# REVISIONTRANSMITTALSHEET BOEINGCOMMERCIAlAIRPLANES POSTOFFCEBOX3707 SEArn.E.WASHIGTOCN961242207 Boeing Service Bulletin 737-53-1116 This sheet transmits REVISION 1,date September 7,1989 of Service Bulletin 737-53-1116, "FUSELAGE - FORWARD GALLEYDOORWAYUPPER CORNERS - INSPECTION, REPAIR,AND PREVENTIVEMODIFICATION". NOTE: This revision constitutesacomplete reissue. SUMMARY This revision is issued to recommend the modification per this service bulletin for incorporation on aging 737 airplanes and to change the forward galley doorupper forward cornerdoubler installation,eliminating interference when incorporating Service Bulletin 737-53-1074. The incorporation threshold for this service bulletin is shown in the Description and Accomplishment Instructions. As a result of the FM-sponsored Aging Fleet Conference, a 737 Structures Working Group withAirline andBoeingmembers and FAA observerswas formed to review structural servicebulletinmodifications andrecommend selected bulletins for incorporation on aging airplanes. Based on a structural review of the 737 airplane, the Structures Working Group has determined that modification per this service bulletin, at or before the indicated threshold, should be accomplished to support the continued structural integrity of aging 737 airplanes. Airplane effectivity isupdated to reflect currentairplane ownership. Airplanes modified per the previous release of this service bulletin do not require additionalwork. Arevisionbar inthe leftmarginalongwith this revisionnumber anddate indicates a change. Absence of a revision bar on apage bearing this revision number and date means only that existing copy has beenmoved or that aminor typographical errorhasbeen corrected. REVISIONHISTORY Original Issue: July 21, 1988 Revision 1: September 7,1989

# 227g7§Y §7g7 SERVICE BULLETIN *S MSUMMARYY BOEINGCOMMERCIALAIRPLANES POSTOFFICEBOX3707 SEATTE.WAS4W'1ONi0T 1 292207 SUBJECT: FUSELAGE
- FORWARD GALLEY ATA: 5331 NUMBER: 737-53-1116 DOORWAY UPPER CORNERS
- 

### DATE:July 21, 1988 INSPECTION, REPAIR, AND 

# I REVISION 1:September 7,1989 PREVENTIVE MODIFICATION BACKGROUND 35,000 flight cycles, accomplish the initial inspection within 3,500 flight Based on a structural review of the cycles after receiving this bulletin. 737 airplane, incorporation of the If no cracks are found accomplish the modification per this service bulletin preventive modification, or repeat the is recommended on aging airplanes. inspection at "C" check intervals until the preventive modification is Six operators have found seventeen accomplished. If cracks are found, cracks in the skin and doublers at the install the repair doublers and upper corners of the forward galley triplers over the cracked areas per doorway on eight airplanes. There this bulletin. were eight cracks reported at the upper aft corner on three airplanes, EFFECTIVITY and nine cracks in the skin at the forward corner on five airplanes. The 737 airplanes Line Number 1-1560, less airplanes had accumulated from 29,000 PJ201-PJ219 to 47,300 flight hours, and from 40,500 to 60,800 flight cycles. MANPOWER Cause of the cracking is attributed to Elapsed fatigue from pressurization cycles, Total Time and if not corrected could result in Applicability Man-Hours (Hours) cabin pressurization difficulties, and unscheduled downtime for repairs. Inspection 5 2.5 Preventive ACTION Modification 0.7 0.7 Repair -per corner 14 14 As recommended by the 737 Aging Fleet Structures Working Group, accomplish MATERIAL INFORMATION the modification per the Accomplishment Instructions at or 

### EPrice before the accumulation of 75,000 flight cycles. 65C33800-12 $422.00 65C33800-13 $401.00 Prior to reaching 35,000 flight 65C33800-14 $292.00 cycles, accomplish high and low 65C33800-15 $301.00 frequency eddy current inspections for 65C33800-16 $214.00 cracks in the skin, skin doubler, or bearstrap doubler in the upper corners See Paragraph I.F for applicable terms of the forward galley doorway. For and conditions. airplanes having accumulated over Summary Page 1of2BOEING SERVICE BULLETIN 737-53-1116

S'3

+ < CRACKS + + Oj (TYPICAL)

AFT CORNER SHOWN FORWARD CORNER SIMILAR

Jul 21/88 REV. 1: Sep 7/89 Summary Page 2 of 2

## C5L OEINGCOMPERCIALAIRPLANES POSTOlFICEBOX3707 SEATTLE.WASHMGTONfl1124-2l20 

# SERVICE BULLETIN

ATASYSTEM: 5331 NUMBER: 737-53-1116 DATE:July21, 1988 REVISION 1:September 7,1989 SUBJECT: FUSELAGE - FORWARD GALLEYDOORWAY UPPER CORNERS
- INSPECTION, REPAIR, ANDPREVENTIVE MODIFICATION

