Revision Transmittal Sheet Date: July21, 1988 Revision 3: July 27, 1995 ATA System: 5331

Number: 737-53-1116 Revision Transmittal Sheet Date: July21, 1988 Revision 3: July 27, 1995 ATA System: 5331

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on:

- Airplanes that had a repair installed as shown in Revision 2 of this service bulletin - Airplanes that had a repair installed as shown in the original issue or Revision 1 of this bulletin if the cracks were in the repairable crack area shown in Revision 2 - Airplanes that had a preventive modification installed as shown in the original issue, Revision 1 or Revision 2 of this service bulletin.

No airplanes are added or removed by this revision.

SUMMARY

This revision is sent to:

- Add the contents of the preventive modification and repair kits to Paragraph II.A., Parts Necessary for Each Airplane. This data was accidentally not printed in Revision 2 - Add structural repair manual subject numbers to stop drill 737-300 and 737-400 airplanes as shown in Figure 2 - Add structural repair manual subject numbers to coldwork 737-300 and 737-400 airplanes as shown in Figure 3 - Add reference to the Maintenance Planning Document item number that is related to the inspections in this service bulletin - Add reference to the structural repair manual subject numbers changed by the repairs and modifications shown in this service bulletin.

Paragraph I.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

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

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

REVISION HISTORY

Initial Release: July 21, 1988 Revision 1: September 7, 1989 Revision 2: September 30, 1993 Revision 3: July 27, 1995 Number: 737-53-1116 Summary Date: July 21, 1988 Revision 3: July 27, 1995 ATA System: 5331

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION

BACKGROUND Accomplishment Instructions at or before the accumulation of 75,000 flight cycles. Based on a structural review of the 737 airplane incorporation of the modification per this service Do the inspections prior to reaching 35,000 flight bulletin is recommended on aging airplanes. cycles. On airplanes with 35,000 or more flight cycles, do the inspections at the first available Six operators have found seventeen cracks in the opportunity, recommended at the next maintenance skin and doublers at the upper corners of the interval, not to exceed 4,500 flight cycles after forward galley doorway on eight airplanes. There receipt of this service bulletin. were eight cracks reported at the upper aft corner on three airplanes, and nine cracks in the skin at the If no cracks are found repeat the inspection at 4,500 forward corner on five airplanes. The airplanes had flight cycle intervals until the preventive modification accumulated from 29,000 to 47,300 flight hours, and is accomplished. from 40,500 to 60,800 flight cycles.

Cause of the cracking is attributed to fatigue from EFFECTIVITY pressurization cycles, and if not corrected could result in cabin pressurization difficulties, and 737 airplanes, Line Number 1-1560, less unscheduled downtime for repairs. PJ201-PJ219

ACTION MANPOWER

Accomplish high and low frequency eddy current Total Elapsed Time inspections for cracks in the skin, skin doubler, or Applicability Man-hours (Hours) bearstrap doubler in the upper corners of the forward galley doorway. Inspection 5 2.5 Preventive If no cracks are found, accomplish the preventive Modification 0.7 0.7 modification, or repeat the inspection until the Repair - per corner 14 14 preventive modification is accomplished.

If cracks are found, install the repair doublers and MATERIAL INFORMATION triplers over the cracked areas per this bulletin. Boeing supplied kits COMPLIANCE See Paragraph I.G., Material - Price and Availability. As recommended by the 737 Aging Fleet Structures Task Group, accomplish the modification per the

Summary Page 1 of 2 Jul 21/88 REV 3: Jul 27/95 Summary Page 2 of 2 Number: 737-53-1116 Date: July 21, 1988 Revision 3: July 27, 1995 ATA System: 5331

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION

I. PLANNING INFORMATION

A. Effectivity

1. Airplanes

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

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AER LINGUS (ARL) PK641-PK642 PY322

AERO CONTROLS, INC (AEO) PG629

AERO COSTA RICA (AOR) PK872-PK873

AEROLINEAS ARGENTINAS (ARG) PH705-PH708 PH741-PH743 PK102-PK103 PK464 PY007

AEROSVEET (UKA) PK354

AIR ALGERIE (ALG) PK361 PK631 PK633-PK634 PL717-PL725 PY051 PY053

AIR ATLANTA ICELANDIC (AID) PP839 PY346

AIR CHINA GROUP (BEJ) PM281-PM283 PP521-PP522

AIR EUROPA (ARE) PP501-PP502 PP835 PP840 PP846

AIR FOYLE LTD. (FOY) PJ108 PJ113

AIR FRANCE (AFA) PL502-PL503 PN101-PN117 PP902 PP910

Jul 21/88 737-53-1116 REV 3: Jul 27/95 Page 1 of 27 AIR GABON S.A. (GBN) PY191

AIR GUINEE (GNE) PY651

AIR HOLLAND CHARTER B.V. (HOL) PP504 PP838

AIR MADAGASCAR (MAD) PG375 PL793

AIR MALTA (MLT) PL624-PL625 PP904 PP907

AIR NAMIBIA (NAM) PN492

AIR NEW ZEALAND, LTD. (ANZ) PJ117-PJ119 PK047 PK214 PK216- PK220 PL621-PL623 PM181 PY741

AIR SOUTH, INC. (SOT) PG210 PG215 PK221 PK462 PK466

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 PK461

ALASKA AIRLINES (ASA) PY112 PY134-PY135 PY270 PY461- PY463 PY593

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 PM251 PM253 PP825-PP826 PY231 PY242 PY451

