Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 254 

### Commercial **Airplanes** 

# 737 Service Bulletin

**Number: 737-53A1289** Original Issue: January 14, 2009 Revision 1: November 18, 2009 ATA System: 5300
**SUBJECT:** FUSELAGE - Skin - Inspection Of The Skin For Scribe Lines 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.**BLANK PAGE** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

BLANK PAGE**Table of Contents** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**Table of Contents** Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 76 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 76 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 77 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 79 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 80 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 FIGURE 1: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 126 FIGURE 2: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 129 FIGURE 3: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 132 FIGURE 4: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 135 FIGURE 5: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 138 FIGURE 6: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 141 FIGURE 7: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 144 FIGURE 8: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 147 FIGURE 9: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . . 150 FIGURE 10: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION . . . . . . . . . . . . . . . . . 153 FIGURE 11: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION . . . . . . . . . . . . . . . . . 156**Table of Contents** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 254 

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FIGURE 12: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION . . . . . . . . . . . . . . . . 159 FIGURE 13: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION. . . . . . . . . . . . . . . . . 162 FIGURE 14: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION. . . . . . . . . . . . . . . . . 165 FIGURE 15: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION. . . . . . . . . . . . . . . . . 168 FIGURE 16: FUSELAGE - STA 360 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION . . . . . . 171 FIGURE 17: FUSELAGE - STA 887 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION . . . . . . 173 FIGURE 18: FUSELAGE - STA 500E - CIRCUMFERENTIAL BUTT JOINT - INSPECTION . . . . . 175 FIGURE 19: FUSELAGE - STA 727I - CIRCUMFERENTIAL BUTT JOINT - INSPECTION . . . . . . 177 FIGURE 20: FUSELAGE - DECAL - ZONE 3, ZONE 4, ZONE 5 INSPECTION . . . . . . . . . . . . 179 FIGURE 21: FUSELAGE - DECAL - ZONE 6, ZONE 7, ZONE 8 INSPECTION . . . . . . . . . . . . 182 FIGURE 22: FUSELAGE - DECAL - ZONE 9, ZONE 10, ZONE 11 INSPECTION . . . . . . . . . . 185 FIGURE 23: FUSELAGE - DECAL - ZONE 12, ZONE 13, ZONE 14 INSPECTION . . . . . . . . . . 188 FIGURE 24: FUSELAGE - DECAL - ZONE 15, ZONE 16 INSPECTION . . . . . . . . . . . . . . . 191 FIGURE 25: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTIONS . . . . . . . . . . . 194 FIGURE 26: FUSELAGE - INTERNAL APPROVED REPAIRS - INSPECTION . . . . . . . . . . . . 196 FIGURE 27: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17 198 FIGURE 28: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17 200 FIGURE 29: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17 202 FIGURE 30: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17 204 FIGURE 31: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17 206 FIGURE 32: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18 208 FIGURE 33: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18 210 FIGURE 34: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18 212 FIGURE 35: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18 214 FIGURE 36: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18 216 FIGURE 37: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19 218 FIGURE 38: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19 220 FIGURE 39: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19 222 FIGURE 40: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19 224 FIGURE 41: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19 226 FIGURE 42: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 360 - LIMITED RETURN TO SERVICE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 FIGURE 43: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 887 - LIMITED RETURN TO**Table of Contents** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 254 

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SERVICE PROGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 FIGURE 44: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 500E AND STA 727I - LIMITED RETURN TO SERVICE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 FIGURE 45: EXTERNAL APPROVED REPAIRS - LIMITED RETURN TO SERVICE PROGRAM . . . 235 FIGURE 46: INTERNAL REPAIR DOUBLER - LIMITED RETURN TO SERVICE PROGRAM . . . . . 237 FIGURE 47: REQUIRED INSPECTIONS FOR SCRIBES FOUND WITHIN ONE INCH OF A SKIN LAP JOINT AND EXTERNAL APPROVED REPAIRS . . . . . . . . . . . . . . . . . . . . . 239 APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN 241 APPENDIX B: REPORTING SYSTEM - LIMITED RETURN TO SERVICE PROCEDURE FOR SCRIBE LINE AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 APPENDIX C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES . . . . . . . . . . 250 APPENDIX D: SCRIBE LINE SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253**Table of Contents** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 254 

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BLANK PAGEOriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 254 

### Commercial **Airplanes** 

# 737 Service Bulletin

**Number: 737-53A1289** 

### Revision Transmittal Sheet Original Issue: January 14, 2009 Revision 1: November 18, 2009 ATA System: 5300
**SUBJECT:** FUSELAGE - Skin - Inspection Of The Skin For Scribe Lines

This Revision includes all pages of the service bulletin.
**COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes inspected as shown in the original issue of this service bulletin.
**REASON FOR REVISION** Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. 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. This revision is sent to clarify requirements for inspections of areas of the fuselage having decals and to remove airplanes YL501-YL503 from the effectivity. These sections were changed: 1. Paragraph 1.A. Effectivity - removed airplanes YL501-YL503 2. Paragraph 1.E. Compliance - added additional inspection exception
**REVISION HISTORY** Original Issue: January 14, 2009 Revision 1: November 18, 2009Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

BLANK PAGEOriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 254 

### Commercial **Airplanes** 

# 737 Service Bulletin

**Number: 737-53A1289** 

### Summary Original Issue: January 14, 2009 Revision 1: November 18, 2009 ATA System: 5300
**SUBJECT:** FUSELAGE - Skin - Inspection Of The Skin For Scribe Lines

**CONCURRENT REQUIREMENTS**

None.
**BACKGROUND** This service bulletin gives instructions to inspect for scribe lines in the fuselage skin at lap joints, the splice strap at certain butt joints, the skin or doubler at certain approved repair doublers and the skin at decals. Fatigue cracks can develop at scribe line locations. Any crack that remains undetected could grow large and cause a rapid decompression. Nine operators have reported scribe line damage found adjacent to the skin lap joints, decals and wing to body fairings on 737-600, -700, -700C, -800, -900 airplanes. The scribe lines appear to have been made on the skin when sealant was removed as part of preparation of the airplane for repainting. One 737-700 operator reported scribe lines found around the wing to body fairing between stringer 26L and stringer 25R at station (STA) 727D to STA 727E. A second 737-700 operator reported six vertical scribe lines up to 42 inches long on the upper aft fuselage between stringer 5R and stringer 9R at STA 847 to STA 887. Another 737-700 operator reported scribe lines along stringer 24L and stringer 24R between STA 178 to STA 500B. The depth of the scribes ranged from 0.001inch to 0.004 inch. The airplanes had between 595 flight cycles and 17,571 flight cycles. No cracks as a result of scribe lines found on 737-600, -700, -700C, -800, -900 airplanes have been reported to Boeing. A scribe line is a narrow, shallow, distinct line of damage (typically up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (lap joints and butt joints, respectively). A more detailed definition of a scribe line is included in Accomplishment Instructions paragraph 3.B.7. Part 7 - Identification of a “Typical” Scribe Line. A review of fleet activity yields two separate scenarios that are suspected to have caused scribe lines to the fuselage skin or butt joint splice straps. The first scenario involves the paint stripping and repainting of airplanes. In the process of stripping and preparing the airplane for paint, tools were used to remove sealant and paint buildup at lap joints, butt joints, and at certain external or internal doublers or decals. Tools like scrapers (steel, wood, hard plastic etc.), knives, or utility knives can damage the skin, splice straps, or internal doublers. Fatigue cracks can develop at scribe line locations.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

The second scenario is graphic decal application on or removal from the fuselage. To install the decals across lap joint steps or repairs, investigation into maintenance practices has shown the decals have been cut in place, using some form of knife, to allow the decal to lie flush to the skin at these stepped locations. This operation results in scribe lines at the decal cut location. Based on service reports, sharp tools have also been used for close trimming of the decal’s outline. This type of decal trimming has also left scribe lines on the fuselage skin. The above maintenance operations can each lead to the same type of scribe line damage and subsequent premature fatigue cracks. Airplanes after line number 2309 are not included in the effectivity of this service bulletin because the Aircraft Maintenance Manual (AMM) procedure for paint/sealant removal has been revised. 737-800 series airplanes with a flat pressure bulkhead and 737-900ER series airplanes prior to line number 2310 are not included in the effectivity of this service bulletin. These airplanes have been verified as not being painted since delivery. Boeing Service Related Problem (SRP) 737NG-SRP-53-0245 is related to this service bulletin.
**ACTION** At or before the scribe line inspection thresholds shown in this service bulletin, remove paint and sealant at the applicable zonal locations. Do an external detailed inspection of the skin, butt splice strap or approved repair doubler for any scribe line or any crack. If scribe lines are found, repair before further flight. As an alternative to immediate repair, for a scribe line that qualifies, the provided Limited Return to Service (LRTS) program may be used to allow airplanes to return to revenue flight for a limited period before scribe lines are repaired. This service bulletin contains a LRTS program. The LRTS program consists of repeat inspections to detect any crack where scribe lines were found. Total airplane flight cycles, location, and extent of scribe line must meet specific criteria in order for a scribe line to qualify for an LRTS program. Each affected structural location within an LRTS program will be terminated with a repair. This service bulletin has specific instructions for calculating separate inspection thresholds based on fatigue life for the identified locations. With the use of maintenance records, operators can implement the inspection program based on potential scribe line opportunities in an airplane’s maintenance history. If this maintenance records-based threshold program is not used, then 6,000 flight cycles shall be assigned as the cycle level when scribing occurred. Since a scribe line can occur at any time during the service life of an airplane and at many locations, this program uses both total flight cycles and structural criticality of location to determine the inspection requirements. Criticality of location allows this service bulletin to address the most critical areas first and to provide less critical areas with appropriately reduced compliance requirements. Criticality of location determines the inspection thresholds for each location. This service bulletin uses zones to address all of the critical locations and ranges of inspection thresholds. Each piece of structure susceptible to a scribe line is assigned to a zone. The affected structure in each zone (for each group of airplanes) is identified in individual figures in the service bulletin.
**EFFECTIVITY** 737-600, -700, -700C, -800, -900 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**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. 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.

**MANPOWER** Refer to Paragraph 1.G., Manpower.

**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

1016 STA 360 STA TYPICAL AIRPLANE SHOWN DO AN EXTERNAL DETAILED INSPECTION FOR ANY SCRIBE LINE ALONG LAP JOINTS, CIRCUMFERENTIAL BUTT JOINT, APPROVED REPAIRS AND DECALS. IF A SCRIBE LINE IS FOUND, DO NDT INSPECTIONS FOR ANY CRACK.

727 STA 887 STA S-4L S-10L

S-14L STA 360 STA 540 STA 727 STA 887 STA 1016

S-24L S-14L1542468Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 254 

### Commercial **Airplanes** 

# 737 Service Bulletin

**Number: 737-53A1289** Original Issue: January 14, 2009 Revision 1: November 18, 2009 ATA System: 5300
**SUBJECT:** FUSELAGE - Skin - Inspection Of The Skin For Scribe Lines

**1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document 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** 1 - 737-600 Airplanes line number 1 through 871. 2 - 737-700 Airplanes line number 1 through 871. 3 - 737-800 Airplanes line number 1 through 871. 4 - 737-900 Airplanes line number 1 through 871. 5 - 737-700C Airplanes line number 1 through 871. 6 - 737-600 Airplanes line number 872 through 2309 with fatigue related design improvements in the upper lobe skin between stringers S-3 and S-4 and between S-9 and S-10. 7 - 737-700 Airplanes line number 872 through 2309 with fatigue related design improvements in the upper lobe skin between stringers S-3 and S-4 and between S-9 and S-10.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 254 

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Airplane models:
737-600 737-700 737-700C 737-800 737-900
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AEROLINEAS ARGENTINAS (ARG) 7 YN104 AEROMEXICO (AMX) 7 YB207 YB851–YB863 YB871–YB874 YM501–YM503 YM506–YM512 8 YK580–YK584 AIR ALGERIE (ALG) 3 YD101–YD106 6 YE301–YE305 8 YD107–YD110 AIR BERLIN (BER) 2 YB201 3 YC053–YC068 YC151 YC391 YC461 YC701 YC703 YC705 7 YA356–YA357 YA614–YA615 YB203 8 YC069–YC070 YC730 YD151–YD157 YD159 YD218 YD261 YL023 AIR CHINA (BEJ) 2 YA681–YA682 3 YC943–YC947 YC981–YC983 7 YB584–YB588 YB590–YB598 8 YC948–YC951 YK161–YK165 YK651–YK657 YL001–YL005 8 - 737-800 Airplanes line number 872 through 2309 without a flat pressure bulkhead and with fatigue related design improvements in the upper lobe skin between stringers S-3 and S-4 and between S-9 and S-10, excluding line numbers 2095 and 2162. 9 - 737-900 Airplanes line number 872 through 2309 with fatigue related design improvements in the upper lobe skin between stringers S-3 and S-4 and between S-9 and S-10. 10 - 737-700C Airplanes line number 872 through 2309 with fatigue related design improvements in the upper lobe skin between stringers S-3 and S-4 and between S-9 and S-10. **GROUP CONFIGURATION DESCRIPTION**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 254 

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AIR CHINA CHONGQING BRANCH (CHO) 3 YC941–YC942 7 YB589 AIR CHINA SOUTHWEST BRANCH (XIN) 8 YC426–YC428 AIR CHINA TIANJIN BRANCH (TJA) 7 YB581–YB583 AIR EUROPA (ARE) 3 YC761–YC770 YD046 YD048 8 YD206–YD209 YK002–YK003 YK361–YK367 YK370–YK371 YK602 AIR INDIA EXPRESS (IDC) 8 YJ942–YJ943 YK007 YK151–YK154 YL461–YL467 AIR ITALY (RIT) 8 YK717 AIR MADAGASCAR (MAD) 2 YG016 AIR NATIONAL GUARD (USK) 2 YG067 YG069 7 YG044 AIR NIPPON (ANK) 7 YG251–YG252 YN001–YN011 AIR PACIFIC (APC) 2 YA291 3 YC931–YC932 AIR SENEGAL INTERNATIONAL (SNG) 7 YM541 AIRCOMPANY YAKUTIA (SKK) 7 YB911 AIRCRAFT MAINTENANCE CORP. (AMF) 8 YK631–YK633 AIRES S.A. (AIE) 2 YA573 YA575–YA576 7 YB114–YB115 AIRTRAN AIRWAYS (CQT) 7 YB371–YB392 YM201–YM203 YM205–YM207 YM209–YM221 YM223 YM226–YM228Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 254 

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ALASKA AIRLINES (ASA) 2 YA841–YA856 4 YD501–YD505 7 YA858 YA861–YA862 8 YK403 YK431–YK450 YL101 9 YD506–YD512 AMERICAN AIRLINES (AAL) 3 YC801–YC865 8 YC866–YC877 ARABASCO (RBS) 2 YG029 ARAMCO ASSOCIATED COMPANY (RAS) 10 YG601–YG602 2 YB151–YB153 ARIK AIR (AKD) 2 YA627–YA629 7 YM224–YM225 ASTRAEUS, LTD. (AUA) 2 YA204 7 YA671–YA672 ATLANT-SOYUZ (AYZ) 3 YC906 8 YC491–YC495 AUSTRALIAN WEDGETAIL PROGRAM (ZVI) 7 YG089 YG201 YG203–YG205 AUSTRIAN AIRLINES AG (AUL) 1 YE171–YE172 2 YB171 3 YC381–YC382 7 YB172 8 YC383–YC387 AVENIR WORLDWIDE (BBJ) LIMITED (AWO) 2 YG034 AVIATION CAPITAL GROUP (CGP) 2 YA203 AVJET (AJT) 7 YG079 YG095 BANCO SAFRA (BNS) 2 YG040Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

BAVARIA (BAV) 7 YM581–YM582 BEL AIR LIMITED (ULL) 2 YG022 BLUE AIR (BTR) 3 YC480–YC481 8 YJ934 BOEING DEMONSTRATOR JET (BCJ) 2 YG035–YG036 BOETTI AIR INC. (BBI) 2 YG068 BURAQ AIR (BQA) 8 YK791–YK792 C.I.T. LEASING CORPORATION (TCI) 8 YC490 CANJET (CNJ) 3 YC476 YC478 YC903 8 YC488–YC489 CARIBBEAN AIRLINES LIMITED (CBL) 3 YC136–YC141 8 YD317 CELESTIAL AIRWAYS (LGM) 2 YG062 CHARTWELL (CHP) 2 YG017 CHINA AIRLINES (CHI) 3 YC571 YC574–YC581 8 YC582 CHINA EASTERN AIRLINES (CEA) 2 YA811–YA814 7 YB206 YB561–YB580 YM591–YM593 YN021 8 YK457–YK459 CHINA EASTERN AIRLINES WUHAN (WUH) 8 YD172 YK456 YK460Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

CHINA SOUTHERN AIRLINES (GUN) 3 YC027 7 YB881–YB883 YB886–YB893 YN076–YN077 8 YC921–YC922 YD313 YD316 YD320 YD322 YD324–YD327 YD329 YJ671–YJ694 YL431–YL432 CHINA UNITED AIRLINES (CUL) 7 YB631–YB632 CHINA UNITED AIRLINES LTD. (CUA) 2 YA272 8 YD496 YD499 CHINA XINJIANG AIRLINES (XIJ) 7 YA255–YA256 YA645 YA656 YB884–YB885 YM571–YM572 YN071–YN075 CIMBER AIR (CIM) 2 YA205–YA208 CLAY LACY AVIATION (CYA) 2 YG037 COLOMBIAN AIR FORCE (CLB) 2 YG028 COMMONWEALTH OF AUSTRALIA (GAU) 2 YG072 YG075 CONTINENTAL AIRLINES (CAL) 2 YA501–YA536 3 YC321–YC380 4 YD601–YD602 8 YJ501–YJ517 YJ531–YJ558 9 YD603–YD612 COPA AIRLINES (COP) 2 YA755–YA756 YA961–YA966 7 YA967–YA978 8 YJ591–YJ594 CYPRUS TURKISH AIRLINES (KTHY) (KHT) 3 YC467 YD021–YD022 DALLAH ALBARAKA COMPANY (KAM) 2 YG063 DELTA AIR LINES (DAL) 3 YC601–YC634 YC681–YC696 8 YC635–YC655Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

DOBRO LIMITED (DOB) 2 YG008 DUBAI AIR WING (DAW) 2 YG007 3 YD402 8 YD412 YD414 E & A AVIATION (RSB) 7 YG082 EASTAR JET (ETJ) 1 YE105 7 YB108 YB113 YB116 EASYJET (EZY) 2 YB101–YB103 7 YB106 YB117–YB132 EG&G TECHNICAL SERVICES (EGN) 6 YE201–YE206 EGYPTAIR (EGP) 8 YK981–YK982 EIE EAGLE (EIE) 8 YD409 EL AL ISRAEL AIRLINES (ELA) 2 YA881–YA882 3 YC405 YC591–YC593 8 YC147 YD219 ENERJET (ABQ) 7 YM204 YM208 ETHIOPIAN AIRLINES (ETH) 3 YD171 7 YA666–YA667 YB156–YB158 EUROCYPRIA AIRLINES (ECY) 8 YC186–YC190 YJ947 EVA AIR (EVA) 7 YG083 EXPORT RESTRICTED AIRPLANES (YWV) 8 YD408 FEDERAL GOVERNMENT OF NIGERIA (NGA) 7 YG091Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

FIRST VIRTUAL AIR II, LLC (FVA) 2 YG001 FLYGLOBESPAN.COM (FGS) 7 YB671–YB672 8 YJ941 YJ976–YJ977 YK136–YK137 FTC (SEH) 7 YG096 FUNAIR (FUN) 2 YG027 FUTURA (FUA) 3 YC464 G5 EXECUTIVE (GFE) 7 YG117 GAMA AVIATION LTD (GAV) 2 YG010 GARUDA INDONESIA (GIA) 3 YC482–YC485 YC727 8 YC436–YC437 YC486 YD319 YD323 YJ473 YJ475 YK601 GAZPROMAVIA (GAZ) 2 YA621–YA622 7 YG097 GECAS (GEF) 7 YN102–YN103 YN105–YN106 YN110 GEORGIAN AIRWAYS (GEI) 7 YA860 GERMANIA (GER) 2 YA231 YA233 YA235–YA240 GLOBAL JET AUSTRIA (GLJ) 8 YD404 GLOBAL JET LUXEMBOURG (SIQ) 2 YG038 7 YG093Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

GOL AIRLINES (GOT) 2 YA201–YA202 YA232 YA234 YA241–YA242 YA251–YA252 YA321–YA323 YA571–YA572 YA601–YA602 YA605 YA607–YA608 YA610–YA612 YA683–YA684 YA732–YA733 YB202 YB501 3 YC101 YC402–YC403 YC453 YC471–YC475 YC572–YC573 YC589 7 YA211 YA221 YA631 YA646–YA648 YA650 YA657 YB104–YB105 YB107 YB111–YB112 YB271 YB502 8 YC728–YC729 YD256–YD257 YD302–YD303 YD306–YD307 YJ471–YJ472 YJ944 YK721–YK723 YK725–YK733 GOVT OF EQUATORIAL GUINEA (EGR) 7 YG085 HAINAN AIRLINES (HNA) 2 YA544 YA546 YA603–YA604 YA606 3 YC126–YC127 YC401 YC404 YC409 YC452 YC971–YC973 YD042–YD045 7 YA857 YA859 YB656 8 YC974–YC978 YD216 YK402 YK406 YK701–YK707 YK716 YL012–YL015 YL021–YL022 YL051–YL052 HAMBURG INTERNATIONAL (HAU) 2 YB276 INDIAN AIR FORCE (IDF) 7 YG112 INTEGRATED DEFENSE SYSTEMS (BSP) 7 YG202 YG212 YG214 INTERNATIONAL JETCLUB (IJC) 7 YG116 IRAQI AIRWAYS (IRQ) 7 YM222 JEJU AIR (JJU) 3 YC410 YC704 YC707 JET AIRWAYS (JPL) 2 YA734 YA751–YA754 YB181 3 YC731 YC733–YC737 7 YA630 YB182–YB184 8 YC738–YC749 YD309 YD311–YD312 YD328 YD330 YD334 YK401 YK404 9 YD571–YD572 JET AVIATION AG - ZURICH (JTA) 2 YG015Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

