737 Service Bulletin ALERTALERT Number: 737-53A1166 Date: June 30, 1994 Revision 2 May 25, 2006 ATA System: 5311

ALERT ALERT Commercial Airplane Group 737 Service Bulletin ALERTALERT Number: 737-53A1166 Date: June 30, 1994 Revision 2 May 25, 2006 ATA System: 5311

SUBJECT: FUSELAGE - Frames - Body Station 727 Outboard Chord at Stringer 18A, Inspection and Preventive Modification

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Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

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Table of Contents Revision Transmittal Sheet ...... 5 Summary ...... 7 1. PLANNING INFORMATION ...... 11 A. Effectivity ...... 11 1. Airplanes ...... 11 2. Spares Affected ...... 62 B. Concurrent Requirements ...... 62 C. Reason ...... 62 D. Description ...... 64 E. Compliance...... 67 F. Approval ...... 71 G. Manpower ...... 72 H. Weight and Balance Changes ...... 74 I. Electrical Load Data ...... 74 J. References ...... 75 1. Existing Data: ...... 75 2. Data supplied with this Service Bulletin: ...... 76 3. Installation Drawings Used in the Preparation of this Service Bulletin: ...... 78 K. Publications Affected ...... 78 L. Interchangeability and Intermixability of Parts ...... 78 2. MATERIAL INFORMATION ...... 79 A. Material - Price and Availability...... 79 B. Industry Support Information ...... 80

C. Parts Necessary For Each Airplane ...... 81 1. Kits/Parts: ...... 81 2. Parts and Materials Supplied by the Operator: ...... 105 3. Parts Modified and Reidentified: ...... 108 4. Parts Removed and Not Replaced: ...... 108 D. Parts Necessary to Change Spares ...... 108 E. Special Tooling - Price and Availability...... 108 F. Special Tooling Necessary to do this Service Bulletin ...... 108 3. ACCOMPLISHMENT INSTRUCTIONS ...... 109 A. GENERAL INFORMATION ...... 109 B. WORK INSTRUCTIONS ...... 110 FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 2 ...... 127 FIGURE 2: THIS FIGURE WAS DELETED AT REVISION 2 ...... 128 FIGURE 3: THIS FIGURE WAS DELETED AT REVISION 2 ...... 129 FIGURE 4: THIS FIGURE WAS DELETED AT REVISION 2 ...... 130 FIGURE 5: THIS FIGURE WAS DELETED AT REVISION 2 ...... 131 FIGURE 6: THIS FIGURE WAS DELETED AT REVISION 2 ...... 132 FIGURE 7: EXTERNAL ULTRASONIC INSPECTION OF THE STA 727 FRAME OUTBOARD CHORD FORWARD FLANGE - GROUPS 1 THROUGH 11, CONFIGURATIONS 1 AND 4. . . . 133 FIGURE 8: EDDY CURRENT INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 1. . . . 136 FIGURE 9: SURFACE HFEC INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 4. . . . 138 FIGURE 10: OPEN HOLE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE STA 727

Table of Contents June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

OUTBOARD CHORD FORWARD FLANGE...... 140 FIGURE 11: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 3. . 143 FIGURE 12: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 4. . 145 FIGURE 13: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUP 1 . 147 FIGURE 14: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUPS 2, 3, 4, 5, 6, 9 AND 10 ...... 150 FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR 153 FIGURE 16: TIME-LIMITED REPAIR - SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION FOR CRACK TIP LOCATION ...... 160 FIGURE 17: MAKE THE TIME-LIMITED REPAIR PARTS ...... 163 FIGURE 18: INSTALL THE TIME-LIMITED REPAIR...... 168 FIGURE 19: TIME-LIMITED REPAIR - REMOVAL...... 176 FIGURE 20: MAKE THE REPLACEMENT PARTS TO REPLACE THE TIME-LIMITED REPAIR WITH A NEW FRAME CHORD...... 181 FIGURE 21: STRINGER S-18A OUTBOARD CHORD AFT FASTENERS - INSPECTION - GROUP 1, 2, 3, 4, 5, 6 AND 9 ...... 183 FIGURE 22: STA 727 OUTBOARD CHORD FORWARD FLANGE AT STRINGER 18A - EVALUATION. 185 FIGURE 23: INSTALL THE SHEAR BEAM REPAIR ...... 187 FIGURE 24: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 1; GROUPS 4 THROUGH 11, CONFIGURATION 1 AND 4 ...... 193 APPENDIX A: ADDENDUM ...... 195

Table of Contents June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 198 ALERT ALERT Commercial Airplane Group 737 Service Bulletin ALERTALERT Number: 737-53A1166 Revision Transmittal Sheet Date: June 30, 1994 Revision 2: May 25, 2006 ATA System: 5311

SUBJECT: FUSELAGE - Frames - Body Station 727 Outboard Chord at Stringer 18A, Inspection and Preventive Modification

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive 95-12-17, Amendment 39-9268, is related to this service bulletin.

Airplane line numbers 1000 through 3132 were added to this service bulletin effectivity.

More work is necessary on airplanes changed as shown in the previous releases of this service bulletin. Further inspections as shown in this service bulletin will need to be accomplished.

REASON FOR REVISION

This revision is sent to revise inspections, repairs, modifications and parts fabrication and to expand the airplane effectivity to cover all 737-100/200/300/400/500 series airplanes. Additional inspections are added to address new cracks found in the STA 727 outboard chord frame, STA 727 frame auxiliary chord and the stringer S-18A outboard chord. Instructions are added to modify the STA 727 frame time-limited repair into a permanent repair. Instructions are added to install a preventive modification for the S-18A outboard chord.

Changes to this revision include: — Planning Information - The service history information relating to the new cracks is updated. All references are updated to reflect the inclusion of 737-300/400/500 series airplanes into the effectivity. — Material Information - New top kits are added to this service bulletin revision. — Accomplishment Instructions - Instructions are added to do new inspections, repairs and modifications. — Figures 1, 2, 3, 4, 5 and 6 are deleted. — Figures 7, 8, 9, 10, 11, 12, 13, 14, 16, 21, 22 and 24 are added to show new inspections. — Figure 15 is added to show access for the Time-limited repair. — Figure 17 is added to show the fabrication of parts for the Time-limited repair. — Figure 18 is added to show the installation of the Time-limited repair. — Figure 19 is added to show the removal of the Time-limited repair. — Figures 20 is added to show fabrication of the Time-limited repair replacement parts. — Figures 23 is added to show installation of the Shear Beam Repair. — Appendix A is revised to show the new compliance data.

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 198 The data given in Notice of Status Change 737-53A1166 NSC 1 is included in this revision. Notice of Status Change 737-53A1166 NSC 1 advised operators of a revision to drawing 65C37277, sheet PL, as shown in ADCN 3, supplied with 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: June 30, 1994 Revision 1: May 25, 1995 Revision 2: May 25, 2006

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 198 ALERT ALERT Commercial Airplane Group 737 Service Bulletin ALERTALERT Number: 737-53A1166 Summary Date: June 30, 1994 Revision 2 May 25, 2006 ATA System: 5311

SUBJECT: FUSELAGE - Frames - Body Station 727 Outboard Chord at Stringer 18A, Inspection and Preventive Modification

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

The changes shown in this service bulletin will decrease the probability of cracks in the frame at Station (STA) 727 where Stringer (S)-18A is attached. This area is a primary structural element. Operation with cracks in the frame will decrease the structural integrity of this area. Unscheduled downtime can be necessary to replace a frame that has a crack. Cracks in the S-18A chord are not a safety concern.

Several operators have reported numerous cracks on multiple airplanes in the STA 727 frame outboard chord, where the S-18A outboard chord is attached. The cracks ranged from 0.016 inches, to a severed chord. Cracks initiate common to the 3 fastener holes or close vicinity to the fastener holes and on the forward edge of the frame outboard chords. For the fastener holes susceptible to cracking, several elongated holes were also found. Airplanes have accumulated between 20,000 - 85,000 flight-cycles and 27,000 - 74,000 flight hours. Previous revisions of this service bulletin inspected for cracks on airplanes with 7075-T6 frame outboard chords (Line Number 1-999) only. Since the release of Rev 1, seven operators have reported cracks in 7075-T73 chords with 20,000 - 52,000 flight-cycles. As a result of these new findings, this revision of the service bulletin expands the effectivity to include airplanes with 7075-T73 frame outboard chords. The cracks were caused by fatigue; for line number 1-999 airplanes (7075-T6 frame outboard chord), fretting of adjacent parts contributed to the initiation of the fatigue damage.

Three operators have reported four cracks in the radius of the 65-46547-9 Auxiliary Chord on three airplanes. 1.00 inch cracks were reported. Airplanes have accumulated between 46,000 - 85,000 flight-cycles and 41,000 - 64,000 flight hours.

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 198 Several operators have reported numerous cracks on multiple aircraft in the S-18A outboard chord common to the fastener locations just aft of STA 727. Airplanes have accumulated between 30,000 - 76,000 flight-cycles and 32,000 - 65,000 flight hours. One operator found one crack on one airplane in the S-18A chord, forward of STA 727 in the lower fastener row. The aircraft had 68,000 flight-cycles and 71,000 flight hours. Cracks have been found in S-18A chord sections of thickness at STA 727 of 0.33 inches or less. The cracks were caused by fatigue.

Four operators have reported four cracks on three aircraft with a "T" profile S-18A outboard chord. The vertical flange of the chord has cracked at the base, at the vertical flange run-out, near STA 727. These cracks can grow along the base of the vertical flange in the radius. These cracks have been associated with S-18A outboard chord installation pre-loads.

As part of a service bulletin validation program, the inspection, frame chord replacement, and preventive modification was completed on airplane PG576 before the initial release of this service bulletin.

Boeing Service Related Problem (SRP) 737-SRP-53-0162 is related to this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 95-12-17, is related to this service bulletin. The FAA is considering additional rule making that will make the compliance tasks and times given in Revision 2 of this Service Bulletin mandatory.

Boeing Structural Item Interim Advisory (SIIA) 737-131 is related to this service bulletin.

ACTION

Do inspections of the outboard chord of the frame at STA 727 where S-18A is attached. Look for cracks. Do the inspections at the times given in the Compliance section.

If cracks are found in the outboard chord of the frame at STA 727, install the time-limited repair or replace the chord and, optionally, install the preventive modification. If no cracks are found, install the preventive modification or do the repeat inspections. Do the inspections at the times given in the Compliance section until the STA 727 frame preventive modification is installed. If the STA 727 frame outboard chord preventive modification is installed with an edge margin greater than or equal to 1.7D, there are no further inspection requirements per this bulletin for the STA 727 frame outboard chord.

Do an inspection of the STA 727 frame auxiliary chord for cracks. Do the inspection at the times given in the Compliance section. If cracks are found, repair before further flight. Contact Boeing for repair data. If no cracks are found, but a permanent frame chord modification has not been installed, continue inspections at the times given in the Compliance section. If no cracks are found and STA 727 frame outboard chord modification strap has been installed, and the frame chord is 7075-T73, there are no further inspection or modification requirements for the STA 727 frame auxiliary chord.

Do inspections of the outboard chord of S-18A at STA 727. If cracks are found in the outboard chord of S-18A, do the S-18A repair. If no cracks are found in the outboard chord of S-18A, install the S-18A Preventive Modification. If the S-18A modification or repair is installed, there are no further inspection requirements per this bulletin for the S-18A outboard chord.

More work is necessary for operators that have replaced the outboard chord of the frame at STA 727 as shown in Service Bulletin 737-53-1088 and who have not installed a permanent modification. Refer to the Compliance section.

All 737-100/200/200C/300/400/500 series airplanes. See paragraph 1.A., Effectivity.

COMPLIANCE

See Service Bulletin Paragraph 1.E. for compliance information.

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 I.G. Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits

Refer to Paragraph 2.A., Material - Price and Availability.

STRINGER 18A FAIRING (ON MOST AIRPLANES THE OUTBOARD SUPPORT CHORD OF STRINGER 18A IS A FLAT STRUCTURE PLATE) STA NOT SHOWN 727

TYPICAL CRACK (AIRPLANES WITH A 'T' PROFILE S-18A OUTBOARD CHORD ONLY)

SEE A FOR STA 727 FRAME INSPECTIONS TYPICAL CRACKS INSPECT AREA AUXILIARY FOR CRACKS IN CHORD STRINGER 18A

LEFT SIDE SHOWN STA 727 RIGHT SIDE OPPOSITE BULKHEAD AFT SKIN FWD SKIN (WING-TO-BODY FAIRING NOT SHOWN) WEB INSPECT STA 727 FRAME TYPICAL FORWARD FRAME AFT SKIN CRACK FLANGE FOR CHORD CRACKS INSPECT AUXILIARY CHORD RADIUS FOR CRACKS

AUXILIARY BULKHEAD WEB CHORD SEE B INSPECT TYPICAL FOR FORWARD CRACK UP AUXILIARY EDGE OF CHORD

FWD FLANGE D41500 B INSPECTION A VIEW FROM INSIDE CARGO BAY

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 198 ALERT ALERT Commercial Airplane Group 737 Service Bulletin ALERTALERT Number: 737-53A1166 Date: June 30, 1994 Revision 2: May 25, 2006 ATA System: 5311

SUBJECT: FUSELAGE - Frames - Body Station 727 Outboard Chord at Stringer 18A, Inspection and Preventive Modification

1. 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.

This service bulletin is for the airplanes shown below. Refer to PRR 35005-244RS for data about this change.

NOTE:As the group configurations are described below, a single airplane may meet the description for two separate configurations. The left side configuration may be different than the right side configuration.

GROUP CONFIGURATION DESCRIPTION 1 - 737-100/200/200C Series airplanes, line numbers 1-310. These airplanes have a "T" profile S-18A Outboard Chord with a thickness of 0.20 inch at STA 727. 1 Airplanes with a replaced Station (STA) 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 2 - 737-200/200C Series airplanes, line numbers 311-972. These airplanes have a Flat Strap S- 18A Outboard Chord with a thickness of 0.20 inch at STA 727. 1 Airplanes with a replaced Station (STA) 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 3 - 737-200/200C Series airplanes, line numbers 973-999 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.33 inch at STA 727, early skin panels and early fairing support structure. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 198 GROUP CONFIGURATION DESCRIPTION 4 - 737-200/200C Series airplanes, line numbers 1000-1585 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.33 inch at STA 727, early skin panels and early fairing support structure. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 5 - 737-300/500 Series airplanes, line numbers 1001-2664 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.33 inch at STA 727, early skin panels and later fairing support structure. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 6 - 737-300/500 Series airplanes, line numbers 2667-3130 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.33 inch at STA 727, later skin panels and later fairing support structure. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 7 - 737-400 Series airplanes, line numbers 1487- 2657 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.40 or 0.45 inch at STA 727, later skin panels and early fairing support structure. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 8 - 737-300/400/500 Series airplanes, line numbers 2665-3132 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.40 or 0.45 inch at STA 727, later skin panels and later fairing support structure. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 9 - 737-300/500 Series airplanes, line numbers 2938-2942 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.33 inch on one side and 0.40 or 0.45 inch on the opposite side at STA 727, with later skin panels and later fairing support structure. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 10 - 737-300/500 Series airplanes, line numbers 1842-1896 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.33 inch at STA 727, early skin panels, later fairing support structure and short edge margin repair installed per 65C36009 Detail 7. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

GROUP CONFIGURATION DESCRIPTION 11 - 737-400 Series airplanes, line numbers 1844- 1908 that have a Flat Strap S-18A Outboard Chord with a thickness of 0.40 or 0.45 inch at STA 727, later skin panels, early fairing support structure and short edge margin repair installed per 65C36009 Detail 7. 1 Airplanes with a replaced STA 727 Frame Outboard Chord and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 2 Airplanes with the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 3 Airplanes without the STA 727 Frame Outboard Chord replaced and with the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin. 4 Airplanes without the STA 727 Frame Outboard Chord replaced and without the STA 727 Frame Outboard Chord Preventive Modification installed as shown in previous revisions of this bulletin.

Airplane models:

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

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

ADAM AIR (DAM) 5 PP508 PP840 6PU301 7 PM556 PW009 PW119

ADC AIRLINES (ADN) 2 PJ118–PJ119 3 PN033–PN034

AEGEAN AIRLINES S.A. (CRM) 5 PM392 PS608 6 PR028 PR030 PS961 7 PW002 PW046 PW053 PW157 PW261 PW502 PW564 8 PV287 PW276 PW289

AER LINGUS (ARL) 5 PT167–PT168

AERGO CAPITAL LIMITED (CLJ) 1PY031 2 PK462 PK468 PK772 PK820 4 PK528 PN405

AERO CONTRACTORS OF NIGERIA (NCC) 5 PQ194 PQ196

AERO CONTROLS (AEO) 1 PG312 PG629

AEROCONDOR (EDR) 2 PL401 4 PN491

AEROGAL/GALAPAGOS AIRLINES (ERG) 2PK715 PK827 3 PN030 4 PL624–PL625

AEROLINEAS ARGENTINAS (ARG) 1 PG584–PG585 PH705–PH708 PH741–PH742 PY007 2 PH743 PK102–PK103 PK735–PK737 PK739–PK740 PK747 PN112 4 PK750–PK751 PK755 PK757 PK760–PK765

PN113 5 PP948 PT042 PT303–PT306 PT309 PT509–PT510

AEROLINEAS AUSTRAL CHILE S.A. (LUT) 2 PL405 PM141–PM142

AEROSERVICE (SRI) 1 PL742 2 PL743

AEROSUCRE (SUS) 1PY341 2PY201 PY451

AEROSUR (REO) 2PK594

AEROSVIT (UKA) 2PK564 5 PP924 PQ284 PT614–PT615 7 PW265 PW591–PW592 PW595–PW596

AEROVISTA GULF EXPRESS (GXP) 2 PL556

AIGLE AZUR (AZU) 5 PP962

AIR ALGERIE (ALG) 2 PK633–PK634 PL722 PL724 PY051 PY053

AIR ATLANTA ICELANDIC (AID) 5 PP352 PP913 PQ222 7PW011 PW094

AIR AUSTRAL (AUX) 5PT215 6 PS621

AIR BERLIN (BER) 8 PJ811 PW524 PW528–PW530

AIR CANADA (ACN) 2 PK679–PK680

AIR CANADA JAZZ (ANI) 2 PK310

AIR CHINA (BEJ) 5 PP521–PP522 PQ361–PQ364 6 PQ345–PQ346 PQ373 PQ438 PQ447 PQ971 PQ975 PS957

AIR CHINA INNER MONGOLIAN (IML) 5 PQ365–PQ366 PQ370 PS614–PS617 6 PQ372 PQ988 PQ990

AIR CHINA SOUTHWEST BRANCH (XIN) 5 PP631–PP634 PQ401–PQ406 PQ408–PQ410 6 PS811

AIR CHINA TIANJIN BRANCH (TJA) 5 PQ367–PQ369 PQ371

AIR CORRIDOR (KRD) 2 PK749

AIR EUROPA (ARE) 7PW266

AIR FRANCE (AFA) 5 PT214 PT501–PT508 PT511–PT514

AIR GABON (GBN) 2 PY191

AIR GUINEE (GNE) 2PY651 4 PN456

AIR HORIZONS (AHZ) 1PY004 5PP965 PP967 7PW065

AIR MADAGASCAR (MAD) 1PG375 2 PL793 5 PP852 PQ297 PQ299

AIR MALAWI (AML) 5PS602

AIR MALTA (MLT) 5 PQ791 PQ793 6 PS873–PS874

AIR MEDITERRANEE (AMV) 1 PG028–PG029 PY301

AIR NAMIBIA (NAM) 2PK355 PK731 4 PN492

AIR NAURU (NAU) 7PW556

AIR NEW ZEALAND (ANZ) 5PS651 6 PQ997 PR041 PR062–PR066 PR077–PR080 PR101 PS866–PS868

AIR NIPPON (ANK) 5 PT053 PT060 PT063–PT064 6 PT126 PT128–PT131 PT871–PT886 7PW026 8PJ817

AIR NORTH YUKON'S AIRLINE (AND) 2PK596 PK599

AIR ONE (ADH) 2 PK432 4 PK933 PK938 5 PM410–PM411 PQ228–PQ229 6 PQ347–PQ348 7 PV231–PV234 PV236–PV237 PW041 PW043 PW052 PW054 PW106 PW111–PW112 PW115 PW267 PW288 PW302 PW317 PW526 8PW831 PW851

AIR PHILIPPINES (PHP) 1 PG001 PG039 PG061–PG062 PG066 2 PK099 PK541–PK542 PN021–PN022 PN025 3 PN029 PN031 PN038

AIR PLUS COMET (PLD) 5 PP904 PP912

AIR SAHARA (SAQ) 5PQ306 6 PR012 PR021–PR022 7 PW061 PW064 PW066 8PW264 PW273

AIR SENEGAL INTERNATIONAL (SNG) 5PT023

AIR SLOVAKIA (SLO) 4 PK936

AIR TANZANIA (TNZ) 2 PY611

AIR VANUATU (VAN) 6PQ454

AIR ZIMBABWE (ZMB) 4 PN431–PN433

AIRASIA BERHAD (ASW) 10 PM391 5 PM385 PM388 PM390 PM397–PM398 PP002 PP021 PP023 PP234 PP406–PP409 PP411–PP412 PP419 PP421 PP471 PP473 PP504 PP509 PP516–PP517 PP676–PP677 PP684 PP686–PP687 PP848 PP920 PQ184 PQ332 PS657 6PQ448

AIRBALTIC CORPORATION (BCB) 5 PT005 PT161–PT163 6 PU311 PU313

AIRCRAFT 23383, LLC. (LSG) 5PP028

AIRCRAFT MAINTENANCE CORP. (AMF) 2PK254

AIRFAST INDONESIA (PTF) 1PY343 2PK562 4 PN481

AIRTRAN AIRWAYS (CQT) 2PK697

AIRWORK NZ (ANX) 2PY741 5PQ026

AIRZENA (GEI) 5 PP044 PT611 7PW262

ALASKA AIRLINES (ASA) 2 PY112 PY134 PY270 PY461–PY462

4 PY463 PY593–PY594 7 PJ301–PJ302 PW116 PW231–PW249 8 PJ601–PJ615 PW250–PW252

ALBARKA AIR SERVICES (ABF) 2 PL111

ALOHA AIRLINES (ALO) 2 PK905 PK926 PY231 3 PN085 4 PK934–PK935 PL626 PM251 PM253 PN473 PY592 PY595 PY721

ALTER BAIL AVIATION (ABH) 2PK215 PK359

AMERICA WEST AIRLINES (AMW) 2 PL081 PL559–PL560 5 PP022 PP029 PP183–PP187 PP189 PP194–PP195 PP197–PP199 PP383 PP472 PP474–PP475 PP831 PP833–PP834 PP846 PP891 PP893 PP895 PP898–PP899 PP901 PP931–PP934 PP936 PS666–PS669 6 PR067

AMERICAN FALCON AIR (FAK) 2 PK464 PL026

AMERISTAR AIR CARGO (CGG) 1 PY345–PY346 2 PK221 PK560 PM051

APOLLO AVIATION CAPITAL, LLC. (APV) 1 PL761

ARAL (RII) 7PW031

ARKIA ISRAELI AIRLINES (ARK) 2 PK822 PL402 PL404 PL414

ASIA AIRLINES (YDO) 1 PY005 2 PY135

ASIANA AIRLINES (AAR) 5PT851 6 PT852–PT853 7PW283 PW286 8 PV204–PV206 PV208 PV226–PV229

ASTRAEUS, LTD. (AUA) 5 PP845 PP929 PP935 PS605

6PQ994

ATA AIRLINES, INC. (AAT) 5PQ188 PQ190

ATA ATLANTICO TRANSPORTE AEREO (AUI) 1 PY003 PY321–PY322 PY361

ATLANTIC AIRLINES (LNL) 2 PL008 PL010 PL622–PL623

ATLAS BLUE (ABT) 11 PW632 7 PW631 PW633–PW636

AURELA (URE) 5PQ307

AUSTRAL - CIELOS DEL SUR (ALA) 2 PN103–PN104 PN110–PN111 4 PN114–PN115 PN117

AUTOMATIC 9W (TMW) 10 PQ191 5PQ193 PQ195

AUTOMATIC LLC (AUM) 2 PJ114–PJ115 PK502 PK504 PK801–PK804 PK821 PK824 PK901 PK974

AVENSA (AVN) 2PK042

AVIACSA AEROEXO (AEJ) 2 PK289 PK598 PK625–PK626 PM101–PM102 PM106–PM107 PM115–PM117 4 PK216–PK220 PM181 PN454

AVIATION CAPITAL GROUP (CGP) 2PK286

AVIATION CONSULTANTS (ACT) 1PG037 PY001 2PK546

AVIOGENEX (AVG) 4 PN501

AVIOR (AWD) 2PK549 PK591

AVOLAR (AOL) 5PT001

AXIS AIRWAYS (AXY) 5 PP947 PQ301 PQ341 7PW033

BAHAMASAIR (BAH) 2 PK672–PK673 PL501 PL506

BALI AIR (ZBL) 2 PL504

BASIC CAPITAL MANAGEMENT (BCM) 4 PN455

BATAVIA AIR (BTV) 2 PJ107 PJ112 PK252 PK283–PK284 PK305 PK360 PK514 PK563 PK617 PK622 PK635 PK711 PK825 4PK515 5PS631 7 PW005 PW015 PW032 PW575

BAYU INDONESIA AIR (BAY) 2PK561

BELAVIA (ITU) 6PT722 PT971

BELLVIEW AIRLINES (BEB) 2 PK203 PK612 PK872 PL028

BLUE AIR (BTR) 10 PT211 5 PS618

BLUE DART AVIATION (BDA) 2 PK231–PK232 PL451 4 PM281 PN521

BLUE PANORAMA AIRLINES (BPA) 11 PW518 7 PW284 PW519 PW741–PW742

BLUEBIRD CARGO (BLS) 5 PM383 PQ242 PQ342–PQ344

BMI BRITISH MIDLAND (BMA) 5 PQ291–PQ292 PQ431 PT186–PT188 PT701–PT703 6 PP520 PQ433–PQ435 PQ974 PQ992 PQ996 PS625 PS861

BOEING (TBC) 1PG051 PG215

BOURAQ AIRLINES (PTB) 2 PK255 PK302–PK303 PK307–PK309 PK501 PK913 PK918–PK920 PK931 PL409–PL410 PM021

BRA TRANSPORTES AEREOS (BRW) 5 PP907 PP946 PP984 PQ226 PQ243 PQ260–PQ261 7 PW020–PW021 PW504

BRITISH AIRWAYS (BAB) 10 PT295 5 PM399 PP841–PP842 PQ283 PQ305 PT009 PT021 PT183 PT185 PT307–PT308 6 PT515–PT516 7 PW101 PW301 PW305–PW308 PW312 PW314–PW315 PW318–PW327

BULGARIA AIR (BLD) 5 PQ224–PQ225 PQ262 PT170 PT427 PT437 6 PR025–PR026

BURAQ AIR (BQA) 2 PL723 PL725

C.I.T. LEASING CORPORATION (TCI) 5PP836 PP964 7PW562

CANADIAN NORTH (ANP) 2 PL415 PY152–PY154 PY422 PY441

CANJET (CNJ) 5 PT424–PT426 PT428–PT429 PT434–PT435 PT438 PT616

CAYMAN AIRWAYS (CAY) 2PJ009 PY244 4PK753 5 PQ293 PQ481

CHANCHANGI AIRLINES (CGI) 2 PL412 PL416–PL417

CHANNEL EXPRESS (AIR SERVICES) (CEX) 5 PP908–PP909 PP914 PQ027 PQ030–PQ039 PQ051–PQ052 PQ054–PQ055 PQ058–PQ059

CHARTER AIR (FIH) 6PS630 PS871

CHILEAN AIR FORCE (CHF) 5PQ053 6PT996

CHINA EASTERN AIRLINES (CEA) 6 PQ977 PQ979 PQ981 PR141–PR143

CHINA EASTERN AIRLINES WUHAN (WUH) 5 PQ472 PQ491–PQ492 6 PR081–PR082 PR131

CHINA EASTERN YUNNAN AIRLINES (YUN) 5 PP651–PP652 PQ263 PQ411–PQ412 6 PQ414–PQ415 PQ417–PQ418 PS622–PS623 PS628 8PQ416

CHINA SOUTHERN AIRLINES (GUN) 5 PM408–PM409 PM412 PM541–PM544 PM547 PM549 PQ252–PQ255 PQ407 PQ479–PQ480 PS836–PS837 PS841–PS844 PT041 PT043–PT049 PT052 PT061–PT062 6 PR121–PR122 PS845–PS846

CHINA UNITED AIRLINES (CUL) 5 PP728–PP729 PQ288–PQ289 PS609–PS610 6 PS896–PS897

CHINA XINHUA AIRLINES (XIH) 5 PM546 PQ264 PQ804–PQ805 PS856 6PR001 8 PW852–PW854

CHINA XINJIANG AIRLINES (XIJ) 5 PM545 PM548

CIRRUS AIRLINES (CSG) 5PT146

CIS AIR HOLDINGS (CIS) 1PG217

COMAIR LIMITED (CML) 2 PK734 PK738 PK744 PK748 PK904 PK907 4 PK754 PK758 5 PQ001 PQ003–PQ006 PQ008 PQ010 7 PW303 PW310–PW311

CONOCOPHILLIPS ALASKA, INC. (ATR) 2 PK610 4 PN452–PN453

CONTINENTAL AIRLINES (CAL) 5 PP671–PP675 PP678 PP680–PP683 PP685 PP688–PP699 PP701 PP703–PP710 PP712–PP726 PP730 PP732–PP733 PT801–PT818 PT826–PT828 6 PT819–PT825 PT829–PT834 PT901–PT905 PT907–PT930

