Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-53A1329

Original Issue: June 04, 2013

ATA System: 5330

SUBJECT: FUSELAGE - Skin - Forward Entry Doorway - Lower Corners - Inspection and Repair

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ECCN: 9E991

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BLANK PAGE
Table of Contents

Summary ...................................................... 5

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

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 19

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 21

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FIGURE 1: FUSELAGE - FORWARD ENTRY DOORWAY - SKIN ASSEMBLY AND BEAR STRAP AT THE

LOWER CORNERS - INSPECTION [Group 2-3] . . . . . . . . . . . . . . . . . . . . . . . 26

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BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

ALERT

Summary Number: 737-53A1329

Original Issue: June 04, 2013

ATA System: 5330

SUBJECT: FUSELAGE - Skin - Forward Entry Doorway - Lower Corners - 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

This service bulletin gives instructions to inspect the lower corners of the forward entry doorway for cracking on

airplanes that do not have an airstair door cutout. If the work in this service bulletin is not done, continued crack

progression can result in possible rapid decompression.

Boeing has received five reports of cracking in the skin at the lower aft corner of the forward entry doorway on

airplanes that do not have an airstair door cutout. The cracks ranged from 0.25 to 2.0 inches in length. The

airplanes had accumulated between 34,813 and 73,083 total flight cycles. Cracks in the lower corners of the

forward entry doorway are caused by fatigue loads in the skin and bear strap which are magnified by local stress

concentrations due to the door cutout and edge margin effects at fastener locations near the corner radius.

Additionally, cracks can be initiated from impact damage due to high usage rate of the forward entry door.

Accomplishment of the work in this service bulletin will make sure that cracking at the lower corners of the

forward entry doorway on airplanes that do not have an airstair door cutout is detected and a repair installed.

Boeing Service Bulletin 737-53-1083 gives instructions for the inspection, modification and repair of the lower

corners of the forward entry doorway on airplanes that have an airstair door cutout.

Boeing Service Related Problem (SRP) 737-SRP-53-0381 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 737 FTD 53-11003 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

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Planning Data Affected Reference

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected Yes Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected No Paragraph 1.K., Publications Affected

(Flight Crew Operations Manual and/or

FAA Approved Airplane Flight Manual)

Kits/Parts Required No Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Group 1:

Contact Boeing to get instructions for the inspections and repairs for this service bulletin 737-53A1329 Original

Issue and do the work instructed by Boeing.

Group 2-3:

Remove the scuff plates at the lower corners of the forward entry doorway.

Group 2:

At the lower corners of the forward entry doorway, do an internal detailed inspection of the skin assembly and

bear strap, an internal High Frequency Eddy Current (HFEC) inspection of the bear strap and an external detailed

and HFEC inspection of the skin assembly for any crack. If any crack is found in the skin assembly or bear strap,

contact Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found, do the repeat

inspections at the intervals given in Paragraph 1.E., Compliance.

Group 3:

At the lower corners of the forward entry doorway, do an internal detailed inspection of the skin assembly and

bear strap, an internal HFEC inspection of the bear strap and an external detailed and HFEC inspection of the

skin assembly for any crack. If any crack is found in the skin assembly or bear strap at the lower aft corner,

install a repair. If any crack is found in the skin assembly or bear strap at the lower forward corner, contact

Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found, do the repeat

inspections at the intervals given in Paragraph 1.E., Compliance.

EFFECTIVITY

737-200/-200C/-300/-400/-500 airplanes that do not have an airstair door cutout. Refer to Paragraph 1.A.1.,

Airplanes, for the list of affected airplane(s).

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BOEING SERVICE BULLETIN 737-53A1329

ALERT ALERT
COMPLIANCE

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

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

mandatory.

FAA AD 2008-09-13 is related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures

given in this service bulletin.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

Group 2 5.00 5.00

Group 3 5.00 5.00

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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ALERT ALERT
Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-53A1329

Original Issue: June 04, 2013

ATA System: 5330

SUBJECT: FUSELAGE - Skin - Forward Entry Doorway - Lower Corners - 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 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

737-200C airplanes, line numbers 72 thru 286 that do not have an

airstair door cutout.

1 -

737-200/-200C airplanes, line numbers 294 thru 1453 that do not

have an airstair door cutout.

