### 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.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 1 of 35 2.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 2 of 35 **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 3 of 35 **BOEING SERVICE BULLETIN 737-54-1046**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 4 of 35 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 5 of 35**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 6 of 35 **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

**DESCRIPTION CONFIGURATION**  **GROUP** 737-600, 737-700, 737-700C, 737-800, 737-900, 737-900ER

- 1

Airplane Models: 737-600, 737-700, 737-700C, 737-800, 737-900, 737-900ER **Group Variable Number** 1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 7 of 35**Group Variable Number** 1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 8 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 9 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 10 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 11 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 12 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 13 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 14 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 15 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 16 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Group**  **Variable Number**1 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 17 of 35 **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 Zone**  **Model** 431, 441 737-600, 737-700, 737-700C, 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 18 of 35 **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. **Elapsed Hours Task Hours**  **Number of Persons Task**  1.0 1.0 1 Open Access 1.0 1.0 1 Figure 1 1.0 1.0 1 Figure 2 1.0 1.0 1 Figure 3 1.0 1.0 1 Figure 4 1.0 1.0 1 Close Access 6.0 6.0 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not applicable.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 19 of 35 **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

**Title Drawing Number**  FAIRING ASSY - THUMBNAIL 313A2110 FAIRING INSTL - STRUT, UPPER 313A2200 HINGE BEAM INSTALLATION 315A2300 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:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 20 of 35 **BOEING SERVICE BULLETIN 737-54-1046 Chapter-Section**  **Publication** 54-52 737 Illustrated Parts Catalog 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 21 of 35 **BOEING SERVICE BULLETIN 737-54-1046**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 22 of 35 **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)**  **QTY Date**  **Name Kit Number**  $2,032.00 51 50 03/05/2010(a) TOP KIT, RETROFIT - THUMBNAIL FAIRINGEDGE 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 4**  **3 2**  **1 Top Kit**  1 1 1 1 002A0001-94
**ALL**
**KIT 002A0001-94**

**NOTES Existing Part**  **Number Name**  **Figure**

**New Part Number 4**  **3 2**  **1 QTY**  SEAL 1 1 313A2114-10 SEAL 1 1 313A2114-9 BOLT, 100 DEG HEX DR 1 1 1 1 BACB30NY5HK4

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 23 of 35 **BOEING SERVICE BULLETIN 737-54-1046 ALL** 
**KIT 002A0001-94**

**NOTES Existing Part**  **Number Name**  **Figure**

**New Part Number 4**  **3 2**  **1 QTY**  NUT 1 1 1 1 BACN10YT08CSA RIVET, 100 DEG 1 1 1 1 BACR15CE5B7

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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 24 of 35 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 25 of 35 **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 26 of 35 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 27 of 35 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 28 of 35 **BOEING SERVICE BULLETIN 737-54-1046 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 6
- BOLT Remove / Keep 1 1
- THUMBNAIL FAIRING ASSY Remove / Keep 1 or 2 bolts mayneed to be removed.(a) - - BOLT Remove 2

1 or 2 nuts mayneed to be removed.(a) - - NUT Remove

1 313A2114-() SEAL Remove Install double flushplug in the composite panel of thethumbnail fairing assembly.(b) 1 BACR15CE5B7 RIVET, 100 DEG Install (New) 3

(a) 1 BACB30NY5HK4 BOLT, 100 DEG HEX DR Install (New) 4

1 313A2114-9 SEAL Install (New) (a) 1 BACN10YT08CSA NUT Install (New) 6
- BOLT Install (Kept) 5 1
- THUMBNAIL FAIRING 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 29 of 35 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 30 of 35 **BOEING SERVICE BULLETIN 737-54-1046 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 6
- BOLT Remove / Keep 1 1
- THUMBNAIL FAIRING ASSY Remove / Keep 1 or 2 bolts mayneed to be removed.(a) - - BOLT Remove 2

1 or 2 nuts mayneed to be removed.(a) - - NUT Remove

1 313A2114-() SEAL Remove Install double flushplug in the composite panel of thethumbnail fairing assembly.(b) 1 BACR15CE5B7 RIVET, 100 DEG Install (New) 3

(a) 1 BACB30NY5HK4 BOLT, 100 DEG HEX DR Install (New) 4

1 313A2114-10 SEAL Install (New) (a) 1 BACN10YT08CSA NUT Install (New) 6
- BOLT Install (Kept) 5 1
- THUMBNAIL FAIRING 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 31 of 35 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 32 of 35 **BOEING SERVICE BULLETIN 737-54-1046 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 6
- BOLT Remove / Keep 1 1
- THUMBNAIL FAIRING ASSY Remove / Keep 1 or 2 bolts mayneed to be removed.(a) - - BOLT Remove 2

1 or 2 nuts mayneed to be removed.(a) - - NUT Remove

1 313A2114-() SEAL Remove Install double flushplug in the composite panel of thethumbnail fairing assembly.(b) 1 BACR15CE5B7 RIVET, 100 DEG Install (New) 3

(a) 1 BACB30NY5HK4 BOLT, 100 DEG HEX DR Install (New) 4

1 313A2114-9 SEAL Install (New) (a) 1 BACN10YT08CSA NUT Install (New) 6
- BOLT Install (Kept) 5 1
- THUMBNAIL FAIRING 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 33 of 35 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 34 of 35 **BOEING SERVICE BULLETIN 737-54-1046 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** 6
- BOLT Remove / Keep 1 1
- THUMBNAIL FAIRING ASSY Remove / Keep 1 or 2 bolts mayneed to be removed.(a) - - BOLT Remove 2

1 or 2 nuts mayneed to be removed.(a) - - NUT Remove

1 313A2114-() SEAL Remove Install double flushplug in the composite panel of thethumbnail fairing assembly.(b) 1 BACR15CE5B7 RIVET, 100 DEG Install (New) 3

(a) 1 BACB30NY5HK4 BOLT, 100 DEG HEX DR Install (New) 4

1 313A2114-10 SEAL Install (New) (a) 1 BACN10YT08CSA NUT Install (New) 6
- BOLT Install (Kept) 5 1
- THUMBNAIL FAIRING 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 16, 2011 737-54-1046 35 of 35 **BOEING SERVICE BULLETIN 737-54-1046**