CONVIASA S.A. (VSS) 5 PQ117 PS604

CORENDON AIRLINES (HVA) 5PQ286 6PQ451

CORSAIR (COR) 7 PW661–PW662

CSA (CSA) 5 PT184 PT301–PT302 PT617–PT621 6 PT136 PT138 PT981–PT985 7 PW039 PW102 PW268 PW304 PW309 PW517 8 PJ816 PV302 PW431–PW435

CSC TRANSPORT (CTC) 7PW007

DASAB AIR (DSB) 2 PN024 3 PN036

DBA (DBA) 5 PP507 PP511 PP515 PP838 PP961 PQ119 PQ152 PS655 6 PR015–PR017

DELTA AIR LINES (DAL) 3 PN131–PN135 4 PN136–PN163 PN401–PN404 PN407–PN420 5 PP231–PP233 PP235–PP243 PP506 PQ086 PQ231–PQ232

DODSON AVIATION (DOO) 1PJ032

DOLPHIN AIR (FDN) 2 PL151 PY241

EARTH AIRLINES (ETL) 1PG352

EAS AIRLINES NIG (EAV)

2 PL453 3 PN032 4PK681

EAST AFRICAN AIRLINES (EAB) 2 PL023

EASYJET (EZY) 5 PP510 PP518–PP519 PS652 6 PR003–PR004 PR167–PR172 PS971 PS974–PS978

EG&G TECHNICAL SERVICES (EGN) 2 PJ205 PJ207–PJ210 PJ218 PL763

EGYPTAIR (EGP) 1PG026 5 PT561 PT563–PT565

ESTAFETA (EST) 2PY131 PY275 3 PY056–PY057 5 PP825–PP826

ESTONIAN AIR (ENA) 5PT010 6 PT137 PT716–PT717 PU312

ETHIOPIAN AIRLINES (ETH) 4PN512

EUROATLANTIC AIRWAYS (MAE) 5 PP985

EUROPE AIRPOST (EUE) 5 PP392 PP832 PP925 PP951–PP952 PQ421 PQ771–PQ772 PS607 PS641–PS644 6PR096

EUROPEAN AVIATION AIR CHARTER (EUL) 2 PK044–PK046 PK048–PK050 PK053 PN001 PY273

EXECUTIVE JET AIRCRAFT COMPANY (EXF) 2 PL441

EXPORT RESTRICTED AIRPLANES (YWV) 1 PA002 PG021 PG041 PG074 PG218–PG219 PG224 PG305 PG307–PG308 PG310–PG311 PG574 PH731 PJ002 PJ102 PY021 2 PJ003 PK391 PL758 PY022

PY141–PY142

EXTRA AIRWAYS (CIN) 1PG279 11 PW503 2PN083 3PN084 PN086 7PW117 PW761

FAA (FAA) 2 PL768

FACTS AIR (FAD) 1 PX701

FALCON AIR (FLK) 5 PS636–PS638

FALCON AIR EXPRESS (FAX) 5 PP897

FALCONBRIDGE (NAD) 2 PY612

FASCO AIRWAYS (EAO) 1PG228

FEDERATIVE REPUBLIC OF BRAZIL (BRZ) 2 PK068–PK069

FINOVA (GRB) 4PK759

FIRST AIR (BRS) 2 PK358 PL407 PY133 PY281 PY421

FISCHER AIR POLAND (FSP) 6PS973

FLY AIR (FHA) 5PQ281

FLYGLOBESPAN.COM (FGS) 6 PS962–PS963

FLYING CARPET (FYC) 4 PM064

FLYME (FMA) 5 PP393 PP902 PP910–PP911

FREEDOM AIR INTERNATIONAL (SPT) 6 PR045

FRONTIER AIRLINES (FRO) 2PK495

FUTURA (FUA) 5 PP430 PP892 PQ197 7 PW034–PW035 PW047–PW048 PW114 PW501 PW527 PW561

GARUDA INDONESIA (GIA) 5 PM393–PM394 PM404 PQ285 PQ487 PS606 6 PQ986–PQ987 PR061 PR068–PR072 PR091–PR092 PS956 PT681–PT682 PT684–PT685 7 PV271–PV272 PW022 PW028 PW067 PW461–PW467 8 PV301 PW272 PW441–PW450 PW525 9PT683

GARY 737 LLC (BHA) 2 PL745

GE AVIATION MATERIALS (GML) 5 PP001

GE CAPITAL CORPORATION (GEF) 1 PG220–PG221 PG651–PG652 2 PK026–PK027 PK256 PK465–PK467 5 PM407 7PW051

GENERIC CUSTOMER/SUPPLIER (XXX) 2 PK274

GERMANIA (GER) 5 PP503 PQ087 PQ230 PQ233–PQ237

GLOBAL AIR (YCH) 2 PK548 PL013

GOL AIRLINES (GOT) 5 PQ056 PQ123–PQ124 PQ144–PQ145 PQ159–PQ160 PQ162–PQ163

HAINAN AIRLINES (HNA) 5 PQ088–PQ091 PQ156–PQ157 PQ473–PQ474 PS611 PS613 6 PQ475 PR005 PR010 7 PV203 PW093 8 PV356–PV357 PW086–PW088

HAMRA AIR (HMA) 5 PP420

HAPAG LLOYD EXPRESS (HLX) 5PT104

HAPAG-LLOYD FLUG (HAP) 10 PT101 5 PT102–PT103 PT105

HEMUS AIR (HEU) 7 PM554

HEWA BORA AIRWAYS (EXD) 1PG274

HOLA AIRLINES (HLB) 10 PQ304 5 PP894

ICARO (IKA) 2 PK742

INDIAN AIR FORCE (IDF) 1 PH712–PH713 3 PM016–PM017

INDIAN AIRLINES (IND) 2 PK237–PK240 PM001–PM006 PY631

INTAL AIR (IRT) 2PY242 PY274

INTER AIR (ITI) 1 PY046–PY047

INTERLEASE AVIATION (ILA) 1PG210

INTERNATIONAL AIR LEASES (IAL) 1 PL803

INTERNATIONAL AIR PARTS (IAO) 1PG580

INTERNATIONAL TRANSPORT (YIT) 1PG304

INT'L AVIATION SERVICES GROUP (ISG) 2PK318

ISRAEL AIRCRAFT INDUSTRIES (IAI) 1PG575 2PK692

JAL INTERNATIONAL (JAL) 8 PW411–PW418

JANCO AIRCRAFT AND ENGINES (JNC) 4 PM282–PM283

JAPAN TRANSOCEAN AIR (SWL) 7 PW401 PW515–PW516 PW520 PW681–PW683 8 PW402–PW408 PW521

JAT YUGOSLAV AIRLINES (JAT) 5 PP771–PP779 PQ241 7 PV023–PV024 PW092

JATAYU AIR (JAJ) 1PG068 2 PJ117 PK257 PK511 4PK937

JERRY CONWAY (JCW) 2PK552

JET AIRWAYS (JPL) 7 PW215–PW216 8 PV207 PV209 PW421–PW424

JET FREIGHT (JFO) 5PQ158 PQ161

JET MIDWEST (JMI) 2 PK558

JETALLIANCE (JFB) 6 PS862

JETCONNECT LIMITED (JCL) 5 PQ002 PQ007 PQ009 PQ011–PQ015 7 PW537–PW539

JETRAN INTERNATIONAL, LTD. (JTI) 1PC005 2 PK306 PK592–PK593 PK601 PK605 PK607 PL552 PL557 PM103–PM105 3 PM118–PM119 PN035 5 PP009–PP010 PP013 7 PV041–PV043

JETSCAPE LEASING (IAN) 7PW091

JETSTAR AIRCRAFT SALES (JTS) 1PG306

JORDAN AVIATION (JOR) 4 PY410 5 PP896 PQ187

K.A.B. (KBH) 2 PK315

KALININGRADAVIA (JSK) 5 PP305 PP801 PP843–PP844 PP916 PQ302

KARTHAGO AIRLINES (KAG) 5 PP926 PP928 PP930 6 PQ432 PR029

KENYA AIRWAYS (KEN) 2 PK641–PK642 PY272 6 PR031–PR034

KITTY HAWK AIR CARGO (KHC) 5 PM382 PM396 PM405 PP847 PP862 PQ221 PQ223

KLM - ROYAL DUTCH AIRLINES (KLM) 5 PP861 PP863–PP866 PP868–PP869 PP871–PP875 6 PP876–PP877 7 PW014 PW017 PW611–PW622

KRASAIR (ZXD) 5PQ792

LAB (LAB) 6PQ951

LAC (CQC) 2PY113

LAM (LAM) 4 PL455–PL456 PN451

LAN AIRLINES (LAN) 1PJ104 2 PJ006 PJ105–PJ106 PJ109 PK212 PK431 PK433 PK524–PK525 PK745 PK775 PK902–PK903 PK908–PK912 PK914–PK916 PK921–PK923 PK927 PL025

LAPA ARGENTINA (LAZ) 2PK051

LIBYAN AIRLINES (LAA)

2PK361

LINA CONGO (LNA) 2PY411

LINEAS AEREAS AZTECA (AZX) 5 PP802 PP915 PP923 PP983 PP986 PQ116

LION AIR (MLI) 7 PW016 PW023 PW025 PW027 PW037–PW038 PW042

LITHUANIAN AIRLINES (LIJ) 2 PK632 PL611 5PT169 6 PT721 PT723 PT972–PT973

LOCALEASE (LLA) 2PK282

LOCKHEED MARTIN (LMA) 5PQ057

LOGISTIC AIR, INC. (LGA) 1 PY303–PY304

LOT POLISH AIRLINES (LOT) 5 PT651–PT656 6PQ978 PQ980 7 PV281–PV284 8 PV285–PV286

LUFTHANSA GERMAN AIRLINES (DLH) 5 PQ060–PQ085 PQ092 PS701–PS703 PT331–PT360 6 PS704–PS706

LUXAIR (LUX) 5 PT671–PT672

MACEDONIAN AIRLINES, MACEDONIA (MCC) 5 PP043

MAERSK AIR (MRS) 6PT135

MAGIC CARPET AVIATION (MCI) 5 PP991

MAGNICHARTERS (MAM) 2 PJ004 PK143 PK145 PK595 PL454 PL554 PL558

5PQ028 PQ168

MALAYSIA AIRLINES (MAS) 7 PJ551–PJ556 PW201–PW214 PW217–PW230 8 PJ557–PJ561

MANDALA AIRLINES (MND) 2 PK354 PK463 PK614 PK636–PK637 PK874 PK925 PL027 PL061 PL421 PN002 7PW004 PW010

MARANATHA LEASING CORPORATION (MNT) 1PG436 2 PK201–PK202 PL011 PM062

MERPATI NUSANTARA AIRLINES (PNM) 2 PK615 PK623–PK624 PK819 PK917 PK929–PK930

MEXICAN AIR FORCE (MXA) 4PN041

MEXICO'S PRESIDENTIAL AIRCRAFT (MXG) 5 PP919 PQ155

MNG AIRLINES (MHK) 7 PW282 PW285 PW512 PW514 PW593

NAT AVIATION U.S.A. (NTV) 2 PK258 PK551 PK557 PK732

NATIONWIDE AIRLINES (NWR) 2 PJ007–PJ008 PK357 PK741 PK871 PK906 PK928 PK932 PL631–PL632 PN107 PN109 5 PT612–PT613

NEWJET (NES) 2 PL172 PL562

NIGERIA AIRWAYS (NIA) 2 PL785 PL788

NORTHROP GRUMMAN CORPORATION (GRU) 1PG208

NORTHSTAR PRESIDIO MANAGEMENT (INH) 2 PK094–PK095

NORWEGIAN AIR SHUTTLE AS (NSB) 10 PP807 5 PM381 PM389 PM401–PM402 PP805–PP806

PP808 PP918 PS654 6 PQ983 PQ985 PR002

NOVA AIR (PDM) 2 PL007 PL406

OLYMPIC AIRLINES (OLY) 11 PW063 2 PM022 5PQ298 7 PW044 PW062 PW068 PW072 PW296 PW711–PW717 PW771

ORENBURG AIRLINES (ORG) 7PW036

OZJET AIRLINES (OZJ) 2PK041 PK052

PACE AIRLINES (PIE) 1PG075 PG203 11 PW563 2 PL001 PL502–PL503 PN102 PN105 PN108 4PN116 5 PP181–PP182 PP196 PP835 PP837 PP867 PP870

PAKISTAN INT'L AIRLINES (PIA) 5 PP281–PP286 PS612

PEGASUS AIRLINES (PGS) 11 PW030 8PW263

PEGASUS AVIATION, INC. (PSS) 1 PL712 2 PK043 PK233 PK235 PL403 PL413 4 PK752 PK756

PEMCO WORLD AIR SERVICES (PEF) 5PQ154

PERUVIAN AIR FORCE (PRF) 1 PG251 PG253 PG351 6PT517

PHILIPPINE AIRLINES (PAL) 5 PM384 PM395 PQ803 PS601 7 PM561 PW029 PW156

PHOENIX AVIATION (PHX) 1 PG578–PG579 2 PK213–PK214 PK222 PK671 PK823 PK826 PK830 4 PM252

PHUKET AIRLINES (PHK) 1 PG581–PG582 3PN037 4PN039

PLM INTERNATIONAL (PLI) 2 PK675

PLUNA (PLU) 2 PL201–PL203 5PQ287

PREMIER AIRLINES (PMN) 4PN493

PULKOVO AIRLINES (STG) 5 PT164–PT166

Q AVIATION (QAV) 10 PQ189 2 PK288 PK603–PK604 PK883 5 PQ192 PT397

QANTAS (QAN) 5PQ016 7 PW531–PW536 PW540–PW547 PW557 8 PW548–PW550

QWEST AIR PARTS (QWE) 1PG438

REPEX AIRLINES (REX) 1PY344 2 PY102–PY103

REPUBLIC FINANCIAL CORPORATION (RFC) 1 PA011 PG199 PG225 PG433 PG502–PG503 PG622 PG704

REPUBLIC OF INDONESIA (IDO) 2 PL601–PL602 3 PL603

REPUBLIC OF KOREA AIR FORCE (KAF) 5PP221

REPUBLIC OF NIGER (NIR) 2PY166

REPUBLIC OF VENEZUELA (VNZ) 2PK070

REPUBLICAIR (RPB) 2 PL553 PL555

RICO (RLA) 2 PK119–PK120

ROYAL AIR MAROC (RAM) 2 PK271–PK272 PY671 3PY672 5 PT581–PT584 6 PT585–PT586

ROYAL THAI AIR FORCE (TAF) 3PK519 8PV296

RUTACA AIRLINES (ZRU) 2 PK281 PK611 PK613

RYAN INTERNATIONAL AIRLINES (RYN) 2 PK097 PK543 PK602 PK606 PK608 PN106

RYANAIR (RYR) 2 PK503

RYM AIRLINES (RYM) 2 PL017–PL019

SAFAIR (SFA) 1 PY002 2 PK733 PK743 PK746 PK771 PL110

SAMCO AVIATION (SMO) 2 PL581

SAS BRAATHENS (BRT) 10 PT022 11 PW573 5 PT002–PT004 PT006–PT008 PT011–PT012 PT024–PT025 6 PT013–PT015 7PW574 PW576 8 PV351

SAT AIRLINES (SKH) 2 PL221

SAUDI ARABIAN AIRLINES (SVA) 1 PL727–PL728 PY036 2 PK312 PK316–PK317 PL729–PL733 PL735

SEB MANAGEMENT CORPORATION (YNS) 5PT219

SHAHEEN INTERNATIONAL (SHK) 2 PL003 PL551 PL561

SHANDONG AIRLINES (SHG) 5 PM413–PM414 6 PQ391–PQ395 PR007–PR009 PR013–PR014 PR161 9PR006

SHANTOU AIRLINES (SHT) 5 PM415–PM417

SHEIKH MUSTAFA EDREES (SME) 2 PL505

SHENZHEN AIRLINES (SHZ) 5 PQ486 PS691–PS692 PS851–PS852 6 PQ972 PQ976 PQ995 PS629

SIBERIA AIRLINES (SBR) 5 PT381 PT388–PT389 PT396 PT401 PT420–PT421 PT430–PT431 PT433

SIERRA PACIFIC AIRLINES (SRP) 2 PK627 PL621

SILVER AIR (SARI) (SVT) 1 PL726 2 PK313–PK314 PL734

SKY AIRLINES (SYC) 7 PV235 PW001 PW278 PW281 PW293

SKY KING (SKN) 1PG059 2 PK351–PK353 PK696 PL002 PL006

SKY SERVICE (SSV) 1 PL736 PL740 2 PK628–PK629 PK881 PK884 PK971 PK973 4 PK526–PK527

SKYEUROPE (SKP) 5 PT050–PT051 PT054 PT056–PT057 PT147–PT148 6 PR162–PR166

SKYNET ASIA AIRWAYS (SNU) 7 PM555 8 PW274 PW855–PW856

SLOK AIR (SRO) 2 PM108–PM113

SLOVAK AIRLINES (SLV) 5PP851 PP903

SOUTH AFRICAN AIRWAYS (SAA) 2 PK774 PK776 PL102 PL104–PL109 PL112–PL113

SOUTHERN AIRCRAFT SERVICES (HUZ) 2 PL471

SOUTHERN WINDS (SOW) 2 PJ005 PK029 PK047 PK116 PK146 PK253 PK616

SOUTHWEST AIRLINES (SWA) 5 PP101–PP169 PP188 PP190–PP193 PP202–PP205 PP301–PP304 PP351 PP353 PP376–PP382 PP402–PP403 PP501–PP502 PP727 PP731 PP803–PP804 PP821–PP824 PP827 PS751–PS778 PU001–PU025 6 PS779–PS799 PS901–PS941

SPACE WORLD AIRLINE/SWA (WIN) 2 PL021–PL022

SRIWIJAYA AIR (SJA) 2 PK304 PN023 PN026–PN027 4 PL746 PM254

STA SUPPLIES PTE. LTD. (SSP) 5 PQ040–PQ041

STAR AIR (SRH) 2 PK777 PL744 4 PN040 PN042–PN043

STAR UP S.A. (SRU) 2 PY101

STERLING EUROPEAN AIRLINES (STR) 5PT121 PT125 6 PT127 PT132–PT134

SUNDOWNER OKLAHOMA CITY LLC (SDO) 5 PP514 PS653 7PW313 PW316

TAAG (ANGOLA AIRLINES) (ANG) 2 PK661 PK664 PY162 4 PK665–PK666

TACA INTERNATIONAL AIRLINES (TAC) 1 PL737

TAF AEREAS LINHAS (TFL) 1 PY323 PY342 2 PK118

TANS (TAX) 2 PK113 PL101 PL103 PN082

TAROM - ROMANIAN AIR TRANSPORT (TRM) 5 PQ931–PQ934 6PQ935

TEEBAH AIRLINES (EBH) 2PN028

THAI AIRWAYS INTERNATIONAL (TII) 7 PW161–PW162 PW164–PW167 PW594 8 PW168–PW171

THE PEGASUS AVIATION COMPANY (PEG) 2PK285

THOMSONFLY (BRI) 5 PT123–PT124 PT181–PT182 6 PQ436–PQ437 PR011 PR024 9 PR023

TITAN AIRWAYS (TIU) 5 PM387 PP505 PS620

TNT AIRWAYS (TNB) 5 PP384 PP391 PP414 PP416 PP702 PP711

TRANS AIR CONGO (TSC) 2PY243

TRANSAERO AIRLINES (TRX) 2 PK451–PK452 PK773 PK779 5PP963 PP966 7 PW024 PW040 PW113 PW120

TRANSMILE AIR SERVICES (TML)

1PY381 2PY151 4 PN472 PN474

TRAVEL SERVICE (TSF) 5PT432 PT436 7PW006

TRITON AVIATION SERVICES (TIA) 1PJ101 PJ103 2 PK674 PK677–PK678 PL408 PL411 PL770 PN101

TUI AIRLINES BELGIUM (TLB) 7PW511 PW513 8PW522

TUNISAIR (TUN) 2 PK861–PK863 PY621 5 PT641–PT643 6PT644

TURKISH AIRLINES (THY) 7 PM552–PM553 PM557 PM559–PM560 PM562–PM564 PW012 PW018–PW019 PW045 PW049–PW050 PW287 8 PW290–PW291

TURKMENISTAN AIRLINES (TUE) 5 PQ265 PQ801–PQ802

UKRAINE INTERNATIONAL AIRLINES (UKR) 5 PQ251 PT055 PT059 6 PQ991 PR042 PR181 7 PM551 PW701–PW702

UNICAPITAL AIR GROUP (UAG) 2 PK695

UNITED AIRLINES (UAL) 1 PG024 PG052 PG054–PG055 PG057 PG067 PG069–PG071 2 PL004–PL005 PL009 PL012 PL014–PL016 PL020 5 PQ101–PQ115 PQ118 PQ120–PQ122 PQ125–PQ143 PQ146–PQ151 PQ164–PQ167 PQ169–PQ183 PQ185–PQ186 PQ198–PQ199 PQ201–PQ202 PT382–PT387 PT390–PT395 PT398–PT399 PT402–PT419 PT422–PT423

UNIVERSAL ASSET MANAGEMENT (UAM)

2 PM054 PM056–PM061

US AIR FORCE (USF) 2 PJ202 PJ206 PJ211 PJ213–PJ217 PJ219

US AIRWAYS (USA) 11 PV032 PV038 2 PK597 PK609 PM114 5 PP003–PP008 PP012 PP014–PP020 PP024–PP027 PP030–PP032 PP034–PP042 PP045–PP054 PP401 PP404–PP405 PP410 PP413 PP415 PP417–PP418 PP422–PP429 PP431–PP440 7 PV001–PV010 PV012–PV022 PV025–PV031 PV033–PV037 PV039–PV040 PV044–PV055

UT FINANCE CORPORATION (ZZJ) 5PQ153

VARIG AIRLINES (VAR) 10 PQ331 2 PK111–PK112 PK114 PK144 PK211 5 PP839 PP905–PP906 PP917 PP921–PP922 PP927 PP981–PP982 PP987–PP990 PQ227 PQ256–PQ259 PQ266–PQ267 PQ290 PQ303 PS619 PT058 PT212–PT213 PT216–PT218 PT220 6 PR043–PR044 PR132 PS624 PS627 PS872 PT724–PT725 PT854 7 PV201–PV202 PW008 PW118

VASP AIRLINES (VSP) 1PG472 2PK581

VIRGIN EXPRESS AIRLINES (EBA) 5PS656 6 PQ984 PQ989 PQ993 PS972 7 PW013 PW571–PW572 8PW271 PW275

VIRGIN NIGERIA (VNA) 6PQ982

VISION AIR (VEG) 6PS626

WEBJET LINHAS AEREAS LTDA. (WJL) 5PP679 PS603

WELLS FARGO (FSB) 1 PL741 2 PJ110–PJ111

WESTAIR CARGO AIRLINES (WCO) 1PY037

WESTJET (WJI) 2 PJ108 PJ113 PK241 PK713–PK714 PK716 PL171 4PK565

XIAMEN AIRLINES (XIA) 5 PQ295–PQ296 PQ471 PQ493 PT026–PT029 6 PT030–PT031

IDENTIFICATION BY VARIABLE NUMBER

Variable Group PA001–PA022 1 PA099 1 PA231–PA232 1 PC001–PC005 1 PG001–PG075 1 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 2 PH011–PH013 2 PH021–PH024 2 PH701–PH715 1 PH731–PH732 1 PH741–PH742 1 PH743 2 PJ001–PJ002 1 PJ003–PJ009 2 PJ031–PJ032 1 PJ071–PJ072 1 PJ101–PJ104 1 PJ105–PJ119 2 PJ201–PJ219 2 PJ301–PJ302 7 PJ551–PJ556 7

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 198 Variable Group PJ557–PJ561 8 PJ601–PJ615 8 PJ811 8 PJ816–PJ817 8 PK026–PK029 2 PK041–PK053 2 PK061–PK070 2 PK081–PK082 2 PK091–PK099 2 PK101–PK103 2 PK111–PK120 2 PK141–PK146 2 PK201–PK204 2 PK211–PK215 2 PK216–PK220 4 PK221–PK223 2 PK231–PK241 2 PK251–PK258 2 PK271–PK274 2 PK281–PK289 2

PK291 2 PK301–PK318 2 PK341 2 PK351–PK361 2 PK391 2 PK431–PK433 2 PK451–PK452 2 PK461–PK469 2 PK495 2 PK501–PK504 2 PK511–PK514 2 PK515 4 PK519 3 PK521–PK525 2 PK526–PK528 4 PK541–PK564 2 PK565 4 PK581 2 PK591–PK599 2

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 198 Variable Group PK601–PK617 2 PK621–PK637 2 PK641–PK642 2 PK661–PK664 2 PK665–PK666 4 PK671–PK680 2 PK681 4 PK691–PK697 2 PK711–PK716 2 PK731–PK749 2 PK750–PK765 4 PK771–PK779 2 PK801–PK804 2 PK819–PK827 2 PK830 2 PK861–PK863 2 PK871–PK874 2 PK881–PK884 2 PK901–PK932 2 PK933–PK938 4

PK971–PK974 2 PL001–PL028 2 PL061 2 PL081 2 PL101–PL113 2 PL151 2 PL171–PL172 2 PL201–PL203 2 PL221 2 PL401–PL417 2 PL421 2 PL441 2 PL451–PL454 2 PL455–PL456 4 PL471 2 PL491 2 PL501–PL506 2 PL551–PL562 2 PL581 2

Variable Group PL601–PL602 2 PL603 3 PL611 2 PL621–PL623 2 PL624–PL626 4 PL631–PL632 2 PL711–PL712 1 PL716 1 PL717–PL725 2 PL726–PL728 1 PL729–PL735 2 PL736–PL742 1 PL743–PL745 2 PL746–PL747 4 PL756 1 PL758 2 PL761 1 PL762–PL770 2 PL781–PL788 2 PL793 2

PL801–PL803 1 PM001–PM006 2 PM016–PM017 3 PM021–PM023 2 PM051–PM062 2 PM063–PM066 4 PM101–PM117 2 PM118–PM119 3 PM141–PM142 2 PM171 4 PM181 4 PM251–PM255 4 PM281–PM283 4 PM381–PM390 5 PM391 10 PM392–PM399 5 PM401–PM417 5 PM541–PM550 5 PM551–PM564 7

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 198 Variable Group PN001–PN002 2 PN021–PN028 2 PN029–PN038 3 PN039–PN043 4 PN081–PN083 2 PN084–PN086 3 PN101–PN112 2 PN113–PN117 4 PN131–PN135 3 PN136–PN163 4 PN401–PN420 4 PN431–PN433 4 PN451–PN456 4 PN471–PN474 4 PN481 4 PN491–PN493 4 PN501–PN502 4 PN511–PN512 4 PN521 4 PP001–PP054 5

PP101–PP169 5 PP181–PP199 5 PP201–PP205 5 PP221 5 PP231–PP243 5 PP281–PP286 5 PP301–PP305 5 PP351–PP353 5 PP376–PP384 5 PP391–PP393 5 PP401–PP440 5 PP471–PP475 5 PP501–PP519 5 PP520 6 PP521–PP522 5 PP631–PP634 5 PP651–PP652 5 PP671–PP699 5 PP701–PP733 5

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 198 Variable Group PP771–PP779 5 PP801–PP806 5 PP807 10 PP808 5 PP821–PP827 5 PP831–PP848 5 PP851–PP852 5 PP861–PP875 5 PP876–PP877 6 PP891–PP899 5 PP901–PP936 5 PP946–PP948 5 PP951–PP952 5 PP961–PP967 5 PP981–PP991 5 PP993 5 PQ001–PQ016 5 PQ026–PQ041 5 PQ051–PQ092 5 PQ101–PQ188 5

PQ189 10 PQ190 5 PQ191 10 PQ192–PQ199 5 PQ201–PQ202 5 PQ221–PQ237 5 PQ241–PQ243 5 PQ251–PQ267 5 PQ281–PQ299 5 PQ301–PQ303 5 PQ304 10 PQ305–PQ307 5 PQ331 10 PQ332 5 PQ341–PQ344 5 PQ345–PQ348 6 PQ361–PQ371 5 PQ372–PQ373 6 PQ391–PQ395 6

Variable Group PQ401–PQ413 5 PQ414–PQ415 6 PQ416 8 PQ417–PQ418 6 PQ421 5 PQ431 5 PQ432–PQ438 6 PQ447–PQ448 6 PQ451 6 PQ454 6 PQ471–PQ474 5 PQ475 6 PQ479–PQ481 5 PQ486–PQ487 5 PQ491–PQ493 5 PQ771–PQ772 5 PQ791–PQ793 5 PQ801–PQ805 5 PQ931–PQ934 5 PQ935 6

PQ951 6 PQ971–PQ997 6 PR001–PR005 6 PR006 9 PR007–PR017 6 PR021–PR022 6 PR023 9 PR024–PR034 6 PR041–PR045 6 PR061–PR072 6 PR077–PR082 6 PR091–PR092 6 PR096 6 PR101 6 PR121–PR122 6 PR131–PR132 6 PR141–PR143 6 PR161–PR172 6 PR181 6

Variable Group PS601–PS620 5 PS621–PS630 6 PS631 5 PS636–PS638 5 PS641–PS644 5 PS651–PS657 5 PS666–PS669 5 PS691–PS692 5 PS701–PS703 5 PS704–PS706 6 PS751–PS778 5 PS779–PS799 6 PS811 6 PS836–PS837 5 PS841–PS844 5 PS845–PS846 6 PS851–PS852 5 PS856 5 PS861–PS863 6 PS866–PS868 6

