Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-53A1214

Original Issue: June 17, 1999

Revision 4: December 16, 2011

ATA System: 5311

SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and

Repair

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

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persons from specific countries. The controller of this data has the individual responsibility to abide by all export

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ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 1999 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more

information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

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connection with this document unless provided in writing by Boeing.

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5.0
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BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 37

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 39

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 39

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

FIGURE 1: LFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM

STRINGER S-15L TO S-15R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

FIGURE 2: HFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM

STRINGER S-15L TO S-15R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

FIGURE 3: ONE-TIME NDT INSPECTION OF WEB AT THE OUTER CIRCUMFERENTIAL TEAR STRAP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

FIGURE 4: NDT INSPECTION OF WEB AT THE "Y" CHORD IN THE LOWER BULKHEAD FROM

STRINGER S-15LTO S-15R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

FIGURE 5: DETAILED INSPECTION FOR OIL-CAN DAMAGE IN THE BULKHEAD WEB . . . . . . 56

FIGURE 6: NDT INSPECTION OF THE DOME CAP AT THE CENTER OF THE BULKHEAD . . . . . 58

FIGURE 7: NDT INSPECTION OF THE FORWARD FLANGE OF THE "Z" STIFFENER AT THE DOME

CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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BOEING SERVICE BULLETIN 737-53A1214

ALERT ALERT
Appendix A: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 3 OR 737-300/400/500 53-80-08 REPAIR 1 -

TYPICAL REPAIR FOR DAMAGE TO WEB AND STRAP . . . . . . . . . . . . . . . . . . 63

Appendix B: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 3 OR 737-300/400/500 53-80-08 REPAIR 1 -

TYPICAL REPAIR FOR DAMAGE TO WEB . . . . . . . . . . . . . . . . . . . . . . . . . 65

Appendix C: OBSOLETE 737-100/200 SRM 53-10-4, FIGURE 5 OR 737-300/400/500 SRM 53-80-08 REPAIR

2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Appendix D: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 12 OR 737-300/400/500 SRM 53-80-08 REPAIR

4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Appendix E: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 13 OR 737-300/400/500 SRM 53-80-08 REPAIR

5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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BOEING SERVICE BULLETIN 737-53A1214

ALERT ALERT
Commercial 

Airplanes 737

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 737-53A1214

Original Issue: June 17, 1999

Revision 4: December 16, 2011

ATA System: 5311

SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and

Repair

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on the airplanes changed in accordance with Revision 3 of this service bulletin.

REASON FOR REVISION

This revision is sent to change the compliance time for Detailed Inspection for Oil-Cans and to delete incorrect

paragraph reference in Paragraph 3.B., Work Instructions, Part VI.

These sections were changed:

1. Summary Background: FAA Airworthiness Directive statement deleted. SIIA and SRP statements added.

2. Paragraph 1.C., Reason: FAA Airworthiness Directive statement deleted.

3. Paragraph 1.E., Compliance: Table 4, Compliance Time changed. Table 8 SRM reference corrected.

4. Paragraph 1.J.1., Existing Data: Revised.

5. Paragraph 3.A., General Information: Note 5 revised. Note 9 and 10 added.

6. Paragraph 3.B., Work Instructions: Part I, step 5. note, SRM reference corrected.

7. Paragraph 3.B., Work Instructions: Part VI, step 1.b. and 1.c., incorrect paragraph reference removed.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: June 17, 1999

Revision 1: June 22, 2000

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Revision 2: May 24, 2001

Revision 3: January 19, 2011

Revision 4: December 16, 2011

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BOEING SERVICE BULLETIN 737-53A1214

ALERT ALERT
Commercial 

Airplanes 737

Service Bulletin

ALERT

Summary Number: 737-53A1214

Original Issue: June 17, 1999

Revision 4: December 16, 2011

ATA System: 5311

SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and

Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None

BACKGROUND

Cracks have been reported in four general areas on the aft pressure bulkhead: cracks in the web at the web-to-"Y"

chord interface; cracks in the web at the outer circumferential tear strap; cracks in the web near the dome cap;

and cracks in the "Z" stiffeners near the dome cap. Undetected cracking could result in loss of ability to maintain

cabin pressure, rapid decompression of the airplane, and significant structural damage to the aft fuselage.

Cracks reported in the web at the web-to-"Y" chord interface occurred in the aft row of fasteners connecting the

web to the "Y" chord. In all of the cases, the cracks ran in the circumferential direction. Most of the cracks have

been at Stringer S-6L and S-6R, but there have been reports of cracks at other locations. The airplanes had

accumulated between 22,966 and 68,000 flight cycles and between 45,500 and 61,000 flight hours.

There have been two reports of cracking in the bulkhead web at the outer circumferential tear strap. The airplanes

had 21,246 and 26,162 flight cycles and 17,500 and 24,132 flight hours respectively.

Since revision 2 of this service bulletin, there have been reports of cracking in the center of the web near the

dome cap. The cracks occurred at the center of the bulkhead at the end of the web gore sections. The airplanes

had accumulated more than 30,000 flight cycles and 36,000 flight hours. There have also been two reports of

cracks located on the "Z" stiffeners forward flange at the attach location to the dome cap pan. The cracks

extended from the outboard fastener hole and ran circumferentially.

Boeing Structural Item Interim Advisory (SIIA) SIIA 737-52 and SIIA 737-269 are related to this service bulletin.

Boeing Service Related Problem (SRP) 737-SRP-53-0109, 737-SRP-53-0116, and 737-SRP-53-0155 are related

to this service bulletin.

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ACTION (PRR 35005-229R)

Get access to the forward or aft side of the aft pressure bulkhead and do a Non-Destructive Test (NDT) inspection

for any cracking in the web at the "Y" chord. If damage is found from the aft side, get access to the forward side

of the bulkhead and do a High Frequency Eddy Current (HFEC) inspection for any cracking in the web at the

"Y" chord for the section of web where the damage was found. If any cracking is found, repair the crack(s) in

accordance with the Structural Repair Manual (SRM) or contact Boeing for repair instructions.

From either side of the bulkhead, do a NDT inspection for any cracking in the web at the outer circumferential

tear strap for 360 degrees. Also, do an inspection for oil-canning in the web of the entire bulkhead and do repeat

inspections at the times shown in the Compliance Section. If you find any cracking, repair the crack(s) in

accordance with the SRM or contact Boeing.

From the aft side of the bulkhead, do a NDT inspection for any cracking in the bulkhead web at the lap joints.

Do the inspection from the edge of the gore section at the center of bulkhead to approximately ten inches

outboard of the center. Do repeat inspections at the times shown in the Compliance Section. If you find any

cracking, contact Boeing or repair the crack(s) in accordance with the SRM.

EFFECTIVITY

All 737-100/-200/-200C/-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected

airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Federal Aviation Administration (FAA) Airworthiness Directive AD 99-08-23, is related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

None.

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BLANK PAGE
Commercial 

Airplanes 737

Service Bulletin

ALERT

Number: 737-53A1214

Original Issue: June 17, 1999

Revision 4: December 16, 2011

ATA System: 5311

SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and

Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is for the airplanes shown below. Refer to PRR 35005-229R for data about

this change.

GROUP CONFIGURATION DESCRIPTION

All 737-100/200/200C/300/400/500 Series Airplanes, Line Numbers

1-3132.

1 -

Airplane Models:

737-100, 737-200, 737-200C, 737-300, 737-400, 737-500

Variable Number Group

PA001 - PA022 1

PA099 1

PA231 - PA232 1

PC001 - PC005 1

PG001 - PG075 1

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Variable Number Group

PG199 1

PG201 - PG230 1

PG251 - PG255 1

PG271 - PG279 1

PG301 - PG314 1

PG331 - PG332 1

PG351 - PG356 1

PG375 1

PG401 - PG403 1

PG431 - PG442 1

PG471 - PG475 1

PG501 - PG505 1

PG571 - PG586 1

PG621 - PG630 1

PG651 - PG652 1

PG701 - PG705 1

PH001 1

PH011 - PH013 1

PH021 - PH024 1

PH701 - PH715 1

PH731 - PH732 1

PH741 - PH743 1

PJ001 - PJ009 1

PJ031 - PJ032 1

PJ071 - PJ072 1

PJ101 - PJ119 1

PJ201 - PJ219 1

PJ301 - PJ302 1

PJ551 - PJ561 1

PJ601 - PJ615 1

PJ811 1

PJ816 - PJ817 1

PK026 - PK029 1

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Variable Number Group

PK041 - PK053 1

PK061 - PK070 1

PK081 - PK082 1

PK091 - PK099 1

PK101 - PK103 1

PK111 - PK120 1

PK141 - PK146 1

PK201 - PK204 1

PK211 - PK223 1

PK231 - PK241 1

PK251 - PK258 1

PK271 - PK274 1

PK281 - PK289 1

PK291 1

PK301 - PK318 1

PK341 1

PK351 - PK361 1

PK391 1

PK431 - PK433 1

PK451 - PK452 1

PK461 - PK469 1

PK495 1

PK501 - PK504 1

PK511 - PK515 1

PK519 1

PK521 - PK528 1

PK541 - PK565 1

PK581 1

PK591 - PK599 1

PK601 - PK617 1

PK621 - PK637 1

PK641 - PK642 1

PK661 - PK666 1

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Variable Number Group

PK671 - PK681 1

PK691 - PK697 1

PK711 - PK716 1

PK731 - PK765 1

PK771 - PK779 1

PK801 - PK804 1

PK819 - PK827 1

PK830 1

PK861 - PK863 1

PK871 - PK874 1

PK881 - PK884 1

PK901 - PK938 1

PK971 - PK974 1

PL001 - PL028 1

PL061 1

PL081 1

PL101 - PL113 1

PL151 1

PL171 - PL172 1

PL201 - PL203 1

PL221 1

PL401 - PL417 1

PL421 1

PL441 1

PL451 - PL456 1

PL471 1

PL491 1

PL501 - PL506 1

PL551 - PL562 1

PL581 1

PL601 - PL603 1

PL611 1

PL621 - PL626 1

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Variable Number Group

PL631 - PL632 1

PL711 - PL712 1

PL716 - PL747 1

PL756 1

PL758 1

PL761 - PL770 1

PL781 - PL788 1

PL793 1

PL801 - PL803 1

PM001 - PM006 1

PM016 - PM017 1

PM021 - PM023 1

PM051 - PM066 1

PM101 - PM119 1

PM141 - PM142 1

PM171 1

PM181 1

PM251 - PM255 1

PM281 - PM283 1

PM381 - PM399 1

PM401 - PM417 1

PM541 - PM564 1

PN001 - PN002 1

PN021 - PN043 1

PN081 - PN086 1

PN101 - PN117 1

PN131 - PN163 1

PN401 - PN420 1

PN431 - PN433 1

PN451 - PN456 1

PN471 - PN474 1

PN481 1

PN491 - PN493 1

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Variable Number Group

PN501 - PN502 1

PN511 - PN512 1

PN521 1

PP001 - PP054 1

PP101 - PP169 1

PP181 - PP199 1

PP201 - PP205 1

PP221 1

PP231 - PP243 1

PP281 - PP286 1

PP301 - PP305 1

PP351 - PP353 1

PP376 - PP384 1

PP391 - PP393 1

PP401 - PP440 1

PP471 - PP475 1

PP501 - PP522 1

PP631 - PP634 1

PP651 - PP652 1

PP671 - PP699 1

PP701 - PP733 1

PP771 - PP779 1

PP801 - PP808 1

PP821 - PP827 1

PP831 - PP848 1

PP851 - PP852 1

PP861 - PP877 1

PP891 - PP899 1

PP901 - PP936 1

PP946 - PP948 1

PP951 - PP952 1

PP961 - PP967 1

PP981 - PP991 1

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Variable Number Group

PP993 1

PQ001 - PQ016 1

PQ026 - PQ041 1

PQ051 - PQ092 1

PQ101 - PQ199 1

PQ201 - PQ202 1

PQ221 - PQ237 1

PQ241 - PQ243 1

PQ251 - PQ267 1

PQ281 - PQ299 1

PQ301 - PQ307 1

PQ331 - PQ332 1

PQ341 - PQ348 1

PQ361 - PQ373 1

PQ391 - PQ395 1

PQ401 - PQ418 1

PQ421 1

PQ431 - PQ438 1

PQ447 - PQ448 1

PQ451 1

PQ454 1

PQ471 - PQ475 1

PQ479 - PQ481 1

PQ486 - PQ487 1

PQ491 - PQ493 1

PQ771 - PQ772 1

PQ791 - PQ793 1

PQ801 - PQ805 1

PQ931 - PQ935 1

PQ951 1

PQ971 - PQ997 1

PR001 - PR017 1

PR021 - PR034 1

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Variable Number Group

PR041 - PR045 1

PR061 - PR072 1

PR077 - PR082 1

PR091 - PR092 1

PR096 1

PR101 1

PR121 - PR122 1

PR131 - PR132 1

PR141 - PR143 1

PR161 - PR172 1

PR181 1

PS601 - PS631 1

PS636 - PS638 1

PS641 - PS644 1

PS651 - PS657 1

PS666 - PS669 1

PS691 - PS692 1

PS701 - PS706 1

PS751 - PS799 1

PS811 1

PS836 - PS837 1

PS841 - PS846 1

PS851 - PS852 1

PS856 1

PS861 - PS863 1

PS866 - PS868 1

PS871 - PS874 1

PS896 - PS897 1

PS901 - PS941 1

PS956 - PS957 1

PS961 - PS963 1

PS971 - PS978 1

PT001 - PT015 1

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Variable Number Group

PT021 - PT031 1

PT041 - PT064 1

PT101 - PT105 1

PT121 - PT138 1

PT146 - PT148 1

PT161 - PT170 1

PT181 - PT188 1

PT211 - PT220 1

PT295 1

PT301 - PT309 1

PT331 - PT360 1

PT381 - PT399 1

PT401 - PT438 1

PT501 - PT517 1

PT561 - PT565 1

PT581 - PT586 1

PT611 - PT621 1

PT641 - PT644 1

PT651 - PT656 1

PT671 - PT672 1

PT681 - PT685 1

PT701 - PT703 1

PT716 - PT717 1

PT721 - PT725 1

PT801 - PT834 1

PT851 - PT854 1

PT871 - PT886 1

PT901 - PT930 1

PT971 - PT973 1

PT981 - PT985 1

PT996 1

PU001 - PU025 1

PU301 1

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Variable Number Group

PU311 - PU313 1

PV001 - PV055 1

PV201 - PV209 1

PV226 - PV229 1

PV231 - PV237 1

PV271 - PV272 1

PV281 - PV287 1

PV296 1

PV301 - PV302 1

PV351 1

PV356 - PV357 1

PW001 - PW054 1

PW061 - PW068 1

PW072 1

PW086 - PW088 1

PW091 - PW094 1

PW101 - PW102 1

PW106 1

PW111 - PW120 1

PW156 - PW157 1

PW161 - PW171 1

PW201 - PW252 1

PW261 - PW268 1

PW271 - PW276 1

PW278 1

PW281 - PW293 1

PW296 1

PW301 - PW327 1

PW401 - PW408 1

PW411 - PW418 1

PW421 - PW424 1

PW431 - PW435 1

PW441 - PW450 1

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Variable Number Group

PW461 - PW467 1

PW501 - PW504 1

PW511 - PW522 1

PW524 - PW550 1

PW556 - PW557 1

PW561 - PW564 1

PW571 - PW576 1

PW591 - PW596 1

PW611 - PW622 1

PW631 - PW637 1

PW661 - PW662 1

PW681 - PW683 1

PW701 - PW702 1

PW711 - PW717 1

PW741 - PW742 1

PW761 1

PW771 1

PW831 1

PW851 - PW856 1

PX071 1

PX701 1

PY001 - PY008 1

PY021 - PY022 1

PY031 1

PY036 - PY037 1

PY046 - PY048 1

PY051 - PY053 1

PY056 - PY057 1

PY101 - PY103 1

PY111 - PY113 1

PY131 - PY135 1

PY141 - PY143 1

PY151 - PY154 1

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Variable Number Group

PY156 - PY157 1

PY161 - PY162 1

PY166 1

PY191 1

PY201 1

PY221 - PY222 1

PY231 1

PY241 - PY244 1

PY270 - PY275 1

PY281 1

PY286 1

PY301 - PY304 1

PY321 - PY323 1

PY341 - PY346 1

PY361 - PY362 1

PY381 1

PY401 1

PY409 - PY411 1

PY421 - PY422 1

PY441 1

PY451 1

PY461 - PY463 1

PY591 - PY595 1

PY611 - PY612 1

PY621 1

PY631 1

PY651 1

PY671 - PY672 1

PY721 1

PY741 1

2. Spares Affected

None

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B. Concurrent Requirements

None

C. Reason

Cracks have been reported in four general areas on the aft pressure bulkhead: cracks in the web at

the web-to-"Y" chord interface; cracks in the web at the outer circumferential tear strap; cracks in the

web near the dome cap; and cracks in the "Z" stiffeners near the dome cap. Undetected cracking could

result in loss of ability to maintain cabin pressure, rapid decompression of the airplane, and significant

structural damage to the aft fuselage.

As of the initial release of this service bulletin, six operators had reported finding cracks in the aft

pressure bulkhead web of sixteen 737-200 and -300 airplanes. In all of the cases, the cracks ran in

the circumferential direction along the aft row of fasteners connecting the web assembly to the bulkhead

"Y" chord. Fifteen airplanes had cracks at Stringer (S)-6L and one airplane had cracks at S-6L and

S-6R. The airplanes had accumulated between 25,500 and 68,000 flight cycles and between 45,500

and 61,000 flight hours.

Since the initial release of this bulletin, there have been additional reports of cracking. The cracks were

similar to the previously reported cracks. Cracks have been reported on airplanes with a range of

between 22,966 and 67,937 flight cycles.

Also, there have been two reports of cracking in the bulkhead web at the outer circumferential tear

strap. The first report happened in 1978 and resulted in the release of a Structural Item Interim Advisory

(SIIA) SIIA 737-52. In that event, the airplane experienced a sudden cabin pressure drop as a result

of a 42 inch crack in the bulkhead web. The crack ran along the outer circumferential tear strap from

S-15R to S-21, turned 90 degrees inwards and ran along the radial stiffener at S-21R, stopping at the

middle circumferential tear strap. The second report happened in January of 1999 and resulted in the

release of SIIA 737-269. The operator discovered an eight inch crack during a heavy maintenance

check. The crack ran along the outer circumferential tear strap from S-15R to S-18R. The airplanes

had 21,246 and 26,162 flight cycles and 17,500 and 24,132 flight hours respectively.

Since revision 2 of this bulletin, there have been reports of cracking in the web near the dome cap.