ALYEMDA DEM. YEMEN AIRLINES (ALY) PY409-PY410

Jul 21/88 737-53-1116 REV 3: Jul 27/95 2 AMC AVIATION (AMF) PK254

AMERICA WEST AIRLINES, INC. (AMW) PC004 PG036 PK283 PK696 PL081 PL172 PL551-PL562 PL801 PP181-PP187 PP189 PP831 PP833 PP891-PP899 PP901 PP903 PP931-PP934

AMERICAN EXPRESS BANK LTD. (AXP) PY592

AMERICANA DE AVIATION S. A. (AMY) PG276 PJ001

AMIRI FLIGHT (ABD) PK495

AMORA FLIGHT CHARTER SERVICES (FCA) PG047

AMWAY CORPORATION (AMA) PP991

ANGOLA AIR CHARTER (AOH) PG431

ANGOLA AIRLINES (ANG) PK661 PK664 PK666 PY162

ANSETT AUSTRALIA (ANS) PP908-PP909 PQ026-PQ037

ANSETT WORLDWIDE AVIATION SERVICES (AWW) PA001 PA003-PA004

ARAMCO ASSOCIATED CO. (ARM) PL151 PL456 PY241 PY243-PY244

ARCO (ATR) PN452-PN453

ARKIA ISRAELI AIRLINES, LTD (ARK) PG575

ASEAN AVIATION (L) INC. (ASJ) PG578-PG583 PK920

AVENSA (AVN) PK042-PK043

AVIATECA (AVT) PL736-PL737 PL740-PL741 PL747

AVIATION CONSULTANTS (ACT) PG037 PY001

AVIOGENEX AIR TRANSPORT (AVG) PL501 PL506 PN501-PN502

Jul 21/88 737-53-1116 REV 3: Jul 27/95 3 BOEING SERVICE BULLETIN 737-53-1116

BOURAQ INDONESIA AIRLINES (PTB) PK501 PK913 PK918 PK931 PL742-PL744 PL746

BRITISH AIRWAYS (BAB) PK731-PK732 PK734-PK742 PK744-PK752 PK754-PK765 PK771-PK772 PK774-PK777 PK779

CALDWELL AIRCRAFT TRADING CO. (CAS) PG402

CAMBODIAN INTERNATIONAL AIRLINES (CAK) PJ072

CAMEROON AIRLINES (CAM) PM171 PY046-PY047

CANADIAN AIRLINES INTERNATIONAL LTD. (CDI) PK358 PK671-PK675 PK677-PK681 PK822 PK881 PK884 PL401-PL417 PL764-PL770 PM141-PM142 PY151-PY154 PY303-PY304 PY421-PY422 PY441

CANAIR CARGO (CAZ) PK026-PK027 PK352

CARNIVAL AIR (CVL) PG305 PG312 PJ007-PJ008 PL712

CASINO EXPRESS (CIN) PG279 PG436

CAYMAN AIRWAYS (CAY) PJ009 PK753

CHINA AIR LINES, INC. (CHI) PN472

CHINA SOUTHWEST AIRLINES (XIN) PP631-PP634

CHINA YUNNAN AIRLINES (YUN) PP651-PP652

COMAIR (CML) PG353-PG354 PG356 PK355

CONSOLIDATED PRESS HOLDINGS (CPH) PJ109

CONTINENTAL AIRLINES, INC. (CAL) PA006-PA009 PA011-PA012 PA014 PA016-PA020 PG056 PG064 PG199 PG225 PG433 PG501-PG505 PG621-PG625 PG627-PG628 PG630 PG704 PL001 PP671-PP699 PP701-PP726 PP730 PP732-PP733

COPA COMPANIA PANAMENA DE AVIATION S.A. (COP) PJ107 PJ112 PK465 PK617 PL745 PY201 PY341

Jul 21/88 737-53-1116 REV 3: Jul 27/95 4 CROATIA AIRLINES (CRH) PK904 PK906-PK907 PK928 PK932

DAMANIA AIRWAYS LTD. (DAI) PL451-PL452 PN081-PN082

DELTA AIR LINES, INC. (DAL) PK611 PK613 PL221 PN131-PN163 PN401-PN404 PN407-PN420 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 PY006