PS871–PS874 6 PS896–PS897 6 PS901–PS941 6 PS956–PS957 6 PS961–PS963 6 PS971–PS978 6 PT001–PT012 5 PT013–PT015 6 PT021 5 PT022 10 PT023–PT029 5 PT030–PT031 6 PT041–PT064 5 PT101 10 PT102–PT105 5 PT121–PT125 5 PT126–PT138 6 PT146–PT148 5 PT161–PT170 5

Variable Group PT181–PT188 5 PT211 10 PT212–PT220 5 PT295 10 PT301–PT309 5 PT331–PT360 5 PT381–PT399 5 PT401–PT438 5 PT501–PT514 5 PT515–PT517 6 PT561–PT565 5 PT581–PT584 5 PT585–PT586 6 PT611–PT621 5 PT641–PT643 5 PT644 6 PT651–PT656 5 PT671–PT672 5 PT681–PT682 6 PT683 9

PT684–PT685 6 PT701–PT703 5 PT716–PT717 6 PT721–PT725 6 PT801–PT818 5 PT819–PT825 6 PT826–PT828 5 PT829–PT834 6 PT851 5 PT852–PT854 6 PT871–PT886 6 PT901–PT930 6 PT971–PT973 6 PT981–PT985 6 PT996 6 PU001–PU025 5 PU301 6 PU311–PU313 6 PV001–PV031 7

Variable Group PV032 11 PV033–PV037 7 PV038 11 PV039–PV055 7 PV201–PV203 7 PV204–PV209 8 PV226–PV229 8 PV231–PV237 7 PV271–PV272 7 PV281–PV284 7 PV285–PV287 8 PV296 8 PV301–PV302 8 PV351 8 PV356–PV357 8 PW001–PW029 7 PW030 11 PW031–PW054 7 PW061–PW062 7 PW063 11

PW064–PW068 7 PW072 7 PW086–PW088 8 PW091–PW094 7 PW101–PW102 7 PW106 7 PW111–PW120 7 PW156–PW157 7 PW161–PW167 7 PW168–PW171 8 PW201–PW249 7 PW250–PW252 8 PW261–PW262 7 PW263–PW264 8 PW265–PW268 7 PW271–PW276 8 PW278 7 PW281–PW288 7 PW289–PW292 8

Variable Group PW293 7 PW296 7 PW301–PW327 7 PW401 7 PW402–PW408 8 PW411–PW418 8 PW421–PW424 8 PW431–PW435 8 PW441–PW450 8 PW461–PW467 7 PW501–PW502 7 PW503 11 PW504 7 PW511–PW517 7 PW518 11 PW519–PW520 7 PW521–PW522 8 PW524–PW525 8 PW526–PW527 7 PW528–PW530 8

PW531–PW547 7 PW548–PW550 8 PW556–PW557 7 PW561–PW562 7 PW563 11 PW564 7 PW571–PW572 7 PW573 11 PW574–PW576 7 PW591–PW596 7 PW611–PW622 7 PW631 7 PW632 11 PW633–PW636 7 PW637 8 PW661–PW662 7 PW681–PW683 7 PW701–PW702 7 PW711–PW717 7

Variable Group PW741–PW742 7 PW761 7 PW771 7 PW831 8 PW851–PW856 8 PX071 1 PX701 1 PY001–PY008 1 PY021 1 PY022 2 PY031 1 PY036–PY037 1 PY046–PY047 1 PY048 2 PY051–PY053 2 PY056–PY057 3 PY101–PY103 2 PY111–PY113 2 PY131–PY135 2 PY141–PY143 2

PY151–PY154 2 PY156–PY157 2 PY161–PY162 2 PY166 2 PY191 2 PY201 2 PY221–PY222 2 PY231 2 PY241–PY244 2 PY270–PY275 2 PY281 2 PY286 2 PY301–PY304 1 PY321–PY323 1 PY341–PY346 1 PY361–PY362 1 PY381 1 PY401 2 PY409–PY410 4

Variable Group PY411 2 PY421–PY422 2 PY441 2 PY451 2 PY461–PY462 2 PY463 4 PY591–PY595 4 PY611–PY612 2 PY621 2 PY631 2 PY651 2 PY671 2 PY672 3 PY721 4 PY741 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

The changes shown in this service bulletin will decrease the probability of cracks in the frame at STA 727 where Stringer (S)-18A is attached. This area is a primary structural element. Operation with cracks in the frame will decrease the structural integrity of this area. Unscheduled downtime can be necessary to replace a frame that has a crack. Cracks in the S-18A chord are not a safety concern.

Several operators have reported numerous cracks on multiple aircraft in the S-18A outboard chord common to the fastener locations just aft of STA 727. Airplanes have accumulated between 30,000 - 76,000 flight-cycles and 32,000 - 65,000 flight hours. One operator found one crack on one airplane in the S-18A chord, forward of STA 727 in the lower fastener row. The aircraft had 68,000 flight-cycles and 71,000 flight hours. Cracks have been found in S-18A chord sections at STA 727 of a thickness of 0.33 inches or less. The cracks were caused by fatigue.

Boeing Service Related Problem (SRP) 737-SRP-53-0162 is related to this service bulletin.

Boeing Supplemental Structural Inspection Document D6-37089, Section 8.2, SSI Number F.29, is related to this service bulletin.

Boeing Structural Item Interim Advisory (SIIA) 737-131 is related to this service bulletin. Boeing Structural Item Interim Advisory (SIIA) 737-44, 737-60, 737-74, 737-194, 737-274 impact the area of this bulletin but are not related.

Revision 1 was sent to add a S-18A outer chord repair. In addition, instructions were added, to trim the "Time Limited Repair" parts, to eliminate interference with fasteners.

Revision 2 is sent to revise inspections, repairs, modifications and parts fabrication and to expand the airplane effectivity to cover all 737-100/200/300/400/500 series airplanes. Additional inspections are added to address new cracks found in the STA 727 outboard chord frame, STA 727 frame auxiliary chord and the stringer S-18A outboard chord. Instructions are added to modify the STA 727 frame time-limited repair into a permanent repair. Instructions are added to install a preventive modification for the S-18A outboard chord.

As part of a service bulletin validation program, the inspection, frame chord replacement, and preventive modification was completed on airplane PG576 before the initial release of this bulletin.

D. Description

The airplane effectivity is divided in 11 groups because of differences in airplane configuration. Do the inspections that follow at the times given in the Compliance section.

Do an external (wheel well) ultrasonic inspection of the STA 727 frame outboard chord at S-18A. Do an external (wheel well) HFEC inspection of the STA 727 frame outboard chord at S-18A. Do a detailed inspection for loose fasteners common to the four holes of the STA 727 frame outboard chord, forward flange at S-18A. Do an open hole eddy current inspection for cracks and a detailed inspection for hole elongation in stringer S-18A. Do these inspections as shown in PART 1 of the Accomplishment Instructions at the times given in the Compliance section.

As part of the accomplishment of this Service Bulletin, a frame chord replacement may be required. Boeing Service Bulletin 737-53-1088 Revision 1, dated May 25, 2006 in conjunction with this service bulletin provides instructions on the STA 727 frame outboard chord replacement. Boeing Service Bulletin 737-53-1088 Revision 1, dated May 25, 2006 replaces the STA 727 frame outboard chord in two parts, an upper and lower outboard chord segment. Only the upper STA 727 frame outboard chord segment replacement is required to satisfy the requirements of this service bulletin.

NOTE:Boeing recommends that the STA 727 frame outboard chord preventive modification be installed with the replaced STA 727 frame outboard chord. Operators may install the STA 727 frame outboard chord modification at a later time, however inspections may be required and increased installation costs will be incurred. Boeing also recommends replacing both chord segments at the same time. Replacing both chord segments at the same time will reduce inspection requirements and task hours required to perform the STA 727 frame outboard chord

replacement.

If cracks are found in the STA 727 frame outboard chord, replace the frame outboard chord and optionally add the preventive modification, or install the time-limited frame chord repair as shown in this service bulletin before any more flights or ask Boeing for repair data.

If the preventive modification is installed on a new or crack free existing STA 727 frame outboard chord where the final edge margins are equal to or greater than 1.7D, then the modification is permanent and inspection requirements are terminated.

If the preventive modification is installed on a new or crack free existing STA 727 frame outboard chord where the final edge margins are equal to or greater than 1.5D but less than 1.7D, then do a one-time HFEC hole inspection as shown in PART 8 of the Accomplishment Instructions at the times given in the Compliance section.

If a new or crack free existing STA 727 frame outboard chord is installed without the preventive modification then perform inspections as shown in PART 1 of the Accomplishment Instructions at the times given in the Compliance section.

As an option to the STA 727 frame outboard chord replacement, a time-limited repair can be fabricated and installed. A time-limited repair can be used to repair cracks that extend from the forward edge of the STA 727 frame outboard chord, or from the forward fastener hole, but do not extend past the second fastener hole aft on the forward flange. The time-limited repair angle replaces the forward splice angle of the STA 727 frame outboard chord if a chord replacement kit has been previously installed per Boeing Service Bulletin 737-53-1088.

NOTE:The time-limited repair is intended to provide an option if a replacement chord is not available in a timely manner. Boeing recommends that a replacement chord be used whenever possible. The time-limited repair will result in additional work and future chord replacement.

Within 4500 flight cycles after the time-limited repair was installed, remove the repair and perform a STA 727 frame outboard chord replacement using additional instructions provided in the accomplishment instructions and optionally add the preventive modification as previously described, including an evaluation of the chord’s condition.

If no cracks are found in the STA 727 frame outboard chord, then continue inspections as shown in the accomplishment instructions or optionally add the preventive modification as shown in this service bulletin.

NOTE:Boeing recommends that the stringer S-18A outboard chord preventive modification be installed when the STA 727 frame outboard chord preventive modification is installed.

To convert a modification with inspection requirements to a permanent modification, ask Boeing for repair instructions.

NOTE:This conversion will likely use a STA 727 frame outboard chord replacement with the installation of a modification strap.

Do an internal (cargo hold) detailed and eddy current inspection of the STA 727 frame auxiliary chord for cracks in the radius, between stringer S-17 and S-23 (end of chord) per PART 1 of the Accomplishment Instructions at times given in the compliance section.

If cracks are found, repair before further flight. Contact Boeing for repair data.

NOTE:A local repair will be provided to address the STA 727 frame auxiliary chord cracks.

Report airplane flight-cycles, crack length, location and growth direction to Boeing for any size cracks in the STA 727 frame auxiliary chord. Provide photographs if possible.

If no cracks are found, and a permanent frame chord modification has not been installed, continue inspections as shown in PART 1 of the Accomplishment Instructions at times given in the Compliance section. If no cracks are found, repeat auxiliary chord inspections until the frame chord is replaced with 7075-T73 and modified per PART 6 of the Accomplishment Instructions.

Do an external detailed inspection of the S-18A outboard chord at STA 727 for cracks. Do an external surface HFEC inspection of the S-18A outboard chord at STA 727 for cracks.

Do a surface eddy current inspection on airplanes that have a "T" profile on the stringer outboard chord. Inspect the run-out of the vertical flange across the run-out face and the radii on both sides of the flange from the run-out to two inches forward.

Perform these inspections per PART 2 of the Accomplishment Instructions at times given in the Compliance section.

If cracks are found in the S-18A outboard chord, install the S-18A outboard chord permanent repair as shown in this service bulletin before further flight or ask Boeing for repair instructions. Inspection requirements for S-18A outboard chord are terminated once the S-18A chord is repaired.

If no cracks are found, continue inspections as shown in PART 2 Accomplishment Instructions. Optionally install the S-18A outboard chord preventive modification. The S-18A outboard chord preventive modification is permanent and inspection requirements for the S-18A outboard chord are terminated.

NOTE:Boeing recommends that the S-18A outboard chord preventive modification be installed when the STA 727 frame outboard chord preventive modification is installed.

More work is necessary for operators that have replaced the chord as shown in the initial release of Service Bulletin 737-53-1088. Refer to Paragraph 1.E., Compliance of this service bulletin.

Airplanes modified or repaired per a previous issue require additional inspections.

NOTE:

1. The changes given in Boeing Service Bulletin 737-53A1039, "Fuselage - Skin Lap Joint Inspection and Repair" can be made on applicable airplanes before or during the changes given in this service bulletin.

2. The changes given in Boeing Service Bulletin 737-53-1066, "Fuselage - Stringer 18A Shear Beam Inspection, Repair and Modification", can be made on applicable airplanes before or during the changes given in this service bulletin.

3. The changes given in Boeing Service Bulletin 737-53-1076, "Fuselage - Circumferential Butt Splices and Bonded Doublers Inspection, Repair and Modification", can be made on applicable airplanes before or during the changes given in this service bulletin.

4. The changes given in Boeing Service Bulletin 737-53-1077, "Fuselage - Skin Inspection,

Repair, and Modification Aft of Body Station 727 Between Stringer S-18 and S-21", can be made on applicable airplanes before or during the changes given in this service bulletin.

5. The changes given in Boeing Service Bulletin 737-53-1089, "Fuselage - Skin Cracks at Stringer 17 Inspection and Preventive Modification", can be made on applicable airplanes before or during the changes given in this service bulletin.

6. The changes given in Boeing Service Bulletin 737-53-1124, "Fuselage - Bonded Doublers (Tear Straps) - Inspection and Repair - For Delamination above Stringer 26 Between Stations 259 and 1016", can be made on applicable airplanes before or during the changes given in this service bulletin.

PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION RESULTS WHEN EACH INSPECTION IS COMPLETE. REFER TO THE FLIGHT SAFETY SECTION IN THE ADDENDUM.

E. Compliance

This bulletin has a Flight Safety Inspection Program that is the minimum necessary to keep the structural integrity of the STA 727 frame outboard chord.

Table 1 inspection of the S-18A outboard chord is recommended as an economic inspection to find cracks prior to causing extensive damage needing a costly repair.

Table 2 through 5 inspections of the STA 727 frame and auxiliary chord are required inspections to maintain safety of flight.

Group 1-6, 9 and 10: Table 1 - Inspection for cracks in S-18A Outboard Chord with a thickness of 0.33 inches or less (Recommended Economic Inspection)

Threshold (which ever occurs Terminating later) Repeat Interval action for Total Airplane Airplane Flight (Not to Exceed Repeat Condition Action Flight Cycles Cycles Flight Cycles) Inspection No Detailed Inspection 27,000 5,000 after the 5,000 Repair or previous as shown in date of this modification of the inspections Accomplishment Service Bulletin S-18A Outboard Instructions, Revision 2 Chord as shown Paragraph 3.B., in PART 2 - Economic Accomplishment Inspection Program Instructions, Eddy Current 42,000 20,000 after the 15,000 Paragraph 3.B., Inspection as date of this PART 5 - S-18A Outboard Chord

shown in Service Bulletin Accomplishment Revision 2 Repair or Instructions, Paragraph 3.B., Paragraph 3.B., PART 7 - S-18A PART 2 - Economic Outboard Chord Inspection Program Preventive Modification Inspected Detailed Inspection - At next repeat 5,000 Repair or as given in as shown in interval as given in modification of the a previous Accomplishment this service S-18A Outboard release of Instructions, bulletin, Revision Chord as shown this Service Paragraph 3.B., 1 or original issue, in Bulletin PART 2 - Economic or within 5,000 Accomplishment Inspection Program after Revision 2 Instructions, release, whichever Paragraph 3.B., is sooner. PART 5 - S-18A Eddy Current - At next repeat 15,000 Outboard Chord Inspection as interval as given in Repair or shown in this service Paragraph 3.B., Accomplishment bulletin, Revision PART 7 - S-18A Instructions, 1 or original issue, Outboard Chord Paragraph 3.B., or within 20,000 Preventive PART 2 - Economic after Revision 2 Modification Inspection Program release, whichever is sooner.

June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 67 of 198 Groups 1-11 Configuration 4: Table 2 - Inspection for cracks in STA 727 Frame Outboard Chord for airplanes with original production frame chord and without the STA 727 Frame Modification Installed (Required minimum for safety)

Threshold (which ever occurs Terminating later) Repeat Interval action for Total Airplane Airplane Flight (Not to Exceed Repeat Condition Action Flight Cycles Cycles Flight Cycles) Inspection No Ultrasonic and 27,000 5,000 after the 5,000 Modification of the previous surface HFEC date of this STA 727 inspections Inspections as Service Bulletin Outboard Chord shown in Revision 2 as shown in Accomplishment Accomplishment Instructions, Instructions, Paragraph 3.B., Paragraph 3.B., PART 1 - Flight PART 6 - STA 727 Safety Inspection Frame Outboard Program Chord Preventive Open hole Eddy 27,000 10,000 after the 15,000 Modification Current Inspection date of this as shown in Service Bulletin Accomplishment Revision 2 Instructions, Paragraph 3.B., PART 1 - Flight Safety Inspection Program Inspected Ultrasonic and - At next repeat 5,000 Modification of the as given in surface HFEC interval as given STA 727 a previous Inspections as in this service Outboard Chord release of shown in bulletin, Revision as shown in this Service Accomplishment 1 or original Accomplishment Bulletin Instructions, issue, or within Instructions, Paragraph 3.B., 5,000 after Paragraph 3.B., PART 1 - Flight Revision 2 PART 6 - STA 727 Safety Inspection release, Frame Outboard Program whichever is Chord Preventive sooner. Modification Open hole Eddy - At next repeat 15,000 Current Inspection interval as given as shown in in this service Accomplishment bulletin, Revision Instructions, 1 or original Paragraph 3.B., issue, or within PART 1 - Flight 10,000 after Safety Inspection Revision 2 Program release, whichever is sooner.

Groups 1-11 Configuration 1: Table 3 - Inspection for cracks in the STA 727 Frame Outboard Chord for airplanes with the Outboard Chord replaced without the Modification of the STA 727 Frame Outboard Chord accomplished. (Required minimum for safety) Threshold (which ever occurs later) Total Airplane Airplane Flight Flight Cycles Cycles Repeat Interval Terminating After Chord (Not to Exceed action for Repeat Condition Action Replacement Flight Cycles) Inspection No previous Ultrasonic, LFEC 27,000 5,000 after the 5,000 Modification of the inspections and edge HFEC date of this STA 727 Outboard Inspections as Service Bulletin Chord as shown in shown in Revision 2 Accomplishment Accomplishment Instructions, Instructions, Paragraph 3.B., Paragraph 3.B., PART 6 - STA 727 PART 1 - Flight Frame Outboard Safety Inspection Chord Preventive Program Modification Open hole Eddy 27,000 10,000 after the 15,000 Current date of this Inspection as Service Bulletin shown in Revision 2 Accomplishment Instructions, Paragraph 3.B.,

PART 1 - Flight Safety Inspection Program Inspected as Ultrasonic, LFEC - At next repeat 5,000 Modification of the given in a and edge HFEC interval as given STA 727 Outboard previous Inspections as in this service Chord as shown in release of shown in bulletin, Accomplishment this Service Accomplishment Revision 1 or Instructions, Bulletin Instructions, original issue, or Paragraph 3.B., Paragraph 3.B., within 5,000 PART 6 - STA 727 PART 1 - Flight after Revision 2 Frame Outboard Safety Inspection release, Chord Preventive Program whichever is Modification sooner. Open hole Eddy - At next repeat 15,000 Current interval as given Inspection as in this service shown in bulletin, Accomplishment Revision 1 or Instructions, original issue, or Paragraph 3.B., within 10,000 PART 1 - Flight after Revision 2 Safety Inspection release, Program whichever is sooner.

Table 4 - "One-Time" Follow On Inspection for cracks in STA 727 Frame Outboard Chord at S-18A for airplanes with the Outboard Chord Interim modification accomplished (Edge Margin less than 1.7D but equal to or greater than 1.5). (Required minimum for Safety). Threshold Lowest Airplane Highest Airplane Flight Cycles after Flight Cycles after the STA 727 frame the STA 727 frame outboard chord outboard chord Repeat Interval modification was modification was (Not to Exceed Condition Action accomplished accomplished Flight Cycles) Each location Open Hole Eddy Current 50,000 60,000 None where the fastener as shown in edge margin in the Accomplishment STA 727 Frame Instructions, Paragraph Outboard Chord 3.B., PART 8 - One Time forward flange is Inspection of STA 727 equal to or greater Frame Outboard Chord than 1.5D and less Interim Modification. than 1.7D

Groups 1-3, Configurations 1, 3 and 4; Group 4-11, Configurations 1 and 4: Table 5 - Inspection for cracks in STA 727 Auxiliary Chord on Airplanes without the STA 727 outboard chord modification accomplished or with 7075-T6 Frames. (Required minimum for Safety) Threshold (whichever occurs later) Airplane Flight (a) Total Cycles after the Repeat Interval Airplane date of this Service (Not to Exceed Terminating action for Action Flight Cycles Bulletin Revision 2 Flight Cycles) Repeat Inspection Detailed Inspection as 27,000 5,000 15,000 Modification of the STA shown in 727 Outboard Chord as Accomplishment shown in Accomplishment Instructions, Instructions, Paragraph Paragraph 3.B., PART 3.B., PART 6 - STA 727 1 - Flight Safety Frame Outboard Chord Inspection Program Preventive Modification Eddy Current 27,000 5,000 15,000 and complete chord Inspection as shown replacement as shown in in Accomplishment Accomplishment Instructions, Instructions Paragraph Paragraph 3.B., PART 3.B., Part 3 - STA 727 1 - Flight Safety Frame Outboard Chord Inspection Program Repair. (b) (a) Groups 1-11, Configuration 1 - Airplane Flight Cycles After Frame Chord Replacement (b) Accomplishment of the terminating actions does not prevent cracks in the auxiliary chord but mitigates the safety concern related to the STA 727 frame outboard chord. Inspections of the auxiliary chord after completion of the terminating actions are optional.

Table 6: STA 727 Frame Outboard Chord Time-Limited Repair Compliance Time (Not to Exceed Flight Cycles from the Time of Condition Action Installation of the Repair) STA 727 Frame Outboard Replace the Time-Limited 4,500 Chord Time-Limited Repair as shown in Repair installed Accomplishment Instructions, Paragraph 3.B., Part 9 - Replacement of the Time- Limited Repair

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.

This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the compliance and accomplishment instructions (i.e. compliance times, inspection or modification) defined in this service bulletin as an alternative method of compliance (AMOC) to the requirements of paragraph (a), (b), (c), (d), (e), (f) and (g) of AD 95-12-17. All provisions of AD 95-12-17 that are not specifically referenced in the above statement remain fully applicable and must be complied with. As part of this latest revision, inspections of the outboard chord of stringer S-18A are no longer required. The FAA is considering further rule making that would mandate the recommendations included in Revision 2 of this Service Bulletin.

The compliance information provided in Appendix A, Table 1, of this service bulletin, Revision 2, are approved as an alternative method of compliance to paragraph (b) and (c) of Airworthiness Directive (AD) 98-11-04 R1 for the inspections of Structurally Significant Item F-29 of Supplemental Structural Inspection Document, D6-37089. This AMOC only applies to the areas inspected per this service bulletin, Revision 2, and to those airplanes identified in this service bulletin, Revision 2. All provisions of 98-11-04 R1 that are not specifically referenced in the above statements remain fully applicable and must be complied with. If operators choose this AMOC, then they must revise their FAA approved maintenance or inspection program with these alternative inspections.

The data below shows an estimate of the man-hours necessary to do the inspection, repair, and preventive modification for each airplane. 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: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to make the parts — Time to find the tools.

PART 1 - Flight Safety Inspection Program Number of Task Persons Task-Hours Elapsed Hours Access 2 2 1 Figure 7 2 2.10 1.05 Figure 8 1 1 1 Figure 9 1 0.75 0.75 Figure 11 2 1.75 0.87 Figure 12 2 1.75 0.87 Figure 24 2 1.75 0.87 Close Access 2 2 1 TOTAL FOR EACH AIRPLANE 13.10 7.41

Group 1, 2, 3, 4, 5, 6, 9 and 10 PART 2 - Economic Inspection Program Number of Task Persons Task-Hours Elapsed Hours Access 2 2 1 Figure 13 2 1.50 0.75 Figure 14 2 1.50 0.75 Close Access 2 2 1 TOTAL FOR EACH AIRPLANE 7 3.5

PART 3 - STA 727 Frame Outboard Chord Repair Number of Task Persons Task-Hours Elapsed Hours Access 5 5 1 TOTAL FOR EACH AIRPLANE 5 1

PART 4 - STA 727 Frame Outboard Chord Time-Limited Repair Number of Task Persons Task-Hours Elapsed Hours Access 5 11.50 2.30 Inspection 2 1 0.50 Figure 15 2 8 4 Figure 16 1 1 1 Figure 17 (a) - - - Figure 18 4 30 7.50 Close Access 5 11.50 2.30 TOTAL FOR EACH AIRPLANE 63 17.60 (a) Time to make parts not included.

Group 1, 2, 3, 4, 5, 6, and 9 PART 5 - S-18A Outboard Chord Repair Number of Task Persons Task-Hours Elapsed Hours Access 5 11.50 2.30 Figure 21 4 26 6.50 Close Access 5 11.50 2.30 TOTAL FOR EACH AIRPLANE 49 11.10

PART 6 - STA 727 Frame Outboard Chord Preventive Modification Number of Task Persons Task-Hours Elapsed Hours Access 5 11.50 2.30 Inspection 2 2 1 Figure 7 2 2.10 1.05 Figure 8 1 1 1 Figure 9 1 0.75 0.75 Figure 10 2 5 2.50 Figure 22 1 0.25 0.25 Close Access 5 11.50 2.30 TOTAL FOR EACH AIRPLANE 34.10 11.15

Group 1, 2, 3, 4, 5, 6, and 9 PART 7 - S-18A Outboard Chord Preventive Modification Number of Task Persons Task-Hours Elapsed Hours Access 2 2 1 Close Access 2 2 1 TOTAL FOR EACH AIRPLANE 4 2

PART 8 - One-Time Inspection of the STA 727 Frame Outboard Chord Interim Modification Number of Task Persons Task-Hours Elapsed Hours Access 2 2 1 Figure 10 2 5 2.50 Close Access 2 2 1 TOTAL FOR EACH AIRPLANE 9 4.50

PART 9 - Replacement of the Time-Limited Repair Number of Task Persons Task-Hours Elapsed Hours Access 2 6.50 3.25 Figure 19 4 10 2 Figure 20 (a) - - - Figure 23 4 30 7.50 Close Access 2 6.50 3.25 TOTAL FOR EACH AIRPLANE 53 16 (a) Time to make parts not included.