I. PLANNING INFORMATION A. Effectivity 1. AirplanesAffected See Service Bulletin Index Part 3 for cross reference of Variable Number toAirplane SerialNumber. This change isapplicable only to airplanes listedbelow. CODE VARIABLE NUMBER AAL PG201 PG204 PG217 PG222 PG271-PG272 PG276 PG278 PG351 PG403 PG438 PP161-PP168 ADD PK495 ABL PP380 AFA PL502-PL503 PNO1I-PN117 AID PY002 ALG PK361 PK631 PK633-PK634 PL717-PL725 PY051-PY053 ALK PY591-PY595 ALO PG046 PG629 PG705 PK286 PK305-PK306 PK691-PK695 PK697 PP730 PP733 PY001 PY003 PY005 PY451
Jul 21/88 737-53-1116 REV. 1: Sep 7/89 Page 1of 22BOEING SEhVICE BULLETIN 737-53-1116
CODE VARIABLE NUMBER (CONTINUED) ALY PY409-PY410 AMW FC004 PG036 PG331-PF332 PG577 PJ102 PK082 PK283 PK565 PK625-PK626 PK696 PLO81 PL172 PL551-PL562 PL801 PP181-PP192 PP378 PP381 PP891-PP899 PP901 ANA PG578-PG581 PG583-PG586 PK711-PK716 ANG PK661 PK664-PK666 PY162 ANK PG582 ANS PQ026-PQ037 ANW PP904 PP907 ANZ PK047 PK211 PK213-PK214 PK216-PK220 PM181 PY741 APC PL151 ARE PP352 PP384 PP835 PP846 PP946-PP947 ARG PH705-PH708 PH741-PH743 PK102-PK103 PY007-PY008 ARL PG251 PG253-PG255 PG573 PG575 PK029 PK614 PK641-PK642 PP951-PP952 PY281 PY321-PY323 ARM PY241 PY243-PY244 ASA PY112 PY134-PY135 PY270 PY461-PY463 ASC PG224 PG401-PG402 PG572 PG574 PY343 AUK PK612 PL171 AUS PQOO1-PQ012 AVG PN501-PN502 AZE PA001 PA003-PA004 PCO03 PL802

Jul 21/88 737-53-1116 REV. 1: Sep 7/89 2BOEING SERVICE BULLETIN 737-53-1116
CODE VARIABLE NUMBER (CONTINUED) BAH PK351-PK353 PL061 BAB PK731.PK765 PK771-PK777 PK779 PK819 PK830 BAV PL451-PL452 PL455-PL456 BCI PG214 BEJ PM281-PM283 PP521-PP522 BER PP822 BMA PP908-PP909 BNF PC034 PG202 PG205 PG207 PG209 PG211-PG212 PG216 PG218 PG220-PG221 PG273-PG275 PK287 BRI PJ101 PJ103-PJ1O8 PJ110-PJ119 PK212 PK215 PK801-PK804 PY361-PY362 BRT PJOOI-PJOO9 PJ031 PJ072 PK882 PL803 PN451-PN456 BRZ PK068-PK069 BZB PY401 CAL PG199 PP671-PP699 PP701-PP726 CAM PH171 PY046-PY047 CDI PG651-PG652 PJ032 PK026-PK028 PK221-PK223 PK358 PK561 PK671-PK675 PK677-PK681 PK822-PK823 PK881 PK884 PL4O1-PL417 PL712 PL761-PL762 PL764-PL770 PM141-PM142 PY151-PY154 PY301-PY304 PY421-PY422 PY441 CHI PN471-PN472 CIN PG279 COP PCOOI PY341 COR PP831 PP838 CRU PK141-PK146

* Jul 21/88 737-53-1116 REV. 1: Sep 7/89 3BOEING SERVICE BULLETIN 737-53-1116
CODE VARIABLE NUMiER (CONTINUED) DAL PG203 PG219 PK611 PK613 PK615 PK623-PK624 PK632 PL221 PL611 PN131-PN163 PN401-PN404 PN407-PN420 PP231-PP243 DAN PK820 PL421 PNO01-PNO02 PP351 PP353 DFI PP991 DLH PK901-PK938 PQ051-PQ065 PQ086-PQO090 PY345-PY346 DRG PK357 PK617 PK871 PK873 EAG PG436 PY381 EGN PG037 PG208 PG210 PG215 PG431 PL763 EOP PK252-PK258 ELA PL631-PL632 ERA PG026 PG028-PG029 PY004 PY006 EUR PK203 PK359 PK564 FAT PA002 PA005 PG055 PG226 PG228 PG230 PK562 PN481 FCT PCO02 PG213 PG252 FRO PG056 PG064 PG225 PG229 PG432-PG433 PG441-PG442 PG621-PG628 PG630 PG704 PLOOl GAX PA231-PA232 GBN PY191 GER PQ231-PQ233 GNE PY651 GUL PK461-PK468 GUN PK635-PK637 PM251-PH254 PN405 PY056-PY057 HAP PL501 PL504-PL506

