April 07, 2005

Revision 1 September 15, 2005 737-78-1074

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 38

Commercial

Airplane

Group 737

SPECIAL ATTENTION

Service Bulletin

Number: 737-78-1074

Date: April 07, 2005

Revision 1 September 15, 2005

ATA System: 7831

SUBJECT: EXHAUST - Thrust Reverser - Blocker Door Aero/Fire Seal Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2005 The Boeing Company

Unpublished Work - All Rights Reserved

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

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

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

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

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

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9, 

DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery are all trademarks 

owned by The Boeing Company; and no trademark license is granted in connection with this document unless 

provided in writing by Boeing.
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 Table of Contents

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BOEING SERVICE BULLETIN 737-78-1074

Table of Contents

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

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

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 26

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 28

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 29

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 1: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 1 ENGINE, LEFT AND RIGHT

THRUST REVERSER HALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 2: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 2 ENGINE, LEFT AND RIGHT

THRUST REVERSER HALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 3: REMOVE AND REPLACE AERO/FIRE SEALS - LEFT AND RIGHT SPARE THRUST

REVERSER HALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Commercial

Airplane

Group 737

SPECIAL ATTENTION

Service Bulletin

Number: 737-78-1074 Revision Transmittal Sheet

Date: April 07, 2005

Revision 1 September 15, 2005

ATA System: 7831

SUBJECT: EXHAUST - Thrust Reverser - Blocker Door Aero/Fire Seal Replacement

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed as shown in the initial release of this service bulletin.

REASON FOR REVISION

Revision 1 is sent to change the compliance data, the industry support data and to add more data about the 

sealant given in the initial release of this service bulletin. 

The compliance data given in the Summary and in paragraph 1.E., Compliance is changed from 24 months or 

4000 flight cycles to 60 months or 8200 flight cycles (the first to occur). The warranty date given in the Summary 

and in paragraph 2. B., Industry Support Information is changed from May 22, 2003 to December 25, 2001.

More data is added for the sealant used to install the new aero/fire seals as given in paragraph 2.C.2., Parts and 

Materials Supplied by the Operator.

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: April 7, 2005

Revision 1: September 15, 2005
 

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Commercial

Airplane

Group 737

SPECIAL ATTENTION

Service Bulletin

Number: 737-78-1074 Summary

Date: April 07, 2005

Revision 1 September 15, 2005

ATA System: 7831

SUBJECT: EXHAUST - Thrust Reverser - Blocker Door Aero/Fire Seal Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Boeing has found that the top three inches of the blocker door aero/fire seal on the thrust reverser torque box 

does not have sufficient fire resistant properties. The aero/fire seals are made of material which could let a fire 

to go from the fan compartment (a fire zone) to the thrust reverser actuator compartment (a flammable leakage 

zone). The aero/fire seals on the thrust reverser torque box are not in compliance with Federal Aviation 

Regulation FAR 25.1191.

This service bulletin gives instructions to replace the aero/fire seals on the torque box of the thrust reverser. 

Replacement of the aero/fire seals as given in this service bulletin is necessary for FAR 25.1191 compliance.

Boeing Service Related Problem (SRP) 737-SRP-71-0036 is related to this service bulletin.

ACTION (PRR 38275-62S)

Open the thrust reverser on each engine and replace two aero/fire seals.

EFFECTIVITY

737-600, -700, -700C, -800, -900 Airplanes. Refer to service bulletin Paragraph 1.A.1. for effectivity. 

COMPLIANCE

Boeing recommends that operators do the changes given in this service bulletin in 60 months or 8200 flight 

cycles (the first to occur) from the release date of Revision 1 of this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of December 25, 2001. Please refer to 

Paragraph 2.B., Industry Support Information.
 

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MANPOWER

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

Engines Total Task Hours Elapsed Hours

Two Installed Engines 6.0 3.0

Each Spare Thrust Reverser 

Assembly

2.0 1.0

Note: The man-hours do not include the time necessary to cure the sealant.

FWD FWD

ON EACH THRUST REVERSER HALF.

REPLACE EACH AERO/FIRE SEAL

TORQUE BOX TORQUE BOX

W72693
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Commercial

Airplane

Group 737

SPECIAL ATTENTION

Service Bulletin

Number: 737-78-1074

Date: April 07, 2005

Revision 1 September 15, 2005

ATA System: 7831

SUBJECT: EXHAUST - Thrust Reverser - Blocker Door Aero/Fire Seal Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

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. An equivalent change is on subsequent 

production airplanes. Refer to PRR 38275-62S for data about this change.