H. Weight and Balance Changes

Task Change in Weight Change in Moment

(Pounds) (Pound-Inches) STA 727 Frame Preventive Modification Kit: +8 +5,800 65C37277-1, -2, -3, -4, -5, -6, -7, -8. STA 727 Frame Time Limited Repair +6 +4,360 Time Limited Repair Modification None None (Shear Beam Repair) S-18A Preventive Modification +4 +2,900 Kit: 65C38491-1, -2. STA 727 Frame and S-18A Preventive +10 +7,270 Modification Combination Kit: 65C37277-17, -18, -19, -20, -21, -22. STA 727 Frame and S-18A Preventive Modification +7.8 +5,670 Combination Kit: 65C37277-23, -24, -25, -26. S-18A Chord Repair: Repair Kit 65C37565-5, -6, -7, -8 +6.4 +4,650 S-18A Chord Repair: Repair Kit 65C38642-1, -2, -3, -4, +13.4 +9,740 -5, -6 S-18A Chord Repair: Repair Kit 65C38642-7, -8, -9, -10 +10 +7,270

I. Electrical Load Data

Not applicable

J. References

1. Existing Data:

a. 737-100/200 Maintenance Manual (AMM) Subjects 25-52-51, 25-52-123, 25-52-131, 25-52-141, 26-21-11, 27-51-141, 27-51-261, 53-23-1, 53-51-21

b. 737-300/400/500 Maintenance Manual (AMM) Subject 25-52-51, 25-52-73, 25-52-81, 25-52-91, 26-21-11, 27-51-32, 27-51-67, 53-23-12, 53-51-21

c. 737-100/200 Structural Repair Manual (SRM) Subjects 51-10-6, 51-20-1, 51-50-1

d. 737-300 Structural Repair Manual (SRM) Subject 51-10-02, 51-30-01, 51-50-02

e. 737-400 Structural Repair Manual (SRM) Subject 51-10-02, 51-30-01, 51-50-02

f. 737-500 Structural Repair Manual (SRM) Subject 51-10-02, 51-30-01, 51-50-02

g. 737 Nondestructive Test (NDT) Manual D6-37239, Part 4, Subject 51-40-00, Figure 1

h. 737 Nondestructive Test (NDT) Manual D6-37239, Part 4, Subject 53-10-01

i. 737 Nondestructive Test (NDT) Manual D6-37239, Part 6, Subject 51-00-00, Figures 4, 16 and 23

j. 737 Nondestructive Test (NDT) Manual D6-37239, Part 6, Subject 53-30-00, Figure 5

k. Boeing Standard Overhaul Practices Manual (SOPM) Subject 20-41-02, 20-43-03

l. Service Related Problem (SRP) 737-SRP-53-0162

m. 737 Structural Item Interim Advisory (SIIA) 737-131, 737-44, 737-60, 737-74, 737-194, 737-274

n. 737 Supplemental Structural Inspection Document (SSID) D6-37089, Section 8.2, SSI Number F.29

o. Boeing Service Bulletin 737-53-1088, “Fuselage - Station Number 727 Bulkhead - Outboard Chord Inspection and Replacement”

p. Boeing Service Bulletin 737-53A1039, "Fuselage - Skin Lap Joint Inspection and Repair"

q. Boeing Service Bulletin 737-53-1066, "Fuselage - Stringer 18A Shear Beam Inspection, Repair and Modification"

r. Boeing Service Bulletin 737-53-1076, "Fuselage - Circumferential Butt Splices and Bonded Doublers Inspection, Repair and Modification"

s. Boeing Service Bulletin 737-53-1077, "Fuselage - Skin Inspection, Repair, and Modification Aft of Body Station 727 Between Stringer S-18 and S-21"

t. Boeing Service Bulletin 737-53-1089, "Fuselage - Skin Cracks at Stringer 17 Inspection and Preventive Modification"

u. Boeing Service Bulletin 737-53-1124, "Fuselage - Bonded Doublers (Tear Straps) - Inspection and Repair - For Delamination above Stringer 26 Between Stations 259 and 1016"

v. Boeing Service Bulletin 737-53-1170, "Fuselage - Stringer 18A Web at BS 727- Inspection, Repair and Preventive Change"

w. Boeing Service Bulletin 737-53-1179, "Fuselage - Bonded Skin Doublers (Tear Straps) - Delamination Inspection and Repair"

x. FAA Airworthiness Directive 03-14-06, Amendment 39-13225

y. FAA Airworthiness Directive 95-12-17, Amendment 39-9268

z. FAA Airworthiness Directive 88-22-11, Amendment 39-6432

aa. FAA Airworthiness Directive 89-09-03, Amendment 39-6184

ab. FAA Airworthiness Directive 91-08-12, Amendment 39-6967

ac. FAA Airworthiness Directive 92-25-09, Amendment 39-8424

ad. FAA Airworthiness Directive 98-11-04, Amendment 39-10984

ae. Boeing Drawing 65C36009

2. Data supplied with this Service Bulletin:

a. Drawings:

Drawing Number Title Sheet DCN ADCN 65C38491-1 (a) S-18A Preventive Modification KPL A - 65C38491-2 (a) KPL A - 65C38491 (a) 1 - -

Drawing Number Title Sheet DCN ADCN 65C37277-17 (a) Strap Installation - Station 727 KPL A - 65C37277-18 (a)Bulkhead, S-18 to S-20, Preventive KPL A - Modification (Top Kit) 65C37277-19 (a) KPL A - 65C37277-20 (a) KPL A - 65C37277-21 (a) KPL A - 65C37277-22 (a) KPL A - 65C37277-23 (a) KPL A - 65C37277-24 (a) KPL A - 65C37277-25 (a) KPL A - 65C37277-26 (a) KPL A - 65C37277 PL - 3 (a) 1- - 2 (a) - - 3 (a) - - 4 (a) - - 5 (a) - - 6 (a) - - 65C38642-1 (a) Strap Installation - S-18A Outboard KPL A - 65C38642-2 (a)Chord Repair - Station 727 KPL A - 65C38642-3 (a) KPL A -

65C38642-4 (a) KPL A - 65C38642-5 (a) KPL A - 65C38642-6 (a) KPL A - 65C38642-7 (a) KPL A - 65C38642-8 (a) KPL A - 65C38642-9 (a) KPL A - 65C38642-10 (a) KPL A - 65C38642 (a) 1 - - 2- - 3- - 4- - 5- - 65C37565 (b) Strap Installation - S-18A Outboard PL - - Chord Repair - Station 727 1- - (a) Sent with Revision 2. (b) Sent with Revision 1.

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

Drawing Number Title 65-45771 Skin Panel Installation - S-10 to S-18A, STA 540 to STA 727 65-45774 Skin Panel Installation - S-14L to S-25L, STA 727 to STA 908 65-45775 Skin Panel Installation - S-14R to S-25R, STA 727 to STA 908 65-45776 Skin Panel Installation - S-25L to S-25R, STA 727 to STA 1016 65-46547 Bulkhead installation - STA 727 65-46877 Strap and Beam Installation - Stringer 18A, STA 639 to STA 747 65-48654 Frame Installation - Aft Wing/Body Fairing, STA 729.38

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

Publication Chapter-Section 737 Non-Destructive Test Manual Part 4 and Part 6 737-100/200 Structural Repair Manual 53-10-2 737-300 Structural Repair Manual 53-10-00 737-400 Structural Repair Manual 53-10-00 737-500 Structural Repair Manual 53-10-00

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits/parts shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown below. If there is a limit to the quantity (QTY) of available kits/parts, a supply sequence is given by Spares. More kits/parts become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

Kit/Part ROLT Unit Price thru Name Date QTY Number (weeks) Jan 31/06 65C37277-1 Top Kit, Left Side - - 48 $6,836.00 65C37277-2 Top Kit, Right Side - - 48 $6,836.00 65C37277-3 Top Kit, Left Side - - 48 $6,567.00 65C37277-4 Top Kit, Right Side - - 48 $6,567.00 65C37277-5 Top Kit, Left Side - - 48 $6,583.00 65C37277-6 Top Kit, Right Side - - 48 $6,583.00 65C37277-7 Top Kit, Left Side Inactive for procurement 65C37277-8 Top Kit, Right Side Inactive for procurement 65C37565-1 Top Kit, Left Side Inactive for procurement 65C37565-2 Top Kit, Right Side Inactive for procurement 65C37565-3 Top Kit, Left Side Inactive for procurement 65C37565-4 Top Kit, Right Side Inactive for procurement

65C37565-5 Top Kit, Left Side - - 48 $5,357.00 65C37565-6 Top Kit, Right Side - - 48 $5,357.00 65C37565-7 Top Kit, Left Side - - 48 $4,937.00 65C37565-8 Top Kit, Right Side - - 48 $4,937.00 65C37277-17 Top Kit, Left Side March/21/06 5 48 $6,642.00 65C37277-18 Top Kit, Right Side March/21/06 5 48 $6,642.00 65C37277-19 Top Kit, Left Side March/21/06 10 48 $6,393.00 March/24/06 10 March/29/06 5 65C37277-20 Top Kit, Right Side March/21/06 10 48 $6,393.00 March/24/06 10 March/29/06 5 65C37277-21 Top Kit, Left Side March/21/06 1 48 $6,405.00 65C37277-22 Top Kit, Right Side March/21/06 1 48 $6,405.00 65C37277-23 Top Kit, Left Side March/21/06 1 48 $6,198.00 65C37277-24 Top Kit, Right Side March/21/06 1 48 $6,198.00 65C37277-25 Top Kit, Left Side March/21/06 1 48 $6,257.00 65C37277-26 Top Kit, Right Side March/21/06 1 48 $6,257.00 65C38491-1 Top Kit, Left Side - - 48 $3,545.00

Kit/Part ROLT Unit Price thru Name Date QTY Number (weeks) Jan 31/06 65C38491-2 Top Kit, Right Side - - 48 $3,545.00 65C38642-1 Top Kit, Left Side - - 48 $8,279.00 65C38642-2 Top Kit, Right Side - - 48 $8,279.00 65C38642-3 Top Kit, Left Side - - 48 $8,256.00 65C38642-4 Top Kit, Right Side - - 48 $8,256.00 65C38642-5 Top Kit, Left Side - - 48 $8,206.00 65C38642-6 Top Kit, Right Side - - 48 $8,308.00 65C38642-7 Top Kit, Left Side - - 48 $8,932.00 65C38642-8 Top Kit, Right Side - - 48 $8,932.00 65C38642-9 Top Kit, Left Side - - 48 $8,493.00 65C38642-10 Top Kit, Right Side - - 48 $8,493.00 65C38643-1 Shear Beam Web, Left - - 48 $519.00 Side 65C38643-2 Shear Beam Web, - - 48 $519.00 Right Side 69-78347-1 Shear Beam Web, Left - - 48 $519.00 Side 69-78347-2 Shear Beam Web, - - 48 $519.00 Right Side

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price (and ROLT) data is applicable. Prices are in United States Dollars. Terms: Net 30 days.

Send purchase orders and letters about the supply data to the Director of Spares and refer to this service bulletin number.

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:

Usage Kit Number Effectivity Kit Action Remarks STA 727 65C37277-1 (Left Side) Group 1 (a) Install (1) Concurrent incorporation of Frame 65C37277-2 (Right Side) external 65C38491-1/-2 (add Preventive strap for S-18A Preventive Modification) Modification 65C37277-3 (Left Side) Group 1 (b) Frame recommended. (without S-18A 65C37277-4 (Right Side) Preventive (2) If S-18A Chord Repair is needed, Preventive 65C37277-5 (Left Side) Group 2 Modification see 65C38642. (Note 65C37565 Modification) repair kits are also satisfactory for 65C37277-6 (Right Side) usage, however they are not compatible with 65C33722 Frame replacement kit). S-18A Chord is 0.20 inch thick with early frames. S-18A Chord 65C38491-1 (Left Side) Group 1 Install (1) For use with Frame Preventive Preventive 65C38491-2 (Right Side) and 2 external Modification 65C37277-1 through -6. Modification strap for (2) For airplanes that have S-18A incorporated 65C37277-( ), see flag Chord notes on 65C38491-( ) for fastener Preventive information. S-18A Chord is 0.20 inch Modification thick. STA 727 65C37277-17 (Left Side) Group 3 Install Kit includes both Frame and S-18A Frame and 65C37277-18 (Right Side) and 4 external Preventive Modification Strap. S-18A S-18A Chord straps for Chord is 0.33 thick, early skin panels Preventive Frame and early fairing panels.

Modification 65C37277-19 (Left Side) Group 5 Preventive Kit includes both Frame and S-18A Combination Modification 65C37277-20 (Right Side) and 10 Preventive Modification Strap. S-18A and S-18A Chord is 0.33 inch thick, later skin Chord panels and early fairing panels. Preventive 65C37277-21 (Left Side) Group 6 Modification Kit includes both Frame and S-18A 65C37277-22 (Right Side) and 9 (c) Preventive Modification Strap. S-18A Chord is 0.33 inch thick, later skin panels and later fairing panels. STA 727 65C37277-23 (Left Side) Group 7 Install Kit includes Frame Preventive Frame 65C37277-24 (Right Side) and 11 external Modification only. S-18A Chord is Preventive straps for 0.40 or 0.45 inch thick, later skin Modification Frame panels and early fairing panels. 65C37277-25 (Left Side) Group 8 Preventive Kit includes Frame Preventive Modification 65C37277-26 (Right Side) and 9 (d) Modification only. S-18A Chord is 0.40 or 0.45 inch thick, later skin panels and later fairing panels.

Usage Kit Number Effectivity Kit Action Remarks S-18A Chord 65C37565-5 (Left Side) Group 1 (b) Install Not compatible with 65C33722 Frame Repair 65C37565-6 (Right Side) external replacement. See 65C38642-7/-8 or - strap for 9/-10. 65C37565-1 through -4 are 65C37565-7 (Left Side) Group 2 S-18A used without 65C37277-1 through -6 65C37565-8 (Right Side) Chord installed (obsolete). Superseded by repair 65C38642-7/-8 or-9/-10. 65C37565-5 through -8 are used with 65C37277-1 through -6 installed. S-18A Chord is 0.20 inch thick. S-18A Chord 65C38642-7 (Left Side) Group 1 (b) Install Kit includes S-18A Chord Repair and Repair 65C38642-8 (Right Side) external Frame Preventive Modification straps strap for (Tee S-18A Chord). S-18A Chord is Frame 0.20 inch thick. Modification and S-18A Chord Repair. S-18A Chord 65C38642-9 (Left Side) Group 2 Install Kit includes S-18A Chord Repair and Repair 65C38642-10 (Right Side) external Frame Preventive Modification straps strap for (Flat S-18A Chord). S-18A Chord is Frame 0.20 inch thick. Modification and S-18A

Chord Repair. S-18A Chord 65C38642-5 (Left Side) Group 3 Install Kit includes S-18A Chord Repair and Repair 65C38642-6 (Right Side) and 4 external Frame Preventive Modification straps. strap for S-18A Chord is 0.33 inch thick, early Frame skin panels and early fairings. Modification and S-18A Chord Repair. S-18A Chord 65C38642-1 (Left Side) Group 5 Install Kit includes S-18A Chord Repair and Repair 65C38642-2 (Right Side) and 10 external Frame Preventive Modification straps. strap for S-18A Chord is 0.33 inch thick, later Frame skin panels and early fairings. Modification and S-18A Chord Repair.

Usage Kit Number Effectivity Kit Action Remarks S-18A Chord 65C38642-3 (Left Side) Group 6 Install Kit includes S-18A Chord Repair and Repair 65C38642-4 (Right Side) and 9 (c) external Frame Preventive Modification straps. strap for S-18A Chord is 0.33 inch thick, later Frame skin panels and later fairings. Modification and S-18A Chord Repair (a) For Group 1 Airplanes, Line Number 1-23 only. (b) For Group 1 Airplanes, Line Number 24-310 only. (c) This kit is only applicable to one side of Group 9 airplanes where the S-18A Chord thickness is 0.33inches. (d) This kit is only applicable to one side of Group 9 airplanes where the S-18A Chord thickness is 0.40 or 0.45 inches.

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

Group 1and 2 Kit 65C37277 - STA 727 Frame Preventive Modification (Without S-18A Preventive Modification) QTY

New Part Number -6 -5 -4 -3 -2 -1 Name Notes

65C37277-1 . . . . . - PREVENTIVE MOD KIT - (a) LEFT SIDE 65C37277-2 . . . . - . PREVENTIVE MOD KIT - (a) RIGHT SIDE 65C37277-3 . . . - . . PREVENTIVE MOD KIT - (b) LEFT SIDE 65C37277-4 . . - . . . PREVENTIVE MOD KIT - (b) RIGHT SIDE 65C37277-5 . - . . . . PREVENTIVE MOD KIT - (c) LEFT SIDE 65C37277-6 - . . . . . PREVENTIVE MOD KIT - (c) RIGHT SIDE 65C37277-11 1 1 1 1 1 1 FILLER - TAPERED 65C37277-12 . . . . 1 1 FASTENER ASSY 65C37277-13 . . 1 1 . . FASTENER ASSY 65C37277-14 1 1 . . . . FASTENER ASSY 65-48654-10 2 2 2 2 2 2 FILLER - TAPERED 65-48654-14 1 1 1 1 1 1 FILLER - FLAT 69-78767-3 . 1 . 1 . . ATTACH ANGLE 69-78767-4 1 . 1 . . . ATTACH ANGLE

Group 1and 2 Kit 65C37277 - STA 727 Frame Preventive Modification (Without S-18A Preventive Modification) QTY

New Part Number -6 -5 -4 -3 -2 -1 Name Notes 69-78767-5 . . . . . 1 ATTACH ANGLE 69-78767-6 . . . . 1 . ATTACH ANGLE 69-78768-2 1 1 1 1 . . WEB 69-78768-3 . . . . 1 1 WEB 69-78769-1 . 1 1 . . STIFFENER 69-78769-2 1 . 1 . . . STIFFENER 69-78769-3 . . . . . 1 STIFFENER 69-78769-4 . . . . 1 . STIFFENER 69-78769-5 . 1 . 1 . 1 ANGLE 69-78769-6 1 . 1 . 1 . ANGLE 69-78770-1 . 1 . 1 . 1 STRAP-EXTERNAL 69-78770-2 1 . 1 . 1 . STRAP-EXTERNAL 69-78773-1 1 1 1 1 . . FILLER - FLAT 69-78773-2 . . . . 1 1 FILLER - FLAT 69-78773-3 . . . . 1 1 FILLER - TAPERED

69-78773-4 . . . . 1 1 FILLER - TAPERED 69-78773-5 . . . . 1 1 FILLER - TAPERED 69-78773-6 1 1 1 1 . . FILLER - TAPERED 69-78773-7 1 1 1 1 . . FILLER - TAPERED 69-78773-8 1 1 1 1 . . FILLER - TAPERED 69-78773-10 1 1 1 1 . . SHIM - LAMINATED BACF3F008W011NG 1 1 1 1 1 1 FILLER - FLAT BACF3F023L083AG . . . . 2 2 FILLER - FLAT (a) For Group 1 airplanes, Line numbers 1 - 23 only. (b) For Group 1 airplanes, Line numbers 24 - 310 only. (c) For Group 2 airplanes.

Group 3, 4, 5, 6, 9 and 10 Kit 65C37277 - STA 727 Frame and S-18A Preventive Modification Combination QTY New Part Number -22-21-20-19-18-17 Name Notes 65C37277-17.....-STA 727 FRAME (a) AND S-18A MOD KIT 65C37277-18....-.STA 727 FRAME (a) AND S-18A MOD KIT 65C37277-19 . . . - . . STA 727 FRAME (b) AND S-18A MOD KIT 65C37277-20 . . - . . . STA 727 FRAME (b) AND S-18A MOD KIT 65C37277-21.-....STA 727 FRAME (c) (d) AND S-18A MOD KIT 65C37277-22-.....STA 727 FRAME (c) (d) AND S-18A MOD KIT 65-48654-82 222222FILLER 65-48654-84 333333FILLER 65C37277-11 111111FILLER-TAPERED 65C38496-1 111111STRAP S-18A OUTBD CHORD MOD, STA 727 DETAIL.

69-78767-7 . . . 1 . 1 ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78767-8 . . 1 . 1 . ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78767-9 .1....ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78768-4 . . 1111WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78768-5 11....WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-5 . . . 1 . 1 ANGLE 69-78769-6 . . 1 . 1 . ANGLE 69-78769-7 .1....DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38

Group 3, 4, 5, 6, 9 and 10 Kit 65C37277 - STA 727 Frame and S-18A Preventive Modification Combination QTY New Part Number -22-21-20-19-18-17 Name Notes 69-78769-8 1.....DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-9 . . . 1 . 1 STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78770-3 . 1 . 1 . 1 STRAP-EXTERNAL, STA 727 69-78770-4 1 . 1 . 1 . STRAP-EXTERNAL, STA 727 69-78773-1 ....11FILLER-FLAT 69-78773-6 1111 . .FILLER-TAPERED 69-78773-7 ....11FILLER-TAPERED 69-78773-9 ....11FILLER 69-78767-10 1.....ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38

69-78769-10 . . 1 . 1 . STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-11 .1....DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-12 1.....DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78773-10 ....11SHIM,LAMINATED 69-78773-11 1111 . .FILLER-DETAILS 69-78773-12 1111 . .FILLER DETAILS 69-78773-13 ....11FILLER DETAILS 69-78773-14 1111 . .FILLER-DETAILS 69-78773-15 1111 . .FILLER-DETAILS 69-78773-16 111111FILLER DETAILS BACB30MB10A16333333BOLT, PROTRUDING (e) HD BACB30MB10A17111133BOLT, PROTRUDING (e) HD

Group 3, 4, 5, 6, 9 and 10 Kit 65C37277 - STA 727 Frame and S-18A Preventive Modification Combination QTY New Part Number -22-21-20-19-18-17 Name Notes BACB30MB10A182222 . .BOLT, PROTRUDING (e) HD BACB30MB10A19222222BOLT, HEX DRIVE(e) BACB30MY8K10Y333322BOLT, PROTRUDING (e) HD BACB30MY8K11X111111BOLT, PROTRUDING (e) HD BACB30MY8K11Y111111BOLT, PROTRUDING (e) HD BACB30MY8K12Y333333BOLT, PROTRUDING (e) HD BACB30MY8K13Y222222BOLT, PROTRUDING (e) HD BACB30MY8K14X111111BOLT, PROTRUDING (e) HD BACB30MY8K14Y888888BOLT, PROTRUDING (e) HD BACB30MY8K15Y777777BOLT, PROTRUDING (e) HD

BACB30MY8K16X111111BOLT, PROTRUDING (e) HD BACB30MY8K16Y777777BOLT, PROTRUDING (e) HD BACB30MY8K17Y333333BOLT, PROTRUDING (e) HD BACB30MY8K18Y666666BOLT, PROTRUDING (e) HD BACB30MY8K20Y111111BOLT, PROTRUDING (e) HD BACB30MY8K6X111111BOLT, PROTRUDING (e) HD BACB30MY8K7X111111BOLT, PROTRUDING (e) HD BACB30MY8K7Y252525252525BOLT, PROTRUDING (e) HD BACB30MY8K8X666666BOLT, PROTRUDING (e) HD BACB30MY8K8Y999999BOLT, PROTRUDING (e) HD BACB30MY8K9Y444444BOLT, PROTRUDING (e) HD

Group 3, 4, 5, 6, 9 and 10 Kit 65C37277 - STA 727 Frame and S-18A Preventive Modification Combination QTY New Part Number -22-21-20-19-18-17 Name Notes BACB30NX6K3777777BOLT, PROTRUDING (e) HD BACB30NX6K4333333BOLT, PROTRUDING (e) HD BACB30NX6K4X999999BOLT, PROTRUDING (e) HD BACB30NX6K5X111111BOLT, PROTRUDING (e) HD BACB30NX8K7555555BOLT, HEX DRIVE(e) BACB30YP6K5222222BOLT, 100 DEG HEX (e) DR BACB30YP8K5111111BOLT, 100 DEG HEX (e) DR BACC30BH10888888COLLAR BACC30BH6 10 10 10 10 10 10 COLLAR BACC30BH8 555555COLLAR BACC30BL6 222222COLLAR BACC30BL8 111111COLLAR

BACC30M6 101010101010COLLAR BACC30M8 111111111212COLLAR BACC30R8 868686868686COLLAR BACF3F009N010NN111111FILLER, FLAT. BACF3T01E07-10111111TAPERED FILLER BACF3T03R34-10111111FILLER, TAPERED BACF3T04R26-10111111FILLER, TAPERED. BACR15BB6D6C 45 45 45 45 45 45 RIVET, UNIVERSAL (e) HD BACR15BB6D7C777777RIVET, UNIVERSAL (e) HD BACS40R010B046F....11SHIM, LAMINATED BACS40R010B054F111111SHIM, LAMINATED BACS40R021B097F1111. .SHIM, LAMINATED BACW10BN31AP101010101010WASHER, PLAIN BACW10BN3AP 12 12 12 12 12 12 WASHER BACW10BN41AP101010101010WASHER, COUNTERSUNK, OVERSIZE

Group 3, 4, 5, 6, 9 and 10 Kit 65C37277 - STA 727 Frame and S-18A Preventive Modification Combination QTY New Part Number -22-21-20-19-18-17 Name Notes BACW10BN42AP 86 86 86 86 86 86 WASHER, COUNTERSUNK, OVERSIZE BACW10BN4AP666666WASHER, PLAIN BACW10BN5AP888888WASHER, COUNTERSUNK, OVERSIZE BACW10CA104CC393939393939WASHER, SELF- ALIGN BACW10CA104CV383838383838WASHER, SELF- ALIGN BACW10CA104PV111111WASHER, SELF- ALIGN BACW10CA5CC888888WASHER BACW10CA5CV888888WASHER (a) For Group 3 and 4 airplanes. (b) For Group 5 and 10 airplanes. (c) For Group 6 and 9 airplanes. (d) This kit is only applicable to one side of Group 9 airplanes where the S-18A Chord thickness is

0.33inches. (e) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes.

Group 7, 8, 9 and 11 Kit 65C37277 - STA 727 Frame Preventive Modification QTY New Part Number -26-25-24-23 Name Notes 65C37277-23 . . . - STA 727 FRAME PREVENTIVE MODIFICATION (a) 65C37277-24 . . - . STA 727 FRAME PREVENTIVE MODIFICATION (a) 65C37277-25 . - . . STA 727 FRAME PREVENTIVE MODIFICATION (b) (c) 65C37277-26 - . . . STA 727 FRAME PREVENTIVE MODIFICATION (b) (c) 65-48654-82 2222FILLER 65-48654-84 3333FILLER 65C37277-11 1111FILLER-TAPERED 69-78767-7 . . . 1 ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38

Group 7, 8, 9 and 11 Kit 65C37277 - STA 727 Frame Preventive Modification QTY New Part Number -26 -25 -24 -23 Name Notes 69-78767-8 . . 1 . ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78767-9 . 1 . . ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78768-4 . . 1 1 WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78768-5 1 1 . . WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-5 . . . 1 ANGLE 69-78769-6 . . 1 . ANGLE 69-78769-7 . 1 . . DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-8 1 . . . DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-9 . . . 1 STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78770-3 . 1 . 1 STRAP-EXTERNAL, STA 727 69-78770-4 1 . 1 . STRAP-EXTERNAL, STA 727 69-78773-6 1111FILLER-TAPERED

69-78767-10 1 . . . ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-10 . . 1 . STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-11 . 1 . . DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-12 1 . . . DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78773-11 1111FILLER-DETAILS 69-78773-12 1111FILLER DETAILS 69-78773-14 1111FILLER-DETAILS 69-78773-15 1111FILLER-DETAILS 69-78773-16 1111FILLER DETAILS BACB30MB10A162222BOLT, PROTRUDING HD (d) BACB30MB10A172222BOLT, PROTRUDING HD (d) BACB30MB10A182222BOLT, PROTRUDING HD (d) BACB30MB10A192222BOLT, HEX DRIVE (d) BACB30MY8K10Y3333BOLT, PROTRUDING HD (d) BACB30MY8K11X1111BOLT, PROTRUDING HD (d)

Group 7, 8, 9 and 11 Kit 65C37277 - STA 727 Frame Preventive Modification QTY New Part Number -26-25-24-23 Name Notes BACB30MY8K11Y3333BOLT, PROTRUDING HD (d) BACB30MY8K12Y4444BOLT, PROTRUDING HD (d) BACB30MY8K13Y1111BOLT, PROTRUDING HD (d) BACB30MY8K14X1111BOLT, PROTRUDING HD (d) BACB30MY8K14Y6666BOLT, PROTRUDING HD (d) BACB30MY8K15Y6666BOLT, PROTRUDING HD (d) BACB30MY8K16X1111BOLT, PROTRUDING HD (d) BACB30MY8K16Y8888BOLT, PROTRUDING HD (d) BACB30MY8K17Y5555BOLT, PROTRUDING HD (d) BACB30MY8K18Y6666BOLT, PROTRUDING HD (d) BACB30MY8K20Y1111BOLT, PROTRUDING HD (d) BACB30MY8K6X1111BOLT, PROTRUDING HD (d) BACB30MY8K7X1111BOLT, PROTRUDING HD (d) BACB30MY8K7Y 23 23 23 23 BOLT, PROTRUDING HD (d) BACB30MY8K8X6666BOLT, PROTRUDING HD (d) BACB30MY8K8Y8888BOLT, PROTRUDING HD (d) BACB30MY8K9Y4444BOLT, PROTRUDING HD (d)

BACB30NX6K37777BOLT, PROTRUDING HD (d) BACB30NX6K43333BOLT, PROTRUDING HD (d) BACB30NX6K4X9999BOLT, PROTRUDING HD (d) BACB30NX6K5X1111BOLT, PROTRUDING HD (d) BACB30NX8K75555BOLT, HEX DRIVE (d) BACB30YP6K52222BOLT, 100 DEG HEX DR (d) BACB30YP8K51111BOLT, 100 DEG HEX DR (d) BACC30BH10 8888COLLAR BACC30BH6 10 10 10 10 COLLAR BACC30BH8 5555COLLAR BACC30BL6 2222COLLAR BACC30BL8 1111COLLAR BACC30M6 10101010COLLAR BACC30M8 12121212COLLAR BACC30R8 86868686COLLAR BACF3F009N010NN1111FILLER, FLAT. BACF3F010G025NN2222FILLER BACF3T01E07-101111TAPERED FILLER BACF3T03R34-101111FILLER, TAPERED

Group 7, 8, 9 and 11 Kit 65C37277 - STA 727 Frame Preventive Modification QTY New Part Number -26 -25 -24 -23 Name Notes BACF3T04R26-101111FILLER, TAPERED. BACR15BB6D6C 45 45 45 45 RIVET, UNIVERSAL HD (d) BACR15BB6D7C7777RIVET, UNIVERSAL HD (d) BACS40R010B054F1111SHIM, LAMINATED BACS40R021B097F1111SHIM, LAMINATED BACW10BN31AP 10 10 10 10 WASHER, PLAIN BACW10BN3AP 12 12 12 12 WASHER BACW10BN41AP 10 10 10 10 WASHER, COUNTERSUNK, OVERSIZE BACW10BN42AP 86 86 86 86 WASHER, COUNTERSUNK, OVERSIZE BACW10BN4AP6666WASHER, PLAIN BACW10BN5AP8888WASHER, COUNTERSUNK, OVERSIZE BACW10CA104CC 39 39 39 39 WASHER, SELF-ALIGN BACW10CA104CV 38 38 38 38 WASHER, SELF-ALIGN BACW10CA104PV1111WASHER, SELF-ALIGN BACW10CA5CC8888WASHER BACW10CA5CV8888WASHER (a) For Group 7 and 11 airplanes.

(b) For Group 8 and 9 airplanes. (c) This kit is only applicable to one side of Group 9 airplanes where the S-18A Chord thickness is 0.40 or 0.45 inches. (d) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes.

