. (e)

Any crack found in 

the fuselage skin.

Do the repair as given in 

Accomplishment Instruction 

3.B.5. Part 5 - Permanent 

Repair. (c) (d)

or 

Do the repair as given in 

Accomplishment Instruction 

3.B.6. Part 6 - Time-Limited 

Repair.(c)

Before further 

flight.

- -

Time Limited 

Repair is installed 

and is located at 

lap splice.

Do an external detailed 

inspection of the repaired area 

for any cracks and loose, 

missing or damaged fasteners 

as given in Accomplishment 

Instruction 3.B.6.a.(1).(a).3).

Within 3,000 flight cycles from the 

time the repair was installed.

3,000 flight 

cycles. (d)

Time Limited 

Repair is installed 

and is not located 

at lap splice.

Do an external detailed 

inspection of the repaired area 

for any cracks and loose, 

missing or damaged fasteners 

as given in Accomplishment 

Instruction 3.B.6.a.(2).(c).

Within 3,000 flight cycles from the 

time the repair was installed.

3,000 flight 

cycles. (d)

Damaged or loose 

fasteners found.

Replace any damaged or loose 

fasteners.

Before further flight. -
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Crack found at a 

Time Limited 

Repair.

Contact Boeing for repair 

instructions and install the 

repair. 

Before further flight. -

Time Limited 

Repair is installed 

and is located at 

lap splice.

Install permanent repair as 

given in Accomplishment 

Instruction 3.B.6.a.(1).(a).4).

(f)

Within 6,000 

flight cycles 

from the time 

the repair was 

installed.

Within 1,000 flight 

cycles from the 

date of revision 3 

of this service 

bulletin. 

-

Time Limited 

Repair is installed 

and is not located 

at lap splice.

Install permanent repair as 

given in Accomplishment 

Instruction 3.B.6.a.(2).(d).

(f)

Within 6,000 

flight cycles 

from the time 

the repair was 

installed.

Within 1,000 flight 

cycles from the 

date of revision 3 

of this service 

bulletin.

-

(a) Areas that have been inspected according to the previous releases of this service bulletin need to have 

repeat inspections according to the requirements of this table.

(b) It is not required to inspect areas under existing external repair doublers provided either:

1. The installed repair was approved by the FAA or by a Boeing company authorized representative who 

was authorized by the FAA to make such findings, and the installed repair extends a minimum of three 

rows of fasteners on each side of the chem-mill, Or

2. The doubler extends a minimum of 2 rows beyond the chem-mill step and was accomplished in 

accordance with Figure 42 or 48 of 737-100/200 SRM 53-30-3, or Repair 30 or 31 of 737-300 SRM 

53-00-01, 737-400 SRM 53-00-01 or 737-500 SRM 53-00-01. Inspections are not required directly 

under the repair doubler. Do the inspections required in areas adjacent to the repair doubler.

 If the repair does not meet the above conditions, then inspect the chem-mill step internally in the area 

covered by the doubler as given in 737 NDT, Part 6, 53-30-20. 

(c) If the repair given in Accomplishment Instructions, PART 5 or PART 6 are not applicable, contact Boeing 

for repair instructions and install repair before further flight.

(d) Accomplishment of the Part 5 - Permanent Repair is terminating action for repeat inspections under the 

repair area only.

(e) It is optional to do general visual inspections at 1,000 flight cycle intervals in lieu of the detailed 

inspections.

(f) Accomplishment of the permanent repair is terminating action for repeat inspections under the repair area 

only.

Group 3, 5, 9-10, 12, 14-15, 17-21: Table 7 - Post Repair Inspection - Skin Chem-mill Line Crack at Stringer

12 Repair

Condition Action Compliance Time Repeat Interval

Repair Installed as 

given in Figure 24

Do external LFEC inspections 

of the skin at the critical row of 

fasteners in the repair as 

given in Accomplishment 

Instructions 3.B.8.b. 

Within 43,000 Flight Cycles from 

the installation of the repair.

3,500 Flight Cycles

Group 1-21: Table 6 - Skin Inspection Requirements - Fuselage Lower Lobe Area and Section 41 - Horizontal

Chem-Mill Line Cracks

Condition Action

Compliance Time

(Whichever Occurs Later)

Repeat Interval 

(Not to Exceed)
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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.

For airplanes identified in the service bulletin, Revision 3, the repair and/or modification of this service 

bulletin, Revision 3, have been reviewed as required by paragraph (g) of Airworthiness Directive (AD) 

98-11-04 R1. Those repairs in this service bulletin that contain directed inspection satisfy the 

requirement of AD 98-11-04 R1, paragraph (g). All permanent repairs called out in this service bulletin 

are installed per the SRM. These contain the guidance necessary to determine if it affects an SSI or 

creates a new SSI and also contains the necessary inspection. However, any repair that results from 

the inspection findings of this service bulletin, should be assessed with respect to the requirements of 

AD 98-11-04 R1, paragraph (g), to determine if it affects or creates a SSI.

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

Aircraft Certification Office approves the inspections, repairs, and modifications defined in this service 

bulletin as an alternative method of compliance to the requirements of paragraph (a), (b), (c), (d), (e), 

(f), (g), and (i) of AD 2004-18-06. All provisions of 2004-18-06 that are not specifically referenced in 

the above statement remain fully applicable and must be complied with.

Skin panels replaced according to the instructions of SB 737-53-1168, SB 737-53-1187 or SB 737-53-

1273 are approved as an Alternative Method of Compliance (AMOC) to the Airworthiness Directive 

2004-18-06 paragraphs (a), (b), (c), (d) and (e) in the areas of replaced skin panel only. All provisions 

of AD 2004-18-06 that are not specifically referenced in the above statement remain fully applicable 

and must be complied with.

G. Manpower

The table below shows an estimate of the man-hours necessary to do this inspection for each airplane. 

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator 

man-hour data if necessary. The estimate does not include lost time. These are some examples of 

lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts
 

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ALERT ALERT

— Time to find the tools.

Group 1: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 3 6 131.00 23.50

Figure 11 4 53.00 13.25

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 23 4 55.00 13.75

Figure 28 1 2.00 2.00

Figure 30 - (c) (c)

Figure 32 1 2.00 2.00

Figure 38 - (a) (a)

Figure 49 4 17.00 4.25

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 262.00 60.75

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

Group 2: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 4 6 156.00 26.00

Figure 12 4 59.00 14.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 23 4 55.00 13.75

Figure 28 1 2.00 2.00

Figure 30 - (c) (c)

Figure 33 1 4.00 4.00

Figure 38 - (a) (a)

Figure 40 4 20.00 5.00

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 298.00 67.50

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Group 3: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 5 6 396.00 66.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 13 4 59.00 14.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 26 6 75.00 12.50

Figure 28 1 2.00 2.00

Figure 30 - (c) (c)

Figure 34 4 17.00 14.25

Figure 35 2 5.00 2.50

Figure 38 - (a) (a)

Figure 39 4 23.00 5.75

Figure 42 1 4.00 4.00

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 653.25 140.75

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 4: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 6 6 441.00 73.50

Figure 14 4 35.00 8.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 22 4 40.00 10.00

Figure 23 4 55.00 13.75

Figure 25 4 27.00 6.75

Figure 28 1 2.00 2.00

Figure 30 - (c) (c)

Figure 31 1 2.00 2.00
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Figure 36 1 1.25 1.25

Figure 38 - (a) (a)

Figure 43 4 10.00 2.50

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 615.25 122.50

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

Group 5: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 7 6 357.00 59.50

Figure 10 4 45.00 (d) 11.25 (d)

Figure 15 4 27.00 6.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 22 4 40.00 10.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 27 4 11.00 2.75

Figure 28 1 2.00 2.00

Figure 30 - (c) (c)

Figure 37 1 1.25 1.25

Figure 38 - (a) (a)

Figure 40 4 20.00 5.00

Figure 44 1 4.00 4.00

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 534.50 110.25

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 4: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Group 6: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 17 - (a) (a)

Figure 18 - (c) (c)

Figure 21 4 12.00 3.00

Figure 26 6 75.00 12.50

Figure 29 4 44.00 11.00

Figure 30 - (a) (a)

Figure 38 - (b) (b)

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 133.00 28.5

(a) More time will be necessary to perform internal inspections if required.

(b) More time will be necessary for repairs if any crack is found.

(c) More time will be necessary to inspect time limited repairs.

Group 7: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 14 4 35.00 8.75

Figure 17 - (a) (a)

Figure 18 - (c) (c)

Figure 21 4 12.00 3.00

Figure 30 - (a) (a)

Figure 31 1 2.00 2.00

Figure 38 - (b) (b)

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 51.00 15.75

(a) More time will be necessary to perform internal inspections if required.

(b) More time will be necessary for repairs if any crack is found.

(c) More time will be necessary to inspect time limited repairs.

Group 8: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 15 4 27.00 6.75

Figure 17 - (a) (a)

Figure 18 - (c) (c)
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Figure 21 4 12.00 3.00

Figure 27 4 11.00 2.75

Figure 30 - (a) (a)

Figure 38 - (b) (b)

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 52.00 14.50

(a) More time will be necessary to perform internal inspections if required.

(b) More time will be necessary for repairs if any crack is found.

(c) More time will be necessary to inspect time limited repairs.

Group 9-10: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 5 6 396.00 66.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 26 6 75.00 12.50

Figure 29 4 44.00 11.00

Figure 30 - (c) (c)

Figure 34 4 17.00 4.25

Figure 35 2 5.00 2.50

Figure 38 - (a) (a)

Figure 39 4 23.00 5.75

Figure 42 1 4.00 4.00

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 648.25 128.00

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 8: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Group 11: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 6 6 441.00 73.50

Figure 14 4 35.00 8.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 25 4 27.00 6.75

Figure 30 - (c) (c)

Figure 31 1 2.00 2.00

Figure 36 1 1.25 1.25

Figure 38 - (a) (a)

Figure 43 4 10.00 2.50

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 585.25 113.50

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

Group 12: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 7 6 357.00 59.50

Figure 10 4 45.00 (d) 11.25 (d)

Figure 15 4 27.00 6.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 27 4 11.00 2.75

Figure 30 - (c) (c)

Figure 37 1 1.25 1.25

Figure 38 - (a) (a)

Figure 40 4 20.00 5.00

Figure 44 1 4.00 4.00

Figure 48 1 1.25 1.25
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 504.50 101.25

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 13: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 4 6 156.00 26.00

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 22 4 40.00 10.00

Figure 23 4 55.00 13.75

Figure 28 1 2.00 2.00

Figure 30 - (c) (c)

Figure 33 1 4.00 4.00

Figure 38 - (a) (a)

Figure 40 4 20.00 5.00

Figure 41 4 44.00 11.00

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 323.00 73.75

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

Group 14: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 5 6 396.00 66.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 22 4 40.00 10.00

Figure 23 4 55.00 13.75

Group 12: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Figure 24 - (a) (a)

Figure 26 6 75.00 12.50

Figure 28 1 2.00 2.00

Figure 29 4 44.00 11.00

Figure 30 - (c) (c)

Figure 34 4 17.00 4.25

Figure 35 2 5.00 2.50

Figure 38 - (a) (a)

Figure 39 4 23.00 5.75

Figure 42 1 4.00 4.00

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 678.25 137.00

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 15: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 5 6 396.00 66.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 26 6 75.00 12.50

Figure 29 4 44.00 11.00

Figure 30 - (c) (c)

Figure 34 4 17.00 4.25

Figure 35 2 5.00 2.50

Figure 38 - (a) (a)

Figure 39 4 23.00 5.75

Figure 42 1 4.00 4.00

Figure 48 1 1.25 1.25

Group 14: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 648.25 128.00

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 16: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 1 1.00 1.00

Figure 6 6 441.00 73.50

Figure 14 4 35.00 8.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 25 4 27.00 6.75

Figure 30 - (c) (c)

Figure 31 1 2.00 2.00

Figure 36 1 1.25 1.25

Figure 38 - (a) (a)

Figure 43 4 10.00 2.50

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 585.25 113.50

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

Group 17: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 7 6 357.00 59.50

Figure 10 4 45.00 (d) 11.25 (d)

Figure 15 4 27.00 6.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Group 15: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 27 4 11.00 2.75

Figure 30 - (c) (c)

Figure 37 1 1.25 1.25

Figure 38 - (a) (a)

Figure 40 4 20.00 5.00

Figure 44 1 4.00 4.00

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 504.50 101.25

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 18: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 26 6 75.00 12.50

Figure 29 4 44.00 11.00

Figure 30 - (c) (c)

Figure 34 4 17.00 4.25

Figure 35 2 5.00 2.50

Figure 38 - (a) (a)

Figure 42 1 4.00 4.00

Figure 45 6 291.00 48.50

Figure 47 4 17.00 4.25

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

Group 17: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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TOTAL FOR EACH AIRPLANE 582.25 120.25

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 19: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 15 4 27.00 6.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 22 4 40.00 10.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 27 4 11.00 2.75

Figure 28 1 2.00 2.00

Figure 30 - (c) (c)

Figure 37 1 1.25 1.25

Figure 38 - (a) (a)

Figure 44 1 4.00 4.00

Figure 46 6 267.00 44.50

Figure 47 4 17.00 4.25

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 441.50 94.50

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Group 18: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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Group 20: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 15 4 27.00 6.75

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 21 4 12.00 3.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 27 4 11.00 2.75

Figure 30 - (c) (c)

Figure 37 1 1.25 1.25

Figure 38 - (a) (a)

Figure 44 1 4.00 4.00

Figure 46 6 267.00 44.50

Figure 47 4 17.00 4.25

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 411.50 85.50

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

(e) More time will be necessary to perform post repair inspections.

Group 21: 

Task

Number of 

Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Figure 10 4 45.00 (d) 11.25 (d)

Figure 17 - (a) (a)

Figure 18 - (b) (b)

Figure 22 4 40.00 10.00

Figure 23 4 55.00 13.75

Figure 24 - (a) (a)

Figure 26 6 75.00 12.50

Figure 28 1 2.00 2.00

Figure 29 4 44.00 11.00

Figure 30 - (c) (c)
 

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H. Weight and Balance Changes

I. Electrical Load Data

Not changed

Figure 34 4 17.00 4.25

Figure 35 2 5.00 2.50

Figure 38 - (a) (a)

Figure 42 1 4.00 4.00

Figure 45 6 291.00 48.50

Figure 47 4 17.00 4.25

Figure 48 1 1.25 1.25

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 612.25 129.25

(a) More time will be necessary for repairs if any crack is found.

(b) More time will be necessary to inspect time limited repairs.

(c) More time will be necessary to perform internal inspections if required.

(d) Estimate does not include time to manufacture parts.

Service Bulletin Repair Figure Change in Weight 

(Pounds) +{-}

Change in Moment 

(Pound-Inches) +{-}

Figure 10 - Preventive Modification +2.4 (b) (d)

Figure 17 and 38 - Time limited Skin Repair +0.6 (a) (b) (c) (d)

Figure 24 - Stringer S-12 crack repair +3.5 (b) (d)

(a) For 737-200 airplanes measure the straight - line “X” distance in inches from the airplane's nose to 

the center of the repair. Add 94 inches to get the Balance Arm (BA). Multiply BA times the weight of 

the repair. The product is the desired “Change in Moment”. 

(b) For 737-300 airplanes measure the straight - line “X” distance in inches from the airplane's nose to 

the center of the repair. Add 50 inches to get the Balance Arm (BA). Multiply BA times the weight of 

the repair. The product is the desired “Change in Moment”.

(c) For 737-400 airplanes measure the straight - line “X” distance in inches from the airplane's nose to 

the center of the repair. Subtract 22 inches to get the Balance Arm (BA). Multiply BA times the 

weight of the repair. The product is the desired “Change in Moment”.

(d) For 737-500 airplanes measure the straight - line “X” distance in inches from the airplane's nose to 

the center of the repair. Add 104 inches to get the Balance Arm (BA). Multiply BA times the weight of 

the repair. The product is the desired “Change in Moment”.

Example: A 737-400 received one Figure 10, 17 and 24 modification at “X” distance measured as 

400, 600 and 800 inches respectively.

What is the Change in Moment?

Answer: (400-22)(2.4)=907, (600-22)(0.6)=347 and (800-22)(3.5)=2,723

Summing 907+347+2,723 = 3,977 Pound - Inches

Group 21: 

Task

Number of 

Persons Task Hours Elapsed Hours
 

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J. References

1. Existing Data:

a. 737-100/200 Aircraft Maintenance Manual (AMM) 25-21-311, 25-21-341, 25-21-347, 

25-22-0, 25-23-311, 25-24-311, 53-51-11, 53-51-21.

b. 737-100/200 Structural Repair Manual (SRM) 51-30-08, 53-30-3.

c. 737-300 Structural Repair Manual (SRM) 51-10-01, 51-20-01, 51-20-05, 51-40-08, 

53-00-01.

d. 737-300/400/500 Aircraft Maintenance Manual (AMM) 25-21-39, 25-21-45, 25-21-46, 

25-22-00, 25-23-61, 25-24-31, 25-27-15, 25-52-73, 51-21-00, 53-51-19, 53-51-20, 53-51-21

e. 737-400 Structural Repair Manual (SRM) 51-20-05, 51-40-08, 53-00-01.

f. 737-500 Structural Repair Manual (SRM) 51-10-01, 51-20-01, 51-20-05, 51-40-08, 

53-00-01.

g. 737 Non-Destructive Testing (NDT) Manual, Part 6, 51-00-00, Part 6, 51-30-00, Part 6, 

53-30-00, Part 6, 53-30-05, Part 6, 53-30-09, Part 6, 53-30-12, Part 6, 53-30-16, Part 6, 

53-30-18, Part 6, 53-30-19, Part 6, 53-30-20, Part 6, 53-30-20., Part 6, 53-30-25.

h. Boeing Document D6-56722, Customer Cost Benefit Methodology Guide.

i. Boeing Service Bulletins 

737-53-1065, “Fuselage - Aft Skin - Inspection, Repair, and Modification” 

737-53A1039, “Fuselage Skin Lap Joint Inspection and Repair” 

737-53-1076, “Fuselage - Circumferential Butt Splices and Bonded Doublers - Inspection, 

Repair and Modification” 

737-53-1078, “Fuselage Window Belt Skin Panel Inspection and Repair” 

737-53-1124, “Fuselage - Bonded Doublers (Tear Straps) - Inspection and Repair For 

Delamination Above Stringer 26 Between Stations 259 and 1016" 

737-53-1168, “Fuselage - Aft Skin - Inspection, Modification, and Replacement” 

737-53A1177, “Fuselage - Skin - Repair Methods For Cracks in Lower Skins at Lap Joints” 

737-53-1178, “Fuselage Frames - STA 663.75, Outboard Chord at Stringers 1, 2, 3, 4, and 

5 Inspection and Preventive Modification”

737-53-1179, “Fuselage - Bonded Skin Doublers (Tear Straps) - Delamination Inspection 

and Repair”

737-53-1187, “Fuselage - Aft Skin - Inspection - Modification And Replacement”

SIIA 737-242, “Fuselage - Plates and Skin - Skin Crack Between Stringers 11 and 13 at 

Station 500D + 10

j. Standard Overhaul Practices Manual (SOPM) 20-50-12, 20-50-19.

k. FAA Airworthiness Directive 2004-18-06 and 98-11-04 R1.

