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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-25A1544 Original Issue: October 04, 2006 Revision 4: February 15, 2022 ATA System: 2524 SUBJECT: EQUIPMENT/FURNISHING - Passenger Cabin Partitions and Compartments - Support Fitting Assembly Air Conditioning Extrusions Replacement EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.
9E991ECCN:
Copyright © 2006 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: October 04, 2006 737-25A1544Revision 4: February 15, 2022 1 of 202
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
Revision Transmittal Sheet5
S u m m a r y9
1. PLANNING INFORMATION ........................................ 1 5 A . E f f e c t i v i t y ............................................... 1 5
1. Airplanes ............................................ 1 5 2 . S p a r e s A f f e c t e d ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 2 0 E. Compliance .............................................. 2 2 F . A p p r o v a l ............................................... 2 4 G. Manpower .............................................. 2 5 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 3 1 J . R e f e r e n c e s .............................................. 3 1
1. Existing Data: ......................................... 3 1
2. Data Supplied with this Service Bulletin: ........................... 3 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 2 K. Publications Affected ........................................ 3 3 L. Interchangeability and Intermixability of Parts ........................... 3 3 M. Software Accomplishment Summary ................................ 3 3
2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 B. Industry Support Information .................................... 3 6 C. Parts Necessary for Each Airplane ................................. 3 6 1 . K i t s / P a r t s : ........................................... 3 6
2. Parts and Materials Supplied by the Operator: ........................ 4 0
3. Parts Modified and Reidentified: ............................... 4 7
4. Parts Removed and Not Replaced: .............................. 4 7 D. Parts Necessary to Change Spares ................................. 4 7 E. Special Tooling - Price and Availability ............................... 4 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 0 FIGURE 1: INSPECTION OF FRAME ON LEFT SIDE OF THE AIRPLANE ............... 5 9 FIGURE 2: INSPECTION OF FRAME ON RIGHT SIDE OF THE AIRPLANE .............. 6 2 FIGURE 3: INSTALLATION OF REPAIR ANGLES WITH HI-LOKS ON LEFT SIDE OF THE AIRPLANE .................................................. 6 5 FIGURE 4: INSTALLATION OF REPAIR ANGLES WITH HI-LOKS ON RIGHT SIDE OF THE AIRPLANE .................................................. 7 3 FIGURE 5: INSTALLATION OF REPAIR ANGLES WITH RIVETS ON LEFT SIDE OF THE AIRPLANE . 81 FIGURE 6: INSTALLATION OF REPAIR ANGLES WITH RIVETS ON RIGHT SIDE OF THE AIRPLANE .................................................. 8 8 FIGURE 7: REMOVAL OF SUPPORT FITTING ASSEMBLY - AIR CONDITIONING EXTRUSIONS ON L E F T S I D E O F T H E A I R P L A N E ................................ 9 5 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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FIGURE 8: REMOVAL OF SUPPORT FITTING ASSEMBLY - AIR CONDITIONING EXTRUSIONS ON R I G H T S I D E O F T H E A I R P L A N E ............................... 9 7 FIGURE 9: INSTALLATION OF SUPPORT FITTING ASSEMBLY - AIR CONDITIONING EXTRUSIONS O N L E F T S I D E O F T H E A I R P L A N E ............................. 9 9 FIGURE 10: INSTALLATION OF SUPPORT FITTING ASSEMBLY - AIR CONDITIONING EXTRUSIONS O N R I G H T S I D E O F T H E A I R P L A N E ............................ 1 0 1 FIGURE 11: LEFT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION (OPTION 1 AND 2) - CUT OUT [Group 1-4, 6] ...... 1 0 3 FIGURE 12: RIGHT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION (OPTION 1 AND 2) - CUT OUT [Group 1-4, 6] ...... 1 1 1 FIGURE 13: LEFT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - MAKE REPAIR PARTS (OPTION 1) [Group 1-4, 6] . . . 119 FIGURE 14: RIGHT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - MAKE REPAIR PARTS (OPTION 1) [Group 1-4, 6] . . . 128 FIGURE 15: LEFT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - INSTALL REPAIR PARTS (OPTION 1) [Group 1-4, 6] . 