# Boeing Alert Service Bulletin 737-52A1153: No revision named - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2012-1156; AD 2013-13-12 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 737-52A1153](https://openairdocs.org/service-documents/boeing/737-52a1153.md) - Title as filed: Boeing - Service Bulletin - Pages: 239 - PDF: https://openairdocs.org/files/sha256/b9/ae/b9ae385b1c4ee4acb087575737f5f85feb4bbb6ce688c263ff6e9bfbc90dd894 - Page: https://openairdocs.org/service-documents/boeing/737-52a1153/file/b9ae385b1c4e ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 1 of 239 4.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 2 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Summary ...................................................... 7 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 3 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 4 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 4 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 5 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 5 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 6 FIGURE 42: AFT CARGO DOOR - LOWER CROSS BEAM - AFT END - SUPPLEMENTAL STRUCTURAL INSPECTION ......................................... 2 3 7 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 6 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 7 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 7 of 239 ### Page 8 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 8 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 9 (OCR) 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. Original Issue: July 13, 2011 737-52A1153 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 239 ### Page 10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 10 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT BLANK PAGE ### Page 11 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 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. 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 11 of 239 ### Page 12 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 12 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 13 GroupVariable Number 5PG001 - PG075 5PG199 5PG201 - PG230 5PG251 - PG255 5PG271 - PG279 5PG301 - PG314 5PG331 - PG332 5PG351 - PG356 5PG375 5PG401 - PG403 5PG431 - PG442 5PG471 - PG475 5PG501 - PG505 5PG571 - PG586 5PG621 - PG630 5PG651 - PG652 5PG701 - PG705 5PH001 5PH011 - PH013 5PH021 - PH024 5PH701 - PH715 5PH731 - PH732 5PH741 - PH743 5PJ001 - PJ009 5PJ031 - PJ032 5PJ071 - PJ072 5PJ101 - PJ119 5PJ201 - PJ219 3PJ301 - PJ302 4PJ551 - PJ561 4PJ601 - PJ615 4PJ811 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 13 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 14 GroupVariable Number 4PJ816 - PJ817 5PK026 - PK029 5PK041 - PK053 5PK061 - PK070 5PK081 - PK082 5PK091 - PK099 5PK101 - PK103 5PK111 - PK120 5PK141 - PK146 5PK201 - PK204 5PK211 - PK215 1PK216 - PK220 5PK221 - PK223 5PK231 - PK241 5PK251 - PK258 5PK271 - PK274 5PK281 - PK289 5PK291 5PK301 - PK318 5PK341 5PK351 - PK361 5PK391 5PK431 - PK433 5PK451 - PK452 5PK461 - PK469 5PK495 5PK501 - PK503 1PK504 5PK511 - PK514 1PK515 1PK519 5PK521 - PK524 1PK525 - PK528 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 14 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 15 GroupVariable Number 5PK541 - PK564 1PK565 5PK581 5PK591 - PK599 5PK601 - PK617 5PK621 - PK630 1PK631 - PK637 5PK641 - PK642 5PK661 - PK663 1PK664 - PK666 5PK671 - PK678 1PK679 - PK681 5PK691 - PK696 1PK697 5PK711 - PK716 5PK731 - PK749 1PK750 - PK765 5PK771 - PK779 5PK801 - PK802 1PK803 - PK804 5PK819 - PK826 1PK827 5PK830 5PK861 - PK863 5PK871 - PK874 5PK881 - PK884 5PK901 - PK932 1PK933 - PK938 5PK971 - PK974 5PL001 - PL023 1PL024 - PL028 5PL061 5PL081 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 15 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 16 GroupVariable Number 5PL101 - PL112 1PL113 5PL151 5PL171 1PL172 5PL201 - PL203 1PL221 5PL401 - PL412 1PL413 - PL417 5PL421 5PL441 5PL451 - PL454 1PL455 - PL456 5PL471 5PL491 5PL501 - PL506 5PL551 - PL561 1PL562 5PL581 5PL601 1PL602 - PL603 1PL611 1PL621 - PL626 1PL631 - PL632 5PL711 - PL712 5PL716 - PL745 1PL746 - PL747 5PL756 5PL758 5PL761 - PL770 5PL781 - PL783 1PL784 - PL788 5PL793 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 16 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 17 GroupVariable Number 5PL801 - PL803 5PM001 - PM002 