Commercial 

Airplanes 737

Service Bulletin

SPECIAL ATTENTION

Number: 737-54-1046

Original Issue: February 16, 2011

ATA System: 5452 7831

SUBJECT: NACELLES/PYLONS - Strut to Wing Fairings - Thumbnail Fairing Edge Seal

Replacement

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2011 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Unpublished Work - All Rights Reserved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, 787, Dreamliner,

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2.0
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BOEING SERVICE BULLETIN 737-54-1046

BLANK PAGE
Table of Contents

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

1. PLANNING INFORMATION ........................................ 7

A. Effectivity ................................................ 7

1. Airplanes ............................................. 7

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 20

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 24

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIGURE 1: ENGINE 1 - LEFT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION . . . . . . 28

FIGURE 2: ENGINE 1 - RIGHT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION . . . . . 30

FIGURE 3: ENGINE 2 - LEFT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION . . . . . . 32

FIGURE 4: ENGINE 2 - RIGHT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION . . . . . 34

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BOEING SERVICE BULLETIN 737-54-1046
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BOEING SERVICE BULLETIN 737-54-1046

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

SPECIAL ATTENTION

Summary Number: 737-54-1046

Original Issue: February 16, 2011

ATA System: 5452 7831

SUBJECT: NACELLES/PYLONS - Strut to Wing Fairings - Thumbnail Fairing Edge Seal

Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Several operators reported repetitive occurrences of excessive in-service wear damage of the thumbnail fairing

edge seal, the fan cowl panel rub strip, and the fan cowl skin assembly. Identical abrasion damage was also

reported at the location where the thumbnail fairing edge seal rests against the top surface of the hinge beam

forward firewall. This service bulletin requires replacement of the thumbnail fairing edge seal with a Nitronic 60

stainless steel alloy seal. Failure to incorporate this service bulletin could lead to excessive wear damage of the

thumbnail fairing edge seal and fan cowl panel rub strip as well as the fan cowl skin assembly. Excessive wear

damage of the thumbnail fairing edge seal could lead to the edge of the seal breaking off and excessive abrasion

of the rub strip locally could lead to a hole forming in the rub strip and subsequently in the fan cowl skin assembly.

The edge of the seal breaking off could allow a fire to spread beyond the firewall.

Boeing Service Related Problem (SRP) 737-[SRP-54-0126] is related to this service bulletin.

ACTION (PRR 38275-149S)

Gain access to the 2 existing thumbnail fairing edge seals on each of the 2 engines and replace them with new

thumbnail fairing edge seals.

EFFECTIVITY

737-600, 737-700, 737-700C, 737-800, 737-900, 737-900ER Airplanes. Refer to Paragraph 1.A.1., Airplanes,

for the list of affected airplanes.

COMPLIANCE

Refer to Paragraph 1.E., 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.

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737-54-1046

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INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of February 01, 2008. Please refer to

Paragraph 2.B., Industry Support Information.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN 737-54-1046
Commercial 

Airplanes 737

Service Bulletin

SPECIAL ATTENTION

Number: 737-54-1046

Original Issue: February 16, 2011

ATA System: 5452 7831

SUBJECT: NACELLES/PYLONS - Strut to Wing Fairings - Thumbnail Fairing Edge Seal

Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

GROUP CONFIGURATION DESCRIPTION

1 - 737-600, 737-700, 737-700C, 737-800, 737-900, 737-900ER

Airplane Models:

737-600, 737-700, 737-700C, 737-800, 737-900, 737-900ER

Variable Number Group

YA001 - YA099 1

YA101 - YA199 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

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Variable Number Group

YA336 - YA345 1

YA351 1

YA356 - YA357 1

YA366 - YA367 1

YA371 - YA377 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

YA811 - YA814 1

YA831 - YA835 1

YA841 - YA862 1

YA881 - YA882 1

YA891 - YA892 1

YA961 - YA978 1

YB001 - YB006 1

YB101 - YB132 1

YB151 - YB153 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YB156 - YB158 1

