# zm7G7xYm' n57 SERVICE BULLETIN 1__-_SUMMARY B WCCA9fiERCM.ALAFSNES 

### rOSTOFFKYBOX3707 SEATTE,WASHInWoN9124-2207 

### SUBJECT:FUSELAGE
- FORWARDGALLEY ATA:5331 NUMBER:737-53-1116 DOORWAYUPPERCORNERS - 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 inthe skin at the Total Time forwardcorner 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 isattributed to Repair -per corner 14 14 fatigue from pressurization cycles, and ifnot 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 of2BOEING SERVICEBULLETIN 737-53-1116 0

-Pt +

| + + 4 CRACK

+++ m

AFT CORNER SHOWN FORWARD CORNER SIMILAR

S
Jul 1/88Summary Page 2BOEIMCOMMERCIALAIRPLANFS POSTOFFIEBOX3707 SEATTLE,WASHOUTSW24-7 

# SERVICE BULLETIN

ATASYSTEM: 5331 NUMBER:737-53-1116 DATE:July21, 1988

SUBJECT: FUSELAGE
- FORWARD GALLEY DOORWAY UPPERCORNERS
- 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 toairplanes listedbelow.
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 Iof 22BOEING 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 3BOEING 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 21/88 737-53-1116BOEING 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 5BOEING 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 6BOEING 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 8BOEING 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 

### 9BOEING SERVICE BULLETIN 737-53-1116
B. Reason Inspection of the upper corners of the forward galley doorwaywill 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 servicebulletin. Five operators have reported cracks in the upper corners of the forward galley doorways on a total of seven airplanes. Three airplaneshad atotal ofeight cracks in theupper aft corner,with crack lengths of up to 2 inches in the skin, and a 2 inch long crack in the bearstrapdoubler onone 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 from40,500 to 60,800 flight cycles. C. Description Prior to accumulating 35,000 flight cycles, accomplishhigh 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. Ifno cracks are found, accomplish the preventive modification per this bulletin, or repeat the inspection at "C" check intervals until thepreventive 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 complywith the applicable FederalAviation Regulations (FAR's)and are FM approved.



### Jul 21/88 737-53-1116 

### 10BOEING 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 isrequired to accomplish thispreventive modificationperdoorwaycorner. Approximately 14 man-hours are required to accomplish this crack repairper doorway corner. The following breakdownof 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 necessarybased onyourownexperience.Elapsed Time Operation Crew Size Han-Hours (Hours) Access 1 1 1 Crack Repair (maximum) 1 12 12 Restoration 1 1 1 TOTALPERDOORWAY CORNER 14 14

Jul 21/88 737-53-1116 11BOEING SERVICEBULLETIN 737-53-1116
F. Haterial

- Price and &vailabilitv The kits identified inParagraph II.A.1maybeobtained 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 limitedand tooling ormaterial availability is the pacing factor, operator purchase orders will receive an allocation from the available quantities based on receipt date ofpurchase 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 willbe available as indicated in theReorder LeadTime (ROLT) column. Reorder lead time is computed from date of receipt of operator's purchase order. Delivery Data ROLT Unit 

### KitNumber DesitiEon Date Q e 

### Wks 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 DateJiah;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 toDirector of Spares, andrefer to this servicebulletin number.

Jul 21/88 737-53-1116 12BOEING SERVICE BULLETIN 737-53-1116 The parts and materials identified in Paragraph II.A.1 may be furnishedor fabricated from operator's existing stockorpurchased directly from industry sources. The followingBoeing pricedata is provided for planningpurposes 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 30days. Address purchase orders and correspondence pertaining to this quotation to Director of Spares, andrefer to this servicebulletin number. G. Tooling
- PriceandAvailability 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 andpowerunits, aswell as engineering and service, is Fatigue Technology, Inc. Also available from Fatigue Technology, Inc. isakit of expendable coldwork tooling specifically tailored to therequirements of this servicebulletin. Ref: FEI KitNumber: FTI-737-53-1116-1 Fatigue Technology, Inc. P.O. Box C-88388 Seattle,WA 98188 TelexNumber 321004 Tnx910-444-4128