Airplane models:

737-600 737-700 737-700C 737-800

737-900

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AERO CONTRACTORS LTD (YAT)

1 YG042

AEROMEXICO (AMX)

1 YB207 YB851–YB859 YB861–YB862 YB871–YB872

AIR ALGERIE (ALG)

1 YD101–YD107 YE301–YE305

AIR ASTANA (AKZ)

1 YA356–YA357 YC151

GROUP CONFIGURATION DESCRIPTION

1 - All airplanes
 

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AIR BERLIN (BER)

1 YB201 YB203 YB911 YC051–YC070

YC461 YC701 YC703 YC705

YD151–YD157 YD218 YD261

AIR CHINA (BEJ)

1 YA681–YA682 YB584–YB586 YC944–YC951 YC981–YC983

AIR CHINA CHONGQING BRANCH (CHO)

1 YC941–YC943

AIR CHINA SOUTHWEST BRANCH (XIN)

1 YC426–YC428 YE201–YE206

AIR CHINA TIANJIN BRANCH (TJA)

1 YB581–YB583

AIR EUROPA (ARE)

1 YC761–YC770 YC907 YD206–YD209 YK002–YK003

YK361

AIR HORIZONS (AHZ)

1 YC727

AIR MAURITANIE (MAR)

1 YA302 YB651

AIR NATIONAL GUARD (USK)

1 YG044 YG067 YG069

AIR PACIFIC (APC)

1 YA291 YC931–YC932

AIR SAHARA (SAQ)

1 YA253–YA254 YA351 YA731 YB204–YB205

YC462 YC901–YC902 YG001

AIR SENEGAL INTERNATIONAL (SNG)

1 YA683–YA684

AIR SHAMROCK (SHI)

1 YG016

AIRTRAN (CQT)

1 YB371–YB375 YM201–YM202

ALASKA AIRLINES (ASA)

1 YA841–YA862 YD501–YD512

ALOHA AIRLINES (ALO)

1 YA608 YA610 YA614–YA615 YA627–YA629

YA631 YA732–YA733 YB656
 

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AMERICAN AIRLINES (AAL)

1 YC801–YC877

AMIRI FLIGHT (ABD)

1 YD410 YG023 YG026

ARAMCO ASSOCIATED COMPANY (RAS)

1 YB151–YB153 YG601–YG602

ASTRAEUS, LTD. (AUA)

1 YA671–YA672

ATA AIRLINES, INC. (AAT)

1 YD301 YD304–YD305 YD308 YD310

YD313–YD333

AUSTRALIAN WEDGETAIL PROGRAM (ZVI)

1 YG089 YG201

AUSTRIAN (AUL)

1 YB171–YB172 YC381–YC384 YE171–YE172

BANCO SAFRA (BNS)

1 YG040

BB FIVE, INC (YIP)

1 YG066

BBJ ONE (BBI)

1 YG068

BEL AIR LIMITED (ULL)

1 YG022

BELAVIA (ITU)

1 YD408

BNJ SALES COMPANY (BNJ)

1 YG031 YG033 YG036 YG038

BOEING DEMONSTRATOR JET (BCJ)

1 YG071

BRAATHENS (BRT)

1 YA311 YA543 YA545 YA547–YA552

YB005–YB006

BRITANNIA AIRWAYS (BRI)

1 YD001–YD003 YD005–YD007

BWIA WEST INDIES AIRWAYS (TTA)

1 YC136–YC141 YJ001
 

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CASINO EXPRESS AIRLINES (CIN)

1 YC437

CHARTWELL (CHP)

1 YG017

CHINA AIRLINES (CHI)

1 YC571 YC574–YC583 YC589

CHINA EASTERN AIRLINES (CEA)

1 YB206 YB561–YB570

CHINA EASTERN AIRLINES WUHAN (WUH)

1 YD171–YD172

CHINA EASTERN YUNNAN AIRLINES (YUN)

1 YA811–YA814

CHINA SOUTHERN AIRLINES (GUN)

1 YB881–YB885 YJ671–YJ682

CHINA UNITED AIRLINES (CUL)

1 YB631–YB632

CHINA XINJIANG AIRLINES (XIJ)

1 YA255–YA256 YA645 YA656

COLOMBIAN AIR FORCE (CLB)

