Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-53A1116

Original Issue: July 21, 1988

Revision 4: September 30, 2013

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Forward Galley Service Doorway Upper and Lower Corners -

Inspection, Repair and Preventive Modification

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

CFR 300-774). 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 © 1989 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and

Boeing liveries 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.

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7.0
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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 44

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 45

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 45

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

FIGURE 1: THIS FIGURE IS DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

FIGURE 2: THIS FIGURE IS DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

FIGURE 3: THIS FIGURE IS DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

FIGURE 4: FORWARD GALLEY SERVICE DOORWAY - UPPER AFT CORNER INSPECTION . . . 57

FIGURE 5: FORWARD GALLEY SERVICE DOORWAY - UPPER FORWARD CORNER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

FIGURE 6: FORWARD GALLEY SERVICE DOORWAY - LOWER AFT CORNER INSPECTION . . . 61

FIGURE 7: FORWARD GALLEY SERVICE DOORWAY - LOWER FORWARD CORNER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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ALERT ALERT
Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 737-53A1116

Original Issue: July 21, 1988

Revision 4: September 30, 2013

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Forward Galley Service Doorway Upper and Lower Corners -

Inspection, Repair and Preventive Modification

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-08-23, AD 2008-09-13, AD 90-06-02

and AD 98-11-04 R1 are related to this service bulletin.

More work is necessary on airplane(s) inspected or changed in accordance with the original issue, Revision 1,

2 or 3 of this service bulletin. Airplanes that have installed the preventive modification in accordance with original

issue, Revision 1, 2 or 3 of this service bulletin, require follow-on inspection. Airplanes that have installed a

repair at the upper forward corner in accordance with original issue, Revision 1, 2, or 3 require follow-on inspection.

All airplanes require new inspections at the forward galley service doorway lower corners.

Airplane line numbers 1561 thru 3132 were added to this service bulletin effectivity.

REASON FOR REVISION

This revision is sent to add airplane line numbers 1561 thru 3132 to the effectivity of this service bulletin and to

revise the compliance information and the inspection instructions. The repairs and kits provided in the previous

revisions are deleted and replaced with Structural Repair Manual (SRM) repairs.

Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph

3.A., General Information - Notes.

The following sections are changed:

1. The service bulletin subject is updated.

2. The Summary Background is updated and a Summary Evaluation Table is added.

3. The Summary Action, Summary Effectivity, Summary Compliance, Summary Manpower, Summary

Material Information and Summary Illustration are updated.

4. Paragraph 1.A.1., Airplanes - 737-300/-400 airplanes line numbers 1001 through 1560 are moved from

Group 1 to Group 2. Airplane line numbers 1-291 are moved from group 1 to new Group 5.

737-300/-400/-500 airplanes line numbers 1561 through 3132 are added to new Group 3. 737-200

airplanes line numbers 1565 through 1585 are added to new Group 4.

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5. Paragraph 1.D., Description is updated and affected maintenance zones are added.

6. Paragraph 1.E., Compliance - Reference to FAA Airworthiness Directives AD 2008-08-23, AD

2008-09-13, AD 90-06-02 and AD 98-11-04 R1 is added and compliance information is updated.

7. Paragraph 1.F., Approval - Alternative Method of Compliance (AMOC) statements are added.

8. Paragraph 1.G., Manpower - Manpower information is updated.

9. Paragraph 1.H., Weight and Balance Changes - The Weight and Balance table is deleted.

10. Paragraph 1.J.1., Existing Data - References are updated.

11. Paragraph 1.J.2., Data Supplied with this Service Bulletin - The Drawings table is deleted.

12. Paragraph 1.K., Publications Affected - Reference to 737-500 SRM is added, reference 737-100/200

SRM is deleted and a Damage Tolerance Inspection (DTI) statement is added.

13. Paragraph 2.A., Material - Price and Availability - This information is deleted.

14. Paragraph 2.C.1., Kits/Parts - The kits are deleted.

15. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - The parts and materials table is

deleted.

16. Paragraph 2.E., Special Tooling - Price and Availability - The cold working tools information is deleted.

17. Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin - The cold working tools information

is deleted.

18. Paragraph 1.M., Software Accomplishment Summary - Section is added.

19. Paragraph 3.A., General Information - Notes are added.

20. Paragraph 3.B., Work Instructions - Inspections instructions are added.

21. Figures 1, 2 and 3 are deleted and Figures 4 thru 7 are added.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: July 21, 1988

Revision 1: September 07, 1989

Revision 2: September 30, 1993

Revision 3: July 20, 1995

Revision 4: September 30, 2013

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Commercial 

Airplanes 737

Service Bulletin

ALERT

Summary Number: 737-53A1116

Original Issue: July 21, 1988

Revision 4: September 30, 2013

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Forward Galley Service Doorway Upper and Lower Corners -

Inspection, Repair and Preventive Modification

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Based on a structural review of the 737 airplane, incorporation of the modification per this service bulletin is

recommended on aging airplanes. This service bulletin gives instructions to inspect the skin and bearstrap in

the forward galley service doorway upper and lower corners for cracking. If the work in this service bulletin is

not done, undetected cracking in the forward galley service doorway corners could extend and result in rapid

loss of cabin pressure and cause unscheduled maintenance.

Six operators have found seventeen cracks in the skin and doublers at the upper corners of the forward galley

service doorway on eight airplanes. There were eight cracks reported at the upper aft corner on three airplanes

and nine cracks in the skin at the forward corner on five airplanes. The airplanes had accumulated from 29,000

to 47,300 flight hours and from 40,500 to 60,800 flight cycles. Cause of the cracking is attributed to fatigue from

pressurization cycles.

There have been nine reports of cracking at the upper forward and aft corner fastener locations of the forward

galley service doorway in airplanes beyond the effectivity of Revision 3 of this service bulletin. A 0.5 inch long

crack was reported on an airplane with 23,426 total flight cycles. Two cracks were reported common to the upper

forward and aft corner radius fastener locations of the forward galley service doorway on airplanes that had

incorporated the preventive modification in accordance with the original issue, Revision 1, 2 and 3 of this service

bulletin. Multiple cracks were reported outside the inspection area of Revision 3 of this service bulletin common

to the upper forward and aft door corners of the forward galley service doorway. A 6.5 inch long bearstrap crack

was reported just below the upper forward corner inspection zone. The airplane had accumulated 59,804 total

flight cycles.

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Service bulletin 737-53-1074 provides inspection, preventive modification and repair instructions for the forward

galley service doorway lower forward and aft corner areas for 737 airplane line numbers 1 thru 1014. Multiple

cracks have been reported common to the skin and bearstrap at the lower forward and aft doorway corners in

737 airplane line numbers 1015 thru 3132 that are beyond the effectivity of service bulletin 737-53-1074. Several

cracks ranging from 0.5 inch to 2 inches were reported in the skin and bearstrap at the lower forward doorway

corner on airplanes that had accumulated between 44,796 and 73,109 total flight cycles. Multiple cracks ranging

from 0.03 inch to 2.5 inches were reported in the skin and bearstrap at the lower aft doorway corner on airplanes

that had accumulated between 28,040 and 70,456 total flight cycles. New inspections have been added to

service bulletin 737-53A1116 for cracking of the forward galley service doorway lower forward and aft corners

for all airplanes within this service bulletin's effectivity. After accomplishing the inspections in accordance with

service bulletin 737-53A1116 Revision 4, operators do not need to accomplish service bulletin 737-53-1074

inspections for the forward service doorway lower corners.