Jul 21/88 737-5t-1116 ; REV. 1: Sep 7/89 '4BOEING SERVICE BULLETIN 737-53-1116 CODE VARIABLE NUMBER (CONTINUED) HGA PK284-PK285 PK827 HLA PP833-PP834 PP839-PP840 PP903 ICS PY342 PY344 IDF PH016-PMO17 IDO PL601-PL603 IER PP841-PP842 IND PH021-PH022 PH024 PH709 PH711-PH713 PK231-PK240 PL026-PLO28 PL711 PMOO1-PM006 PY631 INT PK616 PP931-PP936 PP948 IRN PH731 PK391 PY021-PY022 IRQ PY141-PY142 JAT PP771-PP779 JTA PL441 KAF FP221 K11M4 PP861-PP870 LAL PP851-PP852 LAM PHOOl PH703 PY031 LAN PK360 PK825 PLO25 PY242 LNA PY411 LNM PH701 LUX PK451-PK452 MAD PG375 PL793 HAL PL716 HAS PK281 PL736-PL738 PL740-PL747 PY201 

# Aa * Jul 21/88 737-53-1116 REV. 1: Sep 7/69 5BOEING SERVICE BULLETIN 737-53-1116
CODE VARIABLE NUMBER (CONTINUED) KID PK621-PK622 PK627-PK629 PN491-PN493 KLT PL621-PL626 MON PP821 PP823-PP824 PP832 MRS PK872 PK874 PP501-PP504 MXG PCO05 PG223 NAS PA099 NAU PK356 PK581 PY286 NIA PL781-PL782 PL784-PL788 NIR PY166 NTA PY132-PY133 OLY PK301-PK304 PK307-PK310 PM021-PM023 ORN PK826 PP201-PP205 PP732 PAA PG020-PGO21 PG043 PG047-PG048 PEX PA006-PA022 PG501-PG505 PIA PP281-PP286 PLU PL201-PL203 PRS PX701 PRW PJ109 PK563 PTI PP728-PP729 PTS PL471 RAM PK271-PK274 PY671-PY672 RBA PK051 PY231 SAM PG353-PG356 PL101-PL113 SAB PK041 PK044-PK046 PK048-PK050PK052-PK053 PK431-PK433 PP961-PP965 PY272-PY275 

# a

.Jul21/88 737-53-1116 

# V REV. 1: Sep 7/89 6BOEING SERVICE BULLETIN 737-53-1116 CODE VARIABLE NUMBER (CONTINUED) SAH PG434 PK081 SHJ PL581 SRF PK318 SUD PY156-PY157 SVA PK311-PK317 PL726-PL735 PY036-PYO37 SWA PK091-PK099 PK541-PK560 PK630 PM051-PM066 PP101-PP135 SIJL PK521 PK523-PK527 TAC PG059 PG352 PP727 PY131 TAF PK519 TAN PJ071 TAP PK971 PK973-PK974 PN081-PNO86 PY721 TAV PG074 PK501-PK504 PK821 PP801-PP804 PY101-PY103 TBL PP825-PP826 PP836-PP837 PP847-PP848 PQ241-PQ242 

# * TEA PK042-PK043 PK282 TII PK511 PK514-PK515 TNZ PY611-PY612 TUN PK861-PK863 PY621 UAL PGOO1-PG004 PGO06-PG019 PG022-PG025 PG027 PG030 PG032-PG033 PGO38-PG040 PG044-PG045 PG051-PG054 PG057 PG060-PG063 PGO65-PG072 PG075 PK201-PK202 PLO02-rL024 PQ101-PQ123 UNV PP379 PP382 PP731 USA PG041-PG042 PG049 PG073 PG206 PG301-PG314 PG474 PG576 PK288-PK289 PK591-PK599 PK601-PK610 PK883 PM1O1-PM119 PNO21-PN043 PP001-PP045 PP376-PP377 PP383 PP401-PP436 PP471-PP475 PV001-PV004 

# V Jul 21/88 737-53-116 REV. 1: Sep 7/89 7BOEING SERVICE BULLETIN 737-53-1116
CODE VARIABLE NUMBER (CONTINUED) UTA PP902 PP910 VAR PK111-PK12C PL453-PL454 PP905-PP906 PP981-PP982 VAT PK824 PL758 VIV PP169 PP391-PP392 VNZ PK070 VSP PG435 PG437 PG439-PG440 PG471-PG471 PHOll-PHG13 PK061-PK062 PK06S-PK067 PK241 PK354-PK355 PL756 PP301-PP305 PP827 PX071 PY222 XIA PM255 PN406 XIN PP631-PP634 YEM PK341 YUN PP651-PP652 ZAI PYlll PY113 ZAM PK291 ZMB PN431-PN433

