Number: 737-53-1116 Revision Transmittal Sheet Date: July21, 1988

Revision 3: July 27, 1995

ATA System: 5331

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

REPAIR, AND PREVENTIVE MODIFICATION

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on:

- Airplanes that had a repair installed as shown in Revision 2 of this service bulletin - Airplanes that had a repair installed as shown in the original issue or Revision 1 of this bulletin if the cracks

were in the repairable crack area shown in Revision 2

- Airplanes that had a preventive modification installed as shown in the original issue, Revision 1 or

Revision 2 of this service bulletin.

No airplanes are added or removed by this revision.

SUMMARY

This revision is sent to:

- Add the contents of the preventive modification and repair kits to Paragraph II.A., Parts Necessary for

Each Airplane. This data was accidentally not printed in Revision 2 - Add structural repair manual subject numbers to stop drill 737-300 and 737-400 airplanes as shown in

Figure 2

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

Figure 3

- Add reference to the Maintenance Planning Document item number that is related to the inspections in this

service bulletin

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

shown in this service bulletin.

Paragraph I.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 I.A., Effectivity, to show the location

of important changes.

Pages with a revision number and date, but no vertical lines, have no important changes.

REVISION HISTORY

Initial Release: July 21, 1988

Revision 1: September 7, 1989

Revision 2: September 30, 1993

Revision 3: July 27, 1995
Number:

Date:

Revision 3:

ATA System:

737-53-1116

July 21, 1988

July 27, 1995

5331

Summary

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

REPAIR, AND PREVENTIVE MODIFICATION

BACKGROUND

Based on a structural review of the 737 airplane

incorporation of the modification per this service

bulletin is recommended on aging airplanes.

Six operators have found seventeen cracks in the

skin and doublers at the upper corners of the

forward galley doorway on eight airplanes. There

were eight cracks reported at the upper aft corner on

three airplanes, and nine cracks in the skin at the

forward corner on five airplanes. The airplanes had

accumulated from 29,000 to 47,300 flight hours, and

from 40,500 to 60,800 flight cycles.

Cause of the cracking is attributed to fatigue from

pressurization cycles, and if not corrected could

result in cabin pressurization difficulties, and

unscheduled downtime for repairs.

Accomplishment Instructions at or before the

accumulation of 75,000 flight cycles.

Do the inspections prior to reaching 35,000 flight

cycles. On airplanes with 35,000 or more flight

cycles, do the inspections at the first available

opportunity, recommended at the next maintenance

interval, not to exceed 4,500 flight cycles after

receipt of this service bulletin.

If no cracks are found repeat the inspection at 4,500

flight cycle intervals until the preventive modification

is accomplished.

EFFECTIVITY

737 airplanes,

PJ201-PJ219

Line Number 1-1560, less

MANPOWER

Accomplish high and low frequency eddy current

inspections for cracks in the skin, skin doubler, or

bearstrap doubler in the upper corners of the

forward galley doorway.

If no cracks are found, accomplish the

modification, or repeat the inspection

preventive modification is accomplished.

preventive

until the

If cracks are found, install the repair doublers and

triplers over the cracked areas per this bulletin.

COMPLIANCE

As recommended by the 737 Aging Fleet Structures

Task Group, accomplish the modification per the

Applicability

Inspection

Preventive

Modification

Repair - per corner

Total Elapsed Time

Man-hours (Hours)

5 2.5

0.7

14

0.7

14

MATERIAL INFORMATION

Boeing supplied kits

See Paragraph I.G., Material - Price and Availability.

Summary Page 1 of 2

ACTION
Jul 21/88

REV 3: Jul 27/95 Summary Page 2 of 

2
Number: 737-53-1116

Date: July 21, 1988

Revision 3: July 27, 1995

ATA System: 5331

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

REPAIR, AND PREVENTIVE MODIFICATION

I. 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.

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AER LINGUS (ARL)

PK641-PK642 PY322

AERO CONTROLS, INC (AEO)

PG629

AERO COSTA RICA (AOR)

PK872-PK873

AEROLINEAS ARGENTINAS (ARG)

PH705-PH708 PH741-PH743 PK102-PK103 PK464 PY007

AEROSVEET (UKA)

PK354

AIR ALGERIE (ALG)

PK361 PK631 PK633-PK634 PL717-PL725 PY051 PY053

AIR ATLANTA ICELANDIC (AID)

PP839 PY346

AIR CHINA GROUP (BEJ)

PM281-PM283 PP521-PP522

AIR EUROPA (ARE)

PP501-PP502 PP835 PP840 PP846

AIR FOYLE LTD. (FOY)

PJ108 PJ113

AIR FRANCE (AFA)

PL502-PL503 PN101-PN117 PP902 PP910

Jul 21/88 737-53-1116

REV 3: Jul 27/95 Page 1 of 27
AIR GABON S.A. (GBN)

PY191

AIR GUINEE (GNE)

PY651

AIR HOLLAND CHARTER B.V. (HOL)

PP504 PP838

AIR MADAGASCAR (MAD)

PG375 PL793

AIR MALTA (MLT)

PL624-PL625 PP904 PP907

AIR NAMIBIA (NAM)

PN492

AIR NEW ZEALAND, LTD. (ANZ)