Boeing Service Related Problem (SRP) 737-SRP-53-0380 is related to this service bulletin.

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

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

information.

Planning Data Affected Reference

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

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

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

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

Publications Affected Yes Paragraph 1.K., Publications Affected

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

Operations Manual and/or FAA Approved Airplane Flight Manual)

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

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

by the Operator

Operator Supplied Material No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Get access to the interior surface of the forward galley service doorway.

Group 1:

At the upper and lower forward and aft corners of the forward galley service doorway, where no repair is installed

that covers the corner radius fasteners, do an external Low Frequency Eddy Current (LFEC) inspection for

cracking in the skin and bearstrap at the corner radius fasteners. Do an external detailed inspection for cracking

in the skin and do an internal detailed inspection for cracking in the skin and bearstrap. If any crack is found in

the skin or bearstrap at the upper aft corner, install a repair in accordance with this service bulletin or contact

Boeing for repair instructions and do the work instructed by Boeing. If any crack is found in the skin or bearstrap

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
at the upper forward corner, lower aft corner or lower forward corner, contact Boeing for repair instructions and

do the work instructed by Boeing. If no cracking is found, repeat the inspections at the intervals given in Paragraph

1.E., Compliance, or to terminate repeat inspections install the preventive modification in accordance with this

service bulletin or contact Boeing for preventive modification instructions and do the work instructed by Boeing,

as applicable.

Group 2-3:

At the upper and lower forward and aft corners of the forward galley service doorway where no Boeing approved

repair is installed that covers the corner radius fasteners, do an external LFEC inspection for cracking in the

skin and bearstrap at the corner radius fasteners. Do an external detailed inspection for cracking in the skin and

do an internal detailed inspection for cracking in the skin and bearstrap. If any crack is found in the skin or

bearstrap at the upper aft corner, lower aft corner or lower forward corner, install a Structural Repair Manual

(SRM) repair or contact Boeing for repair instructions and do the work instructed by Boeing. If any crack is found

in the skin or bearstrap at the upper forward corner, contact Boeing for repair instructions and do the work

instructed by Boeing. If no cracking is found, repeat the inspections at the intervals given in Paragraph 1.E.,

Compliance, or to terminate repeat inspections install the preventive modification in accordance with this service

bulletin or contact Boeing for preventive modification instructions and do the work instructed by Boeing, as

applicable.

Group 4:

At the upper and lower forward and aft corners of the forward galley service doorway where no Boeing approved

repair is installed that covers the corner radius fasteners, do an external LFEC inspection for cracking in the

skin and bearstrap at the corner radius fasteners. Do an external detailed inspection for cracking in the skin and

do an internal detailed inspection for cracking in the skin and bearstrap. If any crack is found contact Boeing for

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

intervals given in Paragraph 1.E., Compliance, or to terminate repeat inspections contact Boeing for preventive

modification instructions and do the work instructed by Boeing.

Group 5:

Contact Boeing to get instructions for the inspections and repairs for this service bulletin 737-53A1116, Revision

4, and do the work instructed by Boeing.

EFFECTIVITY

737-100, -200, -200C, -300, -400 and -500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected

airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-08-23, AD 2008-09-13, AD 90-06-02

and AD 98-11-04 R1 are related to this service bulletin.

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.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service

bulletin.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
MANPOWER

Refer to Paragraph 1.G., Manpower.

Airplanes Total Task Hours Elapsed Hours

Group 1-4 18.30 13.85

MATERIAL INFORMATION

None.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-53A1116

Original Issue: July 21, 1988

Revision 4: September 30, 2013

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Forward Galley Service Doorway Upper and Lower Corners -

Inspection, Repair and Preventive Modification

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

737-200/-200C airplanes line numbers 292 through 1560, excluding

variable numbers PJ201 through PJ219.

1 -

737-300/-400 airplanes line numbers 1001 through 1560. A repair

exists in the Structural Repair Manual for these airplanes.

2 -

737-300/-400/-500 airplanes line numbers 1561 through 3132. These

airplanes have cold worked fastener holes at the forward galley

service doorway upper corners and are added at Revision 4 of this

service bulletin. A repair exists in the Structural Repair Manual for

these airplanes.

3 -

737-200 airplanes line numbers 1565 through 1585. These airplanes

have cold worked fastener holes at the forward galley service doorway

upper corners and are added at Revision 4 of this service bulletin.

4 -

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GROUP CONFIGURATION DESCRIPTION

737-100/-200/-200C airplanes line numbers 1 through 291. These

airplanes have cold bonded skins.

5 -

Airplane Models:

737-100, 737-200, 737-200C, 737-300, 737-400, 737-500

Variable Number Group

PA001 - PA022 5

PA099 5

PA231 - PA232 5

PC001 - PC005 5

PG001 - PG075 5

PG199 5

PG201 - PG230 5

PG251 - PG255 5

PG271 - PG279 5

PG301 - PG314 5

PG331 - PG332 5

PG351 - PG356 5

PG375 5

PG401 - PG403 5

PG431 - PG442 5

PG471 - PG475 5

PG501 - PG505 5

PG571 - PG583 5

PG584 - PG586 1

PG621 - PG630 5

PG651 - PG652 5

PG701 - PG705 5

PH001 1

PH011 - PH013 1

PH021 - PH024 1

PH701 - PH715 5

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PH731 - PH732 5

PH741 - PH742 5

PH743 1

PJ001 - PJ002 5

PJ003 - PJ009 1

PJ031 - PJ032 5

PJ071 - PJ072 5

PJ101 - PJ104 5

PJ105 - PJ119 1

PJ301 - PJ302 3

PJ551 - PJ561 3

PJ601 - PJ615 3

PJ811 3

PJ816 - PJ817 3

PK026 - PK029 1

PK041 - PK053 1

PK061 - PK070 1

PK081 - PK082 1

PK091 - PK099 1

PK101 - PK103 1

PK111 - PK120 1

PK141 - PK146 1

PK201 - PK204 1

PK211 - PK223 1

PK231 - PK241 1

PK251 - PK258 1

PK271 - PK274 1

PK281 - PK289 1

PK291 1

PK301 - PK318 1

PK341 1

PK351 - PK361 1

PK391 1

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PK431 - PK433 1

PK451 - PK452 1

PK461 - PK469 1

PK495 1

PK501 - PK504 1

PK511 - PK515 1

PK519 1

PK521 - PK527 1

PK528 4

PK541 - PK565 1

PK581 1

PK591 - PK599 1

PK601 - PK617 1

PK621 - PK637 1

PK641 - PK642 1

PK661 - PK666 1

PK671 - PK681 1

PK691 - PK697 1

PK711 - PK716 1

PK731 - PK765 1

PK771 - PK779 1

PK801 - PK804 1

PK819 - PK827 1

PK830 1

PK861 - PK863 1

PK871 - PK874 1

PK881 - PK884 1

PK901 - PK938 1

PK971 - PK974 1

PL001 - PL028 1

PL061 1

PL081 1

PL101 - PL113 1

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PL151 1

PL171 - PL172 1

PL201 - PL203 1

PL221 1

PL401 - PL417 1

PL421 1

PL441 1

PL451 - PL456 1

PL471 1

PL491 1

PL501 - PL506 1

PL551 - PL562 1

PL581 1

PL601 - PL603 1

PL611 1

PL621 - PL626 1

PL631 - PL632 1

PL711 - PL712 5

PL716 5

PL717 - PL747 1

PL756 1

PL758 1

PL761 - PL770 1

PL781 - PL788 1

PL793 1

PL801 - PL803 5

PM001 - PM006 1

PM016 - PM017 1

PM021 - PM023 1

PM051 - PM066 1

PM101 - PM119 1

PM141 - PM142 1

PM171 1

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PM181 1

PM251 - PM255 1

PM281 - PM283 1

PM381 - PM399 3

PM401 - PM417 3

PM541 - PM564 3

PN001 - PN002 1

PN021 - PN043 1

PN081 - PN086 1

PN101 - PN117 1

PN131 - PN163 1

PN401 - PN420 1

PN431 - PN433 1

PN451 - PN456 1

PN471 - PN472 1

PN473 - PN474 4

PN481 1

PN491 - PN493 1

PN501 - PN502 1

PN511 1

PN512 4

PN521 4

PP001 - PP045 2

PP046 - PP054 3

PP101 - PP135 2

PP136 - PP160 3

PP161 - PP169 2

PP181 - PP192 2

PP193 - PP199 3

PP201 - PP205 2

PP221 2

PP231 - PP243 2

PP281 - PP286 2

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PP301 - PP305 2

PP351 - PP353 2

PP376 - PP384 2

PP391 - PP392 2

PP393 3

PP401 - PP436 2

PP437 - PP440 3

PP471 - PP475 2

PP501 - PP504 2

PP505 - PP520 3

PP521 - PP522 2

PP631 - PP634 2

PP651 - PP652 2

PP671 - PP699 2

PP701 - PP733 2

PP771 - PP779 2

PP801 - PP804 2

PP805 - PP808 3

PP821 - PP827 2

PP831 - PP842 2

PP843 - PP845 3

PP846 - PP848 2

PP851 - PP852 2

PP861 - PP870 2

PP871 - PP877 3

PP891 - PP899 2

PP901 - PP910 2

PP911 - PP930 3

PP931 - PP936 2

PP946 - PP948 2

PP951 - PP952 2

PP961 - PP965 2

PP966 - PP967 3

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PP981 - PP982 2

PP983 - PP990 3

PP991 2

PP993 3

PQ001 - PQ012 2

PQ013 - PQ016 3

PQ026 - PQ037 2

PQ038 - PQ041 3

PQ051 - PQ065 2

PQ066 - PQ085 3

PQ086 - PQ090 2

PQ091 - PQ092 3

PQ101 - PQ123 2

PQ124 - PQ199 3

PQ201 - PQ202 3

PQ221 - PQ230 3

PQ231 - PQ233 2

PQ234 - PQ237 3

PQ241 - PQ242 2

PQ243 3

PQ251 - PQ267 3

PQ281 - PQ299 3

PQ301 - PQ307 3

PQ331 - PQ332 3

PQ341 - PQ348 3

PQ361 - PQ373 3

PQ391 - PQ395 3

PQ401 - PQ418 3

PQ421 3

PQ431 - PQ438 3

PQ447 - PQ448 3

PQ451 3

PQ454 3

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ALERT ALERT
Variable Number Group

PQ471 - PQ475 3

PQ479 - PQ481 3

PQ486 - PQ487 3

PQ491 - PQ493 3

PQ771 - PQ772 3

PQ791 - PQ793 3

PQ801 - PQ805 3

PQ931 - PQ935 3

PQ951 3

PQ971 - PQ997 3

PR001 - PR017 3

PR021 - PR034 3

PR041 - PR045 3

PR061 - PR072 3

PR077 - PR082 3

PR091 - PR092 3

PR096 3

PR101 3

PR121 - PR122 3

PR131 - PR132 3

PR141 - PR143 3

PR161 - PR172 3

PR181 3

PS601 - PS631 3

PS636 - PS638 3

PS641 - PS644 3

PS651 - PS657 3

PS666 - PS669 3

PS691 - PS692 3

PS701 - PS706 3

PS751 - PS799 3

PS811 3

PS836 - PS837 3

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PS841 - PS846 3

PS851 - PS852 3

PS856 3

PS861 - PS863 3

PS866 - PS868 3

PS871 - PS874 3

PS896 - PS897 3

PS901 - PS941 3

PS956 - PS957 3

PS961 - PS963 3

PS971 - PS978 3

PT001 - PT015 3

PT021 - PT031 3

PT041 - PT064 3

PT101 - PT105 3

PT121 - PT138 3

PT146 - PT148 3

PT161 - PT170 3

PT181 - PT188 3

PT211 - PT220 3

PT295 3

PT301 - PT309 3

PT331 - PT360 3

PT381 - PT399 3

PT401 - PT438 3

PT501 - PT517 3

PT561 - PT565 3

PT581 - PT586 3

PT611 - PT621 3

PT641 - PT644 3

PT651 - PT656 3

PT671 - PT672 3

PT681 - PT685 3

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PT701 - PT703 3

PT716 - PT717 3

PT721 - PT725 3

PT801 - PT834 3

PT851 - PT854 3

PT871 - PT886 3

PT901 - PT930 3

PT971 - PT973 3

PT981 - PT985 3

PT996 3

PU001 - PU025 3

PU301 3

PU311 - PU313 3

PV001 - PV004 2

PV005 - PV055 3

PV201 - PV209 3

PV226 - PV229 3

PV231 - PV237 3

PV271 - PV272 3

PV281 - PV287 3

PV296 3

PV301 - PV302 3

PV351 3

PV356 - PV357 3

PW001 - PW054 3

PW061 - PW068 3

PW072 3

PW086 - PW088 3

PW091 - PW094 3

PW101 - PW102 3

PW106 3

PW111 - PW120 3

PW156 - PW157 3

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PW161 - PW171 3

PW201 - PW252 3

PW261 - PW268 3

PW271 - PW276 3

PW278 3

PW281 - PW293 3

PW296 3

PW301 - PW327 3

PW401 - PW408 3

PW411 - PW418 3

PW421 - PW424 3

PW431 - PW435 3

PW441 - PW450 3

PW461 - PW467 3

PW501 - PW504 3

PW511 - PW522 3

PW524 - PW550 3

PW556 - PW557 3

PW561 - PW564 3

PW571 - PW576 3

PW591 - PW596 3

PW611 - PW622 3

PW631 - PW637 3

PW661 - PW662 3

PW681 - PW683 3

PW701 - PW702 3

PW711 - PW717 3

PW741 - PW742 3

PW761 3

PW771 3

PW831 3

PW851 - PW856 3

PX071 5

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PX701 5

PY001 - PY008 5

PY021 5

PY022 1

PY031 5

PY036 - PY037 1

PY046 - PY048 1

PY051 - PY053 1

PY056 - PY057 1

PY101 - PY103 1

PY111 - PY113 1

PY131 - PY135 1

PY141 - PY143 1

PY151 - PY154 1

PY156 - PY157 1

PY161 - PY162 1

PY166 1

PY191 1

PY201 1

PY221 - PY222 1

PY231 1

PY241 - PY244 1

PY270 - PY275 1

PY281 1

PY286 1

PY301 - PY304 5

PY321 - PY323 5

PY341 - PY346 5

PY361 - PY362 5

PY381 5

PY401 1

PY409 - PY411 1

PY421 - PY422 1

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Variable Number Group

PY441 1

PY451 1

PY461 - PY463 1

PY591 - PY595 1

PY611 - PY612 1

PY621 1

PY631 1

PY651 1

PY671 - PY672 1

PY721 1

PY741 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

As a result of the FAA-sponsored Aging Fleet Conference, a 737 Structures Task Group with Airline

and Boeing members and FAA observers was formed to review structural service bulletin modifications

and recommend selected bulletins for incorporation on aging airplanes. This service bulletin modification

has been recommended for incorporation on aging 737 airplanes. This service bulletin gives instructions

to inspect the skin and bearstrap in the forward galley service doorway upper and lower corners for

cracking. If the work in this service bulletin is not done, undetected cracking in the forward galley service

doorway corners could extend and result in rapid loss of cabin pressure and cause unscheduled

maintenance.

