REVISION TRANSMITTAL SHEET

BOEING COMMERCIAl AIRPLANES POST OFFCE BOX 3707 SEArn.E. WASHIGTOCN 961242207

Boeing Service Bulletin 737-53-1116

This sheet transmits REVISION 1, date September 7, 1989

of Service Bulletin 737-53-1116, "FUSELAGE - FORWARD GALLEY DOORWAY UPPER

CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION".

NOTE: This revision constitutes a complete 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 door upper forward corner doubler 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 with Airline and Boeing members and FAA observers was formed

to review structural service bulletin modifications and recommend selected

bulletins for incorporation on aging airplanes. 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 is updated to reflect current airplane ownership.

Airplanes modified per the previous release of this service bulletin do

not require additional work.

A revision bar in the left margin along with this revision number and date

indicates a change. Absence of a revision bar on a page bearing this

revision number and date means only that existing copy has been moved or

that a minor typographical error has been corrected.

REVISION HISTORY

Original Issue: July 21, 1988

Revision 1: September 7, 1989
227g7§Y §7g7

SERVICE BULLETIN

*S MSUMMARYY

BOEING COMMERCIAL AIRPLANES POST OFFICE BOX 3707 SEATTE. WAS4W'1ON i0T 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 1 of 2
BOEING 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

OE ING COMPERCIAL AIRPLANES POST OlFICE BOX 3707 SEATTLE. WASH MGTON fl1124-2l20

SERVICE BULLETIN

ATA SYSTEM: 5331 NUMBER: 737-53-1116 DATE: July 21, 1988

REVISION 1: September 7, 1989

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION,

REPAIR, AND PREVENTIVE MODIFICATION

I. PLANNING INFORMATION

A. Effectivity

1. Airplanes Affected

See Service Bulletin Index Part 3 for cross reference of

Variable Number to Airplane Serial Number.

This change is applicable only to airplanes listed below.

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 1 of 22
BOEING 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 2
BOEING 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 3
BOEING 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 '4
BOEING 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 5
BOEING 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-PK050 PK052-PK053

PK431-PK433 PP961-PP965 PY272-PY275

a

.Jul 21/88 737-53-1116 V

REV. 1: Sep 7/89 6
BOEING 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 7
BOEING 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 8
BOEING 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 9
BOEING 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 on aging 737 airplanes.

Inspection of the upper corners of the forward galley doorway will

detect cracking that could result in presturization difficulties.

Repair of cracks or accomplishment of preventive modification on

uncracked structure is terminating action for inspection per this

service bulletin.

Six operators have reported cracks in the upper corners of the

forward galley doorways on a total of eight airplanes. Three

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

crack lengths of up to 2 inches in the skin, and a 2 inch long

crack in the bearstrap doubler on one airplane. Five airplanes had

a total of nine cracks from 0.1 inch to 1.5 inches in length in the

upper forward corner skin.

The ai planes 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 Aging Fleet 737 Structures Working Group and

to change the forward galley doorway upper forward corner repair

doubler installation. The installation change eliminates one

fastener and moves one fastener to make the repair compatible with

the Service Bulletin 737-53-1074 modification.

The forward galley door upper forward corner modification,

installed per this service bulletin, overlaps the preventive

modification installed per Service Bulletin 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

additional work per this revision.

a

Jul 21/88 737-53-1116

REV. 1: Sep 7/89 10
BOEING SERVICE BULLETIN 737-53-1116

C. Descriptiof

Based on a structural review of the 737 airplane, it is recommended

that the modification per the Accomplishment Instructions of this

service bulletin be accomplished prior to, or upon accumulation of

75,000 flight cycles.

Prior to accumulating 35,000 flight cycles, accomplish high and 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, or bearstrap doubler.

For airplanes with over 35,000 flight cycles, accomplish this

inspection no later than 3,500 flight cycles after receipt of this

bulletin.

If no cracks are found, accomplish the preventive modification per

this bulletin, or repeat the inspection at "C" check intervals

until the preventive modification is accomplished.

If cracks 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 and Modificatiorf', is

suggested on commonly 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

comply with the applicable Federal Aviation Regulations (FAR's) and

are FM approved.

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 alternate means of compliance

for modifications specified in Boeing Document D6-38505, which is

the subject of Notice of Proposed Rule Making (NPRM) Docket Number

89-NM-67-AD.

a Ju i tnjoS 737-53-1116

REV. 1: Sep 7/89 11
BOEING 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 1 is required to accomplish

this preventive modification per doorway corner.

Approximately 14 man-hours are required to accomplish this crack

repair per doorway corner.

The following breakdown of manpower requirements is suggested 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, tool acquisition, or lost time. Factor

this estimate as necessary based on your own experience.

Elapsed

Time

Operation Crew Size Man-Hours (Hours)

Access 1 1 1

Crack Repair (maximum) 1 12 12

Restoration 1 1 1

TOTAL PER DOORWAY CORNER 14 14

a

Jul 21/88 

737-53-1116 W

REV. 1: Sep 7/89 

12
BOEING SERVICE BULLETIN 737-53-1116

F. Material - Price and Availability

The kits identified in Paragraphs II.A and II.B may be obtained

from Boeing within the terms and conditions defined below. The

quotation is computed 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.