PJ117-PJ119 PK047 PK214 PK216-

PY741

AIR SOUTH, INC. (SOT)

PG210 PG215 PK221 PK462

AIR TANZANIA (TNZ)

PY611-PY612

AIR TOULOUSE INTERNATIONAL (TOL)

PK215 PK282 PK612 PL716

AIR ZAIRE (ZAI)

PY113

AIR ZIMBABWE (ZMB)

PN431-PN433

AIRTRAN AIRWAYS, INC. (CQT)

PG438 PK028 PK351 PK353

ALASKA AIRLINES (ASA)

PY112 PY134-PY135 PY270 PY461-

ALBATROS AIRLINES (ABS)

PG251 PG253

ALIADRIATICA (ADH)

PK432

ALL NIPPON AIRWAYS CO. LTD. (ANA)

PG584-PG586 PK711-PK716

ALOHA (ALO)

PG046 PK286-PK287 PK691-PK695 PL626

PP825-PP826 PY231 PY242 PY451

ALYEMDA DEM. YEMEN AIRLINES (ALY)

PY409-PY410

PK220 PL621-PL623 PM181

PK466

PK461

PY463 PY593

PM251 PM253

Jul 21/88

REV 3: Jul 27/95

737-53-1116

2
AMC AVIATION (AMF)

PK254

AMERICA WEST AIRLINES, INC. (AMW)

PC004 PG036 PK283 PK696 PL081 PL172

PL551-PL562 PL801 PP181-PP187 PP189 PP831 PP833

PP891-PP899 PP901 PP903 PP931-PP934

AMERICAN EXPRESS BANK LTD. (AXP)

PY592

AMERICANA DE AVIATION S. A. (AMY)

PG276 PJ001

AMIRI FLIGHT (ABD)

PK495

AMORA FLIGHT CHARTER SERVICES (FCA)

PG047

AMWAY CORPORATION (AMA)

PP991

ANGOLA AIR CHARTER (AOH)

PG431

ANGOLA AIRLINES (ANG)

PK661 PK664 PK666 PY162

ANSETT AUSTRALIA (ANS)

PP908-PP909 PQ026-PQ037

ANSETT WORLDWIDE AVIATION SERVICES (AWW)

PA001 PA003-PA004

ARAMCO ASSOCIATED CO. (ARM)

PL151 PL456 PY241 PY243-PY244

ARCO (ATR)

PN452-PN453

ARKIA ISRAELI AIRLINES, LTD (ARK)

PG575

ASEAN AVIATION (L) INC. (ASJ)

PG578-PG583 PK920

AVENSA (AVN)

PK042-PK043

AVIATECA (AVT)

PL736-PL737 PL740-PL741 PL747

AVIATION CONSULTANTS (ACT)

PG037 PY001

AVIOGENEX AIR TRANSPORT (AVG)

PL501 PL506 PN501-PN502

Jul 21/88 737-53-1116

REV 3: Jul 27/95 3
BOEING SERVICE BULLETIN 737-53-1116

BOURAQ INDONESIA AIRLINES (PTB)

PK501 PK913 PK918 PK931 PL742-PL744 PL746

BRITISH AIRWAYS (BAB)

PK731-PK732 PK734-PK742 PK744-PK752 PK754-PK765 PK771-PK772 PK774-PK777

PK779

CALDWELL AIRCRAFT TRADING CO. (CAS)

PG402

CAMBODIAN INTERNATIONAL AIRLINES (CAK)

PJ072

CAMEROON AIRLINES (CAM)

PM171 PY046-PY047

CANADIAN AIRLINES INTERNATIONAL LTD. (CDI)

PK358 PK671-PK675 PK677-PK681 PK822 PK881 PK884

PL401-PL417 PL764-PL770 PM141-PM142 PY151-PY154 PY303-PY304 PY421-PY422

PY441

CANAIR CARGO (CAZ)

PK026-PK027 PK352

CARNIVAL AIR (CVL)

PG305 PG312 PJ007-PJ008 PL712

CASINO EXPRESS (CIN)

PG279 PG436

CAYMAN AIRWAYS (CAY)

PJ009 PK753

CHINA AIR LINES, INC. (CHI)

PN472

CHINA SOUTHWEST AIRLINES (XIN)

PP631-PP634

CHINA YUNNAN AIRLINES (YUN)

PP651-PP652

COMAIR (CML)

PG353-PG354 PG356 PK355

CONSOLIDATED PRESS HOLDINGS (CPH)

PJ109

CONTINENTAL AIRLINES, INC. (CAL)

PA006-PA009 PA011-PA012 PA014 PA016-PA020 PG056 PG064

PG199 PG225 PG433 PG501-PG505 PG621-PG625 PG627-PG628

PG630 PG704 PL001 PP671-PP699 PP701-PP726 PP730

PP732-PP733

COPA COMPANIA PANAMENA DE AVIATION S.A. (COP)

PJ107 PJ112 PK465 PK617 PL745 PY201

PY341

Jul 21/88 737-53-1116

REV 3: Jul 27/95 4
CROATIA AIRLINES (CRH)

PK904 PK906-PK907 PK928 PK932

DAMANIA AIRWAYS LTD. (DAI)