2 -

737-300/-400/-500 airplanes, line numbers 1001 thru 3132 that do

not have an airstair door cutout.

3 -

Airplane Models:

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

Variable Number Group

PJ301 - PJ302 3

PJ551 - PJ561 3

PJ601 - PJ615 3

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Variable Number Group

PJ811 3

PK041 - PK046 2

PK048 - PK050 2

PK052 - PK053 2

PK431 - PK433 2

PK911 - PK938 2

PK971 - PK974 2

PL101 - PL113 2

PL736 - PL747 2

PL758 2

PN401 - PN420 2

PP001 - PP054 3

PP102 - PP169 3

PP181 - PP199 3

PP231 - PP243 3

PP281 - PP286 3

PP301 - PP305 3

PP401 - PP440 3

PP471 - PP475 3

PP631 - PP634 3

PP671 - PP699 3

PP701 - PP733 3

PP771 - PP779 3

PP861 - PP877 3

PP961 - PP967 3

PP981 - PP991 3

PQ001 - PQ016 3

PQ026 - PQ041 3

PQ051 - PQ092 3

PQ101 - PQ199 3

PQ201 - PQ202 3

PQ231 - PQ237 3

PQ292 - PQ297 3

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Variable Number Group

PQ299 3

PQ301 - PQ307 3

PQ331 - PQ332 3

PQ341 - PQ348 3

PQ431 - PQ438 3

PQ451 3

PQ454 3

PQ471 3

PQ479 - PQ481 3

PQ486 - PQ487 3

PQ491 - PQ493 3

PQ771 - PQ772 3

PQ791 - PQ793 3

PQ801 - PQ805 3

PQ931 - PQ935 3

PR031 - PR034 3

PR041 - PR045 3

PR061 - PR072 3

PR077 - PR080 3

PR181 3

PS643 - PS644 3

PS666 - PS669 3

PS691 - PS692 3

PS701 - PS706 3

PS751 - PS799 3

PS901 - PS941 3

PT001 - PT015 3

PT021 - PT031 3

PT101 - PT105 3

PT186 - PT188 3

PT301 - PT309 3

PT331 - PT360 3

PT381 - PT399 3

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Variable Number Group

PT401 - PT438 3

PT561 - PT565 3

PT581 - PT586 3

PT611 - PT621 3

PT641 - PT644 3

PT651 - PT656 3

PT681 - PT685 3

PT701 - PT703 3

PT716 - PT717 3

PT801 - PT834 3

PT851 - PT854 3

PT901 - PT930 3

PT971 - PT973 3

PT981 - PT985 3

PU001 - PU025 3

PV001 - PV055 3

PV201 - PV209 3

PV226 - PV229 3

PV231 - PV237 3

PV271 - PV272 3

PV281 - PV287 3

PV351 3

PW062 - PW068 3

PW201 - PW252 3

PW401 - PW408 3

PW411 - PW418 3

PW421 - PW424 3

PW431 - PW435 3

PW441 - PW450 3

PW461 - PW467 3

PW511 - PW522 3

PW524 - PW550 3

PW561 - PW564 3

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ALERT ALERT
Variable Number Group

PW571 - PW576 3

PW611 - PW622 3

PW631 - PW637 3

PW681 - PW683 3

PW711 - PW717 3

PW761 3

PW771 3

PX701 1

PY001 - PY008 1

PY021 1

PY022 2

PY036 - PY037 2

PY046 - PY048 2

PY056 - PY057 2

PY111 - PY113 2

PY131 - PY135 2

PY141 - PY143 2

PY151 - PY154 2

PY156 - PY157 2

PY162 2

PY166 2

PY191 2

PY201 2

PY241 - PY244 2

PY270 - PY275 2

PY301 - PY304 1

PY401 2

PY409 - PY410 2

PY421 - PY422 2

PY451 2

PY461 - PY463 2

PY591 - PY595 2

PY671 - PY672 2

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BOEING SERVICE BULLETIN 737-53A1329

ALERT ALERT
Variable Number Group

PY721 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions to inspect the lower corners of the forward entry doorway for

cracking on airplanes that do not have an airstair door cutout. If the work in this service bulletin is not

done, continued crack progression can result in possible rapid decompression.