YB161 - YB164 1

YB171 - YB172 1

YB181 - YB184 1

YB201 - YB208 1

YB271 1

YB276 1

YB301 - YB310 1

YB371 - YB392 1

YB501 - YB502 1

YB521 - YB526 1

YB541 - YB544 1

YB551 1

YB561 - YB598 1

YB601 - YB635 1

YB651 1

YB656 1

YB671 - YB672 1

YB851 - YB863 1

YB871 - YB874 1

YB881 - YB893 1

YB901 - YB903 1

YB911 1

YB961 - YB974 1

YB986 - YB995 1

YC001 - YC030 1

YC051 - YC084 1

YC091 - YC095 1

YC101 - YC104 1

YC111 - YC113 1

YC121 1

YC126 - YC127 1

YC136 - YC141 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YC146 - YC147 1

YC151 - YC156 1

YC166 - YC171 1

YC176 - YC179 1

YC186 - YC190 1

YC201 - YC203 1

YC206 - YC207 1

YC301 - YC305 1

YC321 - YC387 1

YC391 - YC394 1

YC396 1

YC401 - YC417 1

YC421 - YC422 1

YC426 - YC428 1

YC436 - YC439 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 - YC752 1

YC761 - YC770 1

YC781 - YC793 1

YC801 - YC892 1

YC901 - YC907 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YC921 - YC922 1

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 - YD110 1

YD121 - YD126 1

YD151 - YD159 1

YD171 - YD172 1

YD201 - YD203 1

YD206 - YD209 1

YD216 - YD219 1

YD251 - YD254 1

YD256 - YD257 1

YD261 1

YD301 - YD334 1

YD391 1

YD401 - YD410 1

YD412 - YD416 1

YD481 - YD485 1

YD491 - YD499 1

YD501 - YD512 1

YD531 - YD535 1

YD541 - YD547 1

YD561 - YD564 1

YD571 - YD572 1

YD591 - YD595 1

YD601 - YD612 1

YD651 - YD655 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YE001 - YE020 1

YE051 1

YE101 - YE109 1

YE151 - YE157 1

YE171 - YE172 1

YE201 - YE206 1

YE301 - YE305 1

YE321 - YE326 1

YE371 - YE383 1

YF001 - YF006 1

YF021 - YF039 1

YF046 1

YF051 - YF060 1

YF086 1

YF106 - YF107 1

YF111 - YF114 1

YF116 - YF117 1

YF121 - YF123 1

YF176 - YF178 1

YF191 - YF192 1

YF201 - YF245 1

YF401 - YF402 1

YF451 - YF455 1

YF501 - YF578 1

YF701 - YF705 1

YF801 - YF802 1

YF831 - YF832 1

YF901 - YF903 1

YF921 - YF922 1

YG001 - YG044 1

YG061 - YG064 1

YG066 - YG089 1

YG091 - YG099 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YG101 - YG103 1

YG111 - YG114 1

YG116 - YG125 1

YG201 - YG205 1

YG211 - YG214 1

YG221 - YG223 1

YG251 - YG252 1

YG501 - YG509 1

YG601 - YG602 1

YG701 1

YG711 1

YH001 - YH012 1

YH031 - YH048 1

YH051 - YH055 1

YH101 - YH130 1

YH201 - YH202 1

YH206 - YH207 1

YH301 - YH305 1

YH321 - YH322 1

YJ001 - YJ013 1

YJ021 1

YJ471 - YJ480 1

YJ501 - YJ517 1

YJ531 - YJ577 1

YJ591 - YJ599 1

YJ631 - YJ632 1

YJ671 - YJ694 1

YJ801 - YJ867 1

YJ871 - YJ880 1

YJ901 - YJ904 1

YJ908 - YJ929 1

YJ931 - YJ937 1

YJ941 - YJ956 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YJ976 - YJ977 1