2. Data supplied with this Service Bulletin:

None.
 

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

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 and new DTI requirements for the 

structure affected are contained in Paragraph 1.E., Compliance of this service bulletin.

L. Interchangeability and Intermixability of Parts

None.

Drawing Number Title

65-73742 Skin Diagram Body Model 737

65-45766 Panel Instl - STA 360 to STA 540 S-10 to S-14

65C32356 Skin Assy - Window STA 360 to STA 54 S-10 to S-14
 

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2. MATERIAL INFORMATION

A. Material - Price and Availability

None

B. Industry Support Information

Boeing warranty remedies are not available for the inspection and 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: The parts that follow are used to accomplish a typical time-limited skin repair as given in

Figure 17. Number of fasteners, size, type, and grip length may vary, depending on the

specific repair.

Part Number / 

Specification QTY Name Notes

A 1 Doubler (a)

B 1 Filler (a)

C 1 Filler (a)

BACR15FR5E2R 68 Rivet (b)

BACR15FR5E3R 63 Rivet (b)

BACR15FR5E4R 25 Rivet (b)

BACR15FR6E3R 3 Rivet (c)

BACR15FR6E4R 6 Rivet (c)

BMS 5-95 AR Sealant (d)

(a) Make as given in Figure 17.

(b) NAS1738E5-( ) Optional.

(c) NAS1738E6-( ) Optional. 

(d) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for 

supplier data.
 

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NOTE: The parts that follow are used to modify a typical time-limited skin repair into a

permanent skin repair as given in Figure 10. Number of fasteners, size, type, and grip

length may vary, depending on the specific repair.

NOTE: The parts that follow are used to install a stringer 12 repair as given in Figure 24. Number

of fasteners, size, type, and grip length may vary, depending on the specific repair.

Part Number / 

Specification QTY Name Notes

A 1 Internal Doubler (a)

B 4 Pocket Filler (a)

C 1 Filler, under S-12 (a)

D 8 Tapered shim (a)

BACR15BB5D( ) 74 Rivet

BACR15CE6D( ) 103 Rivet

BAC1534-33F AR Shim

BMS 5-95 Class B-1/2, -2 16 ounces Sealant (b)

BMS 3-23 4 ounces Corrosion Inhibitor (b)

(a) Make as given in Figure 10.

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

Part Number / 

Specification QTY Name Notes

.032 inch 2024-T3 1 Doubler (a)

.050 inch 2024-T3 1 Tripler (a)

.040 inch 2024-T3 1 Tapered Filler (a)

.040 inch 2024-T3 1 Tapered Filler (a)

BACR15BB6AD( ) 38 Rivet (b)

BACR15CE5D( ) 153 Rivet (b)

BACR15BB6D( ) 47 Rivet (b)

BACR15BB10D( ) 16 Rivet (b)

BACB30FM10A( ) 16 Bolt (b)(c)

BACC30M10 16 Nut (b)(c)

Type 2, Class A 4 Ounces Chemical Conversion Coating (b)

BMS 5-95 Class B-1/2, -2 16 ounces Sealant (b)

BMS 3-23 4 ounces Corrosion Inhibitor (b)

BMS10-79 type II or type III 

primer

1/2 Pint Primer (a)

(a) Make as given in Figure 24.

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

(c) These parts are only required if the existing fasteners were nuts and bolts.
 

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NOTE: The parts that follow are used to accomplish a typical time-limited skin repair as given in

Figure 38.

NOTE: The parts that follow are used to modify the typical time-limited skin repair given in

Figure 38 into a permanent skin repair.

3. Parts Modified and Reidentified:

None.

Part Number / 

Specification QTY Name Notes

2024-T3 clad sheet 1 Repair Doubler (a)

BACR15FR5E5R or 

BACR15FR5E6R

As Required Rivet (b)

BACR15FR6E6R or 

BACR15FR6E7R

As Required Rivet (b)

BMS 5-95 Class B-1/2, -2 16 ounces Sealant (c) (d)

BMS10-79 type II or type 

III primer

1/2 Pint Primer (c)

(a) Make as given in Figure 38.

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

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

(d) See SOPM 20-50-12.

Part Number / 

Specification QTY Name Notes

2024-T3 clad sheet 1 Repair Doubler (a)

BACR15BB6AD6 or 

BACR15BB6AD7 or 

BACR15BB7AD7 or 

BACR15BB7AD8

As Required Rivet (b)

BACR15FR6E6R or 

BACR15FR6E7R

As Required Rivet (b)

BMS 5-95 Class B-1/2, -2 16 ounces Sealant (c) (d)

BMS10-79 type II or type 

III primer

1/2 Pint Primer (c)

BMS 3-23 4 ounces Corrosion Inhibitor (c)

(a) Make as given in Figure 38.

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

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

(d) See SOPM 20-50-12.
 

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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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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 given in 737 SRM, Chapter 51

— Torque limits to tighten nuts and bolts are given in 737 SRM, Chapter 51.

4. For approved fastener and process material substitutions, refer to 737 SRM, Chapter 

51, Alternate fasteners are given in 737 SRM Chapter 51 and Boeing Drawing 

65-88700.

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

installation standards given in SRM Chapter 51, then a fastener of the same 

specification, or an approved substitute, with a length which meets the installation 

standards given in SRM Chapter 51 may be used.

6. 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 procedures may be required.

7. 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 ensure visual access to all surfaces in the inspection area. This 

level of inspection is made under normal 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.

8. These work instructions refer to procedures included on 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 “as given in” are 
 

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included in the instruction, the procedure in the Boeing document must be used.

9. Refer to Appendix A for Cost Benefit Analysis.

10. Some areas identified for chem-mill inspections may not have a chem-mill step 

depending on the specific airplane skin configuration. If a chem-mill step does not exist 

in an area identified for inspection in this service bulletin, then the inspection is not 

required in that specific area.

11. Some areas identified for chem-mill inspections may not be chem-milled all of the way 

through the bonded doubler to the bond line. Inspections as given in this service bulletin 

are not required in these areas where the chem-mill is not completely through the 

thickness of the bonded doubler. This cannot be determined visually. Drawing 

verification is required.

B. WORK INSTRUCTIONS

1. PART 1 - CROWN AREA SKIN INSPECTION

a. Group 1: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 3.

NOTE: For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R

it is optional to do general visual inspections at reduced intervals in lieu of the

detailed inspections. Refer to Paragraph 1.E., Compliance.

(2) Do a High Frequency Eddy Current (HFEC) sliding probe inspection of the fuselage 

skin at tear strap attachments as given in Figure 23.

NOTE: These inspections are only required at tearstrap tab locations where chem-mill

step inspections are required. If a tearstrap tab detail as shown in Figure 23

does not exist in a chem-mill inspection area then the inspections as given in

Figure 23 are not required at that location.

(3) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 32.

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - Do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - Do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, either accomplish 

the permanent repair as given in Part 5 or contact Boeing for repair 

instructions and install the repair.
 

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(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

b. Group 2, 13: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 4.

NOTE: For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R

it is optional to do general visual inspections at reduced intervals in lieu of the

detailed inspections. Refer to Paragraph 1.E., Compliance.

(2) Do a High Frequency Eddy Current (HFEC) sliding probe inspection of the fuselage 

skin at tear strap attachments as given in Figure 23.

NOTE: These inspections are only required at tearstrap tab locations where chem-mill

step inspections are required. If a tearstrap tab detail as shown in Figure 23

does not exist in a chem-mill inspection area then the inspections as given in

Figure 23 are not required at that location.

(3) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 33.

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - Do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - Do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, either accomplish 

the permanent repair as given in Part 5 or contact Boeing for repair 

instructions and install the repair.

(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

c. Group 3, 9-10, 14-15: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 5.

NOTE: For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R

it is optional to do general visual inspections at reduced intervals in lieu of the

detailed inspections. Refer to Paragraph 1.E., Compliance.

(2) Do a High Frequency Eddy Current (HFEC) sliding probe inspection of the fuselage 

skin at tear strap attachments as given in Figure 23.
 

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NOTE: These inspections are only required at tearstrap tab locations where chem-mill

step inspections are required. If a tearstrap tab detail as shown in Figure 23

does not exist in a chem-mill inspection area then the inspections as given in

Figure 23 are not required at that location.

(3) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 34.

(4) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 35.

(5) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - Do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - Do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, either accomplish 

the permanent repair as given in Part 5 or contact Boeing for repair 

instructions and install the repair.

(6) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

d. Group 4, 11, 16: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 6.

NOTE: For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R

it is optional to do general visual inspections at reduced intervals in lieu of the

detailed inspections. Refer to Paragraph 1.E., Compliance.

(2) Do a High Frequency Eddy Current (HFEC) sliding probe inspection of the fuselage 

skin at tear strap attachments as given in Figure 23.

NOTE: These inspections are only required at tearstrap tab locations where chem-mill

step inspections are required. If a tearstrap tab detail as shown in Figure 23

does not exist in a chem-mill inspection area then the inspections as given in

Figure 23 are not required at that location.

(3) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 36.

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - Do the PERMANENT REPAIR as given in PART 5.
 

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1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - Do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, either accomplish 

the permanent repair as given in Part 5 or contact Boeing for repair 

instructions and install the repair.

(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

e. Group 5, 12, 17: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 7.

NOTE: For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R

it is optional to do general visual inspections at reduced intervals in lieu of the

detailed inspections. Refer to Paragraph 1.E., Compliance.

(2) Do a High Frequency Eddy Current (HFEC) sliding probe inspection of the fuselage 

skin at tear strap attachments as given in Figure 23.

NOTE: These inspections are only required at tearstrap tab locations where chem-mill

step inspections are required. If a tearstrap tab detail as shown in Figure 23

does not exist in a chem-mill inspection area then the inspections as given in

Figure 23 are not required at that location.

(3) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 37.

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - Do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - Do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, either accomplish 

the permanent repair as given in Part 5 or contact Boeing for repair 

instructions and install the repair.

(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.
 

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f. Group 18, 21: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 45.

NOTE: For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R

it is optional to do general visual inspections at reduced intervals in lieu of the

detailed inspections. Refer to Paragraph 1.E., Compliance.

(2) Do a High Frequency Eddy Current (HFEC) sliding probe inspection of the fuselage 

skin at tear strap attachments as given in Figure 23.

NOTE: These inspections are only required at tearstrap tab locations where chem-mill

step inspections are required. If a tearstrap tab detail as shown in Figure 23

does not exist in a chem-mill inspection area then the inspections as given in

Figure 23 are not required at that location.

(3) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 34.

(4) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 35.

(5) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - Do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - Do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, either accomplish 

the permanent repair as given in Part 5 or contact Boeing for repair 

instructions and install the repair.

(6) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

g. Group 19-20: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 46.

NOTE: For non lap splice areas between STA 360 to STA 1016 and S-10L to S-10R

it is optional to do general visual inspections at reduced intervals in lieu of the

detailed inspections. Refer to Paragraph 1.E., Compliance.

(2) Do a High Frequency Eddy Current (HFEC) sliding probe inspection of the fuselage 

skin at tear strap attachments as given in Figure 23.
 

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NOTE: These inspections are only required at tearstrap tab locations where chem-mill

step inspections are required. If a tearstrap tab detail as shown in Figure 23

does not exist in a chem-mill inspection area then the inspections as given in

Figure 23 are not required at that location.

(3) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

cracks as given in Figure 37.

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - Do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - Do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, either accomplish 

the permanent repair as given in Part 5 or contact Boeing for repair 

instructions and install the repair.

(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

h. Put the airplane back to a serviceable condition.

NOTE:

1. The inspections given in PART 1 are not necessary in areas repaired as given 

in Figure 42 or 48 of 737-100/200 SRM 53-30-3, or Repair 30 or 31 of 737-300 

SRM 53-00-01, 737-400 SRM 53-00-01 or 737-500 SRM 53-00-01. 

Inspections are not required directly under the repair doubler. Do the 

inspections required in areas adjacent to the repair doubler.

2. The installation of external repair doublers as given in Boeing Service Bulletin 

737-53A1177, Revision 2 or later constitutes terminating action for the PART 

1 inspections in the repaired area only. 

2. PART 2 - WINDOW BELT INSPECTION - HORIZONTAL CHEM-MILL LINE CRACKS

a. Group 3, 9-10, 14-15, 18, 21: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack in the window belt area between STA 500D and STA 520, S-10 to S-14 as 

given in Figure 42.

(a) If any crack is found, do the repair as given in PART 8 - SKIN CHEM-MILL LINE 

CRACK AT STRINGER 12 - REPAIR INSTRUCTIONS. If the repair given in 

PART 8 is not applicable, contact Boeing for repair instructions and install the 

repair.
 

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(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance. As an option do the preventive modification as given in PART 7 - 

PREVENTIVE MODIFICATION.

b. Group 4, 11, 16: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack in the window belt area between STA 500E and STA 500F and STA 500G 

and STA 520, S-10 to S-14 as given in Figure 43.

(a) If any crack is found, contact Boeing for repair instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

c. Group 5, 12, 17, 19-20: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack window belt area between STA 482B to STA 520 and S-10 to S-14 as given 

in Figure 44.

(a) If any crack is found, do the repair as given in PART 8 - SKIN CHEM-MILL LINE 

CRACK AT STRINGER 12 - REPAIR INSTRUCTIONS. If the repair given in 

PART 8 is not applicable, contact Boeing for repair instructions and install the 

repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance. As an option do the preventive modification as given in PART 7 - 

PREVENTIVE MODIFICATION.

d. Put the airplane back to a serviceable condition.

3. PART 3 - VERTICAL CRACK INSPECTION

a. Group 2, 5, 12-13, 17: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 40.

(a) If any crack is found, do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

b. Group 1: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 49.

(a) If any crack is found, do the PERMANENT REPAIR as given in PART 5.
 

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1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

c. Group 3, 9-10, 14-15: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 39.

(a) If any crack is found, do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

d. Group 4, 11, 16: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 25.

(a) If any crack is found, do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

e. Group 18-21: 

(1) Do an external detailed inspection and eddy current inspection of the fuselage skin for 

any crack as given in Figure 47.

(a) If any crack is found, do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

f. Put the airplane back to a serviceable condition.
 

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4. PART 4 - LOWER LOBE AREA AND SECTION 41 SKIN INSPECTION

NOTE: Some areas of these inspections are also included in Boeing Service Bulletins 737-53-

1065, 737-53-1187 and 737-53-1168. The inspections given in this service bulletin do

not replace the required inspections in Service Bulletins 737-53-1065, 737-53-1187 and

737-53-1168. However, operators may be able to receive credit for accomplishment of

the Service Bulletin 737-53-1065, 737-53-1187 and 737-53-1168 inspections if the

inspections given in this service bulletin satisfies the requirements of Service Bulletins

737-53-1065, 737-53-1187 and 737-53-1168.

a. Gain access by removing the Wing - To - Body Fairing as required. Refer to 737-300/400/

500 AMM 53-51-19, 737-300/400/500 AMM 53-51-20, 737-300/400/500 AMM 53-51-21 and 

737-100/200 AMM 53-51-11, 737-100/200 AMM 53-51-21 as an accepted procedure.

b. Group 1: 

(1) Do an external detailed inspection of the fuselage skin for any cracks as given in Figure 

11.

(a) If any crack is found, do one of the options that follow:

1) Option 1 - do the PERMANENT REPAIR as given in PART 5.

{a} If the permanent repairs given in PART 5 are not applicable, contact 

Boeing for repair instructions and install the repair.

2) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect 

and replace at the times given in Paragraph 1.E., Compliance.

{a} If the time-limited repair given in PART 6 is not applicable, then either 

do a permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

c. Group 2: 

(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 12.

(a) If any crack is found, do one of the options that follow:

1) Option 1 - do the PERMANENT REPAIR as given in PART 5.

{a} If the permanent repairs given in PART 5 are not applicable, contact 

Boeing for repair instructions and install the repair.

2) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect 

and replace at the times given in Paragraph 1.E., Compliance.

{a} If the time-limited repair given in PART 6 is not applicable, then either 

do a permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.
 

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(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

d. Group 3: 

(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 13.

(2) Do an eddy current inspection of the fuselage skin for cracks at the locations as given 

in Figure 26. 

(3) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, then either do a 

permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(4) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

e. Group 4, 11, 16: 

(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 14.

(2) Do an eddy current inspection of the fuselage skin for cracks at the locations as given 

in Figure 31.

(3) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, then either do a 

permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(4) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

f. Group 5, 12, 17, 19-20: 
 

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(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 15.

(2) Do an eddy current inspection of the fuselage skin for cracks as given in Figure 27.

(3) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, then either do a 

permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(4) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

g. Group 9-10, 14-15, 18, 21: 

(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 29.

(2) Do an eddy current inspection of the fuselage skin for cracks at the locations as given 

in Figure 26. 

(3) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, then either do a 

permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(4) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

h. Group 13: 

(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 41.

(a) If any crack is found, do one of the options that follow:

1) Option 1 - do the PERMANENT REPAIR as given in PART 5.
 

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{a} If the permanent repairs given in PART 5 are not applicable, contact 

Boeing for repair instructions and install the repair.

2) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect 

and replace at the times given in Paragraph 1.E., Compliance.

{a} If the time-limited repair given in PART 6 is not applicable, then either 

do a permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(2) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

i. Group 9-12, 15-18, 20: 

(1) Do an external detailed inspection of the fuselage skin for any crack between Station 

(STA) 259.5 and STA 360 as given in Figure 21.

(a) If any crack is found, do one of the options that follow:

1) Option 1 - do the PERMANENT REPAIR as given in PART 5.

{a} If the permanent repairs given in PART 5 are not applicable, contact 

Boeing for repair instructions and install the repair.

2) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect 

and replace at the times given in Paragraph 1.E., Compliance.

{a} If the time-limited repair given in PART 6 is not applicable, then either 

do a permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

j. Group 4-5, 13-14, 19, 21: 

(1) Do an external detailed inspection for any crack between STA 259.5 and STA 360 as 

given in Figure 22.

(a) If any crack is found, do one of the options that follow:

1) Option 1 - do the PERMANENT REPAIR as given in PART 5.

{a} If the permanent repairs given in PART 5 are not applicable, contact 

Boeing for repair instructions and install the repair.

2) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect 

and replace at the times given in Paragraph 1.E., Compliance.

{a} If the time-limited repair given in PART 6 is not applicable, then either 

do a permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.
 

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(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

k. Group 1-5, 13-14, 19, 21: 

(1) Do an eddy current inspection for any crack at the stringer locations as given in Figure 

28.

(a) If any crack is found, do one of the options that follow:

1) Option 1 - do the PERMANENT REPAIR as given in PART 5.

{a} If the permanent repairs given in PART 5 are not applicable, contact 

Boeing for repair instructions and install the repair.

2) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect 

and replace at the times given in Paragraph 1.E., Compliance.

{a} If the time-limited repair given in PART 6 is not applicable, then either 

do a permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(b) If no crack is found, do the inspections again at the times given in Paragraph 1.E., 

Compliance.

l. Group 6: 

(1) Do an external detailed inspection of the fuselage skin for any crack between Station 

(STA) 259.5 and STA 360 as given in Figure 21.

(2) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 29.

(3) Do an eddy current inspection of the fuselage skin for cracks at the locations as given 

in Figure 26. 

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, then either do a 

permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

m. Group 7: 
 

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(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 14.

(2) Do an external detailed inspection of the fuselage skin for any crack between Station 

(STA) 259.5 and STA 360 as given in Figure 21.

(3) Do an eddy current inspection of the fuselage skin for cracks at the locations as given 

in Figure 31.

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, then either do a 

permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.

n. Group 8: 

(1) Do an external detailed inspection of the fuselage skin for cracks as given in Figure 15.

(2) Do an external detailed inspection of the fuselage skin for any crack between Station 

(STA) 259.5 and STA 360 as given in Figure 21.

(3) Do an eddy current inspection of the fuselage skin for cracks at the locations as given 

in Figure 27.

(4) If any crack is found in the above inspections, do one of the options that follow:

(a) Option 1 - do the PERMANENT REPAIR as given in PART 5.

1) If the permanent repairs given in PART 5 are not applicable, contact Boeing 

for repair instructions and install the repair.

(b) Option 2 - do the TIME-LIMITED REPAIR as given in PART 6, then inspect and 

replace at the times given in Paragraph 1.E., Compliance.

1) If the time-limited repair given in PART 6 is not applicable, then either do a 

permanent repair as given in Option 1 or contact Boeing for repair 

instructions and install the repair.

(5) If no crack is found in the above inspections, do the inspections again at the times given 

in Paragraph 1.E., Compliance.
 

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o. Install the Wing - To - Body Fairing as required and put the airplane back to a serviceable 

condition.

5. PART 5 - PERMANENT REPAIR

a. Do a permanent repair as applicable as given in 737-100/200 SRM 53-30-3 Figure 48 or 

737-300 SRM 53-00-01 Figure 201, Repair 31, or 737-400 SRM 53-00-01 Figure 201, 

Repair 31, or 737-500 SRM 53-00-01 Figure 201, Repair 31.

b. Put the airplane back to a serviceable condition.

6. PART 6 - TIME-LIMITED REPAIR

NOTE: The time-limited repairs apply to all groups of airplanes. However for Groups 6, 7 and 8

they only apply to the lower lobe below stringer 14, and section 41.

a. Do one of the repairs that follow:

(1) Repair chem-mill cracks found at lap splice.

CAUTION: USE CAUTION WHEN LOCATING BLIND FASTENERS RELATIVE TO

HIDDEN INTERNAL STRUCTURE. DRILLING INTO HIDDEN

INTERNAL STRUCTURE OR EQUIPMENT, MAY RESULT IN

DOWNTIME FOR EXPENSIVE REPAIR.

(a) The repair that follows is subject to these limitations:

NOTE:

1. Figure 17 should only be used for cracks at the chemically milled 

step in the upper skins at lap joints.

2. For a 10 inch wide tear strap spacing, this repair is limited to a crack 

with a maximum length of 5 inches, that is completely contained 

within the cutout shown in Figure 17. For smaller tear strap spacing, 

widths, the maximum crack length will be smaller. (Example: for a 9 

inch wide tearstrap spacing, the maximum crack length is 4 inches). 

Do not use this repair in areas where the tearstrap spacing is greater 

than 10 inches. 

3. Figure 17 repair is limited in size to one 10 inch tear strap bay, with 

the crack completely contained in that bay. For cracks in multipleadjacent tearstrap bays repair as applicable as given in 737-100/200 

SRM 53-30-3 Figure 48, or 737-300 SRM 53-00-01 Figure 201, 

Repair 31, or 737-400 SRM 53-00-01 Figure 201, Repair 31, or 

737-500 SRM 53-00-01 Figure 201, Repair 31 or contact Boeing for 

repair instructions and install the repair.

4. Figure 17 repair can not be used in areas where existing bolts, 

Hi-Loks or lockbolts would be common to the repair.

5. Figure 17 repair can not be used in areas where existing fasteners 

are larger than 3/16 inch diameter.
 

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ALERT ALERT

6. Figure 17 repair can not be installed in an area where it would be 

common to a skin butt joint.

7. Figure 17 repair can not be used in door cutout bear strap locations. 

Contact Boeing for repair instructions and install the repair.

8. Figure 17 repairs can not be installed within 20 inches of an adjacent 

repair.

9. On airplanes line number 292 - 519, this repair can not be installed 

common to the window belt doubler at S-10 or S-14, between STA 

360 and 540 or between STA 727 and 908. If the blind fasteners are 

installed in these areas, the insurance cut requirements of Boeing 

Service Bulletin 737-53-1178 can not be satisfied.

1) Install a time-limited skin repair as given in Figure 17. If the repair limits in the 

above note and in Figure 17 can not be maintained, then repair as applicable 

as given in 737-100/200 SRM 53-30-3 Figure 48, or 737-300 SRM 53-00-01 

Figure 201, Repair 31, or 737-400 SRM 53-00-01 Figure 201, Repair 31, or 

737-500 SRM 53-00-01 Figure 201, Repair 31 or contact Boeing for repair 

instructions and install the repair.

2) Put the airplane back to a serviceable condition.

3) Do an external detailed inspection of the repaired area for any cracks and 

loose, missing or damaged fasteners at the time given in paragraph 1.E., 

Compliance.

{a} If any crack is found in the repaired area, contact Boeing for repair 

instructions and install the repair.

{b} If any fastener is loose or missing or damaged, replace it with the same 

type and size of blind fastener.

4) Make the repair permanent at the time given in Paragraph 1.E., Compliance 

as follows:

{a} Remove the following equipment from the passenger cabin as 

necessary for internal access to the area of the skin crack:

Equipment 737-200 AMM Subject 737-300/-400/-500 AMM 

Subject

Passenger Seats 737-100/200 AMM 25-22-0 737-300/400/500 AMM 25-22-00

Sidewall Linings 737-100/200 AMM 25-21-311 737-300/400/500 AMM 25-21-46

Sidewall Insulation 737-100/200 AMM 25-21-347 737-300/400/500 AMM 25-21-39

Overhead Stowage Bins 737-100/200 AMM 25-24-311 737-300/400/500 AMM 25-24-31

Passenger Service Units 737-100/200 AMM 25-23-311 737-300/400/500 AMM 25-23-61

Ceiling Panels 737-100/200 AMM 25-21-341 737-300/400/500 AMM 25-21-45
 

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ALERT ALERT

CAUTION: USE CARE WHEN REMOVING FASTENERS. DO NOT

DAMAGE THE HOLES. 

{b} Remove the time limited repair.

{c} Do internal and external inspections of the repaired area for any cracks 

or delamination as given in Figure 18 and Figure 30.

1} If any crack or delamination is found in the repaired area, contact 

Boeing for repair instructions and install the repair.

{d} Install the permanent repair as applicable as given in 737-100/200 SRM 

53-30-3 Figure 48, or 737-300 SRM 53-00-01 Figure 201, Repair 31, or 

737-400 SRM 53-00-01 Figure 201, Repair 31, or 737-500 SRM 

53-00-01 Figure 201, Repair 31.

NOTE: If a time limited repair was installed in accordance with the

original issue, revision 1 or revision 2 of this service bulletin,

then it is not required to stagger the fasteners common to the

tear straps that were previously installed in the time limited

repair. All new fasteners common to the tear straps in the

permanent repair must be staggered as specified in the SRM.

{e} Install the equipment in the passenger cabin that was removed for 

internal access.

5) Put the airplane back to a serviceable condition.

(2) Repair Chem-mill cracks found at areas other than lap splice.

CAUTION: USE CAUTION WHEN LOCATING BLIND FASTENERS RELATIVE TO

HIDDEN INTERNAL STRUCTURE. DRILLING INTO HIDDEN

INTERNAL STRUCTURE OR EQUIPMENT, MAY RESULT IN

DOWNTIME FOR EXPENSIVE REPAIR.

(a) For typical cracking in the skin at the chem-mill step, except at the lap splice, do 

the repairs as given in Figure 38.

NOTE: Internal inspections of the tearstrap must also be done as given in

Paragraph 1.E., Compliance.

(b) Put the airplane back to a serviceable condition.

(c) Do external detailed inspection of the repaired area for any cracks and loose, 

missing or damaged fasteners at the time given in Paragraph 1.E., Compliance.

1) If any crack is found in the repaired area contact Boeing for repair instructions 

and install the repair.

2) If any fastener is loose or missing or damaged, replace it with the same type 

and size of blind fastener.
 

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ALERT ALERT

(d) Make the repair permanent at the time given in Paragraph 1.E., Compliance as 

follows:

1) Access the repair area as follows:

— Remove the passenger seats. Refer to 737-300/400/500 AMM 25-22-00 

as an accepted procedure.

— Remove the passenger carpets. Refer to 737-300/400/500 AMM 

25-27-15 as an accepted procedure.

— Remove the passenger cabin sidewall panels. Refer to 737-300/400/

500 AMM 25-21-46 as an accepted procedure.

— Remove the passenger cabin sidewall insulation blankets. Refer to 

737-300/400/500 AMM 25-21-39 as an accepted procedure.

— Remove the aft cargo compartment sidewall panels and insulation 

blankets. Refer to 737-300/400/500 AMM 25-52-73 as an accepted 

procedure.

2) Remove the time limited repair.

3) Inspect the tearstrap internally as given in Figure 30.

4) Install the permanent repair as applicable as given in 737-100/200 SRM 

53-30-3 Figure 48, or 737-300 SRM 53-00-01 Figure 201, Repair 31, or 

737-400 SRM 53-00-01 Figure 201, Repair 31, or 737-500 SRM 53-00-01 

Figure 201, Repair 31.

5) Install the furnishings that were removed for access:

— Install the aft cargo compartment sidewall panels and insulation 

blankets. Refer to 737-300/400/500 AMM 25-52-73 as an accepted 

procedure.

— Install the passenger cabin sidewall insulation blankets. Refer to 

737-300/400/500 AMM 25-21-39 as an accepted procedure.

— Install the passenger cabin sidewall panels. Refer to 737-300/400/500 

AMM 25-21-46 as an accepted procedure.

— Install the passenger carpets. Refer to 737-300/400/500 AMM 25-27-15 

as an accepted procedure.

— Install the passenger seats. Refer to 737-300/400/500 AMM 25-22-00 

as an accepted procedure.

(e) Put the airplane back to a serviceable condition.

7. Group 3, 5, 9-10, 12, 14-15, 17-21: PART 7 - PREVENTIVE MODIFICATION

a. The preventive modification is subject to these limitations:

(1) This preventive modification is applicable only to Group 3, 5, 9, 10, 12, 14-15, 17-21 

airplanes.

(2) This preventive modification should only be used at the chem-milled pockets in the 

upper skins at S-12 between STA 500D to STA 520 for 737-300 and STA 482B to STA 

520 for 737-500 airplanes.

(3) The preventive modification can not be used in areas where existing bolts, Hi-Loks or 

lockbolts can be common to the modification.
 

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ALERT ALERT

b. Remove the following equipment from the passenger cabin as necessary for internal access 

to the area of the skin modification:

c. Install the preventive modification as given in Figure 10.

d. Install the equipment in the passenger cabin that was removed for internal access.

e. Put the airplane back to a serviceable condition.

f. Do the inspections in PART 2 again at the times as given in Paragraph 1.E., Compliance.

8. Group 3, 5, 9-10, 12, 14-15, 17-21: PART 8 - SKIN CHEM-MILL LINE CRACK AT STRINGER 

12 - REPAIR INSTRUCTIONS AND POST REPAIR INSPECTION

a. REPAIR INSTRUCTIONS - SKIN CHEM-MILL LINE CRACK AT STRINGER 12

(1) Do the stringer 12 repair as given in Figure 24.

(2) Put the airplane back to a serviceable condition.

b. POST REPAIR INSPECTION - SKIN CHEM-MILL CRACK REPAIR AT STRINGER 12

(1) Do post repair inspection of the skin chem-mill crack repair at stringer 12 as given in 

Figure 48.

Equipment 737-300/-400/-500 AMM Subject

Passenger Seats 737-300/400/500 AMM 25-22-00

Sidewall Linings 737-300/400/500 AMM 25-21-46

Sidewall Insulation 737-300/400/500 AMM 25-21-39

Overhead Stowage Bins 737-300/400/500 AMM 25-24-31

Passenger Service Units 737-300/400/500 AMM 25-23-61

Ceiling Panels 737-300/400/500 AMM 25-21-45
 FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 2

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 2

THIS FIGURE IS DELETED.

COMPLIANCE INFORMATION MOVED TO PARAGRAPH 1.E.

1840387

(SHEET 1 OF 1)
 FIGURE 2: THIS FIGURE WAS DELETED AT REVISION 2

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 2: THIS FIGURE WAS DELETED AT REVISION 2

THIS FIGURE IS DELETED.

COMPLIANCE INFORMATION MOVED TO PARAGRAPH 1.E.

1840388

(SHEET 1 OF 1)
 FIGURE 3: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

FIGURE 3: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

SEE B

1 2

SEE B

1 2

1 2

SEE A

1 2

SEE C

SEE C

3

727A+10

737-200C AIRPLANE

TYPICAL

STA

480

STA

500

STA

500A

STA

380

STA

360

STA

928

STA

STA

908

FOR TYPICAL

INSPECTION AREA

STA

727

INSPECT ALONG ALL OF THE LAP

JOINTS SHOWN IN BOLD LINES

S-10L

S-14L

S-20L

S-25L

S-10R

S-14R

S-4R

S-4L

S-14R

S-10R

S-14L

S-10L

S-4R

S-4L

259.50

STA

540

STA STA

1016

STA

1006

V21665

(SHEET 1 OF 5)
 FIGURE 3: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

SKIN

UPPER

CRACK

TYPICAL

INSPECTION AREA

LOWER

SKIN

DOUBLER

UPPER

CRACK

TYPICAL

A

1 2

INSPECTION

AREA

TYPICAL

A

A

LOWER

SKIN

UPPER

SKIN

INBD

UP

FRAME

C/L

10.00

3

STRINGER

CRACK

A-A

STRINGER

C/L

V21671

(SHEET 2 OF 5)
 FIGURE 3: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

INSPECTION AREA

FWD

CRACKS

TYPICAL

STA

540

STA

520

S-16

S-15

S-14

TYPICAL CRACKS

TYPICAL CRACKS

TYPICAL CRACKS

B

1 2

1 2

V27370

(SHEET 3 OF 5)
 FIGURE 3: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

This Figure applies to Group 1: 

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

NOTE: The crown area inspections that follow are not necessary at lap joint locations that have been modified

as given in Revision 4, 5 or 6 of Boeing Service Bulletin 737-53A1177.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Inspect Fuselage Skin - - (c)

INSPECTION AREA

STA

927

STA

918.12

STA

908

S-9

S-10

CHEM-MILLED STEP IS HIGHER

THAN NORMAL AT THIS LOCATION

TYPICAL

CRACK

FWD

TYPICAL

CRACK

C

1 2 3

1484830

(SHEET 4 OF 5)
 FIGURE 3: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 

or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(c) Do a detailed or general visual inspection of the non-lap-splice areas between STA 360 to STA 

1016 and S-10L to S-10R for horizontal chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 5 OF 5)
 FIGURE 4: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

FIGURE 4: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

1 2

1 2

SEE A

SEE B

SEE B

3 1 2

1 2

SEE C

SEE C

STA

727A+10

INSPECTION AREA

FOR TYPICAL

INSPECT ALONG ALL OF THE LAP

S-10L

S-14L

S-20L

S-25L

S-10R

S-14R

S-4R

S-4L

STA

928

737-200 AIRPLANE

TYPICAL

JOINTS SHOWN IN BOLD LINES

S-14R

S-10R

S-14L

S-10L

S-4R

S-4L

259.50

STA

360

STA

540

STA STA

727

STA

908

STA

1016

587

STA

633

STA

STA

1006

V21669

(SHEET 1 OF 5)
 FIGURE 4: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

UPPER

DOUBLER

SKIN

LOWER

INSPECTION AREA

TYPICAL

CRACK

UPPER

SKIN

TYPICAL

CRACK

1 2

A

3

10.00

C/L

FRAME

UP

INBD

SKIN

UPPER

SKIN

LOWER

A

A

TYPICAL

AREA

INSPECTION

CRACK

C/L

STRINGER

A-A

STRINGER

V21672

(SHEET 2 OF 5)
 FIGURE 4: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

INSPECTION AREA

FWD

CRACKS

TYPICAL

STA

540

STA

520

S-16

S-15

S-14

TYPICAL CRACKS

TYPICAL CRACKS

TYPICAL CRACKS

B

1 2

1 2

V27371

(SHEET 3 OF 5)
 FIGURE 4: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 2, 13: 

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

NOTE: The crown area inspections that follow are not necessary at lap joint locations that have been modified

as given in Revision 4, 5 or 6 of Boeing Service Bulletin 737-53A1177.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Inspect Fuselage Skin - - (c)

INSPECTION AREA

STA

927

STA

918.12

STA

908

S-9

S-10

CHEM-MILLED STEP IS HIGHER

THAN NORMAL AT THIS LOCATION

UPPER

SKIN

TYPICAL

CRACK

FWD

TYPICAL

CRACK

C

1 2 3

1484831

(SHEET 4 OF 5)
 FIGURE 4: SKIN INSPECTIONS IN THE CROWN AREA AND OTHER AREAS OF KNOWN CRACKING

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ALERT ALERT

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 

or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(c) Do a detailed or general visual inspection of the non-lap-splice areas between STA 360 to STA 

1016 and S-10L to S-10R for horizontal chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 5 OF 5)
 FIGURE 5: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

FIGURE 5: CROWN AREA SKIN INSPECTIONS

737-300 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

1 3 2

SEE A

FWD

727A+10

STA

727

STA

928

STA

908

STA

S-14L

S-10L

S-4L

S-14L

S-10L

S-4R

540

STA

BL

0

1016

STA

S-4R

BL S-4L

0

360

STA

540

STA

INSPECTION

AREA

FOR TYPICAL

587

STA 664

STA

V21730

(SHEET 1 OF 3)
 FIGURE 5: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

This Figure applies to Group 3, 9-10, 14-15: 

UPPER

DOUBLER

SKIN

LOWER

INSPECTION AREA

TYPICAL

CRACK

UPPER

SKIN

TYPICAL

CRACK

1 2

A

3

10.00

C/L

FRAME

UP

INBD

SKIN

UPPER

SKIN

LOWER

A

A

TYPICAL

AREA

INSPECTION

C/L

STRINGER

A-A

CRACK

STRINGER

V21734

(SHEET 2 OF 3)
 FIGURE 5: CROWN AREA SKIN INSPECTIONS

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

NOTE: The crown area inspections that follow are not necessary at lap joint locations that have been modified

as given in Revision 4, 5 or 6 of Boeing Service Bulletin 737-53A1177.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Inspect Fuselage Skin - - (c)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 

NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do a detailed or general visual inspection of the non-lap-splice areas between STA 360 to STA 1016 and 

S-10L to S-10R for horizontal chem-mill cracks. If general visual inspections are accomplished in lieu of 

detailed inspections, then repeat inspection intervals are reduced as given in Paragraph 1.E., Compliance.