Inspection of the upper corners of the forward galley service doorway will detect cracking that could

result in pressurization difficulties. Repair of cracks or accomplishment of preventive modification on

uncracked structure is terminating action for inspection per this service bulletin. Cause of the cracking

is attributed to fatigue from pressurization cycles.

Six operators have reported cracks in the upper corner of the forward galley service doorways on a

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

lengths of up to 2 inches in the skin, and a 2 inch long crack in the bearstrap doubler on one airplane.

Five airplanes had a total of nine 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 47,300 flight hours, and from 40,500 to 60,800

flight cycles.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
There have been nine reports of cracking at the upper forward and aft corner fastener locations of the

forward galley service doorway in airplanes beyond the effectivity of Revision 3 of this service bulletin.

A 0.5 inch long crack was reported on an airplane with 23,426 total flight cycles. Two cracks were

reported common to the upper forward and aft corner radius fastener locations of the forward galley

service doorway on airplanes that had incorporated the preventive modification in accordance with the

original issue, Revision 1, 2 and 3 of this service bulletin. Multiple cracks were reported outside the

inspection area of Revision 3 of this service bulletin common to the upper forward and aft door corners

of the forward galley service doorway. A 6.5 inch long bearstrap crack was reported just below the

upper forward corner inspection zone. The airplane had accumulated 59,804 total flight cycles.

Service bulletin 737-53-1074 provides inspection, preventive modification and repair instructions for

the forward galley service doorway lower forward and aft corner areas for 737 airplane line numbers

1 thru 1014. Multiple cracks have been reported common to the skin and bearstrap at the lower forward

and aft doorway corners in 737 airplane line numbers 1015 thru 3132 that are beyond the effectivity

of service bulletin 737-53-1074. Several cracks ranging from 0.5 inch to 2 inches were reported in the

skin and bearstrap at the lower forward doorway corner on airplanes that had accumulated between

44,796 and 73,109 total flight cycles. Multiple cracks ranging from 0.03 inch to 2.5 inches were reported

in the skin and bearstrap at the lower aft doorway corner on airplanes that had accumulated between

28,040 and 70,456 total flight cycles. New inspections have been added to service bulletin 737-53A1116

for cracking of the forward galley service doorway lower forward and aft corners for all airplanes within

this service bulletin's effectivity. After accomplishing the inspections in accordance with service bulletin

737-53A1116 Revision 4, operators do not need to accomplish service bulletin 737-53-1074 inspections

for the forward service doorway lower corners.

Boeing Service Related Problem (SRP) 737-SRP-53-0380 is related to this service bulletin.

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

Revision 1 of this service bulletin was issued to provide the recommendations of the Aging Fleet 737

Structures Working Group and to change the forward galley service doorway upper forward corner

repair doubler installation. The installation change eliminates one fastener and moves one fastener to

make the repair compatible with the service bulletin 737-53-1074 modification.

Revision 2 was sent to provide a list of reference service bulletins applicable to 737 door corners and

hinge cutouts. Also, the crack location and limits that can be repaired with instructions in this bulletin

were defined in this revision.

Revision 3 was sent to:

– Add the contents of the preventive modification and repair kits to Paragraph 2.C., Parts Necessary

for Each Airplane. This data was inadvertently omitted in Revision 2.

– Add structural repair manual subject numbers to stop drill 737-300 and 737-400 airplanes in

accordance with Figure 2.

– Add structural repair manual subject numbers to coldwork 737-300 and 737-400 airplanes in

accordance with Figure 3.

– Add reference to the Maintenance Planning Document item number that is related to the inspections

in this service bulletin.

– Add reference to the structural repair manual subject numbers changed by the repairs and

modifications shown in this service bulletin.

Revision 4 is sent to add airplane line numbers 1561 thru 3132 to the effectivity of this service bulletin

and to revise the compliance information and the inspection instructions. The repairs and kits provided

in the previous revisions are deleted and replaced with Structural Repair Manual (SRM) repairs.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
The forward galley door upper forward corner repair installed in accordance with this service bulletin

overlaps the preventive modification for the upper hinge cutout installed in accordance with service

bulletin 737-53-1074. Service bulletin 737-53-1074 has similar access requirements as this service

bulletin.

D. Description

Get access to the interior surface of the forward galley service doorway.

Group 1:

At the upper and lower forward and aft corners of the forward galley service doorway, where no repair

is installed that covers the corner radius fasteners, do an external Low Frequency Eddy Current (LFEC)

inspection for cracking in the skin and bearstrap at the corner radius fasteners. Do an external detailed

inspection for cracking in the skin and do an internal detailed inspection for cracking in the skin and

bearstrap. If any crack is found in the skin or bearstrap at the upper aft corner, install a repair in

accordance with this service bulletin or contact Boeing for repair instructions and do the work instructed

by Boeing. If any crack is found in the skin or bearstrap at the upper forward corner, lower aft corner

or lower forward corner, contact Boeing for repair instructions and do the work instructed by Boeing.

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

to terminate repeat inspections install the preventive modification in accordance with this service bulletin

or contact Boeing for preventive modification instructions and do the work instructed by Boeing, as

applicable.

Group 2-3:

At the upper and lower forward and aft corners of the forward galley service doorway where no Boeing

approved repair is installed that covers the corner radius fasteners, do an external LFEC inspection

for cracking in the skin and bearstrap at the corner radius fasteners. Do an external detailed inspection

for cracking in the skin and do an internal detailed inspection for cracking in the skin and bearstrap. If

any crack is found in the skin or bearstrap at the upper aft corner, lower aft corner or lower forward

corner, install a Structural Repair Manual (SRM) repair or contact Boeing for repair instructions and do

the work instructed by Boeing. If any crack is found in the skin or bearstrap at the upper forward corner,

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

repeat the inspections at the intervals given in Paragraph 1.E., Compliance, or to terminate repeat

inspections install the preventive modification in accordance with this service bulletin or contact Boeing

for preventive modification instructions and do the work instructed by Boeing, as applicable.

Group 4:

At the upper and lower forward and aft corners of the forward galley service doorway where no Boeing

approved repair is installed that covers the corner radius fasteners, do an external LFEC inspection

for cracking in the skin and bearstrap at the corner radius fasteners. Do an external detailed inspection

for cracking in the skin and do an internal detailed inspection for cracking in the skin and bearstrap. If

any crack is found contact Boeing for repair instructions and do the work instructed by Boeing. If no

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

terminate repeat inspections contact Boeing for preventive modification instructions and do the work

instructed by Boeing.

Group 5:

Contact Boeing to get instructions for the inspections and repairs for this service bulletin 737-53A1116,

Revision 4, and do the work instructed by Boeing.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Revision 4 - More work is necessary on airplane(s) inspected or changed in accordance with the original

issue, Revision 1, 2 or 3 of this service bulletin. Airplanes that have installed the preventive modification

in accordance with original issue, Revision 1, 2 or 3 of this service bulletin, require follow-on inspection.

Airplanes that have installed a repair at the upper forward corner in accordance with original issue,

Revision 1, 2, or 3 require follow-on inspection. All airplanes require new inspections at the forward

galley service doorway lower corners.