1PM003 - PM006 1PM016 - PM017 5PM021 - PM023 1PM051 - PM066 5PM101 - PM104 1PM105 - PM119 5PM141 - PM142 1PM171 1PM181 1PM251 - PM255 1PM281 - PM283 2PM381 3PM382 - PM399 3PM401 - PM414 4PM415 - PM417 4PM541 - PM550 3PM551 - PM558 4PM559 - PM564 1PN001 - PN002 1PN021 - PN043 1PN081 - PN086 1PN101 - PN117 1PN131 - PN163 1PN401 - PN420 1PN431 - PN433 1PN451 - PN456 1PN471 - PN474 1PN481 1PN491 - PN493 1PN501 - PN502 1PN511 - PN512 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 17 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 18 GroupVariable Number 1PN521 2PP001 - PP047 3PP048 - PP054 2PP101 - PP139 3PP140 - PP159 4PP160 2PP161 - PP169 2PP181 - PP197 3PP198 - PP199 2PP201 - PP205 2PP221 2PP231 - PP243 2PP281 - PP286 2PP301 - PP305 2PP351 - PP353 2PP376 - PP384 2PP391 - PP393 2PP401 - PP440 2PP471 - PP475 2PP501 - PP507 3PP508 - PP517 4PP518 - PP520 2PP521 - PP522 2PP631 - PP634 2PP651 - PP652 2PP671 - PP699 2PP701 - PP733 2PP771 - PP779 2PP801 - PP804 3PP805 - PP808 2PP821 - PP827 2PP831 - PP848 2PP851 - PP852 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 18 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 19 GroupVariable Number 2PP861 - PP872 3PP873 - PP874 4PP875 - PP877 2PP891 - PP899 2PP901 - PP914 3PP915 - PP930 2PP931 - PP936 2PP946 - PP948 2PP951 - PP952 2PP961 - PP965 3PP966 - PP967 2PP981 - PP984 3PP985 - PP990 2PP991 3PP993 2PQ001 - PQ012 3PQ013 - PQ016 2PQ026 - PQ041 2PQ051 - PQ065 3PQ066 - PQ085 2PQ086 - PQ090 3PQ091 - PQ092 2PQ101 - PQ145 3PQ146 - PQ199 3PQ201 - PQ202 2PQ221 - PQ222 3PQ223 - PQ230 2PQ231 - PQ236 3PQ237 2PQ241 - PQ243 2PQ251 3PQ252 - PQ267 3PQ281 - PQ294 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 19 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 20 GroupVariable Number 4PQ295 - PQ299 3PQ301 - PQ307 3PQ331 - PQ332 3PQ341 - PQ344 4PQ345 - PQ348 3PQ361 - PQ367 4PQ368 - PQ373 4PQ391 - PQ395 3PQ401 - PQ404 4PQ405 - PQ410 3PQ411 - PQ413 4PQ414 - PQ418 3PQ421 4PQ431 - PQ438 4PQ447 - PQ448 4PQ451 4PQ454 4PQ471 - PQ475 4PQ479 - PQ481 3PQ486 4PQ487 3PQ491 - PQ492 4PQ493 4PQ771 - PQ772 4PQ791 - PQ793 4PQ801 - PQ805 4PQ931 - PQ935 4PQ951 4PQ971 - PQ997 4PR001 - PR017 4PR021 - PR034 4PR041 - PR045 4PR061 - PR072 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 20 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 21 GroupVariable Number 4PR077 - PR082 4PR091 - PR092 4PR096 4PR101 4PR121 - PR122 4PR131 - PR132 4PR141 - PR143 4PR161 - PR172 4PR181 3PS601 - PS616 4PS617 - PS630 3PS631 3PS636 - PS638 3PS641 - PS644 3PS651 - PS657 3PS666 - PS669 3PS691 - PS692 3PS701 - PS703 4PS704 - PS706 4PS751 - PS799 4PS811 4PS836 - PS837 4PS841 - PS846 4PS851 - PS852 4PS856 4PS861 - PS863 4PS866 - PS868 4PS871 - PS874 4PS896 - PS897 4PS901 - PS941 4PS956 - PS957 4PS961 - PS963 4PS971 - PS978 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 21 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 22 GroupVariable Number 3PT001 - PT010 4PT011 - PT015 3PT021 - PT026 4PT027 - PT031 3PT041 - PT059 4PT060 - PT064 3PT101 - PT105 3PT121 - PT125 4PT126 - PT138 3PT146 - PT148 3PT161 - PT168 4PT169 - PT170 3PT181 - PT187 4PT188 3PT211 - PT220 3PT295 3PT301 - PT302 4PT303 - PT309 3PT331 - PT360 3PT381 - PT399 3PT401 - PT429 4PT430 - PT438 3PT501 - PT509 4PT510 - PT517 3PT561 - PT565 3PT581 - PT583 4PT584 - PT586 3PT611 - PT621 3PT641 4PT642 - PT644 3PT651 - PT654 4PT655 - PT656 3PT671 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 22 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 23 GroupVariable Number 4PT672 4PT681 - PT685 3PT701 - PT703 4PT716 - PT717 4PT721 - PT725 4PT801 - PT834 4PT851 - PT854 4PT871 - PT886 4PT901 - PT930 4PT971 - PT973 4PT981 - PT985 4PT996 3PU001 - PU025 4PU301 4PU311 - PU313 2PV001 - PV010 3PV011 - PV055 3PV201 - PV202 4PV203 - PV209 4PV226 - PV229 3PV231 - PV237 3PV271 - PV272 4PV281 - PV287 4PV296 4PV301 - PV302 4PV351 4PV356 - PV357 2PW001 - PW005 3PW006 - PW054 2PW061 3PW062 - PW068 3PW072 4PW086 - PW088 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 23 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 24 GroupVariable Number 2PW091 3PW092 - PW094 3PW101 4PW102 4PW106 3PW111 - PW120 3PW156 - PW157 3PW161 - PW166 4PW167 - PW171 3PW201 - PW213 4PW214 - PW230 3PW231 - PW238 4PW239 - PW252 3PW261 4PW262 - PW264 3PW265 4PW266 - PW268 4PW271 - PW276 4PW278 3PW281 4PW282 - PW292 3PW293 3PW296 3PW301 - PW319 4PW320 - PW327 4PW401 - PW408 4PW411 - PW418 4PW421 - PW424 