137 FIGURE 16: RIGHT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - INSTALL REPAIR PARTS (OPTION 1) [Group 1-4, 6] . 145 FIGURE 17: LEFT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - MAKE REPAIR PARTS (OPTION 2) [Group 1-4, 6] . . . 152 FIGURE 18: RIGHT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - MAKE REPAIR PARTS (OPTION 2) [Group 1-4, 6] . . . 160 FIGURE 19: LEFT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - INSTALL REPAIR PARTS (OPTION 2) [Group 1-4, 6] . 168 FIGURE 20: RIGHT SIDE, STA 907 FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - INSTALL REPAIR PARTS (OPTION 2) [Group 1-4, 6] . 175 FIGURE 21: STA 360 THRU STA 887, Z-SECTION FRAME, SUPPORT BRACKET ATTACHMENT HOLES AT THE AIR CONDITIONING EXTRUSION - FULL FRAME SECTION REPAIR ..... 1 8 1 FIGURE 22: INSPECTION OF STA - 907 FRAME ON LEFT SIDE AND RIGHT SIDE OF THE AIRPLANE - PART 3 FRAME REPAIR OPTION 1 ............................ 1 8 6 FIGURE 23: INSPECTION OF STA - 907 FRAME ON LEFT SIDE AND RIGHT SIDE OF THE AIRPLANE - PART 3 FRAME REPAIR OPTION 2 ............................ 1 8 9 FIGURE 24: INSPECTION OF STA - 559 FRAME ON LEFT SIDE OF THE AIRPLANE ........ 1 9 2 FIGURE 25: INSPECTION OF STA - 559 FRAME ON RIGHT SIDE OF THE AIRPLANE ....... 1 9 4 APPENDIX A: 737 AIRPLANE FRAME STATUS AT AIR CONDITIONING SUPPORT BRACKET ATTACHMENT ................................................. 1 9 6 APPENDIX B: STRINGER 8L CLIP FABRICATION STA 907, AT S-8L [Group 1-4, 6] .......... 1 9 9 APPENDIX C: STRINGER 8R CLIP FABRICATION STA 907, AT S-8R [Group 1-4, 6] .......... 2 0 1 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 04, 2006 737-25A1544Revision 4: February 15, 2022 4 of 202 BOEING SERVICE BULLETIN 737-25A1544
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-25A1544Original Issue: October 04, 2006 Revision 4: February 15, 2022 ATA System: 2524 SUBJECT: EQUIPMENT/FURNISHING - Passenger Cabin Partitions and Compartments - Support Fitting Assembly Air Conditioning Extrusions Replacement This revision includes all pages of the Service Bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-01-02 is related to this Service Bulletin.
The effective date of AD 2009-01-02 is February 27, 2009.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this Service Bulletin. The Airworthiness Directive will make the compliance tasks and times given in this Service Bulletin mandatory.
Airplane variable numbers YG044, YG067, YG069, YG074, YG081, YG084, YG088, YG201, and YG211 were moved from Group 2 to new Group 6.
Effects of this Revision on airplanes on which Original Issue, Revision 1, Revision 2, or Revision 3 was previously done:
1. No More work is necessary on the airplane(s) changed in accordance with the Original Issue, Revision 1 or Revision 2.
2. More work is necessary on the airplane(s) that has done the repair at STA 907 in accordance with the Revision 3 of this Service Bulletin. The more work is to do the post repair inspections and on conditions corrective actions at STA 907.
REASON FOR REVISION This revision is sent to change this Service Bulletin to an Alert Service Bulletin to add the required Damage Tolerance Inspections (DTI) for Station (STA) 907 repair, add new figures for the inspection at STA 559 and move 9 airplanes from Group 2 to new Group 6.
These sections were changed:
1. Summary, Manpower, revised Manpower table to add Figure 22, Figure 23, Figure 24, Figure 25.
2. Summary, Material Information, revised the Material Table - STA 907 to add Stringer Clips Part number 147A3500-13 and 147A3500- () Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 04, 2006 737-25A1544Revision 4: February 15, 2022 5 of 202
3. In Paragraph 1.A., Effectivity, added Service Bulletin index information and applicable line number information. Added new Group 6 to Group/Configuration table.
4. In Paragraph 1.C., Reason, updated reason statement. Added reason for revision statement.
5. In Paragraph 1.D., Description: Added instructions for new post repair inspections and new affected maintenance zones.
6. In Paragraph 1.E., Compliance, updated Federal Aviation Administration (FAA) Airworthiness Directive (AD) statement for possible release. Added the Boeing Business Jet (BBJ) lower cabin altitude statement, accomplish required action(s) statement, options and conditions statement, and new compliance tables.