EUROBELGIAN AIRLINES (EBA) PP391

FAR EASTERN AIR TRANSPORT (FAT) PA002 PA005 PG055 PG226 PG228 PG230 PK562 PN481

FAUCETT (COMPANIA DE AVIATION S.A. (FCT) PC002 PG034 PG213 PK241 PL711 PL758

FLIGHTSTAR AVIATION CORPORATION (FST) PG274

FRENCH POSTAL OFFICE (FPO) PP947 PP951-PP952 PY101-PY103 PY302 PY344

FRONTIER AIRLINES (FRO) PG304 PG306 PG308 PG310-PG311

GARUDA INDONESIAN AIRWAYS (GIA) PK917 PK929-PK930

GATARI AIR SERVICE (GRI) PL441

Jul 21/88 737-53-1116 REV 3: Jul 27/95 5 GB AIRWAYS (GBA) PJ110-PJ111

GE CAPITAL AVIATION SERVICES, INC. (GEH) PG218-PG219 PG272 PG651-PG652 PP384

GERMANIA FLUGGESELLSCHAFT MBH (GER) PP503 PQ086-PQ087 PQ231-PQ233

GOVERNMENT OF BRAZIL (BRZ) PK068-PK069

GOVERNMENT OF MEXICO (MXG) PC005 PG223

GOVERNMENT OF SHARJAH (SHJ) PL581

GPA GROUP LTD. (GUI) PK252 PK623-PK624 PP847-PP848

GULF AIR (GUL) PK467-PK468

HAPAG LLOYD (HAP) PL504

INDIAN AIR FORCE (IDF) PH712-PH713 PM016-PM017

INDIAN AIRLINES (IND) PH021 PH024 PH711 PK231-PK233 PK235-PK240 PM001-PM006 PY631

INDONESIAN AIR FORCE (IDO) PL601-PL603

INTEGRATED RESOURCES (INH) PG271 PG273 PG403 PK697

INTERNATIONAL AIR LEASES (IAL) PG048

INTERNATIONAL AIRLINE SUPPORT GROUP (ASG) PG021

INTERNATIONAL LEASE FINANCE (ILF) PK222

INTERNATIONAL PACIFIC TRADING CO. (IPT) PG572 PG574 PJ102

IRAN AIR (IRN) PH731 PK391 PY021-PY022

IRAQI AIRWAYS (IRQ) PY141-PY142

Jul 21/88 737-53-1116 REV 3: Jul 27/95 6 JAPAN TRANSOCEAN AIR CO., LTD. (SWL) PK523-PK527 PN451 PN454 PN456

JETALL HOLDING CORPORATION (JEL) PY002 PY005

JUGOSLOVENSKI AEROTRANSPORT (JAT) PP771-PP779

KENYA AIRWAYS (KEN) PK253 PK256

KLM ROYAL DUTCH AIRLINES (KLM) PP861-PP870

KOREAN AIR FORCE (KAF) PP221

LACSA (LAC) PK357 PK871

LADECO (LDE) PJ004-PJ006 PK029 PK212 PK281 PK826 PK830 PL802

LAN-CHILE S.A. (LAN) PK360 PK733 PK743 PK825 PL025-PL026 PL028

LAPA (LAZ) PG355 PK051 PK463 PK614

LAPSA AIR PARAGUAY (LAQ) PK211 PK561

LAUDA AIR LUFTFAHRT AG (LAL) PP851-PP852

LINA CONGO (LNA) PY411

LINHAS AEREAS DE MOZAMBIQUE (LAM) PH703 PY031

LITHUANIAN AIRLINES (LIJ) PK563 PK632

LUFTHANSA GERMAN AIRLINES (DLH) PK901-PK903 PK911-PK912 PK914-PK916 PK919 PK921-PK923 PK926-PK927 PK933-PK938 PP948 PQ051-PQ065 PQ088-PQ090 PY345