Boeing has received five reports of cracking in the skin at the lower aft corner of the forward entry

doorway on airplanes that do not have an airstair door cutout. The cracks ranged from 0.25 to 2.0

inches in length. The airplanes had accumulated between 34,813 and 73,083 total flight cycles. Cracks

in the lower corners of the forward entry doorway are caused by fatigue loads in the skin and bear strap

which are magnified by local stress concentrations due to the door cutout and edge margin effects at

fastener locations near the corner radius. Additionally, cracks can be initiated from impact damage due

to high usage rate of the forward entry door.

Accomplishment of the work in this service bulletin will make sure that cracking at the lower corners of

the forward entry doorway on airplanes that do not have an airstair door cutout is detected and a repair

installed. Boeing Service Bulletin 737-53-1083 gives instructions for the inspection, modification and

repair of the lower corners of the forward entry doorway on airplanes that have an airstair door cutout.

Boeing Service Related Problem (SRP) 737-SRP-53-0381 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 737 FTD 53-11003 is related to this service bulletin.

D. Description

Group 1:

Contact Boeing to get instructions for the inspections and repairs for this service bulletin 737-53A1329

Original Issue and do the work instructed by Boeing.

Group 2-3:

Remove the scuff plates at the lower corners of the forward entry doorway.

Group 2:

At the lower corners of the forward entry doorway, do an internal detailed inspection of the skin assembly

and bear strap, an internal High Frequency Eddy Current (HFEC) inspection of the bear strap and an

external detailed and HFEC inspection of the skin assembly for any crack. If any crack is found in the

skin assembly or bear strap, contact Boeing for repair instructions and do the work instructed by Boeing.

If no cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E., Compliance.

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BOEING SERVICE BULLETIN 737-53A1329

ALERT ALERT
Group 3:

At the lower corners of the forward entry doorway, do an internal detailed inspection of the skin assembly

and bear strap, an internal HFEC inspection of the bear strap and an external detailed and HFEC

inspection of the skin assembly for any crack. If any crack is found in the skin assembly or bear strap

at the lower aft corner, install a repair. If any crack is found in the skin assembly or bear strap at the

lower forward corner, contact Boeing for repair instructions and do the work instructed by Boeing. If no

cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E., Compliance.

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

Group 1:

Affected Maintenance Zones

Model Zone

737-200C 1-5

Group 2:

Affected Maintenance Zones

Model Zone

737-200, 737-200C 1-5

Group 3:

Affected Maintenance Zones

Model Zone

737-300, 737-400, 737-500 105

E. Compliance

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

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

this service bulletin mandatory.

FAA AD 2008-09-13 is related to this service bulletin.

Group 1:

Contact Boeing to get instructions for the inspections and repairs for this service bulletin 737-53A1329

Original Issue and do the work instructed by Boeing within 120 days after the original issue date of this

service bulletin.

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ALERT ALERT
Group 2:

Table 1: Forward Entry Doorway - Lower Corners Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the original

issue date of

this service

bulletin.

Before 27,000

total flight cycles.

At the forward entry doorway lower

aft corner, do an internal detailed

inspection of the skin assembly

and bear strap, an internal High

Frequency Eddy Current (HFEC)

inspection of the bear strap and

an external detailed and HFEC inspection of the skin assembly for

any crack in accordance with

Paragraph 3.B., Work Instructions,

PART 2, step 1.a.

All airplanes.

Within 4,500 4,500 flight cycles.

flight cycles after the original

issue date of

this service

bulletin.

Before 27,000

total flight cycles.

At the forward entry doorway lower

forward corner, do an internal detailed inspection of the skin assembly and bear strap, an internal

HFEC inspection of the bear strap

and an external detailed and

HFEC inspection of the skin assembly for any crack in accordance

with Paragraph 3.B., Work Instructions, PART 2, step 1.b.

Contact Boeing for repair instruc- Before further flight. -

tions and do the work instructed

by Boeing.

If any crack is found

in the skin assembly

or bear strap.

Group 3:

Table 2: Forward Entry Doorway - Lower Corners Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the original

issue date of

this service

bulletin.

Before 27,000

total flight cycles.

At the forward entry doorway lower

aft corner, do an internal detailed

inspection of the skin assembly

and bear strap, an internal HFEC

inspection of the bear strap and

an external detailed and HFEC inspection of the skin assembly for

any crack in accordance with

Paragraph 3.B., Work Instructions,

PART 2, step 2.a.