(SHEET 3 OF 3)
 FIGURE 6: CROWN AREA SKIN INSPECTIONS

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 6: CROWN AREA SKIN INSPECTIONS

737-400 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

SEE A

3 1 2

FWD

928

STA

STA

908

727A+10

STA

STA

727

S-4L

S-10L

S-14L

FOR TYPICAL

INSPECTION AREA STA

1016

STA

540

STA

360

S-4L

S-4R

0

BL

540

STA

S-4R

0

BL

S-10L

S-14L

550

STA

653

STA

V21736

(SHEET 1 OF 3)
 FIGURE 6: CROWN AREA SKIN INSPECTIONS

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 4, 11, 16: 

UPPER

DOUBLER

SKIN

LOWER

INSPECTION AREA

TYPICAL

CRACK

UPPER

SKIN

TYPICAL

CRACK

A

1 2

3

AREA

INSPECTION

LAP JOINT

TYPICAL

10.00

C/L

FRAME

UP

INBD

SKIN

UPPER

SKIN

LOWER

A

A

C/L

STRINGER

A-A

CRACK

STRINGER

V21737

(SHEET 2 OF 3)
 FIGURE 6: CROWN AREA SKIN INSPECTIONS

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Inspect Fuselage Skin - - (c)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 

53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do a detailed or general visual inspection of the non-lap-splice areas between STA 360 to STA 

1016 and S-10L to S-10R for horizontal chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given 

in Paragraph 1.E., Compliance.

(SHEET 3 OF 3)
 FIGURE 7: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

FIGURE 7: CROWN AREA SKIN INSPECTIONS

737-500 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

SEE A

3

1 2

1 2

FWD

STA

928

727A+10

STA

FOR TYPICAL

INSPECTION

AREA

STA

540

STA

360

0

S-4L BL

S-4R

STA

STA

908

1016

0

BL

STA

STA

540

727

S-4R

S-10L

S-14L

S-4L

S-10L

S-14L

587

STA

664

STA

STA

727C

V21738

(SHEET 1 OF 3)
 FIGURE 7: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

This Figure applies to Group 5, 12, 17: 

UPPER

DOUBLER

SKIN

LOWER

INSPECTION AREA

TYPICAL

CRACK

UPPER

SKIN

TYPICAL

CRACK

A

1 2

3

TYPICAL

LAP JOINT

AREA

INSPECTION

10.00

C/L

FRAME

UP

INBD

SKIN

UPPER

SKIN

LOWER

A

A

C/L

STRINGER

A-A

CRACK

STRINGER

V21739

(SHEET 2 OF 3)
 FIGURE 7: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Inspect Fuselage Skin - - (c)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do a detailed or general visual inspection of the non-lap-splice areas between STA 360 to STA 1016 

and S-10L to S-10R for horizontal chem-mill cracks. If general visual inspections are accomplished in lieu 

of detailed inspections, then repeat inspection intervals are reduced as given in Paragraph 1.E., 

Compliance.

(SHEET 3 OF 3)
 FIGURE 8: THIS FIGURE WAS DELETED AT REVISION 2

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ALERT ALERT

FIGURE 8: THIS FIGURE WAS DELETED AT REVISION 2

THIS FIGURE IS DELETED.

.

1553909

(SHEET 1 OF 1)
 FIGURE 9: THIS FIGURE WAS DELETED AT REVISION 2

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ALERT ALERT

FIGURE 9: THIS FIGURE WAS DELETED AT REVISION 2

THIS FIGURE IS DELETED.

.

1553909

(SHEET 1 OF 1)
 FIGURE 10: PREVENTIVE MODIFICATION

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ALERT ALERT

FIGURE 10: PREVENTIVE MODIFICATION

737-300 AND 737-500 AIRPLANES

AND INSTALLATION

FABRICATION

FOR PART

AND FASTENER REMOVAL

INSPECTION AREA

FOR TYPICAL

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

SEE B

SEE A

540 S-4R

S-14L

S-10L

BL

0

S-4L

360

STA

STA

FWD

V58074

(SHEET 1 OF 7)
 FIGURE 10: PREVENTIVE MODIFICATION

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ALERT ALERT

INSPECTION AREA

TYPICAL CRACK

500D 737-300 500D+10 737-300

482B 737-500

STA

STA

482B+10 737-500

STA

STA STA

520

S-12

FWD

VIEW LOOKING INBOARD

3

A

4

4

5 1

1 2

2

1 2

1 2

V58075

(SHEET 2 OF 7)
 FIGURE 10: PREVENTIVE MODIFICATION

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ALERT ALERT

VIEW LOOKING OUTBOARD

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I I

I

I

I I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I I I I I I I I I I I I I I I I I I

I

I

I

I I I I I I I I I I I I I I I I

I I I I I I I I I I I I I I I I I

I

I I

I

I

I

I

I

I

I

I

I

1.00 (TYPICAL)

21 EQUAL SPACES

0.75 (TYPICAL)

18 EQUAL SPACES

C

S-13

S-11

A A

B

C

B

500D+10 737-300 500D 737-300 520

STA

482B+10 737-500

STA

STA

482B 737-500

STA

STA

S-12

FWD

9 10

7 13

B

8 10

16 17

6 10 14

9 10

7 10

9 10

9 10 11 13

11

15

11

10 11

12

C C C C C C C C C

C

C C C C C C C C

C C C C C

C

C

C

C C

C C

C C

C C

C C

C C

C C

C C

C C

C

C

C

C

C C

C

C C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

V58264

(SHEET 3 OF 7)
 FIGURE 10: PREVENTIVE MODIFICATION

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ALERT ALERT

This Figure applies to Group 3, 5, 9-10, 12, 14-15, 17-21: 

SKIN

S-12

BONDED

DOUBLER

FILLER

FILLER

POCKET

DOUBLER

INTERNAL

TAPERED

SHIM

FRAME

SKIN

SKIN

DOUBLER

BONDED DOUBLER

BONDED

INTERNAL

DOUBLER

INTERNAL

DOUBLER

FILLER

POCKET

S-12

S-11

S-13

S-11

S-12

S-13

TAPERED

SHIM

FWD

A-A

12

13

14

11

14

14

13

11

B-B C-C

V62813

(SHEET 4 OF 7)
 FIGURE 10: PREVENTIVE MODIFICATION

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ALERT ALERT

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

NOTE:

1. This modification cannot be used in areas where bolts, hi-locks or lockbolts were installed in 

production.

2. Install fasteners using the fastener pattern that exists and this figure as a guide to determine 

fastener pitch. Make the new fasteners spacing 1.5 to 2.0 inch. Maintain a minimum edge margin 

of two times the fastener diameter for new fastener locations and 1.7 times the fastener diameter 

for fastener locations that exist.

3. In the typical modification shown in this figure may be different, depending on the specific location. 

Use this figure as a guide, maintaining the same number and pattern of fasteners around the 

preventive modification, and common to the tear straps or shear ties.

INSPECTION

FASTENER REMOVAL

PART FABRICATION

NOTE:

1. Size the repair parts to maintain a minimum edge margin of two times the fastener diameter at new 

fastener locations, and of 1.7 times the fastener diameter at existing fastener locations.

2. Maintain a minimum corner radius of 0.5 inch unless specified differently in the figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)(c)

STEP TASK NAME IDENTIFICATION QTY MORE DATA

3

Remove Fasteners - - In the area that will be 

common to the 

preventive modification.

4

Inspect Fastener Holes - - Common to the 

preventive modification 

(d)

5 Inspect Fuselage Skin - - (e)

STEP TASK NAME IDENTIFICATION QTY MORE DATA

6 Make Internal Doubler “A” 2024-T3 clad sheet 1 0.032 inch thick (f)

7 Make Pocket Filler “B” 2024-T3 clad sheet 4 0.040 inch thick (f)

8 Make Filler “C” under S-12 2024-T3 clad sheet 1 0.032 inch thick (f)

(SHEET 5 OF 7)
 FIGURE 10: PREVENTIVE MODIFICATION

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ALERT ALERT

INSTALLATION

NOTE:

1. Shim under shear ties, stringers and all gaps from 0.01 - 0.032 inch prior to fastener installation. 

Contact Boeing for instructions for gaps greater than 0.032 inch.

2. Clean the faying surfaces of the fuselage skin and modification parts prior to the application of 

sealant. Refer to SOPM 20-50-19 as an accepted procedure.

9 Make Tapered Shim “D” BAC 1534 8 0.032 to 0.010 inch with 

100:1 taper.

10

Apply Chemical Film 

Treatment

Alodine or Iridite - -

Primer BMS 10-79 TYPE II - 1 coat.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

11 Install Tapered Shim “D” 8 With BMS 5-95 faying 

surface sealant.

12 Install Filler, under S-12 “C” 1 With BMS 5-95 faying 

surface sealant.

13 Install Pocket Filler “B” 4 With BMS 5-95 faying 

surface sealant.

14 Install Internal Doubler “A” 1 With BMS 5-95 faying 

surface sealant.

15

Apply Fillet Seal - - Use BMS 5-95 sealant 

around the edges of the 

repair parts

16 Apply Finish - - To the repaired area to 

match adjacent structure.

17

Apply Organic Corrosion 

Inhibitor

- - Use BMS 3-23 to the 

internal surfaces of the 

repaired area.

(a) Do a detailed inspection using a bright light and a 10X magnifying glass of the surface of the skin panels 

for skin cracks.

(b) Do a subsurface Eddy Current inspection or Magneto Optical Imaging (MOI) inspection for subsurface 

skin cracks along the edge of the bonded doubler. Inspect in areas as given in Paragraph 1.E. Compliance. 

Do the MFEC Inspection as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or do the 

Magneto Optical Imaging (MOI) inspection as given in 737 NDT, Part 6, 53-30-19 or do the C-Scan 

inspection as given in 737 NDT, Part 6, 53-30-25.

(c) If external eddy current inspections can not be accomplished because of interference with external 

doublers or other interferences, internal eddy current inspection as given in 737 NDT, Part 6, 53-30-20 may 

be substituted. Do not substitute external inspections for internal unless external inspections are not 

possible.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 6 OF 7)
 FIGURE 10: PREVENTIVE MODIFICATION

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ALERT ALERT

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 are used to 

determine the part numbers used as substitutes. 

(d) Use 737 NDT, Part 6, 51-00-00, Figure 16 with .03 notch standard and 737 NDT, Part 6, 51-30-00, 

Figure 3. If cracks are found, contact Boeing. If no cracks are found, it is not necessary to make the holes 

oversize.

(e) Do a detailed inspection of the skin in the area of the modification for corrosion or disbonded doublers. 

Look for bulging, white powder, or a thin black line. If corrosion or disbond is found, contact Boeing. If no 

corrosion or disbond is found, continue with the modification.

(f) Pre-form to the contour of the fuselage.

CODE NAME IDENTIFICATION HOLE DIA MORE DATA

C Rivet BACR15BB5D( ) 0.159 - 0.171 (a)

I Rivet BACR15CE6D( ) 0.190 - 0.196 (b)

(a) The minimum diameter of the driven head of the rivet is 1.4 times the fastener diameter.

(b) Maintain a minimum edge margin at the shear tie of 1.5 times the fastener diameter. If this 

edge margin cannot be maintained, contact Boeing.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

EXAMPLE OF FASTENER SYMBOL

FASTENER

LENGTH/GRIP

FASTENER

D 6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

V77720

(SHEET 7 OF 7)
 FIGURE 11: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

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ALERT ALERT

FIGURE 11: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41 

TYPICAL

INSPECTION AREA

SEE A

SEE A

737-200C AIRPLANES

1016

STA

908

STA

727

STA STA

540

STA

360

STA

259.50

S-4L

S-4R

S-19R

S-26R

BL 0

BL 0

S-10L

S-14L

S-19L

S-24L

S-10R

S-14R

S-19R

S-4L

S-4R

S-14R

S-20R

S-25R

S-10R

S-25L

S-20L

S-14L

S-10L

S-24R

S-19L

S-26L

V21775

(SHEET 1 OF 3)
 FIGURE 11: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

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ALERT ALERT

This Figure applies to Group 1: 

CRACKS

TYPICAL

SKIN

LOWER

TYPICAL

CRACK

UPPER

DOUBLER

UPPER

SKIN

A

C/L

FRAME

1

INSPECTION

TYPICAL

AREA

1

C/L

STRINGER

V32393

(SHEET 2 OF 3)
 FIGURE 11: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

(SHEET 3 OF 3)
 FIGURE 12: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

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ALERT ALERT

FIGURE 12: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

S-4L

S-4R

S-19R

S-26R

1016

STA

908

STA

727

STA STA STA

360

STA

259.50 540

BL 0

BL 0

S-25L

S-20L

S-14L

S-10L

S-10R

S-14R

S-20R

S-4L

S-10L

S-14L

S-19L

S-24L

S-4R

S-10R

S-14R

S-19R

S-24R

S-25R

737-200 AIRPLANE

S-26R

S-19R

INSPECTION AREA

SEE A

SEE A

TYPICAL

V21780

(SHEET 1 OF 3)
 FIGURE 12: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 2: 

CRACKS

TYPICAL

SKIN

LOWER

TYPICAL

CRACK

UPPER

DOUBLER

UPPER

SKIN

A

C/L

FRAME

1

INSPECTION

TYPICAL

AREA

1

C/L

STRINGER

V32394

(SHEET 2 OF 3)
 FIGURE 12: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

Original Issue: December 14, 2000

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

(SHEET 3 OF 3)
 FIGURE 13: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

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ALERT ALERT

FIGURE 13: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

259.50

STA

360

STA

540

STA STA

727

STA

908

STA

1016

S-26R

S-19R S-25R

S-24R

S-19R

S-14R

S-24L

S-19L

S-14L

S-20R

S-14R

S-14L

S-20L

S-25L

BL 0

BL 0

737-300 AIRPLANE

TYPICAL

INSPECTION AREA

SEE A

SEE A

V21812

(SHEET 1 OF 3)
 FIGURE 13: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 3: 

CRACKS

TYPICAL

SKIN

LOWER

TYPICAL

CRACK

UPPER

DOUBLER

UPPER

SKIN

A

C/L

FRAME

1

INSPECTION

TYPICAL

AREA

1

C/L

STRINGER

V32395

(SHEET 2 OF 3)
 FIGURE 13: SKIN INSPECTIONS IN THE LOWER LOBE AREA AND IN SECTION 41

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

(SHEET 3 OF 3)
 FIGURE 14: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

FIGURE 14: SKIN INSPECTIONS IN THE LOWER LOBE AREA

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

STA

540

1016

STA

STA

540

RIGHT SIDE SHOWN

LEFT SIDE OPPOSITE

(EXCEPT AS NOTED)

INSPECTION AREA

907

STA

727

STA

727G

STA

(RIGHT SIDE ONLY)

CARGO DOOR CUTOUT

BL 0

S-25R

S-25L

S-20L

S-14L

S-10L

360

STA

SEE B

SEE B

UP

FWD

UP

FWD

S-26R

S-19R

S-10R

S-14R

S-26L

V21779

(SHEET 1 OF 3)
 FIGURE 14: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 4, 7, 11, 16: 

CRACKS

TYPICAL

SKIN

LOWER

TYPICAL

CRACK

UPPER

DOUBLER

UPPER

SKIN

B

C/L

FRAME

1

INSPECTION

TYPICAL

AREA

1

C/L

STRINGER

V32399

(SHEET 2 OF 3)
 FIGURE 14: SKIN INSPECTIONS IN THE LOWER LOBE AREA

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

(SHEET 3 OF 3)
 FIGURE 15: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

FIGURE 15: SKIN INSPECTIONS IN THE LOWER LOBE AREA

(EXCEPT AS NOTED)

LEFT SIDE OPPOSITE

RIGHT SIDE SHOWN

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

INSPECTION AREA

S-25R

S-25L

S-20L

S-14L

S-10L

BL 0

STA

1016

(RIGHT SIDE ONLY)

CARGO DOOR CUTOUT

540

STA

360

STA

S-26R

S-14R

S-19R

S-10R

S-26L

SEE B

SEE B

UP

FWD

UP

FWD

540

727

STA

STA

908

STA

V21783

(SHEET 1 OF 3)
 FIGURE 15: SKIN INSPECTIONS IN THE LOWER LOBE AREA

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 5, 8, 12, 17, 19-20: 

CRACKS

TYPICAL

SKIN

LOWER

TYPICAL

CRACK

UPPER

DOUBLER

UPPER

SKIN

B

C/L

FRAME

1

INSPECTION

TYPICAL

AREA

1

C/L

STRINGER

V32403

(SHEET 2 OF 3)
 FIGURE 15: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

(SHEET 3 OF 3)
 FIGURE 16: THIS FIGURE WAS DELETED AT REVISION 2

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ALERT ALERT

FIGURE 16: THIS FIGURE WAS DELETED AT REVISION 2

THIS FIGURE IS DELETED.