The cracks occurred at the center of the bulkhead at the edge of web gore sections. The airplanes had

accumulated more than 30,000 flight cycles and 36,000 flight hours. There have also been reports of

cracking in the radial "Z" stiffeners where they attach to the dome cap. The cracks extended from the

outboard fastener hole and ran circumferentially.

Revision 1 was sent to:

— Modify Industry Support Information.

— add an SRM repair reference for repairing cracking in the web periphery at S-6L or S-6R.

— add a visual inspection for oil-canning for the entire bulkhead web.

— add an NDT inspection for cracking in the web at the outer circumferential tear strap around the

entire bulkhead.

— add an inspection for cracking in the web at the "Y" chord below S-15L and S-15R.

Revision 2 was sent to:

— Clarify the inspection threshold in the compliance section.

— Change two SRM figure references and add a note. The note states that more work is required if

an operator used the wrong SRM figure to do a web crack repair.

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Revision 3 was sent to:

— Add an inspection for cracking in the web joints in the center of the aft pressure bulkhead.

— Add inspections for cracking in the radial "Z" stiffeners where they attach to the dome cap.

— Add repeat inspections for oil cans.

— Add Appendices A to D to show post repair inspections for repairs that have been deleted from

the SRM.

— Add Appendix E to show the removal and replacement of a repair that has been deleted from the

SRM.

— Add SRM references for new oil can repairs and repairs for web cracking at the center of the

bulkhead.

— Change the Industry Support Information statement.

— Clarify the inspection in Figure 1, step 2.

Revision 4 is sent to change the compliance time for Detailed Inspection for Oil-Cans and to delete

incorrect paragraph reference in Paragraph 3.B., Work Instructions, Part VI.

Boeing Service Related Problem (SRP) 737-SRP-53-0109, 737-SRP-53-0116, and 737-SRP-53-0155

are related to this service bulletin.

D. Description

Inspect the web for cracking at the "Y" chord in the upper bulkhead from S-15L to S-15R:

— Get access to the aft side of the aft pressure bulkhead and do a Low Frequency Eddy Current

(LFEC) inspection for any cracking in the web periphery. Do the inspection for circumferential

cracking in the web where it attaches to the "Y" chord along the aft row of fasteners. Do the

inspection in the upper fuselage from S-15L to S-15R. Also do a Detailed Inspection for any cracking

in the web and for any incorrectly drilled or elongated fastener hole(s).

— If either cracking, incorrectly drilled fastener hole or elongated fastener hole is found, you must

get access to the forward side of the bulkhead and do a High Frequency Eddy Current (HFEC)

inspection for any cracking and a Detailed Inspection from the forward side. Do the HFEC

inspections for circumferential cracking along the aft row of fasteners at the "Y" chord for the section

of web where the cracking, incorrectly drilled fastener hole or elongated fastener hole was found.

It is not necessary to do the HFEC inspection beyond the web splices of the web section containing

the cracking, incorrectly drilled fastener hole or elongated fastener hole. Do the Detailed Inspection

for any cracking in the web and for any incorrectly drilled or elongated fastener hole(s). If you find

damage at S-6L or S-6R, repair it as shown in the 737-100/200 or 737-300/400/500 SRM as

applicable. If you install the SRM repair, there are future inspection requirements as defined in the

SRM repair. If you find any cracking in the web periphery that is not covered by the SRM, contact

Boeing for repair instructions and install the repair.

— As an option to doing the inspections on the aft side of the bulkhead, you can do the HFEC and

Detailed Inspection from the forward side of the bulkhead directly at less frequent intervals.

— Do repeat inspections at the times shown in Paragraph 1.E., Compliance. Once the SRM repair

is accomplished, subsequent inspections become less frequent.

Inspect the web for cracking at the "Y" chord in the lower bulkhead from S-15L to S-15R:

— This inspection is identical to the inspection above stringers S-15L and S-15R (upper lobe) and is

done using a LFEC, HFEC, and Detailed Inspection procedures from the forward and the aft side.

The compliance time for this inspection is different than the compliance time for the upper-lobe

inspection. Refer to Paragraph 1.E., Compliance for compliance information.

— Do repeat inspections at the times shown in Paragraph 1.E., Compliance.

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— If you find any cracking in this area, contact Boeing for repair instructions and install the repair.

Inspect the web for any cracking at the outer circumferential tear strap:

— From the aft side of the bulkhead, do a LFEC inspection for any cracking in the web at the outer

circumferential tear strap around the entire bulkhead. As an option, you can do a HFEC inspection

from the forward side of the bulkhead. Refer to Paragraph 1.E., Compliance for compliance

information.

— If you find any cracking in this area, repair in accordance with the SRM or contact Boeing for repair

instructions and install the repair.

Inspect the web for oil-cans:

— From the aft side of the bulkhead, do a Detailed Inspection for oil-cans.

— If you find oil-cans beyond SRM allowable limits, repair it as shown in the SRM.

— If you find an oil-can within SRM allowable limits, repair as shown in the SRM, OR if the oil can is

within the SRM allowable limits you can monitor the condition with repeat inspections and repair

as shown in the SRM within the time shown in Paragraph 1.E., Compliance.

— Do repeat inspections at the times shown in Paragraph 1.E., Compliance.

Inspect the web for any cracking at the dome cap at the center of the bulkhead:

— From the aft side of the bulkhead, do a NDT inspection for any cracking in the bulkhead web near

the dome cap.

— If you find any cracking in this area, repair as shown in the SRM.

— Do repeat inspections at the times shown in Paragraph 1.E., Compliance.

Inspect the forward flange of the "Z" stiffeners for any cracking at the dome cap at the center of the

bulkhead:

— From the fwd side of the bulkhead, do a NDT inspection for any cracking in the forward flange of

the "Z" stiffeners at the dome cap. Do the inspection at both fastener rows common to the dome.

— If you find any cracking in this area, contact Boeing for repair instructions and install the repair.

— Do repeat inspections at the times shown in Paragraph 1.E., Compliance.

Revision 3:

— More work is necessary on airplanes that have repairs installed in accordance with 737-100/200

SRM 53-10-4, Figures 3, 5, and 12, or 737-300/400/500 SRM 53-80-08, Repair 1, 2, and 4: Repeat

inspections must be performed at the times shown in Paragraph 1.E., Compliance.

— More work is necessary on airplanes that have repairs installed in accordance with 737-100/200

SRM 53-10-4, Figure 13 or 737-300/400/500 SRM 53-80-08, Repair 5. Repairs must be replaced

at the time shown in Paragraph 1.E., Compliance.

NOTE: Service Bulletins 737-53A1075 and 737-53-1123 have common access and can be

done concurrently with this bulletin.

1.

2. If any cracking, incorrectly drilled holes or elongated holes are found that are not

within the repairable limits of applicable repairs, write to Boeing for repair instructions.

Give the size and location of the damage. When possible, send sketches and

photographs. If the damage includes corrosion, send data on the length, width, and

largest depth of clean up.

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ALERT ALERT
Send to: BOEING COMMERCIAL AIRPLANE GROUP ATTENTION: MANAGER, AIRLINE

SUPPORT

Revision 4 - No more work is necessary on airplanes changed in accordance with Revision 3 of this

service bulletin.

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

737-100, 737-200, 737-200C 7-1, 2-20

Group 1:

Affected Maintenance Zones

Model Zone

737-300, 737-400, 737-500 220, 701

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Federal Aviation Administration (FAA) Airworthiness Directive AD 99-08-23, is related to this service

bulletin.

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ALERT ALERT
TABLE 1: INSPECTION REQUIREMENTS - NDT INSPECTION OF WEB AT "Y" CHORD IN THE UPPER

BULKHEAD FROM S-15L TO S-15R

Repeat Interval Flight Cycles (Not

to Exceed) (a)

Compliance Time

(whichever occurs later) (a)

Condition Action

Above S-15L to S15R except S-5L

to S-7L and S-5R

to S-9R

S-5L to S-7L

and S-5R to S9R

Upper Fuselage from S15L to S-15R

6,000 Flight Cycles

from last LFEC Inspection,

1,200 Flight Cycles from last

LFEC Inspection,

Within 375 Flight Cycles

of the effective date of

AD 99-08-23,

OR

Eddy Current Inspection

and Detailed Inspection

for any cracking and any

incorrectly drilled or elongated fastener hole(s) in

accordance with Paragraph 3.B., Work Instructions, PART I.

25,000 Total

Flight Cycles or

more

OR

12,000 Flight Cycles from last

HFEC Inspection.

OR

3,800 Flight Cycles from the last

HFEC Inspection.

WIthin 1,200 flight cycles

or within 12 months after

the last inspection accomplished in accordance

with Paragraph (a)(2) of

AD 99-08-23, whichever

occurs first.

OR

Within 1,200 flight cycles

after the last LFEC (aft

side) inspection,

OR

Within 3,800 flight cycles

after the last HFEC (fwd

side) inspection.

HFEC Inspection and De- Before Further Flight - -

tailed Inspection from the

forward side for any

cracking and any incorrectly drilled or elongated fastener hole(s). (b)

Any cracking or

incorrectly drilled

fastener hole or

elongated fastener hole is found

Repeat inspections at - - -

specified intervals

No cracking or incorrectly drilled or

elongated fastener hole(s) found

Repair in accordance with Before Further Flight - -

the Structural Repair

Manual

Any cracking or

any incorrectly

drilled or elongated fastener

hole(s) found at

S-5L to S-7L or at

S-5R to S-9R

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TABLE 1: INSPECTION REQUIREMENTS - NDT INSPECTION OF WEB AT "Y" CHORD IN THE UPPER

BULKHEAD FROM S-15L TO S-15R

Repeat Interval Flight Cycles (Not

to Exceed) (a)

Compliance Time

(whichever occurs later) (a)

Condition Action

Above S-15L to S15R except S-5L

to S-7L and S-5R

to S-9R

S-5L to S-7L

and S-5R to S9R

Upper Fuselage from S15L to S-15R

Contact Boeing for repair Before Further Flight - -

instructions and install the

repair.

