zm7G7xYm' n57

SERVICE BULLETIN

1 __-_SUMMARY

B WCCA9fiERCM. ALAFSNES rOST OFF KYBOX3707 SEATTE,WASHInWoN 9124-2207

SUBJECT: FUSELAGE - FORWARD GALLEY ATA: 5331 NUMBER: 737-53-1116

DOORWAY UPPER CORNERS - DATE: July 21, 1988

INSPECTION, REPAIR, AND

PREVENTIVE MODIFICATION

BACKGROUND EFFECTIVITY

Five operators have found sixteen 737 airplanes Line Number 1-1560, less

cracks in the skin and doublers at the PJ201-PJ219

upper corners of the forward galley

doorway on seven airplanes. There MANPOWER

were eight cracks reported at the

upper aft corner on three airplanes, Elapsed

and eight cracks in the skin at the Total Time

forward corner on four airplanes. The Auolicabilitv_ f Man-Hours (Hours)

airplanes had accumulated from 29,000

to 44,600 flight hours, and from Inspection 5 2.5

40,500 to 60,800 flight cycles. Preventive

Modification 0.7 0.7

Cause of the cracking is attributed to Repair -per corner 14 14

fatigue from pressurization cycles,

and if not corrected could result in MATERIAL INFORMATION

cabin pressurization difficulties, and

unscheduled downtime for repairs. Kit Price

ACTION 65C33800-12 $408.00

65C33800-13 $387.00

Prior to reaching 35,000 flight 65C33800-14 $282.00

cycles, accomplish high and low 65C33800-15 $291.00

frequency eddy current inspections for 65C33800-16 $207.00

cracks in the skin, skin doubler, or

bea strap doubler in the upper corners See Paragraph I.F for applicable terms

of the forward galley doorway. For and conditions.

airplanes having accumulated over

35,000 flight cycles, accomplish the

initial inspection within 3500 flight

cycles after receiving this bulletin.

If no cracks are found accomplish the

preventive modification, or repeat the

inspection at "Cm check intervals

until the preventive modification is

accomplished. If cracks are found,

install the repair doublers and

triplers over the cracked areas per

this bulletin.

Summary Page 1 of 2
BOEING SERVICE BULLETIN 737-53-1116 0

-Pt +

| + CRACK+ 4 

+ + + m

AFT CORNER SHOWN

FORWARD CORNER SIMILAR

S

Jul 1/88Summary Page 2
BOEIM COMMERCIAL AIRPLANFS POST OFFIE BOX 3707 SEATTLE, WASHOUTS W24-7

SERVICE BULLETIN

ATA SYSTEM: 5331 NUMBER: 737-53-1116 DATE: July 21, 1988

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION,

REPAIR, AND PREVENTIVE MODIFICATION

I. PLANNING INFORMATION

A. EffectlvL&y

1. Airplanes Affected

See Service Bulletin Index Part 3 for cross reference of

Variable Number to Airplane Serial Number.

This change is applicable only to airplanes listed below.

LISTING BY CUSTOMER CODE AND VARIABLE NUMBER

AAL PGO34 PG201 PG204 PG217 PG222

PG271-PG276 PG278 PG403 PG438 PK287

PP161-PP168 PY132-PY133

ABD PK495

ABL PP380

Jul 21/88 737-53-1116

Page I of 22
BOEING SERVICE BULLETIN 737-53--1116

LISTING BY CUSTOMER CODE AND VARIABLE NUMBER (CONTINUED)

ABR PJ109 PK563

AFA PL502-PLS03 PN101-PN117

ALG PK361 PK631 PK633-PK634 PL717-PL725 PYOS1-PY053

ALK PY591-PY595

ALO PGO46 PG629 PG701 PG705 PK305-PK306

PK691-PK695 PK697 PP730 PP733 PYOO1

PYO03 PY0os PY451

ALY PY409-PY410

AMW PCD04 PG036 PGS331-PG332 PG577 PJ102

PK082 PK283 PK285 PK56S PK62S-PK626

PK696 PL081 PL172 PL551-PL562 FL758

PL764 PL801 PP181-PP192 PP378 PP381

PP891-PP899 PP901

ANA PG578-PG581 PG583-PGS86 PK711-PK716

ANG PK661 PK664-PK666 PY162

ANK PG582

ANS PQ026-PQ037

ANW PP904 PP907

ANZ PK211 PK213-PK214 PK216-PK220 PM181 PY741

APC PL151

ARE PP352 PP384 PP835-PP837 PP846 PP946-PP947

ARG PH705-PH708 PH741-PH743 PK1O1-PK103 PY007-PY008

ARL PG251 PG253-PG255 PG573 PG575 PK029

PK641-PK642 PP951-PP952 PY281 PY321-PY323

ARM PY241 PY243-PY244

ASA PY134-PY135 PY270 PY461-PY4S3

ASC PG224 PG401-PG402 PG436 PG572 PY343

AUK PK612 PL171

Jul 21/88 737-53-1116

2
BOEING SERVICE BULLETIN 737-S3-1116

. LISTING BY CUSTOMER CODE AND VARIABLE NUMBER (CONTINUED)