Jul 21/88 737-53-1116 

# 3 REV. 1: Sep 7/89 8BOEING SERVICE BULLETIN 737-53-1116
LISTING BY VARIABLE NUMBER PA001-PA022 PA099 PA231-PA232 PC001-PC005 PGO01-PG075 PG199 PG201-PG230 PG251-PG255 PG271-PG279 PG301-PG314 PG331-PG332 PG351-PG356 PG375 PG401-PG403 PG431-PG442 PG471-PG475 PG501-PG505 PG571-PG586 PG621-PG630 PV651-PG652 PG701-PG705 PH001 PHOll-PH013 PH021-PH024 PH701-PH715 PH731-PH732 PH741-PH743 PJ001-PJ009 PJ031-FJ032 PJ071-PJ072 PJ101-PJ119 PK026-PK029 PK041-PK053 PK061-PK070 PR081-PK082 PK091-PK099 PK101-PK103 PK111-PK120 PK141-PK146 PK201-PK20O PK211-PK223 PK231-PK241 PK251-PK258 PK271-PK274 PK281-PK289 PK291 PK301-PK318 PK341 PK351-PK361 PK391 PK431-PK433 PK451-PK452 PK461-PK469 PK495 PK501-PK504 PK511-PK515 PK519 PK521-PK527 PK541-PK565 PK581 PK591-PR599 PK601-PK617 PK621-PK637 PK641-PK642 PK661-PK666 PK671-PK681 PK691-PK697 PK711-PK716 PK731-PK765 PK771-PK779 PK801-PK804 PK819-PK827 PK830 PK861-PK863 PK871-PK874 PK881-PK884 PK901-PK938 PK971-PK974 PLOO1-PL028 PL061 PLO81 PL101-PL113 PLISl PL171-PL172 PL201-PL203 PL221 PL401-PL417 PL421 PL441 PL451-PL456 PU471 PU.91 PL501-PL506 PL551-PL562 PL581 PL601-PL603 PL611 PL621-PL626 PL631-PL632 PL711-PL712 PL716-PL747 PL756 PL758 FL761-PL770 PL781-PL788 PL793 PL801-PL803 PMOO1-PM006 PM016-PM017 PM021-PM023 PM051-PM066 PH101-PM119 PH141-PM142 PK171 PM181 PM251-PM255 PM281-PM283 PNOO1-PN002 PNO21-PN043 PNO81-PN086 PNI01-PN117 PN131-PN163 PN401-PN420 PN431-PN433 PN451-PN456 PN471-PN472 PN481 PN491-PN493 PNS01-PN502 PNS11 PPOO1-PP045 PP101-PP135 PP161-PP169 PP181-PP192 PP201-PP205 PP221 PP231-PP243 PP281-PP286 PP301-PP305 PP351-PP353 PP376-PP384 PP391-PP392 PP401-PP436 PP471-PP475 PP501-PP504 PP521-PP522 PP631-PP634 PP651-PP652 PP671-PP699 PP701-PP733 PP771-PP779 PP801-PP804 PP821-PP827 PP831-PP842 PP846-PF848 PP851-PP852 PP861-PP870 PP891-PP899 PP901-PP910 PP931-PP936 PP946-PP948 PP951-PP952 PP961-PP965 PP981-PP982 PP991 PQ001-PQ012 PQ026-PQ037 PQ051-PQ065 PQ086-PQ090 PQ101-PQ123 PQ231-PQ233 PQ241-PQ242 PV001-PV004 PX071 PX701 PY001-PY008 PY021-PY022 PY031 PY036-PY037 PY046-PY048 PY051-PY053 PY056-PY057 PY101-PY103 PYl11-P1113 PY131-PY135 PY141-PY143 PY151-PY154 PY156-PY157 PY161-PY162 PY166 PY191 PY201 PY221-PY222 PY231 PY241-PY244 PY270-PY275 PY281 PY286 PY301-PY304 PY321-PY323 PY341-PY346 PY361-PY362 PY381 PY401 PY409-PY411 PY421-PY422 PY441 PY451 PY461-PY463 PY591-PY595 PY611-PY612 PY621 PY631 PY651 PY671-PY672 PY721 PY741 2. Spares Affected None

Jul 21/88 737-53-1116 REV. 1: Sep 7/89 9BOEING SERVICE BULLETIN 737-53-1116
B. Reason 

# a As a result of the FAA-sponsored Aging Fleet Conference, a 737 

# W Structures Working Group with Airline and Boeing members and FM observers was formed to review structural service bulletin modifications and recommend selected bulletins for incorporation on aging airplanes. This service bulletin modification has been recommended for incorporation onaging 737 airplanes. Inspection of the upper corners of the forward galley doorway will detect cracking that could result inpresturization difficulties. Repair of cracks or accomplishment of preventive modification on uncracked structure isterminating action for inspection per this servicebulletin. Six operators have reported cracks in the upper corners of the forward galley doorways on a total of eight airplanes. Three airplanes hada total ofeight cracks in theupper aft corner,with crack lengths of up to 2 inches inthe skin, and a 2 inch long crack in the bearstrap doubler onone airplane. Five airplaneshad atotal ofnine cracks from 0.1 inch to 1.5 inches in length inthe upper forwardcorner skin. The aiplanes had accumulated from 29,000 to 47,300 flight hours, and from 40,500 to 60,800 flight cycles. Revision 1 of this bulletin is issued to provide the recommendations of the AgingFleet 737 StructuresWorkingGroup and to change the forward galley doorway upper forward corner repair doubler installation. The installation change eliminates one fastener andmoves one fastener to make the repaircompatible with the Service Bulletin 737-53-1074 modification. The forward galley door upper forward corner modification, installed per this service bulletin, overlaps the preventive modification installedper ServiceBulletin 737-53-1074, therefore, it is suggested that prior or concurrent incorporation of the preventive modification per service bulletin 737-53-1074 be considered prior to the repair per this bulletin. Airplanes repaired per the original issue of this bulletin do not require additionalworkper this revision.