Any cracking or

any incorrectly

drilled or elongated fastener

hole(s) found at

S-15L to S-7L, S15R to S-9R or

above S-5L to S5R

(a) If you install the SRM repair doubler at S-6L or S-6R in accordance with 737-100/200 SRM 53-10-4, Figure

15 or 737-300 SRM 53-80-08, Repair 7 or 737-400 SRM 53-80-08, Repair 7 or 737-500 SRM 53-80-08,

Repair 7, refer to the SRM for Inspection threshold and repeat Inspection intervals for the area of the web

covered by the repair doubler.

(b) Do the HFEC Inspection for any cracking in the section of web where the cracking or incorrectly drilled or

elongated fastener hole was found. It is not necessary to do the HFEC Inspection beyond the web splices

of the web section containing the cracking, incorrectly drilled fastener hole or elongated fastener hole.

Table 2: Inspection Requirements - NDT Inspection of Web at "Y" Chord in the Lower Bulkhead from S15L to S-15R

Repeat Interval Flight

Cycles (Not to Exceed)

Condition Action Compliance Time

6,000 Flight Cycles from

the last LFEC Inspection

(aft side). (a)

Before 30,000 Total

Flight Cycles.

Eddy Current Inspection and Detailed Inspection for any cracking

and for any incorrectly drilled or

elongated fastener hole(s) or corrosion in accordance with Paragraph

3.B., Work Instructions, PART III.

Less than 24,000

Total Flight Cycles

OR

12,000 Flight Cycles from

the last HFEC Inspection

(forward side). (a)

6,000 Flight Cycles from

the last LFEC Inspection

(aft side). (a)

Within 6,000 Flight Cycles or Two years,

whichever comes first,

from the date of Revision 3 of this service

bulletin.

Eddy Current Inspection and Detailed Inspection for any cracking

and for any incorrectly drilled or

elongated fastener hole(s) or corrosion in accordance with Paragraph

3.B., Work Instructions, PART III.

24,000 Total Flight

Cycles or more

OR

12,000 Flight Cycles from

the last HFEC Inspection

(forward side). (a)

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Table 2: Inspection Requirements - NDT Inspection of Web at "Y" Chord in the Lower Bulkhead from S15L to S-15R

Repeat Interval Flight

Cycles (Not to Exceed)

Condition Action Compliance Time

Contact Boeing for repair instructions Before Further Flight -

and install the repair.

Any cracking, any

incorrectly drilled or

elongated fastener

hole(s) or corrosion

found

(a) In many areas the access is limited and you can do an inspection from only one side: either the forward

side (HFEC) or the aft side (LFEC). In these areas, do the inspection from the side which provides access.

Table 3: Inspection Requirements - NDT Inspection under Tear Strap

Repeat Interval

Flight Cycles

(Not to Exceed)

Condition Action Compliance Time

One-time inspection only.Before 16,200 Total Flight

Cycles

Eddy Current Inspection for any

cracking in accordance with Paragraph

3.B., Work Instructions, PART II, Step

1.

Less than 15,000

Total Flight Cycles

One-time inspection only.Within 1,200 Flight Cycles or

six months, whichever

comes first, after the date of

Revision 1 to this Service

Bulletin

Eddy Current Inspection for any

cracking in accordance with Paragraph

3.B., Work Instructions, PART II, Step

1.

15,000 Total Flight

Cycles or more

Contact Boeing for repair instructions Before Further Flight -

and install the repair.

Any cracking found

Table 4: Inspection Requirements - Detailed Inspection for Oil-Cans

Repeat Interval

Flight Cycles

(Not to Exceed)

Condition Option Action Compliance Time

Before 15,000 Total Flight -

Cycles

Detailed Inspection for OilCans in accordance with

Paragraph 3.B., Work Instructions, PART II, Step 2.

Initial Inspection -

for Oil-Cans

OR

Within 1,200 Flight Cycles

after the date of Revision 1

to this Service Bulletin,

Whichever comes later.

Contact Boeing for repair in- Before further flight. -

structions and install the repair.

Any cracking is -

found.

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Table 4: Inspection Requirements - Detailed Inspection for Oil-Cans

Repeat Interval

Flight Cycles

(Not to Exceed)

Condition Option Action Compliance Time

Within 6,000 Flight Cycles 6,000

from prior Inspection.

Detailed Inspection for OilCans in accordance with

Paragraph 3.B., Work Instructions, PART II, Step 2.

No Oil-Cans on -

Initial Inspection

or Repeat Inspections.OR

Within 1,200 Flight Cycles

after the date of Revision 3

to this Service Bulletin,

Whichever comes later.

Contact Boeing for repair in- Before further flight. -

structions and install the repair.

Any cracking is -

found.

Detailed and NDT Inspection Before further flight. 1,200 (a)

in accordance with Paragraph

3.B., Work Instructions,

PART II, Step 2.

Option 1 (defer repair)Oil-Cans found

within limits defined in SRM.

Within 12,000 Flight Cycles -

from the time when the oil

can is found.

Install the repair in accordance with Paragraph 3.B.,

Work Instructions, PART II,

Step 2.

Install the repair in accor- Before Further Flight. -

dance with Paragraph 3.B.,

Work Instructions, PART II,

Step 2.

Option 2 (repair immediately)

Contact Boeing for repair in- Before further flight. -

structions and install the repair.

Any cracking is -

found.

Install the repair in accor- Before further flight. -

dance with Paragraph 3.B.,

Work Instructions, PART II,

Step 2.

Oil-Cans found -

outside of allowable limits defined in SRM.

(a) Repeat inspections are terminated when the repair is installed.

Table 5: Inspection Requirements - NDT Inspection of the Dome Cap at the Center of the Bulkhead

Repeat Interval

Flight Cycles (Not

to Exceed)

Condition Action Compliance Time

Before 30,000 Total 6,000

Flight Cycles.

Eddy Current Inspection of the Dome Cap

for any cracking in accordance with Paragraph 3.B., Work Instructions, PART IV.

Less than 24,000

Total Flight Cycles

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Table 5: Inspection Requirements - NDT Inspection of the Dome Cap at the Center of the Bulkhead

Repeat Interval

Flight Cycles (Not

to Exceed)

Condition Action Compliance Time

Within 6,000 Flight 6,000

Cycles or 2 years,

whichever comes

first, after the date of

Revision 3 to this

Service Bulletin.

Eddy Current Inspection of the Dome Cap

for any cracking in accordance with Paragraph 3.B., Work Instructions, PART IV.

24,000 Total Flight

Cycles or more

Before Further -

Flight.

Install the repair in accordance with Paragraph 3.B., Work Instructions, PART IV.Any cracking found

Table 6: Inspection Requirements - NDT Inspection of the Forward Flange of the "Z" Stiffeners at

the Dome Cap

Repeat Interval

Flight Cycles

(Not to Exceed)

Condition Action Compliance Time

Before 30,000 Total 12,000

Flight Cycles.

HFEC Inspection of the forward

flanges of the "Z" stiffener for any

cracking in accordance with Paragraph 3.B., Work Instructions, PART

V.

Less than 24,000

Total Flight Cycles

Within 6,000 Flight Cy- 12,000

cles or 2 years,

whichever comes first,

after the date of Revision 3 to this Service

Bulletin.

HFEC Inspection of the forward

flanges of the "Z" stiffener for any

cracking in accordance with Paragraph 3.B., Work Instructions, PART

V.

24,000 Total Flight

Cycles or more

Contact Boeing for repair instructions Before Further Flight. -

and install the repair

Any cracking found

Table 7: Inspection Requirements - Inspection for Existing Repairs

Condition Action Compliance Time

Within 4,500 flight cycles after the date

of Revision 3 to this Service Bulletin.

Do a detailed inspection of the bulkhead web

and stiffeners to find existing repairs on the

bulkhead in accordance with Paragraph 3.B.,

Work Instructions, Part VI.

All Airplanes

At the applicable time in accordance

with Table 8.

Do Eddy Current Inspections or repair replacement as necessary, in accordance with Paragraph 3.B., Work Instructions, PART II.Obsolete SRM repair installed.

At the applicable time in accordance

with the SRM.

Do Eddy Current Inspections in accordance with

Paragraph 3.B., Work Instructions, PART II.

Current SRM repair

installed.

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Table 7: Inspection Requirements - Inspection for Existing Repairs

Condition Action Compliance Time

At the time in accordance with the FAA

approved Damage Tolerance Inspections.

Do the FAA approved Damage Tolerance Inspections.Non SRM repair installed and the repair has FAA approved Damage

Tolerance Inspections.

Within 4,500 flight cycles after the date

of Revision 3 to this Service Bulletin.

Contact Boeing for FAA approved Damage Tolerance Inspections.Non SRM repair installed and the repair does not have

FAA approved

Damage Tolerance

Inspections.

At the time in accordance with the FAA

approved Damage Tolerance Inspections.

Do the FAA approved Damage Tolerance Inspections.

