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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-52A1153 Original Issue: July 13, 2011 ATA System: 5231 SUBJECT: DOORS - Aft Cargo - Cross Beam E, Adjacent Lower Corner Frames and Reinforcing Angles - Inspection, Repair and Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

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

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the 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

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 2 7 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 7 D. Description .............................................. 2 7 E. Compliance .............................................. 2 8 F. Approval ............................................... 3 8 G. Manpower .............................................. 4 0 H. Weight and Balance Changes .................................... 4 5 I. Electrical Load Data ......................................... 4 6 J. References .............................................. 4 6

1. Existing Data: ......................................... 4 6

2. Data supplied with this Service Bulletin: ........................... 4 7

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 8

4. Process Data: ......................................... 4 8 K. Publications Affected ........................................ 4 8 L. Interchangeability and Intermixability of Parts ........................... 4 8

2. MATERIAL INFORMATION ........................................ 4 9 A. Material - Price and Availability ................................... 4 9 B. Industry Support Information .................................... 4 9 C. Parts Necessary For Each Airplane ................................. 5 0

1. Kits/Parts: ........................................... 5 0

2. Parts and Materials Supplied by the Operator: ........................ 5 4

3. Parts Modified and Reidentified: ............................... 5 5

4. Parts Removed and Not Replaced: .............................. 5 6 D. Parts Necessary to Change Spares ................................. 5 6 E. Special Tooling - Price and Availability ............................... 5 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 7

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 9 A. GENERAL INFORMATION ..................................... 5 9 B. WORK INSTRUCTIONS ....................................... 6 0 FIGURE 1: FORWARD END OF CROSS BEAM E - INSPECT - GROUPS 1, 2, 3, 4 AND 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1-5, Configuration 1] ........... 8 2 FIGURE 2: FORWARD END OF CROSS BEAM E - INSPECT - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ......................................... 8 6 FIGURE 3: AFT END OF CROSS BEAM E - INSPECT - GROUPS 1, 2, 3, 4 AND 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1-5, Configuration 1] ............. 9 0 FIGURE 4: AFT END OF CROSS BEAM E - INSPECT - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ......................................... 9 4

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FIGURE 5: FORWARD LOWER CORNER FRAME AND REINFORCING ANGLE - INSPECT - GROUPS 1, 2, 3, 4 AND 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1-5, Configuration 1] ......................................... 9 8 FIGURE 6: FORWARD LOWER CORNER FRAME - INSPECT - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ........................................ 1 0 2 FIGURE 7: AFT LOWER CORNER FRAME - INSPECT - GROUPS 1, 2, 3, 4 AND 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1-5, Configuration 1] ............ 1 0 6 FIGURE 8: AFT LOWER CORNER FRAME - INSPECT - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ........................................ 1 1 0 FIGURE 9: FORWARD END OF CROSS BEAM E REPAIR - PREPARE - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1] ........................................ 1 1 4 FIGURE 10: FORWARD END OF CROSS BEAM E REPAIR - PREPARE - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1] . 118 FIGURE 11: FORWARD END OF CROSS BEAM E REPAIR - PREPARE - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ..................................... 1 2 2 FIGURE 12: FORWARD END OF CROSS BEAM E REPAIR - INSTALL - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1] ........................................ 1 2 6 FIGURE 13: FORWARD END OF CROSS BEAM E REPAIR - INSTALL - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1] . 130 FIGURE 14: FORWARD END OF CROSS BEAM E REPAIR - INSTALL - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ..................................... 1 3 4 FIGURE 15: AFT END OF CROSS BEAM E REPAIR - PREPARE - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1 ] ................................................ 1 3 8 FIGURE 16: AFT END OF CROSS BEAM E REPAIR - PREPARE - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1] ........... 1 4 2 FIGURE 17: AFT END OF CROSS BEAM E REPAIR - PREPARE - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ........................................ 1 4 6 FIGURE 18: AFT END OF CROSS BEAM E REPAIR - INSTALL - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1 ] ................................................ 1 5 0 FIGURE 19: AFT END OF CROSS BEAM E REPAIR - INSTALL - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1] ........... 1 5 4 FIGURE 20: AFT END OF CROSS BEAM E REPAIR - INSTALL - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ........................................ 1 5 8 FIGURE 21: FORWARD END CROSS BEAM E - INSPECT - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1] . 162 FIGURE 22: FORWARD END CROSS BEAM E - INSPECT - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1] ............ 1 6 6 FIGURE 23: FORWARD END OF CROSS BEAM E - INSPECT - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ........................................ 1 7 0