Kit Number Description Delivery Unit Price

65C33800-12 Kit - Repair 26 weeks $422.00

65C33800-13 Kit - Repair 26 weeks $401.00

65C33800-14 Kit - Repair 22 weeks $292.00

65C33800-15 Kit - Repair 22 weeks $301.00

65C33800-16 Kit - Gutter 22 weeks $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 of Spares, and refer to this service bulletin

number.

The following kit identified in Paragraph II.A.1 may be furnished

or fabricated from operator's existing stock or purchased directly

from industry sources. The following Boeing price data is provided

for planning purposes or in the event operators desire to purchase

kits from Boeing. Delivery data will be provided upon request.

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 in United States Dollars.

Terms: Net 30 days.

Address purchase orders and correspondence pertaining to this

quotation to Director of Spares, and refer to this service bulletin

number.

V Jul 21/88 737-53-1116

REV. 1: Sep 7/89 13
BOEING 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 well as 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 of kit incorporation.

NOTE: Incorporation of Preventive Modification kit 65C33801-1

has no effect on airplane weight and balance.

Jul 21/88 737-53-1116

REV. 1: Sep 7/89 14
BOEING SERVICE BULLETIN 737-53-1116

1. References

1. Existing Data:

a. 737 Structural Repair Manual Subjects 51-10-1, 51-30-9

b. 737 Nondestructive Test Manual Part 6 Subject 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 in support of this service bulletin:

Drawings

Drawing No. Sheet DCN ADCN Title

65C33800 PL A - Skin and Stringer

Installation - Repair

(Top Kit)

65C33800 1 C(a) -

(a) Supplied in support of Revision 1.

3. Process Data:

Boeing Process Specifications that are listed on drawings

supplied in support of this service bulletin are not detailed

in this service bulletin since they are common practices

which can be accomplished in accordance with operator's

normal procedures.

J. Publications Affected

None

Jul 21/88 737-53-1116

REV. 1: Sep 7/89 15
BOEING SERVICE BULLETIN 737-53-1116

II. MATERIAL INFORMATION

A. Parts Required Per Airplane

The following is provided to aid in kit selection.

Usae

Preventive Modification 65C33801-1

Both Corners

Repair Forward Corner

Skin and bearstrep cracks 65C33800-12

Skin or bearstrap crack 65C33800-14

Repair - Aft Corner

Skin and bearstrap cracks 65C33800-13

Skin or bearstrap crack 65C33800-15

Rain Gutter Replacement 65C33800-16

(Required with repair) I

1. The kits may be obtained as noted in Paragraph I.F.

NOTE: One or more kits and operator furnished materials

listed in Paragraph II.A.2 are required to modify or

repair each airplane.

65C33800 - SKIN AND STRINGER INSTALLATION - SKIN REPAIR (TOP KIT)

-16 -15 -14 -13 -12 @

Ouantitv Part Number Nomenclaturel

, , . - 65C33800-12 Kit - Forward Corner,

Skin and Doubler Repair

65C33800-13 Kit - Aft Corner, Skin and

Doubler Repair

65C33800-14 Kit - Forward Corner, Skin

or Doubler Repair

65C33800-15 Kit - Aft Corner, Skin or

Doubler Repair

- 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 16
BOEING 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 Part Number Nomenclature

- 65C33801-1 (a) Top Kit

8 BACR15BB8B9 Rivet

6 BACR15BB8B1O Rivet

1 BACR15BB8B13 Rivet

(a) Kit fasteners may be furnished from operator's existing

stocks.

Jul 21/88 737-53-1116

REV. 1: Sep 7/89 17
BOEING SERVICE BULLETIN 737-53-1116

2. The following materials are to be furnished by the operator.

Part Number or

Quantity Slcficato Nomenclatur

As Required BMS 5-95, Class B Sealant

As Required BMS 10-11, Type I Primer

As Required BMS 10-11, Type II Enamel - Color to hatch

Airplane

B. Parts Required to Modify Snares

None

C. Svecial Tools and Ecuinment Required

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 18
BOEING SERVICE BULLETIN 737-53-1116

III. ACCOMPLISHMENT INSTRUCTIONS

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 the modification per this service bulletin,

Figure 3 of the Accomplishment Instructions prior to, or upon

the accumulation of 75,000 flight cycles.

3. On the figures, unless otherwise specified:

- All linear dimensions are in inches

- Tolerance on linear dimensions other than rivet and

bolt edge margin is plus or minus 0.03

- Tolerance on rivet and bolt edge margin is plus or

minus 0.05

- Hole size for standard solid rivets is per 737

Structural Repair Hanual Chapter 51 1

A. Open the forward galley door for access to interior surface of door

cutout to accomplish inspection and rework of doorway upper

corners.

B. Accomplish an eddy current inspection of the skin, skin doubler,

and bearstrap doubler in each upper corner of the doorway per

Figure 1.

