### 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 revisionincludesall pages ofthe servicebulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on:



### - Airplanesthat had a repair installed as shown in Revision2 ofthis service bulletin

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

were inthe 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

EachAirplane. This data wasaccidentallynot printed in Revision2

- 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 referenceto the MaintenancePlanning Documentitem numberthat isrelatedto the inspectionsinthis

service bulletin

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

shown inthis service bulletin. Paragraph I.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraphfor changes. Vertical lines are puton the left edge of each page,except in ParagraphI.A., Effectivity,to show the location of importantchanges. 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, 1995Number: 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 bulletinis recommendedon 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 reportedat the upper aftcorner on three airplanes, and nine cracks in the skin at the forward corner on five airplanes. The airplanes had accumulatedfrom29,000to 47,300flight hours,and from40,500to 60,800flight cycles. Cause of the cracking is attributed to fatigue from pressurization cycles, and if not corrected could result in cabin pressurization difficulties, and unscheduleddowntimefor repairs. Accomplishment Instructions at or before the accumulationof 75,000flightcycles. 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, recommendedat the next maintenance interval, not to exceed 4,500 flight cycles after receiptof this service bulletin. If no cracks are found repeat the inspection at 4,500 

### flight cycle intervalsuntil 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 preventivemodificationis accomplished. preventive until the
If cracks are found, install the repair doublers and triplersover thecrackedareas per this bulletin. COMPLIANCE As recommended by the 737 Aging Fleet Structures 

### Task Group, accomplish the modification per the Applicability Inspection Preventive

Modification Repair
- percorner Total ElapsedTime Man-hours (Hours) 5 

### 2.5 0.7 14 

### 0.7 14
MATERIAL INFORMATION 

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

Summary Page 1 of 2 ACTION

### Jul21/88 REV 3: Jul 27/95 Summary Page 2 of 2Number: 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 27AIR 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 2AMC 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 4CROATIA 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 5GB 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 6JAPAN 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 7MARKAIR, 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 

### PAKISTANINTERNATIONALAIRLINES 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 8PRESIDENTIAL 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



### Jul21/88 737-53-1116 REV 3: Jul 27/95 9T 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 PL803VARSA (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 11IDENTIFICATION 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 modificationsand recommend selected bulletinsfor incorporationon aging airplanes. This service bulletin modification has been recommended for incorporation on aging 737 airplanes. 

### Inspectionof the upper corners of the forward galleydoorwaywilldetect crackingthat could result in pressurization difficulties. Repair of cracks or accomplishment of preventive modification on uncrackedstructureis terminating actionfor inspectionperthis servicebulletin. Sixoperators have reportedcracks in the upper corners of the forwardgalleydoorways on a total of eight airplanes. Three airplanes had atotal of eightcracks inthe upperaft 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 accumulatedfrom 29,000to 47,300flight hours, andfrom 40,500to 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 upperforward corner repair doublerinstallation. The installationchangeeliminatesonefastenerand movesonefastener to make the repaircompatiblewith the ServiceBulletin737-53-1074modification. Revision 2 was sent to provide a list of reference service bulletins applicable to 737 door corners and 

### hingecutouts. Also, the crack location and limitsthat can be repairedwith instructionsin this bulletin were defined inthis revision. Revision 3 is sent to:



### - Add thecontents of the preventive modificationand repair kitsto ParagraphII.A., Parts Necessary

for EachAirplane. This datawas accidentallynot printed in Revision2

- 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

inspectionsinthis service bulletin

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

modificationsshown inthis service bulletin. The forward galley door upperforward corner repair, installed per this service bulletin, overlapsthe preventive modification for the upper hinge cutout installed per Service Bulletin 737-53-1074, therefore, it is suggested that prior or concurrent incorporationof the preventive modification per servicebulletin 737-53-1074 beaccomplishedpriorto the repairperthis bulletin. There are four otherservice bulletinsfor 737-100and 737-200 doorcutoutcracks. Table Ishows the service bulletins andthe areasthey cover.