Group 1 and 2 Kit 65C37565 - S-18A Chord Repair QTY New Part Number -8 -7 -6 -5 Name Notes 65C37565-5 . . . - S-18A REPAIR KIT - LEFT SIDE (a) 65C37565-6 . . - . S-18A REPAIR KIT - RIGHT SIDE (a) 65C37565-7 . - . . S-18A REPAIR KIT - LEFT SIDE (b) 65C37565-8 - . . . S-18A REPAIR KIT - RIGHT SIDE (b) 65C37565-17 1111FASTENER KIT 65C37566-10 1111FILLER 65C37566-2 1111STRAP 65C37566-3 1111STRAP

Group 1 and 2 Kit 65C37565 - S-18A Chord Repair QTY New Part Number -8 -7 -6 -5 Name Notes 65C37566-4 1111STRAP 65C37566-5 . . . 1 STRAP 65C37566-6 . . 1 . STRAP 65C37566-7 . 1 . . STRAP 65C37566-8 1 . . . STRAP 65C37566-9 1111FILLER 69-87822-1 . 1 . 1 SPLICE ANGLE 69-87822-2 1 . 1 . SPLICE ANGLE BACF3F008J017NN1111FILLER BACF3F016J018NN1111FILLER BACS40R023B027P 1111SHIM, LAMINATED 65C37565-10 1 . 1 . STIFFENER 65C37565-11 . 1 . 1 ATTACH ANGLE 65C37565-12 1 . 1 . ATTACH ANGLE 65C37565-13 . 1 . 1 ATTACH ANGLE 65C37565-14 1 . 1 . ATTACH ANGLE 65C37565-15 1111WEB

65C37565-9 . 1 . 1 STIFFENER (a) For Group 1 airplanes, Line numbers 24 - 310 only. (b) For Group 2 airplanes.

Group 1 and 2 Kit 65C38491 - S-18A Chord Preventive Modification QTY New Part Number -2 -1 Name Notes 65C38491-1 . - S-18A PREVENTIVE MOD 65C38491-2 - . S-18A PREVENTIVE MOD 65-46877-31 1 1 FILLER-TAPERED 65-48654-82 2 2 FILLER 65-48654-84 3 3 FILLER 65C38496-1 1 1 STRAP S-18A OUTBD CHORD MOD, STA 727 DETAIL. 69-78767-7 . 1 ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78767-8 1 . ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38

Group 1 and 2 Kit 65C38491 - S-18A Chord Preventive Modification QTY New Part Number -2 -1 Name Notes 69-78768-4 1 1 WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-9 . 1 STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-10 1 . STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 BACB30MB10A14 2 2 BOLT, PROTRUDING HD (a) BACB30MB10A15 2 2 BOLT, PROTRUDING HD (a) BACB30MB10A16 4 4 BOLT, PROTRUDING HD (a) BACB30MB10A17 4 4 BOLT, PROTRUDING HD (a) BACB30MB10A18 2 2 BOLT, PROTRUDING HD (a) BACB30MB10A19 2 2 BOLT, HEX DRIVE (a) BACB30MC10A14 2 2 BOLT, PROTRUDING HD (a) BACB30MC10A15 2 2 BOLT, PROTRUDING HD (a) BACB30MC10A16 4 4 BOLT, PROTRUDING HD (a) BACB30MC10A17 4 4 BOLT, PROTRUDING HD (a) BACB30MC10A18 2 2 BOLT, PROTRUDING HD (a) BACB30MC10A19 2 2 BOLT, HEX DRIVE (a)

BACB30MY8K10X 1 1 BOLT, PROTRUDING HD (a) BACB30MY8K10Y 2 2 BOLT, PROTRUDING HD (a) BACB30MY8K11X 2 2 BOLT, PROTRUDING HD (a) BACB30MY8K11Y 7 7 BOLT, PROTRUDING HD (a) BACB30MY8K12X 1 1 BOLT, PROTRUDING HD (a) BACB30MY8K12Y 11 11 BOLT, PROTRUDING HD (a) BACB30MY8K13Y 7 7 BOLT, PROTRUDING HD (a) BACB30MY8K14Y 5 5 BOLT, PROTRUDING HD (a) BACB30MY8K15Y 5 5 BOLT, PROTRUDING HD (a) BACB30MY8K16Y 2 2 BOLT, PROTRUDING HD (a) BACB30MY8K17Y 2 2 BOLT, PROTRUDING HD (a) BACB30MY8K18Y 1 1 BOLT, PROTRUDING HD (a) BACB30MY8K7X 5 5 BOLT, PROTRUDING HD (a) BACB30MY8K7Y 12 12 BOLT, PROTRUDING HD (a) BACB30MY8K8X 1 1 BOLT, PROTRUDING HD (a) BACB30MY8K8Y 1 1 BOLT, PROTRUDING HD (a) BACB30MY8K9X 6 6 BOLT, PROTRUDING HD (a) BACB30MY8K9Y 13 13 BOLT, PROTRUDING HD (a)

Group 1 and 2 Kit 65C38491 - S-18A Chord Preventive Modification QTY New Part Number -2 -1 Name Notes BACB30NX6K3 7 7 BOLT, PROTRUDING HD (a) BACB30NX6K4 4 4 BOLT, PROTRUDING HD (a) BACB30NX6K4X 9 9 BOLT, PROTRUDING HD (a) BACC30BH10 8 8 COLLAR BACC30BH6 11 11 COLLAR BACC30M6 9 9 COLLAR BACC30M8 9 9 COLLAR BACC30R8 37 37 COLLAR BACF3F010N027NN 1 1 FILLER BACF3T01E07-10 1 1 TAPERED FILLER BACF3T03R34-10 1 1 FILLER, TAPERED BACF3T04R26-10 1 1 FILLER, TAPERED. BACR15BB6D6C 40 40 RIVET, UNIVERSAL HD (a) BACR15BB8D5C 2 2 RIVET, UNIVERSAL HD (a) BACS40R010B027F 1 1 SHIM, LAMINATED BACS40R010E045F 1 1 SHIM, LAMINATED BACS40R010E055F 1 1 SHIM, LAMINATED

BACW10BN31AP 9 9 WASHER, PLAIN BACW10BN3AP 9 9 WASHER BACW10BN41AP 9 9 WASHER, COUNTERSUNK, OVERSIZE BACW10BN42AP 25 25 WASHER, COUNTERSUNK, OVERSIZE BACW10BN5AP 8 8 WASHER, COUNTERSUNK, OVERSIZE BACW10CA104CC 13 13 WASHER, SELF-ALIGN BACW10CA104CV 13 13 WASHER, SELF-ALIGN BACW10CA5CC 8 8 WASHER BACW10CA5CV 8 8 WASHER (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes.

Group 3, 4, 5, 6, 9 and 10 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -6 -5 -4 -3 -2 -1 Name Notes 65C38642-1 .....-S-18A REPAIR(a) 65C38642-2 . . . . - . S-18A REPAIR (a) 65C38642-3 . . . - . . S-18A REPAIR (b) (c) 65C38642-4 . . - . . . S-18A REPAIR (b) (c) 65C38642-5 .-....S-18A REPAIR(d) 65C38642-6 -.....S-18A REPAIR(d) 65-48654-84 333333FILLER 65C37277-11 111111FILLER-TAPERED 65C37566-3 . . 1111STRAP 65C37566-12 111111STRAP S-18A OUTBD CHORD REPAIR, STA 727, KIT 65C37566-15 . 1 . 1 . 1 STRAP S-18A OUTBD CHORD REPAIR, STA 727, KIT 65C37566-16 1 . 1 . 1 . STRAP S-18A OUTBD CHORD

REPAIR, STA 727, KIT 65C37566-1711....STRAP S-18A OUTBD CHORD REPAIR, STA 727, KIT 65C37566-18 111111STRAP S-18A OUTBD CHORD REPAIR, STA 727, KIT 69-78768-6 1 1 . . 1 1 WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78768-7 . . 1 1 . . WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-5 . 1 . . . 1 ANGLE 69-78769-6 1 . . . 1 . ANGLE 69-78769-7 . . . 1 . . DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38

Group 3, 4, 5, 6, 9 and 10 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -6 -5 -4 -3 -2 -1 Name Notes 69-78769-8 . . 1 . . . DETAILS - AFT WING BODY FAIRING, STA 727 + 2.38 69-78770-3 . 1 . 1 . 1 STRAP- EXTERNAL, STA 727 69-78770-4 1 . 1 . 1 . STRAP- EXTERNAL, STA 727 69-78773-1 11....FILLER-FLAT 69-78773-7 11....FILLER-TAPERED 69-78773-9 11....FILLER 69-78767-11 . 1 . 1 . 1 ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78767-12 1 . 1 . 1 . ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-13 . 1 . . . 1 STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-14 1 . . . 1 . STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-15 . . . 1 . . STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-16 . . 1 . . . STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78773-11 . . 1111FILLER-DETAILS 69-78773-12 . . 1111FILLER DETAILS 69-78773-14 . . 1111FILLER-DETAILS 69-78773-15 . . 1111FILLER-DETAILS 69-78773-16 111111FILLER DETAILS

Group 3, 4, 5, 6, 9 and 10 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -6 -5 -4 -3 -2 -1 Name Notes BACB30MB10A17222222BOLT, (e) PROTRUDING HD BACB30MB10A18444444BOLT, (e) PROTRUDING HD BACB30MB10A20222222BOLT, (e) PROTRUDING HD BACB30MY8K10Y333333BOLT, (e) PROTRUDING HD BACB30MY8K11X111111BOLT, (e) PROTRUDING HD BACB30MY8K12Y222222BOLT, (e) PROTRUDING HD BACB30MY8K14X111111BOLT, (e) PROTRUDING HD BACB30MY8K14Y 12 12 12 12 12 12 BOLT, (e) PROTRUDING HD BACB30MY8K15Y333333BOLT, (e) PROTRUDING HD BACB30MY8K16X111111BOLT, (e)

PROTRUDING HD BACB30MY8K16Y 11 11 11 11 11 11 BOLT, (e) PROTRUDING HD BACB30MY8K17Y333333BOLT, (e) PROTRUDING HD BACB30MY8K18Y666666BOLT, (e) PROTRUDING HD BACB30MY8K21Y111111BOLT, (e) PROTRUDING HD BACB30MY8K5Y333333BOLT, (e) PROTRUDING HD BACB30MY8K6X111111BOLT, (e) PROTRUDING HD BACB30MY8K7X113311BOLT, (e) PROTRUDING HD BACB30MY8K7Y232323232323BOLT, (e) PROTRUDING HD BACB30MY8K8X666666BOLT, (e) PROTRUDING HD BACB30MY8K8Y999999BOLT, (e) PROTRUDING HD

Group 3, 4, 5, 6, 9 and 10 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -6 -5 -4 -3 -2 -1 Name Notes BACB30MY8K9Y222222BOLT, (e) PROTRUDING HD BACB30NX6K3777777BOLT, (e) PROTRUDING HD BACB30NX6K4333333BOLT, (e) PROTRUDING HD BACB30NX6K4X999999BOLT, (e) PROTRUDING HD BACB30NX6K5X111111BOLT, (e) PROTRUDING HD BACB30NX8K7555555BOLT, HEX DRIVE(e) BACB30YP6K5222222BOLT, 100 DEG (e) HEX DR BACB30YP8K5111111BOLT, 100 DEG (e) HEX DR BACC30BH10 888888COLLAR BACC30BH6 10 10 10 10 10 10 COLLAR BACC30BH8 555555COLLAR BACC30BL6 222222COLLAR

BACC30BL8 111111COLLAR BACC30M6 101010101010COLLAR BACC30M8 111111111111COLLAR BACC30R8 868686868686COLLAR BACF3F009N010NN.. 1111FILLER, FLAT. BACF3F009P010NN11....FILLER BACF3F010A030BN11....FILLER, FLAT BACF3F024A166BN11....FILLER, FLAT BACF3T01F08-10B333333FILLER BACF3T01T36-10111111FILLER, TAPERED. BACF3T01T38-10111111FILLER, TAPERED. BACF3T02F12-10111111FILLER, TAPERED BACR15BB6D6C404040404040RIVET, (e) UNIVERSAL HD BACR15BB6D7C777777RIVET, (e) UNIVERSAL HD BACR15BB8AD5C222222RIVET, (e) UNIVERSAL HD

Group 3, 4, 5, 6, 9 and 10 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -6 -5 -4 -3 -2 -1 Name Notes BACS40R010A025P111111SHIM, LAMINATED BACW10BN31AP101010101010WASHER, PLAIN BACW10BN3AP 12 12 12 12 12 12 WASHER BACW10BN41AP101010101010WASHER, COUNTERSUNK, OVERSIZE BACW10BN42AP868686868686WASHER, COUNTERSUNK, OVERSIZE BACW10BN4AP666666WASHER, PLAIN BACW10BN5AP888888WASHER, COUNTERSUNK, OVERSIZE BACW10CA104CC 19 19 19 19 19 19 WASHER, SELF- ALIGN BACW10CA104CV 18 18 18 18 18 18 WASHER, SELF- ALIGN BACW10CA104PV111111WASHER, SELF- ALIGN

BACW10CA5CC888888WASHER BACW10CA5PV888888WASHER, SELF- ALIGN (a) For Group 5 and 10 airplanes. (b) For Group 6 airplanes. (c) For Group 9 airplanes where the S-18A Chord thickness is 0.33 inches. (d) For Group 3 and 4 airplanes. (e) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes.

Group 1 and 2 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -10-9-8-7 Name Notes 65C38642-7 . . . - S-18A REPAIR (a) 65C38642-8 . . - . S-18A REPAIR (a) 65C38642-9 . - . . S-18A REPAIR (b) 65C38642-10 - . . . S-18A REPAIR (b)

Group 1 and 2 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -10-9-8-7 Name Notes 65-48654-82 2222FILLER 65-48654-84 3333FILLER 65C37277-11 1111FILLER-TAPERED 65C37566-2 1111STRAP 65C37566-4 1111STRAP 65C37566-5 . . . 1 STRAP 65C37566-6 . . 1 . STRAP 65C37566-7 . 1 . . STRAP 65C37566-8 1 . . . STRAP 65C37566-17 1111STRAP S-18A OUTBD CHORD REPAIR, STA 727, KIT 69-78767-7 . 1 . 1 ATTACH ANGLE - AFT WING BODY FAIRING, STA 727 + 2.38 69-78767-8 1 . 1 . ATTACH ANGLE - AFT WING BODY

FAIRING, STA 727 + 2.38 69-78768-4 1111WEB - AFT WING BODY FAIRING, STA 727 + 2.38 69-78769-5 . 1 . 1 ANGLE 69-78769-6 1 . 1 . ANGLE 69-78769-9 . 1 . 1 STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78770-3 . 1 . 1 STRAP- EXTERNAL, STA 727 69-78770-4 1 . 1 . STRAP- EXTERNAL, STA 727 69-78773-1 1111FILLER-FLAT 69-78773-7 1111FILLER-TAPERED 69-78773-9 1111FILLER

Group 1 and 2 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -10-9-8-7 Name Notes 69-78769-10 1 . 1 . STIFFENER - AFT WING BODY FAIRING, STA 727 + 2.38 69-78773-16 1111FILLER DETAILS BACB30MB10A162222BOLT, (c) PROTRUDING HD BACB30MB10A174444BOLT, (c) PROTRUDING HD BACB30MB10A191122BOLT, HEX DRIVE(c) BACB30MB10A20 1 1 . . BOLT, (c) PROTRUDING HD BACB30MY8K10Y . . 8 8 BOLT, (c) PROTRUDING HD BACB30MY8K11X1122BOLT, (c) PROTRUDING HD BACB30MY8K11Y1144BOLT, (c) PROTRUDING HD BACB30MY8K12X . . 1 1 BOLT, (c)

PROTRUDING HD BACB30MY8K12Y 4 4 12 12 BOLT, (c) PROTRUDING HD BACB30MY8K13Y4488BOLT, (c) PROTRUDING HD BACB30MY8K14X 1 1 . . BOLT, (c) PROTRUDING HD BACB30MY8K14Y 12 12 4 4 BOLT, (c) PROTRUDING HD BACB30MY8K15Y5522BOLT, (c) PROTRUDING HD BACB30MY8K16X 1 1 . . BOLT, (c) PROTRUDING HD BACB30MY8K16Y 8 8 . . BOLT, (c) PROTRUDING HD BACB30MY8K17Y 3 3 . . BOLT, (c) PROTRUDING HD BACB30MY8K19Y1111BOLT, (c) PROTRUDING HD BACB30MY8K5Y3333BOLT, (c) PROTRUDING HD

Group 1 and 2 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -10-9-8-7 Name Notes BACB30MY8K6X1111BOLT, (c) PROTRUDING HD BACB30MY8K7X5511BOLT, (c) PROTRUDING HD BACB30MY8K7Y 28 28 28 28 BOLT, (c) PROTRUDING HD BACB30MY8K8X6666BOLT, (c) PROTRUDING HD BACB30MY8K8Y6666BOLT, (c) PROTRUDING HD BACB30MY8K9Y4433BOLT, (c) PROTRUDING HD BACB30NX6K37777BOLT, (c) PROTRUDING HD BACB30NX6K43333BOLT, (c) PROTRUDING HD BACB30NX6K4X9999BOLT, (c) PROTRUDING HD BACB30NX6K5X1111BOLT, (c)

PROTRUDING HD BACB30NX8K75555BOLT, HEX DRIVE(c) BACB30YP6K52222BOLT, 100 DEG (c) HEX DR BACB30YP8K51111BOLT, 100 DEG (c) HEX DR BACC30BH10 8888COLLAR BACC30BH6 10 10 10 10 COLLAR BACC30BH8 5555COLLAR BACC30BL6 2222COLLAR BACC30BL8 1111COLLAR BACC30M6 10101010COLLAR BACC30M8 11111111COLLAR BACC30R8 86868686COLLAR BACF3F009P010NN 1111FILLER BACF3F010A030BN 1111FILLER, FLAT BACF3F024A166BN 1111FILLER, FLAT BACF3T01R30-101111FILLER, TAPERED. BACF3T01R38-101111FILLER, TAPERED BACF3T02F12-101111FILLER, TAPERED

Group 1 and 2 Kit 65C38642 - S-18A Chord Repair QTY New Part Number -10-9-8-7 Name Notes BACR15BB6D6C40404040RIVET, (c) UNIVERSAL HD BACR15BB6D7C7777RIVET, (c) UNIVERSAL HD BACR15BB8AD5C2222RIVET, (c) UNIVERSAL HD BACW10BN31AP 10 10 10 10 WASHER, PLAIN BACW10BN3AP 12121212WASHER BACW10BN41AP 10 10 10 10 WASHER, COUNTERSUNK, OVERSIZE BACW10BN42AP 86 86 86 86 WASHER, COUNTERSUNK, OVERSIZE BACW10BN4AP6666WASHER, PLAIN BACW10BN5AP8888WASHER, COUNTERSUNK, OVERSIZE BACW10CA104CC 25 25 25 25 WASHER, SELF-

ALIGN BACW10CA104CV 24 24 24 24 WASHER, SELF- ALIGN BACW10CA104PV1111WASHER, SELF- ALIGN BACW10CA5CC8888WASHER BACW10CA5PV8888WASHER, SELF- ALIGN (a) For Group 1 airplanes. (b) For Group 2 airplanes. (c) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes.

Groups 1 and 2, Configurations 1 and 4: Part 65C38643 New Part Number QTY Name Notes 65C38643-1 1 Shear Beam Web, Left (a) (b) Side (c) 65C38643-2 1 Shear Beam Web, (a) (b) Right Side (c) (a) Discard the existing part. (b) This part is not used in production. (c) This part is required for the replacement of the STA 727 Frame Outboard Chord Time-Limited Repair.

Groups 3 through 9, Configurations 1 and 4: Part 69-78347 New Part Number QTY Name Notes 69-78347-1 1 Shear Beam Web, Left (a) (b) Side (c) 69-78347-2 1 Shear Beam Web, (a) (b) Right Side (c) (a) Discard the existing part. (b) This part is not used in production. (c) This part is required for the replacement of the STA 727 Frame Outboard Chord Time-Limited Repair.

2. Parts and Materials Supplied by the Operator:

a. Parts and Materials Supplied by the Operator for the STA 727 Frame Outboard Chord Time-Limited Repair:

The table that follows shows the parts necessary at each installation.

Part Number / Specification QTY Name Notes BMS 5-95 Type I or II, Class 16 Ounces Sealant (a) B1/2 or B2. BMS 10-11, Type 1 16 Ounces Primer (a) Type 2, Class A 8 Ounces Chemical Conversion Coating (b) AND10134-2008 x 20.8 1Frame Repair Angle inches, 7075-T6 or equivalent 1.25 x 4.25 x 0.032 inch 1 Shim A (c) 1.25 x 6 x 0.18 inch 1 Repair Strap (c) 1.2 x 1.4 x 0.14 inch 1 Filler A (c) (d) 8.2 x 1.4 x 0.202 inch 1 Filler B (c) (e) 8.2 x 4.25 x 0.15 inch 1 Shear Beam Repair Angle (f) 2.1 x 11.4 x 0.18 inch 1 Shim B (c)

Part Number / Specification QTY Name Notes 1.2 x 8.7 x 0.18 inch 1 Shim C (c) 6.9 x 1.9 x 0.09 inch 1 Filler (Tapered) (c) BACB30MB8A( ) 70 Bolt (g) (h) (i) (m) BACB30FN8A( ) 1 Bolt (g) (i) (k) BACC30BH8 70 Collar (j) (m) BACC30M8 1 Collar (l) BACR15BA6D( )C 8 Rivet (g) (i) BACR15BB6D( )C 8 Rivet (g) (i) OR BACR15FT6D( )C BACB30ZB4-6 3 Bolt (g) (n) BACB30ZB4-7 2 Bolt (g) (n) BACB30ZB4-8 1 Bolt (g) (n) NAS1149D0463H 4 Washer NAS679A4W 4 Nut (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Refer to Boeing Standard Overhaul Practices Manual 20-43-03 or 737 Structural Repair Manual, Chapter 51, for material sources. (c) Fabricate from 7075-T6 Aluminum Alloy Sheet as shown in Figure 17. (d) If shear beam flange thickness is 0.125 inches, make Filler A 0.125 inch thick.

(e) If shear beam thickness is 0.125 inches, make Filler B 0.217 inch thick. (f) Fabricate from 7075-T0 Aluminum Alloy Sheet as shown in Figure 17. (g) Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners. (h) If 1/64 oversize is required, use BACB30MC( )A( ) bolts. If 1/32 oversize is required, use BACB30MD( )A( ) bolts. (i) Fastener length determined on installation. (j) If a 1/32 oversize bolt is required, use BACC30AC( ) collar. (k) If 1/64 oversize is required, use BACB30FQ( )A( ) bolts. If 1/32 oversize is required, use BACB30KF( )A( ) bolts. (l) If a 1/32 oversize bolt is required, use BACC30R( ) collar. (m) There are more parts than are required. (n) A total of 4 BACB30ZB4-( ) bolts are required for installation.

b. Parts and Materials Supplied by the Operator for the replacement of the STA 727 Frame Outboard Chord Time-Limited Repair:

The table that follows shows the parts necessary at each installation.

Part Number / Specification QTY Name Notes BMS 5-95 Type I or II, Class 16 Ounces Sealant (a) B1/2 or B2. BMS 10-11, Type 1 16 Ounces Primer (a) Type 2, Class A 8 Ounces Chemical Conversion Coating (b) 1.2 x 1.4 x inch 1 Filler A (c) (d) 1 x 6 x 0.15 inch 1 Filler B (c) (e) BACB30MB8A( ) 60 Bolt (f) (g) (h) (l) BACB30FN8A( ) 1 Bolt (f) (j) (k) BACC30BH8 60 Collar (i) (l) BACC30M8 1 Collar (k) BACR15BA6D( )C 8 Rivet (f) (h) BACR15BB6D( )C 8 Rivet (f) (h) OR BACR15FT6D( )C BACB30ZB4-6 3 Bolt (f) (m) BACB30ZB4-7 2 Bolt (f) (m) BACB30ZB4-8 1 Bolt (f) (m)

NAS1149D0463H 4 Washer NAS679A4W 4 Nut (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Refer to Boeing Standard Overhaul Practices Manual 20-43-03 or 737 Structural Repair Manual, Chapter 51, for material sources. (c) Fabricate from 7075-T6 Aluminum Alloy Sheet as shown in Figure 20. (d) Thickness to match existing WL 190 stiffener. Target thickness is 0.156 or 0.125 inches. (e) Part is longer than required. (f) Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners. (g) If 1/64 oversize is required, use BACB30MC( )A( ) bolts. If 1/32 oversize is required, use BACB30MD( )A( ) bolts. (h) Fastener length determined on installation. (i) If a 1/32 oversize bolt is required, use BACC30AC( ) collar. (j) If 1/64 oversize is required, use BACB30FQ( )A( ) bolts. If 1/32 oversize is required, use BACB30KF( )A( ) bolts. (k) If a 1/32 oversize bolt is required, use BACC30R( ) collar. (l) There are more parts than are required. (m) A total of 4 BACB30ZB4-( ) bolts are required for installation.

c. Parts and Materials Supplied by the Operator for the replacement of fasteners after open hole HFEC inspection (Figure 10):

The table that follows shows the parts necessary for each airplane.

Part Number / Specification QTY Name Notes BMS 5-95 Type I or II, Class 2 Ounces Sealant (a) B1/2 or B2. BACB30MB8A( ) (Steel) 8 Bolt (b) (c) (d) (e) OR BACB30NX8K( ) (Titanium) BACC30BH8 8 Collar (f) (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Refer to 737 Structural Repair Manual Chapter 51 for alternative fasteners. (c) Steel bolts only - If 1/64 oversize is required, use BACB30MC8A( ) bolts. If 1/32 oversize is required, use BACB30MD8A( ) bolts. If 3/64 oversize is required, use BACB30ME8A( ) bolts. (d) Titanium bolts only - If 1/64 oversize is required, use BACB30NX8K( )X bolts. If 1/32 oversize is required, use BACB30NX8K( )Y bolts. (e) Fastener length determined on installation. (f) If a 1/32 oversize bolt is required, use BACC30AC8 collar. If a 3/64 oversize bolt is required use BACC30U8 collar (for steel bolts only).

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. Also, maintenance and overhaul tools in manuals shown in Paragraph I.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

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 are given in 737 Structural Repair Manual, Chapter 51 — Torque limits to tighten nuts and bolts are given in 737 Structural Repair Manual, Chapter 51 — Edge margins for fasteners are given in 737 Structural Repair Manual, Chapter 51

4. For approved fastener substitutions, refer to 737 Structural Repair Manual, Chapter 51 or refer to Boeing D-590 Supersession List for standard parts.

5. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used.

6. Fastener installation is given in 737 Structural Repair Manual Chapter 51. Hex drive bolts and lock bolts may be oversized by up to 1/32 inch diameter, unless stated otherwise, while maintaining edge margin requirements.

7. All Hex drive bolts, lock bolts and bolts unless otherwise specified shall be installed wet with BMS5-95. Rivets shall be installed dry. Install hex drive bolts, lock bolts and bolts in transition fit holes or close ream fit holes for steel parts.

8. Shim all gaps greater than 0.01 inch up to a max of 0.04 inch prior to fastener installation unless otherwise stated.

9. 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.

10. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.

B. WORK INSTRUCTIONS

PART 1 - FLIGHT SAFETY INSPECTION PROGRAM

1. Access

Groups 1 through 3, Configurations 1, 3 and 4; Groups 4 through 11, Configurations 1 and 4:

a. Fully extend the trailing edge flaps. Get access to the outboard side of the frame at STA 727 through the opening in the flap fairing. At the operators option, for more access, remove the fairing for the inboard track of the inboard flap as given in 737-100/200 AMM 27-51-141 or 737-300/400/500 AMM 27-51-32. Keep the fairing and all fasteners for installation.

b. Get access to the inboard side of the frame at STA 727 from inside the wheel well. On the left side, at the operators option for more access, disconnect the connectors for the gauge and the detonator on the aft fire bottle as given in 737-100/200 AMM 26-21-11 or 737-300/ 400/500 AMM 26-21-11.

2. Auxiliary Chord Inspection

Groups 1 through 3, Configurations 1, 3 and 4; Groups 4 through 11, Configurations 1 and 4: Do the inspection that follows at the threshold specified in Paragraph 1.E., Compliance, Table 5.

a. Groups 1 through 3, Configuration 3: Do the internal detailed inspection and eddy current inspection of the STA 727 auxiliary chord radius shown in Figure 11.

b. Groups 1 through 3, Configuration 4: Do the internal detailed inspection and eddy current inspection of the STA 727 auxiliary chord radius shown in Figure 12.

c. Groups 1 through 3, Configuration 1; Groups 4 through 11, Configurations 1 and 4: Do the internal detailed inspection and eddy current inspection of the STA 727 auxiliary chord radius shown in Figure 24.

d. If cracks are found, repair before further flight. Contact Boeing for repair data.

NOTE:A local repair will be provided to address the STA 727 frame auxiliary chord cracks.

3. STA 727 Frame Outboard Chord Inspection

Groups 1 through 11, Configurations 1 and 4: Do the inspections that follow at the thresholds specified in Paragraph 1.E., Compliance, Table 2 or 3 as applicable.

a. Do the external ultrasonic inspection of the STA 727 frame outboard chord forward flange as shown in Figure 7.

b. Groups 1 through 11, Configuration 1: Do the external (wheel well) eddy current inspection of the replaced STA 727 frame outboard chord forward flange shown in Figure 8.

c. Groups 1 through 11, Configuration 4: Do the external (wheel well) surface HFEC inspection of the STA 727 frame outboard chord forward flange as shown in Figure 9.

CAUTION: MAKE SURE FASTENER HOLES ARE ROUND BEFORE PERFORMING THE FIGURE 10 INSPECTIONS.

d. Do the open hole eddy current inspection of the STA 727 frame outboard chord forward flange shown in Figure 10.

NOTE:The inspection provided in Figure 10 inspects for cracks in the aluminum STA 727 frame chord. Inspection of steel parts with this inspection procedure may produce false positive crack indications. This service bulletin does not require the inspection of the steel repair doubler used for short edge margin repair for Group 10 and Group 11 airplane.

NOTE:When performing the open hole eddy current inspections of the STA 727 frame outboard chord shown in Figure 10, it is recommended to minimize the growth of the fastener hole diameter when inspecting the hole or installing a fastener. Larger fastener holes may impact future inspections and the accomplishment of PART 6 - STA 727 Frame Outboard Chord Preventive Modification.