Table 8: Requirements for Obsolete SRM Repairs

Repeat Interval

Flight Cycles

(Not to Exceed)

Compliance Time

(Whichever Occurs

Later)

Reference Condition Action

12,000 for HFEC

Inspection. 6,000

for LFEC Inspection.

Within 12,000 Flight

Cycles after the repair was installed,

OR

Do a HFEC inspection of the

web at fastener locations not

common to a tear strap in

accordance with APPENDIX

A

737-300 SRM 53-80-08,

Repair 1 or 737-400

SRM 53-80-08, Repair

1 or 737-500 SRM 53-

80-08, Repair 1 installed (obsolete - older

SRM) or 737-100/200

SRM 53-10-4, Figure 3

repair installed (obsolete - older SRM)

APPENDIX A

- Repair For

Damage to

Web and

Strap Within 6,000 Flight

Cycles after the date

of Revision 3 to this

Service Bulletin.

OR

At the operators option, do a

LFEC inspection of the web

in accordance with APPENDIX A

12,000 for HFEC

Inspection. 6,000

for LFEC Inspection.

Within 12,000 Flight

Cycles after the repair was installed,

OR

Do a HFEC inspection of the

web at fastener locations

common to a tear strap in

accordance with APPENDIX

A Within 6,000 Flight

Cycles after the date

of Revision 3 to this

Service Bulletin.

OR

At the operators option, do a

LFEC inspection of the web

in accordance with APPENDIX A

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Table 8: Requirements for Obsolete SRM Repairs

Repeat Interval

Flight Cycles

(Not to Exceed)

Compliance Time

(Whichever Occurs

Later)

Reference Condition Action

12,000 for HFEC

Inspection. 6,000

for LFEC Inspection.

Within 12,000 Flight

Cycles after the repair was installed,

OR

Do a HFEC inspection of the

web and repair plate in accordance with APPENDIX B

OR

737-300 SRM 53-80-08,

Repair 1 or 737-400

SRM 53-80-08, Repair

1 or 737-500 SRM 53-

80-08, Repair 1 installed (obsolete - older

SRM) or 737-100/200

SRM 53-10-4, Figure 3

repair installed (obsolete - older SRM)

APPENDIX B

- Repair For

Damage to

Web

Within 6,000 Flight

Cycles after the date

of Revision 3 to this

Service Bulletin.

At the operators option, do a

LFEC inspection of the web

in accordance with APPENDIX B

12,000 for HFEC

Inspection. 6,000

for LFEC Inspection.

Within 12,000 Flight

Cycles after the repair was installed,

OR

Do a HFEC inspection of the

web in accordance with APPENDIX C

OR

737-300 SRM 53-80-08,

Repair 2 or 737-400

SRM 53-80-08, Repair

2 or 737-500 SRM 53-

80-08, Repair 2 installed (obsolete - older

SRM) or 737-100/200

SRM 53-10-4, Figure 5

repair installed (obsolete - older SRM)

APPENDIX C

- Repair For

Oil Can in

Web.

Within 6,000 Flight

Cycles after the date

of Revision 3 to this

Service Bulletin.

At the operators option, do a

LFEC inspection of the web

in accordance with APPENDIX C

Within 12,000 Flight 6,000

Cycles after the repair was installed,

Do a LFEC inspection of the

web in accordance with APPENDIX D

737-300 SRM 53-80-08,

Repair 4 or 737-400

SRM 53-80-08, Repair

4 or 737-500 SRM 53-

80-08, Repair 4 installed (obsolete - older

SRM) or 737-100/200

SRM 53-10-4, Figure 12

repair installed (obsolete - older SRM)

APPENDIX D

- Repair For

Oil Can in

Web (Not at

Strap)

OR

Within 6,000 Flight

Cycles after the date

of Revision 3 to this

Service Bulletin.

Within 12,000 Flight 12,000

Cycles after the repair was installed,

Do a HFEC inspection of the

web in accordance with APPENDIX D

OR

Within 6,000 Flight

Cycles after the date

of Revision 3 to this

Service Bulletin.

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Table 8: Requirements for Obsolete SRM Repairs

Repeat Interval

Flight Cycles

(Not to Exceed)

Compliance Time

(Whichever Occurs

Later)

Reference Condition Action

Within 6,000 Flight -

Cycles after the date

of Revision 3 to this

Service Bulletin.

Remove the existing repair

and replace in accordance

with 737-100/200 SRM 53-

10-4, Figure 3A repair, or

737-300 SRM 53-80-08, Repair 11 or 737-400 SRM 53-

80-08 , Repair 11 or 737-500

SRM 53-80-08, Repair 11 as

applicable.

737-300 SRM 53-80-08,

Repair 5 or 737-400

SRM 53-80-08, Repair

5 or 737-500 SRM 53-

80-08, Repair 5 installed (obsolete - older

SRM) or 737-100/200

SRM 53-10-4, Figure 13

repair installed (obsolete - older SRM)

APPENDIX E

- Repair For

Oil Can in

Web and

Strap.

F. Approval

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

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

The Manager of the FAA Seattle Aircraft Certification Office has approved the inspection methods,

locations, and repetitive inspection intervals as specified in Revision 4 of this service bulletin as an

alternate method of compliance to paragraphs (a)(1), (a)(2), (c), (d)(1), (d)(2), and (g) of AD 99-08-23,

Amendment 39-11132. All provisions of the AD that are not specifically referenced in the preceding

sentence remain fully applicable and must be complied with.

Operators should be aware that a number of SRM repairs which pertain to this Service Bulletin do not

have AMOC approval statements for AD 98-11-04 R1, AD 99-08-23, AD 2008-08-23, and AD 2008-09-13.

Until these SRMs are revised to include the appropriate AMOC approval statements, operators should

request approval from the Boeing Company.

When this Service Bulletin specifies contacting Boeing for repair instructions, the repair instructions

must be approved by the FAA in accordance with paragraph (e) of AD 99-08-23, paragraph (i) of AD

98-11-04 R1, paragraph (l) of AD 2008-08-23, or paragraph (l) of AD 2008-09-13, as applicable.

G. Manpower

The table below shows an estimate of the man-hours necessary to do the inspections and modifications.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

man-hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

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— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Table 1A:

Web Inspection at "Y" Chord - Option A: LFEC Inspection from the Aft Side of the Bulkhead

Elapsed Time

(Hours)

Task Number of Persons Man-Hours

LFEC Inspection 2 8 4

TOTAL FOR EACH AIRPLANE 8 4

Table 1B:

Web Inspection at "Y" Chord - Option B: HFEC Inspection from the Forward Side of the Bulkhead

Elapsed Time

(Hours)

Task Number of Persons Man-Hours

Access 2 26 13

HFEC Inspect Web 2 2 (a) 1 (a)

Close Access 2 32 16

TOTAL FOR EACH AIRPLANE 60 30

(a) Adding the NDT inspection below S-15 would take an additional 24 hours.

Table 2:

Web Inspection under Outer Circumferential Tear Strap and Detailed Inspection for Oil-Cans

Task Number of Persons Task-Hours Elapsed Hours

LFEC Inspection and Detailed 2 14 7

Inspection (a)

Optional HFEC Inspection and 2 8 (b) 4 (b)

Detailed Inspection (a)

TOTAL FOR EACH AIRPLANE - LFEC OPTION 14 7

TOTAL FOR EACH AIRPLANE - HFEC OPTION 8 4

(a) The repeat oil-can Detailed Inspections would take 1 person 0.5 hours.

(b) This estimate does not include access and close access for the forward side of the web. Refer

to Table 1B for an estimate of the man-hours needed to get access and close access for the

forward side of the bulkhead.

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Table 3:

NDT Inspection of Bulkhead Lap Splices at the Center of the Bulkhead

Task Number of Persons Task-Hours Elapsed Hours

Inspection 2 6 (a) 3 (a)

TOTAL FOR EACH AIRPLANE 6 3

(a) This estimate does not include access and close access for the forward side of the

web. Refer to Table 1B for an estimate of the man-hours needed to get access and

close access for the forward side of the bulkhead.

Table 4:

NDT Inspection of "Z" Stiffeners at the Dome Cap

Task Number of Persons Task-Hours Elapsed Hours

Inspection 2 8 (a) 4 (a)

TOTAL FOR EACH AIRPLANE 8 4

(a) This estimate does not include access and close access for the forward side of the

web. Refer to Table 1B for an estimate of the man-hours needed to get access and

close access for the forward side of the bulkhead.

H. Weight and Balance Changes

None

I. Electrical Load Data

Not applicable

J. References

1. Existing Data:

a. Engineering Change Memo PRR 35005-229R

b. Boeing Service Bulletin 737-53-1123, 737-53A1075

c. Boeing Service Related Problem (SRP) 737-SRP-53-0109, 737-SRP-53-0116,

737-SRP-53-0155

d. Boeing Structural Item Interim Advisory (SIIA) 737-269, 737-52

e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2008-08-23, 2008-09-13,

98-11-04, 99-08-23

f. Service Bulletin Index D6-19567

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g. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Part 6, 53-10-41, Part 6, 53-10-54,

Part 6, 53-10-64, Part 6, 53-30-00

h. 737-100/200 Aircraft Maintenance Manual (AMM) 25-31-61, 25-40-0, 38-11-11

i. 737-100/200 Structural Repair Manual (SRM) 53-10-1, 53-10-11, 53-10-4

j. 737-300/400/500 Aircraft Maintenance Manual (AMM) 25-31-41, 25-40-01, 38-11-11

k. 737-300 Structural Repair Manual (SRM) 53-80-08

l. 737-400 Structural Repair Manual (SRM) 53-80-08

m. 737-500 Structural Repair Manual (SRM) 53-80-08

2. Data supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

65-46568 Bulkhead Installation - STA 1016

Support Installation - Toilet Compartments

Section 46

65-46812

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS and new DTI requirements for the structure

affected are contained in Paragraph 1.E., Compliance of this service bulletin.