NOTE: This service bulletin is listed in Boeing Document D6-38505.

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

Group 1:

Affected Maintenance Zones

Model Zone

737-200, 737-200C 1-6

Group 2:

Affected Maintenance Zones

Model Zone

737-300, 737-400 106

Group 3:

Affected Maintenance Zones

Model Zone

737-300, 737-400, 737-500 106

Group 4:

Affected Maintenance Zones

Model Zone

737-200 1-6

Group 5:

Affected Maintenance Zones

Model Zone

737-100, 737-200, 737-200C 1-6

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-08-23, AD 2008-09-13, AD

90-06-02 and AD 98-11-04 R1 are related to this service bulletin.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
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.

Group 5:

Contact Boeing to get instructions for the inspections and repairs for this service bulletin 737-53A1116,

Revision 4, and do the work instructed by Boeing within 120 days of the issue date of this service

bulletin.

Group 1:

Table 1: Forward Galley Service Doorway Upper Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition (a) Action

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external Low Frequency Eddy Current

(LFEC) inspection of the

skin and bearstrap for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

2.a.(1).

Airplanes that have not accomplished the preventive

modification or the repair

in accordance with the

original issue, Revision 1,

2 or 3 of this service bulletin.

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

2.a.(1).

18,000 flight cycles.Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

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

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 1:

Table 1: Forward Galley Service Doorway Upper Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition (a) Action

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Within 35,000

flight cycles after the installation of the preventive modification.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

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

Airplanes that have accomplished the preventive

modification in accordance

with the original issue, Revision 1, 2 or 3 of this service bulletin.

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

2.a.(1)

18,000 flight cycles.Within 9,000

flight cycles after the Revision

4 date of this

service bulletin.

Within 35,000

flight cycles after the installation of the preventive modification.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

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

Contact Boeing for repair Before further flight. -

instructions and do the

work instructed by Boeing.

If any crack is found in the

skin or bearstrap.

(a) Accomplishment of a repair in accordance with the original issue or Revision 1, 2 or 3 of this service

bulletin terminates the requirement for repeat inspections as given in Table 1 for the repaired doorway

corner. Post repair inspections are provided in Table 11.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 2:

Table 2: Forward Galley Service Doorway Upper Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition (b) Action

4,500 flight cycles.

(a)

Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.b.(1).

Airplanes that have not accomplished the preventive

modification or the repair

in accordance with the

original issue, Revision 1,

2 or 3 of this service bulletin. Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

2.b.(1).

18,000 flight cycles. (a)Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.b.(1).

Do the repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

step 2.b.(1)(a).

If any crack is found in the

skin or bearstrap.

(a)

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Within 35,000

flight cycles after the installation of the preventive modification.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.b.(2).

Airplanes that have accomplished the preventive

modification in accordance

with the original issue, Revision 1, 2 or 3 of this service bulletin.

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

2.b.(2).

18,000 flight cycles.Within 9,000

flight cycles after the Revision

4 date of this

service bulletin.

Within 35,000

flight cycles after the installation of the preventive modification.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.b.(2).

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 2:

Table 2: Forward Galley Service Doorway Upper Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition (b) Action

Contact Boeing for repair Before further flight. -

instructions and do the

work instructed by Boeing.

If any crack is found in the

skin or bearstrap.

(a) Accomplishment of a repair or preventive modification in accordance with Revision 4 of this service bulletin

terminates the requirement for repeat inspections as given in Table 2 for the repaired or preventive

modified doorway corner. Post repair and post preventive modification inspections are provided in the

applicable SRM.

(b) Accomplishment of a repair in accordance with the original issue or Revision 1, 2 or 3 of this service

bulletin terminates the requirement for repeat inspections as given in Table 2 for the repaired doorway

corner. Post repair inspections are provided in Table 11.

Group 3:

Table 3: Forward Galley Service Doorway Upper Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

4,500 flight cycles.

(a)

Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.c.(1).

All airplanes

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

2.c.(1).

18,000 flight cycles. (a)Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.c.(1).

Do the repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

step 2.c.(1)(a).

If any crack is found in the

skin or bearstrap.

(a)

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 3:

Table 3: Forward Galley Service Doorway Upper Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

(a) Accomplishment of a repair or preventive modification in accordance with Revision 4 of this service bulletin

terminates the requirement for repeat inspections as given in Table 3 for the repaired or preventive

modified doorway corner. Post repair and post preventive modification inspections are provided in the

applicable SRM.

Group 4:

Table 4: Forward Galley Service Doorway Upper Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.d.(1).

All airplanes

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

2.d.(1).

18,000 flight cycles.Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 2.d.(1).

Contact Boeing for repair Before further flight. -

instructions and do the

work instructed by Boeing.

If any crack is found in the

skin or bearstrap.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 1-2:

Table 5: Forward Galley Service Doorway Upper Forward Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 3.a.

Airplanes that have not accomplished the preventive

modification or installed a

repair at the upper forward

corner in accordance with

original issue, Revision 1,

2 or 3 of this service bulletin. Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

3.a.

18,000 flight cycles.Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of all visible

surfaces of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 3.b.

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Within 35,000

flight cycles after the installation of the preventive modification.

Do an external LFEC inspection of the skin and

bearstrap in accordance

with Paragraph 3.B.,

Work Instructions, step

3.a.

Airplanes that have accomplished the preventive

modification in accordance

with original issue, Revision 1, 2 or 3 of this service

bulletin.

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

3.a.

18,000 flight cycles.Within 9,000

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of all visible

surfaces of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 3.b.

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ALERT ALERT
Group 1-2:

Table 5: Forward Galley Service Doorway Upper Forward Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

No further action is required per this service

bulletin in the repaired

area.

Airplanes with a repair installed that meets the requirements of the Accomplishment Instructions,

Paragraph 3.A.14. of this

service bulletin.

18,000 flight cycles.Within 9,000

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of all visible

surfaces of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 3.b.

Airplanes with a Boeing repair approved by FAA

8100-9 form installed at the

upper forward corner that

does not meet the requirements as given in the Accomplishment Instructions

Paragraph 3.A.14. (a)

Contact Boeing for repair Before further flight. -

instructions and do the

work instructed by Boeing.

If any crack is found in the

skin or bearstrap.

(a) In addition, post repair inspections are provided in the D6-38669 Repair Assessment Guidelines document.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 3-4:

Table 6: Forward Galley Service Doorway Upper Forward Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap in accordance

with Paragraph 3.B.,

Work Instructions, step

3.a.

Airplanes that have not installed a repair at the upper

forward corner.

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

3.a.

18,000 flight cycles.Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of all visible

surfaces of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 3.b.

No further action is required per this service

bulletin in the repaired

area.

Airplanes with a repair installed that meets the requirements of the Accomplishment Instructions,

Paragraph 3.A.14. of this

service bulletin.

18,000 flight cycles.Within 9,000

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of all visible

surfaces of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 3.b.

Airplanes with a Boeing repair approved by FAA

8100-9 form installed at the

upper forward corner that

does not meet the requirements as given in the Accomplishment Instructions

Paragraph 3.A.14. (a)

Contact Boeing for repair Before further flight. -

instructions and do the

work instructed by Boeing.

If any crack is found in the

skin or bearstrap.

(a) In addition, post repair inspections are provided in the D6-38669 Repair Assessment Guidelines document.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 1, 4:

Table 7: Forward Galley Service Doorway Lower Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection for cracking in

the skin and bearstrap in

accordance with Paragraph 3.B., Work Instructions, step 4.a.(1).

All airplanes

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

4.a.(1).