# a Jul 21/88 737-53-1116 REV. 1: Sep 7/89 10BOEING SERVICEBULLETIN 737-53-1116 C. 

### Descriptiof Basedon astructural reviewof the 737 airplane, itisrecommended that the modification per the Accomplishment Instructions of this servicebulletin be accomplished prior to, or upon accumulation of 75,000 flight cycles. Prior to accumulating 35,000 flight cycles, accomplishhighand low frequency eddy current inspections of the area around fasteners in the upper corners of the forward galley doorway to determine if there are cracks in the skin, skin doubler, orbearstrap doubler. For airplanes with over 35,000 flight cycles, accomplish this inspection no later than 3,500 flight cycles after receiptof this bulletin. Ifno cracks are found, accomplish the preventivemodification per this bulletin, or repeat the inspection at "C"check intervals until thepreventivemodification is accomplished. Ifcracks are found, stop drill the crack ends, and install the repair doublers and triplers over the cracked areas per this bulletin. NOTES: 1. Prior or concurrent incorporation of Boeing Service Bulletin 737-53-1074, "Fuselage - Entry and Galley Doorway Skin Cutouts - Inspection andModificatiorf', is suggested oncommonly affected airplanes. 2. This service bulletin is listed in Boeing Document D6-38505. D. Approval This service bulletin has been reviewed by the Federal Aviation Administration (FM) and the repairs and modifications herein complywith the applicable FederalAviationRegulations (FAR's) and are FMapproved. The FAA has determined that modification in accordance with Revision 1 of Service BulLetin 737-53-1116, "Fuselage - Forward Galley Doorway Upper Corners - Inspection, Repair, and Preventive Modification" provides an acceptable alternatemeans of compliance for modifications specified in Boeing Document D6-38505, which is the subject ofNotice of ProposedRule Making (NPRM)Docket Number 89-NM-67-AD.



# a Ju i tnjoS 737-53-1116 REV. 1: Sep 7/89 11BOEING SERVICE BULLETIN 737-53-1116

E. tanlfwB2O Approximately 7 man-hours and a crew of 2 are required to 

# a accomplish this inspection per airplane, plus approximately an additional 0.7 man-hour and a crew of 1isrequired to accomplish this preventivemodificationperdoorwaycorner. Approximately 14 man-hours are required to accomplish this crack repair perdoorway corner. The followingbreakdownofmanpower requirements issuggested as a guide to assist operators in planning and accomplishing this repair. This estimate is for direct labor performed by an experienced crew. It does not include setup, planning, familiarization, cure time, toolacquisition, or lost time. Factor this estimate asnecessarybased onyourown experience.Elapsed Time Operation Crew Size Man-Hours (Hours) Access 1 1 1 Crack Repair (maximum) 1 12 12 Restoration 1 1 1 TOTAL PERDOORWAYCORNER 14 14



# a

Jul 21/88 737-53-1116 

## W REV. 1: Sep 7/89 12BOEINGSERVICEBULLETIN 737-53-1116
F. Material
- PriceandAvailability The kits identified inParagraphs II.A and II.B may be obtained from Boeing within the terms and conditions defined below. The quotation iscomputed from date of receipt of operator's purchase orders. Improved flow times may be possible if necessary to support operator's planned modification schedule. Therefore, operators are requested to include planned dates of incorporation on their purchase orders. KitNumber Description Delivery Unit Price 65C33800-12 Kit
-Repair 26 weeks $422.00 65C33800-13 Kit
-Repair 26weeks $401.00 65C33800-14 Kit
-Repair 22weeks $292.00 65C33800-15 Kit
-Repair 22weeks $301.00 65C33800-16 Kit
- Gutter 22weeks $214.00 Date September 7.1989 The prices quoted are subject to the terms and conditions of Boeing's standard purchase order acknowledgment. Quotations are subject to acceptance within 120 days from date hereon. After expiration of the quotation, price and delivery data will be provided upon request. Prices quoted in United States Dollars. Terms: Net 30 days. Address purchase orders and correspondence pertaining to this quotation to Director ofSpares, and refer to this servicebulletin number. The following kit identified in Paragraph II.A.1may be furnished or fabricated from operator's existing stock or purchased directly from industry sources. The followingBoeingpricedata isprovided forplanning purposes or in the event operators desire to purchase kits fromBoeing. Deliverydatawillbe provideduponrequest. Kit Number Description Unit Price 65C33801-1 Kit
- Preventive $0.60 Modification Date September 7.1989 The prices quoted are subject to the terms and conditions of Boeing's standard purchase order acknowledgment. Quotations are subject to acceptance within 120 days from date hereon. After expiration of the quotation, prices and delivery data will be provided upon request. Prices quoted inUnited States Dollars. Terms: Net 30days. Address purchase orders and correspondence pertaining to this quotation toDirector of Spares, and refer to this servicebulletin number. 