PL451-PL452 PN081-PN082

DELTA AIR LINES, INC. (DAL)

PK611 PK613 PL221 PN131-PN163

PP231-PP243

E G AND G (EGN)

PL763

EAS EUROPE AIRLINES (EUR)

PK203 PK359

EAST WEST AIRLINES (INDIA) (BOM)

PK615-PK616 PK819 PK824 PL171

EASTWIND AIRLINES (ESW)

PG313-PG314

EDRESS, SHIEKH M. (SME)

PL505

EGYPTAIR (EGP)

PK255 PK257-PK258

EL AL ISRAEL AIRLINES, LTD. (ELA)

PL631-PL632

EURALAIR (ERA)

PG026 PG028-PG029 PK564 PY004

EUROBELGIAN AIRLINES (EBA)

PP391

FAR EASTERN AIR TRANSPORT (FAT)

PA002 PA005 PG055 PG226

PK562 PN481

FAUCETT (COMPANIA DE AVIATION S.A. (FCT)

PC002 PG034 PG213 PK241

FLIGHTSTAR AVIATION CORPORATION (FST)

PG274

FRENCH POSTAL OFFICE (FPO)

PP947 PP951-PP952 PY101-PY103 PY302

FRONTIER AIRLINES (FRO)

PG304 PG306 PG308 PG310-PG311

GARUDA INDONESIAN AIRWAYS (GIA)

PK917 PK929-PK930

GATARI AIR SERVICE (GRI)

PL441

PN401-PN404 PN407-PN420

PY006

PG228

PL711

PG230

PL758

PY344

Jul 21/88

REV 3: Jul 27/95

737-53-1116

5
GB AIRWAYS (GBA)

PJ110-PJ111

GE CAPITAL AVIATION SERVICES, INC. (GEH)

PG218-PG219 PG272 PG651-PG652 PP384

GERMANIA FLUGGESELLSCHAFT MBH (GER)

PP503 PQ086-PQ087 PQ231-PQ233

GOVERNMENT OF BRAZIL (BRZ)

PK068-PK069

GOVERNMENT OF MEXICO (MXG)

PC005 PG223

GOVERNMENT OF SHARJAH (SHJ)

PL581

GPA GROUP LTD. (GUI)

PK252 PK623-PK624 PP847-PP848

GULF AIR (GUL)

PK467-PK468

HAPAG LLOYD (HAP)

PL504

INDIAN AIR FORCE (IDF)

PH712-PH713 PM016-PM017

INDIAN AIRLINES (IND)

PH021 PH024 PH711 PK231-PK233 PK235-PK240 PM001-PM006

PY631

INDONESIAN AIR FORCE (IDO)

PL601-PL603

INTEGRATED RESOURCES (INH)

PG271 PG273 PG403 PK697

INTERNATIONAL AIR LEASES (IAL)

PG048

INTERNATIONAL AIRLINE SUPPORT GROUP (ASG)

PG021

INTERNATIONAL LEASE FINANCE (ILF)

PK222

INTERNATIONAL PACIFIC TRADING CO. (IPT)

PG572 PG574 PJ102

IRAN AIR (IRN)

PH731 PK391 PY021-PY022

IRAQI AIRWAYS (IRQ)

PY141-PY142

Jul 21/88

REV 3: Jul 27/95

737-53-1116

6
JAPAN TRANSOCEAN AIR CO., LTD. (SWL)

PK523-PK527 PN451 PN454 PN456

JETALL HOLDING CORPORATION (JEL)

PY002 PY005

JUGOSLOVENSKI AEROTRANSPORT (JAT)

PP771-PP779

KENYA AIRWAYS (KEN)

PK253 PK256

KLM ROYAL DUTCH AIRLINES (KLM)

PP861-PP870

KOREAN AIR FORCE (KAF)

PP221

LACSA (LAC)

PK357 PK871

LADECO (LDE)

PJ004-PJ006 PK029 PK212 PK281 PK826 PK830

PL802

LAN-CHILE S.A. (LAN)

PK360 PK733 PK743 PK825 PL025-PL026 PL028

LAPA (LAZ)

PG355 PK051 PK463 PK614

LAPSA AIR PARAGUAY (LAQ)

PK211 PK561

LAUDA AIR LUFTFAHRT AG (LAL)

PP851-PP852

LINA CONGO (LNA)

PY411

LINHAS AEREAS DE MOZAMBIQUE (LAM)

PH703 PY031

LITHUANIAN AIRLINES (LIJ)

PK563 PK632

LUFTHANSA GERMAN AIRLINES (DLH)

PK901-PK903 PK911-PK912 PK914-PK916 PK919 PK921-PK923 PK926-PK927

PK933-PK938 PP948 PQ051-PQ065 PQ088-PQ090 PY345

MAGNICHARTERS (MAM)

PG224 PJ003

MALEV HUNGARIAN AIRLINES (HGA)

PK284-PK285 PK636-PK637 PK827 PL455

MANDALA AIRLINES (MND)

PK874 PK924-PK925 PL027 PL061 PL421 PN002

Jul 21/88 737-53-1116

REV 3: Jul 27/95 7
MARKAIR, INC. (ALK)

PL611 PN493 PP305 PY056-PY057 PY594-PY595

MODILUFT (MOU)