AUS PQOOI-PQ012

AVG PN501-PN502

AZE PAGOO PAO03-PAO04 PCO03 PL802

BAB PK731-PK765 PK771-PK777 PK779 PK819 PK830

BAH PK351-PK353 PLO61

BAV PL451-PL452 PL455-PL456

BCI PG214

BEJ PM281-PM283 PP521-PP522

BER PP822

BNA PP908-PP909

BNF P6202 PG205 PG207 PG209 PG211-PG212

PG216 PG218 PG220-PG221

BRI PJ101 PJLO3-PJI08 PJ11O-PJ119 PK212 PK21S

PK801-PK804 PY361-PY362

BRT PJ9O1-PJ009 PJ031 PJ072 PK882 PL803

PN451-PN456

BRZ PK068-PK069

BZB PY401

CAL PG199 PP671-PP674 PP676-PP677 PP679 PP682-PP685

PP688-PP694 PP697-PP698 PP702-PP726

CAM PM171 PY046-PY047

CDI PG651-PG652 PJ032 PK026-PK028 PK221-PK223 PK358

PK561 PK671-PK675 PK677-PK681 PK822-PK823 PK881

PK884 PL401-PL417 PL712 PL761-PL762 PL765-PL770

PM141-PM142 PY151-PY154 PY301-PY304 PY421-PY422 PY441

CHI PG574 PN471-PN472

CNV PG351

COP PCOO1 PY341

Jul 21/88 737-53-1116

3
BOEING SERVICE BULLETIN 737-53-1116

LISTING BY CUSTOMER CODE AND VARIABLE NUMBER (CONTINUED) S

COR PP831 PP838

CRU PK14i-PK146

DAL PG203 PG219 PK611 PK613 PK615

PK623-PK624 PK632 PL221 PL611 PN131-PN163

PN401-PN404 PN407-PN420 PP231-PP243

DAN PK820 PL421 PNOO1-PNOO2 PP351

DFI PP991

DLH PK901-PK938 PK971 PQOS1-PQ065 PQ086-PQ090 PY345-PY346

DRG PK357 PK617 PK871

EAG PY381

EGN PG037 PG208 PG210 PG215 PG431

PL763

EGP PK252-PK2SS

ELA PL631-PL632

ERA PG026 PG028-PG029

ETH PN511

EUR PK203 PK359 PK564

FAT PA002 PA005 PG055 PG226 PG228

PG230 PK562 PN481

FCT PCO02 PG213 PG252

FRO PG056 PG064 PG225 PG229 PG432-PG433

PG441-PG442 PG621-PG628 PG630 PG704 PLOO1

PLO25-PL028 PL711

GAX PA231-PA232

GBN PY191

GER PQ231-PQ233

GNE PY651

Jul 21/88 737-53-1116
BOEING SERVICE BULLETIN 737-53-1116

LISTING BY CUSTOMER CODE AND VARIABLE NUMBER (CONTINUED)

GUL PK461-PK468

GUN PK635-PK637 PM251-PM254 PN40 PY056-PY057

HAP PL501 PL504-PL506

HLA PK360 PP833-PP834 PP839-PPS40 PP903

ICS PY342 PY344

IDF PM016-PMOi7

IO PL601-PL603

IER PP841-PP842

ILF PP353

IND PHO21-PH022 PH024 PH709-PH713 PK231-PK240 PM001-PM006

PY631

INT PK614 PK616 PP931-PP936 PP948

. IRN PH731 PK391 PY021-PY022

IRQ PY141-PY142

JAT PP771-PP779

JTE PY002 PY006

KAF PP221

KLM PP861-PP870

LAL PP851-PP852

LAM PHO01 PH703 PY031

LAN PK825 PYZ42

LNA PY411

LNK PH701

LUX PK451-PK452

MAD PG375 PL793

0

Jul 21/88 737-53-1116

5
BOEING SERVICE BULLETIN 737-53-1116

LISTING BY CUSTOMER CODE AND VARIABLE NUMBER (CONTINUED)