# V Jul 21/88 737-53-1116 REV. 1: Sep 7/89 13BOEING SERVICE BULLETIN 737-53-1116

G. IToling - Price and Availability 

# a
All required coldwork tools and sleeves for accomplishment of this service bulletin may be selected from appropriate tables in Structural Repair Manual and procured from industry sources, as required. Two sources that provide coldwork tools, as wellas engineering and service, is Fatigue Technology, Inc., and West Coast Industries, Inc. Also available from both companies is a kit of coldwork tooling specifically tailored to the requirements of this service bulletin. Ref: FrI Kit Number: FTI-737-53-1ll6-l Fatigue Technology, Inc. P.O. Box C-88388 Seattle, WA 98188 Telex Number 321004 Twx 910-444-4128 WCI Kit Number 1WCI-737-53-1116 West Coast Industries, Inc. 1111 North 92nd Seattle, WA 98103 Telex Number 284560 WCIS UR H. Weight and Balance Change in Change in Weight Moment AnlicabilitPounds) (Pound-Inches) 737-100 (a) +9.2 +2825 737-200 (a) +9.2 +3494 737-300 (a) +9.2 +2089 (a)Approximate weight and balance information based on incorporation of 65C33800-12, -13 and -16 kits (worst case) on an airplane. Actual weight and balance to be determined by operator based on extent ofkit incorporation. NOTE: Incorporation of Preventive Modification kit 65C33801-1 has no effect on airplane weight andbalance.

Jul 21/88 737-53-1116 REV. 1: Sep 7/89 14BOEING SERVICEBULLETIN 737-53-1116
1. References 1. ExistingData: a. 737 StructuralRepairManual Subjects 51-10-1, 51-30-9 b. 737Nondestructive TestManual Part 6Subject 51-00-00, 53-10-42 c. Boeing Service bulletin 737-53-1074, "Fuselage - Entry and Galley Doorway Skin Cutouts - Inspection and Modification" d. Boeing Document D6-38505, 'Aging Airplane Service Bulletin Structural Modification Program - Model 737- l00/-200/-200C". 2. Data supplied insupportof this servicebulletin: Drawings DrawingNo. Sheet DCN ADCN Title 65C33800 PL A

- Skin and Stringer Installation - Repair (TopKit) 65C33800 

### 1 C(a)

- (a) Supplied insupport ofRevision 1. 3. Process Data: Boeing Process Specifications that are listed on drawings supplied insupport of this servicebulletin arenotdetailed in this service bulletin since they are common practices which can be accomplished in accordance with operator's normal procedures. J. PublicationsAffected None

Jul 21/88 737-53-1116 REV. 1: Sep 7/89 15BOEINGSERVICE BULLETIN 737-53-1116
II. MATERIAL INFORMATION A. PartsRequired PerAirplane The following isprovidedto aid inkit selection. Usae Preventive Modification 65C33801-1 BothCorners Repair Forward Corner Skin andbearstrepcracks 65C33800-12 Skin orbearstrap crack 65C33800-14 Repair - Aft Corner Skin andbearstrap cracks 65C33800-13 Skinorbearstrapcrack 65C33800-15 RainGutterReplacement 65C33800-16 (Required withrepair) 

# I 1. The kitsmaybe obtained asnoted in Paragraph I.F. NOTE: One or more kits and operator furnished materials listed inParagraph II.A.2 are required to modify or repair each airplane. 65C33800 - SKIN AND STRINGER INSTALLATION - SKIN REPAIR (TOPKIT) -16 -15 -14 -13 -12 

# @ Ouantitv PartNumber Nomenclaturel

, , . - 65C33800-12 Kit - Forward Corner, Skin andDoublerRepair 65C33800-13 Kit
- AftCorner, Skinand DoublerRepair 65C33800-14 Kit
- ForwardCorner, Skin or DoublerRepair 65C33800-15 Kit - Aft Corner, Skin or DoublerRepair

- 65C33800-16 (a) Kit - Gutter Installation 1 1
. 65C33800-17 Repair Strap 1
. 1

. 65C33800-18 Doubler 1

. 65C33800-19 Tripler

. 1
. 1 65C33800-20 Repair Strap 1
. 1 65C33800-21 Doubler 1 65C33800-22 Tripler 1 . . . . 65C33800-23 Filler

. . . 65C33800-24 Filler (a) Kit contains excess parts not required for installation. Discard excess parts or return them to operator's spare stock. 