PK905 PK908-PK910

MONARCH AIRLINES, LTD. (MON)

PP824 PP832

MONTELY II (MOY)

PJ031

NASA (NAS)

PA099

NATIONAL AIRLINES (NAW)

PJ104-PJ106

NATIONAL JET SYSTEMS PTY. LTD. (NJS)

PP352

NICA (NICARAGUENCE DE AVIACION) (NIC)

PK823

NIGERIA AIRWAYS, LTD. (NIA)

PL781-PL782 PL785-PL788

NORDIC EAST (NOE)

PJ002 PP353 PP834

NWT AIR (NTA)

PX701 PY132-PY133 PY281

OLYMPIC AIRWAYS (OLY)

PK301-PK304 PK307-PK310 PM021-PM023

P. T. AIRFAST (PTF)

PG204 PG278 PY343

PAKISTAN INTERNATIONAL AIRLINES CORP. (PIA)

PP281-PP286

PEGUSUS CAPITAL CORPORATION (PSS)

PK565

PETROLAIR SYSTEMS S. A. (PTS)

PL471

PHILIPPINE AIRLINES, INC. (PAL)

PP935-PP936

PLUNA (PLU)

PL201-PL203

POLY TECHNOLOGIES, INC. (PTI)

PP728-PP729

Jul 21/88

REV 3: Jul 27/95

737-53-1116

8
PRESIDENTIAL AIR (PRB)

PC003

PRINCE TALAL (PTA)

PN455

QANTAS AIRWAYS, LTD. (QAN)

PQ001-PQ012

REPUBLIC OF NIGER (NIR)

PY166

ROYAL AIR MAROC (RAM)

PK271-PK274 PY671-PY672

RYANAIR (RYR)

PJ114-PJ115 PK503 PK801-PK804 PN001

SABENA S.A. (SAB)

PK041 PK044-PK046 PK048-PK050 PK052-PK053 PK431 PK433

PP961-PP965 PY272-PY275

SAHARA INDIAN AIRLINES (SAQ)

PK820

SAHSA (SERVICIO AEREO DE HONDURAS,S.A.) (SAH)

PJ071

SAKHALIN AIRLINES (SKH)

PG214

SAUDI ARABIAN AIRLINES CORP. (SVA)

PK311-PK317 PL726-PL735 PY036-PY037

SAUDI ROYAL FLIGHT (SRF)

PK318

SERVICIOS AEREOS RUTAS ORIENTE, (SARO) (SEV)

PA015 PA021-PA022 PJ032

SHAHEEN AIR INTERNATIONAL (SHK)

PK514-PK515

SIERRA PACIFIC AIRLINES (SRP)

PK627

SOUTH AFRICAN AIRWAYS (SAA)

PL101-PL113

SOUTHWEST AIRLINES CO. (SWA)

PK082 PK091-PK099 PK541-PK560 PK621 PK628-PK630 PM051-PM066

PP101-PP135 PP161-PP169 PP188 PP190-PP192 PP201-PP205 PP302-PP304

PP351 PP376-PP382 PP727 PP731 PP821-PP823 PP827

SUDAN (SUD)

PY156-PY157

Jul 21/88 737-53-1116

REV 3: Jul 27/95 9
T A PORTUGUESES (TAP)

PK971 PK973-PK974 PN083-PN086 PY721

TACA INTERNATIONAL AIRLINES, INC. (TAC)

PG059 PG352 PK213

PP946 PY131

PK223

TAESA (TES)

PK622 PK625-PK626 PP841-PP842

TAT EUROPEAN AIRLINES (TTR)

PY003 PY301 PY321 PY361-PY362

THAI AIR FORCE (TAF)

PK519

THAI AIRWAYS INT'L PUBLIC CO., LTD. (TII)

PK511

TITAN CHARTER AVIATION INC. (TCA)

PL761-PL762

TRANSAERO (TRX)

PK451-PK452 PK773

TRANSAVIA AIRLINES (TAV)

PG074 PK502 PK504 PK821 PP801-PP804

TRANSBRASIL AIRLINES INC. (TBL)

PP836-PP837 PQ241-PQ242

TRANSMILE AIR SERVICES (TML)

PY323 PY342 PY381

TUNISAIR (TUN)

PK861-PK863 PY621

UKRAINE INTERNATIONAL AIRLINES (UKR)

PK635 PN405

UNITED AIR LINES, INC. (UAL)

PG001-PG004 PG006-PG013

PG032 PG038-PG040

PG065-PG072 PG075

PG015-PG019

PG045

PK201-PK202

PG022-PG025

PG051-PG054

PL002-PL023

PG027

PG057

PQ101-PQ123

PG030

PG060-PG063

USAIR, INC. (USA)

PG073

PK591-PK599

PP012-PP020

PP471-PP472

PG301

PK601-PK610

PP022-PP032

PP474-PP475

PG303

PK883

PP034-PP045

PV001-PV004

PG307

PM101-PM119

PP383

PG474

PN021-PN043

PP401

PK288-PK289

PP003-PP010

PP404-PP436

VANGUARD AIRLINES (VAG)

PG041-PG042 PG206

VARIG AIRLINES (VAR)