L. Interchangeability and Intermixability of Parts

None

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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

None

B. Industry Support Information

Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None

2. Parts and Materials Supplied by the Operator:

None.

3. Parts Modified and Reidentified:

None

4. Parts Removed and Not Replaced:

None

D. Parts Necessary to Change Spares

None

E. Special Tooling - Price and Availability

None

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

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

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque limits to tighten nuts and bolts are in SRM Chapter 51

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

6. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

7. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

8. Boeing Service Letter 737-SL-51-042, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

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9. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

B. WORK INSTRUCTIONS

PART I - NDT INSPECTION OF THE WEB AT THE "Y" CHORD - UPPER BULKHEAD FROM S-15L

TO S-15R:

1. Do a Detailed Inspection and LFEC inspection of the aft side of the bulkhead web in accordance

with Figure 1. As an option, you can do an inspection of the forward side of the bulkhead web in

accordance with PART I - Step 3 (below).

2. If you find any cracking, or incorrectly drilled fastener hole or elongated fastener hole while you

are doing the LFEC inspection and Detailed Inspection, you must get access to the forward side

of the bulkhead and do a HFEC and Detailed Inspection of the section of web where the cracking,

incorrectly drilled fastener hole or elongated fastener hole was found. Do the inspection in

accordance with FIGURE 2 except the inspection can be limited to only the section of web with

the damage. It is not necessary to do the inspection beyond the web splices of the web section

containing the damage.

3. As an option to doing the LFEC inspection from the aft side of the bulkhead, you can do an

inspection from the forward side of the bulkhead as follows:

a. Get access to the forward side of the bulkhead by removing these items as necessary:

(1) Remove the galley. Refer to 737-100/200 AMM 25-31-61 or 737-300/400/500 AMM

25-31-41 as an accepted procedure.

(2) Remove the lavatory. Refer to 737-100/200 AMM 25-40-0 or 737-300/400/500 AMM

25-40-01 as an accepted procedure.

b. Do an inspection of the forward side of the bulkhead in accordance with FIGURE 2.

4. If no cracking, incorrectly drilled fastener holes or elongated fastener holes are found, put the

airplane back to a serviceable condition by replacing the aft galley and aft lavatory. Refer to the

applicable AMM sections called out in PART I - Step 3 (above).

NOTE: You can install the repair in accordance with 737-100/200 SRM 53-10-4, Figure 15 or

737-300 SRM 53-80-08, Repair 7 or 737-400 SRM 53-80-08, Repair 7 or 737-500 SRM

53-80-08, Repair 7 as a preventive modification. If the SRM repair is installed, do

inspections at the times given in the SRM.

5. If you find any cracking, incorrectly drilled fastener holes or elongated fastener holes at S-6L or

S-6R, cut out the damage and install a repair doubler in accordance with 737-100/200 SRM 53-10-4,

Figure 15 or 737-300 SRM 53-80-08, Repair 7 or 737-400 SRM 53-80-08, Repair 7 or 737-500

SRM 53-80-08, Repair 7. If you find any cracking, incorrectly drilled fastener holes or elongated

fastener holes in the web periphery at a location other than at S-6L or S-6R, contact Boeing for

repair instructions and install the repair.

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NOTE: – More work is required on airplanes with any web cracking repaired in accordance

with 737-100/200 SRM 53-10-4 , Figure 3 or 737-300 SRM 53-80-08, Repair 1 or

737-400 SRM 53-80-08, Repair 1 or 737-500 SRM 53-80-08, Repair 1. If web cracking

at the "Y" Chord was repaired using one of these figures, contact Boeing within 90

days of the release date of Revision 2 of this Service Bulletin to find out what

additional work will be required. Please provide repair details when contacting Boeing.

– If you install the repair in accordance with 737-100/200 SRM 53-10-4, Figure 15 or

737-300 SRM 53-80-08, Repair 7 or 737-400 SRM 53-80-08, Repair 7 or 737-500

SRM 53-80-08, Repair 7, do inspections at the times given in the SRM.

6. If you find any cracking, report it to the Boeing company. Include the crack location, length, and

the airplane flight cycles and flight hours. Send the information to: BOEING COMMERCIAL

AIRPLANE GROUP ATTENTION: MANAGER, AIRLINE SUPPORT

7. Do repeat inspections of unrepaired structure at the times shown in Paragraph 1.E., Compliance.

NOTE: If you installed the repair in accordance with 737-100/200 SRM 53-10-4, Figure 15 or

737-300 SRM 53-80-08, Repair 7 or 737-400 SRM 53-80-08, Repair 7 or 737-500 SRM

53-80-08, Repair 7, do inspections at the times given in the SRM.

PART II - NDT INSPECTION UNDER CIRCUMFERENTIAL TEAR STRAP AND DETAILED

INSPECTION FOR OIL-CANNING:

1. ONE-TIME NDT INSPECTION UNDER THE TEAR STRAP:

a. From the aft side of the bulkhead, do a one-time LFEC inspection of the web under the outer

circumferential tear strap in accordance with FIGURE 3.

b. As an option to doing the LFEC inspection from the aft side, you can do a one-time HFEC

inspection from the forward side in accordance with FIGURE 3.

c. If you find any cracking under the outer circumferential tear strap, contact Boeing for repair

instructions and repair. Do not repair in accordance with the SRM.

2. DETAILED INSPECTION FOR OIL-CANNING:

a. At the times shown in Paragraph 1.E., Compliance, Table 4, accomplish a Detailed Inspection

for oil canning from the aft side of the Bulkhead in accordance with FIGURE 5.

b. If oil canning is found, accomplish the additional NDT inspections in accordance with the

Allowable Damage Section in 737-100/200 SRM 53-10-1, Figure 1 or 737-300 SRM 53-80-08,

Figure 101 or 737-400 SRM 53-80-08, Figure 101 or 737-500 SRM 53-80-08, Figure 101. If

any cracking is found when inspecting the oil canning, or if any of the structural requirements

listed in the SRM Notes cannot be met (for example: proximity to fasteners, damage to adjacent

structure etc.), then contact Boeing for repair instructions and install the repair.

c. Measure the depth and width of the oil can in accordance with the SRM Allowable Damage

Section. If the oil can is within the limits of Graph I (lower curve) where repairs can be deferred,

then choose one of the options that follow:

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(1) Option 1: Install the appropriate repair in accordance with Graph I of the SRM Allowable

Damage Section in 737-100/200 SRM 53-10-1, Figure 1, or 737-300 SRM 53-80-08,

Figure 101 or 737-400 SRM 53-80-08, Figure 101 or 737-500 SRM 53-80-08, Figure 101,

within the time shown in Paragraph 1.E., Compliance. Repeat inspections are required

until the repair is installed. Accomplish the inspection program in accordance with the

SRM Allowable Damage Section.

(2) Option 2: Install the appropriate repair in accordance with Graph I of the SRM Allowable

Damage Section, before further flight.

d. If the oil canning exceeds the limits of Graph I (lower curve) of the Allowable Damage Section

in 737-100/200 SRM 53-10-1, Figure 1 or 737-300 SRM 53-80-08, Figure 101 or 737-400

SRM 53-80-08, Figure 101 or 737-500 SRM 53-80-08, Figure 101, then install the appropriate

repair in accordance with Graph I, before further flight.

e. Note that Graph I of the SRM Allowable Damage Section refers to two repairs, dependent

upon the severity of the oil canning. These repairs are detailed below in Table 1.

Table 1: SRM Repairs for the Aft Pressure Bulkhead

737-300 SRM 53-

80-08

737-400 SRM 53-

80-08

737-500 SRM 53-

80-08

737-100/200 SRM

53-10-4

Subject

BS 1016 Bulkhead Cutout Repair Figure 3A Repair 11

Oil Can Doubler Repair Figure 5A Repair 12

f. If an oil-can repair is installed as listed in Table 1 above, do inspections of the repair at the

times given in the SRM.

g. After you install the SRM oil-can repair(s), verify that remaining oil-cans (if any) are within the

allowable damage limits of the SRM.

h. If you find any oil canning, report it to the Boeing company. Report the oil canning even if you

are going to repair it in accordance with the SRM.

Include the location, depth, size, orientation, and the airplane flight cycles and flight hours.

Send the information to:

BOEING COMMERCIAL AIRPLANE GROUP ATTENTION: MANAGER, AIRLINE SUPPORT

i. Do repeat inspections for oil canning at the times shown in Paragraph 1.E., Compliance.

PART III - NDT AND DETAILED INSPECTION OF THE WEB AT THE "Y" CHORD BELOW S-15

1. Get access to the forward side of the bulkhead by removing these items as necessary:

a. Remove the galley. Refer to 737-100/200 AMM 25-31-61 or 737-300/400/500 AMM 25-31-41

as an accepted procedure.

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b. Remove the lavatory. Refer to 737-100/200 AMM 25-40-0 or 737-300/400/500 AMM 25-40-01.

c. Remove the potable water tank. Refer to 737-100/200 AMM 38-11-11 or 737-300/400/500

AMM 38-11-11.

2. Do an inspection of the web from the forward or aft side of the bulkhead in accordance with FIGURE

4.