JET AVIATION BUSINESS JET INC (JBJ) 2 YG071 JET LITE (JPQ) 2 YA253–YA254 3 YC462 YC901–YC902 7 YA351 YA367 YB651 YM102–YM103 8 YK141–YK142 YK576–YK577 JET4YOU.COM (JFU) 3 YC010 8 YK908–YK909 JETAIRFLY (TLB) 2 YA609 8 YD217 YJ931 KAISERAIR, INC. (KAS) 2 YA685 KENYA AIRWAYS (KEN) 7 YA635–YA636 YA641–YA642 8 YL302–YL303 KLM - ROYAL DUTCH AIRLINES (KLM) 3 YC781–YC793 4 YD531 8 YJ945 YK921 9 YD532–YD535 KOREAN AIR (KAL) 3 YC441–YC447 YC587 YD121–YD125 8 YC448 YD126 YL271–YL272 9 YD541–YD547 YD561–YD564 YD591–YD595 LAS VEGAS JET (LVJ) 2 YG002 LIMITED BRAND INC. (LII) 2 YG005 LOWA CORPORATION (LWA) 8 YD406 LUXAIR (LUX) 7 YB901–YB903 MALAYSIA AIRLINES (MAS) 8 YC439 YK146–YK147Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

MALEV HUNGARIAN AIRLINES LTD. (HGA) 6 YE321–YE326 7 YA371–YA377 8 YC201–YC203 YC206–YC207 MGM MIRAGE (MGM) 7 YG042 MIAMI AIR (MIB) 3 YC146 YC904–YC905 8 YD304 YK121–YK122 YK571 MID EAST JET (SKL) 2 YG013–YG014 YG021 8 YD407 MIDROC AVIATION (MDX) 8 YD405 MIDWEST AIRLINES (MWA) 1 YE106 MONGOLIAN AIRLINES MIAT (MNG) 3 YC477 8 YJ476 MOSKOVIA AIR (MOK) 2 YA731 N720CH, INC. (NCH) 2 YG019 NATIONAL (NJI) 2 YG032 NATIONAL AIR SERVICES (NAR) 3 YD403 7 YG080 YG086–YG087 NEOS (NEO) 8 YC438 YJ002 YJ021 YJ631–YJ632 NETJETS (NJL) 2 YG031 YG033 NEW AXIS AIRWAYS (NXA) 3 YC406 YC451 NEWS AMERICA INCORPORATED (NWS) 2 YG020 NOFA LTD. (NFA) 8 YD413Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

NORWEGIAN AIR SHUTTLE ASA (NSB) 3 YC412 YC455 8 YC907 YJ012–YJ013 YJ933 YK001 OJSC TAIMYR AIRLINES (TYM) 3 YC103 8 YC028–YC029 OKAY AIRWAYS COMPANY LIMITED (OKY) 8 YD332–YD333 OMAN AIR (OMR) 7 YA366 YB551 8 YC171 YJ901–YJ903 ORENBURG AIRLINES (ORG) 3 YC479 YC732 8 YC487 YD308 YD318 ORIENT GLOBAL AVIATION (VTU) 2 YG011 PACIFIC BLUE AIRLINES (BLP) 8 YJ865–YJ866 YK321 YK324 YK326 YK328 YK332 PEGASUS AIRLINES (PGS) 3 YC392 YC466 YD025 8 YC414–YC415 YD391 YL061 PEROLUX S.A.R.L. (PLX) 7 YG099 PICTON II (UNU) 2 YG006 PRESIDENTIAL FLIGHT (ABD) 2 YG039 8 YD410 PRIME AVIATION KZ (PKZ) 2 YG077 PRIMERA AIR (JXL) 2 YA302 3 YC454 YC588 8 YJ001 YK138–YK139 PRIVATAIR (PTS) 2 YG064 7 YG092 8 YJ935–YJ936 YK006Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

QANTAS (QAN) 8 YC878–YC892 YJ911–YJ928 REPUBLIC OF CHINA AIR FORCE (CAF) 3 YC396 ROYAL AIR MAROC (RAM) 2 YA831–YA834 3 YC301–YC303 7 YA835 YN061 8 YC304–YC305 YK301–YK307 YK368–YK369 ROYAL JET (RJT) 2 YG018 YG023–YG026 ROYAL MALAYSIA AIR FORCE (MAF) 2 YG061 ROYAL THAI AIR FORCE (TAF) 8 YK476 RYANAIR (RYR) 8 YC496–YC499 YJ801–YJ860 YK801–YK848 S7 AIRLINES (SBR) 3 YD301 8 YD310 YD314–YD315 SAGA AIRLINES (SGV) 3 YC051–YC052 8 YD305 YD321 SAMSUNG TECHWIN CO. (SST) 7 YG111 SAS (SAS) 1 YE001 YE003–YE005 YE007 YE009 YE011–YE012 YE016 YE018 YE020 YE051 YE101–YE104 YE107–YE109 3 YD047 YD049 YD051 YD082 8 YD052 YD055 YD057 SAS INSTITUTE INC. (SJS) 7 YG041 SAS NORWAY (BRT) 1 YE002 YE006 YE008 YE010 YE013–YE015 YE017 YE019 2 YA311 YA543 YA545 YA547–YA550 YB001–YB006 3 YD041 YD050 YD081 YD083–YD084 7 YA551–YA552 YM671 8 YD053–YD054 YD056Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

SAUDI OGER (SAO) 2 YG073 3 YD401 SHANDONG AIRLINES (SHG) 7 YM551–YM553 8 YK511–YK514 YL066 YL311–YL312 SHANGHAI AIRLINES (SHA) 2 YA312–YA314 YA891–YA892 8 YC166–YC170 YC394 YD491–YD495 YD497–YD498 YJ003–YJ007 YJ871 SHENZHEN AIRLINES (SHZ) 2 YA626 YA686–YA687 YA721–YA722 YA801–YA803 3 YC153–YC154 YC411 YC413 7 YA613 YA809 8 YJ008 YJ948–YJ949 YK101–YK104 YK606–YK607 9 YD651–YD655 SIVA (SVM) 7 YG094 SKY AIRLINES (SYC) 8 YJ950 SKYEUROPE (SKP) 7 YN107 YN109 SKYMARK AIRLINES, INC. (SKM) 8 YK611–YK614 SOUTH AFRICAN AIRFORCE (SFF) 2 YG076 SOUTH AFRICAN AIRWAYS (SAA) 3 YC708–YC715 YC720–YC723 YD023–YD024 8 YC724–YC725 YD481–YD485 SOUTHERN AIRCRAFT SERVICES (HUZ) 2 YG009 SOUTHWEST AIRLINES (SWA) 2 YA001–YA099 YA271 YA301 YA541–YA542 7 YA101–YA199 YB204–YB205 YM251–YM299 YM301–YM328 SPICEJET (ROJ) 3 YC465 8 YD331 YK641–YK642 YK941–YK945 STAR 1 AIRLINES UAB (UAB) 2 YA578Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

STERLING AIR (DSL) 2 YA574 SUN COUNTRY AIRLINES (SCA) 3 YC104 YC121 YC152 7 YB109–YB110 8 YC155–YC156 YK132 SUNEXPRESS (SNS) 3 YC416–YC417 YC702 YC706 YD201–YD202 8 YD158 YJ477–YJ480 YK426–YK427 SUNWING AIRLINES INC. (SUG) 8 YJ946 YJ951 YK004 YL011 SWIFLITE AIRCRAFT CORPORATION (OSF) 7 YG078 TAAG (ANGOLA AIRLINES) (ANG) 7 YM631–YM634 TAROM - ROMANIAN AIR TRANSPORT (TRM) 2 YB161–YB162 7 YB163–YB164 THOMSON AIRWAYS (BRI) 3 YD001–YD004 8 YK907 YL421–YL423 TOWN & COUNTRY FOODS INC. (RUF) 2 YG003 TRACINDA CORP. (TRD) 2 YG004 TRANSAERO AIRLINES (TRX) 3 YC006–YC007 TRANSAVIA AIRLINES (TAV) 3 YC071–YC082 7 YB521–YB526 YB541–YB544 8 YC083–YC084 YC091–YC094 TRANSAVIA FRANCE (TVF) 3 YC751–YC752 8 YK946–YK947 TRAVEL SERVICE (TSF) 3 YC408 YC459 8 YD203 YJ011 YJ474 YK005 YK131 YK166 YK405Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

TUIFLY (HAP) 2 YA577 3 YC001–YC005 YC008–YC009 YC011–YC026 7 YM641–YM644 8 YC030 YK901–YK906 TUIFLY NORDIC (TNS) 3 YD005 8 YD006–YD007 TUNISAIR (TUN) 1 YE151–YE157 2 YA209–YA210 YG030 TURKISH AIR FORCE AEW&C PGM (ZXN) 7 YG211 YG213 TURKISH AIRLINES (THY) 3 YC501–YC524 7 YM504–YM505 YN101 YN108 YN111–YN112 8 YC526 YK551–YK565 YL056 TURKMENISTAN AIRLINES (TUE) 8 YK796–YK797 TURNBERRY (TNY) 2 YG012 TUTOR-SALIBA CORPORATION (TTS) 2 YG070 TY AIR (YIP) 2 YG066 UNITED STATES NAVY (USN) 10 YG505–YG509 5 YG501–YG504 US AIR FORCE (USF) 2 YG074 7 YG081 YG084 YG088 USAF RESERVES (URV) 7 YG101–YG103 VIKING AIRLINES (VAI) 3 YC113 YC407 YC463Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

VIRGIN BLUE AIRLINES (VOZ) 2 YA336–YA338 3 YC421 7 YA339–YA345 YA649 YA658–YA659 YA688–YA691 YB208 YM101 YM521–YM522 8 YC393 YC422 YD251–YD254 YJ861–YJ864 YJ867 YJ932 YK111–YK112 YK322–YK323 YK325 YK327 YK329–YK331 YK333–YK334 VISION AIR (VEG) 3 YC102 WESTJET (WJI) 2 YB301 6 YE371–YE383 7 YB302–YB310 YB601–YB630 YB961–YB967 8 YK480–YK484 WHITE SAPPHIRE (WSP) 7 YG098 XIAMEN AIRLINES (XIA) 2 YA701–YA706 7 YA707–YA710 YM471 YM481–YM484 8 YK621–YK625 YK961–YK968 XL AIRWAYS GERMANY (SXL) 3 YC111–YC112 8 YK148 YL057 YEMENIA (YEM) 8 YC176–YC178 YONA (IOP) 7 YG043
IDENTIFICATION BY VARIABLE NUMBER
**Variable Group** YA001–YA099 2 YA101–YA199 7 YA201–YA210 2 YA211 7 YA221 7 YA231–YA242 2 YA251–YA254 2 YA255–YA256 7 YA271–YA272 2 YA291 2Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

YA301–YA302 2 YA311–YA314 2 YA321–YA323 2 YA336–YA338 2 YA339–YA345 7 YA351 7 YA356–YA357 7 YA366–YA367 7 YA371–YA377 7 YA501–YA536 2 YA541–YA550 2 YA551–YA552 7 YA571–YA578 2 YA601–YA612 2 YA613–YA615 7 YA621–YA622 2 YA626–YA629 2 YA630–YA631 7 YA635–YA636 7 YA641–YA642 7 YA645–YA650 7 YA656–YA659 7 YA666–YA667 7 YA671–YA672 7 YA681–YA687 2 YA688–YA691 7 YA701–YA706 2 YA707–YA710 7 YA721–YA722 2 YA731–YA734 2 YA751–YA756 2 YA801–YA803 2 YA809 7 YA811–YA814 2 YA831–YA834 2 YA835 7 YA841–YA856 2 YA857–YA862 7 YA881–YA882 2 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

YA891–YA892 2 YA961–YA966 2 YA967–YA978 7 YB001–YB006 2 YB101–YB103 2 YB104–YB132 7 YB151–YB153 2 YB156–YB158 7 YB161–YB162 2 YB163–YB164 7 YB171 2 YB172 7 YB181 2 YB182–YB184 7 YB201–YB202 2 YB203–YB208 7 YB271 7 YB276 2 YB301 2 YB302–YB310 7 YB371–YB392 7 YB501 2 YB502 7 YB521–YB526 7 YB541–YB544 7 YB551 7 YB561–YB598 7 YB601–YB632 7 YB651 7 YB656 7 YB671–YB672 7 YB851–YB863 7 YB871–YB874 7 YB881–YB893 7 YB901–YB903 7 YB911 7 YB961–YB967 7 YC001–YC027 3 YC028–YC030 8 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

YC051–YC068 3 YC069–YC070 8 YC071–YC082 3 YC083–YC084 8 YC091–YC094 8 YC101–YC104 3 YC111–YC113 3 YC121 3 YC126–YC127 3 YC136–YC141 3 YC146 3 YC147 8 YC151–YC154 3 YC155–YC156 8 YC166–YC171 8 YC176–YC178 8 YC186–YC190 8 YC201–YC203 8 YC206–YC207 8 YC301–YC303 3 YC304–YC305 8 YC321–YC382 3 YC383–YC387 8 YC391–YC392 3 YC393–YC394 8 YC396 3 YC401–YC413 3 YC414–YC415 8 YC416–YC417 3 YC421 3 YC422 8 YC426–YC428 8 YC436–YC439 8 YC441–YC447 3 YC448 8 YC451–YC455 3 YC459 3 YC461–YC467 3 YC471–YC485 3 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

YC486–YC499 8 YC501–YC524 3 YC525–YC526 8 YC571–YC581 3 YC582–YC583 8 YC587–YC589 3 YC591–YC593 3 YC601–YC634 3 YC635–YC655 8 YC681–YC696 3 YC701–YC715 3 YC720–YC723 3 YC724–YC725 8 YC727 3 YC728–YC730 8 YC731–YC737 3 YC738–YC749 8 YC751–YC752 3 YC761–YC770 3 YC781–YC793 3 YC801–YC865 3 YC866–YC892 8 YC901–YC906 3 YC907 8 YC921–YC922 8 YC931–YC932 3 YC941–YC947 3 YC948–YC951 8 YC971–YC973 3 YC974–YC978 8 YC981–YC983 3 YD001–YD005 3 YD006–YD007 8 YD021–YD025 3 YD041–YD051 3 YD052–YD057 8 YD081–YD084 3 YD101–YD106 3 YD107–YD110 8 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

YD121–YD125 3 YD126 8 YD151–YD159 8 YD171 3 YD172 8 YD201–YD202 3 YD203 8 YD206–YD209 8 YD216–YD219 8 YD251–YD254 8 YD256–YD257 8 YD261 8 YD301 3 YD302–YD334 8 YD391 8 YD401–YD403 3 YD404–YD410 8 YD412–YD414 8 YD481–YD485 8 YD491–YD499 8 YD501–YD505 4 YD506–YD512 9 YD531 4 YD532–YD535 9 YD541–YD547 9 YD561–YD564 9 YD571–YD572 9 YD591–YD595 9 YD601–YD602 4 YD603–YD612 9 YD651–YD655 9 YE001–YE020 1 YE051 1 YE101–YE109 1 YE151–YE157 1 YE171–YE172 1 YE201–YE206 6 YE301–YE305 6 YE321–YE326 6 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

YE371–YE383 6 YG001–YG040 2 YG041–YG044 7 YG061–YG064 2 YG066–YG077 2 YG078–YG089 7 YG091–YG099 7 YG101–YG103 7 YG111–YG112 7 YG116–YG117 7 YG201–YG205 7 YG211–YG214 7 YG251–YG252 7 YG501–YG504 5 YG505–YG509 10 YG601–YG602 10 YJ001–YJ008 8 YJ011–YJ013 8 YJ021 8 YJ471–YJ480 8 YJ501–YJ517 8 YJ531–YJ558 8 YJ591–YJ594 8 YJ631–YJ632 8 YJ671–YJ694 8 YJ801–YJ867 8 YJ871 8 YJ901–YJ903 8 YJ911–YJ928 8 YJ931–YJ936 8 YJ941–YJ951 8 YJ976–YJ977 8 YK001–YK007 8 YK101–YK104 8 YK111–YK112 8 YK121–YK122 8 YK131–YK132 8 YK136–YK139 8 YK141–YK142 8 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

YK146–YK148 8 YK151–YK154 8 YK161–YK166 8 YK301–YK307 8 YK321–YK334 8 YK361–YK371 8 YK401–YK406 8 YK426–YK427 8 YK431–YK450 8 YK456–YK460 8 YK476 8 YK480–YK484 8 YK511–YK514 8 YK551–YK565 8 YK571 8 YK576–YK577 8 YK580–YK584 8 YK601–YK602 8 YK606–YK607 8 YK611–YK614 8 YK621–YK625 8 YK631–YK633 8 YK641–YK642 8 YK651–YK657 8 YK701–YK707 8 YK716–YK717 8 YK721–YK733 8 YK791–YK792 8 YK796–YK797 8 YK801–YK848 8 YK901–YK909 8 YK921 8 YK941–YK947 8 YK961–YK968 8 YK981–YK982 8 YL001–YL005 8 YL011–YL015 8 YL021–YL023 8 YL051–YL052 8 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

2. Spares Affected

None. **B. Concurrent Requirements**

None. YL056–YL057 8 YL061 8 YL066 8 YL101 8 YL271–YL272 8 YL301–YL303 8 YL311–YL312 8 YL421–YL423 8 YL431–YL432 8 YL461–YL467 8 YM101–YM103 7 YM201–YM228 7 YM251–YM299 7 YM301–YM328 7 YM471 7 YM481–YM484 7 YM501–YM512 7 YM521–YM522 7 YM541 7 YM551–YM553 7 YM571–YM572 7 YM581–YM582 7 YM591–YM593 7 YM631–YM634 7 YM641–YM644 7 YM671 7 YN001–YN011 7 YN021 7 YN061 7 YN071–YN077 7 YN101–YN112 7 **Variable Group**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**C. Reason** This service bulletin gives instructions to inspect for scribe lines in the fuselage skin at lap joints, the splice strap at certain butt joints, the skin or doubler at certain approved repair doublers and the skin at decals. Fatigue cracks can develop at scribe line locations. Any crack that remains undetected could grow large and cause a rapid decompression. Nine operators have reported scribe line damage found adjacent to the skin lap joints, decals and wing to body fairings on 737-600, -700, -700C, -800, -900 airplanes. The scribe lines appear to have been made on the skin when sealant was removed as part of preparation of the airplane for repainting. One 737-700 operator reported scribe lines found around the wing to body fairing between stringer 26L and stringer 25R at station (STA) 727D to STA 727E. A second 737-700 operator reported six vertical scribe lines up to 42 inches long on the upper aft fuselage between stringer 5R and stringer 9R at STA 847 to STA 887. Another 737-700 operator reported scribe lines along stringer 24L and stringer 24R between STA 178 to STA 500B. The depth of the scribes ranged from 0.001inch to 0.004 inch. The airplanes had between 595 flight cycles and 17,571 flight cycles. No cracks as a result of scribe lines found on 737-600, -700, -700C, -800, -900 airplanes have been reported to Boeing. A scribe line is a narrow, shallow, distinct line of damage (typically up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (lap joints and butt joints, respectively). A more detailed definition of a scribe line is included in Accomplishment Instructions paragraph 3.B.7. Part 7 - Identification of a “Typical” Scribe Line. A review of fleet activity yields two separate scenarios that are suspected to have caused scribe lines to the fuselage skin or butt joint splice straps. The first scenario involves the paint stripping and repainting of airplanes. In the process of stripping and preparing the airplane for paint, tools were used to remove sealant and paint buildup at lap joints, butt joints, and at certain external or internal doublers or decals. Tools like scrapers (steel, wood, hard plastic etc.), knives, or utility knives can damage the skin, splice straps, or internal doublers. Fatigue cracks can develop at scribe line locations. The second scenario is graphic decal application on or removal from the fuselage. To install the decals across lap joint steps or repairs, investigation into maintenance practices has shown the decals have been cut in place, using some form of knife, to allow the decal to lie flush to the skin at these stepped locations. This operation results in scribe lines at the decal cut location. Based on service reports, sharp tools have also been used for close trimming of the decal’s outline. This type of decal trimming has also left scribe lines on the fuselage skin. The above maintenance operations can each lead to the same type of scribe line damage and subsequent premature fatigue cracks. Airplanes after line number 2309 are not included in the effectivity of this service bulletin because the Aircraft Maintenance Manual (AMM) procedure for paint/sealant removal has been revised. 737-800 series airplanes with a flat pressure bulkhead and 737-900ER series airplanes prior to line number 2310 are not included in the effectivity of this service bulletin. These airplanes have been verified as not being painted since delivery. Boeing Service Related Problem (SRP) 737NG-SRP-53-0245 is related to this service bulletin. Revision 01 is sent to clarify requirements for inspections of areas of the fuselage having decals and to remove airplanes YL501-YL503 from the effectivity.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**D. Description** At or before the scribe line inspection thresholds shown in this service bulletin, remove paint and sealant at the applicable zonal locations. Do an external detailed inspection of the skin, butt splice strap or approved repair doubler for any scribe line or any crack. If scribe lines are found, repair before further flight. As an alternative to immediate repair, for a scribe line that qualifies, the provided Limited Return to Service (LRTS) program may be used to allow airplanes to return to revenue flight for a limited period before scribe lines are repaired. This service bulletin contains a LRTS program. The LRTS program consists of repeat inspections to detect any crack where scribe lines were found. Total airplane flight cycles, location, and extent of scribe line must meet specific criteria in order for a scribe line to qualify for an LRTS program. Each affected structural location within an LRTS program will be terminated with a repair. This service bulletin has specific instructions for calculating separate inspection thresholds based on fatigue life for the identified locations. With the use of maintenance records, operators can implement the inspection program based on potential scribe line opportunities in an airplane’s maintenance history. If this maintenance records-based threshold program is not used, then 6,000 flight cycles shall be assigned as the cycle level when scribing occurred. Since a scribe line can occur at any time during the service life of an airplane and at many locations, this program uses both total flight cycles and structural criticality of location to determine the inspection requirements. Criticality of location allows this service bulletin to address the most critical areas first and to provide less critical areas with appropriately reduced compliance requirements. Criticality of location determines the inspection thresholds for each location. This service bulletin uses zones to address all of the critical locations and ranges of inspection thresholds. Each piece of structure susceptible to a scribe line is assigned to a zone. The affected structure in each zone (for each group of airplanes) is identified in individual figures in the service bulletin. Revision 01 - No more work is necessary on airplanes inspected as shown in the original issue of this service bulletin. **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. For airplanes which have incorporated Boeing Business Jet (BBJ) Lower Cabin Altitude Supplemental Type Certificate (STC) ST01697SE (6500 feet maximum cabin altitude in lieu of 8000 feet) as referenced in Boeing Service Bulletin 737-21-1149, the flight cycle related compliance times are different from those specified in this service bulletin. All initial compliance times (thresholds) specified in flight cycles must be reduced to half of those specified in this service bulletin. All repeat interval compliance times specified in flight cycles must be reduced to one-quarter of those specified in this service bulletin. 1. Inspection Exceptions: Certain inspections are not required under these conditions:Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

a. If operator’s records show that the airplane has never been stripped or repainted since delivery from Boeing, or the airplane was stripped or repainted after the date of July 1, 2007, then the lap joint, butt joint, repair and decal inspections are not required. b. If the operator’s records show the airplane has never had decals installed since delivery, or decals have been installed after the date of July 1, 2007 then the decal area inspections are not required. c. For each repair, if the operator’s records show that the airplane has never been stripped or repainted since the repair has been installed, or the repair was installed after the date of July 1, 2007, then the repair inspections for that specific repair are not required. d. If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then the lap joint and repair inspections in the areas under the wing-to-body fairing are not required. e. If the operator's records show that the removal of sealant at all times since delivery has been accomplished in accordance with the sealant removal process as shown in Appendix A of this service bulletin, or sealant was removed after the date of July 1, 2007, then the lap joint, butt joint and repair inspections are not required. f. If the operator's records show that decal installation and removal procedures were used, at all times since delivery, which included pre-cutting decals prior to installation on the airplane and no use of metallic tooling of any kind during the installation or removal of decals on the airplane, then the inspections per Tables 5 through 9 are not required. Group 1-5: Table 1: Skin Lap Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** All airplanes. Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions paragraph 3.B.1. Part 1 - Skin Lap Joint - Zone 1 Inspection. Before 40,000 total flight cycles plus first scribe line opportunity.(a) Within 4,000 flight cycles after the date on this service bulletin. -