.

1553909

(SHEET 1 OF 1)
 FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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ALERT ALERT

FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT

TYPICAL CRACK

3

FOR PART FABRICATION

A SEE AND INSTALLATION

1

INSPECTION, FASTENER REMOVAL

AND SKIN TRIM

TYPICAL CRACK LOCATION

INSPECTION AREA

1

2X R O.50

1.0 1.0

S-4

S-10S-14

5 4 2

V22961

(SHEET 1 OF 6)
 FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. 10 11 7 9 PART FABRICATION

AND INSTALLATION

9 8

6 9

A

13

1.200.90(TYPICAL)

1.101.10

12

14

G

4

G

4

4

E

4

E

4

E

4

E

4

E

4

E

E

3

E

3

E

3

F

4

E

4

E

4

E

4

F

4

F

34

F

3

F

2

G

2

G

2

G

2

G

2

G

2

G

2

G

2

G

2

G

2

G

E

3

E

3

E

3

E

3

E

3

E

3

E

3

E

3

E

3

E E E E E E E E

3 3 3 3 3 3 3 3

E E E E E E E

3 3 3 3 3 3 3

G G G G G

2 2

G

2

G

2 2

G

2 2 2

G G G G G

2 2

G

2

G

2 2

G

2 2 2

G G G G G

2 2

G

2

G

2 2

G

2 2 2

G G G G G

2 2

G

2

G

2 2

G

2 2 2

G

2

G

3

4

E

4

E

4

E

4

E

4

E

4

E

G

G

3

3

4

E

4

E

4

E

4

E

4

E

4

E

3

E

3

E

3

E

G

2

G

2

G

2

G

2

G

2 3

G

3

G

3

G

3

G

4

G

G

2

G

2

G

2

G

2

G

2

G

2

G

2

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3

G

3 4

F

4

F

4

F

3

F

3

G

3

G

3

G G

2

G

2

G

2

G

2

G

2

(TYPICAL)

EXISTINGFASTENER

V22962

(SHEET 2 OF 6)
 FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

NOTE:

1. This repair cannot be used if the fasteners that exist are larger than 3/16 inch diameter.

2. This repair cannot be used in areas where hi-locks, lockbolts, or bolts were installed in production. 

If these fasteners are installed in the area of a crack, ask Boeing for repair data.

3. Report all cracks found at locations that do not require NDT inspections as given in this service 

bulletin or service bulletins 737-53-1065, 737-53-1168 or 737-53-1187 to Boeing. Include crack 

length, body station and stringer location, airplane identifier, and total accumulated flight-cycles. 

Provide photos when possible.

4. Install fasteners using the fastener pattern that exists as a guide in the fore and aft direction. Use 

this figure to determine fastener pitch in the circumferential direction. Make the distance between 

fasteners 0.90 - 1.20 inch. Maintain a minimum edge margin of two times the fastener diameter 

for new fastener locations and 1.7 times the fastener diameter for fastener locations that exist.

5. In the typical repair shown in this figure, the left side tear strap location shows a typical shear tie 

fastener pattern. The right side tear strap location shows a typical non-shear tied fastener pattern. 

The detail may be different, depending on the specific repair location. Use this figure as a guide, 

maintaining the same number and pattern of fasteners around the cutout, and common to the tear 

straps or shear ties.

INSPECTION

FASTENER REMOVAL AND SKIN TRIM

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Lap Joint - - (b)

(SHEET 3 OF 6)
 FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

NOTE:

1. Trim skin as shown, regardless of crack length.

2. Maintain a minimum edge margin of 2 times the fastener diameter at all fastener locations.

3. Locate the trim lines so that the upper edge of the lower skin is not damaged.

4. Maintain a 63 micro-inch or better surface finish on all trimmed structure. 

PART FABRICATION

NOTE:

1. Size the repair parts to maintain a minimum edge margin of two times the fastener diameter at new 

fastener locations, and of 1.7 times the fastener diameter at existing fastener locations.

2. Maintain a minimum corner radius of 0.5 inch.

INSTALLATION

STEP TASK NAME IDENTIFICATION QTY MORE DATA

3 Remove / Discard Fasteners - - In the area that will be 

common to the repair.

4 Trim Skin - - (c)

Remove Trimmed Skin - 1 -

5

Apply Chemical Film 

Treatment

Alodine or Iridite - (d)

Primer BMS 10-79 TYPE II - 1 coat (d)

STEP TASK NAME IDENTIFICATION QTY MORE DATA

6 Measure Upper Skin Thickness - 1 -

Make Doubler “A” 2024-T3 clad sheet 1 See table 1 (e)

7 Make Filler “B” 2024-T3 clad sheet 1 0.040 inch thick (e) (f)

8 Make Filler “C” 2024-T3 clad sheet 1 0.032 inch thick (e)

9 Apply Chemical Film Treatment Alodine or Iridite - -

Primer BMS 10-79 TYPE II - 1 coat.

(SHEET 4 OF 6)
 FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

NOTE:

1. Shim all gaps from 0.01 - 0.04 inch prior to fastener installation. Contact Boeing for instructions for 

gaps greater than 0.04 inch.

2. Clean the faying surfaces of the fuselage skin and modification parts prior to the application of 

sealant. Refer to SOPM 20-50-19 as an accepted procedure.

Table 1 - Doubler Thickness Table

STEP TASK NAME IDENTIFICATION QTY MORE DATA

10 Install Filler C 1 With BMS 5-95 faying 

surface sealant.

11 Install Filler B 1 With BMS 5-95 faying 

surface sealant.

12 Install Doubler A 1 With BMS 5-95 faying 

surface sealant.

13

Apply Fillet Seal - - Use BMS 5-95 sealant 

around the edges of the 

repair parts.

14 Apply Finish - - To the repaired area to 

match adjacent structure.

(a) Do an external detailed inspection of the skin in the area of chem-milled step for cracks. Also do an 

external detailed inspection of the skin for cracks at the end holes common to the tear strap tabs.

(b) Do an external detailed inspection of the skin and lap joint in the area of the repair for corrosion or 

disbonded doublers. Look for bulging, white powder, or a thin black line. If corrosion or disbond is found, 

contact Boeing. If no corrosion or disbond is found, continue with the repair.

(c) The trim-out must be as shown to eliminate undetected cracks. The trim-out must be a minimum of 0.5 

inch beyond the visible ends of the crack. If this is not possible, then accomplish HFEC inspections as given 

in 737 NDT, Part 6, 51-00-00 Figure 4 or 23. Do the HFEC inspection on the part surface around the trim out 

and on the cut end of the trim out, center the HFEC probe on the edge of the part that had the crack. If no 

cracks are found, trim an additional 0.04 inch around the cutout as an insurance cut.

(d) To all cut edges of the skin.

(e) Pre-form to match the contour of the fuselage.

(f) This thickness is a target value. Use a thickness for this filler that makes the thickness of filler B plus the 

thickness of filler C the same thickness as the lap joint step (the thickness of the upper skin plus the bonded 

doubler), plus or minus 0.01 inch.

Upper Skin 

Thickness 

(inches)

Doubler “A” 

Thickness 

(inches)

0.036 0.040

0.040 0.050

0.045 0.050

0.050 or greater Contact Boeing

(SHEET 5 OF 6)
 FIGURE 17: TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

CODE NAME IDENTIFICATION HOLE DIA MORE DATA

E Blind Rivet BACR15FR5E()R 0.176 - 0.180 (a)(b)(g)

Blind Rivet BACR15FR6E()R 0.205 - 0.209 (a)(c)(d)(g)

F Blind Rivet BACR15FR6E()R 0.205 - 0.209 (a)(e)(g)

G Blind Rivet BACR15FR5E()R 0.176 - 0.180 (f)(g)

(a) Install with a repair washer as given in 737-100/200 SRM 51-30-08, 737-300 SRM 51-40-08, 

737-400 SRM 51-40-08, 737-500 SRM 51-40-08.

(b) If the original fastener was 5/32 inch diameter.

(c) Optional if it is necessary to make the hole larger to remove damage.

(d) If the original fastener was 3/16 inch diameter.

(e) Maintain a minimum edge margin at the shear tie of 1.5 times the fastener diameter. If this 

edge margin cannot be maintained, contact Boeing.

(f) Use caution when locating these fasteners common to the tearstraps. Maintain a minimum 

edge margin of 1.7 times the fastener diameter from the edge of the tearstrap.

(g) NAS1738E()-() optional to BACR15FR()E()R.

EXAMPLE OF FASTENER SYMBOL

FASTENER

LENGTH/GRIP

FASTENER

D 6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

V77720

(SHEET 6 OF 6)
 FIGURE 18: INSPECTION OF THE TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 18: INSPECTION OF THE TIME-LIMITED SKIN REPAIR AT A LAP JOINT S-4 S-10 S-14

3 2

1

SEE A

1

TIME - LIMITED REPAIR

TYPICAL

EXTERNALINSPECTION AREA

INTERNALINSPECTION AREA

V27531

(SHEET 1 OF 3)
 FIGURE 18: INSPECTION OF THE TIME-LIMITED SKIN REPAIR AT A LAP JOINT

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

EXTERNAL INSPECTION

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)(b)

(a) At the chem-milled step in each adjacent bay for cracks. If a crack is found, contact Boeing. If no cracks 

are found, continue with the inspections.

(b) Do an External Subsurface Eddy Current in each adjacent bay for cracks as given in 737 NDT, Part 6, 

53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

COVERS THE LOWER SKIN

TEAR STRAP OR DOUBLER

TYPICAL WHERE THE

THE LOWER SKIN

TYPICAL WHERE

IS NOT COVERED TEAR STRAP

FWD

4

4

3

2

A

ONE LAP JOINT CONFIGURATION SHOWN,

OTHER CONFIGURATIONS SIMILAR

V27657

(SHEET 2 OF 3)
 FIGURE 18: INSPECTION OF THE TIME-LIMITED SKIN REPAIR AT A LAP JOINT

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

ONE-TIME INTERNAL INSPECTION

STEP TASK NAME IDENTIFICATION QTY MORE DATA

2 Inspect Fuselage Skin Under 

Tear Strap

- - (a)(b)(e)

3 Inspect Fuselage Skin - - (a)(c)(e)

4 Inspect Lap Joint - - (a)(d)(e)

(a) Remove equipment as necessary from the passenger compartment to do an internal inspection of the 

skin at the lower row of fasteners in the lap joint. This inspection is only required one-time.

(b) Do a Low Frequency Eddy Current inspection at the lower row of lap joint fasteners for cracks as given in 

737 NDT, Part 6, 53-30-12.

(c) Do a Medium Frequency Eddy Current inspection at the lower row of lap joint fasteners between tear 

straps as given in 737 NDT, Part 6, 53-30-16.

(d) Do a general visual inspection for corrosion. Look for bulging, white powder, or a thin black line.

(e) This inspection is not required at stringers S-10L and S-10R in the areas between STA 540 and STA 727.

(SHEET 3 OF 3)
 FIGURE 19: THIS FIGURE WAS DELETED AT REVISION 2

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 19: THIS FIGURE WAS DELETED AT REVISION 2

THIS FIGURE IS DELETED.

.

1553909

(SHEET 1 OF 1)
 FIGURE 20: THIS FIGURE WAS DELETED AT REVISION 2

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 20: THIS FIGURE WAS DELETED AT REVISION 2

THIS FIGURE IS DELETED.

.

1553909

(SHEET 1 OF 1)
 FIGURE 21: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-19R TO 

24R AND S-4L TO S-4R

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 21: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-19R TO 24R 

AND S-4L TO S-4R

This Figure applies to Group 6-12, 15-18, 20: 

INSPECTION AREA

STA

360

STA

259.5

BL 0

S-24R

S-19R

S-14R

S-4R

S-4L

S-14L

S-24L

BL 0

STA

259.5

STA

360

LAV

FWD

GALLEY

DOOR

FWD

ENTRY

DOOR

1

2

SEE A

A

1484869

(SHEET 1 OF 2)
 FIGURE 21: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-19R TO 

24R AND S-4L TO S-4R

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)(b)

2 Inspect Skin Panel - - (a)(b)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

(b) Skin panel areas which do not have shading are solid skin panels and do not require inspection.

(SHEET 2 OF 2)
 FIGURE 22: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-24R TO S24 L

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 22: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-24R TO S24 L

This Figure applies to Group 4-5, 13-14, 19, 21: 

INSPECTION AREA

STA

360

STA

259.5

BL 0

S-24R

S-19R

S-14R

S-4R

S-4L

S-14L

S-24L

BL 0

STA

259.5

STA

360

LAV

FWD

GALLEY

DOOR

FWD

ENTRY

DOOR

1

SEE A

A

1484872

(SHEET 1 OF 2)
 FIGURE 22: SECTION 41 - EXTERNAL INSPECTION BETWEEN STA 259.5 AND STA 360 - S-24R TO S24 L

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)(b)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced as given in 

Paragraph 1.E., Compliance.

(b) Skin panel areas which do not have shading are solid skin panels and do not require inspection.

(SHEET 2 OF 2)
 FIGURE 23: TEAR STRAP ATTACHMENT TO SKIN INSPECTION

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 23: TEAR STRAP ATTACHMENT TO SKIN INSPECTION

This Figure applies to Group 1-5, 9-21: 

S-14L

S-10L

S-4L

S-4R

UPPER

DOUBLER

SKIN

LOWER

UPPER

SKIN

TYPICAL CRACK

STA

259.5

STA

1016

10.00

C/L

FRAME

TYPICAL

AREA

INSPECTION

C/L

STRINGER

1484891

(SHEET 1 OF 2)
 FIGURE 23: TEAR STRAP ATTACHMENT TO SKIN INSPECTION

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin at the Tear Strap 

Tab End Holes

- - (a)(b)

(a) Do a High Frequency Eddy current (HFEC) inspection of the fuselage skin (external) at each tear strap 

attachment at locations identified in Figures 3-7, 45 and 46 for chem-mill inspections at lap joints as given in 

737 NDT, Part 6, 53-30-05 or 737 NDT, Part 6, 51-00-00 Figure 15.

(b) If external eddy current inspections can not be accomplished because of interference with external 

doublers, then refer to Paragraph 1.E., Compliance for guidance.

(SHEET 2 OF 2)
 FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

ALLOWABLE

TRIM AREA

TYPICAL

CRACK

STA

520

TYPICAL

LAP

DOUBLER

STA

540

STA

360

500D = 737-300

482B = 737-500

S-12

TYPICAL

LAP

DOUBLER

UP

FWD

A

SEE A SEE B

SEE C

3 4 1

RIGHT SIDE SHOWN

LEFT SIDE OPPOSITE

2

1484918

(SHEET 1 OF 7)
 FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

SKIN TRIM

B

5

UP

FWD

6 7 8 9 6 7 8 9

2X R O.50

TYPICAL

CRACK

1485239

(SHEET 2 OF 7)
 FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 3, 5, 9-10, 12, 14-15, 17-21: 

E

E

E

E

E

E

E

E

E

E

E

E

E

E

E

E

S-12

STA

520

D

D

D

D D

D

D

D

D

D

D

D

D

D

D

D

D

TYPICAL LAP

DOUBLER

TYPICAL

LAP

DOUBLER

D D D D D D D D D D D D D D D D D D D

A A A A A A A B A A A A A A A

A A A A A A A B A A A A A A A

DOUBLER

TRIPLER

DOUBLER

500D = 737-300

482B = 737-500

UP

FWD

C C C

C C C

C C C

C

C C C

C C C

C C C

C C

C C

C

C

C

C

C

C

C

C

C

C

C

A A A

A A A

A A

A A

10 11

18 19

20 22 23

21

16 17

15

26 25 21

24

12

14 13

B

B

B

B

B

B

B

C C C C C C C C C C C C C C

C C C C C C C C C C C C C C

C C C C C C C

C C C C C C C

C C C C C C C

C C C C C C C

C C C C C C C

C C C C C C C C C C C C C C

C C C C C C C

C C C C C C C

C C C C C C C

C C C C C C C

C C C C C C C

B

B

B

B

1485261

(SHEET 3 OF 7)
 FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY

MORE 

DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Remove Fasteners - - (c)

4 Inspect Fastener Holes - - (d)

5 Inspect Fuselage Skin - - (e)

6 Cut Fuselage Skin - - (f)

7 Inspect Fuselage Skin - - (g)

8 Cut Fuselage Skin - - (h)

9 Apply Chemical Conversion Coating Type 2, Class A - (i)

10 Make Doubler .032 inch 2024-T3 - (j)

11 Make Tripler .050 inch 2024-T3 - (k)(l)

12 Make Tearstrap Splice Strap .040 inch 2024-T3 - (m)

13 Make Tapered Filler .040 inch 2024-T3 - (m)

14 Make Tapered Filler .040 inch 2024-T3 - (m)

15 Drill Holes - - (n)

16 Mark Holes - - (o)

17 Drill Holes - - (p)

18 Deburr Repair - - (q)

19 Apply Chemical Conversion Coating Type 2, Class A - (r)

20 Apply Primer BMS 10-79 type II 

or type III primer

- (s)

21 Install Repair Washers - - (t)

22 Clean Repair - - (u)

23

Apply Sealant BMS 5-95 - (v)

Locate Repair - -

Install Fasteners - -

24 Apply Fillet Seal BMS 5-95 (w)

25 Apply Corrosion Inhibiting 

Compound

BMS 3-23 type 2 - (x)

26 Apply Finish - - (y)

(a) Do an External Subsurface Eddy Current inspection of the chem-milled step in each adjacent bay for 

chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 

53-30-19 or 737 NDT, Part 6, 53-30-25.

(b) This repair can be used for up to 4 cracks provided they are contained between tearstraps in the shaded 

areas.

(c) From the area that will be common to the repair.

(SHEET 4 OF 7)
 FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

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(d) Do an High Frequency Eddy Current (HFEC) inspections of all fastener holes common to the repair 

doubler, including the window frame as given in 737 NDT, Part 6, 51-00-00 figure 16, using .030 inch notch 

sensitivity.