MAL PL71S

MAS PL736-PL738 PL740-PL747 PY201

MID PK621-PK622 PK627-PK629 PN491-PN493

MIS PL441

MLT PL621--PL626

MON PP8Z1 PP823-PP824 PP832

MRS PK872-PK874 PP501-PP504

MXG PCOOS PG223

NAS PA099

NAU PK356 PK581 PY286

NIA PL78i-PL788

NIR PY166

NYA PP675 PP678 PP680-PP681 PP686-PP687 PP695-PP696

PP699 PP701

OLY PK301-PK304 PK307-PK310 PM021-PM023

ORN PK824 PK826-PK827 PP201-PP205 PP732

PAA PGO20-PGO21 PG043 PG047-PGD48

PEX PA006-PA022 PG501-PGSOS

PIA PP281-PP286

PIE PG041-PG042 PG049 PG073 PG206 PG301-PG314

PG474 PG576 PK288-PK289 PK591-PK599 PK601-PK610

PK883 PM101-PM119 PP376-PP377 PP401-PP436 PP471-PP475

PVOO1-PV004

PLU PL201-PL203

PRS PX701

PTI PP728-PP729

Jul 21/88 737-53-1116

6
BOEING SERVICE BULLETIN 737-53-1116

. LISTING BY CUSTOMER CODE AND VARIABLE NUMBER (CONTINUED)

PTS PL471

RAM PK271-PK274 PY671-PY672

RBA PK047 PK051 PY21

RLI PG279

SAA PG353-PG356 PL0D1-PL113

SAB PK041 PK044-PK046 PK048-PK50 PKO52-PK053 PK431-PK433

PP961-PP965 PY272-PY275

SAH PG434 PK081

SBG PY004

SHJ PL581

SRF PK318

SUD PY156-PY157

O SVA PK311-PK317 PL726-PL735 PY036-PY037

SWA PK091-PX099 PK541-PK560 PK630 PM051-PM066 PP11-PP135

SWL PK521 PK523-PK527

TAC PG059 PG352 PP727 PY131

TAF PK519

TAN PJ071

TAP PK973-PK974 PNO81-PN086 PY721

TAV PG074 PK501-PK504 PK821 PP801-PP804 PY101-PY103

TBL PP825-PP826 PP847-PP848 PQ241-PQ242

TEA PK042-PK043 PK281-PK282 PK284 PK286

TII PK511 PK514-PK51S

TNZ PY611-PY612

TUN PK861-PK863 PY621

Jul 21/88 737-53-1116

7
BOEING SERVICE BULLETIN 737-53-1116

LISTING BY CUSTOMER CODE AND VARIABLE NUMBER (CONTINUED)