MAGNICHARTERS (MAM) PG224 PJ003

MALEV HUNGARIAN AIRLINES (HGA) PK284-PK285 PK636-PK637 PK827 PL455

MANDALA AIRLINES (MND) PK874 PK924-PK925 PL027 PL061 PL421 PN002

Jul 21/88 737-53-1116 REV 3: Jul 27/95 7 MARKAIR, INC. (ALK) PL611 PN493 PP305 PY056-PY057 PY594-PY595

MODILUFT (MOU) PK905 PK908-PK910

MONARCH AIRLINES, LTD. (MON) PP824 PP832

MONTELY II (MOY) PJ031

NASA (NAS) PA099

NATIONAL AIRLINES (NAW) PJ104-PJ106

NATIONAL JET SYSTEMS PTY. LTD. (NJS) PP352

NICA (NICARAGUENCE DE AVIACION) (NIC) PK823

NIGERIA AIRWAYS, LTD. (NIA) PL781-PL782 PL785-PL788

NORDIC EAST (NOE) PJ002 PP353 PP834

NWT AIR (NTA) PX701 PY132-PY133 PY281

OLYMPIC AIRWAYS (OLY) PK301-PK304 PK307-PK310 PM021-PM023

P. T. AIRFAST (PTF) PG204 PG278 PY343

PAKISTAN INTERNATIONAL AIRLINES CORP. (PIA) PP281-PP286

PEGUSUS CAPITAL CORPORATION (PSS) PK565

PETROLAIR SYSTEMS S. A. (PTS) PL471

PHILIPPINE AIRLINES, INC. (PAL) PP935-PP936

PLUNA (PLU) PL201-PL203

POLY TECHNOLOGIES, INC. (PTI) PP728-PP729

Jul 21/88 737-53-1116 REV 3: Jul 27/95 8 PRESIDENTIAL AIR (PRB) PC003

PRINCE TALAL (PTA) PN455

QANTAS AIRWAYS, LTD. (QAN) PQ001-PQ012

REPUBLIC OF NIGER (NIR) PY166

ROYAL AIR MAROC (RAM) PK271-PK274 PY671-PY672

RYANAIR (RYR) PJ114-PJ115 PK503 PK801-PK804 PN001

SABENA S.A. (SAB) PK041 PK044-PK046 PK048-PK050 PK052-PK053 PK431 PK433 PP961-PP965 PY272-PY275

SAHARA INDIAN AIRLINES (SAQ) PK820

SAHSA (SERVICIO AEREO DE HONDURAS,S.A.) (SAH) PJ071

SAKHALIN AIRLINES (SKH) PG214

SAUDI ARABIAN AIRLINES CORP. (SVA) PK311-PK317 PL726-PL735 PY036-PY037

SAUDI ROYAL FLIGHT (SRF) PK318

SERVICIOS AEREOS RUTAS ORIENTE, (SARO) (SEV) PA015 PA021-PA022 PJ032

SHAHEEN AIR INTERNATIONAL (SHK) PK514-PK515

SIERRA PACIFIC AIRLINES (SRP) PK627

SOUTH AFRICAN AIRWAYS (SAA) PL101-PL113

SOUTHWEST AIRLINES CO. (SWA) PK082 PK091-PK099 PK541-PK560 PK621 PK628-PK630 PM051-PM066 PP101-PP135 PP161-PP169 PP188 PP190-PP192 PP201-PP205 PP302-PP304 PP351 PP376-PP382 PP727 PP731 PP821-PP823 PP827

SUDAN (SUD) PY156-PY157

Jul 21/88 737-53-1116 REV 3: Jul 27/95 9 T A PORTUGUESES (TAP) PK971 PK973-PK974 PN083-PN086 PY721

TACA INTERNATIONAL AIRLINES, INC. (TAC) PG059 PG352 PK213 PK223 PK882 PN491 PP946 PY131

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 PG015-PG019 PG022-PG025 PG027 PG030 PG032 PG038-PG040 PG045 PG051-PG054 PG057 PG060-PG063 PG065-PG072 PG075 PK201-PK202 PL002-PL023 PQ101-PQ123

USAIR, INC. (USA) PG073 PG301 PG303 PG307 PG474 PK288-PK289 PK591-PK599 PK601-PK610 PK883 PM101-PM119 PN021-PN043 PP003-PP010 PP012-PP020 PP022-PP032 PP034-PP045 PP383 PP401 PP404-PP436 PP471-PP472 PP474-PP475 PV001-PV004