Jul21/88 737-53-1116 REV 3: Jul 27/95 13TABLE 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) 

### ForwardGalley 737-53-1116 Aft Entry 737-53-1074 

### 737-53-1149 Aft Galley (a) ServiceBulletin737-53-1083 is forthe lowersill
C. Description 

### Accomplish high and low frequency eddy current inspections of the area around fasteners in the upper cornersof the forward galleydoorway to determine if thereare 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 untilthe preventive modification isaccomplished. If cracks are found, stop drill the crack ends, and install the repair doublers and triplers over the crackedareasperthis bulletin. No more work is necessary on:



### - Airplanesthat had a repair installed as shown in Revision2 of this service bulletin

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

thecrackswere inthe repairablecrack area shown in Revision2

- Airplanesthat had a preventive modification installed as shown inthe original issue, Revision 1 or Revision2 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 evaluationform is attached to this service bulletin. Please use this form to tell us what you think ofthequalityof 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. 

### Dothe inspectionsprior to accumulating 35,000flight cycles. On airplaneswith35,000 or moreflight cycles, do the inspections at the first available opportunity, recommendedat the next maintenance interval, notto exceed 4,500 flight cycles after receiptof this service bulletin. If no cracks are found, repeatthe inspectionsat 4,500 flightcycle intervals untilthe preventive modificationis done.

Jul 21/88 REV 3: Jul 27/95 

### 737-53-1116 14E. Approval 

### This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin complywith the applicable FederalAviation 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 agencyapprovalbefore incorporatingthis servicebulletin. F. Manpower 

### Approximately7 man-hours and a crew of 2 are requiredto accomplishthis inspection per airplane, plus approximately an additional 0.7 man-hour and a crew of 1 is required to accomplish this 

### preventivemodificationperdoorwaycorner. Approximately14 man-hoursare requiredto accomplishthis crack repair per doorwaycorner. The following breakdown of manpower requirementsis suggested as a guide to assist operators in planningand accomplishingthis repair. Thisestimate is for direct labor performedby an experienced crew. It does not include setup, planning, familiarization, cure time, tool acquisition, or lost time. Factorthis estimateas necessarybasedon yourown experience. Elapsed Time 

### Operation CrewSize 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 18weeks 65C33800-13 Kit
- Repair 15weeks 65C33800-14 Kit
- Repair 22 weeks 

### 65C33800-15 Kit
- Repair 22weeks 65C33800-16 Kit
- Gutter 22weeks The kits are subject to the terms and conditions of Boeing's standard purchase order acknowledgment. Address purchase orders and correspondence pertainingto this quotation to Director of Spares, and refertothis 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 revisiondoes not show Boeingprice dataforthe kit shown below.

Kit Number Description ROLT 65C33801-1 Kit
- Preventive Modification 22 weeks 

### The kit is subjecttothe terms and conditionsof Boeing'sstandard purchase orderacknowledgment. Address purchase orders and correspondence pertainingto this quotation to Directorof Spares, and referto this servicebulletin number. H. Special Tools- Priceand Availability All required coldwork tools and sleevesfor accomplishment of this service bulletin may be selected fromappropriatetables in Structural RepairManualand procured from industrysources,as required. Two sourcesthat providecoldwork tools, aswell as engineering and service, is Fatigue Technology, Inc., and West Coast Industries, Inc. Also available from both companies is a kit of coldwork tooling 

### specificallytailoredto the requirementsofthis servicebulletin. Refer To: FTI Kit Number: FTI-737-53-1116-1 

### FatigueTechnology, 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) Approximateweight and balance informationbasedon incorporationof 65C33800-12,-13 and -16 kits (worstcase) on an airplane. Actualweight 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 and 

### balance.

Jul 21/88 737-53-1116 REV 3: Jul 27/95 16J. 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, 

### Subject53-10-42 d. Boeing Standard Practices Overhaul Manual (BSOPM) 20-50-12
e. Boeing Service Bulletins: 

### 737-53-1074 "Fuselage
- Entryand Galley DoorwaySkin Cutouts
- Inspectionand Modification" 

### 737-53-1083 "Fuselage
- ForwardEntry DoorwayStructureAt LowerSill
- 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. MaintenencePlanning Document(MPD) ItemsZ53-100-01-2 and S53-22-A. 2. Datasuppliedwith the originalissueand Revision 1of this servicebulletin: 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 Specificationsthat 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 accomplishedinaccordancewithoperators 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 isprovidedto aid in kit selection. Usage 

### PreventiveModification

Forward and aft corners Repair- Forward Corner



### Skinand bearstrapcracks Skin or bearstrapcrack Repair
- Aft Corner

Skin and bearstrap cracks 

### Skin or bearstrapcrack 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 modifyor 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 

### RepairStrap Doubler 

### Tripler RepairStrap 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 kitcontains more partsthan are necessaryfor installation. Discard parts that are not usedor keepthe partsfor 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 operatorcan supplythe fastenersinthis kit.