YK001 - YK007 1

YK101 - YK104 1

YK111 - YK112 1

YK121 - YK122 1

YK131 - YK133 1

YK136 - YK139 1

YK141 - YK142 1

YK146 - YK148 1

YK151 - YK154 1

YK161 - YK167 1

YK171 1

YK176 - YK177 1

YK186 1

YK191 1

YK196 1

YK201 - YK202 1

YK301 - YK313 1

YK321 - YK340 1

YK361 - YK378 1

YK401 - YK406 1

YK426 - YK427 1

YK431 - YK450 1

YK456 - YK465 1

YK471 1

YK476 1

YK480 - YK487 1

YK495 - YK497 1

YK511 - YK516 1

YK521 - YK529 1

YK551 - YK571 1

YK576 - YK577 1

YK580 - YK585 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YK601 - YK602 1

YK606 - YK607 1

YK611 - YK616 1

YK621 - YK634 1

YK641 - YK644 1

YK651 - YK665 1

YK671 - YK672 1

YK676 - YK677 1

YK681 - YK686 1

YK691 1

YK701 - YK713 1

YK716 - YK719 1

YK721 - YK741 1

YK751 - YK770 1

YK776 - YK778 1

YK791 - YK792 1

YK796 - YK797 1

YK801 - YK899 1

YK901 - YK912 1

YK918 - YK919 1

YK921 - YK927 1

YK941 - YK956 1

YK961 - YK992 1

YL001 - YL005 1

YL011 - YL016 1

YL021 - YL024 1

YL051 - YL052 1

YL056 - YL057 1

YL061 1

YL066 - YL069 1

YL076 - YL077 1

YL101 - YL131 1

YL201 - YL218 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YL271 - YL272 1

YL281 - YL284 1

YL301 - YL303 1

YL311 - YL312 1

YL316 - YL321 1

YL351 - YL353 1

YL371 - YL374 1

YL401 1

YL421 - YL429 1

YL431 - YL444 1

YL461 - YL478 1

YL501 - YL509 1

YL531 - YL534 1

YL541 - YL544 1

YL561 - YL568 1

YL591 - YL593 1

YL601 - YL606 1

YL611 - YL612 1

YL616 - YL617 1

YL621 1

YL626 1

YL631 - YL633 1

YL661 - YL664 1

YL676 - YL681 1

YL691 1

YL701 - YL703 1

YL731 1

YL751 - YL752 1

YL761 - YL771 1

YL801 - YL809 1

YL901 - YL910 1

YL921 - YL936 1

YL951 - YL962 1

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BOEING SERVICE BULLETIN 737-54-1046
Variable Number Group

YM101 - YM103 1

YM201 - YM242 1

YM251 - YM299 1

YM301 - YM391 1

YM471 1

YM481 - YM484 1

YM501 - YM515 1

YM521 - YM522 1

YM541 1

YM551 - YM553 1

YM571 - YM572 1

YM581 - YM582 1

YM591 - YM599 1

YM631 - YM634 1

YM641 - YM652 1

YM671 - YM674 1

YM691 - YM696 1

YM701 - YM710 1

YM761 - YM762 1

YN001 - YN016 1

YN021 - YN024 1

YN061 1

YN071 - YN082 1

YN091 - YN092 1

YN101 - YN112 1

YN121 1

YN201 - YN202 1

YN211 - YN219 1

YN231 - YN235 1

YN261 1

YQ001 - YQ003 1

YQ011 1

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BOEING SERVICE BULLETIN 737-54-1046
2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