PK111-PK116 PK118-PK120 PK141-PK146 PL453-PL454 PP905-PP906 PP981-PP982

Jul 21/88

REV 3: Jul 27/95

737-53-1116

10

PK882 PN491

PG576 PL803
VARSA (VAB)

PG351

VASP (VSP)

PG435 PG437 PG439-PG440 PG471-PG473 PH011-PH013 PK061-PK062

PK065-PK067 PK356 PK521 PK581 PL756 PX071

PY286

VENEZUELA - GOVERNMENT OF (VNZ)

PK070

VISCOUNT AIR SERVICE INC. (VAS)

PG201 PG203 PG209 PG212 PG216-PG217 PG220-PG222

PJ101 PJ103 PK305-PK306

VIVA AIR (VIV)

PP392

WESTERN PACIFIC AIRLINES (WPA)

PP001-PP002 PP021 PP301 PP402-PP403 PP473

WESTINGHOUSE ELECTRIC CORPORATION (WEE)

PG208

XIAMEN AIRLINES CO. LTD. (XIA)

PM252 PM254-PM255

YEMEN AIRWAYS (YEM)

PK341

ZAMBIA AIRWAYS (ZAM)

PK291

Jul 21/88 737-53-11

REV 3: Jul 27/95

16

11
IDENTIFICATION BY VARIABLE NUMBER

PA001-PA022

PG201-PG230

PG375

PG621-PG630

PH701-PH715

PJ101-PJ119

PK101-PK103

PK251-PK258

PK351-PK361

PK501-PK504

PK591-PK599

PK691-PK697

PK830

PL001-PL028

PL201-PL203

PL471

PL611

PL758

PM016-PM017

PM181

PN101-PN117

PN481

PP161-PP169

PP301-PP305

PP501-PP504

PP771-PP779

PP861-PP870

PP961-PP965

PQ086-PQ090

PX701

PY051-PY053

PY151-PY154

PY221-PY222

PY301-PY304

PY409-PY411

PY611-PY612

PY741

PA099

PG251-PG255

PG401-PG403

PG651-PG652

PH731-PH732

PK026-PK029

PK111-PK120

PK271-PK274

PK391

PK511-PK515

PK601-PK617

PK711-PK716

PK861-PK863

PL061

PL221

PL491

PL621-PL626

PL761-PL770

PM021-PM023

PM251-PM255

PN131-PN163

PN491-PN493

PP181-PP192

PP351-PP353

PP521-PP522

PP801-PP804

PP891-PP899

PP981-PP982

PQ101-PQ123

PY001-PY008

PY056-PY057

PY156-PY157

PY231

PY321-PY323

PY421-PY422

PY621

PA231-PA232

PG271-PG279

PG431-PG442

PG701-PG705

PH741-PH743

PK041-PK053

PK141-PK146

PK281-PK289

PK431-PK433

PK519

PK621-PK637

PK731-PK765

PK871-PK874

PL081

PL401-PL417

PL501-PL506

PL631-PL632

PL781-PL788

PM051-PM066

PM281-PM283

PN401-PN420

PN501-PN502

PP201-PP205

PP376-PP384

PP631-PP634

PP821-PP827

PP901-PP910

PP991

PQ231-PQ233

PY021-PY022

PY101-PY103

PY161-PY162

PY241-PY244

PY341-PY346

PY441

PY631

PC001-PC005

PG301-PG314

PG471-PG475

PH001

PJ001-PJ009

PK061-PK070

PK201-PK204

PK291

PK451-PK452

PK521-PK527

PK641-PK642

PK771-PK779

PK881-PK884

PL101-PL113

PL421

PL551-PL562

PL711-PL712

PL793

PM101-PM119

PN001-PN002

PN431-PN433

PN511

PP221

PP391-PP392

PP651-PP652

PP831-PP842

PP931-PP936

PQ001-PQ012

PQ241-PQ242

PY031

PY111-PY113

PY166

PY270-PY275

PY361-PY362

PY451

PY651

PG001-PG075

PG331-PG332

PG501-PG505

PH011-PH013

PJ031-PJ032

PK081-PK082

PK211-PK223

PK301-PK318

PK461-PK469

PK541-PK565

PK661-PK666

PK801-PK804

PK901-PK938

PL151

PL441

PL581

PL716-PL747

PL801-PL803

PM141-PM142

PN021-PN043

PN451-PN456

PP001-PP045

PP231-PP243

PP401-PP436

PP671-PP699

PP846-PP848

PP946-PP948

PQ026-PQ037

PV001-PV004

PY036-PY037

PY131-PY135

PY191

PY281

PY381

PY461-PY463

PY671-PY672

PG199

PG351-PG356

PG571-PG586

PH021-PH024

PJ071-PJ072

PK091-PK099

PK231-PK241

PK341

PK495

PK581

PK671-PK681

PK819-PK827

PK971-PK974

PL171-PL172

PL451-PL456

PL601-PL603

PL756

PM001-PM006

PM171

PN081-PN086

PN471-PN472

PP101-PP135

PP281-PP286

PP471-PP475

PP701-PP733

PP851-PP852

PP951-PP952

PQ051-PQ065

PX071

PY046-PY048

PY141-PY143

PY201

PY286

PY401

PY591-PY595

PY721

2. Spares

None

Jul 21/88

REV 3: Jul 27/95

737-53-1116

12
B. Reason

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

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

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

bulletin modification has been recommended for incorporation on aging 737 airplanes.