CAUTION: THE PART 4 - STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR IS LIMITED TO CRACKS THAT EXTEND FROM THE FORWARD EDGE OF THE CHORD, OR FROM THE FASTENER HOLE, BUT DO NOT EXTEND PAST THE SECOND FASTENER HOLE AFT. CRACKS NOT MEETING THIS DESCRIPTION

MUST BE REPAIRED BY PART 3 - STA 727 FRAME OUTBOARD CHORD REPAIR.

e. If cracks are found, repair before further flight as shown in PART 3 - STA 727 Frame Outboard Chord Repair or PART 4 - STA 727 Frame Outboard Chord Time-Limited Repair. If the repairs shown in PART 3 or PART 4 cannot be installed, contact Boeing for repair data. If a PART 3 repair is installed, inspections are still required per Compliance Table 3. If a PART 3 repair is installed along with a PART 6 modification, an inspection may be required per Compliance Table 4. If a PART 4 repair is installed then replacement is required per Compliance Table 6. Refer to Paragraph 1.E., Compliance, Table 3 or 4 or 6 as applicable.

(1) Groups 1 through 9, Configurations 1 and 4: Repair as shown in PART 3 - STA 727 Frame Outboard Chord Repair or PART 4 - STA 727 Frame Outboard Chord Time-Limited Repair. If the repairs shown in PART 3 or PART 4 cannot be installed, contact Boeing for repair data. If a PART 3 repair is installed, inspections are still required per Compliance Table 3. If a PART 3 repair is installed along with a PART 6 modification, an inspection may be required per Compliance Table 4. If a PART 4 repair is installed then replacement is required per Compliance Table 6. Refer to Paragraph 1.E., Compliance, Table 3 or 4 or 6 as applicable.

(2) Groups 10 and 11, Configurations 1 and 4: Contact Boeing for repair data.

f. Groups 1 through 9, Configurations 1 and 4: If no cracks are found, put the airplane back to a serviceable condition or modify as shown in PART 6 - STA 727 Frame Outboard Chord Preventive Modification. If the modification is not installed, repeat the PART 1 inspections at the time specified in Paragraph 1.E., Compliance, Table 2 or 3 as applicable. If a STA 727 frame outboard chord interim modification is installed, do the inspections in PART 8 - STA 727 Frame Outboard Chord Interim Modification at the time specified in Paragraph 1.E., Compliance, Table 4. If a STA 727 frame outboard chord permanent modification is installed, inspections of the STA 727 frame outboard chord are terminated.

g. Groups 10 and 11, Configurations 1 and 4: If no cracks are found, put the airplane back to a serviceable condition or contact Boeing for instructions to install a STA 727 Frame Outboard Chord Preventive Modification. If the modification is not installed, repeat the PART 1 inspections at the time specified in Paragraph 1.E., Compliance, Table 2 or 3 as applicable.

4. Close Access

Groups 1 through 3, Configurations 1, 3 and 4, Groups 4 through 11, Configurations 1 and 4:

a. If disconnected in Step 1. b, install the connectors for the gauge and the detonator on the aft fire bottle as given in 737-100/200 AMM 26-21-11 or 737-300/400/500 AMM 26-21-11.

b. If removed in Step 1. a, install the fairing for the inboard track of the inboard flap as given in 737-100/200 AMM 27-51-141 or 737-300/400/500 AMM 27-51-32.

c. Return the airplane to a serviceable condition.

PART 2 - ECONOMIC INSPECTION PROGRAM

1. Access

Groups 1 through 6, 9 and 10:

NOTE:This inspection program looks for cracks in the stringer (S)-18A outboard chord where the chord thickness is 0.20 or 0.33 inches thick at STA 727.

Group 9: This inspection program applies to one side of the airplane only where the S-18A Outboard Chord has a thickness of 0.33 inch at STA 727. The S-18A Outboard Chord is 0.33 inch thick on the left side of line numbers 2938 and 2940 and on the right side of line number 2942.

2. Stringer 18A Outboard Chord Inspection

Group 1 through 6, 9 and 10: Do the inspections that follow at the thresholds specified in the Compliance section.

a. Group 1: Do the external Detailed Inspection and the Eddy Current Inspection of the S-18A outboard chord as shown in Figure 13.

b. Group 2; Group 3; Group 4; Group 5; Group 6; Group 9; Group 10: Do the external Detailed Inspection and the Eddy Current Inspection of the S-18A outboard chord as shown in Figure 14.

c. Group 1; Group 2; Group 3; Group 4; Group 5; Group 6; Group 9: If cracks are found, repair before further flight as shown in PART 5 - S-18A Outboard Chord Repair. If the repairs shown in PART 5 cannot be installed, contact Boeing for repair data. If a S-18A repair is installed, S-18A outboard chord inspections are terminated.

d. Group 10: If cracks are found, repair before further flight. Contact Boeing for repair data.

e. Group 1; Group 2; Group 3; Group 4; Group 5; Group 6; Group 9: If no cracks are found, put the airplane back to a serviceable condition or modify as shown in PART 7 - S-18A Outboard Chord Preventive Modification. If the S-18A outboard chord modification is not installed, repeat the PART 2 inspections at the time specified in Paragraph 1.E., Compliance, Table 1. If a S-18A outboard chord modification is installed, inspections of the S-18A outboard chord are terminated.

f. Group 10: If no cracks are found, put the airplane back to a serviceable condition or contact Boeing to install a S-18A Outboard Chord Preventive Modification. If the S-18A outboard chord modification is not installed, repeat the PART 2 inspections at the time specified in Paragraph 1.E., Compliance, Table 1.

3. Close Access

Groups 1 through 6, 9 and 10:

a. If disconnected in Step 1. b, install the connectors for the gauge and the detonator on the aft fire bottle as given in 737-100/200 AMM 26-21-11 or 737-300/400/500 AMM 26-21-11.

b. If removed in Step 1. a, install the fairing for the inboard track of the inboard flap as given in 737-100/200 AMM 27-51-141 or 737-300/400/500 AMM 27-51-32.

c. Return the airplane to a serviceable condition.

PART 3 - STA 727 FRAME OUTBOARD CHORD REPAIR

1. Prepare Airplane For Maintenance

Groups 1-9

NOTE:STA 727 Frame Outboard Chord Repair is not available for Groups 10 and 11, contact Boeing for repair data.

a. Support the airplane in the jig position as given in 737-100/200 SRM 51-50-1 or 737-300 SRM 51-50-02 or 737-400 SRM 51-50-02 or 737-500 SRM 51-50-02. If support cradles are used, do not install the cradle at STA 727 to allow access for repair.

2. STA 727 Frame Outboard Chord Repair

a. As of the release date of Revision 2 of this service bulletin, replace the STA 727 frame outboard chord as given in Boeing Service Bulletin 737-53-1088 Revision 1, dated May 25, 2006. If the frame outboard chord was replaced and modified as given in the initial release of Boeing Service Bulletin 737-53-1088, no more work is necessary.

NOTE:

1. When performing the PART 3 - STA 727 frame outboard chord repair, it is recommended to keep expansion of the fastener holes common to the S-18A outboard chord to a minimum. Larger diameter fastener holes may impact future inspections and the accomplishment of PART 6 - STA 727 Frame Outboard Chord Preventive Modification.

2. Boeing recommends that the PART 6 - STA 727 frame outboard chord preventive modification and PART 7 - S-18A outboard chord preventive modification be installed with the replaced STA 727 frame outboard chord. Operators may install the PART 6 - STA 727 frame outboard chord preventive modification and PART 7 - S-18A outboard chord preventive modification at a later time, however inspections may be required and increased installation costs will be incurred.

3. The PART 3 - STA 727 frame outboard chord repair can be accomplished at the same time on both the left and right sides of the airplane.

4. If the Part 6 - STA 727 Frame Outboard Chord Preventive Modification, or the Part 5 - S-18A Outboard Chord Repair or the Part 7 - S-18A Outboard Chord

Preventive Modification is being accomplished at the same time as a STA 727 frame outboard chord replacement using instructions from Boeing Service Bulletin 737-53-1088 Revision 1, dated May 25, 2006, use the fasteners as specified in this service bulletin at common locations.

PART 4 - STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR

1. Prepare Airplane For Maintenance

NOTE:The Time-Limited Repair is intended to provide the operator with options if a replacement chord is not available in a timely manner. Boeing recommends that a replacement chord be used whenever possible. The Time-Limited Repair will result in additional work and future chord replacement.

CAUTION: THE INSTALLATION OF THIS TIME-LIMITED REPAIR USES NESTED ANGLES AND PLATES THAT MAY RESULT IN LOW EDGE MARGINS AND INSUFFICIENT RADIUS CLEARANCE FOR FASTENER INSTALLATIONS. CHECK EXISTING FASTENER LOCATIONS PRIOR TO PROCEEDING WITH

THIS INSTALLATION.

THE PART 4 - STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR IS LIMITED TO CRACKS THAT EXTEND FROM THE FORWARD EDGE OF THE CHORD, OR FROM THE FASTENER HOLE, BUT DO NOT EXTEND PAST THE SECOND FASTENER HOLE AFT. THE EXTENT OF THE CRACK WILL NOT BE KNOWN UNTIL AFTER THE EXISTING STRUCTURE IS TRIMMED OR REMOVED. CRACKS NOT MEETING THIS DESCRIPTION MUST BE REPAIRED BY PART 3 - STA 727 FRAME OUTBOARD CHORD REPAIR.

FOR AIRPLANES WITH A SHEAR BEAM REPAIRED PER S/B 737-53-1170, THE FRAME CHORD MUST BE REPAIRED USING PART 3 - STA 727 FRAME OUTBOARD CHORD REPAIR.

a. If a repair was previously installed per drawing 65C36009 to address short edge margins along S-18A and the existing repair is common to STA 727, contact Boeing for repair data.

b. Support the airplane in the jig position as given in 737-100/200 SRM 51-50-1 or 737-300 SRM 51-50-02 or 737-400 SRM 51-50-02 or 737-500 SRM 51-50-02. If support cradles are used, do not install the cradle at STA 727 to allow access for repair.

c. Fully extend the trailing edge flaps. Get access to the outboard side of the frame at STA 727 through the opening in the flap fairing. At the operators option, for more access, remove the fairing for the inboard track of the inboard flap as given in 737-100/200 AMM 27-51-141 or 737-300/400/500 AMM 27-51-32. Keep the fairing and all fasteners for installation.

d. Remove the following equipment from the wheel well and cargo compartments as necessary for access to the STA 727 Frame Outboard Chord.

Equipment 737-100/-200 AMM Subject 737-300/-400/-500 AMM Subject Wing-to-Body Fairing 53-51-21 53-51-21 Fire Extinguisher Bottles 26-21-11 26-21-11 Cargo Liner 25-52-123 25-52-73 Cargo Floor Panel 25-52-51 25-52-51 Cargo Bulkhead Panel 25-52-131 25-52-81 Auxiliary Fuel Tank (if installed) 53-23-1 53-23-12 Insulation Blankets 25-52-141 25-52-91 Flap Right Angle Gearbox 27-51-261 27-51-67

2. Stringer 18A and STA 727 Outboard Chord Inspection

a. Do a General Visual Inspection to identify the quantity of fasteners attaching the stringer S-18A to the STA 727 frame outboard chord forward flange. If four fasteners are identified then proceed with the time-limited repair. If less than four fasteners are identified, contact Boeing for repair data.

b. Do a Detailed Inspection of the exposed STA 727 outboard chord forward flange for corrosion.

(1) If corrosion is found, remove the corrosion as shown in 737-100/200 SRM 51-10-6 or 737-300 SRM 51-10-02 or 737-400 SRM 51-10-02 or 737-500 SRM 51-10-02.

c. On the forward side of the bulkhead at STA 727, locate the horizontal stiffener at approximately Water Line (WL) 190. Trim the horizontal stiffener and S-18A shear beam web as shown in Figure 15 to allow for the installation of the repair angle.

NOTE:

1. Boeing Service Bulletin 737-53-1066 and 737-53-1170 provide a repair or a preventive modification that installs sheet aluminum components common to the S-18A shear beam and the horizontal stiffener at approximately WL 190.

2. This repair is limited to cracks that extend from the forward edge of the chord, or from the forward fastener hole, but do not extend past the second fastener hole aft. The extent of the crack will not be known until after existing structure is trimmed or removed. Cracks not meeting this description must be repaired by PART 3 - STA 727 Frame Outboard Chord Repair.

d. Do a High Frequency Eddy Current (HFEC) inspection of the inboard surface of the STA 727 frame chord to determine the location of the end of the crack as shown in Figure 16. As an option to trimming the shear beam flange, remove the shear beam web from approximately STA 711 to STA 727 to provide access to the inboard surface of the STA 727 frame outboard chord forward flange.

NOTE:The shear beam web removal option will allow inspection of the frame chord without trimming the shear beam. If the STA 727 frame chord outboard flange is cracked beyond allowable limits for the time-limited repair, this option will allow re-use of the

shear beam web with a STA 727 frame chord replacement.

(1) If the crack extends from the forward edge of the chord, or from the forward fastener hole, but does not extend past the second fastener hole aft, then stop drill the crack using the procedure given in 737-100/200 SRM 51-10-1 or 737-300 SRM 51-10-02 or 737-400 SRM 51-10-02 or 737-500 SRM 51-10-02. Use 737 NDT Part 6 51-00-00 Figure 16 for open hole inspections using the 0.020 notch standard. If the crack is contained within a fastener hole in the STA 727 frame outboard chord, the fastener hole is the stop drill hole, otherwise drill a new hole in the STA 727 frame outboard chord only, as described in the SRM. Existing fastener holes acting as a stop drill hole or a new stop drill hole must be inspected and have an insurance cut as described in the SRM. Contact Boeing if a new stop drill hole location is less than 1.2 stop drill hole diameters from existing holes. For both new and existing holes do the stop drill and insurance cut in the STA 727 frame outboard chord only.

NOTE:Do the stop drill and insurance cut of holes in the STA 727 frame outboard chord from the wheel well side. Protect the structure on the exit side of the hole from potential drill damage.

(2) If the crack or stop drill hole extends past the second fastener hole aft of the forward edge of the chord, do PART 3 - STA 727 Frame Outboard Chord Repair. If the shear beam was optionally removed, reinstall it using the same size and type fasteners as removed unless stated differently in this service bulletin. Install hex drive and lock bolt fasteners in transition fit holes using BMS5-95.

e. Make the repair parts as shown in Figure 17.

f. Install the repair parts as shown in Figure 18.

If the shear beam web was removed, reinstall the shear beam web using the same size and type fasteners as were removed. Install hex drive and lock bolt fasteners in transition fit holes with BMS5-95. Reinstall fasteners common to the repair parts as shown in Figure 18.

NOTE:

1. The repair angle replaces the forward splice angle of the STA 727 frame outboard chord if a chord replacement kit has been previously installed per Boeing Service Bulletin 737-53-1088. Use the existing fastener locations common to the area previously covered by the forward splice angle. Replace fasteners with the same size and type. Install hex drive and lock bolt fasteners in transition fit holes with BMS5-95. Install fasteners in new locations as shown in Figure 18.

2. When performing the STA 727 frame outboard chord Time-Limited repair, it is recommended to keep expansion of the fastener holes common to the S-18A outboard chord to a minimum. Larger diameter fastener holes may impact future inspections and the accomplishment of PART 6 - STA 727 Frame Outboard Chord Preventive Modification.

3. Close Access

a. Install the equipment in the wheel well and cargo hold that was removed for access.

b. At the time specified in Paragraph 1.E. Compliance Table 6, replace the STA 727 frame outboard chord as shown in PART 9: Replacement of the Time-limited Repair.

c. Put the airplane back to a serviceable condition.

PART 5 - STRINGER 18A OUTBOARD CHORD REPAIR

1. Prepare Airplane For Maintenance

Groups 1 through 6 and Group 9:

NOTE:Group 9: This repair only applies to one side of the airplane only where the S-18A Outboard Chord has a thickness of 0.33 inch at STA 727.

NOTE:S-18A repair is not available for Groups 10 and 11, contact Boeing for repair data.

b. Fully extend the trailing edge flaps. Get access to the outboard side of the frame at STA 727 through the opening in the flap fairing. At the operators option, for more access, remove the fairing for the inboard track of the inboard flap as given in 737-100/200 AMM 27-51-141 or 737-300/400/500 AMM 27-51-32. Keep the fairing and all fasteners for installation.

c. Remove the following equipment from the wheel well and cargo compartments as necessary for access to the STA 727 Frame Outboard Chord.

2. Stringer 18A Outboard Chord Inspection

a. Do the inspection as shown in Figure 21 to identify the quantity of fasteners in the aft end of the S-18A outboard chord aft of the STA 727 frame outboard chord aft flange. If there are less than 15 fasteners in a single row, contact Boeing for repair data.

b. Do the S-18A outboard chord repair as shown in drawing 65C38642.

NOTE:

1. Revision 1 and earlier versions of this service bulletin previously installed the S-18A outboard chord repair as shown in drawing 65C37565. Drawing

65C37565 is now superseded by drawing 65C38642.

2. When performing the PART 5 - S-18A Outboard Chord Repair, it is recommended to keep expansion of the fastener holes common to STA 727 frame outboard chord to a minimum when installing fasteners. Larger fastener hole diameters may impact future inspections and the accomplishment of PART 6 - STA 727 Frame Outboard Chord Preventive Modification.

3. Drawing 65C38642 provides repair procedures for airplanes with and without the PART 6 - STA 727 frame outboard chord preventive modification installed.

4. The S-18A repair parts can be purchased as a repair kit 65C38642, refer to Paragraph 2.A., Material - Price and Availability, or, as an option, the S-18A repair parts can be made by the operator. Refer to Drawing 65C38642.

5. The stringer S-18A repair installs new structure to replace most of the STA 727 fairing support structure that was removed.

3. Close Access

a. Install the equipment that was removed for access.

b. Put the airplane back to a serviceable condition.

PART 6 - STA 727 FRAME OUTBOARD CHORD PREVENTIVE MODIFICATION

1. Access

Group 1 through 9

NOTE:

1. STA 727 frame outboard chord preventive modification is not available for Groups 10 and 11, contact Boeing for repair data.

2. When the Part 6 - STA 727 Frame Outboard Chord Preventive Modification, or the Part 5 - S-18A Outboard Chord Repair or the Part 7 - S-18A Outboard Chord Preventive Modification is being accomplished at the same time as a STA 727 frame outboard chord replacement using instructions from Boeing Service Bulletin 737-53-1088 Revision 1, dated May 25, 2006, use the fasteners as specified in this service bulletin at common locations.

3. These instructions provide a STA 727 frame outboard chord modification option to address specific edge margin conditions that result in follow-on inspections.

4. Boeing recommends that the PART 7 - S-18A outboard chord preventive modification be installed with the PART 6 - STA 727 frame outboard chord preventive modification.

a. If a repair was previously installed per drawing 65C36009 to address short edge margins along S-18A and the existing repair is common to the locations to be impacted by the Part 6 Modification, contact Boeing for repair data.

d. Remove the following equipment from the wheel well and cargo compartment as necessary for access to the STA 727 Frame Outboard Chord and the inboard side of S-18A between STA 709 and STA 727.

Equipment 737-100/-200 737-300/-400/-500 AMM Subject AMM Subject Wing-to-Body Fairing 53-51-21 53-51-21 Fire Extinguisher Bottles 26-21-11 26-21-11 Cargo Liner 25-52-123 25-52-73 Cargo Floor Panel 25-52-51 25-52-51 Cargo Bulkhead Panel 25-52-131 25-52-81

Equipment 737-100/-200 737-300/-400/-500 AMM Subject AMM Subject Auxiliary Fuel Tank (if installed) 53-23-1 53-23-11 Insulation Blankets 25-52-141 25-52-91 Flap Right Angle Gearbox 27-51-261 27-51-67

2. STA 727 Frame Outboard Chord Forward and Aft Flange Inspection

a. Do a General Visual Inspection to identify the quantity of fasteners attaching the S-18A stringer to the STA 727 frame outboard chord forward flange. If four fasteners are identified then proceed with the preventive modification. If less than four fasteners are identified, contact Boeing for repair data.

b. Do the inspection as shown in Figure 21 to identify the quantity of fasteners in the aft end of the S-18A outboard chord aft of the STA 727 frame outboard chord aft flange. If there are less than 15 fasteners in a single row, contact Boeing for repair data.

c. Do a Detailed Inspection of the exposed STA 727 outboard chord forward flange for corrosion.

(1) If corrosion is found, remove the corrosion as shown in 737-100/200 SRM 51-10-6 or 737-300 SRM 51-10-02 or 737-400 SRM 51-10-02 or 737-500 SRM 51-10-02.

NOTE:A corrosion inspection is not required when a STA 727 frame outboard chord is replaced and the STA 727 frame outboard chord preventive modification is installed at the same time.

d. Remove fasteners as required for modification.

e. Inspect for disbonding of the doublers from the skins of both the forward and aft skin panels using 737 NDT Manual Part 4, 51-40-00 Figure 1. Inspect the area that will be covered by the STA 727 frame outboard chord preventive modification strap. If disbonding is identified contact Boeing for repair data before further flight.

f. Evaluate the existing condition of the fastener holes in the STA 727 frame outboard chord at the intersection of the S-18A outboard chord as shown below.

(1) Measure the edge margin and inspect fastener holes for roundness at fastener locations in the STA 727 frame outboard chord forward flange common to the S-18A outboard chord as shown in Figure 22.

(2) Do an open hole HFEC inspection of the 4 fastener holes in the STA 727 frame outboard chord forward flange as shown in Figure 10 using a 0.020 notch standard.

NOTE:The use of 0.02 inch notch standards in the open hole inspection may give false crack indications if holes are not clean or round. The holes can be oversized for clean-up within the limitations of tables 1 and 2 provided the appropriate insurance cut and edge margins are obtained.

(3) Do an external ultrasonic inspection of the STA 727 frame outboard chord forward flange as shown in Figure 7.

(4) Groups 1 through 9, Configuration 4: From the wheel well, do a surface HFEC inspection of the STA 727 frame outboard chord forward flange as shown in Figure 9.

(5) Groups 1 through 9, Configuration 1: From the wheel well, do the eddy current inspections (LFEC and HFEC) of the STA 727 frame outboard chord forward flange as shown in Figure 8.

g. If cracks are found, repair before further flight as shown in PART 3 - STA 727 Frame Outboard Chord Repair or PART 4 - STA 727 Frame Outboard Chord Time-Limited Repair. If the repairs shown in PART 3 or PART 4 cannot be installed, contact Boeing for repair data. If a PART 3 or PART 4 repair is installed, inspections are still required. Refer to Paragraph 1.E., Compliance.

h. If no cracks are found, then determine if a permanent modification, interim modification or a frame replacement should be accomplished. If the Edge Margin after insurance cut is 1.7 or greater (Table 1), then install a permanent modification. If the Edge Margin after insurance cut is less than 1.7 but greater than or equal to 1.5 (Table 2), then install an interim modification. If the edge margin is less than 1.5 then replace the 727 frame chord.

NOTE:

1. If the interim modification is installed, then a one-time post modification inspection will be required in accordance with Paragraph 1.E. Compliance, Table 4.

2. The chord replacement as given in this service bulletin installs a chord with extra edge material on the forward flange at stringer 18A.

i. Install the applicable STA 727 frame outboard chord modification. Use drawing 65C37277 and the minimum fastener size required to meet the installation requirements specified in Table 1 or Table 2. Table 3 provides titanium fasteners and associated collars as equivalent to the steel fasteners provided in Table 1 or Table 2.

NOTE:

1. Make sure proper insurance cuts are taken as shown in Tables 1 and 2, after the HFEC hole probe inspection shows no crack indications.

2. Use repair washers as directed by drawing 65C37277 where existing countersink locations are covered by the modification strap.

Table 1: Permanent Modification (Edge Margin greater than 1.7D) (a) Starting Hole Minimum Hole Diameter Final Close Fastener Size (Nominal + Starting Edge Range for Hole Ream Hole Size Oversize) Margin Probe Inspection For Insurance (1.7D Final) (b) Cut 1/4 0.53 0.2495 - 0.2661 0.3120 - 0.3130 BACB30MB10A* + BACC30BH10 1/4 + 1/64 0.53 0.2651 - 0.2661 0.3120 - 0.3130 BACB30MB10A* + BACC30BH10 1/4 + 1/32 0.56 0.2807 - 0.2817 0.3276 - 0.3286 BACB30MC10A* + BACC30BH10

Table 1: Permanent Modification (Edge Margin greater than 1.7D) (a) Starting Hole Minimum Hole Diameter Final Close Fastener Size (Nominal + Starting Edge Range for Hole Ream Hole Size Oversize) Margin Probe Inspection For Insurance (1.7D Final) (b) Cut 1/4 + 3/64 0.58 0.2963 - 0.2973 0.3432 - 0.3442 BACB30MD10A* + BACC30AC10 5/16 0.61 0.312 - 0.313 0.3589 - 0.3599 BACB30ME10A* + BACC30U10 (a) Used on production or replaced STA 727 frame outboard chords. (b) 737 NDT Part 6, 51-00-00 Figure 16 with 0.020 notch standard.

Table 2: Interim Modification With Follow-on Inspections (Edge Margin greater than 1.5D but less than 1.7D) (a) Starting Hole Minimum Hole Diameter Final Close Fastener Size (Nominal + Starting Edge Range for Hole Ream Hole Size Oversize) Margin Probe Inspection For Insurance (1.5D Final) (b) Cut 1/4 0.47 0.2495 - 0.2661 0.3120 - 0.3130 BACB30MB10A* + BACC30BH10 1/4 + 1/64 0.47 0.2651 - 0.2661 0.3120 - 0.3130 BACB30MB10A* + BACC30BH10 1/4 + 1/32 0.49 0.2807 - 0.2817 0.3276 - 0.3286 BACB30MC10A* + BACC30BH10

1/4 + 3/64 0.52 0.2963 - 0.2973 0.3432 - 0.3442 BACB30MD10A* + BACC30AC10 5/16 0.54 0.312 - 0.313 0.3589 - 0.3599 BACB30ME10A* + BACC30U10 (a) Used on production or replaced STA 727 frame outboard chords. (b) 737 NDT Part 6, 51-00-00 Figure 16 with 0.020 notch standard.

Table 3: Titanium Equivalent Fasteners and Collars Steel Fasteners + Titanium Fasteners Collar + Collar BACB30MB*A* + BACB30NX*K* + BACC30BH* BACC30BH* BACB30MC*A* + BACB30NX*K*X + BACC30BH* BACC30BH* BACB30MD*A* + BACB30NX*K*Y + BACC30AC* BACC30AC*

NOTE:

1. Service Bulletin 737-53-1077 installs a repair patch at STA 727 and S-18A. If the repair patch is installed, then the 69-78773-10 filler is not needed. If necessary, install an additional filler forward of STA 727 to match the thickness of the repair patch. If necessary, also use a tapered filler forward of STA 727, same as the 69-78773-7 tapered filler, but with the thickness increased to match the repair patch. Keep the same taper ratio.

2. The preventive modification installs new structure to replace most of the STA 727 fairing support structure that was removed.

3. Close Access

a. Install the equipment that was removed for access.

b. Put the airplane back to a serviceable condition.

PART 7 - STRINGER 18A OUTBOARD CHORD PREVENTIVE MODIFICATION

1. Access

Group 1; Group 2; Group 3; Group 4; Group 5; Group 6; Group 9:

NOTE:

1. S-18A outboard chord preventive modification is not available for Groups 10 and 11, contact Boeing for repair data.

2. Boeing recommends that the PART 7 - S-18A outboard chord preventive modification be installed with the PART 6 - STA 727 frame outboard chord preventive modification.

3. Group 9: The PART 7 - S-18A outboard chord preventive modification only applies to one side of the airplane only where the S-18A Outboard Chord has a thickness of 0.33 inch at STA 727.

b. Remove the Wing-to-Body Fairings as necessary for access to the S-18A Outboard Chord as given in 737-100/200/300/400/500 AMM 53-51-21.

2. Preventive Modification

b. Group 1; Group 2: Do the S-18A outboard chord modification as specified in drawing 65C38491-1/-2.

NOTE:

1. The stringer S-18A preventive modification installs new structure to replace most of the STA 727 fairing support structure that was removed.

2. When performing the PART 7 - S-18A Outboard Chord Preventive Modification, it is recommended to keep expansion of the fastener holes common to the STA 727 frame outboard chord to a minimum when installing fasteners. Larger fastener hole diameters may impact future inspections and the accomplishment of PART 6 - STA 727 Frame Outboard Chord Preventive Modification.

c. Group 3; Group 4; Group 5; Group 6; Group 9: Do the S-18A outboard chord modification as specified in drawing 65C37277.

NOTE:

1. The stringer S-18A preventive modification installs new structure to replace most of the STA 727 fairing support structure that was removed.

3. Close Access

a. Install the equipment that was removed for access.

b. Put the airplane back to a serviceable condition.

PART 8 - ONE TIME INSPECTION OF THE STA 727 FRAME OUTBOARD CHORD INTERIM MODIFICATION

1. Access

2. STA 727 Frame Outboard Chord Inspection

a. Do the inspections that follow at the thresholds specified in paragraph 1.E., Compliance, Table 4.

b. At each fastener location with a frame chord edge margin greater than or equal to 1.5D and less than 1.7D do a one-time HFEC hole probe inspection of the STA 727 frame outboard chord as shown Figure 10.

c. Replace hex drive fasteners and collars with the same size and type. If necessary, use 1/64 inch oversize. Install hex drive fasteners in a close ream fit at these locations with steel parts. Install wet with BMS5-95.