UAL PGOO1-PGO04 PGO06-PGO19 PGO22-PGO25 PGO27 PGO30

PGO32-PG033 PG038-PGO40 PG044-PG045 PGOS1-PGO54 PG057

PGO60-PGO63 PG065-PG072 PGO75 PK201-PK202 PLO02-PLO24

PQ1O1-PQ123

UNV PP379 PP382 PP731

USA PN021-PNO43 PP001-PP045 PP383

UTA PP902 PP910

VAR PK1II-PK120 PL453-PL454 PP905-PP906 PP981-PP982

VIV PP169 PP391-PP392

VNZ PK070

VSP PG435 PG437 PG439-PG440 PG471-PG473 PHOll-PHO13

PK061-PKO62 PK065-PK067 PK241 PK354-PK355 PL756

PP301-PP305 PP827 PX071 PY222

WAI PY112

XIA PM255 PN406

XIN PP631-PP634

YEM PK341

YUN PP651-PP652

ZAI PYl1l PY113

ZAM PK291

ZMB PN431-PN433

Jul 21/88 737-53-111S

8
BOEING SERVICE BULLETIN 737-53-1116

, LISTING BY VARIABLE NUMBER

PAOOI-PA022 PA099 PA231-PA232 PCOOI-PCO05 PGOO1-PGO75

PG199 PG201-PG230 PG251-PG255 PG271-PG279 PG301-PG314

PG331-PG332 PG351-PG356 PG375 PG401-PG403 PG431-PG442

PG4?1-PG475 PG501-PGSOF PG571-PG586 PG621-PG630 PG651-PG652

PG701-PG70S PHOOI PHOII-PHO13 PHO21-PHO24 PH701-PH715

PH731-PH732 PH741-PH743 PJOO1-PJ009 PJ031-PJ032 PJ071-PJ072

PJ101-PJ119 PK02G-PK029 PK041-PK053 PK061-PK070 PK081-PK082

PK091-PK099 PK101-PK103 PKll-PK120 PK141-PK146 PK201-PK204

PK211-PK223 PK231-PK241 PK251-PK258 PK271-PK274 PK281-PK289

PK291 PK301-PK318 PK341 PK351-PK361 PK391

PK431-PK433 PK451-PK452 PK461-PK469 PK495 PK501-PK504

PK511-PK515 PK519 PKS21-PK527 PK541-PK565 PK581

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

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

PK801-PK804 PK819-PK827 PK830 PK861-PK863 PK871-PK874

PK881-PK884 PK901-PK938 PK971-PK974 PLOOI-PL028 PL061

PLO81 PL1O1-P113 PL151 PL171-PL172 PL2O1-PL203

PL221 PL401-PL417 PL421 PL441 PL451-PL456

PL471 PL491 PLSGI-PL506 PLS51-PL562 PL581

PL601-PL603 PL611 PL621-PL626 PL631-PL632 PL711-PL712

PL716-PL747 PL756 PL758 PL761-PL770 PL781-PL788

PL793 PL8O1-PL803 PMO01-PM006 PM016-PM017 PM021-PM023

PM051-PM066 PMIO1-PM119 PM141-PM142 PM171 PM181

PM251-PM255 PM281-PM283 PNOO1-PNO02 PNO21-PNO43 PNO81-PN086

PN101-PN117 PN131-PN163 PN401-PN420 PN431-PN433 PN451-PN456

PN471-PN472 PN481 PN491-PN493 PN501-PNS02 PN511

PPOO1-PP045 PP101-PP13S PP161-PP169 PPi81-PP192 PP201-PP205

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

PP376-PP384 PP391-PP392 PP401-PP436 PP471-PP475 PP501-PP504

PP521-PP522 PP631-PP634 PP651-rF652 PP671-PP699 PP701-PP733

PP771-PP779 PP801-PPS04 PP821-PP827 PP831-PP842 PP846-PP848

PPSS2-PP852 PP861-PP870 PP891-PP899 PP901-PP910 PP931-PP936

PP946-PP948 PP951-PP952 PP961-PP965 PP981-PP982 PP991

PQOO1-PQ012 PQ026-PQ037 PQ051-PQ065 PQO86-PQ090 PQ1O1-PQ123

PQ231-PQ233 PQ241-PQ242 PVOOi-PVOO4 PX071 PX701

PYOO1-PY008 PY021-PY022 PY031 PY036-PYU37 PY046-PY048

PYOS1-PYOS3 PY056-PY057 PY1O1-PY103 PY111-PY113 PY131-PY135

PY141-PY143 PY151-PY154 PY156-PY1S7 PY161-PY162 PY1G6

PY191 PY201 PY221-PY222 PY231 PY241-PY244

PY270-PY275 PY281 PY286 PY301-PY304 PY321-PY323

PY341-PY346 PY361-PY362 PY381 PY401 PY409-PY411

PY421-PY422 PY441 PY451 PY461-PY463 PY591-PY595

PY611-PY612 PY621 PY631 PY651 PY671-PY672

PY721 PY741

2. Spares Affected

None

Jul 21/88 737-53-1116

9
BOEING SERVICE BULLETIN 737-53-1116

B. Reason

Inspection of the upper corners of the forward galley doorway will

detect cracking that could result in pressurization difficulties.

Repair of cracks or accomplishment of preventive modification on

uncracked structure is terminating action for inspection per this

service bulletin.

Five operators have reported cracks in the upper corners of the

forward galley doorways on a total of seven airplanes. Three

airplanes had a total of eight cracks in the upper aft corner, with

crack lengths of up to 2 inches in the skin, and a 2 inch long

crack in the bearstrap doubler on one airplane. Four airplanes had

a total of eight cracks from 0.1 inch to 1.5 inches in length in

the upper forward corner skin.

The airplanes had accumulated from 29,000 to 44,600 flight hours,

and from 40,500 to 60,800 flight cycles.

C. Description

Prior to accumulating 35,000 flight cycles, accomplish high and low

frequency eddy current inspections of the area around fasteners in

the upper corners of the forward galley doorway to determine if

there are cracks in the skin, skin doubler, or bearstrap doubler.

For airplanes with over 35,000 flight cycles, accomplish this

inspection no later than 3500 flight cycles after receipt of this

bulletin.