VANGUARD AIRLINES (VAG) PG041-PG042 PG206 PG576 PL803

VARIG AIRLINES (VAR) PK111-PK116 PK118-PK120 PK141-PK146 PL453-PL454 PP905-PP906 PP981-PP982

Jul 21/88 737-53-1116 REV 3: Jul 27/95 10 VARSA (VAB) PG351

VASP (VSP) PG435 PG437 PG439-PG440 PG471-PG473 PH011-PH013 PK061-PK062 PK065-PK067 PK356 PK521 PK581 PL756 PX071 PY286

VENEZUELA - GOVERNMENT OF (VNZ) PK070

VISCOUNT AIR SERVICE INC. (VAS) PG201 PG203 PG209 PG212 PG216-PG217 PG220-PG222 PJ101 PJ103 PK305-PK306

VIVA AIR (VIV) PP392

WESTERN PACIFIC AIRLINES (WPA) PP001-PP002 PP021 PP301 PP402-PP403 PP473

WESTINGHOUSE ELECTRIC CORPORATION (WEE) PG208

XIAMEN AIRLINES CO. LTD. (XIA) PM252 PM254-PM255

YEMEN AIRWAYS (YEM) PK341

ZAMBIA AIRWAYS (ZAM) PK291

Jul 21/88 737-53-1116 REV 3: Jul 27/95 11 IDENTIFICATION BY VARIABLE NUMBER

PA001-PA022 PA099 PA231-PA232 PC001-PC005 PG001-PG075 PG199 PG201-PG230 PG251-PG255 PG271-PG279 PG301-PG314 PG331-PG332 PG351-PG356 PG375 PG401-PG403 PG431-PG442 PG471-PG475 PG501-PG505 PG571-PG586 PG621-PG630 PG651-PG652 PG701-PG705 PH001 PH011-PH013 PH021-PH024 PH701-PH715 PH731-PH732 PH741-PH743 PJ001-PJ009 PJ031-PJ032 PJ071-PJ072 PJ101-PJ119 PK026-PK029 PK041-PK053 PK061-PK070 PK081-PK082 PK091-PK099 PK101-PK103 PK111-PK120 PK141-PK146 PK201-PK204 PK211-PK223 PK231-PK241 PK251-PK258 PK271-PK274 PK281-PK289 PK291 PK301-PK318 PK341 PK351-PK361 PK391 PK431-PK433 PK451-PK452 PK461-PK469 PK495 PK501-PK504 PK511-PK515 PK519 PK521-PK527 PK541-PK565 PK581 PK591-PK599 PK601-PK617 PK621-PK637 PK641-PK642 PK661-PK666 PK671-PK681 PK691-PK697 PK711-PK716 PK731-PK765 PK771-PK779 PK801-PK804 PK819-PK827 PK830 PK861-PK863 PK871-PK874 PK881-PK884 PK901-PK938 PK971-PK974 PL001-PL028 PL061 PL081 PL101-PL113 PL151 PL171-PL172 PL201-PL203 PL221 PL401-PL417 PL421 PL441 PL451-PL456 PL471 PL491 PL501-PL506 PL551-PL562 PL581 PL601-PL603 PL611 PL621-PL626 PL631-PL632 PL711-PL712 PL716-PL747 PL756 PL758 PL761-PL770 PL781-PL788 PL793 PL801-PL803 PM001-PM006 PM016-PM017 PM021-PM023 PM051-PM066 PM101-PM119 PM141-PM142 PM171 PM181 PM251-PM255 PM281-PM283 PN001-PN002 PN021-PN043 PN081-PN086 PN101-PN117 PN131-PN163 PN401-PN420 PN431-PN433 PN451-PN456 PN471-PN472 PN481 PN491-PN493 PN501-PN502 PN511 PP001-PP045 PP101-PP135 PP161-PP169 PP181-PP192 PP201-PP205 PP221 PP231-PP243 PP281-PP286 PP301-PP305 PP351-PP353 PP376-PP384 PP391-PP392 PP401-PP436 PP471-PP475 PP501-PP504 PP521-PP522 PP631-PP634 PP651-PP652 PP671-PP699 PP701-PP733 PP771-PP779 PP801-PP804 PP821-PP827 PP831-PP842 PP846-PP848 PP851-PP852 PP861-PP870 PP891-PP899 PP901-PP910 PP931-PP936 PP946-PP948 PP951-PP952 PP961-PP965 PP981-PP982 PP991 PQ001-PQ012 PQ026-PQ037 PQ051-PQ065 PQ086-PQ090 PQ101-PQ123 PQ231-PQ233 PQ241-PQ242 PV001-PV004 PX071 PX701 PY001-PY008 PY021-PY022 PY031 PY036-PY037 PY046-PY048 PY051-PY053 PY056-PY057 PY101-PY103 PY111-PY113 PY131-PY135 PY141-PY143 PY151-PY154 PY156-PY157 PY161-PY162 PY166 PY191 PY201 PY221-PY222 PY231 PY241-PY244 PY270-PY275 PY281 PY286 PY301-PY304 PY321-PY323 PY341-PY346 PY361-PY362 PY381 PY401 PY409-PY411 PY421-PY422 PY441 PY451 PY461-PY463 PY591-PY595 PY611-PY612 PY621 PY631 PY651 PY671-PY672 PY721 PY741

2. Spares

None

Jul 21/88 737-53-1116 REV 3: Jul 27/95 12 B. Reason

As a result of the FAA-sponsored Aging Fleet Conference, a 737 Structures Task Group with Airline and Boeing members and FAA observers was formed to review structural service bulletin modifications and recommend selected bulletins for incorporation on aging airplanes. This service bulletin modification has been recommended for incorporation on aging 737 airplanes.

Inspection of the upper corners of the forward galley doorway will detect cracking that could result in pressurization difficulties. Repair of cracks or accomplishment of preventive modification on uncracked structure is terminating action for inspection per this service bulletin.

Six operators have reported cracks in the upper corners of the forward galley doorways on a total of eight airplanes. Three airplanes had a total of eight cracks in the upper aft corner, with crack lengths of up to 2 inches in the skin, and a 2 inch long crack in the bearstrap doubler on one airplane. Five airplanes had a total of nine cracks from 0.1 inch to 1.5 inches in length in the upper forward corner skin.

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

Revision 1 of this bulletin was issued to provide the recommendations of the Aging Fleet 737 Structures Working Group and to change the forward galley doorway upper forward corner repair doubler installation. The installation change eliminates one fastener and moves one fastener to make the repair compatible with the Service Bulletin 737-53-1074 modification.

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

Revision 3 is sent to:

The forward galley door upper forward corner repair, installed per this service bulletin, overlaps the preventive modification for the upper hinge cutout installed per Service Bulletin 737-53-1074, therefore, it is suggested that prior or concurrent incorporation of the preventive modification per service bulletin 737-53-1074 be accomplished prior to the repair per this bulletin.