7. In Paragraph 1.G., Manpower, updated manpower statement and updated and added new manpower tables.
8. In Paragraph 1.H., Weight and Balance Changes, added applicability to weight and balance tables.
9. In Paragraph 1.J.1., Existing Data, reference to PRR, Boeing SRP, Boeing Service Bulletin, Service Bulletin Index, Standard Overhaul Practices Manual (SOPM), Non-Destructive Testing (NDT) Manual, Aircraft Maintenance Manual (AMM), Structural Repair Manual (SRM) and Fleet Team Digest (FTD) are added.
10. In Paragraph 1.K.2., Publications Affected, Damage Tolerance Based Structural Inspections, new statements added.
11. In Paragraph 2.C., Parts Necessary for Each Airplane, added new operator supplied parts table.
12. In Paragraph 3.A., General Information, added new general notes.
13. In Paragraph 3.B., Work Instructions, update work instructions format and high level work instructions to add post repair inspections.
14. Revised Figure 11, Figure 12, Figure 13, Figure 14, Figure 15, Figure 16, Figure 17, Figure 18, Figure 19 and Figure 20 to give instructions for the frame repair at STA 907.
15. Added Figure 22 and Figure 23 to give instructions for Damage Tolerance Inspections (DTI) of the frame repair at STA 907.
16. Added Figure 24 and Figure 25 to give instructions for inspection for STA 559 frame, Group 3-6.
17. APPENDIX C, added Illustration for Stringer clip fabrication.
The data given in Information Notice 737-25-1544 IN 06 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY October 04, 2006Original Issue:
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January 16, 2008Revision 1:
March 23, 2011Revision 2:
May 16, 2016Revision 3:
February 15, 2022Revision 4:
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-25A1544Original Issue: October 04, 2006 Revision 4: February 15, 2022 ATA System: 2524 SUBJECT: EQUIPMENT/FURNISHING - Passenger Cabin Partitions and Compartments - Support Fitting Assembly Air Conditioning Extrusions Replacement
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This Service Bulletin gives instructions to do an inspection, and if necessary a repair of frames, at the air conditioning (A/C) rail bracket attachment fastener locations. Also, instructions are given to remove the support fitting assembly - A/C extrusions and replace them with new support fitting assembly - A/C extrusions that have better slip fitting. If this Service Bulletin is not accomplished, multiple frame failure could occur. Frame failure at the A/C rail attachment brackets could jeopardize the capability of the frame to support the overhead stowage bins under emergency landing loads. Multiple frame failure could exacerbate cracking of the chemically milled steps in the skin above Stringer 10 lap splice as addressed in Boeing Service Bulletin 737-53A1232, or precipitate cracking of the skin lap splice resulting in rapid decompression.
Frame cracks have been found on 737-200/300/400/500 airplanes at the support bracket attachment holes of the air conditioning outlet extrusion. Frame cracks have also been found on 737-200/300/400/500 airplanes up to 0.6 inches long on the inboard flange of the Station (STA) 907 frame adjacent to the support bracket.
The airplane structures on 737-200/300/400/500 and 737-600/700/700C/800/900 airplanes are almost the same in the areas where the frame cracks were discovered.
Boeing has received reports of more than 345 frame cracks on 35 737-200/300/400/500 airplanes at the support bracket attachment holes of the air conditioning outlet extrusion. The cracks were reported by four different operators on 737-200/300/400/500 airplanes. The airplanes range from 12,000 to 62,000 flight cycles. The cracks are attributed to fatigue and are generally less than one inch in length, however one operator has reported a one inch long crack at the Station 907 frame.
The cracks in the frame are fatigue cracks that radiate from multiple initiation sites around the hole. The cracks radiate from only one side of the hole, nearest the frame flanges. The cracks initiate from a combination of forward and aft loads from fuselage expansion, and down loads from fuselage deflection on the attached structure.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 04, 2006 737-25A1544Revision 4: February 15, 2022 9 of 202
Accomplishment of this Service Bulletin on 737-600/700/700C/800/900 airplanes will retain the structural integrity of the airplane and eliminate the need for unscheduled downtime and extensive frame repairs.