NOTE:Do not exceed 3/8 fastener diameter. If final edge margin with replacement fasteners will be less than 1.5D, contact Boeing.

3. Close Access

a. Install and reconnect the equipment in the wheel well that was removed or disconnected for access.

b. Put the airplane back to a serviceable condition.

PART 9 - REPLACMENT OF THE TIME-LIMITED REPAIR

1. Access

NOTE:Boeing recommends that the PART 6 - STA 727 frame outboard chord preventive modification and PART 7 - S-18A outboard chord preventive modification be installed at the same time as the PART 3 - STA 727 frame outboard chord replacement. Operators may do the PART 6 - STA 727 frame outboard chord preventive modification and PART 7 - S-18A outboard chord preventive modification at a later time, however inspections may be required and increased installation costs will be incurred.

b. Remove the following equipment from the wheel well and cargo compartment as necessary for access to the STA 727 Frame Outboard Chord.

Equipment 737-100/-200 AMM Subject 737-300/-400/-500 AMM Subject Wing-to-Body Fairing 53-51-21 53-51-21 Fire Extinguisher Bottles 26-21-11 26-21-11 Cargo Liner 25-52-123 25-52-73

Equipment 737-100/-200 AMM Subject 737-300/-400/-500 AMM Subject Cargo Floor Panel 25-52-51 25-52-51 Cargo Bulkhead Panel 25-52-131 25-52-81 Auxiliary Fuel Tank (if installed) 53-23-1 53-23-11 Insulation Blankets 25-52-141 25-52-91 Flap Right Angle Gearbox 27-51-261 27-51-67

2. Removal of the Time Limited Repair

a. Remove the Time-Limited Repair as shown in Figure 19.

b. Make new parts for the shear beam repair as shown in the Figure 20.

c. Install PART 3 - STA 727 Frame Outboard Chord Repair using Figure 23 to remove and install a new S-18A shear beam web. Remove and replace the shear beam web aft section from approximately STA 711 to STA 727. Use the same size and type fasteners as removed. Install fasteners common to both the STA 727 frame outboard chord and the shear beam web at frame chord installation per instructions provided in Part 3.

(1) Groups 1 and 2, Configurations 1 and 4: Replace the shear beam web using the new part 65C38643-1/-2.

(2) Groups 3 through 9, Configurations 1 and 4: Replace the shear beam web using the new part 69-78347-1/-2.

(3) For Airplane Line Number 3, contact Boeing for repair instructions.

3. Close Access

a. Install the equipment that was removed for access.

b. Put the airplane back to a serviceable condition.

FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 2

NOTE: REVISION 2 REMOVED FIGURE 1

D39061

FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 2 June 30, 1994 (SHEET 1 OF 1) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 127 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 2: THIS FIGURE WAS DELETED AT REVISION 2

NOTE: REVISION 2 REMOVED FIGURE 2

D41118

FIGURE 2: THIS FIGURE WAS DELETED AT REVISION 2 June 30, 1994 (SHEET 1 OF 1) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 128 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 3: THIS FIGURE WAS DELETED AT REVISION 2

NOTE: REVISION 2 REMOVED FIGURE 3

D39063

FIGURE 3: THIS FIGURE WAS DELETED AT REVISION 2 June 30, 1994 (SHEET 1 OF 1) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 129 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 4: THIS FIGURE WAS DELETED AT REVISION 2

NOTE: REVISION 2 REMOVED FIGURE 4

J74437

FIGURE 4: THIS FIGURE WAS DELETED AT REVISION 2 June 30, 1994 (SHEET 1 OF 1) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 130 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 5: THIS FIGURE WAS DELETED AT REVISION 2

NOTE: REVISION 2 REMOVED FIGURE 5

D39065

FIGURE 5: THIS FIGURE WAS DELETED AT REVISION 2 June 30, 1994 (SHEET 1 OF 1) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 131 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 6: THIS FIGURE WAS DELETED AT REVISION 2

NOTE: REVISION 2 REMOVED FIGURE 6

D39067

FIGURE 6: THIS FIGURE WAS DELETED AT REVISION 2 June 30, 1994 (SHEET 1 OF 1) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 132 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 7: EXTERNAL ULTRASONIC INSPECTION OF THE STA 727 FRAME OUTBOARD CHORD FORWARD FLANGE - GROUPS 1 THROUGH 11, CONFIGURATIONS 1 AND 4.

SEE A

LEFT SIDE SHOWN RIGHT SIDE OPPOSITE (WING-TO-BODY FAIRING NOT SHOWN) D39072

FIGURE 7: EXTERNAL ULTRASONIC INSPECTION OF THE STA 727 FRAME OUTBOARD CHORD FORWARD FLANGE - GROUPS 1 THROUGH 11, CONFIGURATIONS 1 AND 4. June 30, 1994 (SHEET 1 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 133 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STRINGER 18A STA (ON MOST AIRPLANES 727 THE OUTER CHORD OF STRINGER 18A IS A FLAT STRAP)

SEE B

FORWARD STA AFT SKIN 727 SKIN

FWD

INBD TYPICAL CRACK A

FRAME FORWARD FLANGE

INSPECTION B AREA (STRINGER 18A AND FAIRING SUPPORT D40369 STRUCTURE NOT SHOWN FOR CLARITY) VIEW LOOKING INBOARD

FIGURE 7: EXTERNAL ULTRASONIC INSPECTION OF THE STA 727 FRAME OUTBOARD CHORD FORWARD FLANGE - GROUPS 1 THROUGH 11, CONFIGURATIONS 1 AND 4. June 30, 1994 (SHEET 2 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 134 of 198 BOEING SERVICE BULLETIN 737-53A1166 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 1 Inspect Frame Chord External Ultrasonic 737 NDT Part 4 (a) (b) For cracks Forward Flange Subject 53-10-01 (a) An External Inspection is done from outside the airplane in the wheel well area. (b) Cracks can also be found between fasteners.

FIGURE 7: EXTERNAL ULTRASONIC INSPECTION OF THE STA 727 FRAME OUTBOARD CHORD FORWARD FLANGE - GROUPS 1 THROUGH 11, CONFIGURATIONS 1 AND 4. June 30, 1994 (SHEET 3 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 135 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 8: EDDY CURRENT INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 1.

INSPECTION AREA

STA 727 STA 727 FRAME OUTBOARD CHORD FWD FLANGE STA 727 BULKHEAD FWD SKIN WEB PANEL

S-18A STA 727 FRAME OUTBOARD OUTBOARD CHORD CHORD SPLICE ANGLE

SHEAR BEAM

S-18A 1 STATION 727 FRAME OUTBOARD CHORD SPLICE STRAP. SEE A FOR POSSIBLE CRACK LOCATIONS AND EDGE INSPECTION DETAIL LOWER EDGE OF FWD SKIN PANEL INBD FWD D39253 VIEW FROM INSIDE THE WHEEL WELL (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR)

FIGURE 8: EDDY CURRENT INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 1. June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 136 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

INSPECTION STA AREA 727

STA 727 FRAME STA 727 FRAME OUTBOARD CHORD OUTBOARD CHORD SPLICE ANGLE

STA 727 FRAME 2 OUTBOARD CHORD SPLICE STRAP

TYPICAL CRACK IN STA 727 FRAME OUTBOARD CHORD

FWD

INBD D39254 A

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA 1 Inspect Frame Chord External Low (a) 737 NDT Part 6 (b) (c) For cracks Forward Flange Frequency Eddy Subject 53-30-00 Current (LFEC) Figure 5 2 Inspect Frame Chord External High 737 NDT Part 6 (b) For cracks Forward Flange Frequency Eddy Subject 51-00-00 Forward Edge Current (HFEC) Figure 4 or 23 (a) Use Reference Standard ANDT1053. (b) The Inspection is done from outside the airplane in the wheel well area. (c) Cracks can also be found between fasteners.

FIGURE 8: EDDY CURRENT INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 1. June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 137 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 9: SURFACE HFEC INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 4.

INSPECTION AREA

STA 727 STA 727 FRAME OUTBD CHORD FORWARD FLANGE STA 727 FRAME OUTBD CHORD UPRIGHT FLANGE

FORWARD STA 727 SKIN PANEL BULKHEAD WEB

S-18A OUTBD CHORD

1 SHEAR BEAM

S-18A

POSSIBLE CRACK LOCATION IN THE STA 727 FRAME OUTBD CHORD

LOWER EDGE OF FORWARD SKIN PANEL FWD

INBD D39258 VIEW FROM INSIDE THE WHEEL WELL (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR)

FIGURE 9: SURFACE HFEC INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 4. June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 138 of 198 BOEING SERVICE BULLETIN 737-53A1166 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 1 Inspect Frame Chord HFEC 737 NDT Part 6 (a) (b) For cracks Forward Flange Subject 51-00-00, Figure 4 or Figure 23 (a) An External Inspection is done from outside the airplane in the wheel well area. (b) Cracks can also be found between fasteners.

FIGURE 9: SURFACE HFEC INSPECTION - GROUPS 1 THROUGH 11, CONFIGURATION 4. June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 139 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 10: OPEN HOLE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE STA 727 OUTBOARD CHORD FORWARD FLANGE

SEE A

LEFT SIDE SHOWN RIGHT SIDE OPPOSITE (WING-TO-BODY FAIRING NOT SHOWN) D39073

FIGURE 10: OPEN HOLE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE STA 727 OUTBOARD CHORD FORWARD FLANGE June 30, 1994 (SHEET 1 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 140 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA STRINGER 18A 727 (ON MOST AIRPLANES THE OUTER CHORD OF STRINGER 18A IS SEE B A FLAT STRAP)

STA 727 FWD SKIN AFT SKIN

FWD 1 2 3 INBD A

TYPICAL CRACK

1 2 3

UP FRAME FWD FLANGE FWD

B D40617 (STRINGER 18A AND FAIRING SUPPORT STRUCTURE NOT SHOWN FOR CLARITY)

FIGURE 10: OPEN HOLE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE STA 727 OUTBOARD CHORD FORWARD FLANGE June 30, 1994 (SHEET 2 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 141 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION: MAKE SURE THE FASTENER HOLES ARE ROUND BEFORE PERFORMING THE HFEC OPEN HOLE INSPECTIONS. LOOSE FASTENERS MAY INDICATE HOLES THAT ARE NOT ROUND. MINIMIZE THE AMOUNT OF FASTENER HOLE REAMING USED TO CLEAN-UP HOLES FOR HFEC OPEN HOLES INSPECTIONS. LARGER FASTENER HOLES MAY IMPACT FUTURE INSPECTIONS AND THE ACCOMPLISHMENT OF PART 6 - STA 727 FRAME OUTBOARD CHORD PREVENTIVE MODIFICATION. 1 Remove Fastener - 4 2 Inspect Fastener Holes HFEC 4 (a) (b) For cracks as given in 737 NDT Part 6 Subject 51-00-00 Figure 16 3 Install Bolt - 4 (c) (d) (e) See Fastener Collar - 4 Table 1 or 2. (a) Use a 0.030 notch standard for inspection and repeat inspection program (b) Use a 0.020 notch standard for modification inspection requirements (c) Only necessary if no cracks are found and the PART 6 - STA 727 frame outboard chord preventive modification is not done before further flight. (d) Grip length to be determined on installation. (e) Use the replacement fasteners identified in Table 1 or Table 2. Select the correct fastener diameter that provides the smallest diameter required for a transition fit for all aluminum parts or a close ream fit for stack-ups that contain steel parts. Select the grip length that matches the removed fastener. Install

wet using BMS5-95. Do not exceed 5/16 diameter

Table 1: Stainless Steel Replacement Fasteners Bolt Collar Nominal BACB30MB*A* BACC30BH* 1/64 OverSize BACB30MC*A* BACC30BH* 1/32 OverSize BACB30MD*A* BACC30AC* 3/64 OverSize BACB30ME*A* BACC30U*

Table 2: Alternate - Titanium Replacement Fasteners Bolt Collar Nominal BACB30NX*K* BACC30BH* 1/64 OverSize BACB30NX*K*X BACC30BH* 1/32 OverSize BACB30NX*K*Y BACC30AC* 3/64 OverSize - -

FIGURE 10: OPEN HOLE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE STA 727 OUTBOARD CHORD FORWARD FLANGE June 30, 1994 (SHEET 3 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 142 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 11: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 3.

STA 540 INSPECTION STA AREA 727 STA 727

SEE A AUXILIARY CHORD S-17 STA 727 S-18

S-19

S-20

SKIN LAP S-21

SPLICE S-22 1 2

S-23 FRAME AFT SKIN CHORD S-24

S-25

S-26 AUXILIARY SKIN CHORD BULKHEAD S-27 WEB BL 0 FWD

TYPICAL VIEW FROM INSIDE REAR CARGO BAY CRACK (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR) D39431 A

FIGURE 11: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 3. June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 143 of 198 BOEING SERVICE BULLETIN 737-53A1166 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 1 Inspect Auxiliary Chord Detailed -For cracks Radius Inspection 2 Inspect Auxiliary Chord High Frequency 737 NDT Part 6 (a) For cracks Radius Eddy Current Subject 51-00-00 (HFEC) Figure 23 (a) 737 NDT Part 6 Subject 51-00-00 Figure 4 is an alternative procedure

FIGURE 11: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 3. June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 144 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 12: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 4.

STA 540 INSPECTION STA AREA 727 STA 727

SEE A AUXILIARY CHORD

S-17 STA 727 S-18

S-19

S-20 SKIN LAP SPLICE S-21

1 2 S-22

S-23

S-24 FRAME AFT SKIN CHORD S-25

S-26 SKIN S-27 AUXILIARY BL 0 CHORD BULKHEAD FWD WEB VIEW FROM INSIDE REAR CARGO BAY (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR) TYPICAL CRACK J23072 A

FIGURE 12: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 4. June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 145 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

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

FIGURE 12: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 4. June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 146 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 13: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUP 1

SEE A

LEFT SIDE SHOWN RIGHT SIDE OPPOSITE (WING-TO-BODY FAIRING NOT SHOWN) D39074

FIGURE 13: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUP 1 June 30, 1994 (SHEET 1 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 147 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727

STRINGER 18A

SEE B

STA 727 FWD FWD SKIN AFT SKIN

FAIRING STRINGER INBD SUPPORT 18A STRUCTURE A

1 2 TYPICAL CRACK

INSPECTION D40618 AREA B

FIGURE 13: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUP 1 June 30, 1994 (SHEET 2 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 148 of 198 BOEING SERVICE BULLETIN 737-53A1166 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 1 Inspect Stringer Chord Detailed -For cracks Inspection 2 Inspect Stringer Chord HFEC 737 NDT Part 6 (a) For cracks Subject 51-00-00 Figure 23 (a) 737 NDT Part 6 Subject 51-00-00 Figure 4 is an alternative procedure

FIGURE 13: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUP 1 June 30, 1994 (SHEET 3 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 149 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 14: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUPS 2, 3, 4, 5, 6, 9 AND 10

SEE A

LEFT SIDE SHOWN RIGHT SIDE OPPOSITE (WING-TO-BODY FAIRING NOT SHOWN) D39075

FIGURE 14: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUPS 2, 3, 4, 5, 6, 9 AND 10 June 30, 1994 (SHEET 1 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 150 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727

STRINGER 18A

SEE B

STA 727 FWD FWD SKIN AFT SKIN

FAIRING INBD STRINGER 18A SUPPORT STRUCTURE A

TYPICAL CRACK

1 2

INSPECTION AREA UP D41124

FWD B

FIGURE 14: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUPS 2, 3, 4, 5, 6, 9 AND 10 June 30, 1994 (SHEET 2 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 151 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

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

FIGURE 14: EXTERNAL DETAILED INSPECTION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S-18A OUTBOARD CHORD - GROUPS 2, 3, 4, 5, 6, 9 AND 10 June 30, 1994 (SHEET 3 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 152 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR

BL 0 STA 727

S-17 BL 0 SEE A

S-18A S-20

S-18A SHEAR

BEAM

S-22

S-23 FLAP TRACK SUPPORT FITTING S-24

S-25

S-26

S-27 INBD FWD D39440 END OF CHORD STA 727 - BULKHEAD (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR)

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR June 30, 1994 (SHEET 1 OF 7) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 153 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727 FRAME OUTBOARD CHORD STA 727 BULKHEAD WEB

FORWARD SKIN

B 2 CLEARANCE MEASUREMENT 2 WL 190 S-18A

A A S-18A B OUTBOARD CHORD

S-18A SHEAR 5 BEAM

S-20

INBD

VIEW LOOKING AFT D39444 AFT SKIN NOT SHOWN (LEFT SIDE SHOWN RIGHT SIDE SIMILAR)

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR June 30, 1994 (SHEET 2 OF 7) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 154 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

AFT SKIN AUXILIARY CHORD

FRAME OUTBOARD CHORD C BULKHEAD 8 9 WEB CLEARANCE 3 MEASUREMENT STA 727

HORIZONTAL STIFFENER C 10 TAPERED FILLER

FWD END OF JOGGLE

FWD SKIN

ANGLE ONLY ON SOME 4 AIRPLANES SHEAR 7 9 BEAM WEB INBD

TRIMMED D39455 FWD AREA A-A

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR June 30, 1994 (SHEET 3 OF 7) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 155 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727

CLEARANCE 1 MEASUREMENT

AUXILIARY CHORD 1 (6 LOCATIONS)

S-18A

SHEAR BEAM

TYPICAL CRACK

AND STOP DRILL

7 9 UP HORIZONTAL STIFFENER FWD FRAME OUTBOARD CHORD

HORIZONTAL STIFFENER AND D40213 BULKHEAD WEB SHEAR BEAM SHOWN IN TRIMMED B-B CONFIGURATION

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR June 30, 1994 (SHEET 4 OF 7) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 156 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727 AUXILIARY CHORD S-18A

CLEARANCE MEASUREMENT SHEAR BEAM

CLEARANCE MEASUREMENT 3 4

HORIZONTAL FRAME OUTBOARD STIFFENER FWD

CHORD

HORIZONTAL STIFFENER AND SHEAR BEAM SHOWN BEFORE TRIM C-C BULKHEAD WEB J66908

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR June 30, 1994 (SHEET 5 OF 7) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 157 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA Inspect Fastener Hole - - (a) (e) 1 Distance Inspect Fastener Hole - - (a) (f) 2 Distance Inspect Fastener Hole - - (a) (g) 3 Distance 4 Inspect Edge Margin - - (a) (h) Remove/ Te e 65-48 692 -( ) 1 Remo ve an d ke ep sh im s 5 Keep if installed. Remove/ Bracket 69-39 436 -( ) 1 Left Side. Remo ve and Keep keep shims if installed. 6 69-39 437 -( ) 1 Righ t Side . Rem ove and keep shims if installed. Cut Shear Beam Web - - (b) (c) Trim the aft part of the outboard vertical side to allow for the installation of the frame 7 chord repair angle. Trim the forward end of the joggle. Remove attaching fasteners.

Cut Horizontal - - (b) (c) Trim the outboard Stiffener part of the vertical leg to allow for the installation 8 of the frame chord repair angle. Remove attaching fasteners. Apply Chemical Type 2, Class A - (d) As given in SOPM Conversion 20-43-03. 9 Coating Primer BMS 10-11, Type 1 - (d) 2 coats as given in SOPM 20-41-02. 10 Remove Tapered Filler 65-46877-( ) 1 (a) If the Time-Limited repair cannot be accomplished, replace the chord as shown in PART 3 - STA 727 Frame Outboard Chord Repair. (b) Maintain a 1.7D minimum edge margin and a 0.375 minimum radius. (c) Protect the remaining structure during trimming. (d) To all trimmed edges. (e) Make sure the replacement fastener collars can clear the radius of the nested frame chord repair angle. Fastener centerline to bulkhead web distance must be more than 0.58 inches to provide collar clearance.

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR June 30, 1994 (SHEET 6 OF 7) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 158 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STEP TASK NAME IDENTIFICATION QTY MORE DATA (f) Make sure replacement fastener collars can clear the nested shear beam repair angle. Fastener centerline to shear beam web distance must be more than 0.36 inches to provide collar clearance. (g) Make sure replacement fastener collars can clear the repair strap. Fastener centerline to horizontal stiffener distance must be more than 0.39 inches to provide collar clearance. (h) The horizontal stiffener repair strap may reduce the available edge margin for the shear beam repair angle. Fastener centerline to the horizontal stiffener distance must be a minimum 0.43 inches to provide sufficient edge margin for installation of 1/4 inch diameter fastener into the shear beam repair angle. This distance must be a minimum 0.45 inches for a 1/4+1/64 oversize fastener. This distance must be a minimum 0.46 inches for a 1/4 + 1/32 oversize fastener.

FIGURE 15: PREPARATION FOR THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR June 30, 1994 (SHEET 7 OF 7) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 159 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 16: TIME-LIMITED REPAIR - SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION FOR CRACK TIP LOCATION

BL 0 STA 727

S-17 BL 0 SEE A

S-18A

S-20 S-18A

SHEAR BEAM

S-22

S-23 FLAP TRACK SUPPORT FITTING S-24

S-25

S-26

S-27 INBD FWD D39443 END OF CHORD STA 727 - BULKHEAD (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR)

FIGURE 16: TIME-LIMITED REPAIR - SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPEC- TION FOR CRACK TIP LOCATION June 30, 1994 (SHEET 1 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 160 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727 FRAME OUTBOARD CHORD STA 727 BULKHEAD WEB

FORWARD SKIN

WL 190 S-18A

S-18A A OUTBOARD CHORD

S-18A SHEAR BEAM

S-20

INBD

VIEW LOOKING AFT

AFT SKIN NOT SHOWN D40214 (LEFT SIDE SHOWN RIGHT SIDE SIMILAR)

FIGURE 16: TIME-LIMITED REPAIR - SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPEC- TION FOR CRACK TIP LOCATION June 30, 1994 (SHEET 2 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 161 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727

MAXIMUM CRACK LENGTH AUXILIARY 1 CHORD S-18A

SHEAR BEAM

TYPICAL CRACK

UP FRAME OUTBOARD CHORD FWD D40215 BULKHEAD WEB A-A

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. REPAIR INSPECTION STEP TASK NAME PROCEDURE REFERENCES MORE DATA 1 Inspect Frame Chord HFEC 737 NDT Part 6 (a) Identify the Forward Flange Subject 51-00-00 location of the crack Figure 23 tip. (a) 737 NDT Part 6 Subject 51-00-00 Figure 4 is an alternative procedure.

FIGURE 16: TIME-LIMITED REPAIR - SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPEC- TION FOR CRACK TIP LOCATION June 30, 1994 (SHEET 3 OF 3) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 162 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 17: MAKE THE TIME-LIMITED REPAIR PARTS

1 10 1 10

A A-A D40216

FIGURE 17: MAKE THE TIME-LIMITED REPAIR PARTS June 30, 1994 (SHEET 1 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 163 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

4.25 6.0

1.25 1.25

2 10 3 10

8.2 1.2

1.4 1.4

5 10 4 10

6 10

AREA OF EXTENDED FLANGE, IF REQUIRED 8.2

6 10

6 10 D39079

FIGURE 17: MAKE THE TIME-LIMITED REPAIR PARTS June 30, 1994 (SHEET 2 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 164 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

11.4

2.1

7 10 8.7

1.2

8 10 6.9 9 10 1.6 1.9

0.09

0.01 J77517

0.01

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME MATERIAL QTY MORE DATA 1MakeFrame Repair AND10134-2008 or equivalent 1(a) (k) Angle x 20.8 inches. 7075-T0 Cut Frame Repair -1(p) Angle Bend Frame Repair - 1 To match frame. Angle Heat Frame Repair - 1 Heat Treat to T6 condition. Treat Angle 2 Make Shim A 7075-T6 clad sheet 1 (a) (b) (j) 0.032 inch thick. 3 Make Repair Strap 7075-T6 clad sheet 1 (a) (j) 0.18 inch thick. 4 Make Filler A 7075-T6 clad sheet 1 (a) (c) 0.14 inch thick. 5 Make Filler B 7075-T6 clad sheet 1 (a) (d) 0.202 inch thick, tolerance +/- 0.01inches. 6 Make Shear Beam 4.25 X 8.2 inches 1 (a) (f) (g) (n) (q) 0.15 inch thick. Repair Angle 7075-T0 clad sheet Bend Vertical Flange - 1 (e) (h) Heat Shear Beam - 1 Heat Treat to T6 condition. Treat Repair Angle 7 Make Shim B 7075-T6 clad sheet 1 (a) (l) 0.18 inch thick

FIGURE 17: MAKE THE TIME-LIMITED REPAIR PARTS June 30, 1994 (SHEET 3 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 165 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STEP TASK NAME MATERIAL QTY MORE DATA 8 Make Shim C 7075-T6 clad sheet 1 (a) (m) 0.18 inch thick 9 Make Filler (Tapered) 7075-T6 clad sheet 1 (a) (o) (r) 0.09 inch thick. 10 Apply Chemical Type 2, Class A - (i) As given in SOPM 20-43-03. Conversion Coating Primer BMS 10-11, Type 1 - (i) 2 coats as given in SOPM 20-41-02. (a) Break sharp edges and remove burrs. (b) Airplanes where the Bulkhead Attachment Angle at WL 190 is 0.125 inch thick, make shim from 7075-T6 clad sheet, 0.063 inch thick. (c) Airplanes where the S-18A Shear Beam flange is 0.125 inch thick, make the Filler from 7075-T6 clad sheet, 0.125 inch thick. (d) Airplanes where the S-18A Shear Beam flange is 0.125 inch thick, make the shim from 7075-T6 clad sheet, 0.217 inch thick, tolerance +/- 0.01inches. (e) Refer to 737-100/200 SRM 51-20-1 or 737-300/400/500 SRM 51-30-01. Minimum bend radius of 0.44. (f) If required, extend the vertical flange aft, as illustrated on sheet 2 of this figure, to obtain a minimum fastener hole edge margin of 1.7D (g) If required, chamfer the vertical flange aft edge to 0.10 x 45 degrees to nest in the radius of the Step 1 frame repair angle. (h) Bend the vertical flange to fit with the Step 5 Filler B and Step 1 Frame Repair Angle on installation. (i) All fabricated parts. (j) These detailed parts have been sized to attach with five fasteners. Interference may occur with the most inboard fastener position. If required, these parts can be trimmed and installed using four fasteners. (k) If required, the inboard edge of the repair angle can be trimmed to prevent interference with fasteners common to the bulkhead inboard of the STA 727 frame chord. Maintain a minimum fastener hole edge margin of 1.7D. (l) Dimensions shown are typical. Use the Tee removed in Step 5 of Figure 15 as a template for the correct size and shape. (m) Dimensions shown are typical. Use the Bracket removed in Step 6 of Figure 15 as a template for the correct size and shape. (n) To provide the operator with additional edge margin in the horizontal flange and to maintain fastener spacing, the repair angle is fabricated 0.25 inch oversize. Trim a maximum of 0.25 inch locally as required. Maintain a minimum fastener hole edge margin of 1.7D. (o) Size the filler and the taper to fit in the gap between the shear beam and the shear beam repair angle.

FIGURE 17: MAKE THE TIME-LIMITED REPAIR PARTS June 30, 1994 (SHEET 4 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 166 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STEP TASK NAME MATERIAL QTY MORE DATA (p) Use the airplane to correctly size and trim the frame repair angle. Trim the upper end of the frame repair angle to install just below S-18. Provide a minimum 1.5D edge margin in the frame repair angle for the first row of fasteners below S-18 common to the skin. Trim the lower end of the frame repair angle providing a minimum 1.5D edge margin for the second fastener row below S-20 common to the frame inboard flange. Trim away the forward leg of the frame repair angle to match the STA 727 frame outboard chord trim. (q) For airplanes with angles installed in production in the center of the shear beam web, trim the inboard edge of the horizontal flange of the shear beam repair to accommodate the production angle. Maintain a 1.5D minimum edge margin. (r) For airplanes with angles installed in production in the center of the shear beam web, trim the inboard edge of the filler to accommodate the production angle. Maintain a 1.5D minimum edge margin. For airplanes without the angle installed in production, the filler shall be 1.9 inches wide.