### Al'
Jul 21/88 737-53-1116 REV. 1: Sep 7/89 16BOEING SERVICE BULIETIN 737-53-1116
65C33800 - (CONTINUED) -16 -15 -14 -13 -12 Ouantitv Part Number Nomenclature 1
. 65C33800-25 Filler 1
. . . 65C33800-26 Filler 1
. 65-49893-2 Gutter

. 20
. 2 BACB3OFN5-5 Hi-Lok 18 BACB3OFN5-6 Hi-Lok 21 9 21 9 BACB30FN6-3 Hi-Lok * 31 12 22 12 BACB30FN6-4 Hi-Lok 7 62 64 28 23 BACB30FN6-5 Hi-Lok 7 34 42 43 55 BACB3OFN6-6 Hi-Lok 4 33 11 32 31 BACB3OFN6-7 Hi-Lok 2
. 24 6 BACB30FN6-8 Hi-Lok

- 1 2 1 BACB30FN6-9 Hi-Lok * 20 20 BACC3OM5 Collar 11 185 142 178 142 BACC3OK6 Collar 5

- BACR15BB4B7 Rivet 5
. . BACR15BB4B9 Rivet 4 4
. BACRl5CE6Bll Rivet 4 4 BACR15CE6B12 Rivet 3 4
. . BACR15CE6B13 Rivet 3 4 BACR15CE6B14 Rivet

. 1
. 1 BACR15CE6D6 Rivet 4 1 BACR15CE6D8 Rivet

, . 3 BACRl5CE6D9 Rivet * 1 1 1 1 BACR15CE6D11 Rivet 4 4 1 1 BACRl5CE6D12 Rivet 3 3 BACRI5CE6Dl3 Rivet 65C33801

- SKIN, AND STRINGER INSTALLATION, SECTION 41, PREVENTIVE MODIFICATION -1 Ouantit PartNumber Nomenclature

- 65C33801-1 (a) Top Kit 8 BACR15BB8B9 Rivet 6 BACR15BB8B1O Rivet 1 BACR15BB8B13 Rivet (a) Kit fasteners maybe furnished from operator's existing stocks.

Jul 21/88 737-53-1116 REV. 1: Sep 7/89 17BOEING SERVICEBULLETIN 737-53-1116
2. The followingmaterials are tobe furnishedby the operator. PartNumber or Quantity Slcficato Nomenclatur As Required BMS 5-95, ClassB Sealant As Required BMS 10-11, Type I Primer As Required BMS 10-11, Type II Enamel - Color tohatch Airplane B. Parts Required toModify Snares None C. Svecial Tools andEcuinmentRequired Coldworking Tools are required during accomplishment of the preventive modification per this service bulletin. See Paragraph l.C. for details. D. Existing Parts Accountability None



# A Jul 21/88 737-53-1116 

# 5 REV. 1: Sep 7/89 18BOEING SERVICE BULLETIN 737-53-1116
III. ACCOMPLISHMENTINSTRUCTIONS NOTES: 1. The following paragraphs outline the general accomplishment instructions. The suggested sequence of operations and detailed accomplishment instructions are indicated by circle notes on the figures. 2. As recommended by the 737 Aging Fleet Structures Working Group, accomplish themodificationper thisservicebulletin, Figure 3of theAccomplishment Instructionsprior to, or upon the accumulationof 75,000 flight cycles. 3. On the figures, unless otherwise specified:

- All linear dimensions are ininches

- Tolerance on linear dimensions other than rivet and bolt edge margin isplus orminus 0.03

- Tolerance on rivet and bolt edge margin isplus or minus 0.05

- Hole size for standard solid rivets is per 737 Structural RepairHanual Chapter 51 1 A. Open the forward galley door for access to interior surface ofdoor cutout to accomplish inspection and rework of doorway upper corners. B. Accomplish an eddy current inspection of the skin, skin doubler, and bearstrap doubler ineach upper corner of the doorway per Figure 1. C. Ifcracked doorway cornersare found, repairper Figure 2. D. If no cracks are found, accomplish preventive modification per Figure 3. As an option, reinstall reveal fittings and rivets and repeat inspection of upper doorway corners at "C"check intervals until the preventivemodification isaccomplished. NOTE: Delayed implementation of the preventive modification may cause oversizing requirements beyond the preventive modificationkit range. E. Refinish the rework area around doorway as required, and restore airplane to operationalconfiguration.

Ja1 CI/bS 737-53-1 16 REV. 1: Sep 7/89 19BOEING SERVICE BULLETIN 737-53-1116

STA STA 332.1 3122

-- .----- r/ S ,\- ............

+ 1 -L TYPICAL (8 PLACES) T7 ICAL INSPESTION |.-|(7 PLACES) -P AREA (TYPICAL) CAtTION: WHEN DRILLING OUT EXISTING FASTENERS, DO NOT USE DRILL BIT SIZE ANY LARGERTHAN EXISTING FASTENER DIAMETER. @ Carefully drill outexistingfasteners in shadedareas. Remove magnes'um reveal corner fittings 65-53594-1 (or -501) and 65- 53595-1 (or -501) frombearstrap doubler andretainfor lateruse. Clean off any sealantresidue from exposedarea ofbearstrap doubler. @ Inspect exposedarea ofskin (outside) andbearstrapdoubler (inside) for cracks around each removed fastener location (Ref. 737 Nondestructive Test Hanual (NDT) D6-37239, Part 6. Subject 51-00-00, Figure 4). Depending on inspection results, take appropriate action per Accomplishment Instructions. Inspect skin doubler (underneath skin) for cracks around each removed fastener location (Ref. 737 NDT Manual D6-37239. Part 6.Subject 53-10- 42). Depending on inspection results, take appropriate action per Accomplishment Instructions. FIGURE 1. FORWARD GALLEY DOORWAYUPPER CORNERK INSPECTION; Jul 21/88 737-5s-1116 20BOEING SERVICEBULLETIN 737-53-1116

STA STA STA 3 332.1 312 291.5

PICA TY ICA CRACKACK

5-9-o0 

## OFWDE2?

Remove existing raingutter. Stop drill endof crack (Ref. 737 Structural RepairManual Subject 51-10- 1). Ifskin assembly or bearstrap doubler is cracked, install repair strap and doublerper drawing 65C33800 usingkit 65C33800-14. 