(e) Do an internal detailed inspection of the skin, bonded doubler and frames in the area of the repair for 

cracks, corrosion or disbonded doublers. Look for bulging, white powder, or a thin black line. If cracks, 

corrosion or disbond is found, contact Boeing. If no cracks, corrosion or disbond is found, continue with the 

repair.

(f) Carefully cut and remove the damaged part of the skin. Make sure that a minimum of .50 inch radius is 

maintained. If necessary, use a thin steel sheet to protect adjacent structure. The cutout must be contained 

between tearstraps. Do not cut into the tearstrap.

(g) HFEC inspect along the edge of the cutouts as given in 737 NDT, Part 6, 51-00-00 figure 4 or 23. Make 

sure there are no cracks, and disbond between the strap and skin.

(h) If there is no further damage, make the cutout larger by .040 inch as insurance cut. All cutout edges must 

have a finish of 63 Ra or better. The cutout must be contained between tearstraps. Do not cut into the 

tearstrap.

(i) Apply one coat of chemical conversion coating to all cut surfaces of the skin panel. Refer to 737-300 SRM 

51-20-01 or 737-500 SRM 51-20-01 as an accepted procedure.

(j) Make doubler from .032 inch 2024-T3 Clad Aluminum. Make sure a 2D edge margin and a 0.50 inch 

minimum outside corner radius is maintained. Pre-form to match the fuselage contour.

(k) Make tripler from .050 inch 2024-T3 Clad Aluminum. Make sure a 2D edge margin and a 0.50 inch 

minimum outside corner radius is maintained. Pre-form to match the fuselage contour.

(l) Chamfer the edges of the tripler. Refer to 737-300 SRM 51-10-01 or 737-500 SRM 51-10-01 as an 

accepted procedure.

(m) Make tearstrap splice strap and tapered fillers from 0.04 inch 2024-T3 clad aluminum. Make sure a 2D 

edge margin and a 0.50 inch minimum outside corner radius is maintained. Taper the fillers from 0.04 to 0.01 

at a minimum 50:1 taper ratio.

(n) Drill existing holes into doubler and tripler.

(o) Mark out new hole positions. Use the guide lines of the figure. Make sure a 2D edge margin and a 

minimum 5D fastener spacing is maintained.

(p) Drill new hole positions into doubler, tripler, splice strap and skin panel.

(q) Remove all nicks, scratches, gouges, burrs, and sharp edges from the skin panel, doubler and tripler. 

Make sure machined surfaces to be 63 Ra or better.

(r) Apply one coat of chemical conversion coating to all bare surfaces of the skin panel, doubler and tripler. 

Refer to 737-300 SRM 51-20-01 or 737-500 SRM 51-20-01 as an accepted procedure.

(s) Apply two coats of BMS 10-79 type II or type III primer to all bare surfaces of the skin panel, doubler and 

tripler. Refer to 737-300 SRM 51-20-01 or 737-500 SRM 51-20-01as an accepted procedure.

(t) Install repair washers in the countersink holes in the skin panels between the doubler and the skin panel. 

Install all repair washers with BMS 5-95 Class B-1/2 or B-2 sealant. Refer to 737-300 SRM 51-40-08 or 

737-500 SRM 51-40-08 and SOPM 20-50-19 as an accepted procedures.

(u) Clean the mating surfaces of the skin panel, doubler and tripler to be sealed. Refer to 737-300 SRM 

51-20-05 or 737-500 SRM 51-20-05 as an accepted procedure.

(v) Apply BMS 5-95 Class B-1/2 or B-2 sealant to the mating surfaces of the skin panel, doubler and tripler. 

Refer to SOPM 20-50-19 as an accepted procedure. Refer to fastener code table for fastener installation. 

STEP TASK NAME IDENTIFICATION QTY

MORE 

DATA

(SHEET 5 OF 7)
 FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

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ALERT ALERT

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the 

number of fasteners necessary for this figure.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65-88700 are used to 

determine the part numbers used as substitutes. 

(w) Apply fillet sealant along the edges of the doubler and tripler. Refer to SOPM 20-50-19 as an accepted 

procedure.

(x) Apply a layer of BMS 3-23 type 2 corrosion inhibiting compound onto the internal surface of the entire

repair area. Refer to 737-300 SRM 51-20-01 or 737-500 SRM 51-20-01 as an accepted procedure.

(y) Restore the original finish of the external surface of the repair area. Refer to 737-300/400/500 AMM 

51-21-00 as an accepted procedure.

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

A Rivet BACR15BB6AD( ) 38 0.190 - 0.196 (a)(b)

B Rivet BACR15BB6D( ) 14 0.190 - 0.196 (a)(b)

C Rivet BACR15CE5D( ) 123 0.159 - 0.165 (a)(b)

D Rivet BACR15BB6D( ) 37 0.190 - 0.196 (a)(b)

E Rivet BACR15BB10D( ) 16 0.316 - 0.322 (a)(c)(d)(e)

Bolt BACB30FM10A( ) 16 0.309 - 0.313

(a) Install all new rivets dry. 

(b) The minimum diameter of the driven head of the rivet is 1.4 times the fastener diameter.

STEP TASK NAME IDENTIFICATION QTY

MORE 

DATA

EXAMPLE OF FASTENER SYMBOL

FASTENER

LENGTH/GRIP

FASTENER

D 6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

V77720

(SHEET 6 OF 7)
 FIGURE 24: SKIN CHEM-MILL LINE CRACK AT STRINGER 12 - REPAIR

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ALERT ALERT

(c) If existing fastener was a rivet, install a new rivet. If existing fastener was a bolt, install a new bolt.

(d) Install all bolts wet with BMS 5-95 Class B-1/2 or B-2. Refer to SOPM 20-50-19 as an accepted procedure. 

(e) Oversize fastener hole to remove the countersink. Make sure a minimum edge margin of 1.7 times the 

fastener diameter is maintained. If this edge margin cannot be maintained, contact Boeing.

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

(SHEET 7 OF 7)
 FIGURE 25: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

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ALERT ALERT

FIGURE 25: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

S-10R

S-19R

S-17R

STA

360

STA

540

STA

727

STA

908

STA

460

STA

312

STA

500C

STA

727G

1

SEE B

SEE C

SEE A

SEE C

SEE C

SEE C

SEE C

SEE C

737-400

AIRPLANES

2

1 9

1 8

1 7

1 6 1 5

1 4

1 3

1488582

(SHEET 1 OF 4)
 FIGURE 25: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

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ALERT ALERT

INSPECTION AREA

TYPICAL

CRACK

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

S-17R

UP

FWD

S-19R

S-20R

LOWER

SKIN

PANEL

LAP

JOINT

UPPER

SKIN

PANEL

B

STA

460

STA

469.90

EDGE OF

SKIN

A

STA

312

1 2

1 4

1488645

(SHEET 2 OF 4)
 FIGURE 25: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

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This Figure applies to Group 4, 11, 16: 

INSPECTION AREA

TYPICAL

CRACK

TYPICAL

CRACK

UP

FWD

STRINGER

STRINGER

STRINGER

STRINGER

STRINGER

C

BUTT

JOINT

LAP

JOINT

UPPER AFT

SKIN PANEL

UPPER FORWARD

SKIN PANEL

TYPICAL CIRCUMFERENTIAL

BUTT SPLICE

1 3 5 6

7 8 9

1494540

(SHEET 3 OF 4)
 FIGURE 25: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)

2 Inspect Skin Panel - - (b)

3 Inspect Skin Panel - - (c)

4 Inspect Skin Panel - - (d)

5 Inspect Skin Panel - - (e)

6 Inspect Skin Panel - - (f)

7 Inspect Skin Panel - - (g)

8 Inspect Skin Panel - - (h)

9 Inspect Skin Panel - - (i)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks. 

(b) Do a Low Frequency Eddy Current (LFEC) or Magneto Optical Imaging (MOI) or C-Scan inspection 

at STA 312 below S-19R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do a LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 360 between S-10L 

and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 

53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(d) Do a LFEC or MOI or C-Scan inspection at STA 460 below S-17R for vertical subsurface skin cracks 

as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 

NDT, Part 6, 53-30-25.

(e) Do a LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 500C between S-10L 

and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 

53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(f) Do a LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 540 between S-10L 

and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 

53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(g) Do a LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 727 between S-10L 

and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 

53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(h) Do a LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 727G between S-10L 

and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 

53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(i) Do a LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 908 between S-10L 

and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 

53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 4 OF 4)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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ALERT ALERT

FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

S-16L

STA

360

S-18L

S-20L

S-22L

S-26L

S-14L

STA

500A

STA

540

STA

440

S-16R

STA

360 S-18R

S-20R

S-22R

S-26R

S-14R

STA

500A

STA

540

STA

440

FWD

FWD

SEE C

SEE B

737-300 LEFT SIDE

SEE A

SEE F

SEE E

SEE D

737-300 RIGHT SIDE

1491147

(SHEET 1 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

S-14L

S-15L

S-16L

S-17L

S-18L

S-19L

S-20L

S-21L

S-22L

S-23L

S-24L

S-25L

S-26L

STA

370

STA

380

STA

390

STA

400

STA

410

STA

420

STA

360

STA

430

STA

440

A

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

FWD

UP

1

SEE G

1494612

(SHEET 2 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

S-14L

S-15L

S-16L

S-17L

S-18L

S-19L

S-20L

S-21L

S-22L

S-23L

S-24L

S-25L

S-26L

STA

450

STA

460

STA

470

STA

480

STA

490

STA

500

STA

440

STA

500A

B

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

FWD

UP

1

SEE G

1491160

(SHEET 3 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

S-14L

S-15L

S-16L

S-17L

S-18L

S-19L

S-20L

S-21L

S-22L

S-23L

S-24L

S-25L

S-26L

STA

500B

STA

500C

STA

500D

STA

510

STA

530

STA

520

STA

540

C

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

FWD

UP

1

SEE G

1494639

(SHEET 4 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

STA

430

STA

420

STA

410

STA

400

STA

390

STA

380

STA

440

STA

370

STA

360

S-14R

S-15R

S-16R

S-17R

S-18R

S-19R

S-20R

S-21R

S-22R

S-23R

S-24R

S-25R

S-26R

UP

FWD

D

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

1

SEE G

1491162

(SHEET 5 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

STA

500A

STA

500

STA

490

STA

480

STA

470

STA

460

STA

450

STA

440

S-14R

S-15R

S-16R

S-17R

S-18R

S-19R

S-20R

S-21R

S-22R

S-23R

S-24R

S-25R

S-26R

UP

E FWD

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

1

SEE G

CARGO DOOR

CUTOUT

1491421

(SHEET 6 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

STA

530

STA

510

STA

500D

STA

500C

STA

500B

STA

520

STA

540

S-14R

S-15R

S-16R

S-17R

S-18R

S-19R

S-20R

S-21R

S-22R

S-23R

S-24R

S-25R

S-26R

UP

F FWD

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

1

SEE G

1494725

(SHEET 7 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 3, 6, 9-10, 14-15, 18, 21: 

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

FRAME FRAME

STRINGER

STRINGER

TYPICAL BAY NEXT TO WING-TO-BODY FAIRING

TYPICAL

CRACK

TYPICAL

CRACK

TYPICAL

CRACK

TYPICAL

CRACK

1

G

G

1

1548926

(SHEET 8 OF 9)
 FIGURE 26: SKIN INSPECTION - LEFT AND RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, 

STRINGER 14 - STRINGER 26

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do an eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 

NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 9 OF 9)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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ALERT ALERT

FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 - 

STRINGER 26

S-16L

S-18L

S-20L

S-22L

S-26L

S-14L

STA

440

STA

540

STA

360

STA

360

STA

440

STA

482A

S-16R

S-18R

S-20R

S-22R

S-26R

S-14R

STA

482A

FWD

FWD

SEE C

SEE B

737-500 LEFT SIDE

SEE A

SEE E

SEE D

737-500 RIGHT SIDE

1494796

(SHEET 1 OF 8)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

S-14L

S-15L

S-16L

S-17L

S-18L

S-19L

S-20L

S-21L

S-22L

S-23L

S-24L

S-25L

S-26L

STA

370

STA

380

STA

390

STA

400

STA

410

STA

420

STA

360

STA

430

STA

440

A

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

FWD

UP

1

SEE F

1494810

(SHEET 2 OF 8)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

EDDY CURRENT INSPECTION

AREA

S-14L

S-15L

S-16L

S-17L

S-18L

S-19L

S-20L

S-21L

S-22L

S-23L

S-24L

S-25L

S-26L

STA

460

STA

482

STA

482A

STA

440

B

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

FWD

UP

1 SEE F

1494824

(SHEET 3 OF 8)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION

AREA

S-14L

S-15L

S-16L

S-17L

S-18L

S-19L

S-20L

S-21L

S-22L

S-23L

S-24L

S-25L

S-26L

STA

482B

STA

520

STA

540

STA

482A

C

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

FWD

UP

1 SEE F

1495099

(SHEET 4 OF 8)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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ALERT ALERT

CARGO

DOOR

CUTOUT

EDDY CURRENT INSPECTION

AREA

STA

430

STA

420

STA

410

STA

400

STA

390

STA

380

STA

440

STA

370

STA

360

S-14R

S-15R

S-16R

S-17R

S-18R

S-19R

S-20R

S-21R

S-22R

S-23R

S-24R

S-25R

S-26R

UP

FWD

D

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

1

SEE F

1495108

(SHEET 5 OF 8)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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ALERT ALERT

EDDY CURRENT INSPECTION AREA

STA

482A

STA

482

STA

460

STA

440

S-14R

S-15R

S-16R

S-17R

S-18R

S-19R

S-20R

S-21R

S-22R

S-23R

S-24R

S-25R

S-26R

UP

FWD

E

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

1 SEE F

CARGO DOOR

CUTOUT

1495109

(SHEET 6 OF 8)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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ALERT ALERT

This Figure applies to Group 5, 8, 12, 17, 19-20: 

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

FRAME FRAME

STRINGER

STRINGER

TYPICAL BAY NEXT TO WING-TO-BODY FAIRING

TYPICAL

CRACK

TYPICAL

CRACK

TYPICAL

CRACK

TYPICAL

CRACK

1

F

F

1

1548936

(SHEET 7 OF 8)
 FIGURE 27: SKIN INSPECTION - RIGHT HAND SIDE BETWEEN STA 360 AND STA 540, STRINGER 14 

- STRINGER 26

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do an eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, 

Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 8 OF 8)
 FIGURE 28: SECTION 41 - SKIN INSPECTION - STRINGER-18R AND STRINGER-19R BETWEEN STA 

303 AND STA 320 AND STRINGER- 15R BETWEEN STA 344 AND STA 352

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ALERT ALERT

FIGURE 28: SECTION 41 - SKIN INSPECTION - STRINGER-18R AND STRINGER-19R BETWEEN STA 303 

AND STA 320 AND STRINGER- 15R BETWEEN STA 344 AND STA 352

EDDY CURRENT INSPECTION

AREA

STA

360

STA

259.5

STA

328

STA

344

STA

352

STA

303

STA

360

SERVICE

DOOR

S-14R

S-15R

S-16R

S-17R

S-18R

S-19R

S-20R

S-21R

STA

320

STA

294.5

STA

312

UP

FWD

SEE A

A

1

2

3

SEE B

SEE B

SEE B

1495114

(SHEET 1 OF 2)
 FIGURE 28: SECTION 41 - SKIN INSPECTION - STRINGER-18R AND STRINGER-19R BETWEEN STA 

303 AND STA 320 AND STRINGER- 15R BETWEEN STA 344 AND STA 352

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ALERT ALERT

This Figure applies to Group 1-5, 13-14, 19, 21: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)

2 Inspect Skin Panel - - (b)

3 Inspect Skin Panel - - (c)

(a) Do a LFEC or MOI or C-Scan inspection between STA 344 and STA 352 below S-14R for subsurface skin 

cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 

737 NDT, Part 6, 53-30-25.

(b) Do a LFEC or MOI or C-Scan inspection between STA 303 and STA 320 below S-18R for subsurface skin 

cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 

737 NDT, Part 6, 53-30-25.

(c) Do a LFEC or MOI or C-Scan inspection between STA 303 and STA 320 above S-19R for subsurface skin 

cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 

737 NDT, Part 6, 53-30-25.

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL

CRACK

TYPICAL

CRACK

1

B

2 3

1548941

(SHEET 2 OF 2)
 FIGURE 29: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

FIGURE 29: SKIN INSPECTIONS IN THE LOWER LOBE AREA

259.50

STA

360

STA

540

STA STA

727

STA

908

STA

1016

S-26R

S-19R S-25R

S-24R

S-19R

S-14R

S-24L

S-19L

S-14L

S-20R

S-14R

S-14L

S-20L

S-25L

BL 0

BL 0

737-300 AIRPLANE

TYPICAL

INSPECTION AREA

SEE A

SEE A

1495639

(SHEET 1 OF 3)
 FIGURE 29: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

This Figure applies to Group 6, 9-10, 14-15, 18, 21: 

CRACKS

TYPICAL

SKIN

LOWER

TYPICAL

CRACK

UPPER

DOUBLER

UPPER

SKIN

A

C/L

FRAME

1

INSPECTION

TYPICAL

AREA

1

C/L

STRINGER

1496492

(SHEET 2 OF 3)
 FIGURE 29: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced. Refer to 

Paragraph 1.E., Compliance for repeat inspection interval requirements.

(SHEET 3 OF 3)
 FIGURE 30: TYPICAL INTERNAL INSPECTION

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ALERT ALERT

FIGURE 30: TYPICAL INTERNAL INSPECTION

480

STA

S-18

S-20

S-22

360

STA

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

S-14

FWD

1 2 SEE A B

1495668

(SHEET 1 OF 3)
 FIGURE 30: TYPICAL INTERNAL INSPECTION

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ALERT ALERT

BONDED

EDGE OF

DOUBLER

CRACKS

SKIN 0.25

0.25

STRINGER

STRINGER

FRAME FRAME

0.25

EDGE OF

BONDED

DOUBLER

ASSEMBLY

SKIN PANEL

FRAME FRAME FRAME

SKIN CRACK

STRINGER

STRINGER

STRINGER

DOUBLER INSPECTION ZONE NEAR SKIN CRACK

CRACK AT WING-TO-BODY FAIRING

1

2

2

2

1

A

B

1495678

(SHEET 2 OF 3)
 FIGURE 30: TYPICAL INTERNAL INSPECTION

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ALERT ALERT

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

When cracking is found in the skin, accomplish the internal inspections of the bonded doubler as follows:

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Bonded Doubler - - (a)

2 Inspect Bonded Doubler - - (b)

(a) Do a detailed inspection of the bonded doubler for disbonding adjacent to the area shown in Step 2. Use 

a wedge made from a material that will not scratch aluminium (Plastic, Phenolic or similar) to check for 

disbonding along the edge of the doubler.