1 YG028

COMMONWEALTH OF AUSTRALIA (GAU)

1 YG072 YG075

CONTINENTAL AIRLINES (CAL)

1 YA501–YA536 YC321–YC380 YD601–YD612 YJ501–YJ517

YJ531–YJ543

COPA AIRLINES (COP)

1 YA755–YA756 YA961–YA974 YJ591–YJ593

CYPRUS TURKISH AIRLINES (KTHY) (KHT)

1 YC467 YD021–YD022

DALLAH AL BARAKA (KAM)

1 YG063

DELTA AIR LINES (DAL)

1 YC601–YC655 YC681–YC696

DOBRO LIMITED (DOB)

1 YG008
 

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DUBAI AIR WING (DAW)

1 YD402 YG007

E & A AVIATION (RSB)

1 YG082

EASYJET (EZY)

1 YB101–YB132

EIE EAGLE (EIE)

1 YD409

EL AL ISRAEL AIRLINES (ELA)

1 YA881–YA882 YC405 YC591–YC593

ETHIOPIAN AIRLINES (ETH)

1 YA666–YA667 YB156–YB157

EUROCYPRIA AIRLINES (ECY)

1 YC186–YC189

EVA AIR (EVA)

1 YG083

EXCEL AIRWAYS (SBE)

1 YC111–YC113 YC903 YC905–YC906 YK131

EXCEL AIRWAYS-CYPRUS (XLC)

1 YC436

FORD AIR SERVICES (FMC)

1 YA541–YA542

FUNAIR (FUN)

1 YG027

FUTURA (FUA)

1 YC407 YC451 YC463–YC464 YC466

YJ011

GAMA AVIATION LTD (GAV)

1 YG010

GE CAPITAL CORPORATION (GEF)

1 YA630

GE CORPORATE AIR TRANSPORT (GEB)

1 YG003 YG012

GERMANIA (GER)

1 YA231 YA233 YA235–YA240
 

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GOL AIRLINES (GOT)

1 YA201–YA202 YA232 YA234 YA241–YA242

YA251–YA252 YA321 YA602 YA605

YA607 YA611–YA612 YA646–YA648 YA650

YA657 YB202 YB271 YD256–YD257

YD302–YD303 YD306–YD307 YJ471–YJ472

GOVT OF EQUATORIAL GUINEA (EGR)

1 YG085

HAINAN AIRLINES (HNA)

1 YA544 YA546 YA603–YA604 YA606

YC126–YC127 YC401 YC404 YC409

YC452 YC971–YC978 YD042–YD045 YD216

HAMBURG INTERNATIONAL (HAU)

1 YA574–YA578 YB276

HAPAG-LLOYD FLUG (HAP)

1 YC001–YC030 YD004 YD219

HELIOS AIRWAYS (HCY)

1 YC416–YC417

ICA BERMUDA (IBL)

1 YG062

INTER AIRLINES (IAW)

1 YJ473 YJ475

JET AIRWAYS (JPL)

1 YA609 YA621–YA622 YA734 YA751–YA754

YB181–YB184 YC402–YC403 YC731–YC741 YD309

YD311–YD312 YD571–YD572

JET AVIATION (JTA)

1 YD405 YG015 YG021

KENYA AIRWAYS (KEN)

1 YA635–YA636 YA641–YA642

KEVINAIR (KVN)

1 YG037

KLM - ROYAL DUTCH AIRLINES (KLM)

1 YC781–YC793 YD531–YD535

KOREAN AIR (KAL)

1 YC441–YC448 YD121–YD126 YD541–YD547 YD561–YD564

YD591–YD593

LAS VEGAS JET (LVJ)

1 YG002
 

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LIMITED BRAND INC. (LII)

1 YG005

LINEAS AEREAS AZTECA (AZX)

1 YA601 YB501–YB502

LOWA CORPORATION (LWA)

1 YD406

LUXAIR (LUX)

1 YB901–YB902

MAERSK AIR (MRS)

1 YA203–YA211 YA221 YA571–YA573

MALEV HUNGARIAN AIRLINES (HGA)

1 YA371–YA375 YC201–YC203 YC206 YE321–YE326

MANDARIN AIRLINES (MDN)

1 YC587–YC588

MIAMI AIR (MIB)

1 YC146 YC904 YK121–YK122

MID EAST JET (SKL)

1 YD407 YG013–YG014

MONGOLIAN AIRLINES MIAT (MNG)