NOTE: In many areas the access is limited and you can do an inspection from only one side:

either the forward side (HFEC) or the aft side (LFEC). In these areas, do the inspection

from the side which provides access.

3. If no cracking or no incorrectly drilled fastener holes or no elongated fastener holes are found, put

the airplane back to a serviceable condition by replacing the galley, lavatory, and potable water

tank, as necessary. Refer to the applicable AMM sections called out in PART III - Step 1 (above).

If any cracking, incorrectly drilled fastener holes or elongated fastener holes are found, contact

Boeing for repair instructions and install the repair. Report all cracking to the Boeing Company.

Include the crack location, the length, and the airplane flight cycles and flight hours. Send the

report to:

BOEING COMMERCIAL AIRPLANE GROUP

ATTENTION: MANAGER, AIRLINE SUPPORT

NOTE: The 737-100/200 SRM 53-10-4, Figure 15 or 737-300 SRM 53-80-08, Figure 7 or 737-400

SRM 53-80-08, Figure 7 or 737-500 SRM 53-80-08, Repair 7 repair for cracking at S-6L

and S-6R cannot be used at other stringer locations.

4. Do repeat inspections at the times shown in Paragraph 1.E., Compliance.

PART IV - NDT INSPECTION OF THE DOME CAP AT THE CENTER OF THE BULKHEAD

1. Do an inspection of the dome cap at the center of the bulkhead in accordance with FIGURE 6.

a. If any cracking in the web is found, install the appropriate SRM repair, in accordance with

Table 3, below.

Table 3: SRM Repairs for the Apex Region of the Aft Pressure Bulkhead

737-300 SRM 53-

80-08

737-400 SRM 53-

80-08

737-500 SRM 53-

80-08

737-100/200 SRM

53-10-11

Subject

BS 1016 Pressure Bulkhead Web Repair - Figure 13 Repair 9

Single Gore Web

BS 1016 Pressure Bulkhead Web Repair - All Figure 14 Repair 10

Gore Webs

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b. Do inspections of the repair at the times given in the SRM.

2. If no cracking is found do repeat inspections at the times shown in Paragraph 1.E., Compliance.

PART V - NDT INSPECTION OF THE FORWARD FLANGE OF THE "Z" STIFFENERS AT THE

DOME CAP

1. Do an inspection for any cracking in the "Z" stiffener flanges at the dome cap in the center of the

bulkhead as in accordance with FIGURE 7.

a. If any cracking in a "Z" stiffener flange is found, contact Boeing for repair instructions and

install the repair.

2. If no cracking is found do repeat inspections at the times shown in Paragraph 1.E., Compliance.

PART VI - DETAILED INSPECTION FOR EXISTING REPAIRS ON THE BULKHEAD

1. Do a detailed inspection of the bulkhead web and stiffeners to find existing repairs on the bulkhead.

a. If no existing repair is found then no additional work is necessary.

b. If an obsolete SRM repair is found then do eddy current Inspections or repair replacement as

necessary, in accordance with Paragraph 1.E., Compliance, Table 8.

NOTE: Refer to Appendices A through E to identify Obsolete SRM repairs.

c. If a repair is installed in accordance with the SRM then Do Eddy Current Inspections in

accordance with the SRM.

d. If a non SRM repair is installed and the repair has FAA approved Damage Tolerance

Inspections do the FAA approved Damage Tolerance Inspections.

e. If a non SRM repair is installed and the repair does not have FAA approved Damage Tolerance

Inspections contact Boeing for FAA approved Damage Tolerance Inspections and do the

inspections.

2. Do an inspection of the aft pressure bulkhead to identify any SRM repairs installed that are listed

in Table 2 below.

a. If a SRM repair is installed that is listed in Table 2 below, do the inspections or repair

replacement in accordance with Appendices A through E, at the times given in Paragraph

1.E., Compliance. Refer to Table 2 below or replace the repair in accordance with Table 1

above.

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Table 2: Obsolete SRM Repairs for the Aft Pressure Bulkhead

737-300 SRM 53- Appendix

80-08

737-400 SRM 53-

80-08

737-500 SRM 53-

80-08

737-100/200 SRM

53-10-4

Subject

BS 1016 Bulkhead Cutout Repair Figure 3 Repair 1 A and B

OIL CAN REPAIR Figure 5 Repair 2 C

OIL CAN REPAIR BETWEEN TEAR STRAPS Figure 12 Repair 4 D

OIL CAN REPAIR ACROSS TEAR STRAP Figure 13 Repair 5 E

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FIGURE 1: LFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM

STRINGER S-15L TO S-15R

(SHEET 1 OF 2)

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

From the aft side, inspect the web at

the aft fastener row of the "Y"

chord/web interface in the upper

fuselage from S-15L to S-15R. It is not

necessary to inspect the web in the

area of the steel straps.

In accordance with

737 NDT Part 6, 53-

10-54.

Low Frequency

Eddy Current

1 Inspect Web

Wherever you are doing the NDT inspection, visually inspect along both

fastener rows of the "Y" chord. Look

for any cracking and incorrectly drilled

or elongated fastener holes.

Detailed Inspec- -

tion

"Y"

chord

2 Inspect

FIGURE 1: LFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM

STRINGER S-15L TO S-15R

(SHEET 2 OF 2)

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FIGURE 2: HFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM

STRINGER S-15L TO S-15R

(SHEET 1 OF 2)

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

From the forward side, inspect the

web at the aft fastener row in the upper fuselage from S-15L to S-15R.

In accordance with

737 NDT Part 6, 51-

00-00, Figure 4 or 23.

High Frequency

Eddy Current

1 Inspect Web

NOTE:

1. Where a radial stiffener overlaps the "Y" chord at the perimeter of the web, you cannot

get access to the web to inspect the fastener holes. Instead, use the reference NDT procedure to inspect the web along the edge of the radial stiffener adjacent to the fastener

holes that need to be inspected. Inspect the web for a distance of one inch each side of

the fastener row.

2. Where the fin terminal fitting doublers overlap the web, use the reference NDT procedure

to inspect the web along the edge of the doublers.

Wherever you are doing the NDT inspection, visually inspect along both

fastener rows of the web. Look for any

cracking and any incorrectly drilled or

elongated fastener hole(s).

Detailed Inspec- -

tion

2 Inspect Web

FIGURE 2: HFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM

STRINGER S-15L TO S-15R

(SHEET 2 OF 2)

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FIGURE 3: ONE-TIME NDT INSPECTION OF WEB AT THE OUTER CIRCUMFERENTIAL TEAR STRAP

(SHEET 1 OF 2)

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

From the aft side, inspect under

the outer circumferential tear

strap for any cracking in the

web. As an option to doing this

LFEC procedure, you can do

the HFEC procedure shown in

Step 2.

In accordance with

737 NDT Part 6, 53-

10-41.

Low Frequency

Eddy Current

1 Inspect (a) Web

Step 2 is optional to Step 1.

From the forward side, inspect

the web at the fasteners that

attach the outer circumferential

strap.

In accordance with

737 NDT Part 6, 51-

00-00, Figure 4 or

23

High Frequency

Eddy Current

2 Inspect (b) Web

The NDT subject referenced in step 1 is an inspection of the web at the lap splices and at all

three tear straps. You only need to inspect the outer tear strap. For airplanes, Line no. 1 - 24,

use Reference Standard 389A.

(a)

For airplanes, Line no. 25 - 3132, use Reference Standard 389B. Contact Boeing if existing oil

can repairs or bulging of the tear strap between fasteners prevents you from doing the LFEC

inspection.

(b) Contact Boeing if existing oil can repairs prevent you from doing the HFEC inspection.

FIGURE 3: ONE-TIME NDT INSPECTION OF WEB AT THE OUTER CIRCUMFERENTIAL TEAR STRAP

(SHEET 2 OF 2)

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FIGURE 4: NDT INSPECTION OF WEB AT THE "Y" CHORD IN THE LOWER BULKHEAD FROM STRINGER

S-15LTO S-15R

(SHEET 1 OF 2)

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

From the forward side, do a HFEC

inspection of the web at the aft

fastener row where possible. (a)

The inspection from the forward

side is not possible at: -the "Y"

chord splice angle -the intersection

of the floor structure and the "Y"

chord -the bottom of the bulkhead

where there is leveling compound

covering the fasteners.

In accordance with

737 NDT Part 6, 51-

00-00, Fig. 4 or 23

High Frequency

Eddy Current

(HFEC)

1 Inspect Web

At these locations, do Step 3 and

4 instead.

The LFEC inspection in Step 3

from the aft side is optional to a

HFEC inspection from the forward

side. However, the inspection intervals will be more frequent. Refer

to Paragraph 1.E., Compliance.

In accordance with

737 NDT Part 6, 53-

10-54.

Low Frequency

Eddy Current

(LFEC)

Wherever possible, visually inspect

the forward side of the bulkhead

along both fastener rows of the

web. Look for any cracking, any

incorrectly drilled or elongated

fastener hole(s), or corrosion.

Detailed Inspec- -

tion

2 Inspect Web

Wherever the HFEC inspection

from the forward side is not possible, do the LFEC inspection on the

aft side of the bulkhead.

In accordance with

737 NDT Part 6, 53-

10-54

Low Frequency

Eddy Current

3 Inspect Web

NOTE:

1. It is possible that the NDT manual shows an inspection area that is different than what

is shown in this bulletin. Use the inspection area shown in this bulletin.

2. It is not possible to inspect the web adjacent to the stringer end-fittings because the NDT

probe cannot fit under the fittings.