If no cracks are found, accomplish the preventive modification per

this bulletin, or repeat the inspection at "C" check intervals

until the preventive modification is accomplished.

If cracks are found, stop drill the crack ends, and install the

repair doublers and triplers over the cracked areas per this

bulletin.

D. Approval

This service bulletin has been reviewed by the Federal Aviation

Administration (FMA) and the repairs and modifications herein

comply with the applicable Federal Aviation Regulations (FAR's) and

are FM approved.

Jul 21/88 737-53-1116

10
BOEING SERVICE BULLETIN 737-53-1116

E. Hanvower

Approximately 7 man-hours and a crew of 2 are required to

accomplish this inspection per airplane, plus approximately an

additional 0.7 man-hour and a crew of 1 is required to accomplish

this preventive modification per doorway corner.

Approximately 14 man-hours are required to accomplish this crack

repair per doorway corner.

The following breakdown of manpower requirements is suggested as a

guide to assist operators in planning and accomplishing this

repair. This estimate is for direct labor performed by an

experienced crew. It does not include setup, planning,

familiarization, cure time, tool acquisition, or lost time. Factor

this estimate as necessary based on your own experience.

Elapsed

Time

Operation Crew Size Han-Hours (Hours)

Access 1 1 1

Crack Repair (maximum) 1 12 12

Restoration 1 1 1

TOTAL PER DOORWAY CORNER 14 14

Jul 21/88 737-53-1116

11
BOEING SERVICE BULLETIN 737-53-1116

F. Haterial - Price and &vailabilitv

The kits identified in Paragraph II.A.1 may be obtained from Boeing

within the terms and conditions defined below. The quotation

indicates the quantity and date when initial kits will be

available. When source capacity is limited and tooling or material

availability is the pacing factor, operator purchase orders will

receive an allocation from the available quantities based on

receipt date of purchase order by the Spares Department and based

on operator's planned modification schedules. Therefore, operators

are requested to include planned dates of incorporation on their

purchase order. When initial quantities are depleted, additional

kits will be available as indicated in the Reorder Lead Time (ROLT)

column. Reorder lead time is computed from date of receipt of

operator's purchase order.

Delivery Data

ROLT Unit

Kit Number DesitiEon Date Q Wks e Price

65C33800-12 Kit - Repair Aug 19, 1988 25 25 $408.00

65C33800-13 Kit - Repair Sep 2. 1988 25 25 $387.00

65C33800-14 Kit - Repair Sep 2, 1988 25 25 $282.00

65C33800-15 Kit - Repair Sep 2, 1988 25 25 $291.00

65C33800-16 Kit - Gutter Sep 2, 1988 25 25 $207.00

Date Jiah;ZL-A2&A

The prices quoted are subject to the terms and conditions of

Boeing's standard purchase order acknowledgment. Quotations are

subject to acceptance within 120 days from date hereon. After

expiration of the quotation, price and delivery data will be

provided upon request. Prices quoted in United States Dollars.

Terms: Net 30 days.

Address purchase orders and correspondence pertaining to this

quotation to Director of Spares, and refer to this service bulletin

number.

Jul 21/88 

737-53-1116

12
BOEING SERVICE BULLETIN 737-53-1116

The parts and materials identified in Paragraph II.A.1 may be

furnished or fabricated from operator's existing stock or purchased

directly from industry sources. The following Boeing price data is

provided for planning purposes or in the event operators desire to

purchase kits from Boeing. Delivery data will be provided upon

request.

KLtNumber Descrirtion nit Price

65C33801-1 Kit - Preventive $0.60

Modification

Date Jly21.-Li.2u

The prices quoted are subject to the terms and conditions of

Boeing's standard purchase order acknowledgment. Quotations are

subject to acceptance within 120 days from date hereon. After

expiration of the quotation, prices and delivery data will be

provided upon request. Prices quoted in United States Dollars.

Terms: Net 30 days.

Address purchase orders and correspondence pertaining to this

quotation to Director of Spares, and refer to this service bulletin

number.

G. Tooling - Price and Availability

All required coldwork tools and sleeves for accomplishment of this

service bulletin may be selected from appropriate tables in

Structural Repair Manual and procured from industry sources, as

required.

One source which provides all coldwork tools including sleeves,

mandrels, nosecaps, pullers and power units, as well as engineering

and service, is Fatigue Technology, Inc. Also available from

Fatigue Technology, Inc. is a kit of expendable coldwork tooling

specifically tailored to the requirements of this service bulletin.