1 YJ476

MULTIFLIGHT (MFL)

1 YD404

N720CH, INC. (NCH)

1 YG019

NATIONAL (NJI)

1 YG032

NATIONAL AIR SERVICES (NAR)

1 YD403 YG080 YG086–YG087

NEOS (NEO)

1 YJ002 YJ021 YJ631–YJ632

NEWS AMERICA INCORPORATED (NWS)

1 YG020

OMAN AIR (OMR)

1 YA366–YA367 YB551 YC171 YJ901

OMNIFLYS (OML)

1 YG077
 

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PACIFIC BLUE AIRLINES (BLP)

1 YK324

PEGASUS AIRLINES (PGS)

1 YC391–YC392 YC406 YC410 YC412

YC414–YC415 YC455 YC572–YC573 YD025

YD391

PICTON II (UNU)

1 YG006

POLYNESIAN AIRLINES (PLY)

1 YC147

PRIVATAIR (PTS)

1 YG018 YG064

QANTAS (QAN)

1 YC878–YC892 YJ911–YJ918

REPUBLIC OF CHINA AIR FORCE (CAF)

1 YC396

ROYAL AIR MAROC (RAM)

1 YA831–YA835 YC301–YC305 YK301–YK302

ROYAL JET (RJT)

1 YG024–YG025

ROYAL MALAYSIA AIR FORCE (MAF)

1 YG061

RYANAIR (RYR)

1 YC471–YC499 YJ801–YJ833

SAFAIR (SFA)

1 YD481–YD485

SAMSUNG TECHWIN CO. (SST)

1 YG079

SAS (SAS)

1 YB001–YB004 YD041 YD046–YD057 YD081–YD084

YE001–YE020 YE051 YE101–YE109

SAS INSTITUTE INC. (SJS)

1 YG041

SAUDI OGER (SAO)

1 YD401 YG073
 

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SHANGHAI AIRLINES (SHA)

1 YA272 YA312–YA314 YA891–YA892 YC166–YC169

YC394 YJ003–YJ004 YJ871

SHARE JET (SJL)

1 YG035

SHENZHEN AIRLINES (SHZ)

1 YA613 YA626 YA686–YA687 YA721–YA722

YA801–YA803 YA809 YC153–YC154 YC411

YC413 YK101–YK104

SIGAIR (SIG)

1 YG034

SKY AIRLINES (SYC)

1 YC730

SOUTH AFRICAN AIRFORCE (SFF)

1 YG076

SOUTH AFRICAN AIRWAYS (SAA)

1 YC708–YC715 YC720–YC725 YD023–YD024

SOUTHERN AIRCRAFT SERVICES (HUZ)

1 YG009

SOUTHWEST AIRLINES (SWA)

1 YA001–YA099 YA101–YA187 YA271 YA301

SPICEJET (ROJ)

1 YC465 YC704 YC707

STERLING EUROPEAN AIRLINES (STR)

1 YC101–YC104 YC751–YC752 YJ933–YJ934 YK001

YK004

SUN COUNTRY AIRLINES (SCA)

1 YC121 YC152 YC155–YC156 YJ935

SUNEXPRESS (SNS)

1 YC453 YC702 YC706 YD201–YD202

YJ477–YJ480

SWIFLITE AIRCRAFT CORPORATION (OSF)

1 YG078

TAROM - ROMANIAN AIR TRANSPORT (TRM)

1 YB161–YB164

TBN AVIATION AVV (TBE)

1 YG029
 

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TRACINDA CORP. (TRD)

1 YG004

TRANSAVIA AIRLINES (TAV)

1 YB521–YB525 YB541–YB544 YC071–YC083 YC091–YC094

TRAVEL SERVICE (TSF)

1 YC408 YC454 YC459 YD203

YJ474 YK005

TUI AIRLINES BELGIUM (TLB)

1 YD217 YJ931

TUNISAIR (TUN)

1 YE151–YE157 YG030

TURKISH AIRLINES (THY)

1 YC501–YC526

TUTOR-SALIBA CORPORATION (TTS)

1 YG070

UNITED STATES NAVY (USN)

1 YG501–YG507

US AIR FORCE (USF)

1 YG074 YG081 YG084 YG088

VARIG AIRLINES (VAR)

1 YA322–YA323 YC728–YC729

VENTURA AVIATION (VTU)

1 YG011

VIRGIN BLUE AIRLINES (VOZ)