Inspect the web along the edge of

the leveling compound.

Detailed Inspec- -

tion

4 Inspect Web

(a) Where a radial stiffener overlaps the "Y" chord at the perimeter of the web, you cannot get access to

the web to inspect the fastener holes. Instead, use the reference NDT procedure to inspect the web

along the edge of the radial stiffener adjacent to the fastener holes that need to be inspected. Inspect

the web for a distance of one inch each side of the fastener row.

FIGURE 4: NDT INSPECTION OF WEB AT THE "Y" CHORD IN THE LOWER BULKHEAD FROM STRINGER

S-15LTO S-15R

(SHEET 2 OF 2)

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FIGURE 5: DETAILED INSPECTION FOR OIL-CAN DAMAGE IN THE BULKHEAD WEB

(SHEET 1 OF 2)

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

Do a Detailed Inspection from

the aft side of the bulkhead for

any cracking. Use a flashlight

held parallel to the web surface

to highlight surface irregularity.

Detailed Inspec- -

tion

1 Inspect Web

FIGURE 5: DETAILED INSPECTION FOR OIL-CAN DAMAGE IN THE BULKHEAD WEB

(SHEET 2 OF 2)

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FIGURE 6: NDT INSPECTION OF THE DOME CAP AT THE CENTER OF THE BULKHEAD

(SHEET 1 OF 2)

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

Inspect the web from the

aft side for any cracking.

In accordance with

737 NDT Part 6, 53-

10-64, Figure 2

1 Inspect Web Eddy Current

FIGURE 6: NDT INSPECTION OF THE DOME CAP AT THE CENTER OF THE BULKHEAD

(SHEET 2 OF 2)

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FIGURE 7: NDT INSPECTION OF THE FORWARD FLANGE OF THE "Z" STIFFENER AT THE DOME CAP

(SHEET 1 OF 3)

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FIGURE 7: NDT INSPECTION OF THE FORWARD FLANGE OF THE "Z" STIFFENER AT THE DOME CAP

(SHEET 2 OF 3)

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA

Inspect the forward flanges

of the "Z" stiffener for any

cracking at both fastener

rows common to the dome

pan.

In accordance with

737 NDT Part 6,

51-00-00, Figure 4

or 23.

High Frequency

Eddy Current

"Z" Stiffener1 Inspect

FIGURE 7: NDT INSPECTION OF THE FORWARD FLANGE OF THE "Z" STIFFENER AT THE DOME CAP

(SHEET 3 OF 3)

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ALERT ALERT
INSPECTION THRESHOLD

12,000 Flight Cycles from the time the repair is installed or 6,000 Flight Cycles after Revision 3 to this Service

Bulletin is released, whichever is later.

REPEAT INSPECTIONS

1. At fastener locations not common to a tear strap, High Frequency Eddy Current (HFEC) inspect the web

from the forward side of the pressure bulkhead every 12,000 Flight Cycles. Do the HFEC inspections in

accordance with 737 NDT Part 6, 51-00-00 Figure 4 or 23.

Appendix A: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 3 OR 737-300/400/500 53-80-08 REPAIR 1 -

TYPICAL REPAIR FOR DAMAGE TO WEB AND STRAP

(SHEET 1 OF 2)

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ALERT ALERT
At the operators option, Low Frequency Eddy Current (LFEC) inspect the web from the aft side of the

pressure bulkhead every 6,000 flight cycles. Do the LFEC inspection in accordance with 737 NDT Part 6,

53-30-00 Figure 5, using reference standard ANDT1049 for calibration.

2. At fastener locations common to a tear strap, HFEC inspect the web from the forward side of the bulkhead

between the radial 'Z' stiffeners every 12,000 Flight Cycles. Do the HFEC inspections in accordance with

737 NDT Part 6, 51-00-00 Figure 4 or 23.

At the operators option, LFEC inspect the web from the aft side of the pressure bulkhead every 6,000 Flight

Cycles. Do the LFEC inspection in accordance with 737 NDT Part 6, 53-10-41 at location C using the

relevant reference standard that matches the thickness of the tear strap and repair strap.

NOTE: For 737-100/200 aircraft: this repair was removed from SRM 53-10-4, Figure 3, and replaced by Figure

3A which installs the repair plate on the forward side of the web.

For 737-300/400/500 aircraft: this repair was removed from SRM 53-80-08, Repair 1, and replaced by

Repair 11 which installs the repair plate on the forward side of the web.

Appendix A: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 3 OR 737-300/400/500 53-80-08 REPAIR 1 -

TYPICAL REPAIR FOR DAMAGE TO WEB AND STRAP

(SHEET 2 OF 2)

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ALERT ALERT
INSPECTION THRESHOLD

12,000 Flight Cycles from the time the repair is installed or 6,000 Flight Cycles after Revision 3 to this Service

Bulletin is released, whichever is later.

REPEAT INSPECTIONS

1. High Frequency Eddy Current (HFEC) inspect the web from the forward side of the pressure bulkhead and

the repair plate from the aft side of the pressure bulkhead every 12,000 Flight Cycles. Do the HFEC

inspections in accordance with 737 NDT Part 6, 51-00-00 Figure 4 or 23.

At the operators option, Low Frequency Eddy Current (LFEC) inspect the web from the aft side of the

pressure bulkhead every 6,000 Flight Cycles. Do the LFEC inspection in accordance with 737 NDT Part 6,

53-30-00 Figure 5, using reference standard ANDT1049 for calibration.

NOTE: For 737-100/200 aircraft: this repair was removed from SRM 53-10-4, Figure 3, and replaced by Figure

3A which installs the repair plate on the forward side of the web.

For 737-300/400/500 aircraft: this repair was removed from SRM 53-80-08, Repair 1, and replaced by

Repair 11 which installs the repair plate on the forward side of the web.

Appendix B: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 3 OR 737-300/400/500 53-80-08 REPAIR 1 -

TYPICAL REPAIR FOR DAMAGE TO WEB

(SHEET 1 OF 1)

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Appendix C: OBSOLETE 737-100/200 SRM 53-10-4, FIGURE 5 OR 737-300/400/500 SRM 53-80-08 REPAIR

2

(SHEET 1 OF 2)

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ALERT ALERT
INSPECTION THRESHOLD

12,000 Flight Cycles from the time the repair is installed or 6,000 Flight Cycles after Revision 3 to this Service

Bulletin is released, whichever is later.

REPEAT INSPECTIONS

1. High Frequency Eddy Current (HFEC) inspect the web from the forward side of the pressure bulkhead every

12,000 Flight Cycles. Do the HFEC inspections in accordance with 737 NDT Part 6, 51-00-00 Figure 4 or

23.

At the operators option, Low Frequency Eddy Current (LFEC) inspect the web from the aft side of the

pressure bulkhead every 6,000 Flight Cycles. Do the LFEC inspection in accordance with 737 NDT Part 6,

53-30-00 Figure 5, using reference standard ANDT1049 for calibration.

NOTE: For 737-100/200 aircraft: this repair was removed from SRM 53-10-4, Figure 5, and replaced by Figure

5A which installs the repair plate on the forward side of the web.

For 737-300/400/500 aircraft: this repair was removed from SRM 53-80-08, Repair 2, and replaced by

Repair 12 which installs the repair plate on the forward side of the web.

Appendix C: OBSOLETE 737-100/200 SRM 53-10-4, FIGURE 5 OR 737-300/400/500 SRM 53-80-08 REPAIR

2

(SHEET 2 OF 2)

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Appendix D: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 12 OR 737-300/400/500 SRM 53-80-08 REPAIR

4

(SHEET 1 OF 3)

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Appendix D: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 12 OR 737-300/400/500 SRM 53-80-08 REPAIR

4

(SHEET 2 OF 3)

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ALERT ALERT
INSPECTION THRESHOLD

12,000 Flight Cycles from the time the repair is installed or 6,000 Flight Cycles after Revision 3 to this Service

Bulletin is released, whichever is later.

REPEAT INSPECTIONS

Repeat inspections at the intervals shown on the first page of this Appendix D.

NOTE: This repair was removed from the 737-100/200 SRM 53-10-4, Figure 12 or the 737-300 SRM 53-80-08,

Repair 4 or 737-400 SRM 53-80-08, Repair 4 or 737-500 SRM 53-80-08, Repair 4 .

Appendix D: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 12 OR 737-300/400/500 SRM 53-80-08 REPAIR

4

(SHEET 3 OF 3)

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ALERT ALERT
Appendix E: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 13 OR 737-300/400/500 SRM 53-80-08 REPAIR

5

(SHEET 1 OF 3)

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Appendix E: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 13 OR 737-300/400/500 SRM 53-80-08 REPAIR

5

(SHEET 2 OF 3)

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ACTION

Remove the repair and replace with the 737-100/200 SRM 53-10-4, Figure 3A repair, or 737-300 SRM 53-80-08,

Repair 11 or 737-400 SRM 53-80-08, Repair 11 or 737-500 SRM 53-80-08, Repair 11 within 6,000 Flight Cycles

after Revision 3 to this Service Bulletin is released.

NOTE: This repair was removed from the 737-100/200 SRM 53-10-4, Figure 13 or 737-300 SRM 53-80-08,

Repair 5 or 737-400 SRM 53-80-08, Repair 5 or 737-500 SRM 53-80-08, Repair 5.

Appendix E: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 13 OR 737-300/400/500 SRM 53-80-08 REPAIR

5

(SHEET 3 OF 3)

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ALERT ALERT