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

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

uncracked structure is terminating action for inspection per this service bulletin.

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 airplanes had accumulated from 29,000 to 47,300 flight hours, and from 40,500 to 60,800 flight cycles.

Revision 1 of this bulletin was 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.

Revision 2 was sent to provide a list of reference service bulletins applicable to 737 door corners and hinge cutouts. Also, the crack location and limits that can be repaired with instructions in this bulletin

were defined in this revision.

Revision 3 is sent to:

- Add the contents of the preventive modification and repair kits to Paragraph II.A., Parts Necessary for Each Airplane. This data was accidentally not printed in Revision 2 - Add structural repair manual subject numbers to stop drill 737-300 and 737-400 airplanes as

shown in Figure 2

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

shown in Figure 3

- Add reference to the Maintenance Planning Document item number that is related to the inspections in this service bulletin - Add reference to the structural repair manual subject numbers changed by the repairs and modifications shown in this service bulletin.

The forward galley door upper forward corner repair, installed per this service bulletin, overlaps the preventive modification for the upper hinge cutout 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 accomplished prior to the repair per this bulletin.

There are four other service bulletins for 737-100 and 737-200 door cutout cracks. Table I shows the service bulletins and the areas they cover.

Jul 21/88 737-53-1116

REV 3: Jul 27/95 13
TABLE I - SERVICE BULLETINS FOR DOOR CUTOUT CRACKING

DOORWAY Upper Upper Aft Lower Lower Aft Upper Lower

Forward Corner Forward Corner Hinge Hinge

Corner Corner Cutout Cutout

Forward Entry 737-53-1163 737-53-1083 (a)

Forward Galley 737-53-1116

Aft Entry 737-53-1074

737-53-1149

Aft Galley

(a) Service Bulletin 737-53-1083 is for the lower sill

C. Description

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.

If no cracks are found, accomplish the preventive modification per this bulletin, or repeat the

inspection 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.

No more work is necessary on:

- Airplanes that had a repair installed as shown in Revision 2 of this service bulletin

- Airplanes that had a repair installed as shown in the original issue or Revision 1 of this bulletin if

the cracks were in the repairable crack area shown in Revision 2

- Airplanes that had a preventive modification installed as shown in the original issue, Revision 1 or

Revision 2 of this service bulletin.

NOTES:

1. Prior or concurrent incorporation of Boeing Service Bulletin 737-53-1074, "Fuselage - Entry and

Galley Doorway Skin Cutouts - Inspection and Modification", is suggested on commonly

affected airplanes.

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

An evaluation form is attached to this service bulletin. Please use this form to tell us what you

think of the quality of this service bulletin.

D. Compliance

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.

Do the inspections prior to accumulating 35,000 flight cycles. On airplanes with 35,000 or more flight

cycles, do the inspections at the first available opportunity, recommended at the next maintenance

interval, not to exceed 4,500 flight cycles after receipt of this service bulletin. If no cracks are found,

repeat the inspections at 4,500 flight cycle intervals until the preventive modification is done.

Jul 21/88

REV 3: Jul 27/95

737-53-1116

14
E. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes

specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and

are FAA approved. This service bulletin and the FAA approval were based on the airplane in its

original Boeing delivery configuration or as modified by other FAA 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.

F. Manpower

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

G. Material - Price and Availability

Boeing can supply the kits shown in Paragraph II.A.1 as shown below. Kit availability is shown in the

Reorder Lead Time (ROLT). This revision does not show Boeing price data for kits shown below.

Kit Number Description ROLT

65C33800-12 Kit - Repair 18 weeks

65C33800-13 Kit - Repair 15 weeks

65C33800-14 Kit - Repair 22 weeks

65C33800-15 Kit - Repair 22 weeks

65C33800-16 Kit - Gutter 22 weeks

The kits are subject to the terms and conditions of Boeing's standard purchase order

acknowledgment.

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. Kit availability is shown in the Reorder Lead Time

Jul 21/88 737-53-1116

REV 3: Jul 27/95 15
(ROLT). This revision does not show Boeing price data for the kit shown below.

Kit Number Description ROLT

65C33801-1 Kit - Preventive Modification 22 weeks

The kit is subject to the terms and conditions of Boeing's standard purchase order acknowledgment.

Address purchase orders and correspondence pertaining to this quotation to Director of Spares, and

refer to this service bulletin number.

H. Special Tools - Price and Availability

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.

Refer To:

FTI Kit Number: FTI-737-53-1116-1

Fatigue Technology, Inc.

P.O. Box C-88388

Seattle, WA 98188

Phone Number (206) 246-2010

Fax (206) 244-9886

Refer To:

WCI Kit Number: WCI-737-53-1116

West Coast Industries,Inc.