4PW431 - PW435 4PW441 - PW450 4PW461 - PW467 3PW501 - PW504 3PW511 - PW520 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 24 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 25 GroupVariable Number 4PW521 - PW522 4PW524 - PW530 3PW531 - PW544 4PW545 - PW550 4PW556 - PW557 3PW561 - PW564 3PW571 - PW576 3PW591 - PW596 3PW611 - PW620 4PW621 - PW622 3PW631 - PW633 4PW634 - PW637 3PW661 - PW662 3PW681 - PW683 3PW701 4PW702 3PW711 - PW716 4PW717 3PW741 - PW742 3PW761 4PW771 4PW831 4PW851 - PW856 5PX071 5PX701 5PY001 - PY008 5PY021 - PY022 5PY031 5PY036 - PY037 5PY046 - PY048 5PY051 - PY053 1PY056 - PY057 5PY101 - PY103 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 25 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 26 GroupVariable Number 5PY111 - PY113 5PY131 - PY135 5PY141 - PY143 5PY151 - PY154 5PY156 - PY157 5PY161 - PY162 5PY166 5PY191 5PY201 5PY221 - PY222 5PY231 5PY241 - PY244 5PY270 - PY275 5PY281 5PY286 5PY301 - PY304 5PY321 - PY323 5PY341 - PY346 5PY361 - PY362 5PY381 5PY401 1PY409 - PY410 5PY411 5PY421 1PY422 5PY441 5PY451 5PY461 - PY462 1PY463 1PY591 - PY595 5PY611 - PY612 5PY621 5PY631 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 26 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 27 GroupVariable Number 5PY651 1PY671 - PY672 1PY721 1PY741 2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use. Also, refer to Paragraph 1.E., Compliance, for information about work on spare aft cargo doors. B. Concurrent Requirements None. C. Reason 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. D. Description 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. Group 1-2, 5, Configuration 2: Accomplish all applicable actions in accordance with Service Bulletin 737-52A1079, Revision 7. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 27 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 28 Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1: Do High Frequency Eddy Current (HFEC) and detailed inspections for cracks in the T-chord and the beam web at the forward and aft ends of cross beam E. Do ultrasonic and detailed inspections for cracks 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 cracks 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. NOTE: Service Bulletin 737-52-1154 has similar access requirements as this service bulletin.1. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1, 5: Affected Maintenance Zones ZoneModel 2-19737-200, 737-200C Group 2: Affected Maintenance Zones ZoneModel 219737-300, 737-400 Group 3-4: Affected Maintenance Zones ZoneModel 219737-300, 737-400, 737-500 E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directives AD 98-11-04 R1, AD 2008-08-23 and AD 2008-09-13 are related to this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 28 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 29 Table 1: Determination of Door Configuration (all airplanes) and Inspections, Repair and Preventative Modification at the Forward End of Cross Beam E Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition --Within 4,500 door flight cy- cles after the original issue date of this ser- vice bulletin. (a) (c) Do an inspection of the door in accordance with Paragraph 3.B.1., Work In- structions 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. All Airplanes in all Groups where the door flight cy- cles are not known. -Within 4,500 door flight cy- cles after the original issue date of this ser- vice bulletin. (a) (c) Before 27,000 door flight cy- cles. Do an inspection of the door in accordance with Paragraph 3.B.1., Work In- structions 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. All Airplanes in all Groups where the door flight cy- cles are known. -At the time given in 737-52A1079 Revision 7. Accomplish all applicable actions in accordance with Revision 7 of Service Bul- letin 737-52A1079. Door found to be originally from a Group 1 Configura- tion 2, Group 2 Configura- tion 2 or Group 5 Configu- ration 2 airplane. 4,500 door flight cycles. (a) (b) (c) -Within 4,500 door flight cy- cles after the original issue date of this ser- vice bulletin. (a) (c) Do High Frequency Eddy Current (HFEC) and detail inspections in accordance with Part 1 of the Work In- structions, Paragraph 3.B.1.b. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 airplanes where the door flight cycles are not known. 