Several operators reported repetitive occurrences of excessive in-service wear damage of the thumbnail

fairing edge seal and the fan cowl panel rub strip and fan cowl skin assembly. Identical abrasion damage

was also reported at the location where the thumbnail fairing edge seal rests against the top surface

of the hinge beam forward firewall. This service bulletin requires replacement of the thumbnail fairing

edge seal with a Nitronic 60 stainless steel alloy seal. Failure to incorporate this service bulletin could

lead to excessive wear damage of the thumbnail fairing edge seal and fan cowl panel rub strip as well

as the fan cowl skin assembly. Excessive wear damage of the thumbnail fairing edge seal could lead

to the edge of the seal breaking off and excessive abrasion of the rub strip locally could lead to a hole

forming in the rub strip and subsequently in the fan cowl skin assembly. The edge of the seal breaking

off could allow a fire to spread beyond the firewall.

Boeing Service Related Problem (SRP) 737-[SRP-54-0126] is related to this service bulletin.

D. Description

Gain access to the 2 existing thumbnail fairing edge seals on each of the 2 engines and replace them

with new thumbnail fairing edge seals.

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

Affected Maintenance Zones

Model Zone

737-600, 737-700, 737-700C, 431, 441

737-800, 737-900, 737-900ER

E. 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.

Boeing recommends that the thumbnail fairing edge seal replacement given in this service bulletin be

done within 60 months after the original issue date of this service bulletin.

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BOEING SERVICE BULLETIN 737-54-1046
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 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 1.0 1.0

Figure 1 1 1.0 1.0

Figure 2 1 1.0 1.0

Figure 3 1 1.0 1.0

Figure 4 1 1.0 1.0

Close Access 1 1.0 1.0

TOTAL FOR EACH AIRPLANE 6.0 6.0

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

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BOEING SERVICE BULLETIN 737-54-1046
J. References

1. Existing Data

a. Engineering Change Memo PRR 38275-149S

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

c. Boeing Service Related Problem (SRP) 737-[SRP-54-0126]

d. 737-600/700/800/900 Aircraft Maintenance Manual (AMM) 71-11-02

e. 737-600 Structural Repair Manual (SRM) 51-40-03

f. 737-700 Structural Repair Manual (SRM) 51-40-03

g. 737-700CONV Structural Repair Manual (SRM) 51-40-03

h. 737-800 Structural Repair Manual (SRM) 51-40-03

i. 737-900 Structural Repair Manual (SRM) 51-40-03

j. 737-900ER Structural Repair Manual (SRM) 51-40-03

2. Data supplied with this Service Bulletin

None.

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

Drawing Number Title

313A2110 FAIRING ASSY - THUMBNAIL

313A2200 FAIRING INSTL - STRUT, UPPER

315A2300 HINGE BEAM INSTALLATION

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

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BOEING SERVICE BULLETIN 737-54-1046
Publication Chapter-Section

737 Illustrated Parts Catalog 54-52

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 does not affect FCS, therefore DTIs are not necessary.

L. Interchangeability and Intermixability of Parts

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

information.

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BOEING SERVICE BULLETIN 737-54-1046

BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane , as shown

below. If there is a limit to the quantity of available kits, a supply sequence is given by Spares. More

kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date

Boeing gets the purchase order.

Unit Price thru

12/30/2010

ROLT

(Weeks)

Kit Number Name Date QTY

TOP KIT, RETROFIT - 03/05/2010(a) 50 51 $2,032.00

THUMBNAIL FAIRING

EDGE SEAL REPLACEMENT

002A0001-94

(a) Approximately every 2 weeks, 50 kits will become available for 11 weeks.

B. Industry Support Information

Boeing warranty remedies are available for 737 airplanes in warranty as of February 01, 2008. For

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

Commercial Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be

supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service

bulletin number and reference the airplane variable number(s) 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.