14900 Whitman Avenue North

Seattle, WA 98133-6532

Phone Number (206) 365-7513

Fax (206) 365-7483

I. Weight and Balance

Change in Weight Change in Moment

Applicabilitv (Pounds) (Pound-Inches)

737-100 (a) +9.2 +2,825

737-200 (a) +9.2 +3,494

737-300 (a) +9.2 +2,089

(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 3: Jul 27/95 16
J. References

1. Existing Data:

a. 737-100/-200 Structural Repair Manual (SRM 737) Subject 51-10-1, 51-30-9

b. 737-300/-400 Structural Repair Manual (SRM 737-300 and SRM 737-400) Subject 51-10-02,

51-40-09

c. 737 Nondestructive Test (NDT) Manual, Part 6, Subject 51-00-00, Figure 4. 737 NDT, Part 6,

Subject 53-10-42

d. Boeing Standard Practices Overhaul Manual (BSOPM) 20-50-12

e. Boeing Service Bulletins:

737-53-1074 "Fuselage - Entry and Galley Doorway Skin Cutouts - Inspection and

Modification"

737-53-1083 "Fuselage - Forward Entry Doorway Structure At Lower Sill - Inspection,

Modification and Repair"

737-53-1149 "Fuselage - Aft Galley and Aft Entry Doorway, Upper Corner Skin Cutout

Inspection, Repair and Modification"

737-53-1163 "Fuselage - Forward Entry Doorway Skin Cutout - Upper Forward and Upper

Aft Corners - Inspection, Modification and Repair "

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

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

g. Maintenence Planning Document (MPD) Items Z53-100-01-2 and S53-22-A.

2. Data supplied with the original issue and Revision 1 of this service bulletin:

Drawings:

Drawing Number Sheet DCN ADCN Title

65C33800 PL A Skin and Stringer Installation - Repair

(Top Kit)

65C33800 1 C

3. Process Data:

Boeing Process Specifications that are listed on the 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 operators normal procedures.

Jul 21/88 737-53-1116

REV 3: Jul 27/95 17
K. Publications Changed

Publication

737-100/200 Structural Repair Manual (SRM 737)

737 -300/400 Structural Repair Manual

(SRM 737-300 and SRM 737-400)

Chapter-Section

53-30-3

53-10-01

L. Electrical Load Data

None

Jul 21/88

REV 3: Jul 27/95

737-53-1116

18
II. MATERIAL INFORMATION

A. Parts Necessary For Each Airplane

The following is provided to aid in kit selection.

Usage

Preventive Modification

Forward and aft corners

Repair- Forward Corner

Skin and bearstrap cracks

Skin or bearstrap crack

Repair - Aft Corner

Skin and bearstrap cracks

Skin or bearstrap crack

Rain Gutter Replacement

(Required with Repair)

Kit

65C33801-1

65C33800-12

65C33800-14

65C33800-13

65C33800-15

65C33800-16

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

NOTE: One or more kits and operator furnished materials listed in Paragraph II.A.2 are required

to modify or repair each airplane.

SKIN AND STRINGER INSTALLATION-SKIN REPAIR, SECTION 41 (TOP KIT)

-14 -13 -12

Part Number

65C33800-12 (a)

65C33800-13 (a)

65C33800-14 (a)

65C33800-15 (a)

65C33800-16 (a)

65C33800-17

65C33800-18

65C33800-19

1 65C33800-20

1 65C33800-21

65C33800-22

65C33800-23

65C33800-24

65C33800-25

65C33800-26

65-49893-2

2 BACB30FN5-5

18 BACB30FN5-6

Name

Top Kit, Skin And St

Top Kit, Skin And St

Top Kit, Skin And St

Top Kit, Skin And St

Top Kit, Skin And St

Repair Strap

Doubler

Tripler

Repair Strap

Doubler

Tripler

Filler

Filler

Filler

Filler

Gutter

Hi-Lok

Hi-Lok

Jul 21/88

REV 3: Jul 27/95

65C33800

-16 -15

1

1

Quantity

1

1

1

1

1

1

1

1

1

1

20

737-53-1116

19
(Continued)

65C33800 SKIN AND STRINGER INSTALLATION-SKIN REPAIR, SECTION 41 (TOP KIT)

-16 -15 -14 -13 -12

Quantity Part Number Name

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 BACB30FN6-6 Hi-Lok

4 33 11 32 31 BACB30FN6-7 Hi-Lok

2 24 6 BACB30FN6-8 Hi-Lok

1 2 1 BACB30FN6-9 Hi-Lok

20 20 BACC30M5 Collar

11 185 142 178 142 BACC30M6 Collar

5 BACR15BB4B7 Rivet

5 BACR15BB4B9 Rivet

4 4 BACR15CE6B11 Rivet

4 4 BACR15CE6B12 Rivet

3 4 . BACR15CE6B13 Rivet

3 4 BACR15CE6B14 Rivet

1 1 1 1 BACR15CE6D11 Rivet

4 4 1 1 BACR15CE6D12 Rivet

3 3 BACR15CE6D13 Rivet

1 1 BACR15CE6D6 Rivet

4 1 BACR15CE6D8 Rivet

3 BACR15CE6D9 Rivet

(a) The kit contains more parts than are necessary for installation. Discard parts that are not

used or keep the parts for spares.

65C33801 SKIN AND STRINGER INSTL- SECTION 41 (TOP KIT)

-1

Quantity Part Number Name

- 65C33801-1 (a) Top Kit, Skin and Str

6 BACR15BB8B10 Rivet

1 BACR15BB8B13 Rivet

8 BACR15BB8B9 Rivet

(a) The operator can supply the fasteners in this kit.