4,500 door flight cycles. (a) (b) (c) Within 4,500 door flight cy- cles after the original issue date of this ser- vice bulletin. (a) (c) Before 27,000 flight cycles. Do High Frequency Eddy Current (HFEC) and detail inspections in accordance with Part 1 of the Work In- structions, Paragraph 3.B.1.b. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 airplanes where the door flight cycles are known. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 29 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 30 Table 1: Determination of Door Configuration (all airplanes) and Inspections, Repair and Preventative Modification at the Forward End of Cross Beam E Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight. (c)Install the repair in accor- dance with Part 2 and Part 3 of the Work Instructions, Paragraph 3.B.2 and 3.B.3. Crack(s) found in the beam web or the T-chord. -Before further flight.Accomplish actions in ac- cordance with Tables 1 through 4 of Service Bul- letin 737-52-1154, Original Issue, Paragraph 1.E., Compliance. (c)Before 36,000 door flight cy- cles. Within 4 years or 9,000 door flight cycles af- ter the original issue date of this service bul- letin, whichever occurs later. Install a preventative modi- fication in accordance with Part 2 and Part 5 of the Work Instructions, Para- graph 3.B.2 and 3.B.5. No crack(s) found in the beam web and the T- chord. (a) If no cracks are found in the beam web or the T-chord, the preventative modification, in accordance with Part 2 and Part 5 of the work instructions, can be installed. (b) These repeat inspections are only required until the repair or preventative modification is installed to both ends of cross beam E. (c) After the repair or preventative modification is installed, supplemental inspections are required in accordance with Table 5. Table 2: Inspections, Repair and Preventative Modification at the Aft End of Cross Beam E Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 door flight cycles. (a) (b) (c) -Within 4,500 door flight cycles after the original issue date of this ser- vice bulletin. (a) (c) Do High Frequency Eddy Current (HFEC) and de- tail inspections in accor- dance with Part 1 of the Work Instructions, Para- graph 3.B.1.c. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 airplanes where the door flight cycles are not known. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 30 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 31 Table 2: Inspections, Repair and Preventative Modification at the Aft End of Cross Beam E Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 door flight cycles. (a) (b) (c) Within 4,500 door flight cy- cles after the original issue date of this ser- vice bulletin. (a) (c) Before 27,000 door flight cycles. Do High Frequency Eddy Current (HFEC) and de- tail inspections in accor- dance with Part 1 of the Work Instructions, Para- graph 3.B.1.c. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 airplanes where the door flight cycles are known. -Before further flight. (c)Install the repair in accor- dance with Part 2 and Part 4 of the Work Instruc- tions, Paragraph 3.B.2 and 3.B.4. Crack(s) found in the beam web or the T-chord. -Before further flight.Accomplish actions in ac- cordance with Tables 1 through 4 of Service Bul- letin 737-52-1154, Origi- nal Issue, Paragraph 1.E., Compliance. (c)Before 36,000 door flight cy- cles. Within 4 years or 9,000 door flight cycles after the original issue date of this ser- vice bulletin, whichever occurs later. Install a preventative modification in accor- dance with Part 2 and Part 6 of the Work Instruc- tions, Paragraph 3.B.2 and 3.B.6. No crack(s) found in the beam web and the T-chord. (a) If no cracks are found in the beam web or the T-chord, the preventative modification, in accordance with Part 2 and Part 6 of the work instructions, can be installed. (b) These repeat inspections are only required until the repair or preventative modification is installed to both ends of cross beam E. (c) After the repair or preventative modification is installed, supplemental inspections are required in accordance with Table 6. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 31 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 32 Table 3: One Time Inspections and Replacement of the Frame and Reinforcing Angle for the Forward Lower Corner Compliance Time (Whichever Occurs Later) ActionCondition -Within 4,500 door flight cycles after the original issue date of this service bulletin. Do one time ultrasonic and detail initial inspections in accordance with Part 1 of the Work Instructions, Paragraph 3.B.1.e. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 air- planes where the door flight cycles are not known. Within 4,500 door flight cycles after the original issue date of this service bulletin. Before 27,000 door flight cycles. Do one time ultrasonic and detail initial inspections in accordance with Part 1 of the Work Instructions, Paragraph 3.B.1.e. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 air- planes where the door flight cycles are known. Before 36,000 door flight cycles. (a) (b) Within 4 years or 9,000 door flight cycles after the original issue date of this service bul- letin, whichever oc- curs later. Do one time HFEC and ultrasonic ter- minating inspection in accordance with Part 1 of the Work Instructions, Para- graph 3.B.1.e. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 air- planes with no crack(s) found from the initial inspection. Before further flight.Replace the frame and reinforcing an- gle in accordance with Part 2 and Part 7 of the Work Instructions, Paragraph 3.B.2 and 3.B.7. Crack(s) found. Before further flight.Install the repair or preventative modi- fication to both ends of cross beam E, if not already installed. Install the repair in accordance with Part 3 or Part 4 of the work instructions as applicable. In- stall the preventative modification in accordance with Part 5 or Part 6 of the work instructions as applicable. Before further flight.Accomplish actions in accordance with Tables 1 through 4 of Service Bulletin 737-52-1154, Original Issue, Para- graph 1.E., Compliance. -No further action is necessary.No crack(s) found during ei- ther initial or terminating in- spections. (a) At the same time as the installation of the repair or preventative modification at the forward end of cross beam E, in accordance with Part 2 and Part 3 or Part 5 of this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 32 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 33 Table 3: One Time Inspections and Replacement of the Frame and Reinforcing Angle for the Forward Lower Corner Compliance Time (Whichever Occurs Later) ActionCondition (b) Ultrasonic inspections are not required if terminating inspections are accomplished at the same time as the initial inspections. Table 4: One Time Inspections and Replacement of the Frame and Reinforcing Angle for the Aft Lower Corner Compliance Time (Whichever Occurs Later) ActionCondition -Within 4,500 door flight cycles after the original issue date of this service bulletin. Do one time ultrasonic and detail initial inspections in accordance with Part 1 of the Work Instructions, Paragraph 3.B.1.f. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 airplanes where the door flight cycles are not known. Within 4,500 door flight cycles after the original issue date of this service bulletin. Before 27,000 door flight cycles. Do one time ultrasonic and detail initial inspections in accordance with Part 1 of the Work Instructions, Paragraph 3.B.1.f. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 airplanes where the door flight cycles are known. Before 36,000 door flight cycles. (a) (b) Within 4 years or 9,000 door flight cycles after the original issue date of this service bul- letin, whichever occurs later. Do one time HFEC and ultrasonic termi- nating inspections in accordance with Part 1 of the Work Instructions, Paragraph 3.B.1.f. Group 1 Configuration 1, Group 2 Configuration 1, Group 3 and Group 4, and Group 5 Configuration 1 airplanes with no crack(s) found from the initial inspec- tions. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 33 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 34 Table 4: One Time Inspections and Replacement of the Frame and Reinforcing Angle for the Aft Lower Corner Compliance Time (Whichever Occurs Later) ActionCondition Before further flight.Replace the frame and reinforcing angle in accordance with Part 2 and Part 8 of the Work Instructions, Paragraph 3.B.2 and 3.B.8. Crack(s) found. Before further flight.Install the repair or preventative modifica- tion to both ends of cross beam E, if not already installed. Install the repair in ac- cordance with Part 3 or Part 4 of the work instructions as applicable. Install the pre- ventative modification in accordance with Part 5 or Part 6 of the work instructions