Jul 21/88 737-53-1116 13BOEING 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 operatorbasedon extent ofkit incorporation. NOTE: Incorporation of Preventive Modification kit 65C33801-1 has no effectonairplane weight andbalance. I. References 1. ExistingData: a. 737 Structural Repair Manual Subjects 51-10-1, 51-30-9 b. 737 NondestructiveTestManual Part 6Subject 51-00-00 2. Data supplied in support of this servicebulletin: 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 insupport of this service bulletinare not detailed in this service bulletin since they are common practices which can be accomplished in accordance with operator's normalprocedures. J. Publications Affected None

Jul 21/88 737-53-1116 14BOEING SERVICE BULLETIN 737-53-1116
II. MATERIAL INFORMATION A. PnrtsRfquired PerAirplane The following isprovided to aid inkit selection. Usage i Preventive Modification 65C33801-1 BothCorners Repair Forward Corner Skin andbearstrap cracks 65C33800-12 Skin orbearstrap crack 65C33800-14 Repair
-Aft Corner Skinand bearstrap cracks 65C33800-13 Skinorbearstrap crack 65C33800-15 RainGutter Replacement 65C33800-16 (Requiredwith repair) 1. The kits maybe 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 eachairplane. 65C33800 - SKIN ANDSTRINGER INSTALLATION - SKINREPAIR (TOPKIT) 

# 0 -16 -15 -14 -13 -12 

# SOantity Part Number Nomenclature

- 65C33800-12 Kit
- Forward Corner, SkinandDoubler Repair

. 65C33800-13 Kit
- AftCorner, Skin and DoublerRepair

. . 65C33800-14 Kit
- Forward Corner, Skin or DoublerRepair 6 ,5C33800-15 Kit
- Aft Corner,Skin or DoublerRepair

. . . 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 excessparts or return themto operator's spare stock.

Jul 21/88 737-53-1116 15BOEING SERVICEBULLETIN 737-53-1116 65C33800

- (Continued) -16 -15 -14 -13 -12 OPartNumber 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, PREVENTIVEMODIFICATION -1 Quantity Laxrt -Numbe N2MenclA=Mr

- 65C33801-1 (a) Top

### Kit 8 BACR15BB8B9 Rivet 6 BACRl5BBSBIO Rivet 1 BACR15BB8B13 Rivet (a) Kit fastenersmay be furnished from operator's existing stocks. 

# S

Jul 21/88 737-53-1116 16

### BOEING SERVICE BULLETIN 737-53-1116 2. The followingmaterials are tobe furnishedby the operator. PartNumberor AsRequired BMS 5-95, Class B Sealant AsRequired EMS 10-il, Type I Primer AsRequired BMS 10-li, Type II Enamel
- 

### Color toMatch Airplane B. PartsReauired toModifySnares None C. Suecial TosadEunetRote Coldworking Tools are required during accomplishment of the preventive modification per this 

### service bulletin. See Paragraph I.G. fordetails. D. Existinua Parts Accountability None

Jul 21/88 737-53-1116 17tBOEING SERVICE BULLETIN 737-53-1116

THIS PAGEINTENTIONALLY LEFT BLANK

Jul 21/88 737-53-1116 18BOEING 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 indicatedby circle notes on the figures. 2. On the figures, unless otherwise specified:

- All lineardimensions are in inches

- Tolerance on linear dimensions other than rivet and bolt edgemargin is plus orminus 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 RepairManual Chapter 51 A. Open the forward galleydoor 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. Ifcrackeddoorway corners are found, repairper 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 preventivemodification isaccomplished. NOTE: Delayed implementation of the preventive modification may cause oversizing requirements beyond the preventive modificationkit range. E. Refinish the rework area around doorway as required, and restore airplane tooperational configuration.

Jul 21/88 737-53-1116 19BOEING SERVICE BULLETIN 737-53-1116

STA STA 332.1 3122



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

- TYP I I NSPECTION (7 PLACES) UP TYIAREA
CAUTION: WHENDRILLING OUT EXISTING FASTENERS, DOMOTUSE DRILLBIT SIZEANY LARGERTHANEXISTING FASTENER DIAMETER. @ Carefully drill outexisting fasteners in shadedareas. @/Remove magnesium reveal comer fittings 65-53594-1 (or -501) and 65- 53S95-1 (or -501) frombearstrapdoublerandretain for later use. Clean off any sealant residue fromexposedarea ofbearstrapdoubler. @Inspectexposedarea of skin (outside)andbearstrapdoubler (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. FORWARDGALLEYDOORWAYUPPERCORNERINSPECTION Jul 21/88 737-53-1116 20