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

Jul 21/88 737-53-1116 REV 3: Jul 27/95 13 TABLE I - SERVICE BULLETINS FOR DOOR CUTOUT CRACKING

DOORWAY Upper Upper Aft Lower Lower Aft Upper Lower Forward Corner Forward Corner Hinge Hinge Corner Corner Cutout Cutout Forward Entry 737-53-1163 737-53-1083 (a) Forward Galley 737-53-1116 Aft Entry 737-53-1074 737-53-1149 Aft Galley (a) Service Bulletin 737-53-1083 is for the lower sill

C. Description

Accomplish high and low frequency eddy current inspections of the area around fasteners in the upper corners of the forward galley doorway to determine if there are cracks in the skin, skin doubler, or bearstrap doubler.

If no cracks are found, accomplish the preventive modification per this bulletin, or repeat the inspection until the preventive modification is accomplished.

If cracks are found, stop drill the crack ends, and install the repair doublers and triplers over the cracked areas per this bulletin.

No more work is necessary on:

NOTES:

1. Prior or concurrent incorporation of Boeing Service Bulletin 737-53-1074, "Fuselage - Entry and Galley Doorway Skin Cutouts - Inspection and Modification", is suggested on commonly affected airplanes.

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

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

D. Compliance

Based on a structural review of the 737 airplane, it is recommended that the modification per the Accomplishment Instructions of this service bulletin be accomplished prior to, or upon accumulation of 75,000 flight cycles.

Do the inspections prior to accumulating 35,000 flight cycles. On airplanes with 35,000 or more flight cycles, do the inspections at the first available opportunity, recommended at the next maintenance interval, not to exceed 4,500 flight cycles after receipt of this service bulletin. If no cracks are found, repeat the inspections at 4,500 flight cycle intervals until the preventive modification is done.

Jul 21/88 737-53-1116 REV 3: Jul 27/95 14 E. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and are FAA approved. This service bulletin and the FAA approval were based on the airplane in its original Boeing delivery configuration or as modified by other FAA approved Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin.

F. Manpower

Approximately 7 man-hours and a crew of 2 are required to accomplish this inspection per airplane, plus approximately an additional 0.7 man-hour and a crew of 1 is required to accomplish this preventive modification per doorway corner.

Approximately 14 man-hours are required to accomplish this crack repair per doorway corner.

The following breakdown of manpower requirements is suggested as a guide to assist operators in planning and accomplishing this repair. This estimate is for direct labor performed by an experienced crew. It does not include setup, planning, familiarization, cure time, tool acquisition, or lost time. Factor this estimate as necessary based on your own experience.

Elapsed Time Operation Crew Size Man-Hours (Hours)

Access 1 1 1 Crack Repair (maximum) 1 12 12 Restoration 1 1 1 TOTAL PER DOORWAY CORNER 14 14

G. Material - Price and Availability

Boeing can supply the kits shown in Paragraph II.A.1 as shown below. Kit availability is shown in the Reorder Lead Time (ROLT). This revision does not show Boeing price data for kits shown below.

Kit Number Description ROLT 65C33800-12 Kit - Repair 18 weeks 65C33800-13 Kit - Repair 15 weeks 65C33800-14 Kit - Repair 22 weeks 65C33800-15 Kit - Repair 22 weeks 65C33800-16 Kit - Gutter 22 weeks

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

Address purchase orders and correspondence pertaining to this quotation to Director of Spares, and refer to this service bulletin number.

The following kit identified in Paragraph II.A.1 may be furnished or fabricated from operator's existing stock or purchased directly from industry sources. Kit availability is shown in the Reorder Lead Time

Jul 21/88 737-53-1116 REV 3: Jul 27/95 15 (ROLT). This revision does not show Boeing price data for the kit shown below.

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

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

Address purchase orders and correspondence pertaining to this quotation to Director of Spares, and refer to this service bulletin number.

H. Special Tools - Price and Availability

All required coldwork tools and sleeves for accomplishment of this service bulletin may be selected from appropriate tables in Structural Repair Manual and procured from industry sources, as required.

Two sources that provide coldwork tools, as well as engineering and service, is Fatigue Technology, Inc., and West Coast Industries, Inc. Also available from both companies is a kit of coldwork tooling specifically tailored to the requirements of this service bulletin.

Refer To:

FTI Kit Number: FTI-737-53-1116-1 Fatigue Technology, Inc. P.O. Box C-88388 Seattle, WA 98188 Phone Number (206) 246-2010 Fax (206) 244-9886

Refer To:

WCI Kit Number: WCI-737-53-1116 West Coast Industries,Inc. 14900 Whitman Avenue North Seattle, WA 98133-6532 Phone Number (206) 365-7513 Fax (206) 365-7483

I. Weight and Balance

Change in Weight Change in Moment Applicabilitv (Pounds) (Pound-Inches)

737-100 (a) +9.2 +2,825 737-200 (a) +9.2 +3,494 737-300 (a) +9.2 +2,089

(a) Approximate weight and balance information based on incorporation of 65C33800-12, -13 and -16 kits (worst case) on an airplane. Actual weight and balance to be determined by operator based on extent of kit incorporation.