All Airplanes Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.2. Part 2 - Skin Lap Joint - Zone 2 inspection. Before 50,000 total flight cycles plus first scribe line opportunity.(a) Within 4,000 flight cycles after the date on this service bulletin. -

No scribe line is found. (b) No further inspections are required.(c) ---

Any scribe line is found. (b) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(d) Before further flight. - -Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found less than 0.001 inch deep.(b) No further inspections are required.(c) Before further flight. - -

Scribe line is found before the Zone 1 or Zone 2 threshold was reached, and is within the limits of a typical scribe line. (b) Do a High Frequency Eddy Current (HFEC) inspection and Ultrasonic (UT) inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.12. Part 12 - Inspection Requirements for Scribes Found Prior to the Initial Inspection Threshold. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the lap joint in Zone 1 and is within limits of a typical scribe line. (b) Do a HFEC inspection and UT inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before 40,000 total flight cycles plus first scribe line opportunity.(a) - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the lap joint in Zone 2 and is within limits of a typical scribe line. (b) Do a HFEC inspection and UT inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before 50,000 total flight cycles plus first scribe line opportunity.(a) - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (b) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to a lap joint in Zone 1 that is within the limits of a typical scribe line with no crack indication. (b) In Zone 17 do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.a. Part 10 - LRTS program inspection.(e) Before 40,000 total flight cycles. Within 3,000 flight cycles after the scribe line is found. 3,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Group 1-5: Table 1: Skin Lap Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found common to a lap joint in Zone 2 that is within the limits of a typical scribe line with no crack indication. (b) In Zone 18 do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.b. Part 10 -LRTS program inspection.(e) Before 50,000 total flight cycles. Within 4,000 flight cycles after the scribe line is found. 4,000 flight cycles.

In Zone 19 do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.c. Part 10 -LRTS program inspection.(e) Before 50,000 total flight cycles. Within 3,000 flight cycles after the scribe line is found. 3,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first paint since delivery is available, then add the airplane flight cycles at first paint to the threshold. 2. If record of first paint since delivery is not available, add 6,000 flight cycles to the threshold. (b) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (c) No further inspections are required at this location, provided that the correct sealant removal procedure is used for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. (d) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. (e) As an option, an UT phased array inspection can be used to replace the UT inspection. Group 1-5: Table 1: Skin Lap Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Group 6-10: Table 2: Skin Lap Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** All airplanes. Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions paragraph 3.B.1. Part 1 - Skin Lap Joint - Zone 1 Inspection. Before 50,000 total flight cycles plus first scribe line opportunity. (a) Within 4,000 flight cycles after the date on this service bulletin. -

No scribe line or damage is found. (b) No further inspections are required.(c) ---

Any scribe line is found. (b) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(d) Before further flight. - -

Scribe line is found less than 0.001 inch deep.(b) No further inspections are required.(c) Before further flight. - -

Scribe line is found before the Zone 1 threshold was reached, and is within the limits of a typical scribe line. (b) Do a High Frequency Eddy Current (HFEC) inspection and Ultrasonic (UT) inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.12. Part 12 - Inspection Requirements for Scribes Found Prior to the Initial Inspection Threshold. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the lap joint in Zone 1 and is within limits of a typical scribe line. (b) Do a HFEC inspection and UT inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before 50,000 total flight cycles plus first scribe line opportunity.(a) - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (b) Contact Boeing for repair instructions and do the repair. Before further flight. - -Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found common to a lap joint in Zone 1 that is within the limits of a typical scribe line with no crack indication. (b) in Zone 17 do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.a. Part 10 - LRTS program inspection.(e) Before 50,000 total flight cycles. Within 4,000 flight cycles after the scribe line is found. 4,000 flight cycles.

In Zone 18 do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.b. Part 10 -LRTS program inspection.(e) Before 50,000 total flight cycles. Within 4,000 flight cycles after the scribe line is found. 4,000 flight cycles.

In Zone 19 do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.c. Part 10 -LRTS program inspection.(e) Before 50,000 total flight cycles. Within 3,000 flight cycles after the scribe line is found. 3,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first paint since delivery is available, then add the airplane flight cycles at first paint to the threshold. 2. If record of first paint since delivery is not available, add 6,000 flight cycles to the threshold. (b) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (c) No further inspections are required at this location, provided that the correct sealant removal procedure is used for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. (d) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. (e) As an option, an UT phased array inspection can be used to replace the UT inspection Group 6-10: Table 2: Skin Lap Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Group 1-3, 5-8, 10: Table 3: Circumferential Butt Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** All Airplanes. Do an external detailed inspection of circumferential butt joint STA 887 between S-10L and S-10R for any scribe line in accordance with the Accomplishment Instructions Paragraph 3.B.3. Part 3- Circumferential Butt Joint - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity. (a) Within 4,000 flight cycles after the date on this service bulletin. -

All Airplanes. Do an external detailed inspection of circumferential butt joint STA 360 between S-10L and S-10R for any scribe line in accordance with the Accomplishment Instructions Paragraph 3.B.3. Part 3 - Circumferential Butt Joint - Inspection. Before 45,000 total flight cycles plus first scribe line opportunity. (a) Within 4,000 flight cycles after the date on this service bulletin. -

No scribe line is found. No further inspections are required.(b) ---

Any scribe line is found. (c) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(d) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (c) No further inspections are required. (b) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection.(e) Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (c) Contact Boeing for repair instructions and do the repair. Before further flight. - -Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found common to circumferential butt joint at STA 360 that is within the limits of a typical scribe line with no crack indication. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.d. Part 10 - LRTS program Circumferential Butt Joint - repeat inspection.(e) Before 45,000 total flight cycles. Within 7,000 flight cycles after the scribe line is found. 7,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to circumferential butt joint at STA 887 that is within the limits of a typical scribe line with no crack indication. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10.d. Part 10 - LRTS program Circumferential Butt Joint - repeat inspection.(e) Before 40,000 total flight cycles. Within 6,000 flight cycles after the scribe line is found. 6,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first paint since delivery is available, then add the airplane cycles at first paint to the threshold. 2. If record of first paint since delivery is not available, add 6,000 flight cycles to the threshold. (b) No further inspections are required at this location, provided that the correct sealant removal procedure is used for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. (c) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (d) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. (e) If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. Group 1-3, 5-8, 10: Table 3: Circumferential Butt Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Group 4, 9: Table 4: Circumferential Butt Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** All Airplanes. Do an external detailed inspection of circumferential butt joint STA 727I between S-10L and S-10R for any scribe line in accordance with the Accomplishment Instructions Paragraph 3.B.3. Part 3- Circumferential Butt Joint - Inspection. Before 14,000 total flight cycles plus first scribe line opportunity.(a) Within 4,000 flight cycles after the date on this service bulletin. -

All Airplanes. Do an external detailed inspection of circumferential butt joint STA 500E between S-10L and S-10R for any scribe line in accordance with the Accomplishment Instructions Paragraph 3.B.3. Part 3- Circumferential Butt Joint - Inspection. Before 30,000 total flight cycles plus first scribe line opportunity.(a) Within 4,000 flight cycles after the date on this service bulletin. -

All Airplanes. Do an external detailed inspection of circumferential butt joint STA 887 between S-10L and S-10R for any scribe line in accordance with the Accomplishment Instructions Paragraph 3.B.3. Part 3- Circumferential Butt Joint - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity.(a) Within 4,000 flight cycles after the date on this service bulletin. -

All Airplanes. Do an external detailed inspection of circumferential butt joint STA 360 between S-10L and S-10R for any scribe line in accordance with the Accomplishment Instructions Paragraph 3.B.3. Part 3- Circumferential Butt Joint - Inspection. Before 45,000 total flight cycles plus first scribe line opportunity.(a) Within 4,000 flight cycles after the date on this service bulletin. -

No scribe line is found. No further inspections are required.(b) - - -

Any scribe line is found. (c) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found. (d) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (c) No further inspections are required. (b) Before further flight. - -Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found within the limits of a typical scribe line . (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection.(e) Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (c) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to circumferential butt joint STA 360 that is within the limits of a typical scribe line with no crack indication. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program Circumferential Butt Joint - repeat inspection.(e) Before 45,000 total flight cycles. Within 7,000 flight cycles after the scribe line is found. 7,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to circumferential butt joint STA 887 that is within the limits of a typical scribe line with no crack indication. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program Circumferential Butt Joint - repeat inspection.(e) Before 40,000 total flight cycles. Within 6,000 flight cycles after the scribe line is found. 6,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Group 4, 9: Table 4: Circumferential Butt Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found common to circumferential butt joint STA 500E that is within the limits of a typical scribe line with no crack indication. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program Circumferential Butt Joint - repeat inspection.(e) Before 30,000 total flight cycles. Within 3,000 flight cycles after the scribe line is found. 3,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to circumferential butt joint STA 727I that is within the limits of a typical scribe line with no crack indication. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection of the scribe line for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program Circumferential Butt Joint - repeat inspection.(e) Before 14,000 total flight cycles. Within 3,000 flight cycles after the scribe line is found. 3,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first paint since delivery is available, then add the airplane cycles at first paint to the threshold. 2. If record of first paint since delivery is not available, add 6,000 flight cycles to the threshold. (b) No further inspections are required at this location, provided that the correct sealant removal procedure is used for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. (c) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (d) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. (e) If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. Group 4, 9: Table 4: Circumferential Butt Joint - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Group 1, 6: Table 5: Decal Zone 3, Zone 4, Zone 5, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** Decal Installed in Zone 3. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 60,000 total flight cycles plus first scribe line opportunity.(b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 60,000 total flight cycles plus first scribe line opportunity.(b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

Decal Installed in Zone 4. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 40,000 total flight cycles plus first scribe line opportunity.(b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity.(b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

Decal Installed in Zone 5. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 25,000 total flight cycles plus first scribe line opportunity.(b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 25,000 total flight cycles plus first scribe line opportunity.(b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

No scribe line is found. (d) No further inspections are required.(e) - - -Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Any scribe line is found. (d) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(f) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (d) No further inspections are required. (e) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (d) Do a HFEC inspection for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (d) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to the decals in Zone 3 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 3 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection.(a) Before 60,000 total flight cycles. Within 10,000 flight cycles after the scribe line is found. 10,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the decals in Zone 4 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 4 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection.(a) Before 40,000 total flight cycles. Within 5,000 flight cycles after the scribe line is found. 5,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the decals in Zone 5 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 5 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection.(a) Before 25,000 total flight cycles. Within 2,500 flight cycles after the scribe line is found. 2,500 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Group 1, 6: Table 5: Decal Zone 3, Zone 4, Zone 5, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) Refer to Figure 20 of this service bulletin for definition of Zones 3, 4 and 5. (b) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first decal installation since delivery is available, then add the airplane flight cycles at first decal installation to the threshold. 2. If record of first decal installation since delivery is not available, add 6,000 flight cycles to the threshold. (c) Accomplishment of the detailed inspection is terminating action for the general visual repeat inspections. (d) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (e) No further inspections are required at this location. (f) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. Group 2, 7: Table 6: Decal Zone 6, Zone 7, Zone 8, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** Decal Installed in Zone 6. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles. (c) Group 1, 6: Table 5: Decal Zone 3, Zone 4, Zone 5, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Decal Installed in Zone 7. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles. (c)

Decal Installed in Zone 8. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 25,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 25,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles. (c)

No scribe line is found. (d) No further inspections are required.(e) - - -

Any scribe line is found. (d) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(f) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (d) No further inspections are required. (e) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (d) Do a HFEC inspection for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Group 2, 7: Table 6: Decal Zone 6, Zone 7, Zone 8, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found not within the limits of a typical scribe line. (d) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to the decals in Zone 6 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 6 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 60,000 total flight cycles. Within 10,000 flight cycles after the scribe line is found. 10,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the decals in Zone 7 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 7 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 40,000 total flight cycles. Within 5,000 flight cycles after the scribe line is found. 5,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the decals in Zone 8 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 8 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection.(a) Before 25,000 total flight cycles. Within 2,500 flight cycles after the scribe line is found. 2,500 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) Refer to Figure 21 of this service bulletin for definition of Zones 6, 7 and 8. (b) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first decal installation since delivery is available, then add the airplane flight cycles at first decal installation to the threshold. 2. If record of first decal installation since delivery is not available, add 6,000 flight cycles to the threshold. (c) Accomplishment of the detailed inspection is terminating action for the general visual repeat inspections. Group 2, 7: Table 6: Decal Zone 6, Zone 7, Zone 8, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(d) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (e) No further inspections are required at this location. (f) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. Group 3, 8: Table 7: Decal Zone 9, Zone 10, Zone 11, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** Decal Installed in Zone 9. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection
Or Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

Decal Installed in Zone 10. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

Decal Installed in Zone 11. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 25,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 25,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c) Group 2, 7: Table 6: Decal Zone 6, Zone 7, Zone 8, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

No scribe line is found. (d) No further inspections are required.(e) - - -

Any scribe line is found. (d) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(f) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (d) No further inspections are required. (e) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (d) Do a HFEC inspection for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (d) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to the decals in Zone 9 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 9 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 60,000 total flight cycles. Within 10,000 flight cycles after the scribe line is found. 10,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the decals in Zone 10 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 10 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 40,000 total flight cycles. Within 5,000 flight cycles after the scribe line is found. 5,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Group 3, 8: Table 7: Decal Zone 9, Zone 10, Zone 11, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found common to the decals in Zone 11 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 11 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with the Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 25,000 total flight cycles. Within 2,500 flight cycles after the scribe line is found. 2,500 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) Refer to Figure 22 of this service bulletin for definition of Zones 9, 10 and 11. (b) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first decal installation since delivery is available, then add the airplane flight cycles at first decal installation to the threshold. 2. If record of first decal installation since delivery is not available, add 6,000 flight cycles to the threshold. (c) Accomplishment of the detailed inspection is terminating action for the general visual repeat inspections. (d) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (e) No further inspections are required at this location. (f) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. Group 3, 8: Table 7: Decal Zone 9, Zone 10, Zone 11, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Group 4, 9: Table 8: Decal Zone 12, Zone 13, Zone 14, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** Decal Installed in Zone 12. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

Decal Installed in Zone 13. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

Decal Installed in Zone 14. (a) Do an external detailed inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 25,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with the Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 25,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

No scribe line is found. (d) No further inspections are required.(e) - - -Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Any scribe line is found. (d) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found. (f) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (d) No further inspections are required. (e) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (d) Do a HFEC inspection for any crack in accordance with Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (d) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to the decals in Zone 12 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 12 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 60,000 total flight cycles. Within 10,000 flight cycles after the scribe line is found. 10,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the decals in Zone 13 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 13 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 40,000 total flight cycles. Within 5,000 flight cycles after the scribe line is found. 5,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to the decals in Zone 14 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 14 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection. (a) Before 25,000 total flight cycles. Within 2,500 flight cycles after the scribe line is found. 2,500 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Group 4, 9: Table 8: Decal Zone 12, Zone 13, Zone 14, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) Refer to Figure 23 of this service bulletin for definition of Zones 12, 13 and 14. (b) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first decal installation since delivery is available, then add the airplane flight cycles at first decal installation to the threshold. 2. If record of first decal installation since delivery is not available, add 6,000 flight cycles to the threshold. (c) Accomplishment of the detailed inspection is terminating action for the general visual repeat inspections. (d) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (e) No further inspections are required at this location. (f) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. Group 5, 10: Table 9: Decal Zone 15, Zone 16 - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** Decal Installed in Zone 15. (a) Do an external detailed inspection for any scribe line at the locations in accordance with Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 60,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c) Group 4, 9: Table 8: Decal Zone 12, Zone 13, Zone 14, - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Decal Installed in Zone 16. (a) Do an external detailed inspection for any scribe line at the locations in accordance with Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection.
Or Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. -

Do an external general visual inspection for any scribe line at the locations in accordance with Accomplishment Instructions Paragraph 3.B.4. Part 4 - Decal - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity. (b) Within 4,000 flight cycles after the date on this service bulletin. 1,000 flight cycles.(c)

No scribe line is found. (d) No further inspections are required.(e) ---

Any scribe line is found. (d) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found. (f) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (d) No further inspections are required. (d) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (d) Do a HFEC inspection for any crack in accordance with Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (d) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to the decals in Zone 15 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 15 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection.(a) Before 60,000 total flight cycles. Within 10,000 flight cycles after the scribe line is found. 10,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Group 5, 10: Table 9: Decal Zone 15, Zone 16 - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 62 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found common to the decals in Zone 16 that is within the limits of a typical scribe line with no crack indication. (a)(d) In Zone 16 do an external detailed inspection and HFEC inspection of the scribe lines for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program repeat inspection.(a) Before 40,000 total flight cycles. Within 5,000 flight cycles after the scribe line is found. 5,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) Refer to Figure 24 of this service bulletin for definition of Zones 15 and 16. (b) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If record of first decal installation since delivery is available, then add the airplane flight cycles at first decal installation to the threshold. 2. If record of first decal installation since delivery is not available, add 6,000 flight cycles to the threshold. (c) Accomplishment of the detailed inspection is terminating action for the general visual repeat inspections. (d) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (e) No further inspections are required at this location. (f) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. Group 5, 10: Table 9: Decal Zone 15, Zone 16 - Scribe Line Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Table 10: External Approved Repair - Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** Existing external approved repair located between STA 360 and STA 1016 and below S-10L and S-10R which is 20 inches or longer in the fore and aft direction with no circumferential limitations. (a) Determine the thickness of the parent skin in the area of the external approved repair in accordance with Accomplishment Instructions Paragraph 3.B.5. Part 5 - External Approved Repair - Inspection. Before 20,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

Existing external approved repair located between STA 360 and STA 1016 and above S-10L and S-10R which is 20 inches or longer in the fore and aft direction or wider than 12 inches circumferentially. (b) Determine the thickness of the parent skin in the area of the external approved repair in accordance with Accomplishment Instructions Paragraph 3.B.5. Part 5 - External Approved Repair - Inspection. Before 20,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

Parent skin thickness 0.040 - 0.044 inch in the area of the external approved repair. Do an external detailed inspection for any scribe line around the edge of the repair in accordance with Accomplishment Instructions Paragraph 3.B.5. Part 5 - External Approved Repair - Inspection. Before 20,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

Parent skin thickness 0.045 - 0.049 inch in the area of the external approved repair. Do an external detailed inspection for any scribe line around the edge of the repair in accordance with Accomplishment Instructions Paragraph 3.B.5. Part 5 - External Approved Repair - Inspection. Before 30,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

Parent skin thickness 0.050 - 0.055 inch in the area of the external approved repair. Do an external detailed inspection for any scribe line around the edge of the repair in accordance with Accomplishment Instructions Paragraph 3.B.5. Part 5 - External Approved Repair - Inspection. (a)(b) Before 50,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

No scribe line is found. No further inspections are required.(d) ---Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Any scribe line is found. (e) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(f) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (e) No further inspections are required. (d) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (e) Do an UT inspection and HFEC inspection for any crack in accordance with Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (e) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to external approved repair with parent skin thickness 0.040 - 0.044 inch and within the limits of a typical scribe line with no crack indication. (e) Do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program external approved repair repeat inspection.(g) Before 20,000 total flight cycles. Within 1,500 flight cycles after the scribe line is found. 1,500 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found common to external approved repair with Parent skin thickness 0.045 - 0.049 inch and within the limits of a typical scribe line with no crack indication. (e) Do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program external approved repair repeat inspection.(g) Before 30,000 total flight cycles. Within 2,000 flight cycles after the scribe line is found. 2,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - Table 10: External Approved Repair - Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Scribe line is found common to external approved repair with Parent skin thickness 0.050 - 0.055 inch and within the limits of a typical scribe line with no crack indication. (e) Do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program external approved repair repeat inspection.(g) Before 50,000 total flight cycles. Within 3,000 flight cycles after the scribe line is found. 3,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - - If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) Inspection is not required on external approved repairs, if all the repair is located below stringer 10 left and stringer 10 right and is less than 20 inches long in the fore and aft direction. (b) Inspection is not required around external approved repairs located above stringer 10 left and stringer 10 right which are less than 20 inches long in the fore and aft direction and smaller than 12 inches wide circumferentially. (c) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If records for repair and paint are unavailable, add 6,000 flight cycles to the threshold. 2. If only repair record is available, add the total airplane flight cycles at the time the repair was installed or 6,000 flight cycles, whichever is more, to the threshold. 3. If only paint record is available, add the airplane flight cycles at first paint to threshold. 4. If both paint and repair records are available, add the airplane flight cycles at the first re-paint after the installation of the repair to the threshold. (d) No further inspections are required at this location, provided that the correct sealant removal procedure is used for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. (e) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (f) As an alternative, an optical micrometer may be used to determine scribe depth greater than 0.001 inch. (g) As an option, an UT phased array inspection can be used to replace the UT inspection. Table 10: External Approved Repair - Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Table 11: Internal Approved Repair - Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)** Existing internal approved repair located between STA 360 and STA 1016 and below S-10L and S-10Rand the skin cutout is greater than 20 inches long in the fore and aft direction with no circumferential limitations. (a) Determine the thickness of the parent skin in the area of the internal approved repair in accordance with Accomplishment Instructions Paragraph 3.B.6. Part 6 - Internal Approved Repair - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