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FIGURE 24: AFT END OF CROSS BEAM E - INSPECT - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1] . 174 FIGURE 25: AFT END OF CROSS BEAM E - INSPECT - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1] ............ 1 7 8 FIGURE 26: AFT END OF CROSS BEAM E - INSPECT - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ........................................ 1 8 2 FIGURE 27: FORWARD END OF CROSS BEAM E PREVENTATIVE MODIFICATION - PREPARE - GROUPS 1, 2, 3, 4 AND 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1-5, Configuration 1] ........................................ 1 8 6 FIGURE 28: FORWARD END OF CROSS BEAM E PREVENTATIVE MODIFICATION - PREPARE - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] .................... 1 9 0 FIGURE 29: FORWARD END OF CROSS BEAM E PREVENTATIVE MODIFICATION - INSTALL - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1] ............................. 1 9 4 FIGURE 30: FORWARD END OF CROSS BEAM E PREVENTATIVE MODIFICATION - INSTALL - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1 ] ................................................ 1 9 8 FIGURE 31: FORWARD END OF CROSS BEAM E PREVENTATIVE MODIFICATION - INSTALL - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] .................... 2 0 2 FIGURE 32: AFT END OF CROSS BEAM E PREVENTATIVE MODIFICATION - PREPARE - GROUPS 1, 2, 3, 4 AND 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1-5, Configuration 1] ........................................ 2 0 6 FIGURE 33: AFT END OF CROSS BEAM E PREVENTATIVE MODIFICATION - PREPARE - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ......................... 2 1 0 FIGURE 34: AFT END OF CROSS BEAM E PREVENTATIVE MODIFICATION - INSTALL - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 1, 5, Configuration 1] ............................. 2 1 4 FIGURE 35: AFT END OF CROSS BEAM E PREVENTATIVE MODIFICATION - INSTALL - GROUPS 2, 3 AND 4 CONFIGURATION 1 AIRPLANES (BONDED INNER SKIN) [Group 2-4, Configuration 1 ] ................................................ 2 1 8 FIGURE 36: AFT END OF CROSS BEAM E PREVENTATIVE MODIFICATION - INSTALL - GROUP 3 CONFIGURATION 2 AND GROUP 4 CONFIGURATION 2 AIRPLANES (CHEMICALLY MILLED INNER SKIN) [Group 3-4, Configuration 2] ......................... 2 2 2 FIGURE 37: FORWARD LOWER CORNER FRAME AND REINFORCING ANGLE - REPLACE - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES [Group 1, 5, Configuration 1 ] ................................................ 2 2 6 FIGURE 38: AFT LOWER CORNER FRAME AND REINFORCING ANGLE - REPLACE - GROUP 1 CONFIGURATION 1 AND GROUP 5 CONFIGURATION 1 AIRPLANES [Group 1, 5, Configuration 1 ] ................................................ 2 2 8 FIGURE 39: FORWARD LOWER CORNER FRAME AND REINFORCING ANGLE - REPLACE - GROUP 2 CONFIGURATION 1, GROUP 3 AND GROUP 4 AIRPLANES [Group 2-3, Configuration 1;