1 YA336–YA345 YA649 YA658–YA659 YA685

YA688–YA691 YB208 YC393 YC421–YC422

YC921–YC922 YD251–YD254 YJ861–YJ867 YJ932

YK111–YK112 YK321–YK323 YK325–YK328 YM101

WESTJET (WJI)

1 YB301–YB310 YB601–YB625

XIAMEN AIRLINES (XIA)

1 YA701–YA710

YEMENIA (YEM)

1 YC176–YC178

YONA AVIATION II, LLC (VRH)

1 YG043
 

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ZEPHYR LIMITED (PFR)

1 YG039

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

YA001–YA099 1

YA101–YA187 1

YA201–YA211 1

YA221 1

YA231–YA242 1

YA251–YA256 1

YA271–YA272 1

YA291 1

YA301–YA302 1

YA311–YA314 1

YA321–YA323 1

YA336–YA345 1

YA351 1

YA356–YA357 1

YA366–YA367 1

YA371–YA375 1

YA501–YA536 1

YA541–YA552 1

YA571–YA578 1

YA601–YA615 1

YA621–YA622 1

YA626–YA631 1

YA635–YA636 1

YA641–YA642 1

YA645–YA650 1

YA656–YA659 1

YA666–YA667 1

YA671–YA672 1

YA681–YA691 1

YA701–YA710 1

YA721–YA722 1

YA731–YA734 1

YA751–YA756 1

YA801–YA803 1

YA809 1
 

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YA811–YA814 1

YA831–YA835 1

YA841–YA862 1

YA881–YA882 1

YA891–YA892 1

YA961–YA974 1

YB001–YB006 1

YB101–YB132 1

YB151–YB153 1

YB156–YB157 1

YB161–YB164 1

YB171–YB172 1

YB181–YB184 1

YB201–YB208 1

YB271 1

YB276 1

YB301–YB310 1

YB371–YB375 1

YB501–YB502 1

YB521–YB525 1

YB541–YB544 1

YB551 1

YB561–YB570 1

YB581–YB586 1

YB601–YB625 1

YB631–YB632 1

YB651 1

YB656 1

YB851–YB859 1

YB861–YB862 1

YB871–YB872 1

YB881–YB885 1

YB901–YB902 1

YB911 1

YC001–YC030 1

YC051–YC083 1

YC091–YC094 1

YC101–YC104 1

YC111–YC113 1

Variable Group
 

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YC121 1

YC126–YC127 1

YC136–YC141 1

YC146–YC147 1

YC151–YC156 1

YC166–YC169 1

YC171 1

YC176–YC178 1

YC186–YC189 1

YC201–YC203 1

YC206 1

YC301–YC305 1

YC321–YC384 1

YC391–YC394 1

YC396 1

YC401–YC417 1

YC421–YC422 1

YC426–YC428 1

YC436–YC437 1

YC441–YC448 1

YC451–YC455 1

YC459 1

YC461–YC467 1

YC471–YC499 1

YC501–YC526 1

YC571–YC583 1

YC587–YC589 1

YC591–YC593 1

YC601–YC655 1

YC681–YC696 1

YC701–YC715 1

YC720–YC725 1

YC727–YC741 1

YC751–YC752 1

YC761–YC770 1

YC781–YC793 1

YC801–YC892 1

YC901–YC907 1

YC921–YC922 1

Variable Group
 

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YC931–YC932 1

YC941–YC951 1

YC971–YC978 1

YC981–YC983 1

YD001–YD007 1

YD021–YD025 1

YD041–YD057 1

YD081–YD084 1

YD101–YD107 1

YD121–YD126 1

YD151–YD157 1

YD171–YD172 1

YD201–YD203 1

YD206–YD209 1

YD216–YD219 1

YD251–YD254 1

YD256–YD257 1

YD261 1

YD301–YD333 1

YD391 1

YD401–YD410 1

YD481–YD485 1

YD501–YD512 1

YD531–YD535 1

YD541–YD547 1

YD561–YD564 1

YD571–YD572 1

YD591–YD593 1

YD601–YD612 1

YE001–YE020 1

YE051 1

YE101–YE109 1

YE151–YE157 1

YE171–YE172 1

YE201–YE206 1

YE301–YE305 1

YE321–YE326 1

YG001–YG044 1

YG061–YG064 1

Variable Group
 

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2. Spares Affected

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

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

the recommended use.