Existing internal approved repair located between STA 360 and STA 1016 and above S-10L and S-10Rand the skin cutout is greater than 20 inches long in the fore and aft direction or wider than 12 inches circumferentially. (b) Determine the thickness of the parent skin in the area of the internal approved repair in accordance with Accomplishment Instructions Paragraph 3.B.6. Part 6 - Internal Approved Repair - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

Parent skin thickness 0.040 - 0.044 inch inches in the area of the internal approved repair. Do an external detailed inspection for any scribe line around the edge of the repair in accordance with Accomplishment Instructions Paragraph 3.B.6. Part 6 - Internal Approved Repair - Inspection. Before 40,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

Parent skin thickness 0.045 - 0.049 inch in the area of the internal approved repair. Do an external detailed inspection for any scribe line around the edge of the repair in accordance with Accomplishment Instructions Paragraph 3.B.6. Part 6 - Internal Approved Repair - Inspection. (a)(b) Before 50,000 total flight cycles plus first scribe line opportunity.(c) Within 4,000 flight cycles after the date on this service bulletin. -

No scribe line is found. No further inspections are required.(d) - - -Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 67 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Any scribe line is found. (e) Do an external detailed inspection and a laser measurement inspection to determine the scribe line depth in accordance with Accomplishment Instructions Paragraph 3.B.8. Part 8 - Scribe Line Found.(f) Before further flight. - -

Scribe line is found less than 0.001 inch deep. (e) No further inspections are required.(d) Before further flight. - -

Scribe line is found within the limits of a typical scribe line. (e) Do an UT inspection and HFEC inspection for any crack in accordance with Accomplishment Instructions Paragraph 3.B.9. Part 9 - Scribe Line Inspection. Before further flight. - -

Or contact Boeing for repair instructions and do the repair. Before further flight. - -
Scribe line is found not within the limits of a typical scribe line. (e) Contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to internal approved repair with parent skin thickness 0.040 - 0.044 inch and within the limits of a typical scribe line with no crack indication. (e) Do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program internal approved repair repeat inspection.(g) Before 40,000 total flight cycles. Within 2,000 flight cycles after the scribe line is found. 2,000 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -

Scribe line is found common to internal approved repair with parent skin thickness 0.045 - 0.049 inch and within the limits of a typical scribe line with no crack indication. (e) Do an external detailed inspection, HFEC inspection and UT inspection or UT phased array inspection of the scribe line for any crack in accordance with Accomplishment Instructions Paragraph 3.B.10. Part 10 - LRTS program internal approved repair repeat inspection.(g) Before 50,000 total flight cycles. Within 2,500 flight cycles after the scribe line is found. 2,500 flight cycles.

Or contact Boeing for repair instructions and do the repair. Before further flight. - -

If any crack is found. Contact Boeing for repair instructions and do the repair. Before further flight. - - Table 11: Internal Approved Repair - Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 68 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**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 inspection 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 All airplanes with scribe line using a LRTS program inspection. Contact Boeing for additional inspections or repair. Before 75,000 total flight cycles. - -

(a) Inspection is not required on internal approved repairs, if all the repair is located below stringer 10 left and stringer 10 right and is less than 20 inches long in the fore and aft direction. (b) Inspection is not required around internal approved repairs located above stringer 10 left and stringer 10 right which are less than 20 inches long in the fore and aft direction and smaller than 12 inches wide circumferentially. (c) First scribe line opportunity is provided by maintenance records. Adjust the compliance time as given below: 1. If records for repair and paint are unavailable, add 6,000 flight cycles to the threshold. 2. If only repair record is available, add the total airplane flight cycles at the time the repair was installed or 6,000 flight cycles, whichever is more, to the threshold. 3. If only paint record is available, add the airplane flight cycles at first paint to threshold. 4. If both paint and repair records are available, add the airplane flight cycles at the first re-paint after the installation of the repair to the threshold. (d) No further inspections are required at this location, provided that the correct sealant removal procedure is used for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. (e) Refer to Accomplishment Instructions Paragraph 3.B.7. Part 7 - for definition of a typical scribe line. (f) The repair dimensions are measured relative to the size of the skin cut-out for internal repair. (g) As an option, an UT phased array inspection can be used to replace the UT inspection Table 11: Internal Approved Repair - Inspection

**Condition Action Compliance Time**  **(Whichever Occurs Later) Repeat Interval**  **(Not to Exceed)**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 69 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

— 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. Group 1:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 1 2 7.00 (a) 3.50 (a) Figure 11 2 9.50 (a) 4.75 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 20 4 24.00 (a) 6.00 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 27 - (b) (b) Figure 32 - (b) (b) Figure 37 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 42.00 15.75 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 2:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 2 2 7.00 (a) 3.50 (a) Figure 12 2 9.50 (a) 4.75 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 21 4 26.00 (a) 6.50 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 28 - (b) (b) Figure 33 - (b) (b)Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 70 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Figure 38 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 44.00 16.25 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 3:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 3 2 7.00 (a) 3.50 (a) Figure 13 2 9.50 (a) 4.75 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 22 4 35.00 (a) 8.75 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 29 - (b) (b) Figure 34 - (b) (b) Figure 39 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 53.00 18.50 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 2:

**Task Number of**  **Persons Task Hours Elapsed Hours**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 71 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Group 4:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 4 2 7.00 (a) 3.50 (a) Figure 14 2 9.50 (a) 4.75 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 18 1 0.75 (a) 0.75 (a) Figure 19 1 0.75 (a) 0.75 (a) Figure 23 4 25.00 (a) 6.25 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 30 - (b) (b) Figure 35 - (b) (b) Figure 40 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 44 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 44.50 17.50 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 5:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 5 2 6.00 (a) 3.00 (a) Figure 15 2 9.00 (a) 4.50 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 24 4 13.00 (a) 3.25 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 31 - (b) (b) Figure 36 - (b) (b) Figure 41 - (b) (b) Figure 42 - (b) (b)Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 72 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 29.50 12.25 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 6:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 6 4 16.00 (a) 4.00 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 20 4 24.00 (a) 6.00 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 27 - (b) (b) Figure 32 - (b) (b) Figure 37 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 41.50 11.50 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 7:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 7 4 16.00 (a) 4.00 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Group 5:

**Task Number of**  **Persons Task Hours Elapsed Hours**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 73 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Figure 21 4 26.00 (a) 6.50 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 28 - (b) (b) Figure 33 - (b) (b) Figure 38 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 43.50 12.00 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 8:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 8 4 16.00 (a) 4.00 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0,75 (a) 0.75 (a) Figure 22 4 35.00 (a) 8.75 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 29 - (b) (b) Figure 34 - (b) (b) Figure 39 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 52.50 14.25 Group 7:

**Task Number of**  **Persons Task Hours Elapsed Hours**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 74 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 9:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 9 4 16.00 (a) 4.00 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 18 1 0.75 (a) 0.75 (a) Figure 19 1 0.75 (a) 0.75 (a) Figure 23 4 25.00 (a) 6.25 (a) Figure 25 - (c) (c) Figure 26 - (c) (c) Figure 30 - (b) (b) Figure 35 - (b) (b) Figure 40 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 44 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 44.00 13.25 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 10:

**Task Number of**  **Persons Task Hours Elapsed Hours** Figure 10 4 15.00 (a) 3.75 (a) Figure 16 1 0.75 (a) 0.75 (a) Figure 17 1 0.75 (a) 0.75 (a) Figure 24 4 13.00 (a) 3.25 (a) Figure 25 - (c) (c) Group 8:

**Task Number of**  **Persons Task Hours Elapsed Hours**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 75 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**H. Weight and Balance Changes**

None.

**I. Electrical Load Data** Not applicable.
**J. References** 1. Existing Data: a. 737 Structural Repair Manual (SRM) Chapter 53. b. 737-600/700/800/900 Aircraft Maintenance Manual (AMM) 06-41-00, 51-21-00, 51-31-00. c. 737 Non-Destructive Testing (NDT) Manual, Part 10, 53-30-01, Part 4, 51-00-00 Figure 2, Part 4, 53-30-05, Part 4, 53-30-06, Part 6, 51-00-00 Figure 4, Figure 23, Part 6, 53-30-22, Part 6, 53-30-23, Part 6, 53-30-24, Part 6, 53-30-26, Part 6, 53-30-27, Part 6, 53-30-29. d. Boeing Drawing 65-88700. e. Boeing Parts Standards Document D-590. f. Service Related Problem (SRP) 737NG-SRP-53-0245. g. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-43-03.

Figure 26 - (c) (c) Figure 31 - (b) (b) Figure 36 - (b) (b) Figure 41 - (b) (b) Figure 42 - (b) (b) Figure 43 - (b) (b) Figure 45 - (b) (b) Figure 46 - (b) (b) Figure 47 - (b) (b) TOTAL FOR EACH AIRPLANE 29.50 8.50 (a) Additional time is required for paint and sealant removal. (b) More time will be required for additional inspections and repairs if scribe lines or other damage is found. (c) More time may be required for inspections around large approved repairs. Group 10:

**Task Number of**  **Persons Task Hours Elapsed Hours**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 76 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

2. Data supplied with this Service Bulletin:

None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:

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 **Drawing Number Title** 141A3110 Skin Installation - Entry Door Panel 141A3310 Skin Installation - Galley Door Panel 141A3502 Skin Installation - Lower Lobe, Section 41 141A3702 Skin Installation - Side Panel, Section 41 141A3910 Crown Panel Installation, Section 41 143A0070 Skin Integration Installation - S-14L to S-14R, STA 360 to STA 540 143A3110 Skin Installation - S-4L to S-4R, STA 360 to 540 143A3130 Skin Installation - S-4 to S-10, STA 360 to 540 143A3150 Skin Installation - S-10 to S-14, STA 360 to 540 143A3210 Skin Installation - STA 360 to 540, S-14L to S-24L 143A3230 Skin Installation - Section 43, Lower Lobe, S-24L to S-24R 143A3250 Skin Installation - STA 360 to 540, S-14R to S-24R 144A3101 Skin Installation - S-9L to S-9R, STA 540 to 727 144A3102 Skin Installation - S-10L to S-10R, STA 540 to 727 144A3301 Skin Installation - STA 540 to STA 727, S-10 to S-18A 144A3302 Skin Installation - STA 540 to STA 727, S-10 to S-18A 144A3311 Skin Assembly - STA 540 to STA 727, S-10 to S-18A 146A3100 Skin Installation, S-4L to S-4R, STA 727 To 888 146A3130 Skin Installation, S-4 to S-10, STA 727 To 888 146A3150 Skin Installation, S-10 to S-14, STA 727 To 888 146A3200 Skin Installation, S-14L to S-23L, STA 727 STA 888 146A3230 Skin Installation, S-23L to S-23R, STA 727 STA 888 146A3250 Skin Installation, S-14R to S-23R, STA 727 STA 888 147A0010 Panel Installation - Entry, Section 47 147A0020 Panel Installation - Galley, Section 47 147A0030 Crown Panel Installation - Section 47 147A0040 Lower Panel Installation - Section 47 147A3100 Skin Assembly - STA 888 to STA 1016, S-4L/R TO S-23L/ROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 77 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

None. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 78 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

BLANK PAGEOriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 79 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**2. MATERIAL INFORMATION A. Material - Price and Availability** 

None. **B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes 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:

3. Parts Modified and Reidentified:

None. 4. Parts Removed and Not Replaced:

None. **D. Parts Necessary to Change Spares**

None. **Part Number / Specification QTY Name Notes**  Type 2, Class A 10 Ounces Chemical Conversion Coating (b)(c)(g) BMS 10-11 Type 1 24 Ounces Primer (a)(c)(g) BMS 10-72 24 Ounces Primer Plus Enamel (a)(c)(d)(e)(f)(g) BMS 10-79, Type II 24 Ounces Primer (a)(c)(d)(e)(f)(g) BMS 10-60, Type II 24 Ounces Topcoat (a)(c)(d)(e)(f)(g) (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Refer to SOPM 20-43-03 or 737 Structural Repair Manual (SRM), Chapter 51 for material sources. (c) This part is only necessary if paint is removed. (d) This part is only necessary if BMS 10-79 and BMS 10-60 or the operators normal decorative paint system is not used. (e) This part is only necessary if BMS 10-72 or the operators normal decorative paint system is not used. (f) Refer to 737-600/700/800/900 AMM 51-21-00 as an accepted procedure for decorative exterior paint system application. (g) The quantity given is an approximation. The actual quantity required will vary depending on the results of the scribe line inspections.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 80 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**E. Special Tooling - Price and Availability** The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Tool price and supply data are not given. **F. Special Tooling Necessary to do this Service Bulletin** To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available.

**Tool Kit Number Name** Model Number 8400K Digital Optical Micrometer (a) (b) Model 966 (Part Number 125632-1) or Model 966A (Part Number 125632) Optical Micrometer (a) (c)
Inspect Cam Model SDMS Laser Measurement System (d) a These are typical optical micrometers. b Rene Company 1005 S. Mountain Ave. Monrovia, Ca. 91016 USA
Toll free: 866.358.9955 Tel: 626.358.9955 Fax: 626.358.1448 Email: info@renecompany.com c Taber® Industries 455 Bryant Street North Tonawanda, New York 14120 USA Toll-Free: 800.333.5300 (in USA or Canada) Phone: 716.694.4000 Fax: 716.694.1450 d Remote Vision Solutions PTY LTD Unit 1 118 Church Street Hawthorn, 3122, Victoria AUSTRALIA Phone: +61 3 9815 0933 Fax: +61 3 9818 5597 sales@remotevs.com US Representative: David Hexter Dallas Texas Cell Phone 817 504 8320 dhexter@remotevs.comOriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 81 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**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. 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. 5. 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. 6. 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 ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal 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. 7. These work instructions refer to procedures included on 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. Refer to Appendix A for sealant removal procedures for exterior pressurized fuselage skin. 9. Refer to Appendix B for reporting system for limited return to service procedure for scribe line airplanes.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 82 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

10. Refer to Appendix C for airplane fuselage scribe line mark summary tables. 11. Refer to Appendix D for scribe line sample. Appendix D includes information for the fabrication or purchase of a scribe line sample for use as a training aid. The use of this sample is not required when performing actions of this service bulletin. This sample is an aid in identifying what a scribe line may look and feel like but is not intended to show all damage that is considered a scribe line. When identifying scribe lines see the definition of a typical scribe line in Part 7 of the accomplishment instructions. 12. In the figures, lap joints and butt joints areas to be inspected are indicated with heavy lines. Decal and repair areas to be inspected are shaded. 13. No repair or additional inspection is required for scribes found in fuselage skin areas not shown in this service bulletin provided they are typical as defined in Part 7, and 0.006 inch or less deep. Contact Boeing if scribe lines are found outside of areas noted in this service bulletin that are deeper than 0.006 inch for repair and inspection instructions. 14. Refer to Part 7 for the definition of a typical scribe line. 15. If an optical micrometer or laser measurement system cannot be used because the upper skin of the lap joint covers a scribe line, then the scribe line depth does not need to be determined at that location.These scribe lines must be considered typical and therefore all inspection and other requirements for a typical scribe line apply. 16. It is required that individuals performing ultrasonic inspections on airplanes with scribe lines to detect cracks per the relevant procedures must be recognized by the operator or repair station as qualified to perform ultrasonic inspections on their airplanes and meet at least one of the following criteria: — The individual must be qualified to at least Level II in the ultrasonic method in accordance with an accepted industry standard, i.e. ATA Specification 105, Mil-Std.-410, NAS-410, SNT-TC-1A, or EN-4179 or equivalent. or — The individual has received specific Boeing training with Boeing providing a certificate stating that the individual has satisfactorily completed the training in the specific techniques. or — The individual has a level I in the ultrasonic method in accordance with an accepted industry standard and has received specific training and a statement from the qualifying entity (employer) that the individual is qualified for this particular inspection. 17. If scribe lines are found during any of the inspections contained in this service bulletin, when determining the requirements for inspection and repair, each scribe line shall be considered individually. 18. Approved repair is identified as any SRM repair, repair provided and approved by Boeing for specific cases that were requested by the operator, or operator developed repair that has Boeing approved Damage Tolerance Analysis. 19. Contact Boeing if any scribe line is detected at a non Boeing approved repair.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 83 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**B. WORK INSTRUCTIONS**

1. **PART 1 - SKIN LAP JOINT - ZONE 1 INSPECTION** Do the skin lap joint - Zone 1 inspection as follows: a. Group 1: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 1. (a) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (b) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 1. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. b. Group 2: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 2. (a) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (b) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 84 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 2. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. c. Group 3: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 3. (a) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (b) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 3. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 85 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

d. Group 4: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 4. (a) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (b) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 4. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. e. Group 5: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 5. (a) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (b) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 5. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 86 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. f. Group 6: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 6. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 6. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 87 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. g. Group 7: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 7. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 7. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 88 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. h. Group 8: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 8. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 8. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 89 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. i. Group 9: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 9. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 9. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 90 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. j. Group 10: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 10. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 10. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 91 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration.

2. **PART 2 - SKIN LAP JOINT - ZONE 2 INSPECTION** Do the skin lap joint - Zone 2 inspection at the time given in Paragraph 1. E., Compliance as follows: a. Group 1: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 11. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 11. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 92 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. b. Group 2: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 12. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 12. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 93 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. c. Group 3: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 13. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 13. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 94 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. d. Group 4: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 14. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 14. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 95 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. e. Group 5: (1) Prepare the skin lap joint for inspection as shown below and at the locations in accordance with Figure 15. (a) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

**NOTE:** If the operator’s records show that the airplane has never been stripped or repainted under the wing-to-body fairings since delivery from Boeing, or the airplane was stripped or repainted under the wing-to-body fairings after the date of July 1, 2007, then inspections in the areas under the wing-to-body fairing are not required.

(b) Remove the sealant as required from the lower edge of all affected lap joints. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (c) Remove the paint as required from below the lower edge of all affected lap joints. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (2) Do an external detailed inspection of the fuselage skin for any scribe line in accordance with Figure 15. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 96 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inches of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. f. Group 6-10: (1) Zone 2 inspections are not required.

3. **PART 3 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION** Do the circumferential butt joint - inspection at the time given in Paragraph 1. E., Compliance as follows:

**NOTE:** If a repair or modification is common to the butt joint and an external scribe line crack inspection is required contact Boeing for the proper inspection method.

a. **Circumferential Butt Joint - STA 360** (1) Prepare the circumferential butt joint STA 360 for inspection as shown below and in accordance with Figure 16. (a) Remove the sealant as required from within the gap of the affected butt joint. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal.

**NOTE:** It is recommended that the primer and paint, if present, not be removed from the butt joint splice plate. If the primer is removed, do not use chemical stripper. (2) Do an external detailed inspection of the circumferential butt joint splice plate for any scribe lines in accordance with Figure 16. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** Scribe lines at butt joints are normally found on the splice plate in the gap between the forward and aft skin edges and run along the butt joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 97 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration.

b. **Circumferential Butt Joint - STA 887** (1) Prepare the circumferential butt joint STA 887 for inspection as shown below and in accordance with Figure 17. (a) Remove the sealant as required from within the gap of the affected butt joint. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal.

**NOTE:** It is recommended that the primer and paint, if present, not be removed from the butt joint splice plate. If the primer is removed, do not use chemical stripper. (2) Do an external detailed inspection of the circumferential butt joint splice plate for any scribe lines in accordance with Figure 17. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** Scribe lines at butt joints are normally found on the splice plate in the gap between the forward and aft skin edges and run along the butt joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. c. Group 4, 9: **Circumferential Butt Joint - STA 500E** (1) Prepare the circumferential butt joint STA 500E for inspection as shown below and in accordance with Figure 18. (a) Remove the sealant as required from within the gap of the affected butt joint. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal.

**NOTE:** It is recommended that the primer and paint, if present, not be removed from the butt joint splice plate. If the primer is removed, do not use chemical stripper. (2) Do an external detailed inspection of the circumferential butt joint splice plate for any scribe lines in accordance with Figure 18. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 98 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** Scribe lines at butt joints are normally found on the splice plate in the gap between the forward and aft skin edges and run along the butt joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration. d. Group 4, 9: **Circumferential Butt Joint - STA 727I** (1) Prepare the circumferential butt joint STA 727I for inspection as shown below and in accordance with Figure 19. (a) Remove the sealant as required from within the gap of the affected butt joint. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal.

**NOTE:** It is recommended that the primer and paint, if present, not be removed from the butt joint splice plate. If the primer is removed, do not use chemical stripper. (2) Do an external detailed inspection of the circumferential butt joint splice plate for any scribe lines in accordance with Figure 19. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** Scribe lines at butt joints are normally found on the splice plate in the gap between the forward and aft skin edges and run along the butt joint. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration.

4. **PART 4 - DECAL - INSPECTION** Do the Zone inspection in areas where decals are installed and at the time given in Paragraph 1.E., Compliance as follows: a. Group 1, 6: (1) Do one of the inspection options that follow: (a) Detailed inspection.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 99 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

1) Prepare the decal Zone for inspection as shown below and at the locations in accordance with Figure 20. {a} Remove the paint as required from the applicable Zone area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal.