### BOEING SERVICEBULLETIN 737-53-1116
STA STA STA 332.1 312 291.5



### S-6-

2 TYPICAL



# O Removeexistingraingutter. 

# 0 Stop drillendofcrack (Ref. 737 StructuralRepairManualSubject 51-10- 1). @j 

### If skin assembly or bearstrap doubler iscracked, install repair strap anddoubler perdrawing65033800usingkit 65C33800-14. @ 

### If skinassemblyandbearstrapdoubler arecracked, installrepair strap, doubler, and triplerperdrawing 65C33800usingkit65C33800-12. @ 

### If skin assembly or bearstrap doubler iscracked, install repair strap anddoublerperdrawing 65C33800usingkit65C33800-15. If skinassembly andbearstrap doublerarecracked, install repair strap, doubler, andtriplerperdrawing65C33800usingkit 65C33800-13. @ 

### Install new rain gutter and appropriate filler strips under gutter per drawing65C33800usingkit 65C33800-16. Trimfiller strips as required, depending onwhich repairkits are installed. 

# 0 FIGURE 2. CRACKREPAIR
- FORWARDGALLEYDOORWAY Jul 21/88 737-53-1116 

### 21BOEING SERVICEBULLETIN 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 \ e +gCORNER UPPER 

### UP AFT 

## CF1ND: CORNER @ Drill out fastenerholes to the appropriate starting hole size for 1/4 

# a inch diameter rivets and high interference sleeved cold working method (Ref. 737 Structural RepairHanual Subject 51-30-9). Cold work fastener holes in uncracked corners using high interference sleevedmethod (Ref. 737 StructuralRepairManual Subject 51-30-9). Drillup fastener holes in reveal fittings to 0.250-0.254 inch diameter. Apply sealant (Ref. BMS 5-95) to faying surfaceof fittings, andposition inplace onbearstrapdoubler. 

# Q Install indicated fasteners fromkit 65C33801 or fromoperators stock. FASTENER CODE * Install rivet BACR15BBSB(*) wet with sealant (Ref. BMS 5-95), with manufacturedheadnear side. 

## S Enlarge countersink far side to 0.425-0.431 inchdiameter. Install rivet BACR15BBSB10wet with sealant (Ref. BMS 5-95) and withmanufactured head near side. Shave the formedhead (far side) as required tobe flushwith 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

# SERVICEBULLETIN EVALUATIONFORM THIS EVALUATION FORM IS PROVIDED FOR THE PURPOSE OF COMMUNICATING INFORMATION TO THE BOEING ORGANIZATION RESPONSIbLE FOR SERVICE BULLETINS AND THEIRCONTENT. THE DATAYOU PROVIDEWILL BEUSED TOIMPROVE THEBOEING SERVICE BULLETIN PROGRAM. NOTE: THIS FORM IS NOT INTENDED TO BE USED FOR REQUESTING SERVICE BULLETIN INCORPORATION INTOBOEING TECHNICAL MANUALS. S/BNO.: 737-53-1116 S/BDATED: JULY 21, 1988 TITLE: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION OPERATOR: 

### _ AIRPLANES AFFECTED OJper S/Beffectivity list (checkone): Oper corrected listbelow: PREPARED BY:
- TITLE: DATE: ORGANIZATION:
- TELEXCODE: EVALUATION:

check ONE ofthe following check ONE ofthe following

five circles AND seven circles.



# . 0

- Will accomplish - Inspection 

# C)

- Partial incorporation 

# O

- Being accomplished I 

# C

- H - Completeincorporation ()-Have accomplished I 0 

### a 0

- Servicebulletin intent



### - 

# !IO

- Uneconomical 

# 0

- Will notaccomplish 

# :0 - Service experience doesnotjustify

- Decision deferred (explain) O -x I -Other (explainbelow) COMMENTS: Bulletin Quality, Suggested Improvements, Other.

FOR ADDITIONAL COMMENTS USEREVERSE SIDE Please forward this form to yourBoeing Field Service Representative ormail directly to: Attention: R. G. Kelsey Boeing CommercialAirplanes Manager, P.O. Box 3707 ServiceBulletin Engineering Seattle, WA 98124 Mail Stop 02-49