NOTE: Incorporation of Preventive Modification kit 65C33801-1 has no effect on airplane weight and balance.

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

1. Existing Data:

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

b. 737-300/-400 Structural Repair Manual (SRM 737-300 and SRM 737-400) Subject 51-10-02, 51-40-09

c. 737 Nondestructive Test (NDT) Manual, Part 6, Subject 51-00-00, Figure 4. 737 NDT, Part 6, Subject 53-10-42

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

e. Boeing Service Bulletins:

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

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

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

737-53-1163 "Fuselage - Forward Entry Doorway Skin Cutout - Upper Forward and Upper Aft Corners - Inspection, Modification and Repair "

f. Boeing Document D6-38505, "Aging Airplane Service Bulletin Structural Modification and Inspection Program - Model 737-100/-200/-200C".

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

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

Drawings:

Drawing Number Sheet DCN ADCN Title 65C33800 PL A Skin and Stringer Installation - Repair (Top Kit) 65C33800 1 C

3. Process Data:

Boeing Process Specifications that are listed on the drawings supplied in support of this service bulletin are not detailed in this service bulletin since they are common practices which can be accomplished in accordance with operators normal procedures.

Jul 21/88 737-53-1116 REV 3: Jul 27/95 17 K. Publications Changed

Publication Chapter-Section

737-100/200 Structural Repair Manual (SRM 737) 53-30-3 737 -300/400 Structural Repair Manual 53-10-01 (SRM 737-300 and SRM 737-400)

L. Electrical Load Data

None

Jul 21/88 737-53-1116 REV 3: Jul 27/95 18 II. MATERIAL INFORMATION

A. Parts Necessary For Each Airplane

The following is provided to aid in kit selection.

Usage Kit Preventive Modification Forward and aft corners 65C33801-1 Repair- Forward Corner Skin and bearstrap cracks 65C33800-12 Skin or bearstrap crack 65C33800-14 Repair - Aft Corner Skin and bearstrap cracks 65C33800-13 Skin or bearstrap crack 65C33800-15 Rain Gutter Replacement 65C33800-16 (Required with Repair)

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

NOTE: One or more kits and operator furnished materials listed in Paragraph II.A.2 are required to modify or repair each airplane.

65C33800 SKIN AND STRINGER INSTALLATION-SKIN REPAIR, SECTION 41 (TOP KIT) -16 -15 -14 -13 -12 Quantity Part Number Name 65C33800-12 (a) Top Kit, Skin And St 65C33800-13 (a) Top Kit, Skin And St 65C33800-14 (a) Top Kit, Skin And St 65C33800-15 (a) Top Kit, Skin And St 65C33800-16 (a) Top Kit, Skin And St 1 1 65C33800-17 Repair Strap 1 1 65C33800-18 Doubler 1 65C33800-19 Tripler 1 1 65C33800-20 Repair Strap 1 1 65C33800-21 Doubler 65C33800-22 Tripler 1 65C33800-23 Filler 1 65C33800-24 Filler 1 65C33800-25 Filler 1 65C33800-26 Filler 1 65-49893-2 Gutter 20 2 BACB30FN5-5 Hi-Lok 18 BACB30FN5-6 Hi-Lok

Jul 21/88 737-53-1116 REV 3: Jul 27/95 19 (Continued)

65C33800 SKIN AND STRINGER INSTALLATION-SKIN REPAIR, SECTION 41 (TOP KIT) -16 -15 -14 -13 -12 Quantity Part Number Name 21 9 21 9 BACB30FN6-3 Hi-Lok 31 12 22 12 BACB30FN6-4 Hi-Lok 7 62 64 28 23 BACB30FN6-5 Hi-Lok 7 34 42 43 55 BACB30FN6-6 Hi-Lok 4 33 11 32 31 BACB30FN6-7 Hi-Lok 2 24 6 BACB30FN6-8 Hi-Lok 1 2 1 BACB30FN6-9 Hi-Lok 20 20 BACC30M5 Collar 11 185 142 178 142 BACC30M6 Collar 5 BACR15BB4B7 Rivet 5 BACR15BB4B9 Rivet 4 4 BACR15CE6B11 Rivet 4 4 BACR15CE6B12 Rivet 3 4 . BACR15CE6B13 Rivet 3 4 BACR15CE6B14 Rivet 1 1 1 1 BACR15CE6D11 Rivet 4 4 1 1 BACR15CE6D12 Rivet 3 3 BACR15CE6D13 Rivet 1 1 BACR15CE6D6 Rivet 4 1 BACR15CE6D8 Rivet 3 BACR15CE6D9 Rivet

(a) The kit contains more parts than are necessary for installation. Discard parts that are not used or keep the parts for spares.