**NOTE:** 1. If decals were previously installed, and it can be determined where the edges of the decals previously were, remove the paint from the area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal. 2. If decals were previously installed, but it can not be determined where the edges of the decal were, remove the paint from all of the affected Zone decal locations. If necessary, use the sealant removal instructions in Appendix A of this service bulletin. 2) Do an external detailed inspection of the fuselage skin for scribe lines in the areas of bare skin in and around decal Zone locations in accordance with Figure 20. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, no further inspection is required at this location. Do the Part 11 - Surface Finish Restoration. (b) General visual inspections.

**NOTE:** The general visual inspections can be accomplished without paint removal. 1) Do a general visual inspection of the entire decal area for any scribe lines. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, repeat the general visual inspections at the time given in paragraph 1.E. Compliance or until the detailed inspections in decal areas as given above have been accomplished.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 100 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

b. Group 2, 7: (1) Do one of the inspection options that follow: (a) Detailed inspection. 1) Prepare the decal Zone for inspection as shown below and at the locations in accordance with Figure 21. {a} Remove the paint as required from the applicable Zone area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal.

**NOTE:** 1. If decals were previously installed, and it can be determined where the edges of the decals previously were, remove the paint from the area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal. 2. If decals were previously installed, but it can not be determined where the edges of the decal were, remove the paint from all of the affected Zone decal locations. If necessary, use the sealant removal instructions in Appendix A of this service bulletin. 2) Do an external detailed inspection of the fuselage skin for scribe lines in the areas of bare skin in and around decal Zone locations in accordance with Figure 21. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, no further inspection is required at this location. Do the Part 11 - Surface Finish Restoration. (b) General visual inspections.

**NOTE:** The general visual inspections can be accomplished without paint removal. 1) Do a general visual inspection of the entire decal area for any scribe lines. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 101 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

{c} If no scribe line is found, repeat the general visual inspections at the time given in paragraph 1.E. Compliance or until the detailed inspections in decal areas as given above have been accomplished. c. Group 3, 8: (1) Do one of the inspection options that follow: (a) Detailed inspection. 1) Prepare the decal Zone for inspection as shown below and at the locations in accordance with Figure 22. {a} Remove the paint as required from the applicable Zone area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal.

**NOTE:** 1. If decals were previously installed, and it can be determined where the edges of the decals previously were, remove the paint from the area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal. 2. If decals were previously installed, but it can not be determined where the edges of the decal were, remove the paint from all of the affected Zone decal locations. If necessary, use the sealant removal instructions in Appendix A of this service bulletin. 2) Do an external detailed inspection of the fuselage skin for scribe lines in the areas of bare skin in and around decal Zone locations in accordance with Figure 22. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, no further inspection is required at this location. Do the Part 11 - Surface Finish Restoration. (b) General visual inspections.

**NOTE:** The general visual inspections can be accomplished without paint removal. 1) Do a general visual inspection of the entire decal area for any scribe lines. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 102 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

{b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, repeat the general visual inspections at the time given in paragraph 1.E. Compliance or until the detailed inspections in decal areas as given above have been accomplished. d. Group 4, 9: (1) Do one of the inspection options that follow: (a) Detailed inspection. 1) Prepare the decal Zone for inspection as shown below and at the locations in accordance with Figure 23. {a} Remove the paint as required from the applicable Zone area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal.

**NOTE:** 1. If decals were previously installed, and it can be determined where the edges of the decals previously were, remove the paint from the area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal. 2. If decals were previously installed, but it can not be determined where the edges of the decal were, remove the paint from all of the affected Zone decal locations. If necessary, use the sealant removal instructions in Appendix A of this service bulletin. 2) Do an external detailed inspection of the fuselage skin for scribe lines in the areas of bare skin in and around decal Zone locations in accordance with Figure 23. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, no further inspection is required at this location. Do the Part 11 - Surface Finish Restoration.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 103 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(b) General visual inspections.

**NOTE:** The general visual inspections can be accomplished without paint removal. 1) Do a general visual inspection of the entire decal area for any scribe lines. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, repeat the general visual inspections at the time given in paragraph 1.E. Compliance or until the detailed inspections in decal areas as given above have been accomplished. e. Group 5, 10: (1) Do one of the inspection options that follow: (a) Detailed inspection. 1) Prepare the decal Zone for inspection as shown below and at the locations in accordance with Figure 24. {a} Remove the paint as required from the applicable Zone area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal.

**NOTE:** 1. If decals were previously installed, and it can be determined where the edges of the decals previously were, remove the paint from the area of the skin all around the edges of the decal. The bared area should be at least half an inch wide on either side of the line at the edge of the decal. 2. If decals were previously installed, but it can not be determined where the edges of the decal were, remove the paint from all of the affected Zone decal locations. If necessary, use the sealant removal instructions in Appendix A of this service bulletin. 2) Do an external detailed inspection of the fuselage skin for scribe lines in the areas of bare skin in and around decal Zone locations in accordance with Figure 24. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 104 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

{c} If no scribe line is found, no further inspection is required at this location. Do the Part 11 - Surface Finish Restoration. (b) General visual inspections.

**NOTE:** The general visual inspections can be accomplished without paint removal. 1) Do a general visual inspection of the entire decal area for any scribe lines. {a} If any skin scribe line is found, do the Part 8 - Scribe Line Found. {b} If any crack is found, contact Boeing for repair procedures and do the repair. {c} If no scribe line is found, repeat the general visual inspections at the time given in paragraph 1.E. Compliance or until the detailed inspections in decal areas as given above have been accomplished.

5. **PART 5 - EXTERNAL APPROVED REPAIR - INSPECTION** Do the external approved repair inspection at the time given in Paragraph 1.E., Compliance as follows: a. If applicable, do the external approved repair inspection as follows: (1) Do one of the options that follow: (a) In areas located between STA 360 and STA 1016 and below stringer 10 left and stringer 10 right. Determine if the external repair doubler is 20 inches or longer in the fore and aft direction with no circumferential limitations.

**NOTE:** Inspection is not required on external approved repairs located between STA 360 and STA 1016 and below stringer 10 left and stringer 10 right which are less than 20 inches long in the fore and aft direction. (b) In areas where all or part of the external approved repair is located between STA 360 and STA 1016 and above stringer 10 left and stringer 10 right. Determine if the external repair doubler is 20 inches or longer in the fore and aft direction or wider than 12 inches circumferentially.

**NOTE:** Inspection is not required around external approved repairs located between STA 360 and STA 1016, above stringer 10 left and stringer 10 right which are less than 20 inches long in the fore and aft direction and smaller than 12 inches circumferentially. (2) Determine the thickness of the parent skin in the area of the repair. Refer to the Boeing drawings if the skin thickness is not known. Refer to 737 SRM chapter 53 for the applicable Boeing drawings. At the operators option refer to 737 NDT, Part 4, 51-00-00 Figure 2 as an accepted procedure to determine the thickness of the parent skin.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 105 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(3) Remove paint and sealant from the area of the skin around the periphery of the external repair doubler. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal.

**NOTE:** The bared area should be at least one inch wide, around the periphery of the repair doubler. (4) Do an external detailed inspection of the fuselage skin for scribe lines in the area of bare skin around the doubler in accordance with Figure 25. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** Scribe lines normally follow the periphery of the doubler. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration.

6. **PART 6 - INTERNAL APPROVED REPAIR - INSPECTION** Do the internal approved repair inspection at the time given in Paragraph 1. E., Compliance as follows: a. If applicable, do the internal approved repair inspection as follows: (1) Do one of the options that follow: (a) In areas located between STA 360 and STA 1016 and below stringer 10 left and stringer 10 right. Determine if the internal approved repair skin cut-out is greater than 20 inches long in the fore and aft direction with no circumferential limitations.

**NOTE:** Inspection is not required on internal approved repairs located between STA 360 and STA 1016 and below stringer 10 left and stringer 10 right which are less than 20 inches long in the fore and aft direction. (b) In areas where all or part of the internal approved repair is located between STA 360 and STA 1016 and above stringer 10 left and stringer 10 right. Determine if the internal approved repair skin cut-out is greater than 20 inches long in the fore and aft direction or wider than 12 inches circumferentially.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 106 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** Inspection is not required around internal approved repairs located between STA 360 and STA 1016 and above stringer 10 left and stringer 10 right which are less than 20 inches long in the fore and aft direction and smaller than 12 inches circumferentially. (2) Determine the thickness of the parent skin in the area of the repair. Refer to the Boeing drawings if the skin thickness is not known. Refer to 737 SRM chapter 53 for the applicable Boeing drawings. At the operators option refer to 737 NDT, Part 4, 51-00-00 Figure 2 as an accepted procedure to determine the thickness of the parent skin. (3) Remove the sealant from within the gap between the skin and the repair filler. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal. (4) Do an external detailed inspection of the repair doubler for scribe lines in the area around the periphery of the filler in accordance with Figure 26. The use of 10X magnifying lens is required for this inspection. Refer to Part 7 for identification of a typical scribe line.

**NOTE:** Scribe lines normally follow the periphery of the repair filler in the gap between the skin and the repair filler. (a) If any skin scribe line is found, do the Part 8 - Scribe Line Found. (b) If any crack is found, contact Boeing for repair procedures and do the repair. (c) If no scribe line is found, no further inspection is required at this location, provided that the correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. Do the Part 11 - Surface Finish Restoration.

7. **PART 7 - IDENTIFICATION OF A "TYPICAL" SCRIBE LINE** a. Determine if the scribe line is "typical": A scribe line is defined as a narrow, shallow, distinct line of damage (typically up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (lap joints and butt joints, respectively). Scribe lines can be both tactile and non-tactile. Discoloration of the aluminum clad layer or small surface imperfections do not qualify as a scribe line. A lightning strike at a lap joint or butt joint does not qualify as a scribe line. In certain cases the scribe lines have also been associated with the trimming of fuselage skin decals. Scribe lines that create a potential safety concern are generally long continuous scribe lines or several adjacent scribe lines in a critical orientation at specific locations with relatively high stresses. Figures are included in the Service Bulletin to depict typical scribe line found common to lap joints, butt joints, repairs, and decals. Grinding, gouging, or other "non-typical" damage, which is more significant (deeper or locally more extensive) than the typical scribe line must be repaired before further flight. Localized scratches, nicks and dents that might be induced in other areas of the fuselage skin during either manufacture or maintenance operations are not considered scribe lines. This type of damage should be addressed via the acceptable maintenance practices detailed in the Structural Repair Manual.

8. **PART 8 - SCRIBE LINE FOUND**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 107 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

a. Document the location of all scribe line that was found. It is recommended that you use the format outlined in Appendix B to document the scribe line. b. Do an external detailed inspection of the scribe line to find the deepest scribe location on the airplane for the applicable Zone. c. At the deepest scribe location, do a laser measurement inspection or a optical micrometer inspection to measure the maximum depth of the scribe line.

**NOTE:** Only the laser measurement inspection in accordance with 737 NDT, Part 10, 53-30-01 can be used to confirm scribe line depth less than 0.001 inch. (1) If the scribe line depth is less than 0.001 inch, no further work or inspection is required at this location provided: (a) No depth along this scribe line is greater than or equal to 0.001 inch. (b) The correct sealant removal procedure is implemented for all future work. Refer to Appendix A of this service bulletin as an accepted sealant removal procedure. (2) If the scribe line depth is greater than or equal to 0.001 inch and less than or equal to 0.006 inch do one of the options that follow: (a) Do the Part 9 - Scribe Line Inspection. (b) Contact Boeing for repair instructions and do the repair. (3) If the scribe line depth is greater than 0.006 inch contact Boeing for repair procedures and do the repair.

9. **PART 9 - SCRIBE LINE INSPECTION**

**NOTE:** Once the deepest scribe line location has been determined to be less than or equal to 0.006 inch and scribe line is crack free, then all other scribe line locations within the applicable lap joints qualify for the Limited Return To Service (LRTS) program repeat inspections.

a. **If the scribe line exists in an affected lap joint location:** At all lap joints where scribe line depth is greater than or equal to 0.001 inches and less than or equal to 0.006 inches, do the inspections of the skin, as follows:

**NOTE:** If a scribe is detected within 0.10 inches of the edge of the lap splice, inspection has to be performed along the entire length of the lap splice, from forward butt joint to aft butt joint. If a scribe line is located in an area outside the 0.10 inch zone, then the inspection is only required locally common to the scribe. (1) If applicable, remove the sealant from the lower edge of the entire lap joint from the butt joint forward of the scribe line to the butt joint aft of the scribe line. Refer to Appendix A of this service bulletin as an accepted procedure for sealant removal.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 108 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(2) If applicable, remove the paint from below the lower edge of the entire lap joint from the butt joint forward of the scribe line to the butt joint aft of the scribe line. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (3) Do the inspections of the fuselage skin to detect any crack at all affected lap joints in accordance with Figure 47. (a) If any crack is found, contact Boeing for repair instruction and do the repair. (b) If no crack is found, do the Part 10 - LRTS program repeat inspection at the times shown in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (4) Do the Part 11 - Surface Finish Restoration. **b. If a scribe line exists in a circumferential butt joint area:** At all circumferential butt joints where scribe line depth is greater than or equal to 0.001 inches and less than or equal to 0.006 inches, do the inspection as follows:

**NOTE:** If a repair or modification is common to the circumferential butt joint and an external scribe line crack inspection is required contact Boeing for the proper inspection method. (1) Do an external Low Frequency Eddy Current (LFEC) sliding probe inspection in accordance with 737 NDT, Part 6, 53-30-24 or an internal Medium Frequency Eddy Current (MFEC) inspection in accordance with 737 NDT, Part 6, 53-30-23 or an external High Frequency Eddy Current (HFEC) pencil probe inspection in accordance with 737 NDT, Part 6, 53-30-29 or a internal HFEC inspection in accordance with 737 NDT, Part 6, 51-00-00 figure 23 to detect any crack.

**NOTE:** If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. (a) If any crack is found, contact Boeing for repair instruction and do the repair. (b) If no crack is found, do the Part 10 - LRTS program repeat inspection at the times shown in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (2) Do the Part 11 - Surface Finish Restoration.

**c. If a scribe line exists around a decal:** At all decal areas where scribe line depth is greater than or equal to 0.001 inches and less than or equal to 0.006 inches, do the inspection as follows: (1) Do the inspections of the fuselage skin to detect any crack at all affected decals as follows: (a) Do a HFEC inspection to detect any crack in scribe lines at all affected decals in accordance with 737 NDT, Part 6, 51-00-00 Figure 4 or Figure 23.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 109 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, do the Part 10 - LRTS program repeat inspection at the times shown in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (2) Do the Part 11 - Surface Finish Restoration.

d. **If a scribe line exists around an external repair doubler:** At all external approved repairs where scribe line depth is greater than or equal to 0.001 inch and less than or equal to 0.006 inch, do the inspection as follows:

**NOTE:** If a scribe is detected within 0.10 inches of the external repair doubler, inspection has to be performed around the entire external repair doubler periphery. If the scribe is located at an area outside the 0.10 inches zone, then the inspection is only required locally common to the scribe. (1) Do the inspections at all affected external approved repairs in accordance with Figure 47. (a) If any crack is found in the above inspections, contact Boeing for repair instruction and do the repair. (b) If no crack is found in the above inspections, do the Part 10 - LRTS program repeat inspection at the times shown in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (2) Do the Part 11 - Surface Finish Restoration.

e. **If a scribe line exists on an internal repair doubler (around the repair filler):** At all internal approved repairs where scribe line depth is greater than or equal to 0.001 inch and less than or equal to 0.006 inch, do the inspection as follows: (1) Do an external Low Frequency Eddy Current (LFEC) sliding probe inspection in accordance with 737 NDT, Part 6, 53-30-24 or an internal Medium Frequency Eddy Current (MFEC) inspection in accordance with 737 NDT, Part 6, 53-30-23 or an external High Frequency Eddy Current (HFEC) pencil probe inspection in accordance with 737 NDT, Part 6, 53-30-29 or an internal HFEC inspection in accordance with 737 NDT, Part 6, 51-00-00, Figure 23 to detect any crack. (a) If any crack is found in the above inspections, contact Boeing for repair instruction and do the repair. (b) If no crack is found in the above inspections, do the Part 10 - LRTS program repeat inspection at the times shown in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (2) Do the Part 11 - Surface Finish Restoration.

10. **PART 10 - LIMITED RETURN TO SERVICE (LRTS) PROGRAM**Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 110 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

a. **Skin lap joint - Zone 17 - Repeat inspection:** Do the Zone 17 inspection as follows:

**NOTE:** 1. If the scribe line is within 0.10 inches of the upper skin lower edge, then repeat inspections are required along the lap joint from the skin butt joint forward of the scribe line to the skin butt joint aft of the scribe line or the edge of a cut out forward or aft of the scribe line to the skin butt joint forward or aft of the scribe line.
2. If the scribe line is located in an area that is outside of the 0.10 inches zone, then repeat inspections are only required locally common to the scribe. (1) Group 1, 6: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 27 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (2) Group 2, 7: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 28 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 111 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (3) Group 3, 8: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 29 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (4) Group 4, 9: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 30 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 112 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (5) Group 5, 10: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 31 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration.

b. **Skin lap joint - Zone 18 - Repeat inspection:** Do the Zone 18 inspection as follows:Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 113 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** 1. If the scribe line is within 0.10 inches of the upper skin lower edge, then repeat inspections are required along the lap joint from the skin butt joint forward of the scribe line to the skin butt joint aft of the scribe line or the edge of a cut out forward or aft of the scribe line to the skin butt joint forward or aft of the scribe line.
2. If the scribe line is located in an area that is outside of the 0.10 inches zone, then repeat inspections are only required locally common to the scribe. (1) Group 1, 6: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 32 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (2) Group 2, 7: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 33 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 114 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (3) Group 3, 8: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 34 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction. (d) Do the Part 11 - Surface Finish Restoration.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 115 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(4) Group 4, 9: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 35 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (5) Group 5, 10: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 36 for location. (b) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (c) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 116 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

c. **Skin lap joint - Zone 19 - Repeat inspection:** Do the Zone 19 inspection as follows:

**NOTE:** 1. If the scribe line is within 0.10 inches of the upper skin lower edge, then repeat inspections are required along the lap joint from the skin butt joint forward of the scribe line to the skin butt joint aft of the scribe line or the edge of a cut out forward or aft of the scribe line to the skin butt joint forward or aft of the scribe line.
2. If the scribe line is located in an area that is outside of the 0.10 inches zone, then repeat inspections are only required locally common to the scribe. (1) Group 1, 6: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 37 for location. (b) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

(c) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (d) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (e) Do the Part 11 - Surface Finish Restoration. (2) Group 2, 7: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 38 for location. **Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 117 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(b) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

(c) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (d) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (e) Do the Part 11 - Surface Finish Restoration. (3) Group 3, 8: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 39 for location. (b) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

(c) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (d) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. **Left Side Right Side** 191 AL 191 AR

**Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 118 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (e) Do the Part 11 - Surface Finish Restoration. (4) Group 4, 9: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 40 for location. (b) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure.

(c) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (d) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (e) Do the Part 11 - Surface Finish Restoration. (5) Group 5, 10: (a) Determine if lap joint area requires inspection. Refer to documentation gathered in Part 8 - scribe line found and Figure 41 for location. (b) If any section of the affected lap joints is under the wing-to-body fairing, remove the appropriate fairing panels for access as shown in the table that follows. Refer to 737-600/700/800/900 AMM 06-41-00 as an accepted procedure. **Left Side Right Side** 191 AL 191 AR

**Left Side Right Side** 191 AL 191 AROriginal Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 119 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(c) If applicable, remove the paint below the lower edge of the lap joint where LRTS inspections to detect any crack are required. The bared area should be at least one inch wide, as measured from the lower edge of the upper skin. (d) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the lower edge of the upper skin, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (e) Do the Part 11 - Surface Finish Restoration.

d. **Circumferential butt joint - Repeat inspections:** If applicable, do the circumferential butt joint repeat inspection at the time given in Paragraph 1. E., Compliance as follows:

**NOTE:** It is not necessary to remove the primer from the circumferential butt joint splice plate. (1) Group 1-3, 5-8, 10: (a) Determine which circumferential butt joint areas require inspections. Refer to documentation gathered in Part 8 - scribe line found and Figure 16 and Figure 17 for locations. (b) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection to detect any crack in the scribe line at circumferential butt joint STA 360 in accordance with Figure 42.

**NOTE:** If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection to detect any crack in the scribe line at circumferential butt joint STA 887 in accordance with Figure 43.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 120 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do the Part 11 - Surface Finish Restoration. (2) Group 4, 9: (a) Determine which circumferential butt joint areas require inspections. Refer to documentation gathered in Part 8 - scribe line found and Figure 16, Figure 17, Figure 18 and Figure 19 for locations. (b) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection to detect any crack in the scribe line at circumferential butt joint STA 360 in accordance with Figure 42.

**NOTE:** If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (c) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection to detect any crack in the scribe line at circumferential butt joint STA 887 in accordance with Figure 43.