Figure Kit

Top Kit 1 2 3 4

002A0001-94 1 1 1 1

ALL

KIT 002A0001-94

NOTES

Existing Part

Name Number

Figure

New Part Number

1 2 3 4

QTY

313A2114-10 1 1 SEAL

313A2114-9 1 1 SEAL

BOLT, 100 DEG

HEX DR

BACB30NY5HK4 1 1 1 1

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BOEING SERVICE BULLETIN 737-54-1046
ALL

KIT 002A0001-94

NOTES

Existing Part

Name Number

Figure

New Part Number

1 2 3 4

QTY

BACN10YT08CSA 1 1 1 1 NUT

BACR15CE5B7 1 1 1 1 RIVET, 100 DEG

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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BOEING SERVICE BULLETIN 737-54-1046
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.

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. The instructions identified in Paragraph 3.B., Work Instructions, and the Figure(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

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

definition of the acronyms.

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

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

– Linear dimensions are in inches

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

or minus 0.03 inch

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

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets are in 737-600 SRM 51-40-03, 737-700

SRM 51-40-03, 737-700CONV SRM 51-40-03, 737-800 SRM 51-40-03, 737-900

SRM 51-40-03, 737-900ER SRM 51-40-03.

– Torque limits to tighten nuts and bolts are in 737-600 SRM 51-40-03, 737-700

SRM 51-40-03, 737-700CONV SRM 51-40-03, 737-800 SRM 51-40-03, 737-900

SRM 51-40-03, 737-900ER SRM 51-40-03.

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

737-600 SRM 51-40-03, 737-700 SRM 51-40-03, 737-700CONV SRM 51-40-03,

737-800 SRM 51-40-03, 737-900 SRM 51-40-03, 737-900ER SRM 51-40-03. Alternate

fasteners are listed in 737-600 SRM 51-40-03, 737-700 SRM 51-40-03, 737-700CONV

SRM 51-40-03, 737-800 SRM 51-40-03, 737-900 SRM 51-40-03, 737-900ER SRM

51-40-03 and Boeing Drawing 65-88700.

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BOEING SERVICE BULLETIN 737-54-1046
6. If the length of any fastener specified in this service bulletin does not meet the

installation standards in 737-600 SRM 51-40-03, 737-700 SRM 51-40-03,

737-700CONV SRM 51-40-03, 737-800 SRM 51-40-03, 737-900 SRM 51-40-03,

737-900ER SRM 51-40-03, then a fastener of the same specification, or an approved

substitute, with a length which meets the installation standards in 737-600 SRM

51-40-03, 737-700 SRM 51-40-03, 737-700CONV SRM 51-40-03, 737-800 SRM

51-40-03, 737-900 SRM 51-40-03, 737-900ER SRM 51-40-03 may be used.

7. 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.

8. 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.

B. WORK INSTRUCTIONS

1. Part 1 - Open Access

a. Open or remove the fan cowl, if necessary, and gain access to the thumbnail fairing edge

seals. Refer to 737-600/700/800/900 AMM 71-11-02 as an accepted procedure.

2. Part 2 - Thumbnail Fairing Edge Seal Replacement

a. Engine 1

(1) Left Side

(a) Replace the thumbnail fairing edge seal in accordance with FIGURE 1.

(2) Right Side

(a) Replace the thumbnail fairing edge seal in accordance with FIGURE 2.

b. Engine 2

(1) Left Side

(a) Replace the thumbnail fairing edge seal in accordance with FIGURE 3.

(2) Right Side

(a) Replace the thumbnail fairing edge seal in accordance with FIGURE 4.

3. Part 3 - Close Access

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BOEING SERVICE BULLETIN 737-54-1046
a. Close or install the fan cowl, if necessary. Refer to 737-600/700/800/900 AMM 71-11-02 as

an accepted procedure.

b. Return the airplane to a serviceable condition.

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BOEING SERVICE BULLETIN 737-54-1046
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 one side of each engine.