# Q If skin assemblyandbearstrap doubler are cracked, install repair strap, doubler, andtripler perdrawing 65C33800using kit 65C33800-12. If skin assembly or bearstrap doubler iscracked, install repair strap and doublerper drawing 65C33800usingkit 65C33800-15. |~@If skin assembly andbearstrap doubler arecracked, install repair strap, doubler, and triplerperdrawing 65C33800usingkit 65C33800-13. 

# Q Install new rain gutter and appropriate filler strips under gutter per drawing 65C33800 using kit 65C33800-16. Trim filler strips as required, depending onwhich repairkits are installed. 

# A FIGURE 2. CRACKREPAIR
- FORWARDGALLEYDOORWAY 

# V Jul 21/88 737-53-1116 21BOEING SERVICEBULLETIN 737-53-1116

STA 332. 

# '
~

2- L--

-: |- - 2-ORAR -~ +++

I /

## e TYPICA 12 

### 11+1 

## / (B PLACES+ 

# H- 1 2 4TYPICAL 

# -i 

# v-LIFT(7 PLACES) ''Li-'-UPPER 5-8 '

-I~'~FORWARD t 

# OCORNER

UPPER 

### UP 

## UAFFTP 

# [:FWD[:: CORNER
@Drill out fastener holes to the appropriate starting hole size for 1/4 inch diameter rivets and high interference sleeve cold working method (Ref. 737 Structural RepairManual Subject 51-30-9). Cold work fastener holes inuncracked corners using high interference sleeve method (Ref. 737 StructuralRepairManual Subject 51-30-9). Enlarge fastener holes inreveal fittings to 0.254-0.265 inch diameter. Apply sealant (Ref. BMS 5-95) to faying surfaceof fittings, andposition inplace onbearstrapdoubler. Install indicated fasteners fromkit 65C33801 or from operators stock. FASTENERCODE * Install rivet BACR15BBSB(*) wet with sealant (Ref. BMS 5-95), with manufacturedheadnear side. 

## $Enlarge countersink far side to 0.425-0.431 inch diameter. Install rivet BACR1SBB8B1O wetwith sealant (Ref. BES 5-95) and withmanufactured head near side. Shave the formedhead (far side) asrequired tobe flushwith structure. (*) Grip length of fastener indicated by number adjacent to fastener symbol.
FIGURE 3. PREVENTIVEMODIFICATION -FORUARDGAILJ.1 tJRlfAY ; Jul 21/88 ,3t-5-1116 22

# nor-ff 

# SERVICEBULLETIN > 

# EVALUATIONFORM THIS EVALUATION FORM IS PROVIDED FOR THE PURPOSE OF CoHeULICatzm INFORlTION TO THE LOEING ORGANIZATION RESPONSIBLE FOR SERVICE BULLETINS AND iIHSI UUUNT. THE DATAYOU PROVIDEWILLBE USEDTO IMPROVE THEBOEING SERVICEBULLETIN PROGRAM. NOTE: THIS FORM IS NOT INTENDED TO BE USED FOR REQUESTING SERVICE BULLETIN INCORPORATION INTOBOEING TECHNICALMANUALS. S/BNO.: 737-53-1116 REV.1 S/B DATED: SEPTEMBER 7, 1989 TITLE: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION OPERATOR: AIRPLANES AFFECTED o perS/Beffectivity list (checkone): o percorrectedlistbelow: PREPARED BY: TITLE: - DATE: ORGANIZATION: TELEX CODE: EVALUATION:

check ONE ofthe following checkONE of the following

five circles AND seven circles.

- Will accomplish O -Inspection n
- Bing accomplished | - Partial incorporation 

# V Q 

### -HBeaccomplished | 

# )

- 

### Complete incorporation {-Have accomplishedI J IQ0 - Service bulletinintent O-Uneonomical 

# C-J Will not accomplish 

# C

- Ue mexperiencedoesnotjustify Decision deferred (explain) I 

# )

- Other (explain below) COMMENTS: Bulletin Quality, Suggested Improvements, Other.

FOR ADDITIONAL COMMENTS USE REVERSE SIDE Please forward this form to yourBoeing FieldService Representative ormail directly to: Attention: B. G.Kelsey B oeing Commercial Airplanes Manager, P.O. Box 3707 Service Bulletin Enginevrira Seattle, WA 98124 Mail Stop 2L-02