**NOTE:** If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (d) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection to detect any crack in scribe line at circumferential butt joint STA 500E and STA 727I in accordance with Figure 44.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 121 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (e) Do the Part 11 - Surface Finish Restoration.

e. **Decal Zone - Repeat inspections:** If applicable, do the decal Zone repeat inspection at the time given in Paragraph 1. E., Compliance as follows:

**NOTE:** Detailed inspections and HFEC inspections are only required at locations where scribe lines have been detected. (1) Group 1, 6: Decal Zone 3, 4 or 5 - Repeat inspections: (a) Refer to documentation gathered in Part 8 - scribe line found and Figure 20 for decal Zone location. (b) Do an external detailed inspection of the fuselage skin to detect any crack around decal Zone locations in accordance with Figure 20. (c) Do a HFEC inspection to detect any crack in scribe lines in accordance with 737 NDT, Part 6, 51-00-00 Figure 4 or Figure 23. (d) If any crack is found in the above inspections, contact Boeing for repair instruction and do the repair. (e) If no crack is found in the above inspections, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (f) Do the Part 11- Surface Finish Restoration. (2) Group 2, 7: Decal Zone 6, 7 or 8 - Repeat inspections: (a) Refer to documentation gathered in Part 8 - scribe line found and Figure 21 for decal Zone location. (b) Do an external detailed inspection of the fuselage skin to detect any crack around decal Zone locations in accordance with Figure 21. (c) Do a HFEC inspection to detect any crack in scribe lines in accordance with 737 NDT, Part 6, 51-00-00 Figure 4 or Figure 23. (d) If any crack is found in the above inspections, contact Boeing for repair instruction and do the repair.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 122 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(e) If no crack is found in the above inspections, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (f) Do the Part 11- Surface Finish Restoration. (3) Group 3, 8: Decal Zone 9, 10 or 11 - Repeat inspections: (a) Refer to documentation gathered in Part 8 - scribe line found and Figure 22 for decal Zone location. (b) Do an external detailed inspection of the fuselage skin to detect any crack around decal Zone locations in accordance with Figure 22. (c) Do a HFEC inspection to detect any crack in scribe lines in accordance with 737 NDT, Part 6, 51-00-00 Figure 4 or Figure 23. (d) If any crack is found in the above inspections, contact Boeing for repair instruction and do the repair. (e) If no crack is found in the above inspections, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (f) Do the Part 11- Surface Finish Restoration. (4) Group 4, 9: Decal Zone 12, 13 or 14 - Repeat inspections: (a) Refer to documentation gathered in Part 8 - scribe line found and Figure 23 for decal Zone location. (b) Do an external detailed inspection of the fuselage skin to detect any crack around decal Zone locations in accordance with Figure 23. (c) Do a HFEC inspection to detect any crack in scribe lines in accordance with 737 NDT, Part 6, 51-00-00 Figure 4 or Figure 23. (d) If any crack is found in the above inspections, contact Boeing for repair instruction and do the repair. (e) If no crack is found in the above inspections, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (f) Do the Part 11- Surface Finish Restoration. (5) Group 5, 10: Decal Zone 15 or 16 - Repeat inspections: (a) Refer to documentation gathered in Part 8 - scribe line found and Figure 24 for decal Zone location. (b) Do an external detailed inspection of the fuselage skin to detect any crack around decal Zone locations in accordance with Figure 24.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 123 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

(c) Do a HFEC inspection to detect any crack in scribe lines in accordance with 737 NDT, Part 6, 51-00-00 Figure 4 or Figure 23. (d) If any crack is found in the above inspections, contact Boeing for repair instruction and do the repair. (e) If no crack is found in the above inspections, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (f) Do the Part 11- Surface Finish Restoration.

f. **External approved repair - Repeat inspection:** Refer to documentation gathered in Part 8 - scribe line found and Figure 45 for location.

**NOTE:** Repairs that end on different thickness skin pockets have different repeat inspection intervals. Refer to Paragraph 1. E., Compliance. (1) Do the inspections at all affected external approved repair as follows:

**NOTE:** If a scribe is detected within 0.10 inches of the repair doubler, inspections to detect any crack per the LRTS have to be performed around the entire repair doubler periphery. (a) Remove paint and sealant as required from the area of the skin around the periphery of the external repair doubler. Refer to Appendix A of this service bulletin as an accepted procedure.

**NOTE:** The bared area should be at least one inch wide, around the periphery of the repair doubler. (b) Do an external detailed inspection, HFEC inspection and an UT inspection to detect any crack in accordance with Figure 47.

**NOTE:** If the scribe damage is within 0.063 inches from the edge of the repair doubler, as an alternative to the above UT inspection and HFEC inspections an UT phased array inspection can be used. UT phased array inspection does not require paint removal. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (c) Do the Part 11 - Surface Finish Restoration.

g. **Internal approved repair - Repeat inspection:** Do the internal repair doubler repeat inspection at the time given in Paragraph 1. E., Compliance as follows:Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 124 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** Repairs that end on different thickness skin pockets have different repeat inspection intervals. Refer to Paragraph 1. E., Compliance. (1) Do the inspections at all affected internal approved repair as follows:

**NOTE:** Scribe lines normally follow the periphery of the repair filler in the gap between the skin and the repair filler. (a) Remove sealant as required from within the gap between the skin and the repair filler. Refer to Appendix A of this service bulletin as an accepted procedure. (b) Do an external LFEC sliding probe inspection or an internal MFEC inspection or an external HFEC pencil probe inspection or an internal HFEC inspection to detect any crack in accordance with Figure 46. 1) If any crack is found, contact Boeing for repair instruction and do the repair. 2) If no crack is found, continue to do the LRTS program inspections at the intervals given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair. (c) Do the Part 11 - Surface Finish Restoration.

11. **PART 11 - SURFACE FINISH RESTORATION**

**NOTE:** To reduce the possibility of future scribing, Boeing recommends that the fillet seal not be reapplied except in the gap at the butt joint.
a. Re-finish the external surface finish as follows: (1) Apply Type 2, Class A chemical conversion coating. Refer to SOPM 20-43-03 as an accepted procedure. (2) Apply BMS 10-72 paint system (primer plus enamel), or BMS 10-79 Type II (primer) plus BMS 10-60 Type II (topcoat), or the operators normal decorative paint system. Refer to 737-600/700/800/900 AMM 51-21-00 as an accepted procedure. b. If applicable, re-finish the internal surface finish as follows: (1) Apply Type 2, Class A chemical conversion coating. Refer to SOPM 20-43-03 as an accepted procedure. (2) Apply BMS 10-11 Type 1 primer. c. Put the airplane back to a serviceable condition.

12. **PART 12 - INSPECTION REQUIREMENTS FOR SCRIBES FOUND PRIOR TO THE INITIAL INSPECTION THRESHOLD**  a. For scribe damage at a lap joint that is within the parameters of a "typical" scribe as defined in Part 7, inspect the fuselage skin locally common to the scribe to detect any crack in accordance with Figure 47.Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 125 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**NOTE:** For scribes found before the applicable threshold, inspections are required only locally in all areas. (1) If any crack is found, contact Boeing for repair instruction and do the repair. (2) If no crack is found, do the Part 9 - Scribe Line Inspection upon reaching the threshold given in Paragraph 1.E., Compliance or contact Boeing for repair instruction and do the repair
b. Do the Part 11 - Surface Finish Restoration.**FIGURE 1: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 126 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 1: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-1S-4LS-10LS-14LS-19LS-24LBL-0BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727737-600S-1ASEE211541652

**(SHEET 1 OF 3) FIGURE 1: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 127 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 1: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 21548894

**(SHEET 2 OF 3) FIGURE 1: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 128 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 2 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 2: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 129 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 2: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0S-20RBL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0STA259.50STA360STA540STA1016STA887STA727737-700S-1S-1ASEE211539140

**(SHEET 1 OF 3) FIGURE 2: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 130 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 2: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 21548895

**(SHEET 2 OF 3) FIGURE 2: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 131 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 2 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 3: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 132 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 3: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**BL-0S-10RS-10LS-20LBL-0S-20R737-800S-24RS-14RS-4RS-4LS-14LS-24LSTA259.50STA360STA540STA1016STA887STA727S-1S-1S-4RS-4LASEE211541657

**(SHEET 1 OF 3) FIGURE 3: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 133 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 3: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 21548896

**(SHEET 2 OF 3) FIGURE 3: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 134 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 2 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 4: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 135 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 4: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**STA1016STA887STA727737-900STA259.50STA360STA540BL-0S-10RS-10LS-20LBL-0S-20RS-1S-4RS-4LASEE211541660

**(SHEET 1 OF 3) FIGURE 4: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 136 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 4: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 21548898

**(SHEET 2 OF 3) FIGURE 4: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 137 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 2 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 5: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 138 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 5: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0737-700CBL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727S-1S-1STA500ASEE211541665

**(SHEET 1 OF 3) FIGURE 5: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 139 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 5: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 21548899

**(SHEET 2 OF 3) FIGURE 5: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 140 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 2 Inspect Lower Skin S-4L, STA 500 To STA 1016. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 6: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 141 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 6: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-1S-4LS-10LS-14LS-19LS-24LBL-0BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727737-600S-1ASEE4356211542489

**(SHEET 1 OF 3) FIGURE 6: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 142 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 6: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 4 5 61548900

**(SHEET 2 OF 3) FIGURE 6: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 143 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016. 3 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 4 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b)

5 Inspect Lower Skin S-14L, STA 360 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 6 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 7: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 144 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 7: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0S-20RBL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0STA259.50STA360STA540STA1016STA887STA727737-700S-1S-1ASEE4356211542492

**(SHEET 1 OF 3) FIGURE 7: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 145 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 7: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 4 5 61548901

**(SHEET 2 OF 3) FIGURE 7: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 146 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016. 3 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 4 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b)

5 Inspect Lower Skin S-14L, STA 360 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 6 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 8: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 147 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 8: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**BL-0S-10RS-10LS-20LBL-0S-20R737-800S-24RS-14RS-4RS-4LS-14LS-24LSTA259.50STA360STA540STA1016STA887STA727S-1S-1S-4RS-4LASEE4356211542494

**(SHEET 1 OF 3) FIGURE 8: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 148 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 8: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 4 5 61548902

**(SHEET 2 OF 3) FIGURE 8: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 149 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016. 3 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 4 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b)

5 Inspect Lower Skin S-14L, STA 360 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 6 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 9: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 150 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 9: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**STA1016STA887STA727737-900STA259.50STA360STA540S-10RS-10LS-20LS-20RS-1S-4RS-4LS-25RS-14RS-14LS-25LBL-0BL-0S-24LS-24RS-1S-4RS-4LS-14RS-14LASEE4356211542496

**(SHEET 1 OF 3) FIGURE 9: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 151 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 9: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 4 5 61548903

**(SHEET 2 OF 3) FIGURE 9: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 152 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016. 3 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 4 Inspect Lower Skin S-4L, STA 360 To STA 1016. (a)(b)

5 Inspect Lower Skin S-14L, STA 360 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 6 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 10: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 153 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 10: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION** STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0737-700CBL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727S-1S-1STA500ASEE4356211542498

**(SHEET 1 OF 3) FIGURE 10: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 154 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 10: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 4 5 61548904

**(SHEET 2 OF 3) FIGURE 10: FUSELAGE - SKIN LAP JOINT - ZONE 1 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 155 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016. 3 Inspect Lower Skin S-4R, STA 360 To STA 1016. (a)(b) 4 Inspect Lower Skin S-4L, STA 500 To STA 1016. (a)(b)

5 Inspect Lower Skin S-14L, STA 500 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 6 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 11: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 156 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 11: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-1S-4LS-10LS-14LS-19LS-24LBL-0BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727737-600S-1ASEE34211542500

**(SHEET 1 OF 3) FIGURE 11: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 157 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 1: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 41548905

**(SHEET 2 OF 3) FIGURE 11: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 158 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016.

3 Inspect Lower Skin S-14L, STA 360 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 4 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 12: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 159 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 12: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION** BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0S-20RBL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0STA259.50STA360STA540STA1016STA887STA727737-700S-1S-1ASEE34211542510

**(SHEET 1 OF 3) FIGURE 12: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 160 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 2: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 41548906

**(SHEET 2 OF 3) FIGURE 12: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 161 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016.

3 Inspect Lower Skin S-14L, STA 360 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 4 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 13: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 162 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 13: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**BL-0S-10RS-10LS-20LBL-0S-20R737-800S-24RS-14RS-4RS-4LS-14LS-24LSTA259.50STA360STA540STA1016STA887STA727S-1S-1S-4RS-4LASEE34211542533

**(SHEET 1 OF 3) FIGURE 13: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 163 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 3: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 41548907

**(SHEET 2 OF 3) FIGURE 13: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 164 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016.

3 Inspect Lower Skin S-14L, STA 360 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 4 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 14: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 165 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 14: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION** STA1016STA887STA727737-900STA259.50STA360STA540BL-0S-10RS-10LS-20LBL-0S-20RS-1S-4RS-4LS-25RS-14RS-14LS-25LS-24LS-24RS-1S-14RS-14LASEE34211542547

**(SHEET 1 OF 3) FIGURE 14: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 166 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 4: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 41548908

**(SHEET 2 OF 3) FIGURE 14: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 167 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016.

3 Inspect Lower Skin S-14L, STA 360 To STA 540. S-14L, STA 727 To STA 1016. (a)(b) 4 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 15: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 168 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 15: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0737-700CBL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727S-1S-1STA50034211542559

**(SHEET 1 OF 3) FIGURE 15: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 169 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 5: 

### TYPICAL SKIN LAP JOINT TYPICAL SKIN SCRIBE LINE LAP JOINT FRAME

UPPER SKIN

STRINGER

LOWER SKIN



### A 1 2 3 41548909

**(SHEET 2 OF 3) FIGURE 15: FUSELAGE - SKIN LAP JOINT - ZONE 2 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 170 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Lower Skin S-24R, STA 259.50 To STA 540. (a)(b)

2 Inspect Lower Skin S-14R, STA 360 To STA 540. (a)(b) S-14R, STA 727 To STA 1016.

3 Inspect Lower Skin S-14L, STA 500 To STA 540. (a)(b) S-14L, STA 727 To STA 1016. 4 Inspect Lower Skin S-24L, STA 259.50 To STA 540. (a)(b) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas near lap joints, scribe lines normally run parallel to the lap joint in the lower skin along the edge of the upper skin. These scribe lines are typically within 0.25 inch of the lower edge of the upper skin. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the lower edge of the upper skin. The ends of these scribe lines sometimes may also turn slightly away from the lap joint.

**(SHEET 3 OF 3) FIGURE 16: FUSELAGE - STA 360 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 171 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 16: FUSELAGE - STA 360 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**

FWD GALLEY

DOOR

FWD ENTRY DOOR FWD CARGO DOOR RIGHT SIDE 

### STA 259.50 STA 360

BL-0

S-24R

S-19R

S-14R S-10R

S-4R

S-1 S-4L

S-10L S-14L

S-19L

S-24L

BL-0



### TYPICAL 737 FORWARD SECTION A SEE 11538798

**(SHEET 1 OF 2) FIGURE 16: FUSELAGE - STA 360 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 172 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Splice Plate Between S-10L and S-10R At STA 360. (a)(b) (a) Do an external detailed inspection of the affected circumferential butt joint for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas of the circumferential butt joint, scribe lines normally run parallel to the butt joint. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the edge of the skin. 

### TYPICAL SKIN BUTT JOINT FORWARD SKIN PANEL

AFT SKIN PANEL

SPLICE PLATE TYPICAL SCRIBE LINES



### A 11548910

**(SHEET 2 OF 2) FIGURE 17: FUSELAGE - STA 887 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 173 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 17: FUSELAGE - STA 887 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**

AFT GALLEY

DOOR

RH AFT CARGO DOOR RIGHT SIDE

AFT GALLEY

DOOR

LH 

### BL-0 S-25R

S-14R
S-10R

S-4R

S-1
S-4L

S-10L
S-14L

S-20L S-25L BL-0 STA 1016

S-20R STA 887



### TYPICAL 737 AFT SECTION A SEE 11538799

**(SHEET 1 OF 2) FIGURE 17: FUSELAGE - STA 887 - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 174 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Splice Plate Between S-10L and S-10R At STA 887. (a)(b) (a) Do an external detailed inspection of the affected circumferential butt joint for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas of the circumferential butt joint, scribe lines normally run parallel to the butt joint. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the edge of the skin. 

### TYPICAL SKIN BUTT JOINT FORWARD SKIN PANEL

AFT SKIN PANEL

SPLICE PLATE TYPICAL SCRIBE LINES



### A 11548911

**(SHEET 2 OF 2) FIGURE 18: FUSELAGE - STA 500E -**  **CIRCUMFERENTIAL BUTT JOINT - INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 175 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 18: FUSELAGE - STA 500E - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**

FWD GALLEY

DOOR

FWD ENTRY DOOR FWD CARGO DOOR RIGHT SIDE STA 259.50 STA 360 STA 540

BL-0

S-24R

S-19R

S-14R S-10R

S-4R

S-1 S-4L

S-10L S-14L

S-19L

S-24L

BL-0



### 737-900 STA 500E A SEE 11539260

**(SHEET 1 OF 2) FIGURE 18: FUSELAGE - STA 500E -**  **CIRCUMFERENTIAL BUTT JOINT - INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 176 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 4, 9: The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Splice Plate Between S-10L and S-10R At STA 500E. (a)(b) (a) Do an external detailed inspection of the affected circumferential butt joint for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas of the circumferential butt joint, scribe lines normally run parallel to the butt joint. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the edge of the skin. 

### TYPICAL SKIN BUTT JOINT FORWARD SKIN PANEL

AFT SKIN PANEL

SPLICE PLATE TYPICAL SCRIBE LINES



### A 11548912

**(SHEET 2 OF 2) FIGURE 19: FUSELAGE - STA 727I - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 177 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 19: FUSELAGE - STA 727I - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**



### AFT GALLEY

DOOR RH AFT CARGO DOOR RIGHT SIDE

AFT ENTRY DOOR LH BL-0 S-25R

S-14R
S-10R

S-4R
S-1
S-4L

S-10L
S-14L

S-20L S-25L BL-0 STA 1016

S-20R STA 887 STA 727



### 737-900 STA 727I A SEE 11539623

**(SHEET 1 OF 2) FIGURE 19: FUSELAGE - STA 727I - CIRCUMFERENTIAL BUTT JOINT - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 178 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 4, 9: The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Splice Plate Between S-10L and S-10R At STA 727I. (a)(b) (a) Do an external detailed inspection of the affected circumferential butt joint for any scribe line. Use a 10X magnifying lens to aid the inspection. (b) In areas of the circumferential butt joint, scribe lines normally run parallel to the butt joint. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the edge of the skin. 

### TYPICAL SKIN BUTT JOINT FORWARD SKIN PANEL

AFT SKIN PANEL

SPLICE PLATE TYPICAL SCRIBE LINES



### A 11548913

**(SHEET 2 OF 2) FIGURE 20: FUSELAGE - DECAL - ZO**  **NE 3, ZONE 4, ZONE 5 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 179 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 20: FUSELAGE - DECAL - ZONE 3, ZONE 4, ZONE 5 INSPECTION**



### STA 360 STA 540



### 737-600 STA 616 S-10R

S-1 S-14R

S-14L S-16L S-10L STA 520 STA 482A

S-8R

S-5R

S-5L S-7L STA 482

STA 559

ZONE 3
ZONE 4
ZONE 5 INSPECTION AREAS

1 21542942

**(SHEET 1 OF 3) FIGURE 20: FUSELAGE - DECAL - ZONE 3, ZONE 4, ZONE 5 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 180 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 1, 6: 

### 737-600 S-10R

S-1 S-14R STA 1016 STA 887 STA 727

S-20R S-25R STA 727C STA 727C STA 807

S-7R

S-4R

S-5L STA 616 STA 685

S-19L S-14L S-10L STA 947.5 STA 663.75 STA 767 STA 847 STA 907

ZONE 3
ZONE 4
ZONE 5 INSPECTION AREAS

1 2 31542953

**(SHEET 2 OF 3) FIGURE 20: FUSELAGE - DECAL - ZO**  **NE 3, ZONE 4, ZONE 5 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 181 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Skin Zone 3 (a) 2 Inspect Skin Zone 4 (a) 3 Inspect Skin Zone 5 (a) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection.

**(SHEET 3 OF 3) FIGURE 21: FUSELAGE - DECAL - ZONE 6, ZONE 7, ZONE 8 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 182 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 21: FUSELAGE - DECAL - ZONE 6, ZONE 7, ZONE 8 INSPECTION**

STA 360 STA 540



### 737-700 STA 616 S-10R

S-1 S-14R

S-14L
S-17L S-10L STA 520 STA 500

S-8R

S-5R

S-5L

S-8L S-17R STA 500D STA 500B

STA 559 STA 597

ZONE 6
ZONE 7
ZONE 8 INSPECTION AREAS

1 21543557

**(SHEET 1 OF 3) FIGURE 21: FUSELAGE - DECAL - ZO**  **NE 6, ZONE 7, ZONE 8 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 183 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 2, 7: 

### 737-700

S-10R

S-1 S-14R STA 1016 STA 887 STA 727 STA 727C STA 727A STA 807

S-4R

S-4L STA 616 STA 685

S-20L S-14L S-10L

S-25L STA 847 STA 927 STA 727E STA 767

ZONE 6
ZONE 7
ZONE 8 INSPECTION AREAS

1 2 31542958

**(SHEET 2 OF 3) FIGURE 21: FUSELAGE - DECAL - ZONE 6, ZONE 7, ZONE 8 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 184 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Skin Zone 6 (a) 2 Inspect Skin Zone 7 (a) 3 Inspect Skin Zone 8 (a) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection.

**(SHEET 3 OF 3) FIGURE 22: FUSELAGE - DECAL - ZO**  **NE 9, ZONE 10, ZONE 11 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 185 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 22: FUSELAGE - DECAL - ZONE 9, ZONE 10, ZONE 11 INSPECTION** 

STA 360 STA 540



### 737-800 S-10R

S-1 S-14R

S-14L S-10L STA 520 STA 500

S-8R

S-4R

S-4L

S-8L STA 500C STA 500B STA 460 STA 500E STA 500H

S-6R

S-6L STA 500G STA 500F

ZONE 9
ZONE 10
ZONE 11 INSPECTION AREAS

1 21543563

**(SHEET 1 OF 3) FIGURE 22: FUSELAGE - DECAL - ZONE 9, ZONE 10, ZONE 11 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 186 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 3, 8: 

### 737-800 S-10R

S-1 S-14R STA 887 STA 727

S-20R STA 727I STA 727A STA 787

S-7R

S-4R

S-5L STA 616 STA 685

S-19L S-14L S-10L STA 847 STA 727D STA 727G STA 727H STA 727F STA 747 STA 807

ZONE 9
ZONE 10
ZONE 11 INSPECTION AREAS

1 2 31543627

**(SHEET 2 OF 3) FIGURE 22: FUSELAGE - DECAL - ZO**  **NE 9, ZONE 10, ZONE 11 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 187 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Skin Zone 9 (a) 2 Inspect Skin Zone 10 (a) 3 Inspect Skin Zone 11 (a) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection.