Jul 21/88 REV 3: Jul 27/95 

### 737-53-1116 20

### 2. The following materialsare to be furnishedbytheoperator. 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
- Colorto Match Airplane (a)See BoeingStandard PracticesOverhaulManual20-50-12.
B. Parts Necessary to Change Spares None C. Special Tools and Equipment 

### Coldworkingtools are required during accomplishmentof the preventive modificationper this service bulletin. See Paragraph I.G. for details. 

### D. Existing PartsAccountability None



### Jul21/88 REV 3: Jul 27/95 

### 737-53-1116 21

### Jul21/88 REV 3: Jul 27/95 

### 737-53-1116 22III. ACCOMPLISHMENT INSTRUCTIONS NOTES: 

### 1. The paragraphs identifiedwith letters give the general work instructions and the necessarytests. 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, Figure3 of theAccomplishmentInstructionspriorto, or uponthe accumulation of 75,000flight cycles. 3. Unless specifieddifferently,thesedimensions andtolerances are used:

- All linear dimensions are in inches



### - Tolerance on lineardimensionsotherthan rivetand boltedge marginis plus or minus 0.03 inch

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



### - Angular toleranceis plusor minus2degrees

- The holedimensionsfor standardsolid rivetsare found in737 Structural Repair ManualChapter

51



### - The torque limitsto tighten nutsandbolts are found in737 Structural RepairManual Chapter51. 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 inthis 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. Accomplishan eddy current inspectionofthe skin, bonded skindoubler,and bearstraptripler in each uppercorner ofthe 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 modificationis accomplished. NOTE: Delayed implementationof the preventive modification may cause oversizing requirements beyondthe preventive modificationkit range. The fastener holes may be oversizedonetime 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 23FIGURE 1. FORWARD GALLEY DOORWAY UPPER CORNER INSPECTION
Jul 21/88 SHEET 1OF 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 25The 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 drawing65C33800using kit 65C33800-14. 4 If both skin assembly and bearstrap doubler are cracked, install repair strap, doubler, and tripler per drawing65C33800using kit 65C33800-12. 5 If skin assembly or bearstrap doubler (but not both) is cracked, install repair strap and doubler per drawing65C33800using kit 65C33800-15. 6 If both skinassembly and bearstrap doubler are cracked, install repair strap, doubler, andtripler per drawing65C33800using kit 65C33800-13 7 Install new rain gutter and appropriate filler strips under gutter per drawing 65C33800 using kit 

### 65C33800-16. Trim filler stripsas required,depending onwhich repair kitsare installed.

FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY
21/88 SHEET 1OF 1 737-53-1116 

### Jul 26 REV 3: Jul 27/95FIGURE 3. PREVENTIVE MODIFICATION
- FORWARD GALLEY DOORWAY
Jul 21/88 SHEET 1OF 1 REV 3: Jul 27/95 

### 737-53-1116 27Number: 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


### Usethis evaluationform to tell uswhat youthink 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:



### - Didthis servicebulletin meetyourestimateof quality?

- Howeasyisthis service bulletinto understand?

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



### - Will youdothis service bulletinfully? If not, pleasetell uswhy.

- Isthe Manpowerestimatesatisfactory? NOTE: Pleasedo not usethis evaluationformto tell us to makechangesto 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 othercomments please use the other side. Thank you for the time you used to completethis form. 

### Givethe completedevaluationform to your Boeing Field Service Representativeor sendthe evaluationform directlyto this address: T.J.Taylor, Manager ServiceBulletin Engineering BoeingCommercialAirplane Group P.O. Box 3707, Mail Stop 2L-02 Seattle, WA 98124-2207