C. If cracked doorway corners are found, repair per 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 preventive modification is accomplished.

NOTE: Delayed implementation of the preventive modification may

cause oversizing requirements beyond the preventive

modification kit range.

E. Refinish the rework area around doorway as required, and restore

airplane to operational configuration.

Ja1 CI/bS 737-53-1 16

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

STA STA

332. 1 3122

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

+ 1 TYPICAL -L 

(8 PLACES)

T7 ICAL INSPESTION

|.-|(7 PLACES) -P AREA

(TYPICAL)

CAtTION: WHEN DRILLING OUT EXISTING FASTENERS, DO NOT USE DRILL BIT SIZE ANY

LARGER THAN EXISTING FASTENER DIAMETER.

@ Carefully drill out existing fasteners in shaded areas.

Remove magnes'um reveal corner fittings 65-53594-1 (or -501) and 65-

53595-1 (or -501) from bearstrap doubler and retain for later use. Clean

off any sealant residue from exposed area of bearstrap doubler.

@ Inspect exposed area of skin (outside) and bearstrap doubler (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 DOORWAY UPPER CORNERK INSPECTION;

Jul 21/88 737-5s-1116

20
BOEING SERVICE BULLETIN 737-53-1116

STA STA STA

332.1 3 312 291.5

PICA T Y ICA

CRACKACK

5-9-o0

OFWDE2?

Remove existing rain gutter.

Stop drill end of crack (Ref. 737 Structural Repair Manual Subject 51-10-

1).

If skin assembly or bearstrap doubler is cracked, install repair strap

and doubler per drawing 65C33800 using kit 65C33800-14.

Q If skin assembly and bearstrap doubler are cracked, install repair strap,

doubler, and tripler per drawing 65C33800 using kit 65C33800-12.

If skin assembly or bearstrap doubler is cracked, install repair strap

and doubler per drawing 65C33800 using kit 65C33800-15.

|~ @If skin assembly and bearstrap doubler are cracked, install repair strap,

doubler, and tripler per drawing 65C33800 using kit 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 on which repair kits are installed.

A FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

V Jul 21/88 737-53-1116

21
BOEING SERVICE BULLETIN 737-53-1116

STA

3 32.~ ' 

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 ' OCORNER t 

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 Repair Manual Subject 51-30-9).

Cold work fastener holes in uncracked corners using high interference

sleeve method (Ref. 737 Structural Repair Manual Subject 51-30-9).

Enlarge fastener holes in reveal fittings to 0.254-0.265 inch diameter.

Apply sealant (Ref. BMS 5-95) to faying surface of fittings, and position

in place on bearstrap doubler.

Install indicated fasteners from kit 65C33801 or from operators stock.

FASTENER CODE

* Install rivet BACR15BBSB(*) wet with sealant (Ref. BMS 5-95), with

manufactured head near side.

$ Enlarge countersink far side to 0.425-0.431 inch diameter. Install rivet

BACR1SBB8B1O wet with sealant (Ref. BES 5-95) and with manufactured head

near side. Shave the formed head (far side) as required to be flush with

structure.

(*) Grip length of fastener indicated by number adjacent to fastener

symbol.

FIGURE 3. PREVENTIVE MODIFICATION - FORUARD GAILJ.1 tJRlfAY ;

Jul 21/88 ,3t-5-1116

22
nor-ff

SERVICE BULLETIN

> EVALUATION FORM

THIS EVALUATION FORM IS PROVIDED FOR THE PURPOSE OF CoHeULICatzm INFORlTION TO

THE LOEING ORGANIZATION RESPONSIBLE FOR SERVICE BULLETINS AND iIHSI UUUNT. THE

DATA YOU PROVIDE WILL BE USED TO IMPROVE THE BOEING SERVICE BULLETIN PROGRAM.

NOTE: THIS FORM IS NOT INTENDED TO BE USED FOR REQUESTING SERVICE BULLETIN

INCORPORATION INTO BOEING TECHNICAL MANUALS.

S/B NO.: 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 per S/B effectivity list

(check one): o per corrected list below:

PREPARED BY: TITLE: - DATE:

ORGANIZATION: TELEX CODE:

EVALUATION:

check ONE of the following check ONE of the following

five circles AND seven circles.

- Will accomplish O - Inspection

- Bing n accomplished | - Partial incorporation V Q -HBe accomplished | ) - Complete incorporation

{ -Have accomplishedI

J IQ0 - Service bulletin intent

O - Uneonomical

C-J Will not accomplish C - Ue mexperience does not justify

Decision deferred (explain) I ) - Other (explain below)

COMMENTS: Bulletin Quality, Suggested Improvements, Other.

FOR ADDITIONAL COMMENTS USE REVERSE SIDE

Please forward this form to your Boeing Field Service Representative or mail

directly to:

Attention: B. G. Kelsey

Boeing Commercial Airplanes Manager,

P.O. Box 3707 Service Bulletin Enginevrira

Seattle, WA 98124 Mail Stop 2L-02