**(SHEET 3 OF 3) FIGURE 23: FUSELAGE - DECAL - ZO**  **NE 12, ZONE 13, ZONE 14 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 188 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 23: FUSELAGE - DECAL - ZONE 12, ZONE 13, ZONE 14 INSPECTION**

STA 360 STA 540



### 737-900 S-10R

S-1 S-14R

S-14L S-10L STA 520

S-7R

S-4R

S-4L S-6L STA 440 STA 500F STA 480 STA 500I STA 500K

S-17R

S-17L STA 500H STA 500G STA 500L

ZONE 12
ZONE 13 INSPECTION AREAS

1 21543669

**(SHEET 1 OF 3) FIGURE 23: FUSELAGE - DECAL - ZONE 12, ZONE 13, ZONE 14 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 189 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 4, 9: 

### 737-900 S-10R

S-1 S-14R STA 887 STA 727

S-19R STA 727J STA 787

S-7R
S-4R

S-5L STA 616 STA 663

S-19L S-14L S-10L STA 847 STA 727B

STA 706

S-3L

S-7L STA 867 STA 827 STA 807 STA 747 STA 727L

ZONE 12
ZONE 13
ZONE 14 INSPECTION AREAS

1 2 31544681

**(SHEET 2 OF 3) FIGURE 23: FUSELAGE - DECAL - ZO**  **NE 12, ZONE 13, ZONE 14 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 190 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Skin Zone 12 (a) 2 Inspect Skin Zone 13 (a) 3 Inspect Skin Zone 14 (a) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection.

**(SHEET 3 OF 3) FIGURE 24: FUSELAGE - DECAL**  **- ZONE 15, ZONE 16 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 191 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 24: FUSELAGE - DECAL - ZONE 15, ZONE 16 INSPECTION** 



### 737-700C S-10R

S-1 S-7R

S-3R

S-5L STA 360 STA 540 STA 500 STA 500B STA 480

S-10L S-3L STA 500D

ZONE 15
ZONE 16 INSPECTION AREAS

1 21544684

**(SHEET 1 OF 3) FIGURE 24: FUSELAGE - DECAL - ZONE 15, ZONE 16 INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 192 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 5, 10: 

### 737-700C S-10R

S-1 S-14R STA 1016 STA 887 STA 727 STA 727C STA 727A STA 807

S-4R

S-4L STA 616 STA 685

S-14L S-10L STA 867 STA 927 STA 727E STA 767

S-7R

S-7L

ZONE 15
ZONE 16 INSPECTION AREAS 1 21544727

**(SHEET 2 OF 3) FIGURE 24: FUSELAGE - DECAL**  **- ZONE 15, ZONE 16 INSPECTION** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 193 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Skin Zone 15 (a) 2 Inspect Skin Zone 16 (a) (a) Do an external detailed inspection of the fuselage skin for any scribe line. Use a 10X magnifying lens to aid the inspection.

**(SHEET 3 OF 3) FIGURE 25: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTIONS**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 194 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 25: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTIONS**



### TYPICAL APPROVED EXTERNAL REPAIR TYPICAL SCRIBE LINES

DOUBLER SKIN PANEL 

### TYPICAL AIRPLANE SHOWN

REPAIR DOUBLER SKIN A A



### A-A STA 360 STA 540 STA 727 STA 887 STA 1016

A SEE



### A 1 APPROVED EXTERNAL REPAIR AREAS (TYPICAL)

1

11548887

**(SHEET 1 OF 2) FIGURE 25: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTIONS**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 195 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA**
1 Inspect Skin STA 360 to STA 1016 At Approved External Repair (a)(b)
(a) Do an external detailed inspection of the fuselage skin around the edge of any approved external repair for any scribe lines. Use a 10X magnifying lens to aide the inspection. (b) Scribe lines normally run parallel to the repair doubler along the edge of the skin. These scribe lines are typically within 0.25 inch. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the edge of the repair doubler.

**(SHEET 2 OF 2) FIGURE 26: FUSELAGE - INTERNAL APPROVED REPAIRS - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 196 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 26: FUSELAGE - INTERNAL APPROVED REPAIRS - INSPECTION**



### TYPICAL APPROVED INTERNAL REPAIR TYPICAL SCRIBE LINES SKIN

REPAIR FILLER

INTERNAL REPAIR DOUBLER

SKIN REPAIR FILLER INTERNAL REPAIR DOUBLER

SKIN SKIN 

### TYPICAL AIRPLANE SHOWN

A A



### A-A STA 360 STA 540 STA 727 STA 887 STA 1016



### A 1 1

1 1 A SEE APPROVED INTERNAL REPAIR AREAS (TYPICAL)1548888

**(SHEET 1 OF 2) FIGURE 26: FUSELAGE - INTERNAL APPROVED REPAIRS - INSPECTION**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 197 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA**
1 Inspect Internal Repair Doubler STA 360 to STA 1016 At Approved Internal Repair (a)(b)
(a) Do an external detailed inspection of the internal repair doubler to detect any crack. Use a 10X magnifying lens to aide the inspection. (b) Scribe lines normally run parallel to the repair filler in the gap between the repair filler and the trimmed edge of the skin. These scribe lines are typically within 0.25 inch. In some cases, portions of the scribe lines may be directly adjacent to or slightly under the edge of the repair doubler.

**(SHEET 2 OF 2) FIGURE 27: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 198 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 27: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**

This Figure applies to Group 1, 6:STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-1S-4LS-10LS-14LS-19LS-24LBL-0BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727737-600S-1211549346

**(SHEET 1 OF 2) FIGURE 27: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 199 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 17 S-4R, STA 360 To STA 1016. - 2 Locate Lower Skin - Zone 17 S-4L, STA 360 To STA 1016. -

**(SHEET 2 OF 2) FIGURE 28: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 200 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 28: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**

This Figure applies to Group 2, 7:BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0S-20RBL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0STA259.50STA360STA540STA1016STA887STA727737-700S-1S-1211549347

**(SHEET 1 OF 2) FIGURE 28: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 201 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 17 S-4R, STA 360 To STA 1016. - 2 Locate Lower Skin - Zone 17 S-4L, STA 360 To STA 1016. -

**(SHEET 2 OF 2) FIGURE 29: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 202 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 29: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**

This Figure applies to Group 3, 8:BL-0S-10RS-10LS-20LBL-0S-20R737-800S-24RS-14RS-4RS-4LS-14LS-24LSTA259.50STA360STA540STA1016STA887STA727S-1S-1S-4RS-4L211549349

**(SHEET 1 OF 2) FIGURE 29: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 203 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 17 S-4R, STA 360 To STA 1016. - 2 Locate Lower Skin - Zone 17 S-4L, STA 360 To STA 1016. -

**(SHEET 2 OF 2) FIGURE 30: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 204 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 30: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**

This Figure applies to Group 4, 9:STA1016STA887STA727737-900STA259.50STA360STA540S-10RS-10LS-20LS-20RS-1S-4RS-4LS-25RS-14RS-14LS-25LBL-0BL-0S-24LS-24RS-1S-4RS-4LS-14RS-14L211549352

**(SHEET 1 OF 2) FIGURE 30: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 205 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 17 S-4R, STA 360 To STA 1016. - 2 Locate Lower Skin - Zone 17 S-4L, STA 360 To STA 1016. -

**(SHEET 2 OF 2) FIGURE 31: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 206 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 31: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**

This Figure applies to Group 5, 10:STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0737-700CBL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727S-1S-1STA500211549353

**(SHEET 1 OF 2) FIGURE 31: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 17**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 207 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 17 S-4R, STA 360 To STA 1016. - 2 Locate Lower Skin - Zone 17 S-4L, STA 500 To STA 1016. -

**(SHEET 2 OF 2) FIGURE 32: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 208 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 32: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**

This Figure applies to Group 1, 6:STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-1S-4LS-10LS-14LS-19LS-24LBL-0BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727737-600S-1211549354

**(SHEET 1 OF 2) FIGURE 32: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 209 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA**

1 Locate Lower Skin - Zone 18 S-14R, STA 360 To STA 540. - S-14R, STA 727 To STA 1016.

2 Locate Lower Skin - Zone 18 S-14l, STA 360 To STA 540. - S-14L, STA 727 To STA 1016.

**(SHEET 2 OF 2) FIGURE 33: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 210 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 33: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**

This Figure applies to Group 2, 7:BL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0S-20RBL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0STA259.50STA360STA540STA1016STA887STA727737-700S-1S-1211549356

**(SHEET 1 OF 2) FIGURE 33: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 211 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA**

1 Locate Lower Skin - Zone 18 S-14R, STA 360 To STA 540. - S-14R, STA 727 To STA 1016.

2 Locate Lower Skin - Zone 18 S-14L, STA 360 To STA 540. - S-14L, STA 727 To STA 1016.

**(SHEET 2 OF 2) FIGURE 34: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 212 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 34: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**

This Figure applies to Group 3, 8:BL-0S-10RS-10LS-20LBL-0S-20R737-800S-24RS-14RS-4RS-4LS-14LS-24LSTA259.50STA360STA540STA1016STA887STA727S-1S-1S-4RS-4L211552967

**(SHEET 1 OF 2) FIGURE 34: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 213 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA**

1 Locate Lower Skin - Zone 18 S-14R, STA 360 To STA 540. - S-14R, STA 727 To STA 1016.

2 Locate Lower Skin - Zone 18 S-14L, STA 360 To STA 540. - S-14L, STA 727 To STA 1016.

**(SHEET 2 OF 2) FIGURE 35: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 214 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 35: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**

This Figure applies to Group 4, 9:STA1016STA887STA727737-900STA259.50STA360STA540S-10RS-10LS-20LS-20RS-1S-4RS-4LS-25RS-14RS-14LS-25LBL-0BL-0S-24LS-24RS-1S-4RS-4LS-14RS-14L211552987

**(SHEET 1 OF 2) FIGURE 35: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 215 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA**

1 Locate Lower Skin - Zone 18 S-14R, STA 360 To STA 540. - S-14R, STA 727 To STA 1016.

2 Locate Lower Skin - Zone 18 S-14L, STA 360 To STA 540. - S-14L, STA 727 To STA 1016.

**(SHEET 2 OF 2) FIGURE 36: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 216 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 36: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**

This Figure applies to Group 5, 10:STA259.50STA360STA540BL-0S-24RS-19RS-14RS-10RS-4RS-4LS-10LS-14LS-19LS-24LBL-0737-700CBL-0S-25RS-14RS-10RS-4RS-4LS-10LS-14LS-20LS-25LBL-0STA1016S-20RSTA887STA727S-1S-1STA500211552991

**(SHEET 1 OF 2) FIGURE 36: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 18**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 217 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA**

1 Locate Lower Skin - Zone 18 S-14R, STA 360 To STA 540. - S-14R, STA 727 To STA 1016.

2 Locate Lower Skin - Zone 18 S-14L, STA 500 To STA 540. - S-14L, STA 727 To STA 1016.

**(SHEET 2 OF 2) FIGURE 37: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 218 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 37: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**

This Figure applies to Group 1, 6: 

### STA 259.50 STA 360 STA 540

BL-0

S-24R

S-19R

S-14R
S-10R

S-4R

S-1 S-4L

S-10L
S-14L

S-19L

S-24L

BL-0



### 737-600 2 11553001

**(SHEET 1 OF 2) FIGURE 37: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 219 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 19 S-24R, STA 259.50 To STA 540. - 2 Locate Lower Skin - Zone 19 S-24L, STA 259.50 To STA 540. -

**(SHEET 2 OF 2) FIGURE 38: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 220 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 38: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**

This Figure applies to Group 2, 7: 

### BL-0 S-24R

S-19R

S-14R S-10R

S-4R

S-4L

S-10L S-14L

S-19L

S-24L

BL-0 STA 259.50 STA 360 STA 540



### 737-700 S-1

2 11553011

**(SHEET 1 OF 2) FIGURE 38: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 221 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 19 S-24R, STA 259.50 To STA 540. - 2 Locate Lower Skin - Zone 19 S-24L, STA 259.50 To STA 540. -

**(SHEET 2 OF 2) FIGURE 39: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 222 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 39: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**

This Figure applies to Group 3, 8: 

### 737-800 S-24R

S-14R

S-4R

S-4L

S-14L

S-24L STA 259.50 STA 360 STA 540

S-1

2 11553026

**(SHEET 1 OF 2) FIGURE 39: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 223 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 19 S-24R, STA 259.50 To STA 540. - 2 Locate Lower Skin - Zone 19 S-24L, STA 259.50 To STA 540. -

**(SHEET 2 OF 2) FIGURE 40: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 224 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 40: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**

This Figure applies to Group 4, 9: 

### 737-900 STA 259.50 STA 360 STA 540

S-24L S-24R

S-1 S-4R

S-4L S-14R

S-14L

2 11553035

**(SHEET 1 OF 2) FIGURE 40: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 225 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 19 S-24R, STA 259.50 To STA 540. - 2 Locate Lower Skin - Zone 19 S-24L, STA 259.50 To STA 540. -

**(SHEET 2 OF 2) FIGURE 41: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 226 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 41: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**

This Figure applies to Group 5, 10: 

### STA 259.50 STA 360 STA 540

BL-0 S-24R

S-19R

S-14R
S-10R

S-4R

S-4L

S-10L S-14L

S-19L

S-24L

BL-0



### 737-700C

S-1 STA 500

2 11553043

**(SHEET 1 OF 2) FIGURE 41: FUSELAGE - SKIN LAP JOINT - LIMITED RETURN TO SERVICE PROGRAM - ZONE 19**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 227 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Lower Skin - Zone 19 S-24R, STA 259.50 To STA 540. - 2 Locate Lower Skin - Zone 19 S-24L, STA 259.50 To STA 540. -

**(SHEET 2 OF 2) FIGURE 42: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 360 - LIMITED RETURN TO SER**  **VICE PROGRAM** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 228 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 42: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 360 - LIMITED RETURN TO SERVICE PROGRAM** 

FWD GALLEY

DOOR

FWD ENTRY DOOR FWD CARGO DOOR RIGHT SIDE 

### STA 259.50 STA 360

BL-0

S-24R

S-19R

S-14R S-10R

S-4R

S-1 S-4L

S-10L S-14L

S-19L

S-24L

BL-0



### TYPICAL 737 FORWARD SECTION 11552955

**(SHEET 1 OF 2) FIGURE 42: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 360 - LIMITED RETURN TO SER**  **VICE PROGRAM** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 229 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Splice Plate Between S-10L and S-10R At STA 360. (a)(b) (a) Do an external Low Frequency Eddy Current (LFEC) sliding probe inspection in accordance with 737 NDT, Part 6, 53-30-24 or an internal Medium Frequency Eddy Current (MFEC) inspection in accordance with 737 NDT, Part 6, 53-30-23 or an external High Frequency Eddy Current (HFEC) pencil probe inspection in accordance with 737 NDT, Part 6, 53-30-29 or a internal HFEC inspection in accordance with 737 NDT, Part 6, 51-00-00 figure 23 to detect any crack. (b) If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections.

**(SHEET 2 OF 2) FIGURE 43: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 887 - LIMITED RETURN TO SER**  **VICE PROGRAM** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 230 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 43: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 887 - LIMITED RETURN TO SERVICE PROGRAM** 

AFT GALLEY

DOOR

RH AFT CARGO DOOR RIGHT SIDE

AFT GALLEY

DOOR

LH 

### BL-0 S-25R

S-14R
S-10R

S-4R

S-1
S-4L

S-10L
S-14L

S-20L S-25L BL-0 STA 1016

S-20R STA 887



### TYPICAL 737 AFT SECTION 11552956

**(SHEET 1 OF 2) FIGURE 43: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 887 - LIMITED RETURN TO SER**  **VICE PROGRAM** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 231 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Splice Plate Between S-10L and S-10R At STA 887. (a)(b) (a) Do an external Low Frequency Eddy Current (LFEC) sliding probe inspection in accordance with 737 NDT, Part 6, 53-30-24 or an internal Medium Frequency Eddy Current (MFEC) inspection in accordance with 737 NDT, Part 6, 53-30-23 or an external High Frequency Eddy Current (HFEC) pencil probe inspection in accordance with 737 NDT, Part 6, 53-30-29 or a internal HFEC inspection in accordance with 737 NDT, Part 6, 51-00-00 figure 23 to detect any crack. (b) If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections.

**(SHEET 2 OF 2) FIGURE 44: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 500E AND STA 727I - LIMITED**  **RETURN TO SERVICE PROGRAM** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 232 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 44: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 500E AND STA 727I - LIMITED RETURN TO SERVICE PROGRAM** 

FWD GALLEY

DOOR

FWD ENTRY DOOR FWD CARGO DOOR RIGHT SIDE STA 259.50 STA 360 STA 540

BL-0

S-24R

S-19R

S-14R S-10R

S-4R

S-1 S-4L

S-10L S-14L

S-19L

S-24L

BL-0



### 737-900 STA 500E 11552958

**(SHEET 1 OF 3) FIGURE 44: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 500E AND STA 727I - LIMITED**  **RETURN TO SERVICE PROGRAM** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 233 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This Figure applies to Group 4, 9: 

### AFT GALLEY DOOR RH AFT CARGO DOOR RIGHT SIDE

AFT ENTRY DOOR LH BL-0 S-25R

S-14R
S-10R

S-4R
S-1
S-4L

S-10L
S-14L

S-20L S-25L BL-0 STA 1016

S-20R STA 887 STA 727



### 737-900 STA 727I 21552959

**(SHEET 2 OF 3) FIGURE 44: FUSELAGE - CIRCUMFERENTIAL BUTT JOINT - STA 500E AND STA 727I - LIMITED**  **RETURN TO SERVICE PROGRAM** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 234 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Splice Plate Between S-10L and S-10R At STA 500E. (a)(b) 2 Inspect Splice Plate Between S-10L and S-10R At STA 727I. (a)(b) (a) Do an external Low Frequency Eddy Current (LFEC) sliding probe inspection in accordance with 737 NDT, Part 6, 53-30-24 or an internal Medium Frequency Eddy Current (MFEC) inspection in accordance with 737 NDT, Part 6, 53-30-23 or an external High Frequency Eddy Current (HFEC) pencil probe inspection in accordance with 737 NDT, Part 6, 53-30-29 or a internal HFEC inspection in accordance with 737 NDT, Part 6, 51-00-00 figure 23 to detect any crack. (b) If internal MFEC or internal HFEC inspections are used, the areas of the splice plate covered by production stringers, shear ties, or production internal splice plates do not require eddy current inspections.

**(SHEET 3 OF 3) FIGURE 45: EXTERNAL APPROVED REPAIRS - LIMITED RETURN TO SERVICE PROGRAM**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 235 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 45: EXTERNAL APPROVED REPAIRS - LIMITED RETURN TO SERVICE PROGRAM**



### TYPICAL APPROVED EXTERNAL REPAIR TYPICAL SCRIBE LINES

DOUBLER SKIN PANEL 

### TYPICAL AIRPLANE SHOWN

REPAIR DOUBLER SKIN A A



### A-A STA 360 STA 540 STA 727 STA 887 STA 1016

A SEE



### A 1 APPROVED EXTERNAL REPAIR AREAS (TYPICAL)

1

11553063

**(SHEET 1 OF 2) FIGURE 45: EXTERNAL APPROVED REPAIRS - LIMITED RETURN TO SERVICE PROGRAM**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 236 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Locate Approved External Repair STA 360 to STA 1016 -

**(SHEET 2 OF 2) FIGURE 46: INTERNAL REPAIR DOUBLER - LIMITED RETURN TO SERVICE PROGRAM**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 237 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 46: INTERNAL REPAIR DOUBLER - LIMITED RETURN TO SERVICE PROGRAM** 



### TYPICAL APPROVED INTERNAL REPAIR TYPICAL SCRIBE LINES SKIN

REPAIR FILLER

INTERNAL REPAIR DOUBLER

SKIN REPAIR FILLER INTERNAL REPAIR DOUBLER

SKIN SKIN 

### TYPICAL AIRPLANE SHOWN

TYPICAL SCRIBE LINES

A A



### A-A S-10L STA 1016

STA 360



### A 1

1 A SEE APPROVED INTERNAL REPAIR AREAS (TYPICAL)

1 11553062

**(SHEET 1 OF 2) FIGURE 46: INTERNAL REPAIR DOUBLER - LIMITED RETURN TO SERVICE PROGRAM**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 238 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

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

**STEP TASK NAME IDENTIFICATION MORE DATA** 1 Inspect Internal Repair Doubler STA 360 to STA 1016 (a) (a) Do an external Low Frequency Eddy Current (LFEC) sliding probe inspection in accordance with 737 NDT, Part 6, 53-30-24 or an internal Medium Frequency Eddy Current (MFEC) inspection in accordance with 737 NDT, Part 6, 53-30-23 or an external High Frequency Eddy Current (HFEC) pencil probe inspection in accordance with 737 NDT, Part 6, 53-30-29 or an internal HFEC inspection in accordance with 737 NDT, Part 6, 51-00-00 Figure 23 to detect any crack.

**(SHEET 2 OF 2) FIGURE 47: REQUIRED INSPECTIONS FOR SC**  **RIBES FOUND WITHIN ONE INCH OF A SKIN LAP JOINT AND EXTERNAL APPROVED REPAIRS**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 239 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**FIGURE 47: REQUIRED INSPECTIONS FOR SCRIBES FOUND WITHIN ONE INCH OF A SKIN LAP JOINT AND EXTERNAL APPROVED REPAIRS** 

In each of the areas defined above, all of the inspections described in the table are necessary if scribes are found.

**NOTE:**

1. The illustration shown above is not to scale. 2. The illustration above shows a typical lap joint. The same dimensions apply to the edges of repair doublers. 3. Initial inspections must be done with the paint removed. 