Group 3, Configuration 2; Group 4, Configuration 1-2] ................... 2 3 0 FIGURE 40: AFT LOWER CORNER FRAME AND REINFORCING ANGLE - REPLACE - GROUP 2 CONFIGURATION 1, GROUP 3 AND GROUP 4 AIRPLANES [Group 2-3, Configuration 1;

Group 3, Configuration 2; Group 4, Configuration 1-2] ................... 2 3 2 FIGURE 41: AFT CARGO DOOR - LOWER CROSS BEAM - FORWARD END - SUPPLEMENTAL STRUCTURAL INSPECTION ................................ 2 3 4

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FIGURE 42: AFT CARGO DOOR - LOWER CROSS BEAM - AFT END - SUPPLEMENTAL STRUCTURAL INSPECTION ......................................... 2 3 7

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-52A1153Original Issue: July 13, 2011 ATA System: 5231 SUBJECT: DOORS - Aft Cargo - Cross Beam E, Adjacent Lower Corner Frames and Reinforcing Angles - Inspection, Repair and 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 This service bulletin gives instructions to inspect for cracks in the forward and aft ends of cross beam E, the adjacent lower corner frames and the reinforcing angles of the aft cargo door. This service bulletin also gives instructions to install a repair and a preventative modification for both the forward and aft ends of cross beam E. The repair or preventative modification will prevent the occurrence of cracks in the affected parts of the door structure. Cracks in the aft cargo door structure are caused by fatigue as a result of cabin pressurization cycles.

Undetected cracks could result in rapid decompression.

One operator reported a 2 inch long crack in the web of cross beam E (the lower cross beam) adjacent to the aft lower stop fitting. A crack of 1.3 inches in length was also found in the aft lower corner frame and reinforcing angle. Boeing was also told of cracks in the T-chord at the forward end of the cross beam E. The cracks in the T-chord measured approximately 0.5 inches in length and were typically common to the fasteners of the stop fitting. These cracks in the door structure were found during regularly scheduled maintenance inspections on airplanes that had accumulated between 24,612 and 31,200 flight cycles, which are similar to those described in Boeing service bulletin 737-52A1079 but are beyond its effectivity. This service bulletin is released to correct these problems for airplane line number 874 thru 3132, which adds to the airplanes that are in the effectivity of Boeing service bulletin 737-52A1079.

Boeing Service Related Problem (SRP) 737-SRP-52-0072 and Boeing Structural Item Interim Advisory (SIIA) SIIA 737-292 are related to this service bulletin.

ACTION (PRR 35005-259RS) Group 1-5:

Do an inspection of the door in accordance with Paragraph 3.B.1., Work Instructions of this service bulletin to determine if the door was originally from a Group 1, Configuration 2, Group 2, Configuration 2, or Group 5, Configuration 2 airplane.

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Group 1-2, 5, Configuration 2:

Accomplish all applicable actions in accordance with Service Bulletin 737-52A1079, Revision 7.

Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1:

Do High Frequency Eddy Current (HFEC) and detailed inspections for crack(s) in the T-chord and the beam web at the forward and aft ends of cross beam E. Do ultrasonic and detailed inspections for crack(s) in the forward and aft lower corner frame and reinforcing angle. If any crack is found in cross beam E, install the repair.

If no crack(s) are found, continue to inspect each end of cross beam E for cracks at the intervals specified in Paragraph 1.E., Compliance. The repair or preventative modification must be installed before the time limit given in Paragraph 1.E., Compliance is exceeded. If any crack is found in the adjacent lower corner frame and reinforcing angle, replace the frame and reinforcing angle.

In addition, if any crack is found, accomplish all applicable actions in accordance with the original issue of Service Bulletin 737-52-1154 at the time specified in Paragraph 1.E., Compliance.