18,000 flight cycles.Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 4.a.(1).

Contact Boeing for repair Before further flight. -

instructions and do the

work instructed by Boeing.

If any crack is found in the

skin or bearstrap.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 2-3:

Table 8: Forward Galley Service Doorway Lower Aft Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

4,500 flight cycles.

(a)

Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 4.b.(1).

All airplanes

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

4.b.(1).

18,000 flight cycles. (a)Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 4.b.(1).

Do the repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

step .4.b.(1)(a)

If any crack is found in the

skin or bearstrap.

(a)

(a) Accomplishment of a repair or preventive modification in accordance with Revision 4 of this service bulletin

terminates the requirement for repeat inspections as given in Table 8 for the repaired or preventive

modified doorway corner. Post repair and post preventive modification inspections are provided in the

applicable SRM.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 1, 4:

Table 9: Forward Galley Service Doorway Lower Forward Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 4,500 4,500 flight cycles.

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 5.a.(1).

All airplanes.

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

5.a.(1).

18,000 flight cycles.Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 5.a.(1).

Contact Boeing for repair Before further flight. -

instructions and do the

work instructed by Boeing.

If any crack is found in the

skin or bearstrap.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
Group 2-3:

Table 10: Forward Galley Service Doorway Lower Forward Corner Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

4,500 flight cycles.

(a)

Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an external LFEC inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 5.b.(1).

All airplanes.

Do an external detailed

inspection of the skin for

any crack in accordance

with Paragraph 3.B.,

Work Instructions, step

5.b.(1).

18,000 flight cycles. (a)Within 4,500

flight cycles after the Revision

4 date of this

service bulletin.

Before 35,000

total flight cycles.

Do an internal detailed

inspection of the skin and

bearstrap for any crack in

accordance with Paragraph 3.B., Work Instructions, step 5.b.(1).

Do the repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

step 5.b.(1)(a).

If any crack is found in the

skin or bearstrap.

(a)

(a) Accomplishment of a repair or preventive modification in accordance with Revision 4 of this service bulletin

terminates the requirement for repeat inspections as given in Table 10 for the repaired or preventive

modified doorway corner. Post repair and post preventive modification inspections are provided in the

applicable SRM.

Group 1-2:

Table 11: Inspection of Fuselage Skin Assembly and Bearstrap for Airplanes With a Boeing Drawing

65C33800 Repair Installed in Accordance With the Original Issue or Revision 1, 2 or 3 of This Service

Bulletin.

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Repeat the inspection at interval in

accordance with

the RAG.

Within 12,000

flight cycles after the repair

was installed.

Before 60,000

total flight cycles.

Do the inspection in accordance with the Repair

Assessment Guidelines

(RAG) D6-38669.

Airplanes that have installed a Boeing drawing

65C33800 repair in accordance with the Original Issue or Revision 1, 2 or 3 of

this Service Bulletin.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
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.

The Manager of the FAA Seattle Aircraft Certification Office (ACO) approves accomplishment of the

applicable inspections, repairs, and modifications, with the corresponding compliance times, provided

in Section 1.E, Compliance, of this service bulletin, Revision 4, as an alternative method of compliance

(AMOC) to the requirements of paragraph A of Airworthiness Directive (AD) 90-06-02. The modification

in accordance with SB 737-53A1116, Figure 3 is no longer required. This AMOC applies only to the

modification specified in Boeing document D6-38505 for SB 737-53A1116. All provisions of AD 90-06-02

that are not specifically referenced above remain fully applicable and must be complied with accordingly.

For Boeing Model 737-100/200 series airplanes, the Manager of the FAA Seattle ACO approves the

supplemental inspection methods, thresholds and repeat intervals as given in the Repair Assessment

Guidelines D6-38669 for the repair defined in the applicable tables of Paragraph 1.E., Compliance, of

this Service Bulletin, Revision 4 as an method of compliance (MOC) to the inspections of Structurally

Significant Item (SSI) F-15A required by paragraph (g), of AD 98-11-04 R1. This approval applies to

this SSI and only for the portions of the bear strap and skin that have been repaired in accordance with

this SB. If operators choose this MOC, then they must revise their FAA-approved maintenance or

inspection program to incorporate these alternative inspections. All provisions of AD 98-11-04 R1 that

are not specifically referenced above remain fully applicable and must be complied with accordingly.

In addition, for Boeing Model 737-200C series airplanes, the Manager of the FAA Seattle ACO approves

the inspection methods, thresholds, repeat intervals, as given in the Repair Assessment Guidelines

D6-38669 for the repairs defined in the applicable tables of Paragraph 1.E., Compliance, of Boeing

Alert Service Bulletin 737-53A1116, Revision 4 as an AMOC to the inspections of SSI F-15A required

by paragraphs (g) and (h) of AD 2008-08-23. This approval applies to this SSI and only for the portions

of the bearstrap and skin that have been repaired in accordance with this service bulletin. If operators

choose this AMOC, then they must revise their FAA-approved maintenance or inspection program to

incorporate these alternative inspections. All provisions of AD 2008-08-23 that are not specifically

referenced above remain fully applicable and must be complied with accordingly.

In addition, for Boeing Model 737-300/-400/-500 series airplanes, the Manager of the FAA Seattle ACO

approves the inspection methods, thresholds, repeat intervals as given in the Repair Assessment

Guidelines D6-38669 for the repairs defined in the applicable tables of Paragraph 1.E., Compliance,

of Boeing Alert Service Bulletin 737-53A11116, Revision 4 as an AMOC to the inspections of SSI F-15A

as required by paragraphs (g) and (h) of AD 2008-09-13. This approval applies to this SSI and only for

the portions of the bearstrap and frame chord that have been repaired in accordance with this service

bulletin. If operators choose this AMOC, then they must revise their FAA-approved maintenance or

inspection program to incorporate these alternative inspections. All provisions of AD 2008-09-13 that

are not specifically referenced above remain fully applicable and must be complied with accordingly.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
G. Manpower

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

airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with

operator task hour data if necessary. The estimate does not include lost time. These are some examples

of lost time:

• 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 1.00 1.00

FIGURE 4 2 4.40 2.20

FIGURE 5 2 4.50 2.25

FIGURE 6 1 3.70 3.70

FIGURE 7 1 3.70 3.70

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 18.30 13.85

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Boeing Service Bulletin 737-53-1074

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

c. Boeing Service Related Problem (SRP) 737-SRP-53-0380

d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2008-08-23, 2008-09-13,

2008-11-04, 90-06-02, 98-11-04 R1

e. Service Bulletin Index D6-19567

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

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
g. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-26

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

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

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

k. Boeing Document D6-38505, "Aging Airplane Service Bulletin Structural Modification and

Inspection Program - Model 737-100/-200/-200C"

2. Data Supplied with this Service Bulletin:

None.

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

None.

K. Publications Affected

1. Publications:

Publication Chapter-Section

737-300 Structural Repair Manual 53-10

737-400 Structural Repair Manual 53-10

737-500 Structural Repair Manual 53-10

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected

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

L. Interchangeability and Intermixability of Parts

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

M. Software Accomplishment Summary

Not affected.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this

service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

None.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

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

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

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

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT

BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

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

– Linear dimensions are in inches

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

or minus 0.03 inch

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

– Angular tolerance is plus or minus 2 degrees

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

Manual (SRM) Chapter 51

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

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

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

6. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

7. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
8. 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.

9. 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.