FIGURE 1: ENGINE 1 - LEFT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 1 OF 2)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove / Keep BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Remove / Keep

1 or 2 bolts may

need to be removed.(a)

2 Remove BOLT - -

1 or 2 nuts may

need to be removed.(a)

Remove NUT - -

Remove SEAL 313A2114-() 1

Install double flush

plug in the composite panel of the

thumbnail fairing assembly.(b)

3 Install (New) RIVET, 100 DEG BACR15CE5B7 1

BOLT, 100 DEG HEX BACB30NY5HK4 1 (a)

DR

4 Install (New)

Install (New) SEAL 313A2114-9 1

Install (New) NUT BACN10YT08CSA 1 (a)

5 Install (Kept) BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Install (Kept)

(a) Original fastener(s) can be reused if not damaged.

(b) This step is required only if there is a hole in the composite panel of the thumbnail fairing assembly at the

location shown.

FIGURE 1: ENGINE 1 - LEFT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-54-1046
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 one side of each engine.

FIGURE 2: ENGINE 1 - RIGHT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-54-1046
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove / Keep BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Remove / Keep

1 or 2 bolts may

need to be removed.(a)

2 Remove BOLT - -

1 or 2 nuts may

need to be removed.(a)

Remove NUT - -

Remove SEAL 313A2114-() 1

Install double flush

plug in the composite panel of the

thumbnail fairing assembly.(b)

3 Install (New) RIVET, 100 DEG BACR15CE5B7 1

BOLT, 100 DEG HEX BACB30NY5HK4 1 (a)

DR

4 Install (New)

Install (New) SEAL 313A2114-10 1

Install (New) NUT BACN10YT08CSA 1 (a)

5 Install (Kept) BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Install (Kept)

(a) Original fastener(s) can be reused if not damaged.

(b) This step is required only if there is a hole in the composite panel of the thumbnail fairing assembly at the

location shown.

FIGURE 2: ENGINE 1 - RIGHT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-54-1046
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 one side of each engine.

FIGURE 3: ENGINE 2 - LEFT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-54-1046
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove / Keep BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Remove / Keep

1 or 2 bolts may

need to be removed.(a)

2 Remove BOLT - -

1 or 2 nuts may

need to be removed.(a)

Remove NUT - -

Remove SEAL 313A2114-() 1

Install double flush

plug in the composite panel of the

thumbnail fairing assembly.(b)

3 Install (New) RIVET, 100 DEG BACR15CE5B7 1

BOLT, 100 DEG HEX BACB30NY5HK4 1 (a)

DR

4 Install (New)

Install (New) SEAL 313A2114-9 1

Install (New) NUT BACN10YT08CSA 1 (a)

5 Install (Kept) BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Install (Kept)

(a) Original fastener(s) can be reused if not damaged.

(b) This step is required only if there is a hole in the composite panel of the thumbnail fairing assembly at the

location shown.

FIGURE 3: ENGINE 2 - LEFT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 737-54-1046
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 one side of each engine.

FIGURE 4: ENGINE 2 - RIGHT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-54-1046
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove / Keep BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Remove / Keep

1 or 2 bolts may

need to be removed.(a)

2 Remove BOLT - -

1 or 2 nuts may

need to be removed.(a)

Remove NUT - -

Remove SEAL 313A2114-() 1

Install double flush

plug in the composite panel of the

thumbnail fairing assembly.(b)

3 Install (New) RIVET, 100 DEG BACR15CE5B7 1

BOLT, 100 DEG HEX BACB30NY5HK4 1 (a)

DR

4 Install (New)

Install (New) SEAL 313A2114-10 1

Install (New) NUT BACN10YT08CSA 1 (a)

5 Install (Kept) BOLT - 6

THUMBNAIL FAIRING - 1

ASSY

Install (Kept)

(a) Original fastener(s) can be reused if not damaged.

(b) This step is required only if there is a hole in the composite panel of the thumbnail fairing assembly at the

location shown.

FIGURE 4: ENGINE 2 - RIGHT SIDE: THUMBNAIL FAIRING EDGE SEAL MODIFICATION

(SHEET 2 OF 2)

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