EFFECTIVITY 737-200/200C/300/400/500 Airplanes. Refer to Service Bulletin Paragraph 1.A.1 for effectivity.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Federal Aviation Administration (FAA) Airworthiness Directives AD 98-11-04 R1, AD 2008-08-23 and AD 2008-09-13 are related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, repair and/or modification and replacement procedures in accordance with this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN 737-52A1153

ALERT ALERT STA STA 1016 907 STA 787 CROSS ' BEAM E

OCOCCOOC FWD&! → INBD TYPICAL FRAME

SEE AND REINFORCING

ANGLE CRACK

FORWARD LOWER CORNER SHOWN

TYPICAL TYPICAL AFT LOWER CORNER OPPOSITE

T-CHORD BEAM WEB (TYPICAL)

CRACK CRACK + + INSPECT FOR CRACKS IN EACH

END OF CROSS BEAM E AND THE

ADJACENT LOWER CORNER FRAME INBD AND REINFORCING ANGLE. IF

ANY CRACK IS FOUND, INSTALL FWD C _ * THE CROSS BEAM E REPAIR AND/OR REPLACEMENT FRAME AND REINFORCING ANGLE. IF NO

TYPICAL CRACKS ARE FOUND, DO REPEAT

REINFORCING FRAME AND A-A INSPECTIONS OF CROSS BEAM E OR DO TERMINATING INSPECTIONS ANGLE CRACK FORWARD END OF CROSS BEAM E SHOWN OF THE FRAME AND INSTALL THE D66947 AFT END OPPOSITE PREVENTATIVE MODIFICATION.

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

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index 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 35005-259RS for data about this change.

NOTE: For Group 1, Group 2 and Group 5 airplanes, it is possible that operators could have removed the aft cargo door that was installed at delivery and installed it on an airplane before line number 1643. It is recommended that operators check their records of airplanes before line number 1643 to identify if the aft cargo door installed is affected by this service bulletin.

DESCRIPTIONCONFIGURATIONGROUP 737-200/200C airplanes, line numbers 874 thru 1642, that were delivered with an aft cargo door that has a bonded inner skin.

- 1 Airplanes with a door configuration that was delivered on line numbers 874 thru 1642.

1 Airplanes with a door configuration that was delivered prior to line number 874 that are subject to modification by service bulletin 737-52A1079.

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DESCRIPTIONCONFIGURATIONGROUP 737-300/400 airplanes, line numbers 874 thru 1642, that were delivered with an aft cargo door that has a bonded inner skin.

- 2 Airplanes with a door configuration that was delivered on line numbers 874 thru 1642.

1 Airplanes with a door configuration that was delivered prior to line number 874 that are subject to modification by service bulletin 737-52A1079.

2 737-300/400/500 airplanes, line numbers 1643 thru 2414 that were delivered with an aft cargo door that has a bonded inner skin. These airplanes are not included in service bulletin 737-52A1079.

- 3 737-300/400/500 airplanes, with a bonded inner skin door configuration that was delivered in the line number range 1643 thru 2414.

1 737-300/400/500 airplanes, with a chemically milled inner skin door configuration that was delivered in the line number range 2415 thru 3132.

2 737-300/400/500 airplanes, line numbers 2415 thru 3132 that were delivered with an aft cargo door that has a chemically milled inner skin. These airplanes are not included in service bulletin 737-52A1079.

- 4 737-300/400/500 airplanes, with a bonded inner skin door configuration that was delivered in the line number range 1643 thru 2414.

1 737-300/400/500 airplanes, with a chemically milled inner skin door configuration that was delivered in the line number range 2415 thru 3132.

2 737-200/200C airplanes, line numbers 6 thru 873 that were delivered with an aft cargo door that has a bonded inner skin. These airplanes are included in this service bulletin to check for swapped doors.

- 5 737-200/200C airplanes with a door configuration that was delivered in the line number range 874 thru 1642.

1 Airplanes with a door configuration that was delivered prior to line number 874 that are subject to modification by service bulletin 737-52A1079.

2 Airplane Models:

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

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