YG066–YG089 1

YG201 1

YG501–YG507 1

YG601–YG602 1

YJ001–YJ004 1

YJ011 1

YJ021 1

YJ471–YJ480 1

YJ501–YJ517 1

YJ531–YJ543 1

YJ591–YJ593 1

YJ631–YJ632 1

YJ671–YJ682 1

YJ801–YJ833 1

YJ861–YJ867 1

YJ871 1

YJ901 1

YJ911–YJ918 1

YJ931–YJ935 1

YK001–YK005 1

YK101–YK104 1

YK111–YK112 1

YK121–YK122 1

YK131 1

YK301–YK302 1

YK321–YK328 1

YK361 1

YM101 1

YM201–YM202 1

Variable Group
 

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B. Concurrent Requirements

None.

C. Reason

Boeing has found that the top three inches of the blocker door aero/fire seal on the thrust reverser 

torque box does not have sufficient fire resistant properties. The aero/fire seals are made of material 

which could let a fire to go from the fan compartment (a fire zone) to the thrust reverser actuator 

compartment (a flammable leakage zone). The aero/fire seals on the thrust reverser torque box are 

not in compliance with Federal Aviation Regulation FAR 25.1191.

This service bulletin gives instructions to replace the aero/fire seals on the torque box of the thrust 

reverser. Replacement of the aero/fire seals as given in this service bulletin is necessary for 

FAR 25.1191 compliance.

Revision 1 is sent to change the compliance data, the industry support data and to add more data 

about the sealant given in the initial release of this service bulletin. 

The compliance data given in the Summary and in paragraph 1.E., Compliance is changed from 24 

months or 4000 flight cycles to 60 months or 8200 flight cycles (the first to occur). 

The warranty date given in the Summary and in paragraph 2. B., Industry Support Information is 

changed from May 22, 2003 to December 25, 2001.

More data is added for the sealant used to install the new aero/fire seals as given in paragraph 2.C.2., 

Parts and Materials Supplied by the Operator.

Boeing Service Related Problem (SRP) 737-SRP-71-0036 is related to this service bulletin.

D. Description

Open the thrust reverser on each engine and replace two aero/fire seals.

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

service bulletin.

E. Compliance

Boeing recommends that operators do the changes given in this service bulletin within 60 months or 

8200 flight cycles (the first to occur) from the release date of Revision 1 of this service bulletin.
 

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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.

G. Manpower

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

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

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

lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to find the tools.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 1.0 0.50

Figure 1 2 2.0 1.0

Figure 2 2 2.0 1.0

Close Access 2 1.0 0.50

TOTAL FOR TWO INSTALLED ENGINES 6.0 3.0

Note: The Man-hours do not include time necessary to cure the sealant.

Task

Number of 

Persons Task-Hours Elapsed Hours

Figure 3 2 2.0 1.0

TOTAL FOR EACH SPARE THRUST 

REVERSER ASSEMBLY

2.0 1.0

Note: The Man-hours do not include time necessary to cure the sealant.
 

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J. References

1. Existing Data:

a. Engineering Change Memo PRR 38275-62S

b. Service Related Problem (SRP) 737-SRP-71-0036

c. 737-600/-700/-800/-900 Maintenance Manual (AMM) 78-31-00, 78-31-24

d. Boeing Standard Overhaul Practices Manual (BSOPM) 20-50-10, 20-50-12

e. Boeing Document D6-19567, Service Bulletin Index

f. Boeing Drawing 65-88700

g. 737 Structural Repair Manual (SRM), Chapter 51

2. Data supplied with this Service Bulletin:

None.

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

None.

K. Publications Affected

L. Interchangeability and Intermixability of Parts

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

information.

Publication Chapter-Section

737-600/-700/-800/-900 Maintenance Manual 78-31
 

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2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kit/parts shown in Paragraph 2.C., Parts Necessary For Each Airplane and 

Paragraph 2.D., Parts Necessary to Change Spares as shown below. If there is a limit to the quantity 

(QTY) of available kits/parts, a supply sequence is given by Spares. More kits/parts become available 

as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the 

purchase order.

The kit/parts are subject to the terms and conditions of the Boeing standard purchase order 

acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in 

United States dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of the methods that follow: 

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

B. Industry Support Information

Boeing warranty remedies are available for 737 airplanes in warranty as of December 25, 2001. For 

man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing 

Commercial Airplanes Group - Warranties. The 012A0042-1 Kit for airplanes in warranty as of that 

date will be supplied at no charge. Send a purchase order for the 012A0042-1 to Boeing Spares. 