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

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

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

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

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

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

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

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

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

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

13. If a Boeing external doubler corner repair approved by FAA 8100-9 form is installed

common to the door corner radius fasteners of the upper aft corner, lower aft corner

or lower forward corner, then the inspections given in this service bulletin are not

required for the repaired area.

Post repair inspections are provided in the FAA 8100-9 form approving the repair.

14. If a Boeing repair approved by FAA 8100-9 form is installed at the upper forward

doorway corner, inspections as given in this service bulletin for the upper forward

corner are not required in the repair area if the repair meets the following

requirements:

– The repair doubler covers the doorway upper forward corner and the upper

hinge cutout.

– The repair has been approved as an Alternative Method of Compliance (AMOC)

to AD 2008-11-04.

Post repair inspections are provided in the FAA 8100-9 form approving the repair.

15. If the external detailed inspection area is hidden by an existing non-corner Boeing

repair approved by FAA 8100-9 form, the external detailed inspection of the skin is

not required common to the hidden area. External detailed inspection is still required

in the area not hidden by the repair.

B. WORK INSTRUCTIONS

Group 5:

Contact Boeing to get instructions for the inspections and repairs for this service bulletin 737-53A1116,

Revision 4, and do the work instructed by Boeing.

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1. Part 1: Access

a. Open the forward galley door for access to interior surface of door cutout to accomplish

inspection and rework of doorway upper and lower corners.

2. Group 1-4:

Part 2: Forward Galley Service Doorway Upper Aft Corner Inspection

a. Group 1:

(1) Do an external LFEC inspection, an internal detailed inspection of the skin and bearstrap

and an external detailed inspection of the skin for any crack at the upper aft corner of the

forward galley service doorway in accordance with FIGURE 4.

(a) If any crack is found, contact Boeing for repair instructions and do the work instructed

by Boeing.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance.

b. Group 2:

(1) Airplanes that have not accomplished the preventive modification or the repair in

accordance with the original issue, Revision 1, 2 or 3 of this service bulletin, do an external

LFEC inspection, an internal detailed inspection of the skin and bearstrap and an external

detailed inspection of the skin for any crack at the upper aft corner of the forward galley

service doorway in accordance with FIGURE 4.

(a) If any crack is found in the skin or bearstrap, do the repair in accordance with

applicable 737-300 SRM 53-10-01 Repair 16 or 737-400 SRM 53-10-01 Repair 16.

NOTE: 1. Installation of 737-300 SRM 53-10-01 Repair 16 or 737-400 SRM

53-10-01 Repair 16 terminates repeat inspection requirements of

this service bulletin for the upper aft corner.

2. Post repair inspections are provided in the applicable SRM.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance or do the preventive modification in accordance with applicable

737-300 SRM 53-10-01 Repair 16 or 737-400 SRM 53-10-01 Repair 16.

NOTE: 1. Installation of the preventive modification in accordance with

737-300 SRM 53-10-01 Repair 16 or 737-400 SRM 53-10-01

Repair 16 terminates repeat inspection requirements of this service

bulletin for the upper aft corner.

2. Post preventive modification inspections are provided in the

applicable SRM.

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(2) Airplanes that have accomplished the preventive modification in accordance with the

original issue, Revision 1, 2 or 3 of this service bulletin, do an external LFEC inspection,

an internal detailed inspection of the skin and bearstrap and an external detailed inspection

of the skin for any crack at the upper aft corner of the forward galley service doorway in

accordance with FIGURE 4.

(a) If any crack is found contact Boeing for repair instructions and do the work instructed

by Boeing.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance.

c. Group 3:

(1) Do an external LFEC inspection, an internal detailed inspection of the skin and bearstrap

and an external detailed inspection of the skin for any crack at the upper aft corner of the

forward galley service doorway in accordance with FIGURE 4.

(a) If any crack is found in the skin or bearstrap, do the repair in accordance with

applicable 737-300 SRM 53-10-01 Repair 16, 737-400 SRM 53-10-01 Repair 16 or

737-500 SRM 53-10-01 Repair 16.

NOTE: 1. Installation of 737-300 SRM 53-10-01 Repair 16, 737-400 SRM

53-10-01 Repair 16 or 737-500 SRM 53-10-01 Repair 16

terminates repeat inspection requirements of this service bulletin

for the upper aft corner.

2. Post repair inspections are provided in the applicable SRM.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance or do the preventive modification in accordance with applicable

737-300 SRM 53-10-01 Repair 16, 737-400 SRM 53-10-01 Repair 16 or 737-500

SRM 53-10-01 Repair 16.

NOTE: 1. Installation of the preventive modification in accordance with

737-300 SRM 53-10-01 Repair 16, 737-400 SRM 53-10-01 Repair

16 or 737-500 SRM 53-10-01 Repair 16 terminates repeat

inspection requirements of this service bulletin for the upper aft

corner.

2. Post preventive modification inspections are provided in the

applicable SRM.

d. Group 4:

(1) Do an external LFEC inspection, an internal detailed inspection of the skin and bearstrap

and an external detailed inspection of the skin for any crack at the upper aft corner of the

forward galley service doorway in accordance with FIGURE 4.

(a) If any crack is found in the skin or bearstrap, contact Boeing for repair instructions

and do the work instructed by Boeing.

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(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance.

3. Group 1-4:

Part 3: Forward Galley Service Doorway Upper Forward Corner Inspection

a. Do an external LFEC inspection of the skin and bearstrap and an external detailed inspection

of the skin for any crack at the upper forward corner of the forward galley service doorway in

accordance with FIGURE 5.

(1) If any crack is found in the skin or bearstrap, contact Boeing for repair instructions and

do the work instructed by Boeing.

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

Compliance.

b. Do an internal detailed inspection of all visible surfaces of the skin and bearstrap for any crack

at the upper forward corner of the forward galley service doorway in accordance with FIGURE

5.

(1) If any crack is found in the skin or bearstrap, contact Boeing for repair instructions and

do the work instructed by Boeing.

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

Compliance.

4. Group 1-4:

Part 4: Forward Galley Service Doorway Lower Aft Corner Inspection

a. Group 1, 4:

(1) Do an external LFEC inspection, an internal detailed inspection of the skin and bearstrap

and an external detailed inspection of the skin for any crack at the lower aft corner of the

forward galley service doorway in accordance with FIGURE 6.

(a) If any crack is found in the skin or bearstrap, contact Boeing for repair instructions

and do the work instructed by Boeing.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance.

b. Group 2-3:

(1) Do an external LFEC inspection, an internal detailed inspection of the skin and bearstrap

and an external detailed inspection of the skin for any crack at the lower aft corner of the

forward galley service doorway in accordance with FIGURE 6.

(a) If any crack is found in the skin or bearstrap, do the repair in accordance with

applicable 737-300 SRM 53-10-01 Repair 19, Repair 20, 737-400 SRM 53-10-01

Repair 19, Repair 20, 737-500 SRM 53-10-01 Repair 19, Repair 20.

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NOTE:

1. For aircraft line numbers 1001 thru 1922, Boeing recommends

installing applicable 737-300 SRM 53-10-01 Repair 20, 737-400

SRM 53-10-01 Repair 20 or 737-500 SRM 53-10-01 Repair 20 if

existing repairs do not prevent the installation of this SRM repair.

2. Installation of the 737-300 SRM 53-10-01 Repair 19, 737-400 SRM

53-10-01 Repair 19, or 737-500 SRM 53-10-01 Repair 19

terminates repeat inspection requirements of this service bulletin

for the lower aft corner.