Ref: FEI Kit Number: FTI-737-53-1116-1

Fatigue Technology, Inc.

P.O. Box C-88388

Seattle, WA 98188

Telex Number 321004

Tnx 910-444-4128

Jul 21/88 737-53-1116

13
BOEING SERVICE BULLETIN 737-53-1116

R. Weigfht and Balance

Change in Change in

Weight Momeat

Applicability 2kBLUP&4;1 525:.a4Lt hfif

737-100 (a) +9.2 +2825

737-200 (a) +9.2 +3494

737-300 (a) +9.2 +2089

(a) Approximate weight and balance information based on

incorporation of 65C33800-12, -13 and -16 kits (worst case) on

an airplane. Actual weight and balance to be determined by

operator based on extent of kit incorporation.

NOTE: Incorporation of Preventive Modification kit 65C33801-1

has no effect on airplane weight and balance.

I. References

1. Existing Data:

a. 737 Structural Repair Manual Subjects 51-10-1, 51-30-9

b. 737 Nondestructive Test Manual Part 6 Subject 51-00-00

2. Data supplied in support of this service bulletin:

Drawings

Drawing No. EhgtS DCN ADCN Title

65C33800 PL A - Skin and Stringer

Installation - Repair

(Top Kit)

65C33800 1 B -

3. Process Data:

Boeing Process Specifications that are listed on drawings

supplied in support of this service bulletin are not detailed

in this service bulletin since they are common practices

which can be accomplished in accordance with operator's

normal procedures.

J. Publications Affected

None

Jul 21/88 737-53-111614
BOEING SERVICE BULLETIN 737-53-1116

II. MATERIAL INFORMATION

A. Pnrts Rfquired Per Airplane

The following is provided to aid in kit selection.

Usage i

Preventive Modification 65C33801-1

Both Corners

Repair Forward Corner

Skin and bearstrap cracks 65C33800-12

Skin or bearstrap crack 65C33800-14

Repair - Aft Corner

Skin and bearstrap cracks 65C33800-13

Skin or bearstrap crack 65C33800-15

Rain Gutter Replacement 65C33800-16

(Required with repair)

1. The kits may be obtained as noted in Paragraph I.F.

NOTE: One or more kits and operator furnished materials

listed in Paragraph II.A.2 are required to modify or

repair each airplane.

65C33800 - SKIN AND STRINGER INSTALLATION - SKIN REPAIR (TOP KIT)

0 -16 -15 -14 -13 -12 SOantity Part Number Nomenclature

- 65C33800-12 Kit - Forward Corner,

Skin and Doubler Repair

. 65C33800-13 Kit - Aft Corner, Skin and

Doubler Repair

. . 65C33800-14 Kit - Forward Corner, Skin

or Doubler Repair

,5C33800-15 6 Kit - Aft Corner, Skin or

Doubler Repair

. . . 65C33800-16 (a) Kit - Gutter Installation

1 . 1 . 65C33800-17 Repair Strap

1 1 , .165C33800-18 Doubler

. . 1 . 65C33800-19 Tripler

. 1 1 65C33800-20 Repair Strap

. 1 . 1 65C33800-21 Doubler

* . . . 1 65C33800-22 Tripler

1 . . 65C33800-23 Filler

1 . . 65C33800-24 Filler

(a) Kit contains excess parts not required for installation. Discard

excess parts or return them to operator's spare stock.

Jul 21/88 737-53-1116

15
BOEING SERVICE BULLETIN 737-53-1116

65C33800 - (Continued)