FIGURE 17: MAKE THE TIME-LIMITED REPAIR PARTS June 30, 1994 (SHEET 5 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 167 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR

BL 0 STA 727

S-17 BL 0 SEE A

S-18A S-20 S-18A SHEAR

BEAM

S-22

S-23 FLAP TRACK SUPPORT FITTING S-24

S-25

S-26

S-27 INBD FWD D39441 END OF CHORD STA 727 - BULKHEAD (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR)

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 1 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 168 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FRAME OUTBOARD CHORD

B S-18 FRAME CHORD REPAIR ANGLE FORWARD 1 2 3 4 5 SKIN

SHEAR BEAM REPAIR ANGLE S-18A REPAIR STRAP 1 2 3 OUTBOARD 1 2 3 4 6 7 4 10 CHORD

WL 190 S-18A A A

TEE

12 13 14 15 16 17 18

BRACKET 12 13 14 15 16 17 19 S-20

B BULKHEAD WEB INBD

A REFERENCE FASTENER REMOVED EXISTING VIEW LOOKING AFT FASTENER AFT SKIN NOT SHOWN D40217 (LEFT SIDE SHOWN RIGHT SIDE SIMILAR)

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 2 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 169 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

AUXILIARY CHORD FRAME OUTBOARD CHORD AFT SKIN SHIM A 1 2 3 4 6 BULKHEAD WEB

STA 727 FRAME CHORD REPAIR ANGLE 1 2 3 4 5 REPAIR STRAP 1 2 3 4 7 1 2 3 4 8 FILLER A

ANGLE ONLY ON SOME AIRPLANES FWD SKIN

SHEAR BEAM WEB

FILLER B 1 2 3 4 10 1 2 3 4 9 SHEAR BEAM REPAIR ANGLE SHEAR BEAM OUTBOARD FLANGE

REMOVED EXISTING INBD FASTENER

NEW FASTENER FWD D40219 A-A

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 3 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 170 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

OUTBOARD BULKHEAD CHORD STA WEB 727

S-18

FWD SKIN

FRAME CHORD AUXILIARY REPAIR ANGLE CHORD 1 2 3 4 5

SHEAR BEAM FILLER A REPAIR ANGLE 1 2 3 4 9 1 2 3 4 8 1 2 3 4 10 FILLER B S-18A

S-19

SHEAR BEAM

1 2 3 4 11 FILLER (TAPERED)

S-20

REFERENCE FASTENER REMOVED EXISTING FASTENER FWD NEW FASTENER D40226 B-B VIEW LOOKING OUTBOARD

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 4 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 171 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for a one side of the airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION: WHEN PERFORMING THE REPLACEMENT OF THE STA 727 FRAME OUTBOARD CHORD TIME-LIMITED REPAIR IT IS DESIRABLE TO MINIMIZE THE GROWTH OF THE FASTENER HOLE DIAMETERS WHEN INSTALLING FASTENERS. LARGER FASTENER HOLES MAY IMPACT FUTURE INSPECTIONS AND THE ACCOMPLISHMENT OF PART 6 - STA 727 FRAME OUTBOARD CHORD PREVENTIVE MODIFICATION Align Frame Chord -1 Repair Angle Shim Shim A 1 Repair Strap - 1 1 Filler Filler A 1 Filler Filler B 1 Shear Beam -1 Repair Angle Filler Filler (Tapered) 1 Drill Frame Chord - 1 (a) (b) (j) Repair Angle Shim Shim A 1 Repair Strap - 1 2 Filler Filler A 1

Filler Filler B 1 Shear Beam -1 Repair Angle Filler Filler (Tapered) 1 Remove Frame Chord -1 Repair Angle Shim Shim A 1 Repair Strap - 1 3 Filler Filler A 1 Filler Filler B 1 Shear Beam -1 Repair Angle Filler Filler (Tapered) 1

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 5 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 172 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STEP TASK NAME IDENTIFICATION QTY MORE DATA Deburr Frame Chord -1 Repair Angle Shim Shim A 1 Repair Strap - 1 4 Filler Filler A 1 Filler Filler B 1 Shear Beam -1 Repair Angle Filler Filler (Tapered) 1 Install Frame Chord - 1 (c) (d) (e) (f) (g) (h) (k) 5 Repair Angle 6 Install Shim Shim A 1 (c) (d) (e) (f) (h) (k) 7 Install Repair Strap - 1 (c) (d) (e) (f) (h) (k) 8 Install Filler Filler A 1 (c) (d) (e) (f) (h) (k) 9 Install Filler Filler B 1 (c) (d) (e) (f) (h) (k) Install Shear Beam - 1 (c) (d) (e) (f) (g) (h) (k) 10 Repair Angle 11 Install Filler Filler (Tapered) 1 (c) (d) (e) (f) (h) (k) Cut Shim Shim B 1 (i) 12 Shim Shim C 1 (i) Apply Chemical Type 2, Class A - To the bare edges as Conversion given in SOPM 20-43-03. 13 Coating Primer BMS 10-11, Type 1 - 2 coats as given in SOPM 20-41-02. Align (New) Shim B - 1 Shim C - 1 14 Align (Kept) Tee 65-48692-( ) 1 Bracket 69-39436-( ) 1 Left Side. 69-39437-( ) 1 Right Side. Drill Shim B - 1 Shim C - 1 15 Tee 65-48692-( ) 1 Bracket 69-39436-( ) 1 Left Side. 69-39437-( ) 1 Right Side. Remove Shim B - 1 Shim C - 1 16 Tee 65-48692-( ) 1 Bracket 69-39436-( ) 1 Left Side. 69-39437-( ) 1 Right Side.

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 6 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 173 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STEP TASK NAME IDENTIFICATION QTY MORE DATA Deburr Shim B - 1 Shim C - 1 17 Tee 65-48692-( ) 1 Bracket 69-39436-( ) 1 Left Side. 69-39437-( ) 1 Right Side. Install Shim Shim B 1 (c) (d) (e) (f) (h) (k) 18 Install (Kept) Tee 65-48692-( ) 1 (l) (m) Removed in Step 5 of Figure 15. Install Shim Shim C 1 (c) (d) (e) (f) (h) (k) Install (Kept) Bracket 69-39436-( ) 1 (l) (m) Left Side. Removed in Step 6 of 19 Figure 15. 69-39437-( ) 1 (l) (m) Right Side. Removed in Step 6 of Figure 15. (a) Drill fastener holes matching the existing fastener hole nominal size, within a close ream tolerance. If necessary holes may be oversized by up to 3/64th, but should not exceed 0.2973 (1/4 + 3/64 oversize). (b) Maintain a 1.7D minimum edge margin. (c) Shim all gaps greater than 0.01 before fastener installation. (d) Install wet with sealant (Ref. BMS 5-95). (e) Replace protruding head hex drive or lock bolt fasteners in transition fit holes with the same size as

removed. If necessary use up to 1/32 oversize. See Fastener Installation Table for replacement fastener and collar types. (f) Replace 100 degree countersunk hex drive or lock bolt fasteners in transition fit holes with the same size as removed. If necessary use up to 1/32 oversize. See Fastener Installation Table for replacement fastener and collar types. (g) For new fastener locations, install BACB30MB8A( ) and BACC30BH8 fasteners and collars. (h) Install hex drive fasteners and bolts wet with sealant (Ref. BMS 5-95). (i) Cut the outboard end of the shim so it will be flush with the frame chord repair angle. (j) Adjust fastener pattern common to the Shear Beam horizontal web to adapt to existing fastener pattern. Maintain 1.7D minimum edge margin. For new fastener locations, maintain 3D to 6D fastener spacing, staggered fastener pattern is acceptable. Use the same quantity of fasteners as indicated. (k) Replace rivets with the same size and type. (l) Common to the STA 727 frame outboard chord, replace hexdrive, lock bolts and bolts with the same type and smallest size to maintain a transition fit hole. Do not exceed 5/16 inch diameter for these fasteners. (m) Common to the STA 727 frame outboard chord, replace rivets with the same type and size rivets. Do not exceed 6/32 inch diameter rivet for replacement of a production 5/32 inch diameter rivet. Do not exceed 1/4 inch diameter rivet for replacement of a production 6/32 inch diameter rivet.

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 7 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 174 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

Fastener Installation Table Removed Existing New Fastener and Collar Fastener Existing Size 1/64 Oversize 1/32 Oversize Protruding Head BACB30MB( )A( ) BACB30MC( )A( ) BACB30MD( )A( ) + + + BACC30BH( ) BACC30BH( ) BACC30AC( ) Countersunk BACB30FN( )A( ) BACB30FQ( )A( ) BACB30KF( )A( ) + + + BACC30M( ) BACC30M( ) BACC30R( ) None BACB30MB8A( ) -- (New Fastener) + BACC30BH8

FIGURE 18: INSTALL THE TIME-LIMITED REPAIR June 30, 1994 (SHEET 8 OF 8) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 175 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 19: TIME-LIMITED REPAIR - REMOVAL

BL 0 STA 727

S-17 BL 0 SEE A

S-18A

S-20 S-18A SHEAR

BEAM

S-22

S-23 FLAP TRACK SUPPORT FITTING S-24

S-25

S-26

S-27 INBD FWD D40866 END OF CHORD STA 727 - BULKHEAD (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR)

FIGURE 19: TIME-LIMITED REPAIR - REMOVAL June 30, 1994 (SHEET 1 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 176 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FRAME OUTBOARD CHORD

FORWARD 8 SKIN

S-18A OUTBOARD 5 3 CHORD

4 WL 190 S-18A A A

2 S-20

B INBD BULKHEAD WEB

A VIEW LOOKING AFT

AFT SKIN NOT SHOWN D40867 (LEFT SIDE SHOWN RIGHT SIDE SIMILAR)

FIGURE 19: TIME-LIMITED REPAIR - REMOVAL June 30, 1994 (SHEET 2 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 177 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FRAME AUXILIARY CHORD OUTBOARD CHORD AFT SKIN

3 BULKHEAD WEB 4

STA 727

REPAIR STRAP 7 1 2 3 4 7

ANGLE ONLY ON SOME AIRPLANES FWD SKIN

SHEAR BEAM WEB

5 6

SHEAR BEAM OUTBOARD FLANGE

INBD

FWD D40868 A-A

FIGURE 19: TIME-LIMITED REPAIR - REMOVAL June 30, 1994 (SHEET 3 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 178 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

OUTBOARD BULKHEAD CHORD STA WEB 727

S-18

FWD SKIN

AUXILIARY CHORD 8

6 5 7 S-18A

S-19

SHEAR BEAM 9

S-20

FWD D40869 B-B VIEW LOOKING OUTBOARD

FIGURE 19: TIME-LIMITED REPAIR - REMOVAL June 30, 1994 (SHEET 4 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 179 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA Remove/Keep Tee 65-48692-( ) 1 1 Remove Shim Shim B 1 Remove/Keep Bracket 69-39436-( ) 1 Left Side. 2 69-39437-( ) 1 Right Side. Remove Shim Shim C 1 3 Remove/Keep Repair Strap - 1 4 Remove Shim Shim A 1 Remove Shear Beam -1 5 Repair Angle 6 Remove Filler Filler B 1 7 Remove Filler Filler A 1 Remove Frame Chord -1 8 Repair Angle 9 Remove Filler Filler (Tapered) 1

FIGURE 19: TIME-LIMITED REPAIR - REMOVAL June 30, 1994 (SHEET 5 OF 5) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 180 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 20: MAKE THE REPLACEMENT PARTS TO REPLACE THE TIME-LIMITED REPAIR WITH A NEW FRAME CHORD

1.5

1.75 1 3

0.02

0.15 2 3

1.0

0.85 D40872

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

Note: Make the repair parts as shown in the table that follows. The dimensions provided are target values, use existing parts as guides to make sure correct fit and a minimum fastener hole edge margin of 1.7D is obtained.

STEP TASK NAME MATERIAL QTY MORE DATA 1 Make Filler A 7075-T6 clad sheet. 1 (a) (b) Thickness to match existing WL 190 Horizontal Stiffener. Target thickness is 0.156 or 0.125 inches. 2 Make Filler B 7075-T6 bare. 1 (a) (c) 3 Apply Chemical Type 2, Class A - (d) As given in SOPM Conversion 20-43-03. Coating Primer BMS 10-11, Type 1 - (d) 2 coats as given in SOPM 20-41-02. (a) Break sharp edges and remove burrs.

FIGURE 20: MAKE THE REPLACEMENT PARTS TO REPLACE THE TIME-LIMITED REPAIR WITH A NEW FRAME CHORD June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 181 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STEP TASK NAME MATERIAL QTY MORE DATA (b) Trim the outboard end to match the contour of the frame. (c) Measure the length of the shear beam joggle gap. Size the length of the constant thickness section of the filler to fill the joggle gap. (d) All fabricated parts.

FIGURE 20: MAKE THE REPLACEMENT PARTS TO REPLACE THE TIME-LIMITED REPAIR WITH A NEW FRAME CHORD June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 182 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 21: STRINGER S-18A OUTBOARD CHORD AFT FASTENERS - INSPECTION - GROUP 1, 2, 3, 4, 5, 6 AND 9

STA STA STA 727 709 716 STA 747 (737-100) S-17 727A (737-200/300/400/500)

S-18

S-18A SEE A

S-19

S-20

LEFT SIDE SHOWN D41498 RIGHT SIDE OPPOSITE (WING-TO-BODY FAIRING NOT SHOWN)

FIGURE 21: STRINGER S-18A OUTBOARD CHORD AFT FASTENERS - INSPECTION - GROUP 1, 2, 3, 4, 5, 6 AND 9 June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 183 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA SKIN ASSEMBLY 727 STA S-18A 747 OUTBOARD (737-100) CHORD STA 727A (737-200/300/400/500)

S-19

1 TYPICAL FASTENER PATTERN SHOWN UP

FWD A D40231 FAIRING SUPPORT STRUCTURE NOT SHOWN FOR CLARITY

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

STEP TASK NAME PROCEDURE REFERENCES MORE DATA 1 Inspect Fasteners General Visual -(a) Inspection (a) Record the quantity of fasteners in the S-18A outboard chord aft of the STA 727 frame.

FIGURE 21: STRINGER S-18A OUTBOARD CHORD AFT FASTENERS - INSPECTION - GROUP 1, 2, 3, 4, 5, 6 AND 9 June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 184 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 22: STA 727 OUTBOARD CHORD FORWARD FLANGE AT STRINGER 18A - EVALUATION

STA 727

BULKHEAD SKIN

WL 190 S-18A

INBD S-20

AFT SKIN NOT SHOWN D39442 LEFT SIDE SHOWN RIGHT SIDE SIMILAR

FIGURE 22: STA 727 OUTBOARD CHORD FORWARD FLANGE AT STRINGER 18A - EVALUATION June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 185 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STA 727 BULKHEAD WEB

FRAME CHORD FORWARD EDGE 2 1 EDGE MARGIN

S-18A AUXILIARY CHORD 1

FWD D39837

A-A

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Measure Edge Margin - 2 (a) 2 Inspect Fastener Holes - 4 (b) (a) Measure the distance from the center of the fastener hole to the forward edge of the STA 727 frame outboard chord. (b) Make sure the fastener holes are round.

FIGURE 22: STA 727 OUTBOARD CHORD FORWARD FLANGE AT STRINGER 18A - EVALUATION June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 186 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 23: INSTALL THE SHEAR BEAM REPAIR

BL 0 STA 727

S-17 BL 0 SEE A

S-18A

S-20 S-18A SHEAR

BEAM

S-22

S-23 FLAP TRACK SUPPORT FITTING S-24

S-25

S-26

S-27 INBD FWD D40884 END OF CHORD STA 727 - BULKHEAD (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR)

FIGURE 23: INSTALL THE SHEAR BEAM REPAIR June 30, 1994 (SHEET 1 OF 6) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 187 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FRAME OUTBOARD CHORD

FORWARD SKIN

S-18A OUTBOARD 1 2 3 4 5 6 7 CHORD REPAIR STRAP AND FILLER A WL 190 S-18A A A

10 9

S-20 B

INBD BULKHEAD WEB

REFERENCE FASTENER A REMOVED EXISTING FASTENER VIEW LOOKING AFT

AFT SKIN NOT SHOWN D40878 (LEFT SIDE SHOWN RIGHT SIDE SIMILAR)

FIGURE 23: INSTALL THE SHEAR BEAM REPAIR June 30, 1994 (SHEET 2 OF 6) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 188 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

AUXILIARY CHORD

FRAME OUTBOARD CHORD AFT SKIN

1 2 3 4 5 6 7 BULKHEAD WEB

STA 727

REPAIR STRAP FILLER A

DOUBLER ONLY 1 2 3 4 5 6 8 ON SOME AIRPLANES FILLER B

ANGLE ONLY ON SOME AIRPLANES FWD SKIN

1 2 3 4 8 SHEAR BEAM

SHEAR BEAM OUTBOARD FLANGE

INBD

FWD D40893 A-A

FIGURE 23: INSTALL THE SHEAR BEAM REPAIR June 30, 1994 (SHEET 3 OF 6) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 189 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

OUTBOARD BULKHEAD CHORD STA WEB 727

S-18

FWD SKIN

AUXILIARY CHORD

1 2 3 4 5 6 8 FILLER B

S-18A

S-19

1 2 3 4 8 SHEAR BEAM

S-20

REMOVED EXISTING FASTENER FWD D40911 B-B VIEW LOOKING OUTBOARD

FIGURE 23: INSTALL THE SHEAR BEAM REPAIR June 30, 1994 (SHEET 4 OF 6) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 190 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA Align Filler A (Refer to Step 1 of Figure 20.) 1 Repair Strap (Refer to Step 3 of Figure 19.) 1 1 Filler B (Refer to Step 2 of Figure 20.) 1 Shear Beam Web - 1 (a) As shown in drawing 65-46877. Drill Filler A (Refer to Step 1 of Figure 20.) 1 (b) (c) Repair Strap (Refer to Step 3 of Figure 19.) 1 (b) (c) 2 Filler B (Refer to Step 2 of Figure 20.) 1 Shear Beam Web - 1 (a) As shown in drawing 65-46877. Remove/ Filler A (Refer to Step 1 of Figure 20.) 1 Keep Repair Strap (Refer to Step 3 of Figure 19.) 1 3 Filler B (Refer to Step 2 of Figure 20.) 1 Shear Beam Web - 1 (a) As shown in drawing 65-46877. Deburr Filler A (Refer to Step 1 of Figure 20.) 1 Repair Strap (Refer to Step 3 of Figure 19.) 1 4 Filler B (Refer to Step 2 of Figure 20.) 1

Shear Beam Web - 1 (a) As shown in drawing 65-46877. Apply Chemical Type 2, Class A - To the bare edges 5 Conversion Coating as given in SOPM 20-43-03. Apply Primer BMS 10-11 Type 1 - 2 coats as given in 6 SOPM 20-41-02. Install Filler A (Refer to Step 1 of Figure 20.) 1 (d) (e) (f) (g) (h) (i) (j) (Kept) 7 Install Repair Strap (Refer to Step 3 of Figure 19.) 1 (d) (e) (f) (g) (h) (i) (j) (Kept) Install Filler B (Refer to Step 2 of Figure 20.) 1 (d) (e) (f) (g) (h) (i) (j) (Kept) 8 Install Shear Beam Web - 1 (a) As shown in (New) drawing 65-46877. Install Tee 65-48692-( ) 1 (k) (l) Install the Tee 9 (Kept) removed in Step 1 of Figure 19.

FIGURE 23: INSTALL THE SHEAR BEAM REPAIR June 30, 1994 (SHEET 5 OF 6) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 191 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

STEP TASK NAME IDENTIFICATION QTY MORE DATA Install Bracket 69-39436-( ) 1 (k) (l) (Kept) Left Side. Install the Bracket removed in Step 2 of Figure 19. 10 69-39437-( ) 1 (k) (l) Right Side. Install the Bracket removed in Step 2 of Figure 19. (a) Refer to Paragraph 3.B. Accomplishment Instructions Part 9 Paragraph e. for part number of Shear Beam Web applicable to Airplane Group. (b) Drill fastener holes matching the existing fastener hole nominal size, within a transition fit tolerance. If necessary holes may be oversized by up to 3/64th, but should not exceed 0.2973 (1/4 + 3/64 oversize). (c) Maintain a 1.7D minimum edge margin. (d) Shim all gaps greater than 0.01 before fastener installation. (e) Install wet with sealant (Ref. BMS 5-95). (f) Replace protruding head hex drive or lockbolt fasteners in transition fit holes with the same size as removed. If necessary use up to 1/32 oversize while maintaining a 1.7D minimum edge margin. Do not exceed 5/16 inch diameter. See Fastener Installation Table. (g) Replace 100 degree countersunk hex drive or lockbolt fasteners in transition fit holes with the same size as removed. If necessary use up to 1/32 oversize while maintaining a 1.7D minimum edge margin. Do not exceed 5/16 inch diameter. See Fastener Installation Table. (h) Install hex drive fasteners and bolts wet with sealant (Ref. BMS 5-95). (i) If PART 3 or PART 6 requires different fasteners, use the fasteners given in PART 3 or PART 6.

(j) Replace rivets with the same size and type. (k) Replace hexdrive, lock bolts and bolts with the same type and smallest size to maintain a transition fit hole. Do not exceed 5/16 inch diameter for these fasteners. (l) Replace rivets with the same type and size rivets. Do not exceed 6/32 inch diameter rivet for replacement of a production 5/32 inch diameter rivet. Do not exceed 1/4 inch diameter rivet for replacement of a production 6/32 inch diameter rivet.

FIGURE 23: INSTALL THE SHEAR BEAM REPAIR June 30, 1994 (SHEET 6 OF 6) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 192 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

FIGURE 24: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 1; GROUPS 4 THROUGH 11, CONFIGURATION 1 AND 4

STA 540 INSPECTION STA AREA 727 STA 727

SEE A

AUXILIARY CHORD

S-17 STA 727 S-18

S-19

S-20 SKIN LAP SPLICE S-21

S-22 1 2

S-23

S-24 FRAME AFT SKIN CHORD S-25

S-26 SKIN S-27 AUXILIARY BL 0 CHORD BULKHEAD FWD WEB VIEW FROM INSIDE REAR CARGO BAY (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR) TYPICAL CRACK U34781 A

FIGURE 24: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 1; GROUPS 4 THROUGH 11, CONFIGURATION 1 AND 4 June 30, 1994 (SHEET 1 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 193 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

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

FIGURE 24: AUXILIARY CHORD INSPECTION - GROUPS 1 THROUGH 3, CONFIGURATION 1; GROUPS 4 THROUGH 11, CONFIGURATION 1 AND 4 June 30, 1994 (SHEET 2 OF 2) Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 194 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

APPENDIX A: ADDENDUM

FLIGHT SAFETY SECTION INSPECTION TO ENSURE STRUCTURAL INTEGRITY OF AIRFRAME

A structural reassessment of the 737 airplane has been conducted under the requirements of Federal Aviation Administration (FAA) Advisory Circular 91-56 in accordance with Federal Aviation Regulation (FAR) 25.571, as amended in 1978, to ensure safe operation of 737 airplanes throughout their operational life.

Table 1 is a summary of the inspections specified in Paragraph 1.E Compliance that are recommended for the detection of cracks in the STA 727 frame outboard chord prior to their reaching critical lengths. Failure to detect cracks prior to their reaching critical length may result in failure of the STA 727 frame outboard chord.

Any cracked structure should be replaced prior to further flight unless specifically approved by your cognizant regulatory agency.

Please report any discrepancies to Boeing Customer Support Engineering using the reporting system described in the addendum.

Table 1 - STA 727 Frame Outboard Chord at Stringer 18A Airplane Condition Compliance STA 727 Frame is in the as delivered condition. The inspection as given in 1.E., Compliance, Table 2 of this service bulletin replaces the local F-29 inspections. The F-29 inspections remain valid for all other areas of F-29 not inspected per Table 2. STA 727 Frame Outboard Chord replaced, but The inspection as given in 1.E., Compliance,

the STA 727 Frame Outboard Chord Table 3 of this service bulletin replaces the local modification per this service bulletin has not F-29 inspections. The F-29 inspections remain been accomplished. valid for all other areas of F-29 not inspected per Table 3. STA 727 Frame Outboard Chord replaced and Service Bulletin 737-53-1088 Revision 1, dated the STA 727 Frame Outboard Chord May 25, 2006 contains the alternate F-29 modification per this service bulletin has been inspections. accomplished. STA 727 Frame Outboard Chord is as The F-29 inspections remain effective. An delivered, but the STA 727 Frame Outboard alternate inspection is not required for this Chord modification per this service bulletin has configuration. been accomplished.

APPENDIX A: ADDENDUM June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 195 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

Boeing requests that operators use the following Structural Significant Item (SSI) Reporting System to report any discrepancies that are found in accomplishing a Flight Safety Inspection.

1. Upon recognition of discrepancy, the following information should be telegraphed to Boeing: Heading: ATTENTION - SSI DISCREPANCY - SERVICE BULLETIN RELATED

- Service Bulletin number - Airplane serial number on which discrepancy was found - Identification of structural item found damaged - Flight cycles and hours on damaged item - Location and description of damage including direction and size - When discovered and inspection method used

Send telegram through Boeing Field Service Representative or directly to:

737 Customer Support Engineering

2. An Operator's Follow-Up Report containing all available pertinent data, relative to the structural discrepancy, shall be sent to Boeing. A summary of the information that should be reported is shown in the DISCREPANT STRUCTURE REPORT form attached. Operators may use this form or any suitable alternative which contains the same information.

3. All data and reports dealing with the Flight Safety Inspection Program shall be submitted either through a Boeing Field Service Representative or directly to:

The Boeing Commercial Airplane Group P.O. Box 3707 Seattle, Washington 98124-2207, USA

Attn: 707/727/737 Service Engineering Director Org. M-7201 Mail Stop 2H-84

4. All reports will be reviewed promptly.

APPENDIX A: ADDENDUM June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 196 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

DISCREPANT STRUCTURE REPORT SIDE 1

1. REPORT DATA A.T.A. INDEX REPORT NO.

AIRLINE/AGENCY STATION MONTH DAY YEAR

2. AIRCRAFT DATA MODEL SERIES TAIL NO.

MFG. SERIAL NO. FLIGHT HOURS FLIGHT CYCLES

3. COMPONENT DATA (AS APPLICABLE AND AVAILABLE):

NAME P/N S/N

IPC/DWG REF SRM REF

COMPLETE THE FOLLOWING IF KNOWN AND DIFFERENT FROM SECTION 2:

COMPONENT FLIGHT HOURS SINCE NEW SINCE OVERHAUL

COMPONENT FLIGHT CYCLES SINCE NEW SINCE OVERHAUL

4. REPAIR DATA PLANNED COMPLETED

4A. ACTION

4B. REFERENCES ASSOCIATED WITH INSPECTION/REPAIR (SPECIFY NO., PAGE, FIGURE, ETC)

SB AD IPC SRM

MPD OTHER (E.G., SDR, MRR) SIIA

STRUCTURAL SIGNIFICANT ITEM NO. SERIES 50 NO.

5. SERVICE BULLLETINS INCORPORATED IN AREA OF DISCREPANCY

SERVICE BULLETIN APPLICABLE SECTION DATE OF TOTAL FLIGHT HOURS AND NO. OF SERVICE BULLETIN INCORPORATION CYCLES AT INCORPORATION

HOURS FLIGHTS

6. INSPECTION DATA (COMPLETE KNOWN INFO., CHECK APPROPRIATE ITEMS FOR DISCREPANT STRUCTURE):

CURRENT INSPECTION INTERVALS (FLIGHT) CORRESPONDING INSPECTION LEVELS 6A. WHEN DISCOVERED 6B. INSPECTION LEVEL 6C. DETECTION METHOD SCHEDULED MAINTENANCE WALK-AROUND VISUAL TAP TEST OVERHAUL GENERAL VISUAL MAG. VISUAL SOUND UNSCHEDULED EXTERNAL SURVEILLANCE DYE PENETRANT SMELL SPECIAL/DIRECTED (AD, SB . . . ) INTERNAL SURVEILLANCE ULTRASONIC FEEL SYMPTOM (FUEL/PRESS. LEAK . . . ) DETAILED X-RAY FUEL LEAK RELATED FLEET EXPERIENCE SPECIAL LOW FREQUENCY PRESS. LOSS ACCIDENT INVESTIGATION EDDY CURRENT SSID HIGH FREQUENCY SERIES 50 EDDY CURRENT BORESCOPE

MAGNETIC W76755 PARTICLE

X 24291 ORIG. 3/84 (FRONT)

APPENDIX A: ADDENDUM June 30, 1994 Revision 2: May 25, 2006 737-53A1166 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 197 of 198 BOEING SERVICE BULLETIN 737-53A1166 ALERT ALERT

DISCREPANT STRUCTURE REPORT SIDE 2

7. DISCREPANCY DESCRIPTION:

Attach sketch, photos and text as required to describe defect and specific location. When applicable, give details of associated discrepancies on the same airplane, related experience with this discrepancy on any airplane, and previous modification(s) to the discrepant structure.

7A. TYPE OF DISCREPANCY: BENT CONTAMINATED DENTED LOOSE WRINKLED BROKEN CORRODED DETACHED MISSING BUCKLED CRACKED IMPROPERLY OUT-OF-TOLERANCE ADJUSTED BURNED DEFORMED STUCK LEAK CLOGGED DELAMINATED WORN

7B. SIZE OF DISCREPANCY: INCHES, OR CENTIMETERS

AREA X DEPTH

CRACK LENGTH INITIALLY DETECTED DATE FINAL MEASUREMENT (IF DIFFERENT) DATE

7C. DISCREPANT PART: FRAME/BULKHEAD SKIN JOINT/SPLICE PRESSURE BULKHEAD PLATE/PANEL LUG FRAME AROUND OPENING CHORD WELD WINDOW FORGING STRINGER NO. BOND KEEL BEAM BEAM OPEN HOLE FLOOR STRUT/BRACE FASTENER HOLE WING CENTER SECTION LINK/ROD CUTOUT

WING DRY-BAY AREA/COMPT LONGERON ACCESS/LIGHTENING HOLE SPAR FITTING NOTCH/GROOVE RIB BRACKET/SLIP DISCONTINUITY LANDING GEAR BEAM STOP BASIC MATERIAL FLAP TRACK FASTENER BUSHING FAIRING PIN

7D. LOCATION OF DISCREPANT PART: GENERAL LOCATION (E.G., BILGE, UNDER GALLEY)

BODY STA NO. DOOR ACCESS PANEL INTERIOR EXTERIOR WING STA NO. RUDDER INBOARD OUTBOARD VERT STAB. STA ELEVATOR LEFT RIGHT HORIZ STAB. STA AILERON FORWARD AFT NACELLE/PYLON FLAP UPPER LOWER COMPARTMENT SLAT LEADING EDGE TRAILING EDGE NOSE LANDING GEAR SPOILER MIDDLE SIDE MAIN LANDING GEAR TAB (ALSO CHECK ABOVE) SPECIFIC LOCATION WING LANDING GEAR BODY LANDING GEAR

INSPECTED BY REPAIRED BY W76756 ORIGINATED BY DATE

X 2491 ORIG. 1/84 (BACK)