3. Installation of the 737-300 SRM 53-10-01 Repair 20, 737-400 SRM

53-10-01 Repair 20 or 737-500 SRM 53-10-01 Repair 20

terminates repeat inspection requirements of this service bulletin

for the lower aft and forward corner.

4. Post repair inspections are provided in the applicable SRM.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance or do the preventive modification in accordance with applicable

737-300 SRM 53-10-01 Repair 19, Repair 20, 737-400 SRM 53-10-01 Repair 19,

Repair 20, or 737-500 SRM 53-10-01 Repair 19, Repair 20.

NOTE: 1. Installation of the preventive modification in accordance with

737-300 SRM 53-10-01 Repair 19, 737-400 SRM 53-10-01 Repair

19, or 737-500 SRM 53-10-01 Repair 19 terminates repeat

inspection requirements of this service bulletin for the lower aft

corner.

2. Installation of the preventive modification in accordance with

737-300 SRM 53-10-01 Repair 20, 737-400 SRM 53-10-01 Repair

20 or 737-500 SRM 53-10-01 Repair 20 terminates repeat

inspection requirements of this service bulletin for the lower aft

and forward corner.

3. Post preventive modification inspections are provided in the

applicable SRM.

5. Group 1-4:

Part 5: Forward Galley Service Doorway Lower Forward Corner Inspection

a. Group 1, 4:

(1) Do an external LFEC inspection, an internal detailed inspection of the skin and bearstrap

and an external detailed inspection of the skin for any crack at the lower forward corner

of the forward galley service doorway in accordance with FIGURE 7.

(a) If any crack is found in the skin or bearstrap, contact Boeing for repair instructions

and do the work instructed by Boeing.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance.

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ALERT ALERT
b. Group 2-3:

(1) Do an external LFEC inspection, an internal detailed inspection of the skin and bearstrap

and an external detailed inspection of the skin for any crack at the lower forward corner

of the forward galley service doorway in accordance with FIGURE 7.

(a) If any crack is found in the skin or bearstrap, do the repair in accordance with

applicable 737-300 SRM 53-10-01 Repair 18, Repair 20, 737-400 SRM 53-10-01

Repair 18, Repair 20, 737-500 SRM 53-10-01 Repair 18, Repair 20.

NOTE:

1. For aircraft line numbers 1001 thru 1922, Boeing recommends

installing applicable 737-300 SRM 53-10-01 Repair 20, 737-400

SRM 53-10-01 Repair 20 or 737-500 SRM 53-10-01 Repair 20 if

existing repairs do not prevent the installation of this SRM repair.

2. Installation of the 737-300 SRM 53-10-01 Repair 18, 737-400 SRM

53-10-01 Repair 18, or 737-500 SRM 53-10-01 Repair 18

terminates repeat inspection requirements of this service bulletin

for the lower forward corner.

3. Installation of the 737-300 SRM 53-10-01 Repair 20, 737-400 SRM

53-10-01 Repair 20 or 737-500 SRM 53-10-01 Repair 20

terminates repeat inspection requirements of this service bulletin

for the lower aft and forward corner.

4. Post repair inspections are provided in the applicable SRM.

(b) If no cracking is found, do the repeat inspections at the interval given in Paragraph

1.E., Compliance or do the preventive modification in accordance with applicable

737-300 SRM 53-10-01 Repair 18, Repair 20, 737-400 SRM 53-10-01 Repair 18,

Repair 20, or 737-500 SRM 53-10-01 Repair 18, Repair 20.

NOTE: 1. Installation of the preventive modification in accordance with

737-300 SRM 53-10-01 Repair 18, 737-400 SRM 53-10-01 Repair

18, or 737-500 SRM 53-10-01 Repair 18 terminates repeat

inspection requirements of this service bulletin for the lower forward

corner.

2. Installation of the preventive modification in accordance with

737-300 SRM 53-10-01 Repair 20, 737-400 SRM 53-10-01 Repair

20 or 737-500 SRM 53-10-01 Repair 20 terminates repeat

inspection requirements of this service bulletin for the lower aft

and forward corner.

3. Post preventive modification inspections are provided in the

applicable SRM.

6. Part 6: Close Access

a. Refinish the rework area around doorway as required, and put the airplane back to a

serviceable condition.

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ALERT ALERT
FIGURE 1: THIS FIGURE IS DELETED

(SHEET 1 OF 1)

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FIGURE 2: THIS FIGURE IS DELETED

(SHEET 1 OF 1)

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ALERT ALERT
FIGURE 3: THIS FIGURE IS DELETED

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 737-53A1116

ALERT ALERT
FIGURE 4: FORWARD GALLEY SERVICE DOORWAY - UPPER AFT CORNER INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-53A1116

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

Step Task Name Identification Qty More Data

1 Inspect Skin and Bearstrap - - (a)

2 Inspect Skin - - (b)

3 Inspect Skin and Bearstrap - - (c)

(a) Do an external Low Frequency Eddy Current (LFEC) inspection for any crack in the skin and bearstrap

around the corner fasteners in accordance with 737 NDT Manual Part 6, 51-00-26.

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

(c) Do an internal detailed inspection for any crack in the skin and bearstrap.

FIGURE 4: FORWARD GALLEY SERVICE DOORWAY - UPPER AFT CORNER INSPECTION

(SHEET 2 OF 2)

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FIGURE 5: FORWARD GALLEY SERVICE DOORWAY - UPPER FORWARD CORNER INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-53A1116

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

Step Task Name Identification Qty More Data

1 Inspect Skin and Bearstrap - - (a)

2 Inspect Skin - - (b)

3 Inspect Skin and Bearstrap - - (c)

(a) Do an external Low Frequency Eddy Current (LFEC) inspection for any crack in the skin and bearstrap

around the corner fasteners in accordance with 737 NDT Manual Part 6, 51-00-26.

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

(c) Do an internal detailed inspection for any crack in the skin and bearstrap.

FIGURE 5: FORWARD GALLEY SERVICE DOORWAY - UPPER FORWARD CORNER INSPECTION

(SHEET 2 OF 2)

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ALERT ALERT
FIGURE 6: FORWARD GALLEY SERVICE DOORWAY - LOWER AFT CORNER INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-53A1116

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

Step Task Name Identification Qty More Data

1 Inspect Skin and Bearstrap - - (a)

2 Inspect Skin - - (b)

3 Inspect Skin and Bearstrap - - (c)

(a) Do an external Low Frequency Eddy Current (LFEC) inspection for any crack in the skin and bearstrap

around the corner fasteners in accordance with 737 NDT Manual Part 6, 51-00-26.

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

(c) Do an internal detailed inspection for any crack in the skin and bearstrap.

FIGURE 6: FORWARD GALLEY SERVICE DOORWAY - LOWER AFT CORNER INSPECTION

(SHEET 2 OF 2)

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FIGURE 7: FORWARD GALLEY SERVICE DOORWAY - LOWER FORWARD CORNER INSPECTION

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 737-53A1116

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

Step Task Name Identification Qty More Data

1 Inspect Skin and Bearstrap - - (a)

2 Inspect Skin - - (b)

3 Inspect Skin and Bearstrap - - (c)

(a) Do an external Low Frequency Eddy Current (LFEC) inspection for any crack in the skin and bearstrap

around the corner fasteners in accordance with 737 NDT Manual Part 6, 51-00-26.

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

(c) Do an internal detailed inspection for any crack in the skin and bearstrap.

FIGURE 7: FORWARD GALLEY SERVICE DOORWAY - LOWER FORWARD CORNER INSPECTION

(SHEET 2 OF 2)

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ALERT ALERT