-16 -15 -14 -13 -12

OPart Number 12mflair

1 . . . . 65C33800-25 Filler

1 . , . . 65C33800-26 Filler

1 . . 65-49893-2 Gutter

20 . 2 BACB3OFN5-5 Hi-Lok

18 BACB3OFNS-6 Hi-Lok

21 9 21 9 BACB30FN6-3 Hi-Lok

* 31 12 22 12 BACB3OFN6-4 Hi-Lok

7 62 64 28 23 BACB3OFN6-5 Hi-Lek

7 34 42 43 55 BACB30FN6-6 Hi-Lok

4 33 11 32 31 BACB30FN6-7 Hi-Lok

2 24 6 BACB3OFNq6-8 Hi-Lok

1 2 1 BACB30FN6-9 Hi-Lok

. 20 . 20 BACC3OSH Collar

11 185 142 178 142 BACC30H6 Collar

5 . BACR15BB4B7 Rivet

5 . . BACR15BB4B9 Rivet

4 4 . . BACRl5CE6Bll Rivet

4 4 BACR1SCE6B12 Rivet

3 4 BACR15CE6Bl3 Rivet

. . 3 4 BACR15CE6B14 Rivet

1 I 1 BACR1SCE6D6 Rivet

4 1 BACR15CE6DR Rivet

3 BACR15CE6D9 Rivet

1 1 1 1 BACR1SCE6Dll Rivet

4 4 1 1 BACRl5CE6D12 Rivet

. . 3 3 BACRICE6D13 Rivet

65C33801 - SKIN, AND STRINGER INSTALLATION, SECTION 41,

PREVENTIVE MODIFICATION

-1

Quantity Laxrt -Numbe N2MenclA=Mr

- 65C33801-1 (a) Top Kit

8 BACR15BB8B9 Rivet

6 BACRl5BBSBIO Rivet

1 BACR15BB8B13 Rivet

(a) Kit fasteners may be furnished from operator's existing

stocks.

S

Jul 21/88 737-53-1116

16
BOEING SERVICE BULLETIN 737-53-1116

2. The following materials are to be furnished by the operator.

Part Number or

As Required BMS 5-95, Class B Sealant

As Required EMS 10-il, Type I Primer

As Required BMS 10-li, Type II Enamel - Color to Match

Airplane

B. Parts Reauired to Modify Snares

None

C. Suecial TosadEunetRote

Coldworking Tools are required during accomplishment of the

preventive modification per this service bulletin. See Paragraph

I.G. for details.

D. Existinua Parts Accountability

None

Jul 21/88 737-53-1116

17t
BOEING SERVICE BULLETIN 737-53-1116

THIS PAGE INTENTIONALLY LEFT BLANK

Jul 21/88 737-53-1116

18
BOEING SERVICE BULLETIN 737-53-1116

III. ACCOMPLISHMENT INSTRUCTIONS

* NOTES: 1. The following paragraphs outline the general accomplishment

instructions. The suggested sequence of operations and

detailed accomplishment instructions are indicated by circle

notes on the figures.

2. On the figures, unless otherwise specified:

- All linear dimensions are in inches

- Tolerance on linear dimensions other than rivet and

bolt edge margin is plus or minus 0.03

- Tolerance on rivet and bolt edge margin is plus or

minus 0.05

- Hole size for standard solid rivets is per 737

Structural Repair Manual Chapter 51

A. Open the forward galley door for access to interior surface of door

cutout to accomplish inspection and rework of doorway upper

corners.

B. Accomplish an eddy current inspection of the skin, skin doubler,

and bearstrap doubler in each upper corner of the doorway per

Figure 1.

0 C. If cracked doorway corners are found, repair per Figure 2.

D. If no cracks are found, accomplish preventive modification per

Figure 3. As an option, reinstall reveal fittings and rivets and

repeat inspection of upper doorway corners at "C" check intervals

until the preventive modification is accomplished.

NOTE: Delayed implementation of the preventive modification may

cause oversizing requirements beyond the preventive

modification kit range.

E. Refinish the rework area around doorway as required, and restore

airplane to operational configuration.

Jul 21/88 737-53-1116

19
BOEING SERVICE BULLETIN 737-53-1116

STA STA

33 2.1 3122

I...l. 4 + -r -a -. t.. 

- TYP I I NSPECTI ON

(7 PLACES ) UP TYIAREA

CAUTION: WHEN DRILLING OUT EXISTING FASTENERS, DO MOT USE DRILL BIT SIZE ANY

LARGER THAN EXISTING FASTENER DIAMETER.

@ Carefully drill out existing fasteners in shaded areas.

@/Remove magnesium reveal comer fittings 65-53594-1 (or -501) and 65-

53S95-1 (or -501) from bearstrap doubler and retain for later use. Clean

off any sealant residue from exposed area of bearstrap doubler.

@Inspect exposed area of skin (outside) and bearstrap doubler (inside) for

cracks around each removed fastener location (Ref. 737 Nondestructive

Test Manual (NDT) D6-37239, Part 6, Subject 51-00-00, Figure 4).

Depending on inspection results, take appropriate cotton per

Accomplishment Instructions.

Inspect skin doubler (underneath skin) for cracks around each removed

fastener location (Ref. 737 NDT Manual D6-37239, Part 6, Subject 53-10-

42). Depending on inspection results, take appropriate action per

Accomplishment Instructions.