(b) Do a HFEC inspection for cracks in the bonded doubler within 0.25 inch of the doubler edge in the area 

showns and as given in 737 NDT, Part 6, 51-00-00, Figure 4 or 737 NDT, Part 6, 51-00-00 Figure 23. 

(SHEET 3 OF 3)
 FIGURE 31: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 490 AND STA 500, STRINGER 17L

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 31: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 490 AND STA 500, STRINGER 17L

EDDY CURRENT INSPECTION

AREA

S-16L

STA

360

S-18L

S-20L

S-22L

S-26L

S-14L

STA

500A

STA

500F

STA

440

S-14L

S-15L

S-16L

S-17L

S-18L

S-19L

S-20L

STA

450

STA

460

STA

470

STA

480

STA

490

STA

500

STA

440

STA

500A

FWD

A

LAP

JOINT

UPPER

SKIN

LOWER

SKIN

FWD

UP

SEE A

737-400 LEFT SIDE

1

SEE B

1495707

(SHEET 1 OF 2)
 FIGURE 31: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 490 AND STA 500, STRINGER 17L

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 4, 7, 11, 16: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do an eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 

NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL

CRACK

TYPICAL

CRACK

1

B

1548951

(SHEET 2 OF 2)
 FIGURE 32: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 727 AND STA 1016

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ALERT ALERT

FIGURE 32: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 727 AND STA 1016

DETAILED AND EDDY CURRENT

INSPECTION AREA

SEE A

S-7L

S-8L

S-9L

S-10L

STA

757

STA

767

STA

777

STA

787

STA

747

SEE B

FWD

STA

908

S-14L

S-10L

S-4L

S-4R

BL

0

STA

1016

A

UPPER

SKIN

FWD

UP

STA

STA 767

757

STA

727

S-9L

1 2

1504460

(SHEET 1 OF 2)
 FIGURE 32: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 727 AND STA 1016

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 1: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 

NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL

CRACK

TYPICAL

CRACK

1

B

2

1548955

(SHEET 2 OF 2)
 FIGURE 33: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 360 AND STA 540 AND STA 727 

AND STA 1016

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ALERT ALERT

FIGURE 33: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 360 AND STA 540 AND STA 727 AND 

STA 1016

737-200 AIRPLANES

SEE C

SEE B

SEE A

S-14L

S-10L

S-4R

BL S-4L

0

360

STA

540

STA

FWD

STA

908

S-14L

S-10L

S-4L

S-4R

BL

0

STA

1016

STA

STA 767

757

STA

727

S-9L

490

STA

480

STA

410

STA

390

STA

S-9L

S-6L

S-5L

FWD

1504461

(SHEET 1 OF 4)
 FIGURE 33: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 360 AND STA 540 AND STA 727 

AND STA 1016

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ALERT ALERT

DETAILED AND EDDY CURRENT

INSPECTION AREA

DETAILED AND EDDY CURRENT

INSPECTION AREA

S-7L

S-8L

S-9L

S-10L

STA

480

STA

490

STA

500

STA

460

S-3L

S-4L

S-5L

S-6L

STA

380

STA

390

STA

400

STA

410

STA

370

S-7L

STA

420

STA

430

STA

500A

B

UPPER

SKIN

FWD

UP

A

UPPER

SKIN

FWD

UP

1 2

1 2 SEE D

SEE D

1504462

(SHEET 2 OF 4)
 FIGURE 33: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 360 AND STA 540 AND STA 727 

AND STA 1016

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ALERT ALERT

This Figure applies to Group 2, 13: 

DETAILED AND EDDY CURRENT

INSPECTION AREA

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL

CRACK

TYPICAL

CRACK

S-7L

S-8L

S-9L

S-10L

STA

757

STA

767

STA

787

STA

747

C

UPPER

SKIN

FWD

UP

1 2 SEE D

1

D

2

1504463

(SHEET 3 OF 4)
 FIGURE 33: SKIN INSPECTION - LEFT HAND SIDE BETWEEN STA 360 AND STA 540 AND STA 727 

AND STA 1016

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 

or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(SHEET 4 OF 4)
 FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540

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ALERT ALERT

FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540

SEE B

SEE A

SEE C

SEE G

SEE F

SEE D

SEE E

737-300 AIRPLANES

FWD

S-14R

S-10R

S-4L

BL S-4R 0

360

STA

540

STA

500

STA

380

STA

S-6R

FWD

STA

500C

520

STA

STA

500C

STA

500B STA

500

STA

480

STA

460 STA

380

STA

360

540

STA

S-14L

S-10L

S-4R

BL S-4L

0

S-6L

1504464

(SHEET 1 OF 6)
 FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540

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ALERT ALERT

DETAILED AND EDDY CURRENT

INSPECTION AREA

DETAILED AND EDDY CURRENT

INSPECTION AREA

S-6L

S-7L

S-8L

S-9L

STA

370

STA

380

STA

360

S-10L

S-6L

S-7L

S-8L

S-9L

STA

500B

STA

500A

STA

500

S-10L

STA

500C

B

FWD

UP

A

FWD

UP

1 2 SEE H

1 2 SEE H

1504472

(SHEET 2 OF 6)
 FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540

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ALERT ALERT

DETAILED AND EDDY CURRENT

INSPECTION AREA

DETAILED AND EDDY CURRENT

INSPECTION AREA

S-6L

S-7L

S-8L

S-9L

STA

500D

STA

500C

S-10L

S-6R

S-7R

S-8R

S-9R

STA

360

STA

380

S-10R

STA

520

STA

370

STA

540

UP

FWD

D

C

FWD

UP

1 2

SEE H

1 2 SEE H

1504475

(SHEET 3 OF 6)
 FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540

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ALERT ALERT

DETAILED AND EDDY CURRENT

INSPECTION AREA

DETAILED AND EDDY CURRENT

INSPECTION AREA

STA

500A

STA

500B

S-6R

S-7R

S-8R

S-9R

STA

460

STA

480

S-10R

STA

500

STA

470

S-6R

S-7R

S-8R

S-9R

S-10R

STA

500C

UP

FWD

UP

FWD

E

UPPER

SKIN

F

UPPER

SKIN

1 2

1 2 SEE H

SEE H

1504477

(SHEET 4 OF 6)
 FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540

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ALERT ALERT

This Figure applies to Group 3, 9-10, 14-15, 18, 21: 

DETAILED AND EDDY CURRENT

INSPECTION AREA

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL

CRACK

TYPICAL

CRACK

STA

520

STA

540

STA

500D

S-6R

S-7R

S-8R

S-9R

S-10R

S-5R

S-4R

STA

500C

UP

FWD

G

UPPER

SKIN

1 2 SEE H

1

H

2

1504478

(SHEET 5 OF 6)
 FIGURE 34: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 360 AND STA 540

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 

or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 6 OF 6)
 FIGURE 35: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 727 AND 1016

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ALERT ALERT

FIGURE 35: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 727 AND 1016

737-300 AIRPLANES

SEE A

SEE B

SEE C

SEE D

FWD

FWD

STA

727C

S-14L

S-10L

S-4L

S-4R

BL 0

STA

1016

S-3L

S-7L

STA

727E

STA

767

STA

827

STA

727

S-14R

S-10R

S-4R

BL 0 S-4L

S-3R

S-7R

STA

1016

STA

727

STA

908

STA

967

STA

867 STA

827

S-1R

1504498

(SHEET 1 OF 4)
 FIGURE 35: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 727 AND 1016

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ALERT ALERT

DETAILED AND EDDY

CURRENT INSPECTION AREA

DETAILED AND EDDY

CURRENT INSPECTION AREA

S-7L

S-8L

S-9L

STA

787

STA

807

STA

767

S-3L

S-4L

S-5L

S-6L

STA

727D

STA

727E

STA

727C

S-2L

S-6L

S-5L

S-4L

STA

827

B

UPPER

SKIN

FWD

UP

A

UPPER

SKIN

FWD

UP

1 2 SEE E

1 2 SEE E

1504502

(SHEET 2 OF 4)
 FIGURE 35: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 727 AND 1016

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ALERT ALERT

DETAILED AND EDDY

CURRENT INSPECTION AREA

DETAILED AND EDDY

CURRENT INSPECTION AREA

S-5R

S-6R

S-7R

STA

996

STA

977

STA

1016

S-2R

S-3R

S-4R

STA

847

STA

827

STA

867

S-1R

S-4R

S-3R

S-2R

S-8R

STA

986.5

STA

967

STA

1006

STA

857

STA

837

C

UPPER

SKIN

FWD

UP

D

UPPER

SKIN

1 2 SEE E

1 2 SEE E

FWD

UP

1504508

(SHEET 3 OF 4)
 FIGURE 35: SKIN INSPECTION - LEFT AND RIGHT SIDE BETWEEN STA 727 AND 1016

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 3, 9-10, 14-15, 18, 21: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 

or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL

CRACK

TYPICAL

CRACK

1 2

E

1853142

(SHEET 4 OF 4)
 FIGURE 36: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540

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ALERT ALERT

FIGURE 36: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540

DETAILED AND EDDY CURRENT

INSPECTION AREA

SEE A

737-400 AIRPLANES

S-8L

S-9L

S-10L

S-7L

S-6L

S-5L

S-4L

STA

360

STA

370

STA

380

STA

390

STA

400

S-14L

S-10L

S-4R

BL S-4L 0

360

STA

540

STA

400

STA

S-8L

FWD

A

UPPER

SKIN

FWD

UP

1 2

SEE B

1504861

(SHEET 1 OF 2)
 FIGURE 36: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 4, 11, 16: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 

or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL CRACK

1 2

B

1549320

(SHEET 2 OF 2)
 FIGURE 37: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 37: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540

DETAILED AND EDDY CURRENT

INSPECTION AREA

737-500 AIRPLANES

S-8L

S-9L

S-10L

S-7L

S-6L

S-5L

S-4L

STA

428A+10

STA

428B

STA

428B+10

STA

520

SEE A

A

UPPER

SKIN

FWD

UP

S-14L

S-10L

S-4R

BL S-4L

0

360

STA

540

STA

STA

428B

S-7L

FWD

520

STA

1 2

SEE B

1504526

(SHEET 1 OF 2)
 FIGURE 37: SKIN INSPECTION - LEFT SIDE BETWEEN STA 360 AND STA 540

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 5, 12, 17, 19-20: 

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 

or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

FRAME FRAME

SKIN DOUBLER

EDGE OF BONDED

STRINGER

STRINGER

TYPICAL BAY

TYPICAL CRACK

1 2

B

1549322

(SHEET 2 OF 2)
 FIGURE 38: TIME LIMITED REPAIR - CHEM-MILL CRACKS - NOT LOCATED AT LAP JOINTS

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ALERT ALERT

FIGURE 38: TIME LIMITED REPAIR - CHEM-MILL CRACKS - NOT LOCATED AT LAP JOINTS

TYPICAL AND INSTALLATION

FOR PART FABRICATION

TYPICAL

PART FABRICATION AND INSTALLATION

(TYPICAL)

STRINGER

(TYPICAL)

0.75 MINIMUM

(IF PRESENT)

SHEAR TIE

(TYPICAL)

STA STA

(TYPICAL)

STAGGER FASTENERS

COMMON TO TEARSTRAPS

2X R 0.50 TYPICAL

CRACK

TYPICAL CRACK LOCATION,

AND SKIN TRIM

INSPECTION, FASTENER REMOVAL,

(TYPICAL)

STRINGER

STA

(TYPICAL)

STA

(TYPICAL)

STA

(TYPICAL)

STA

(TYPICAL)

3 4 2

5 6 7

9

8

5

A

SEE A

1 1

1521704

(SHEET 1 OF 4)
 FIGURE 38: TIME LIMITED REPAIR - CHEM-MILL CRACKS - NOT LOCATED AT LAP JOINTS

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

NOTE:

1. This repair cannot be used if the fasteners that exist are larger than 3/16 inch diameter.

2. This repair cannot be used in areas where hi-locks, lockbolts, or bolts were installed in production. 

If these fasteners are common to the repair, install a permanent repair.

3. Install fasteners using the fastener pattern that exists as a guide in the fore and aft direction. Use 

this figure to determine fastener pitch in the circumferential direction. Make the distance between 

fasteners 0.93-1.10 inch. Maintain a minimum edge margin of 2 times the fastener diameter for 

new fastener locations and 1.7 times the fastener diameter for fastener locations that exist.

4. In the typical repair shown in this figure, the left side tear strap location shows a typical shear tie 

fastener pattern. The right side tear strap location shows a typical non-shear tied fastener pattern. 

The detail may be different, depending on the specific repair location. Use this figure as a guide, 

maintaining the same number and pattern of fasteners around the cutout, and common to the tear 

straps or shear ties.

5. Do not use this repair common to fuselage cutouts, lap joints or butt joints.

6. Trim skin as shown, regardless of crack length provided the crack is contained within the trim-out 

area. Ensure a minimum 2D edge margin is maintained when trimming.

7. The trim line cannot enter the radius of the bonded doubler at the tear straps.

8. Maintain a 63 micro-inch or better surface finish on all trimmed structure.

9. Do not install this repair if other chem-mill cracks exist within 20 inches of this chem-mill crack.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin Detailed Inspection - (a)(b)

2 Remove / Discard Fasteners - - In the area that will be

common to the repair.

3 Trim Skin - - (c)

Remove Trimmed Skin - 1 -

4

Apply Chemical Film 

Treatment

Alodine or Iridite - (d)

Primer BMS 10-11, Type 1 - 1 coat. (d)

NOTE:

Size the repair parts to maintain a minimum edge margin of two times the fastener diameter at 

new fastener locations, and of 1.7 times the fastener diameter at existing fastener locations.

Maintain a minimum corner radius of 0.5 inch.

5

Measure Skin Thickness 

Common To The 

Cutout

- 1 For required doubler

thickness.

Make Repair Doubler 2024-T3 clad sheet 1 See Table 1 (e)

(SHEET 2 OF 4)
 FIGURE 38: TIME LIMITED REPAIR - CHEM-MILL CRACKS - NOT LOCATED AT LAP JOINTS

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

6

Apply Chemical Film 

Treatment

Alodine or Iridite - -

Primer BMS 10-11, Type 1 - 1 coat.

NOTE:

Shim all gaps from 0.01 - 0.04 inch prior to fastener installation. Contact Boeing for instructions for 

gaps greater than 0.04 inch. Do not install shims between the skin and doubler.

Clean the faying surfaces of the fuselage skin (Refer to SOPM 20-30-03 for cleaning 

requirements) and repair parts as given in 737-300 SRM 51-20-05 or 737-400 SRM 51-20-05 or 

737-500 SRM 51-20-05, Note 2, prior to the application of sealant.

7

Install Repair Doubler - 1 With BMS 5-95 faying 

surface sealant.Refer

to SOPM 20-50-19.

8

Apply Fillet Seal - - Use BMS 5-95 sealant

around the edges of the 

repair parts, or ensure 

proper edge sealing per 

SOPM 20-50-19.

9 Apply Finish - - To the repaired area to

match adjacent structure.

(a) Of the skin in the area of chem-milled step cracks.

(b)

Of the skin in the area of the repair for corrosion or disbonded doublers. Look for bulging of the 

skin. If corrosion or disbond is found, contact Boeing. If no corrosion or disbond is found, continue 

with the repair.

(c)

The trim-out must be as shown to eliminate undetected cracks. The trim-out must be a minimum 

of 0.5 inch beyond the visible ends of the crack. If this is not possible then repair as given in 

737-100/200 SRM 53-30-3 Figure 48, or 737-300 SRM 53-00-01 Figure 201, Repair 31, or 

737-400 SRM 53-00-01 Figure 201, Repair 31, or 737-500 SRM 53-00-01 Figure 201, Repair 31, 

as applicable.

(d) To all cut edges of the skin.

(e) Pre-form to match the contour of the fuselage.

Table 1 - Repair Doubler Thickness

Skin Thickness (inches) Repair Doubler Thickness (inches)

0.032 or 0.036 0.040

0.040 0.050

0.050 or greater. Contact Boeing for repair instructions.

BLIND FASTENER INSTALLATION

Existing Rivets

HOLE DIAMETER INSTALL NOTES

0.176 - 0.180 BACR15FR5E( )R (a)(b)(i)

0.205 - 0.209 BACR15FR6E( )R (a)(c)(d)(i)(e)

New Fasteners

HOLE DIAMETER INSTALL NOTES

0.176 - 0.180 BACR15FR5E( )R (f)(g)(h)(i)

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 3 OF 4)
 FIGURE 38: TIME LIMITED REPAIR - CHEM-MILL CRACKS - NOT LOCATED AT LAP JOINTS

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

(a) Install with a repair washer as given in 737-300/400/500 SRM 51-40-08.

(b) If the original fastener was 5/32 inch diameter.

(c) Optional if it is necessary to make the hole larger to remove damage.

(d) If the original fastener was 3/16 inch diameter.

(e) Maintain a minimum edge margin at the shear tie of 1.5 times the fastener diameter. If this 

edge margin cannot be maintained, contact Boeing.

(f) Use caution when locating these fasteners common to the tearstraps. Maintain a minimum 

edge margin of 1.7 times the fastener diameter from the edge of the tearstrap.

(g) Space the fasteners 0.93 to 1.10 inches.

(h) At new fastener locations common to tearstrap minimum spacing is 0.75 inch.

(i) NAS1738E( )-( ) optional to BACR15FR( )E( )R

BLIND FASTENER INSTALLATION

(SHEET 4 OF 4)
 FIGURE 39: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 39: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

S-10R

S-19R

S-17R

STA

360

STA

540

STA

727

STA

908

STA

460

STA

312

SEE B

SEE C

SEE A

SEE C

SEE C

SEE C

737-300

AIRPLANES

1 2

1 7

1 6

1 5

1 4

1 3

1523878

(SHEET 1 OF 4)
 FIGURE 39: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

INSPECTION AREA

TYPICAL

CRACK

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

S-17R

UP

FWD

S-19R

S-20R

LOWER

SKIN

PANEL

LAP

JOINT

UPPER

SKIN

PANEL

B

STA

460

STA

469.90

EDGE OF

SKIN

A

STA

312

2

4

1

1

1523875

(SHEET 2 OF 4)
 FIGURE 39: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 3, 9-10, 14-15: 

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

STRINGER

STRINGER

STRINGER

STRINGER

STRINGER

C

BUTT

JOINT

LAP

JOINT

UPPER AFT

SKIN PANEL

UPPER FORWARD

SKIN PANEL

TYPICAL CIRCUMFERENTIAL

BUTT SPLICE

1 3 5 6

7

1523876

(SHEET 3 OF 4)
 FIGURE 39: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)

2 Inspect Skin Panel - - (b)

3 Inspect Skin Panel - - (c)

4 Inspect Skin Panel - - (d)

5 Inspect Skin Panel - - (e)

6 Inspect Skin Panel - - (f)

7 Inspect Skin Panel - - (g)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external Low Frequency Eddy Current (LFEC) or Magneto Optical Imaging (MOI) or C-Scan 

inspection at STA 312 below S-19R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 

53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 360 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(d) Do an external LFEC or MOI or C-Scan inspection at STA 460 below S-17R for vertical subsurface 

skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 

53-30-19 or 737 NDT, Part 6, 53-30-25.