NOTE: Boeing has received reports of more than 43 frame cracks from multiple operators at the support bracket attachment holes of the air conditioning outlet extrusion. The airplanes range from 11,000 to 34,000 flight cycles. The cracks are attributed to fatigue and are generally less than one inch in length. This same condition is addressed on 737 Classic Service Bulletin 737-53-1216. The bracket configuration most susceptible to frame cracks is the support bracket with a two rivet hole attachment to the frame.
The inspection threshold specified in this Service Bulletin is later than the total airplane flight cycles on some airplanes with reported cracks. This is acceptable based on the growth rate and cracking pattern of the cracks. In all known reported cases the frame cracks grow in a sun ray pattern from one side of the A/C attach bracket holes. The longest cracks grow in a circumferential direction to a total length from tip-to-tip of approximately 1 inch, at which time they appear to stop any significant growth. No significant growth has been reported in the inboard or outboard direction which is the critical direction affecting safety. If cracks longer than 0.5 inches are found growing in the inboard or outboard direction, please contact The Boeing Company with the details.
Boeing Service Related Problem (SRP) 737NG-SRP-25-0229 and 737NG-SRP-53-0600 are related to this Service Bulletin.
Boeing Structural Item Interim Advisory SIIA 737-258 is related to this Service Bulletin.
Boeing Fleet Team Digest (FTD) 737NG-FTD-53-19002 is related to this Service Bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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ACTION (PRR 38275-76S, PRR 39800-021RS) Get access to the support bracket of the air conditioning outlet extrusion by removal of the passenger service units. If more access room is needed, remove as necessary, the passenger seats, the overhead stowage bins, the sidewall lining, and the air conditioning outlet extrusion.
Do a General Visual Inspection (GVI), a Medium Frequency Eddy Current (MFEC) inspection, a Low Frequency Eddy Current (LFEC) inspection and a High Frequency Eddy Current (HFEC) inspection of frames from STA 360 to STA 907 at Stringer 8L and Stringer 8R, for any crack at the air conditioning rail bracket attachment fastener locations, to make sure there are no cracks in the frame and if a frame repair is accomplished do the required Damage Tolerance Inspections (DTI) for Station (STA) 907 repair.
Group 1-2:
NOTE: The LFEC inspection is only required at STA 907 around the installed fastener at the outboard fastener location where the MFEC inspection is not applicable.
Group 3-6:
NOTE: The LFEC inspection is only required at STA 559 and STA 907 around the installed fastener at the outboard fastener location where the MFEC inspection is not applicable.
NOTE: The location of the support brackets vary due to different air conditioning configurations. As a result, all the frames from STA 360 to STA 907 that have a support bracket with a two rivet attachment configuration need to be identified. An identification of the brackets at STA 540, STA 663.75, STA 685 and STA 727 is not necessary. The frames at STA 540, STA 663.75, and STA 727 are machined frames and are not susceptible to the subject frame cracks. The frame at STA 685 has a support bracket with a four rivet attachment and does not need to be inspected as this configuration is not susceptible to cracks. An identification of the brackets at STA 616, and STA 639 on 737-600/700/700C airplanes and STA 578, STA 601, STA 616 and STA 639 on 737-800/900 airplanes is also not necessary because the frames are manufactured from a thicker material and they are not susceptible to the subject frame cracks.
NOTE: An optional airplane frame status table for planning purposes is given in APPENDIX A. The table can be used for initial inspection, frame and bracket tabulation. The tables could benefit planning in subsequent inspections or modifications to reduce the access time for the next inspection or parts fabrication requirements.
If any crack is found, repair the frame in accordance with this Service Bulletin.
Remove the support fitting assembly - A/C extrusions, and install new support fitting assembly - A/C extrusions with better slip fitting on frames from STA 360 to STA 907 at Stringer 8L and Stringer 8R, in accordance with this Service Bulletin.
Install as necessary if removed, the air conditioning outlet extrusion, the sidewall lining, the overhead stowage bins, and the passenger seats. Install the passenger service units.
EFFECTIVITY 737-600/700/700C/800/900 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-01-02 is related to this Service Bulletin.
The effective date of AD 2009-01-02 is February 27, 2009.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 04, 2006 737-25A1544Revision 4: February 15, 2022 11 of 202 BOEING SERVICE BULLETIN 737-25A1544
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The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this Service Bulletin. The Airworthiness Directive will make the compliance tasks and times given in this Service Bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures given in this Service Bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 04, 2006 737-25A1544Revision 4: February 15, 2022 12 of 202 BOEING SERVICE BULLETIN 737-25A1544