### 0.03 0.063

0.10 1.00

DOUBLER LOWER SKIN UPPER SKIN

AREA 1 AREA 2 AREA 3



### TYPICAL LAP JOINT1685245

**(SHEET 1 OF 2) FIGURE 47: REQUIRED INSPECTIONS FOR SCRIBES FOUND WITHIN ONE INCH OF A SKIN LAP**  **JOINT AND EXTERNAL APPROVED REPAIRS** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 240 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**Area 1 Area 2 Area 3 For scribe lines in Area 1, all**  **of the following inspections must be done from butt joint**  **to butt joint, unless otherwise noted.**  **For scribe lines in Area 2, all of the following inspections must be done**  **from butt joint to butt joint, unless otherwise noted.**  **For scribe lines in Area 3, all of the following inspections**  **must be done. Butt joint to butt joint inspections are not**  **required.** Detailed (a) and either Option 1 or Option 2 below. Detailed (a) and either Option 1 or Option 2 below. Detailed (a) and HFEC below.
Option 1: Ultrasound. Single element ultrasonic as given in 737 NDT, Part 4, 53-30-05 (b)(d)

and Surface HFEC as given in 737 NDT, Part 6, 53-30-22 (a) Option 1: Ultrasound. Single element ultrasonic as given in 737 NDT, Part 4, 53-30-05 (b)(d) and one of the following: Surface HFEC (c) as given in 737 NDT, Part 6, 51-00-00 Figure 4 (a), or

737 NDT, Part 6, 51-00-00 Figure 23 (a), or 737 NDT, Part 6, 53-30-26 (rotary probe) (a), or 737 NDT, Part 6, 53-30-27 (spot probe) (a). Surface HFEC (c) as given in:
737 NDT, Part 6, 51-00-00 Figure 4 (a), or
737 NDT, Part 6, 51-00-00Figure 23 (a), or

737 NDT, Part 6, 53-30-26 (rotary probe) (a), or
737 NDT, Part 6, 53-30-27 (spot probe) (a).

Option 2: Ultrasound. Phased array ultrasonic as given in 737 NDT, Part 4, 53-30-06 (a)(d) Option 2: Ultrasound. Phased array ultrasonic as given in 737 NDT, Part 4, 53-30-06 (a)(d) and one of the following: Surface HFEC (c) as given in 737 NDT, Part 6, 51-00-00 Figure 4 (a), or

737 NDT, Part 6, 51-00-00 Figure 23 (a), or 737 NDT, Part 6, 53-30-26 (rotary probe) (a), or 737 NDT, Part 6, 53-30-27 (spot probe) (a). (a) After the initial inspection with the paint removed, subsequent inspections using this method can be accomplished with the paint in place. (b) The paint must be removed for this inspection. (c) This inspection is only required in the scribed area. (d) The skin thickness must be known when conducting the UT inspection. Refer to 737 SRM chapter 53 for the applicable Boeing drawings. At the operators option refer to 737 NDT, Part 4, 51-00-00 Figure 2 as an accepted procedure to determine the skin thickness.

**(SHEET 2 OF 2) APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 241 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN**
1. MATERIAL REQUIRED: A. Scrapers. 1. AC Tech Scraper, TS 1275-4 (6 inch length). Supplier: Advanced Chemistry & Technology (AC TECH) Address: 7341 Anaconda Avenue, Garden Grove, CA 92841, USA Phone: 714-373-2837 extension 119 or 117 Fax: 714-373-1913, Attn: Customer Service email: rosie.cruze@actechaero.com

**NOTE:** Handles are also available for these products for better comfort and control. The handle best suited for the TS 1275-4 scraper can be purchased under the part number SHR 0272-T from AC Tech. 2. SEMCO Scraper: P/N 234350 (6 inch length). Supplier: PPG Aerospace: SEMCO Division Address: PPG-Aerospace (ASC-Seattle), 14126 NE 190th Street, Woodinville, WA 98072, USA Phone: North America 800 237-6649 (This connects to the closest PPG Aerospace facility in North America. For North America and International contacts visit the web site.) China (Suzhou) 86 512 6661 5858 Dubai UAE 971 4 883 9666 France 33 0 5 6149 4849 Germany 49 40 742 193 10 Hong Kong 852 2861 0918 South Africa 27 11 608 5656 Singapore 65 861 1119 United Kingdom 44 0 1388 770222 Web Site: www.ppg.com/prc-desoto/main.asp?img=asc email: Cheryl.Chittenden@PPG.com?subject=Semco Scrapers (PN-234350) 3. Jus N Tyme Scrapers: P/N JNT 411B60 (6 inch length), P/N JNT 411B90 (9 inch length -tapered). Supplier: Jus N Tyme Tooling Address: 2167 Green Canyon Road, Fallbrook, CA 92028, USA Phone: 760 723-5985 Fax: 760 723-5820 Contacts: Cheryl or Bob Hancock Web Site: www.JusNTyme.com email: Bob@JusNTyme.com

**NOTE:** Scraper P/N JNT 411B90 is designed for removing sealant from butt joints with a 1/ 4 inch or larger gap. 4. PnJ Scrapers: P/N DFD5019, SCD5019, SFD7519, DAD5013 (5 and 9 inch lengths of varying widths); Plastic handles: P/N SHN0272, SHW0215, SHR0272.**APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 242 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Supplier: PnJ Machining, Inc. Address: 2601 Inter Avenue, Puyallup, WA 98372, USA Phone: 253 841-0500 Fax: 253 840-1695 Contact: Paul Hogeboom Web site: www.pnjmachining.com

**NOTE:** Scraper P/N DAD5013 is designed for removing sealant from butt joints with a 1/8 inch or larger gap. 5. Elixair Scrapers: P/N 311/03/04, 311/06/06, 311/12/04, 311/12/06, 311/24/04, 311/24/06, 311/ 38/04, and 311/38/06 (7.5 inch length with handle of varying widths); Skyholder Rubber Handle: P/N 310/1; Skymill Pneumatic Scraper Sharpener: P/N 309/3; Skybag for sharpener: P/N 309/ 3B. Supplier: Elixair International Limited Address: Roman Hill Business Park, Broadmayne, Dorset DT2 8LY, United Kingdom Phone: 44 0 1305 853019 (within the UK); 44 1305 853019 (within the USA) Fax: 44 0 1305 852060 (within the UK); 44 1305 852060 (within the USA) Contact: Len McLaughlin Web site: www.elixair.co.uk email: sales@elixair.com or lenmclaughlin@elixair.co.uk

**NOTE:** 1. Scraper P/N 311/03/06 is designed for removing sealant from butt joints with a 3 mm or larger gap. 2. The pneumatic sharpener can be used to sharpen most plastic scrapers. 6. Custom Components LTD Scraper: P/N 10810 (6 inch length). Supplier: Custom Components LTD Address: Unit 3, Feltrim Business Park, Swords Co., Dublin Ireland Phone: 353 1 8901909 Fax: 353 1 8901907 7. Bomatic, Inc. Scraper: P/N 1-6390-A (9 inch length - tapered). Supplier: Bomatic, Inc. Address: 1841 E. Acacia St., Ontario, CA 91761, USA Phone: 909 947 3900 Fax: 909 947 5969 Contact: Kjeld Hestehave, Cathy Macri Web site: www.bomatic.com

**NOTE:** Scraper P/N 1-6390-A is designed for removing sealant from butt joints with a 1/4 inch or larger gap. 8. General Tool & Supply Scraper: P/N ST982L-9ACE (9 inch length).**APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 243 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Supplier: General Tool & Supply Address: 355 Trek Drive, Tukwila, WA 98188, USA Phone: 206 762-1500 Toll: 1 800-321-3305 Fax: 206 767-7026 Contact: Dean Zetty Web site: www.generaltool.com email: dzetty@generaltool.com

B. Power Tools
1. 3M SR cutter - No. 3, 0.40 inch diameter, P/N 48011-30096-2.

**NOTE:** Any power tool that will accept the 3M SR Cutter and has a maximum speed of 850 RPM (at the cutter) can be used.
C. Solvents 1. Methyl Ethyl Ketone (MEK), ASTM D740. 2. Methyl Propyl Ketone (MPK), BMS 11-9, Grades 1 and 2. 3. Aliphatic Naptha, TT-N-95, Type I and Type III.
4. Toulene, TT-T-548 or ASTM D362. 5. Isopropyl Alcohol TT-I-736.

D. Miscellaneous 1. Aluminum Oxide abrasive paper, 400 grit or finer. 2. Paper or wipers that meet the requirements of BSM 15-5.
2. SEALANT REMOVAL NOTES: This appendix provides procedures for removing sealant from the exterior pressurized fuselage. Using these procedures will minimize the risk of damaging clad aluminum surfaces during sealant removal. The main areas of concern are: A. Lap joints. B. Butt joints (including underlying splice plates). C. Other areas where sealant is present (i.e. wing to body fairings, windows, access doors, etc.). Boeing recommends only approved scrapers and tools listed in Paragraph 1 of this appendix be used for removing sealant from the exterior fuselage. Alternately, it is acceptable to use other scrapers provided the meet the requirements of BSS7384 (Method for Evaluating Tool Materials for use on Unpainted Clad Aluminum). Commonly used scraper materials such as Lexan polycarbonate, acrylic (Plexiglas), Micarta fiber reinforced phenolic resins, metal, wood, and other hard plastics have been tested and found to scratch clad aluminum.**APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 244 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

3. SEALANT REMOVAL PROCESS: LAP JOINT FILLET A. To remove the lap joint fillet, follow this procedure:
**CAUTION:** PLEASE NOTE THAT THERE IS A POTENTIAL FOR THE SR CUTTER TO "RUN AWAY" AND CAUSE DAMAGE AT THE LAP JOINT AND SURROUNDING AREA. ALSO, IF THE CUTTER CONTACTS BARE METAL BENEATH THE SEALANT, THE CLAD ALUMINUM SKIN COULD BE DAMAGED. BEFORE USING THE 3M SR CUTTER, OPERATORS SHOULD BE TRAINED ON PROPER USAGE OF THIS TOOL AND SHOULD PRACTICE ON TEST PANELS OR PIECES TO PERFECT THEIR SKILLS IN WORKING WITH THE TOOL. 1. Remove the majority of the fillet seal at the lap joint using any of the approved scrapers listed in Paragraph 1.A. of this appendix. As an alternative, the 0.4 inch diameter 3M SR Cutter listed in Paragraph 1.B. of this appendix can be used. To prevent the cutter from damaging the clad aluminum surface, do not remove the sealant to bare metal. There should be a thin layer of sealant remaining on the surface after removing the majority of the sealant with the 3M SR Cutter. 2. After removing the majority of the sealant with approved scrapers or the 3M SR Cutter, remove the remaining sealant with any of the solvents listed in Paragraph 1.C. of this appendix. An approved scraper (Paragraph 1.A.) or wiper (Paragraph 1.D.) can be used along with the solvent to help with the removal.
4. SEALANT REMOVAL: BUTT JOINTS AND OTHER AREAS WHERE SEALANT IS PRESENT ON THE EXTERIOR FUSELAGE A. To remove sealant in butt joints and other areas on the exterior fuselage, follow this procedure:
**CAUTION:** THE 3M SR CUTTER IS RECOMMENDED FOR REMOVING SEALANT FROM LAP JOINTS, BUT NOT FROM BUTT JOINTS OR OTHER AREAS. 1. Remove the bulk of the sealant using any of the approved scrapers in Paragraph 1.A. of this appendix. Scrapers designed specifically for removing sealant from butt joints are available (i.e. PnJ, Elixair, Bomatic, Jus N Tyme). The shape of an approved scraper can be modified to fit a butt joint or other areas, as required. One possible modification is shown below.**APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 245 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

2. After removing the majority of the sealant with approved scrapers or the 3M SR Cutter, remove the remaining sealant with any of the solvents listed in Paragraph 1.C. of this appendix. An approved scraper (Paragraph 1.A.) or wiper (Paragraph 1.D.) can be used along with the solvent to help with the removal.
5. SCRAPER MAINTENANCE A. Scrapers dulled from use can be sharpened with 400 grit or finer aluminum oxide paper. Before using a sharpened scraper, the scraper should be rubbed on paper or cheesecloth (Paragraph 1.D.2.) to remove loose sanding particles. If an alternate method of sharpening is used, such as a metal sharpening wheel (including the Elixair Internation Limited pneumatic sharpener), rub the scraper on 400 grit or finer aluminum oxide paper after sharpening to remove debris, and then rub the scraper on paper or cheesecloth to remove loose particles.
6. USE OF CHEMICAL STRIPPERS TO ASSIST IN SEALANT REMOVAL FOR SCRIBE LINE INSPECTION
A. MATERIALS
1. Cee-Bee E-1058, McGean-Rohco, Inc. Atlanta GA. 2. Eldorado PR-5044, Eldorado Chemical Company, Inc. San Antonio TX. 3. Elixair - Skyrestore (Thick), Elixair International Limited, Dorchester, England. 4. Naftosolv FN, Chemetall GMBH, Frankfurt, Germany. 5. Skycleen 2000 Aviation Cleaner, Solutia Inc. St. Louis, MO. 6. Turco 5351, Henkel Corporation, Madison Heights, MI.
B. SEALANT REMOVAL Use one of the following methods to remove sealant along lap and butt joints on the exterior fuselage.
1. Method 1 - Mechanical/Chemical 

### POSSIBLE SCRAPER MODIFICATION TO FIT A BUTT JOINT SCRAPER WIDTH BUTT JOINT GAP WIDTH1548889**APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 246 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Remove sealant fillet with an approved scraper in accordance with Paragraph 1.A., above. Chemically strip any sealant remaining on the surface as follows: a. Mask surrounding areas as necessary to prevent contact with chemical strippers. Do not allow chemical strippers to contact substrates other than aluminum. Do not use chemical strippers on reverse lap joints.

**NOTE:** Chemical strippers will soften and remove paint. b. Using a natural bristle brush, apply a thin coating of chemical stripper on the sealant.
**CAUTION:** CHEMICAL STRIPPER MAY PENETRATE INTO JOINTS IF GAPS ARE PRESENT DUE TO MISSING FAYING SURFACE SEALANT. (1) Do not apply excessive chemical stripper. Stripper should hang and not flow. (2) Let the stripper dwell until the sealant can be easily removed by dry wiping, but do not exceed 40 minutes dwell time. (3) Remove softened sealant with clean dry wipers (BMS 15-5 Class A). Approved scrapers may be used in accordance with 737-600/700/800/900 AMM 51-31-00 to facilitate removal. c. After chemical stripping is complete, remove stripper by thoroughly washing with a waterbased alkaline cleaner approved for painted surfaces in accordance with SOPM 20- 30-03. Rinse off alkaline cleaner with water.
2. Method 2 - Chemical/Mechanical/Chemical a. Mask surrounding areas as necessary to prevent contact with chemical strippers. Do not allow chemical strippers to contact substrates other than aluminum.

b. Using a natural bristle brush, apply a thin coating of chemical stripper on the sealant fillet. c. Let the chemical stripper dwell for a maximum of 4 hours, except use a maximum dwell time of 2 hours if Turco 5351 is used. A thin coat of stripper may be brushed on every hour as necessary to maintain a wet surface. Do not apply excessive stripper. Stripper should hang and not flow. d. Do not apply chemical stripper to areas where the joint is exposed. e. Remove softened sealant with an approved scraper in accordance with 737-600/700/800/ 900 AMM 51-31-00 and clean dry wipers (BMS 15-5 Class A). f. Repeat steps b., c., d., and e. if necessary, but do not apply chemical stripper to areas where the joint is exposed. g. If any sealant remains on the surface after removing the sealant fillet, follow the procedure outlined in Method 1.**APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 247 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

h. After chemical stripping is complete, remove stripper by thoroughly washing with a waterbased alkaline cleaner approved for painted surfaces in accordance with SOPM 20-30-03. Rinse off alkaline cleaner with water.**APPENDIX B: REPORTING SYSTEM - LIMITED RETURN TO SERVICE PROCEDURE FOR SCRIBE LINE AIRPLANES**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 248 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**APPENDIX B: REPORTING SYSTEM - LIMITED RETURN TO SERVICE PROCEDURE FOR SCRIBE LINE AIRPLANES**  Boeing recommends that operators use the format that follows to report the results of the inspections in this service bulletin to Boeing. Use of this standard format will result in a more rapid review and approval of the data. A Return to Service Proposal will be provided by Boeing after review of the data.

**INTRODUCTION:** The following is a summary of the work carried out on airplane ___________ as part of a return to service work pack.

Airplane Model: Airplane Registration: Airplane Variable Number: Airplane Line Number: Airplane Serial Number: Airplane Total Hours / Flight Cycles: Airplane Flight Cycles Since Scribe Line Introduction:

BACKGROUND: __________________________ has completed the following work on airplane ______________________: INSPECTIONS: The following inspections were completed on airplane _______________________: Detailed Visual Inspections: Lap Joints: Fuselage lap joints between STA 360 - STA 1016. Findings: (Include a detailed description of any damage found, including locations, message numbers, etc. Attach additional pages as necessary.) Action:

Circumferential Butt Joint: Fuselage skin, circumferential butt joints at STA 360 & STA 887 (all 737NG airplanes) and STA 500E & STA 727I (737-900 airplanes). Findings: (Include a detailed description of any damage found, including locations, message numbers, etc. Attach additional pages as necessary.) Action:

External Doublers/Repairs: Fuselage skin around certain external doublers/Repairs. Findings: (Include a detailed description of any damage found, including locations, message numbers, etc. Attach additional pages as necessary.) Action:**APPENDIX B: REPORTING SYSTEM - LIMITED RETURN TO SERVICE PROCEDURE FOR SCRIBE LINE AIRPLANES**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 249 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

Decals: Fuselage skin around decals. Findings: (Include a detailed description of any damage found, including locations, message numbers, etc. Attach additional pages as necessary.) Action:

Maximum Observed Scribe line Depth: The maximum scribe line depth for all locations (lap joints, butt joints, skin doublers at certain repair doublers, and decals) is ______ inches.

NDT Inspections: All NDT inspections for cracks at scribe line locations have been accomplished as shown in Section 3., Accomplishment Instructions, of Service Bulletin 737-53A1289. Findings: (Include a detailed description of any damage found, including locations, message numbers, etc. Attach additional pages as necessary.) Action: **INTRODUCTION: APPENDIX C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES**  Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 250 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**APPENDIX C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES**

**Location Length (inches)**  **Distance From Lap (Inches) Depth (inches)**
**Stringer Forward Body**  **Station Aft Body**  **Station L d_fwd (a) d_min (b) d_aft (c)** 

(a) d_fwd = Distance from the edge of the upper skin of the forward end of the scribe line. (b) d_min = Minimum distance of the scribe line at any point along the entire length of the scribe line from the edge of the upper skin. (c) d_aft = Distance from the edge of the upper skin of the aft end of the scribe line. 

### L d_fwd d_min d_aft

SCRIBE LINE LAP JOINT UPPER SKIN

LOWER SKIN1548890**APPENDIX C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 251 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**Body Station**  **Length (inches)**  **Distance From Stringer (Inches) Depth (inches)**  **L Upper Stringer d-x (a) Lower Stringer d-y (b)**S- SS- SS- SS- S- (a) d_x = Distance of the scribe upper end from the upper stringer. (b) d_y = Distance of the scribe lower end from the lower stringer. 

### SPLICE STRAP

BUTT JOINT

FORWARD SKIN AFT SKIN 

### d_y STRINGER Y CENTER LINE STRINGER X CENTER LINE 

### d_X

L1548891**APPENDIX C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 252 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**Forward Body**  **Station Aft Body**  **Station Stringer Length**  **(inches) Distance From Stringer**  **(Inches) Depth (inches)** 

**L d_fwd (a) d_aft (b)**

ssss- (a) d_fwd = Distance of the forward end of the scribe from the stringer. (b) d_aft = Distance of the aft end of the scribe from the stringer. 

### STRINGER X CENTER LINE 

### d_aft d_fwd L

SCRIBE FUSELAGE SKIN1548892**APPENDIX D: SCRIBE LINE SAMPLE** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 253 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

**APPENDIX D: SCRIBE LINE SAMPLE** The instructions that follow can be used to make representative samples of the kinds of scribe line marks that may be found during the inspections specified in this service bulletin. This design is a visual inspection aid that can be used to familiarize visual inspectors with scribe lines and assure consistency between visual inspectors. The flag note 1 scribe line is intended to show the inspector how a scribe line can be hidden under a lap chamfer, requiring the inspector to look at an oblique angle to the lap joint edge to detect some scribes lines. The flag note 2 scribe line is intended to demonstrate a typical tactile scribe line. The flag note 3 scribe line is intended to demonstrate a shallow non-tactile scribe line.

**NOTE:** 1. Minimum surface roughness is 125 micro inches. 2. Unless otherwise noted, the following dimensions and tolerances are used: — All dimensions are in inches. — Tolerance on linear dimensions, other than rivet or bolt edge margins, is plus or minus 0.03 inch. — Tolerance on rivet or bolt edge margin is plus or minus 0.05 inch. — Angular tolerance is plus of minus 2 degrees. — Hole dimensions for standard solid rivets are given in 737 Structural Repair Manual, Chapter 51. 1. Make part A from bare 2024-T3 aluminum, 0.040 inch thick. 0.060 inch thick bare 2024-T3 is an acceptable substitute. 2. Make part B from bare 2024-T3 aluminum, 0.071 inch thick. 3. Fasten part B to part A with five 5/32 inch diameter countersunk rivets. Make the countersinks in part B. 4. Make three typical scribe line marks on part A as follows: A. Flag Note 1: Scribe line part A with the tip of a razor knife, using one to two pounds down load with finger pressure on the knife handle. Displaced material from the scribing operation should remain on part A. Make sure that the scribe line is under the 20 degree chamfer on the edge of part B. Make sure the scribe line can be seen visually. B. Flag Note 2: Scribe line part A with the tip of a razor knife, using one to two pounds down load with finger pressure on the knife handle. Displaced material from the scribing operation should remain on part A. Make sure the scribe line is tactile (a fingernail can catch on the scribe line). C. Flag Note 3: Scribe line part A with one pass from the tip of a ball point pen, using 0.25 to 0.5 pound down load. Make sure the scribe line is not tactile (a fingernail does not catch on the scribe line). As an alternative to a ball point pen, use the edge of a 0.040 inch wide CRES plate, with 0.25 inch diameter radii at the corners of the plate.**APPENDIX D: SCRIBE LINE SAMPLE** Original Issue: January 14, 2009 Revision 1: November 18, 2009 737-53A1289 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 254 of 254 

### BOEING SERVICE BULLETIN 737-53A1289

This sample can be obtained from the following vendors:

EC/NDT 1020 South 344th St. Suite 214 Federal Way, WA 98003 USA Phone: [253] 815-0797 Fax: [253] 815-0827 DT ENGINEERING CORP 19620 Russell Road Kent, WA 98032 USA

Phone: [253] 872-3565 Fax: [253] 872-0857

2.0 (TYPICAL)

2.0 (TYPICAL) 1.0 2.0 1.0 2.0

12.0 4.00 3.50

2.90 FASTENER (TYPICAL, 5 LOCATIONS)

PART B PART A



### A-A CHAMFER 20° 

### SCRIBE SAMPLE

A A

3 2 1

11548893