Please refer to this service bulletin number and reference the airplane variable number in your 

purchase order.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

Note: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the 

Number Name

ROLT 

(Weeks)

Unit Price thru

12/31/05

012A0042-1 Top Kit (a) 21 $3837.00

315A2245-7 Seal Assembly - Aero/Fire Seal (b) 21 $931.00

315A2245-8 Seal Assembly - Aero/Fire Seal (b) 21 $931.00

(a) One Kit is necessary for each airplane.

(b) One seal is necessary for each spare thrust reverser.
 

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Operator, are necessary for each airplane.

2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the 

number of parts changed on each airplane.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.

E. Special Tooling - Price and Availability

None.

012A0042 TOP KIT - SEAL ASSEMBLY - AERO / FIRE SEAL

New Part Number

QTY

Name

Existing Part 

-1 Number Notes

012A0042-1 - Top Kit -- --

315A2245-7 2 Seal Assembly - Aero/Fire Seal 315A2245-1 (a)

315A2245-8 2 Seal Assembly - Aero/Fire Seal 315A2245-2 (a)

(a) Discard the existing part. 

Part Number / Specification QTY Name Notes

BMS 5-63, Type II, 

Class B1/2 or B4

3 (3 Ounce Kit) Sealant Kit (a) 

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

supplier data.

Existing Part 

Number QTY Name New Part Number Notes

315A2245-1 2 Seal Assembly - Aero/Fire Seal 315A2245-7 (a)

315A2245-2 2 Seal Assembly - Aero/Fire Seal 315A2245-8 (a)

(a) This is the part number after the change given in this service bulletin.

Part Number Name QTY

315A2245-7 Seal Assembly - Aero/Fire Seal (a) 1

315A2245-8 Seal Assembly - Aero/Fire Seal (a) 1

(a) Install with BMS 5-63. See Paragraph 2.C.2., Parts and Materials Supplied by the Operator.
 

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F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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BLANK PAGE
 

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BOEING SERVICE BULLETIN 737-78-1074

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.

— Angular tolerance is plus or minus 2 degrees

4. The work instructions are divided into two Parts. Part 1 gives instructions to replace the 

aero/fire seals on the airplane. Part 2 gives instructions to replace the aero/fire seals on 

the spare thrust reverser.

B. WORK INSTRUCTIONS

Part 1 - Replace Aero/Fire Seals on Airplanes

1. Open the left and right side thrust reversers on engine number 1 as given in 

737-600/700/800/900 AMM 78-31-00.

2. Remove and replace the aero/fire seals on the thrust reverser torque box as shown in Figure 1.

Note: Use BMS 5-63 sealant to install the aero/fire seals on the thrust reverser halves.

3. Open the left and right side thrust reversers on engine number 2 as given in 

737-600/700/800/900 AMM 78-31-00

4. Remove and replace the aero/fire seals on the thrust reverser torque box as shown in Figure 2.

5. After replacement of the aero/fire seals, identify the thrust reverser identification (ID) plate with 

the service bulletin number. Refer to Boeing Standard Overhaul Practices Manual 20-50-10. 

6. Put the airplane back to a serviceable condition.
 

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Part 2 - Replace Aero/Fire Seals on Spare Thrust Reversers Assemblies With Part Numbers

 Less Than 315A2295-195

1. Remove and replace the aero/fire seal on the left and right thrust reverser halves of the spare 

thrust reversers as shown in Figure 3.

Note: Thrust reverser assemblies with part numbers 315A2295-195 or higher received the same 

aero/fire seals (315A2245-7 and 315A2245-8) as this service bulletin installs. 

Note: Use BMS 5-63 sealant to install the aero/fire seals on the thrust reverser halves.

2. After replacement of the aero/fire seals, identify the thrust reverser identification (ID) plate with 

the service bulletin number. Refer to Boeing Standard Overhaul Practices Manual 20-50-10.
 FIGURE 1: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 1 ENGINE, LEFT AND RIGHT 

THRUST REVERSER HALVES

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FIGURE 1: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 1 ENGINE, LEFT AND RIGHT 

THRUST REVERSER HALVES

FWD

1 3

LEFT THRUST

REVERSER

SEE A

RIGHT THRUST

REVERSER

SEE B

TORQUE BOX

LEFT THRUST REVERSER

A

W72682

(SHEET 1 OF 2)
 FIGURE 1: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 1 ENGINE, LEFT AND RIGHT 

THRUST REVERSER HALVES

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

numbers shown below are the number of parts necessary for each engine.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/

Discard

Aero/Fire Seal 315A2245-1 1 Left thrust reverser halves. 