All airplanes.

(a)

Install the repair in accordance Before further flight. -

with Paragraph 3.B., Work Instructions, PART 2, step 2.a.(1).

If any crack is found

in the skin assembly

or bear strap at the

lower aft corner. (a)

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ALERT ALERT
Group 3:

Table 2: Forward Entry Doorway - Lower Corners Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the original

issue date of

this service

bulletin.

Before 27,000

total flight cycles.

At the forward entry doorway lower

forward corner, do an internal detailed inspection of the skin assembly and bear strap, an internal

HFEC inspection of the bear strap

and an external detailed and

HFEC inspection of the skin assembly for any crack in accordance

with Paragraph 3.B., Work Instructions, PART 2, step 2.b.

All airplanes.

Contact Boeing for repair instruc- Before further flight. -

tions and do the work instructed

by Boeing.

If any crack is found

in the skin assembly

or bear strap at the

lower forward corner.

(a) Accomplishment of the repair in accordance with this service bulletin terminates the repeat inspections

required by this service bulletin in the area common to the repair. Supplemental inspections are provided

in the applicable Structural Repair Manual (SRM).

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 737-300/-400/-500 airplanes as required by paragraph (i) of AD 2008-09-13, the repair identified

in this service bulletin has been evaluated to determine if it affects the Boeing Supplemental Structural

Inspection Document D6-82669, Revision New Inspections as required by paragraph (g) and (h) of the

AD. The SRM repair identified in Paragraph 3.B, Work Instructions, Part 2, Step 2.a(1) of this bulletin

may affect certain areas of Significant Structural Item F-13A inspections. Supplemental inspections

are provided in the noted SRM repair.

G. Manpower

The table below shows an estimate of the task hours necessary to do this service bulletin 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:

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• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 1.50 1.50

FIGURE 1 1 2.00 2.00

Close Access 1 1.50 1.50

TOTAL FOR EACH AIRPLANE (a) 5.00 5.00

(a) No manpower information is given for the repair.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Boeing Service Bulletin 737-53-1083

b. Boeing Service Letter 737-SL-51-042

c. Boeing Service Related Problem (SRP) 737-SRP-53-0381

d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2008-09-13

e. Service Bulletin Index D6-19567

f. 737 Fleet Team Digest (FTD) 53-11003

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

h. 737-100/200 Aircraft Maintenance Manual (AMM) 52-11-00

i. 737-300/400/500 Aircraft Maintenance Manual (AMM) 52-11-00, 53-13-01

j. 737-300 Structural Repair Manual (SRM) 53-10-01

k. 737-400 Structural Repair Manual (SRM) 53-10-01

l. 737-500 Structural Repair Manual (SRM) 53-10-01

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2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

65-45800 SKIN AND STRINGER INSTALLATION - SECTION 41

SKIN AND STRINGER INSTALLATION - FORWARD ENTRY

AND GALLEY DOORS

65C34778

The table above lists applicable drawings used to prepare this service bulletin. The drawings are

not necessary to make the specified changes, and are not supplied with this service bulletin. The

drawings may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

Publication Chapter-Section

737-300 Structural Repair Manual 53-10

737-400 Structural Repair Manual 53-10

737-500 Structural Repair Manual 53-10

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. DTI requirements for the structure affected

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

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary

Not affected.

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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes, inspection and/or repair

procedures given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

None.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

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

– Linear dimensions are in inches

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

or minus 0.03 inch

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

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

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

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

SRM Chapter 51.

5. 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.

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

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

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

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

must be used.

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

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

additional structural repair instructions. The Service Letter describes what information

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

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

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

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

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

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

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

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

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

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

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

B. WORK INSTRUCTIONS

Group 1:

1. Contact Boeing to get instructions for the inspections and repairs for this service bulletin

737-53A1329 Original Issue and do the work instructed by Boeing.

Group 2-3:

PART 1 - ACCESS

1. Open the forward entry door. Refer to 737-300/400/500 AMM 52-11-00 or 737-100/200 AMM

52-11-00 as an accepted procedure.

2. Remove the forward entry doorway scuff plates and their support structures at the forward entry

doorway. Refer to 737-300/400/500 AMM 53-13-01 as an accepted procedure.