(e) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 540 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(f) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 727 between 

S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, 

Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(g) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 908 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 4 OF 4)
 FIGURE 40: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 40: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

S-10R

S-19R

S-17R

STA

360

STA

540

STA

727

STA

908

STA

460

STA

312

SEE B

SEE C

SEE A

SEE C

SEE C

SEE C

737-500 AIRPLANES

737-200 MODELS ARE SIMILAR

1 2

1 3

1 4

1 5

1 6

1 7

1523889

(SHEET 1 OF 4)
 FIGURE 40: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

INSPECTION AREA

TYPICAL

CRACK

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

S-17R

UP

FWD

S-19R

S-20R

LOWER

SKIN

PANEL

LAP

JOINT

UPPER

SKIN

PANEL

B

STA

460

STA

469.90

EDGE OF

SKIN

A

STA

312

1 2

1 4

1523880

(SHEET 2 OF 4)
 FIGURE 40: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 2, 5, 12-13, 17: 

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

STRINGER

STRINGER

STRINGER

STRINGER

STRINGER

C

BUTT

JOINT

LAP

JOINT

UPPER AFT

SKIN PANEL

UPPER FORWARD

SKIN PANEL

TYPICAL CIRCUMFERENTIAL

BUTT SPLICE

1 3 5 6

7

1523879

(SHEET 3 OF 4)
 FIGURE 40: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)

2 Inspect Skin Panel - - (b)

3 Inspect Skin Panel - - (c)

4 Inspect Skin Panel - - (d)

5 Inspect Skin Panel - - (e)

6 Inspect Skin Panel - - (f)

7 Inspect Skin Panel - - (g)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks. 

(b) Do an external Low Frequency Eddy Current (LFEC) or Magneto Optical Imaging (MOI) or C-Scan 

inspection at STA 312 below S-19R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 

53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(c) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 360 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(d) Do an external LFEC or MOI or C-Scan inspection at STA 460 below S-17R for vertical subsurface 

skin crack as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 

53-30-19 or 737 NDT, Part 6, 53-30-25. 

(e) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 540 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(f) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 727 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(g) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 908 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 4 OF 4)
 FIGURE 41: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

FIGURE 41: SKIN INSPECTIONS IN THE LOWER LOBE AREA

S-4L

S-4R

S-19R

S-26R

1016

STA

908

STA

727

STA STA STA

360 540

BL 0

BL 0

S-25L

S-20L

S-14L

S-10L

S-10R

S-14R

S-20R

S-4L

S-10L

S-14L

S-19L

S-24L

S-4R

S-10R

S-14R

S-19R

S-24R

S-25R

737-200 AIRPLANE INSPECTION AREA

SEE A

SEE A

TYPICAL

1549324

(SHEET 1 OF 3)
 FIGURE 41: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

This Figure applies to Group 13: 

CRACKS

TYPICAL

SKIN

LOWER

TYPICAL

CRACK

UPPER

DOUBLER

UPPER

SKIN

A

C/L

FRAME

1

INSPECTION

TYPICAL

AREA

1

C/L

STRINGER

1549325

(SHEET 2 OF 3)
 FIGURE 41: SKIN INSPECTIONS IN THE LOWER LOBE AREA

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

(a) Do a detailed or general visual inspection for chem-mill cracks. If general visual inspections are 

accomplished in lieu of detailed inspections, then repeat inspection intervals are reduced. Refer to 

Paragraph 1.E., Compliance for repeat inspection interval requirements.

(SHEET 3 OF 3)
 FIGURE 42: FUSELAGE WINDOW BELT AREA INSPECTION

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ALERT ALERT

FIGURE 42: FUSELAGE WINDOW BELT AREA INSPECTION

737-300 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

SEE A

S-14L

S-10L

S-4R

BL S-4L

0

360

STA

540

STA

1574948

(SHEET 1 OF 3)
 FIGURE 42: FUSELAGE WINDOW BELT AREA INSPECTION

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ALERT ALERT

This Figure applies to Group 3, 9-10, 14-15, 18, 21: 

TYPICAL CRACK

INSPECTION AREA

S-12

520

STA

500D+10

STA STA

500D

FWD

1 2

A

1 2

1574949

(SHEET 2 OF 3)
 FIGURE 42: FUSELAGE WINDOW BELT AREA INSPECTION

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 

NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 3 OF 3)
 FIGURE 43: FUSELAGE WINDOW BELT AREA INSPECTION

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ALERT ALERT

FIGURE 43: FUSELAGE WINDOW BELT AREA INSPECTION

737-400 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

SEE A

SEE B

STA

360

S-4L

S-4R

0

BL

540

STA

S-10L

S-14L

1574951

(SHEET 1 OF 4)
 FIGURE 43: FUSELAGE WINDOW BELT AREA INSPECTION

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ALERT ALERT

TYPICAL

CRACK

INSPECTION AREA

S-12

500F

STA

500E+10

STA STA

500E

S-14

S-10

S-13

S-11

C/L

FWD

1 2

A

1574953

(SHEET 2 OF 4)
 FIGURE 43: FUSELAGE WINDOW BELT AREA INSPECTION

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ALERT ALERT

This Figure applies to Group 4, 11, 16: 

TYPICAL

CRACK

INSPECTION AREA

S-12L

520

STA

500G+10

STA STA

500G

S-14L

S-10L

S-13L

S-11L

C/L

FWD

1 2

B

1574954

(SHEET 3 OF 4)
 FIGURE 43: FUSELAGE WINDOW BELT AREA INSPECTION

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 

53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 4 OF 4)
 FIGURE 44: FUSELAGE WINDOW BELT AREA INSPECTION

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ALERT ALERT

FIGURE 44: FUSELAGE WINDOW BELT AREA INSPECTION

737-500 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

STA

540

STA

360

0

S-4L BL

S-4R

S-10L

S-14L

SEE A

1574955

(SHEET 1 OF 3)
 FIGURE 44: FUSELAGE WINDOW BELT AREA INSPECTION

Original Issue: December 14, 2000

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ALERT ALERT

This Figure applies to Group 5, 12, 17, 19-20: 

TYPICAL CRACK

INSPECTION AREA

S-12

520

STA

500D+10

STA STA

500D

FWD

1 2

A

1 2

1574956

(SHEET 2 OF 3)
 FIGURE 44: FUSELAGE WINDOW BELT AREA INSPECTION

Original Issue: December 14, 2000

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ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 3 OF 3)
 FIGURE 45: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

FIGURE 45: CROWN AREA SKIN INSPECTIONS

737-300 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

1 3 2

SEE A

1 2

FWD

727A+10

STA

727

STA

928

STA

908

STA

S-14L

S-10L

S-4L

S-14L

S-10L

S-4R

540

STA

BL

0

1016

STA

S-4R

BL S-4L

0

360

STA

540

STA

INSPECTION

AREA

FOR TYPICAL

587

STA 664

STA

727E

STA

1652902

(SHEET 1 OF 3)
 FIGURE 45: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

This Figure applies to Group 18, 21: 

UPPER

DOUBLER

SKIN

LOWER

INSPECTION AREA

TYPICAL

CRACK

UPPER

SKIN

TYPICAL

CRACK

1 2

A

3

10.00

C/L

FRAME

UP

INBD

SKIN

UPPER

SKIN

LOWER

A

A

TYPICAL

AREA

INSPECTION

C/L

STRINGER

A-A

CRACK

STRINGER

1652903

(SHEET 2 OF 3)
 FIGURE 45: CROWN AREA SKIN INSPECTIONS

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Inspect Fuselage Skin - - (c)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 

NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do a detailed or general visual inspection of the non-lap-splice areas from STA 360 to STA 540 between 

S-10L to S-10R, from STA 727 to 727E between S-4L to S-4R, and from STA 727E to STA 1016 between 

S-10L to S-10R for horizontal cracks at the chem-mill lines.

NOTE: If general visual inspections are accomplished in lieu of detailed inspections, then repeat inspection 

intervals are reduced. Refer to Paragraph 1.E., Compliance for repeat inspection interval requirements.

(SHEET 3 OF 3)
 FIGURE 46: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

FIGURE 46: CROWN AREA SKIN INSPECTIONS

737-500 AIRPLANES

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

SEE A

3

1 2

1 2

FWD

STA

928

727A+10

STA

FOR TYPICAL

INSPECTION

AREA

STA

540

STA

360

0

S-4L BL

S-4R

STA

STA

908

1016

0

BL

STA

STA

540

727

S-4R

S-10L

S-14L

S-4L

S-10L

S-14L

587

STA

664

STA

STA

727C

1652910

(SHEET 1 OF 3)
 FIGURE 46: CROWN AREA SKIN INSPECTIONS

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ALERT ALERT

This Figure applies to Group 19-20: 

UPPER

DOUBLER

SKIN

LOWER

INSPECTION AREA

TYPICAL

CRACK

UPPER

SKIN

TYPICAL

CRACK

A

1 2

3

TYPICAL

LAP JOINT

AREA

INSPECTION

10.00

C/L

FRAME

UP

INBD

SKIN

UPPER

SKIN

LOWER

A

A

C/L

STRINGER

A-A

CRACK

STRINGER

1652912

(SHEET 2 OF 3)
 FIGURE 46: CROWN AREA SKIN INSPECTIONS

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fuselage Skin - - (a)

2 Inspect Fuselage Skin - - (b)

3 Inspect Fuselage Skin - - (c)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external eddy current inspection for chem-mill cracks as given in 737 NDT, Part 6, 53-30-09 or 737 

NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do a detailed or general visual inspection of the non-lap-splice areas from STA 360 to STA 540 between 

S-10L to S-10R, from STA 727 to 727C between S-4L to S-4R, and from STA 727C to STA 1016 between 

S-10L to S-10R for horizontal cracks at the chem-mill lines.

NOTE: If general visual inspections are accomplished in lieu of detailed inspections, then repeat inspection 

intervals are reduced. Refer to Paragraph 1.E., Compliance for repaet inspection interval requirements.

(SHEET 3 OF 3)
 FIGURE 47: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 47: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

S-10R

S-19R

S-17R

STA

360

STA

540

STA

727

STA

908

STA

460

STA

312

SEE B

SEE C

SEE A

SEE C

SEE C

SEE C

737-300 AIRPLANE SHOWN

737-500 SIMILAR

1 2

1 7

1 6

1 5

1 4

1 3

1652922

(SHEET 1 OF 4)
 FIGURE 47: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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ALERT ALERT

INSPECTION AREA

TYPICAL

CRACK

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

S-17R

UP

FWD

S-19R

S-20R

LOWER

SKIN

PANEL

LAP

JOINT

UPPER

SKIN

PANEL

B

STA

460

STA

469.90

EDGE OF

SKIN

A

STA

312

1 2

1 4

1652923

(SHEET 2 OF 4)
 FIGURE 47: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 18-21: 

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

STRINGER

STRINGER

STRINGER

STRINGER

STRINGER

C

BUTT

JOINT

LAP

JOINT

UPPER AFT

SKIN PANEL

UPPER FORWARD

SKIN PANEL

TYPICAL CIRCUMFERENTIAL

BUTT SPLICE

1 3 5 6

7

1652924

(SHEET 3 OF 4)
 FIGURE 47: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)

2 Inspect Skin Panel - - (b)

3 Inspect Skin Panel - - (c)

4 Inspect Skin Panel - - (d)

5 Inspect Skin Panel - - (e)

6 Inspect Skin Panel - - (f)

7 Inspect Skin Panel - - (g)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks.

(b) Do an external Low Frequency Eddy Current (LFEC) or Magneto Optical Imaging (MOI) or C-Scan 

inspection at STA 312 below S-19R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 

53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(c) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 360 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(d) Do an external LFEC or MOI or C-Scan inspection at STA 460 below S-17R for vertical subsurface 

skin cracks as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 

53-30-19 or 737 NDT, Part 6, 53-30-25.

(e) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 540 

between S-10L and S-10R on the forward side of the butt joint only for vertical subsurface skin cracks 

as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 

NDT, Part 6, 53-30-25.

(f) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 727 between 

S-4L and S-4R on the aft side of the butt joint only for vertical subsurface skin cracks as given in 737 

NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 

53-30-25.

(g) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 908 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 4 OF 4)
 FIGURE 48: POST REPAIR INSPECTION - SKIN CHEM-MILL CRACK REPAIR AT STRINGER 12

Original Issue: December 14, 2000

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ALERT ALERT

FIGURE 48: POST REPAIR INSPECTION - SKIN CHEM-MILL CRACK REPAIR AT STRINGER 12

This Figure applies to Group 3, 5, 9-10, 12, 14-15, 17-21: 

STA

520

TYPICAL

LAP

DOUBLER

STA

540

STA

360

500D = 737-300

482B = 737-500

S-12

TYPICAL

LAP

DOUBLER

INSPECTION

AREA

TRIPLER DOUBLER

UP

FWD

A

SEE A

RIGHT SIDE SHOWN

LEFT SIDE OPPOSITE

1

1654055

(SHEET 1 OF 2)
 FIGURE 48: POST REPAIR INSPECTION - SKIN CHEM-MILL CRACK REPAIR AT STRINGER 12

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin - - Inspect the skin at the critical row of fasteners. 

(a)

(a) Do LFEC inspections for cracks in the skin as given in 737 NDT, Part 6, 53-30-00 Figure 5.

(SHEET 2 OF 2)
 FIGURE 49: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

FIGURE 49: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

727

STA

312

STA

908

STA

540

STA

460

STA

360

STA

S-19R

S-17R

S-10R

S-2L

SEE B SEE C

SEE A

SEE C

SEE C

SEE C

737-200C

1 2

1 4 1 3 1 5

1 6

1 7

1659372

(SHEET 1 OF 4)
 FIGURE 49: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

INSPECTION AREA

TYPICAL

CRACK

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

S-17R

UP

FWD

S-19R

S-20R

LOWER

SKIN

PANEL

LAP

JOINT

UPPER

SKIN

PANEL

B

STA

460

STA

469.90

EDGE OF

SKIN

A

STA

312

1 2

1 4

1659374

(SHEET 2 OF 4)
 FIGURE 49: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

Revision 3: July 16, 2009 737-53A1210

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

This Figure applies to Group 1: 

INSPECTION AREA

TYPICAL

CRACK

UP

FWD

STRINGER

STRINGER

STRINGER

STRINGER

STRINGER

C

BUTT

JOINT

LAP

JOINT

UPPER AFT

SKIN PANEL

UPPER FORWARD

SKIN PANEL

TYPICAL CIRCUMFERENTIAL

BUTT SPLICE

1 3 5 6

7

1659375

(SHEET 3 OF 4)
 FIGURE 49: INSPECTION FOR VERTICAL CRACKS AT CHEM-MILL LINES OF FUSELAGE SKIN

Original Issue: December 14, 2000

Revision 3: July 16, 2009 737-53A1210

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BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

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

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Skin Panel - - (a)

2 Inspect Skin Panel - - (b)

3 Inspect Skin Panel - - (c)

4 Inspect Skin Panel - - (d)

5 Inspect Skin Panel - - (e)

6 Inspect Skin Panel - - (f)

7 Inspect Skin Panel - - (g)

(a) Do an external detailed inspection of the fuselage skin for chem-mill cracks. 

(b) Do an external Low Frequency Eddy Current (LFEC) or Magneto Optical Imaging (MOI) or C-Scan 

inspection at STA 312 below S-19R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 

53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(c) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 360 

between S-2L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25. 

(d) Do an external LFEC or MOI or C-Scan inspection at STA 460 below S-17R for vertical subsurface 

skin crack as given in 737 NDT, Part 6, 53-30-09 or 737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 

53-30-19 or 737 NDT, Part 6, 53-30-25. 

(e) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 540 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(f) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 727 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(g) Do an external LFEC or MOI or C-Scan inspection at the circumferential butt splice STA 908 

between S-10L and S-10R for vertical subsurface skin cracks as given in 737 NDT, Part 6, 53-30-09 or 

737 NDT, Part 6, 53-30-18 or 737 NDT, Part 6, 53-30-19 or 737 NDT, Part 6, 53-30-25.

(SHEET 4 OF 4)
 APPENDIX A: COST BENEFIT ANALYSIS

Original Issue: December 14, 2000

Revision 3: July 16, 2009 737-53A1210

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 267 of 267

BOEING SERVICE BULLETIN 737-53A1210

ALERT ALERT

APPENDIX A: COST BENEFIT ANALYSIS

Boeing did a cost benefit analysis on the changes given in this service bulletin. The data that follows was used 

to do the analysis. Operators can use the data to do their own cost benefit analysis. The “Before the Change” 

data are average fleet data based on in-service experience. The “After the Change” data are estimated fleet 

data. Refer to Customer Cost Benefit Methodology Guide, Document D6-56722, for details on how to prepare 

a cost benefit analysis.

Part Name: Part Number:

Analysis Inputs Before the 

Change

After the Change

Delays / 100 Revenue Departures 0.0 0.0

Cancellations / 100 Revenue Departures 0.0 0.0

MTBUR (flight hours) 0.0 0.0

MTBF (flight hours) 0.0 0.0

MTBO (flight hours or cycles) 0.0 0.0

Fuel Factor (weight in pounds) 0.0 0.0

Line Maintenance Hours / Removal 0.0 0.0

Line Maintenance Hours / Maintenance Action

(Non Removal)

0.0 0.0

Maintenance Actions / 1,000 Flight Hours

(Non Removal)

0.0 0.0

Scheduled Maintenance Hours / 1,000 Flight Hours 0.120000 0.00000

Shop Material Cost / Failure 0.0 0.0

Shop Labor Hours / Removal 0.0 0.0