Remove seal as given in 

737-600/700/800/900 AMM 

78-31-24.

2 Remove/

Discard

Aero/Fire Seal 315A2245-2 1 Right thrust reverser halves. 

Remove seal as given in 

737-600/700/800/900 AMM 

78-31-24.

3 Install Aero/Fire Seal 315A2245-7 1 Left thrust reverser halves, use 

BMS 5-63 sealant. Install seal 

as given in 737-600/700/800/900 

AMM 78-31-24.

4 Install Aero/Fire Seal 315A2245-8 1 Right thrust reverser halves, use 

BMS 5-63 sealant. Install seal

as given in 737-600/700/800/900 

AMM 78-31-24.

FWD

RIGHT THRUST REVERSER

B

2 4

TORQUE BOX

W72688

(SHEET 2 OF 2)
 FIGURE 2: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 2 ENGINE, LEFT AND RIGHT 

THRUST REVERSER HALVES

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FIGURE 2: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 2 ENGINE, LEFT AND RIGHT 

THRUST REVERSER HALVES

FWD

1 3

A

LEFT THRUST REVERSER

TORQUE BOX

SEE B

REVERSER

RIGHT THRUST

SEE A

REVERSER

LEFT THRUST

W72689

(SHEET 1 OF 2)
 FIGURE 2: REMOVE AND REPLACE AERO/FIRE SEALS - NUMBER 2 ENGINE, LEFT AND RIGHT 

THRUST REVERSER HALVES

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

numbers shown below are the number of parts necessary for each engine.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/

Discard

Aero/Fire Seal 315A2245-1 1 Left thrust reverser halves. 

Remove seal as given in 

737-600/700/800/900 AMM 

78-31-24.

2 Remove/

Discard

Aero/Fire Seal 315A2245-2 1 Right thrust reverser halves. 

Remove seal as given in 

737-600/700/800/900 AMM 

78-31-24.

3 Install Aero/Fire Seal 315A2245-7 1 Left thrust reverser halves, use 

BMS 5-63 sealant. Install seal

as given in 737-600/700/800/900 

AMM 78-31-24.

4 Install Aero/Fire Seal 315A2245-8 1 Right thrust reverser halves, use 

BMS 5-63 sealant Install seal 

as given in 737-600/700/800/900 

AMM 78-31-24.

FWD

RIGHT THRUST REVERSER

B

2 4

TORQUE BOX

W72691

(SHEET 2 OF 2)
 FIGURE 3: REMOVE AND REPLACE AERO/FIRE SEALS - LEFT AND RIGHT SPARE THRUST 

REVERSER HALVES

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FIGURE 3: REMOVE AND REPLACE AERO/FIRE SEALS - LEFT AND RIGHT SPARE THRUST 

REVERSER HALVES

FWD

1 3

SPARE LEFT THRUST REVERSER

TORQUE BOX

499097

(SHEET 1 OF 2)
 FIGURE 3: REMOVE AND REPLACE AERO/FIRE SEALS - LEFT AND RIGHT SPARE THRUST 

REVERSER HALVES

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

numbers shown below are the number of parts necessary for left and right spare thrust reverser halves.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/

Discard

Aero/Fire Seal 315A2245-1 1 Spare left thrust reverser halves. Remove 

seal as given in 737-600/700/800/900 AMM 

78-31-24.

2 Remove/

Discard

Aero/Fire Seal 315A2245-2 1 Spare right thrust reverser halves. Remove 

seal as given in 737-600/700/800/900 AMM 

78-31-24.

3 Install Aero/Fire Seal 315A2245-7 1 Spare left thrust reverser halves, use 

BMS 5-63 sealant. Install seal as given in

737-600/700/800/900 AMM 78-31-24.

4 Install Aero/Fire Seal 315A2245-8 1 Spare right thrust reverser halves, use 

BMS 5-63 sealant. Install seal as given in

737-600/700/800/900 AMM 78-31-24.

FWD

SPARE RIGHT THRUST REVERSER

2 4

TORQUE BOX

499096

(SHEET 2 OF 2)