FIGURE 1. FORWARD GALLEY DOORWAY UPPER CORNER INSPECTION

Jul 21/88 737-53-1116

20
BOEING SERVICE BULLETIN 737-53-1116

STA STA STA

332.1 312 291. 5

S-6-

2 TYPICAL

O Remove existing rain gutter.

0 Stop drill end of crack (Ref. 737 Structural Repair Manual Subject 51-10-

1).

@j If skin assembly or bearstrap doubler is cracked, install repair strap

and doubler per drawing 65033800 using kit 65C33800-14.

@ If skin assembly and bearstrap doubler are cracked, install repair strap,

doubler, and tripler per drawing 65C33800 using kit 65C33800-12.

@ If skin assembly or bearstrap doubler is cracked, install repair strap

and doubler per drawing 65C33800 using kit 65C33800-15.

If skin assembly and bearstrap doubler are cracked, install repair strap,

doubler, and tripler per drawing 65C33800 using kit 65C33800-13.

@ Install new rain gutter and appropriate filler strips under gutter per

drawing 65C33800 using kit 65C33800-16. Trim filler strips as required,

depending on which repair kits are installed.

0 FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

Jul 21/88 737-53-1116

21
BOEING SERVICE BULLETIN 737-53-1116

STA 4

332.1

i, + + / - TYPICAL \-

+ (a PL+CES)-c

< -

1+ TYP+IC-ALI~~i CS( PLACES) @0+

1++i/J

- a. UPPER

+ 1+ .iFORWARD

\ +gCORNER e 

UPPER UP

AFT CF1ND:

CORNER

@ Drill out fastener holes to the appropriate starting hole size for 1/4 a

inch diameter rivets and high interference sleeved cold working method

(Ref. 737 Structural Repair Hanual Subject 51-30-9).

Cold work fastener holes in uncracked corners using high interference

sleeved method (Ref. 737 Structural Repair Manual Subject 51-30-9).

Drill up fastener holes in reveal fittings to 0.250-0.254 inch diameter.

Apply sealant (Ref. BMS 5-95) to faying surface of fittings, and position

in place on bearstrap doubler.

Q Install indicated fasteners from kit 65C33801 or from operators stock.

FASTENER CODE

* Install rivet BACR15BBSB(*) wet with sealant (Ref. BMS 5-95), with

manufactured head near side.

S Enlarge countersink far side to 0.425-0.431 inch diameter. Install rivet

BACR15BBSB10 wet with sealant (Ref. BMS 5-95) and with manufactured head

near side. Shave the formed head (far side) as required to be flush with

structure.

(*) Grip length of fastener indicated by number adjacent to fastener

symbol.

FIGURE 3. PREVENTIVE MODIFICATION - FORWARD GALLEY DOORWAY

Jul 21/88 737-53-1116

22
SERVICE BULLETIN

EVALUATION FORM

THIS EVALUATION FORM IS PROVIDED FOR THE PURPOSE OF COMMUNICATING INFORMATION TO

THE BOEING ORGANIZATION RESPONSIbLE FOR SERVICE BULLETINS AND THEIR CONTENT. THE

DATA YOU PROVIDE WILL BE USED TO IMPROVE THE BOEING SERVICE BULLETIN PROGRAM.

NOTE: THIS FORM IS NOT INTENDED TO BE USED FOR REQUESTING SERVICE BULLETIN

INCORPORATION INTO BOEING TECHNICAL MANUALS.

S/B NO.: 737-53-1116 S/B DATED: JULY 21, 1988

TITLE: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS -

INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION

OPERATOR: _ AIRPLANES AFFECTED OJper S/B effectivity list

(check one): Oper corrected list below:

PREPARED BY: - TITLE: DATE:

ORGANIZATION: - TELEX CODE:

EVALUATION:

check ONE of the following check ONE of the following

five circles AND seven circles.

. 0 - Will accomplish - Inspection C) - Partial incorporation O - Being accomplished I

C - H - Complete incorporation

()-Have accomplished I

0 a 0 - Service bulletin intent

- !

IO - Uneconomical

0 - Will not accomplish : 0 - Service experience does not justify

- Decision deferred (explain) O

-x I - Other (explain below)

COMMENTS: Bulletin Quality, Suggested Improvements, Other.

FOR ADDITIONAL COMMENTS USE REVERSE SIDE

Please forward this form to your Boeing Field Service Representative or mail

directly to:

Attention: R. G. Kelsey

Boeing Commercial Airplanes Manager,

P.O. Box 3707 Service Bulletin Engineering

Seattle, WA 98124 Mail Stop 02-49