65C33801 SKIN AND STRINGER INSTL- SECTION 41 (TOP KIT) -1 Quantity Part Number Name - 65C33801-1 (a) Top Kit, Skin and Str 6 BACR15BB8B10 Rivet 1 BACR15BB8B13 Rivet 8 BACR15BB8B9 Rivet

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

Jul 21/88 737-53-1116 REV 3: Jul 27/95 20 2. The following materials are to be furnished by the operator.

Quantity Specification Nomenclature As Required BMS 5-95, Type I, Class B-1/2, Sealant -2 or-4 (a) As Required BMS 10-11, Type I (a) Primer As Required BMS 10-11, Type II Enamel - Color to Match Airplane

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

B. Parts Necessary to Change Spares

None

C. Special Tools and Equipment

Coldworking tools are required during accomplishment of the preventive modification per this service bulletin. See Paragraph I.G. for details.

D. Existing Parts Accountability

None

Jul 21/88 737-53-1116 REV 3: Jul 27/95 21 Jul 21/88 737-53-1116 REV 3: Jul 27/95 22 III. ACCOMPLISHMENT INSTRUCTIONS

NOTES:

1. The paragraphs identified with letters give the general work instructions and the necessary tests. The instructions identified with numbers on the figure(s) give the recommended sequence of steps.

2. As recommended by the 737 Aging Fleet Structures Task Group, accomplish the modification per this service bulletin, Figure 3 of the Accomplishment Instructions prior to, or upon the accumulation of 75,000 flight cycles.

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

- All linear dimensions are in inches - Tolerance on linear dimensions other than rivet and bolt edge margin is plus or minus 0.03 inch - Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch - Angular tolerance is plus or minus 2 degrees - The hole dimensions for standard solid rivets are found in 737 Structural Repair Manual Chapter 51 - The torque limits to tighten nuts and bolts are found in 737 Structural Repair Manual Chapter 51.

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

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

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

A. Open the forward galley door for access to interior surface of door cutout to accomplish inspection and rework of doorway upper corners.

B. Accomplish an eddy current inspection of the skin, bonded skin doubler, and bearstrap tripler in each upper corner of the doorway per Figure 1.

C. If cracked doorway corners are found, repair per Figure 2.

D. If no cracks are found, accomplish preventive modification per Figure 3. As an option, reinstall reveal fittings and rivets and repeat inspection of upper doorway corners until the preventive modification is accomplished.

NOTE: Delayed implementation of the preventive modification may cause oversizing requirements beyond the preventive modification kit range. The fastener holes may be oversized one time only (Maximum hole size allowed before cold working is 0.238 inch)

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

Jul 21/88 737-53-1116 REV 3: Jul 27/95 23 FIGURE 1. FORWARD GALLEY DOORWAY UPPER CORNER INSPECTION

Jul 21/88 SHEET 1 OF 2 737-53-1116 REV 3: Jul 27/95 24 FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

Jul 21/88 SHEET 2 OF 2 737-53-1116 REV 3: Jul 27/95 25 The instruction numbers shown below agree with the numbers shown inside the circle symbols in the figure.

NOTE: This repair can only be used if cracks are within the area indicated by the shaded area of Detail I. Contact Boeing for a repair if cracks are not within the area indicated.

1 Remove existing rain gutter.

2 Stop drill the end of the crack as shown in the 737 Structural Repair Manual (SRM 737 51-10-1, SRM 737-300 51-10-02 and SRM 737-400 51-10-02). Typical cracks are shown. Only cracks 2.5 inches long or less, within the shaded area shown in Detail I, can be repaired as shown in this figure.

3 If skin assembly or bearstrap doubler (but not both) is cracked, install repair strap and doubler per drawing 65C33800 using kit 65C33800-14.

4 If both skin assembly and bearstrap doubler are cracked, install repair strap, doubler, and tripler per drawing 65C33800 using kit 65C33800-12.

5 If skin assembly or bearstrap doubler (but not both) is cracked, install repair strap and doubler per drawing 65C33800 using kit 65C33800-15.

6 If both skin assembly and bearstrap doubler are cracked, install repair strap, doubler, and tripler per drawing 65C33800 using kit 65C33800-13

7 Install new rain gutter and appropriate filler strips under gutter per drawing 65C33800 using kit 65C33800-16. Trim filler strips as required, depending on which repair kits are installed.

FIGURE 2. CRACK REPAIR - FORWARD GALLEY DOORWAY

Jul 21/88 SHEET 1 OF 1 737-53-1116 REV 3: Jul 27/95 26 FIGURE 3. PREVENTIVE MODIFICATION - FORWARD GALLEY DOORWAY

Jul 21/88 SHEET 1 OF 1 737-53-1116 REV 3: Jul 27/95 27 Number: 737-53-1116 Evaluation Form Date: July 21, 1988 Revision 3: July 27, 1995 ATA System: 5331 Prepared By: Manuel Hernandez

SUBJECT: FUSELAGE - FORWARD GALLEY DOORWAY UPPER CORNERS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION

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