Group 2-3:

PART 2 - INSPECTION

1. Group 2:

a. At the forward entry doorway lower aft corner, do an internal detailed inspection of the skin

assembly and bear strap, an internal High Frequency Eddy Current (HFEC) inspection of the

bear strap and an external detailed and HFEC inspection of the skin assembly for any crack

in accordance with FIGURE 1.

(1) If any crack is found in the skin assembly or bear strap, contact Boeing for repair

instructions and do the work instructed by Boeing.

(2) If no cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E.,

Compliance.

b. At the forward entry doorway lower forward corner, do an internal detailed inspection of the

skin assembly and bear strap, an internal HFEC inspection of the bear strap and an external

detailed and HFEC inspection of the skin assembly for any crack in accordance with FIGURE

1.

(1) If any crack is found in the skin assembly or bear strap, contact Boeing for repair

instructions and do the work instructed by Boeing.

(2) If no cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E.,

Compliance.

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2. Group 3:

a. At the forward entry doorway lower aft corner, do an internal detailed inspection of the skin

assembly and bear strap, an internal HFEC inspection of the bear strap and an external

detailed and HFEC inspection of the skin assembly for any crack in accordance with FIGURE

1.

(1) If any crack is found in the skin assembly or bear strap, do the following:

(a) Install a repair in accordance with applicable 737-300 SRM 53-10-01 Repair 12 or

737-400 SRM 53-10-01 Repair 12 or 737-500 SRM 53-10-01 Repair 12.

NOTE: Installation of the SRM repair terminates the repeat inspection requirements

of this Service Bulletin for the area common to the repair. Supplemental

inspections are provided in the applicable Structural Repair Manual (SRM).

(2) If no cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E.,

Compliance.

b. At the forward entry doorway lower forward corner, do an internal detailed inspection of the

skin assembly and bear strap, an internal HFEC inspection of the bear strap and an external

detailed and HFEC inspection of the skin assembly for any crack in accordance with FIGURE

1.

(1) If any crack is found in the skin assembly or bear strap, contact Boeing for repair

instructions and do the work instructed by Boeing.

(2) If no cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E.,

Compliance.

Group 2-3:

PART 3 - CLOSE ACCESS

1. Install the forward entry doorway scuff plates and their support structures at the forward entry

doorway. Refer to 737-300/400/500 AMM 53-13-01 as an accepted procedure.

2. Close the forward entry door. Refer to 737-300/400/500 AMM 52-11-00 or 737-100/200 AMM

52-11-00 as an accepted procedure.

3. Put the airplane back to a serviceable condition.

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This Figure applies only to: Group 2-3.

FIGURE 1: FUSELAGE - FORWARD ENTRY DOORWAY - SKIN ASSEMBLY AND BEAR STRAP AT THE

LOWER CORNERS - INSPECTION

(SHEET 1 OF 4)

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FIGURE 1: FUSELAGE - FORWARD ENTRY DOORWAY - SKIN ASSEMBLY AND BEAR STRAP AT THE

LOWER CORNERS - INSPECTION

(SHEET 2 OF 4)

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

FIGURE 1: FUSELAGE - FORWARD ENTRY DOORWAY - SKIN ASSEMBLY AND BEAR STRAP AT THE

LOWER CORNERS - INSPECTION

(SHEET 3 OF 4)

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Step Task Name Identification Qty More Data

1 Inspect Bear Strap - - (a)

2 Inspect Skin Assembly - - (b)

3 Inspect Skin Assembly - - (c)

Bear Strap and Skin - - (d)

Assembly

4 Inspect

(a) Do an internal High Frequency Eddy Current (HFEC) inspection of the bear strap for any crack around

the fasteners shown in accordance with 737 NDT Manual Part 6, 51-00-00, Figure 4 or Figure 23.

(b) Do an external detailed inspection of the skin assembly for any crack.

(c) Do an external HFEC inspection of the skin assembly for any crack around the fasteners shown in accordance with 737 NDT Manual Part 6, 51-00-00, Figure 4 or Figure 23.

(d) Do an internal detailed inspection of all the visible surfaces of the bear strap and skin assembly for any

crack.

FIGURE 1: FUSELAGE - FORWARD ENTRY DOORWAY - SKIN ASSEMBLY AND BEAR STRAP AT THE

LOWER CORNERS - INSPECTION

(SHEET 4 OF 4)

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