Jul 21/88

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737-53-1116

20
2. The following materials are to be furnished by the operator.

Quantity

As Required

As Required

As Required

Specification

BMS 5-95, Type I, Class B-1/2,

-2 or-4 (a)

BMS 10-11, Type I (a)

BMS 10-11, Type II

Nomenclature

Sealant

Primer

Enamel - Color to Match

Airplane

(a) See Boeing Standard Practices Overhaul Manual 20-50-12.

B. Parts Necessary to Change Spares

None

C. Special Tools and Equipment

Coldworking tools are required during accomplishment of the preventive modification per this service

bulletin. See Paragraph I.G. for details.

D. Existing Parts Accountability

None

Jul 21/88

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737-53-1116

21
Jul 21/88

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737-53-1116

22
III. ACCOMPLISHMENT INSTRUCTIONS

NOTES:

1. The paragraphs identified with letters give the general work instructions and the necessary tests.

The instructions identified with numbers on the figure(s) give the recommended sequence of steps.

2. As recommended by the 737 Aging Fleet Structures Task 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. Unless specified differently, these dimensions and tolerances are used:

- All linear dimensions are in inches

- Tolerance on linear dimensions other than rivet and bolt edge margin is plus or minus 0.03 inch - Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

- Angular tolerance is plus or minus 2 degrees

- The hole dimensions for standard solid rivets are found in 737 Structural Repair Manual Chapter

51

- The torque limits to tighten nuts and bolts are found in 737 Structural Repair Manual Chapter 51.

4. Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners.

5. Obey all warnings and cautions in the specified manual sections.

6. Maintenance Planning Document (MPD) Items Z53-100-01-2 and S53-22-A are related to the

inspections in this service bulletin.

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, bonded skin doubler, and bearstrap tripler 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 until the preventive modification is

accomplished.

NOTE: Delayed implementation of the preventive modification may cause oversizing requirements

beyond the preventive modification kit range. The fastener holes may be oversized one time

only (Maximum hole size allowed before cold working is 0.238 inch)

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

configuration.

Jul 21/88

REV 3: Jul 27/95

737-53-1116

23
FIGURE 1. FORWARD GALLEY DOORWAY UPPER CORNER INSPECTION

Jul 21/88 SHEET 1 OF 2

REV 3: Jul 27/95

737-53-1116

24
Jul 21/88

REV 3: Jul 27/95

FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

SHEET 2 OF 2 737-53-1116

25
The instruction numbers shown below agree with the numbers shown inside the circle symbols in the

figure.

NOTE: This repair can only be used if cracks are within the area indicated by the shaded area of

Detail I. Contact Boeing for a repair if cracks are not within the area indicated.

1 Remove existing rain gutter.

2 Stop drill the end of the crack as shown in the 737 Structural Repair Manual (SRM 737 51-10-1, SRM

737-300 51-10-02 and SRM 737-400 51-10-02). Typical cracks are shown. Only cracks 2.5 inches

long or less, within the shaded area shown in Detail I, can be repaired as shown in this figure.

3 If skin assembly or bearstrap doubler (but not both) is cracked, install repair strap and doubler per

drawing 65C33800 using kit 65C33800-14.

4 If both skin assembly and bearstrap doubler are cracked, install repair strap, doubler, and tripler per

drawing 65C33800 using kit 65C33800-12.

5 If skin assembly or bearstrap doubler (but not both) is cracked, install repair strap and doubler per

drawing 65C33800 using kit 65C33800-15.

6 If both skin assembly and bearstrap doubler are cracked, install repair strap, doubler, and tripler per

drawing 65C33800 using kit 65C33800-13

7 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.

FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

Jul 21/88 SHEET 1 OF 1 737-53-1116

26 REV 3: Jul 27/95
FIGURE 3. PREVENTIVE MODIFICATION - FORWARD GALLEY DOORWAY

Jul 21/88 SHEET 1 OF 1

REV 3: Jul 27/95

737-53-1116

27
Number:

Date:

Revision 3:

ATA System:

Prepared By:

737-53-1116

July 21, 1988

July 27, 1995

5331

Manuel Hernandez

Evaluation Form

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

REPAIR, AND PREVENTIVE MODIFICATION

Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data

that you give us to improve the quality of our service bulletins. Please include data about these or other

items:

- Did this service bulletin meet your estimate of quality?

- How easy is this service bulletin to understand?

- Are the Planning Information, Material Information and Accomplishment Instructions satisfactory?

- Will you do this service bulletin fully? If not, please tell us why.

- Is the Manpower estimate satisfactory?

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these

changes, please use a Publication Change Request (PCR) form.

Please give us this data:

0

OPERATOR: TODAY'S DATE:

PREPARED BY:

ORGANIZATION:

TITLE:

TELEX CODE:

TELEPHONE NUMBER:

COMMENTS:

If you have other comments please use the other side. Thank you for the time you used to complete this

form.

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form

directly to this address:

T.J. Taylor, Manager

Service Bulletin Engineering

Boeing Commercial Airplane Group

P.O. Box 3707, Mail Stop 2L-02

Seattle, WA 98124-2207