as applicable. Before further flight.Accomplish actions in accordance with Tables 1 through 4 of Service Bulletin 737-52-1154, Original Issue, Paragraph 1.E., Compliance. -No further action is necessary.No crack(s) found during either initial or terminating inspections. (a) At the same time as the installation of the repair or preventative modification at the aft end of cross beam E, in accordance with Part 2 and Part 4 or Part 6 of this service bulletin. (b) Ultrasonic inspections are not required if terminating inspections are accomplished at the same time as the initial inspections. Table 5: Supplemental Structural Inspections for Airplanes with a Preventative Modification or Repair Installed on the Forward End of Cross Beam E Repeat Inter- val (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 door flight cycles. Within 4,500 door flight cycles from the original issue date of this service bulletin. Before 56,000 total door flight cycles, or, Within 18,000 door flight cycles after the preventative modification is installed, whichever comes first. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in accordance with Work Instructions, Part 10 - Sup- plemental Structural Inspec- tions. Airplanes with a pre- ventative modification installed on the for- ward end of cross beam E in accordance with this service bul- letin and the door flight cycles are known. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 34 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 35 Table 5: Supplemental Structural Inspections for Airplanes with a Preventative Modification or Repair Installed on the Forward End of Cross Beam E Repeat Inter- val (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flightContact Boeing for repair instructions and do the re- pair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bul- letin 737-52-1154, Original Issue, Paragraph 1.E., Compliance. 4,500 door flight cycles. Within 4,500 door flight cycles from the original issue date of this service bulletin. Within 4,500 door flight cycles after the preven- tive modification is in- stalled. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in accordance with Work Instructions, Part 10 - Sup- plemental Structural Inspec- tions. Airplanes with a pre- ventative modification installed on the for- ward end of cross beam E in accordance with this service bul- letin and the door flight cycles are not known. -Before further flightContact Boeing for repair instructions and do the re- pair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bul- letin 737-52-1154, Original Issue, Paragraph 1.E., Compliance. 4,500 door flight cycles. Within 4,500 door flight cycles from the original issue date of this service bulletin. Before 56,000 total door flight cycles, or, Within 18,000 door flight cycles after the cross beam E repair is installed, whichever comes first. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in accordance with Work Instructions, Part 10 - Sup- plemental Structural Inspec- tions. Airplanes with a repair installed on the for- ward end of cross beam E in accordance with this service bul- letin and the door flight cycles are known. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 35 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 36 Table 5: Supplemental Structural Inspections for Airplanes with a Preventative Modification or Repair Installed on the Forward End of Cross Beam E Repeat Inter- val (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flightContact Boeing for repair instructions and do the re- pair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bul- letin 737-52-1154, Original Issue, Paragraph 1.E., Compliance. 4,500 door flight cycles Within 4,500 door flight cycles from the original issue date of this service bulletin. Within 4,500 door flight cycles after the cross beam E repair is in- stalled. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in accordance with Work Instructions, Part 10 - Sup- plemental Structural Inspec- tions. Airplanes with a repair installed on the for- ward end of cross beam E in accordance with this service bul- letin and the door flight cycles are not known. -Before further flightContact Boeing for repair instructions and do the re- pair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bul- letin 737-52-1154, Original Issue, Paragraph 1.E., Compliance. Table 6: Supplemental Structural Inspections for Airplanes with a Preventative Modification or Repair Installed on the Aft End of Cross Beam E Repeat Inter- val (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 door flight cycles Within 4,500 door flight cycles from the original issue date of this service bulletin. Before 56,000 total door flight cycles, or, Within 18,000 door flight cycles after the preventative modifica- tion is installed, whichever comes first. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in ac- cordance with Work Instruc- tions, Part 10 - Supplemen- tal Structural Inspections. Airplanes with a pre- ventative modification installed on the aft end of cross beam E in accordance with this service bulletin and the door flight cy- cles are known. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 36 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 37 Table 6: Supplemental Structural Inspections for Airplanes with a Preventative Modification or Repair Installed on the Aft End of Cross Beam E Repeat Inter- val (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flightContact Boeing for repair in- structions and do the repair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bulletin 737-52- 1154, Original Issue, Para- graph 1.E., Compliance. 4,500 door flight cycles Within 4,500 door flight cycles from the original issue date of this service bulletin. Within 4,500 door flight cycles after the preventative modifica- tion is installed. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in ac- cordance with Work Instruc- tions, Part 10 - Supplemen- tal Structural Inspections. Airplanes with a pre- ventative modification installed on the aft end of cross beam E in accordance with this service bulletin and the door flight cy- cles are not known. -Before further flightContact Boeing for repair in- structions and do the repair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bulletin 737-52- 1154, Original Issue, Para- graph 1.E., Compliance. 4,500 door flight cycles Within 4,500 door flight cycles from the original issue date of this service bulletin. Before 56,000 total door flight cycles, or, Within 18,000 door flight cycles after the cross beam E repair is installed, whichever comes first. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in ac- cordance with Work Instruc- tions, Part 10 - Supplemen- tal Structural Inspections. Airplanes with a repair installed on the aft end of cross beam E in accordance with this service bulletin and the door flight cy- cles are known. -Before further flightContact Boeing for repair in- structions and do the repair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bulletin 737-52- 1154, Original Issue, Para- graph 1.E., Compliance. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 37 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 38 Table 6: Supplemental Structural Inspections for Airplanes with a Preventative Modification or Repair Installed on the Aft End of Cross Beam E Repeat Inter- val (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 door flight cycles Within 4,500 door flight cycles from the original issue date of this service bulletin. Within 4,500 door flight cycles after the cross beam E repair is installed. Do a detailed inspection and a LFEC inspection of the cross beam for cracks in ac- cordance with Work Instruc- tions, Part 10 - Supplemen- tal Structural Inspections. Airplanes with a repair installed on the aft end of cross beam E in accordance with this service bulletin and the door flight cy- cles are not known. -Before further flightContact Boeing for repair in- structions and do the repair. Crack(s) found -Before further flight.Accomplish actions in accor- dance with Tables 1 through 4 of Service Bulletin 737-52- 1154, Original Issue, Para- graph 1.E., Compliance. 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. For airplanes identified in the original issue of this service bulletin, the repairs and/or modifications of this service bulletin have been reviewed as required by paragraphs (g) and (i) of Airworthiness Directive AD 2008-08-23, paragraphs (e) and (g) of AD 98-11-04 R1, and paragraphs (g) and (i) of AD 2008-09-13. The repairs and/or modifications are found to affect Structurally Significant Item (SSI) F-1 of Supplemental Structural Inspection Documents (SSID) D6-37089, Revisions D and E, and D6-82669, but the F-1 inspections remain effective with the repairs and/or modifications installed. Therefore, an alternative inspection is not necessary for F-1. Do the existing F-1 inspections as required per paragraph (i) of AD 2008-08-23, paragraph (c) of AD 98-11-04 R1, and paragraph (i) of AD 2008-09-13. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 38 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 39 For 737-100/200 series airplanes with a repair or modification installed in accordance with Boeing Alert Service Bulletin 737-52A1153, Original lssue that affects inspection of SSI F-1, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the inspection methods, thresholds and repeat intervals defined in Tables 5 and 6, as applicable, of Paragraph 1.E, Compliance, of Boeing Alert Service Bulletin 737-52A1153, original issue, as a method of compliance to the inspections of SSI F-1 required by paragraph (g) of AD 98-11-04 R1. This approval applies only to this SSI and only for the portions of the cross beam repaired or modified in accordance with this service bulletin. Operators must revise their FAA-approved maintenance or inspection program to comply with paragraph (g) of AD 98-11-04 R1 when incorporating the changes specified in this SB. For 737-100/200 series airplanes with unrepaired structure, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the inspection methods, thresholds and repeat intervals defined in Tables 1 and 2 of Paragraph 1.E, Compliance, of Boeing Alert Service Bulletin SB 737-52A1153, original issue, as an alternative method of compliance (AMOC) to the inspections of SSI F-1 required by paragraphs (b) and (c) of AD 98-11-04 R1. This approval applies only to this SSI and only for the portions of the cross beam inspected in accordance with this service bulletin. If operators choose this AMOC, then they must revise their FAA-approved maintenance or inspection program to incorporate these alternative inspections. In addition, for 737-200C series airplanes, the Manager of the FAA Seattle ACO approves the inspection methods, thresholds, repeat intervals, repairs and modifications defined in Tables 1, 2, 5, and 6 of Paragraph 1.E, Compliance, of Boeing Alert Service Bulletin 737-52A1153, original issue, as an AMOC to the inspections of SSI F-1 required by paragraphs (g) and (h), and repairs required by paragraph (j), of AD 2008-08-23. This approval applies only to this SSI and only for the portions of the cross beam that have been inspected, repaired, or modified in accordance with this service bulletin. If operators choose this AMOC, then they must revise their FAA-approved maintenance or inspection program to incorporate these alternative inspections. In addition, for 737-300/-400/-500 series airplanes, the Manager of the FAA Seattle (ACO) approves the inspection methods, thresholds, repeat intervals, repairs, and modifications defined in Tables 1, 2, 5, and 6 of Paragraph 1.E. Compliance, of Boeing Alert Service Bulletin 737-52A1153, original issue, as an AMOC to the inspections of SSI F-1 required by paragraphs (g) and (h), and repairs required by paragraph (j), of AD 2008-09-13. This approval applies only to this SSI and only for the portions of the cross beam that have been inspected, repaired, or modified in accordance with this service bulletin. If operators choose this AMOC, then they must revise their FAA-approved maintenance or inspection program to incorporate these alternative inspections. All provisions of AD 98-11-04 R1, AD 2008-08-23 and AD 2008-09-13 that are not specifically referenced above remain fully applicable and must be complied with accordingly. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (i) of AD 98-11-04 R1, paragraph (l) of AD 2008-08-23, or paragraph (l) of AD 2008-09-13, as applicable. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 39 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 40 G. Manpower The table below shows an estimate of the task-hours necessary to do this service bulletin for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-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 cure the materials — Time to make the parts — Time to find the tools. Group 1, 5, Configuration 1: Group 1, Configuration 1; Group 5, Configuration 1: Elapsed HoursTask-HoursNumber of Per- sons Task Forward and Aft End of Cross Beam E and Adjacent Lower Corner Frame In- spection Part 1 0.250.251Prepare Aft Cargo Door 2.304.602FIGURE 1 2.304.602FIGURE 3 0.250.502FIGURE 5 0.250.502FIGURE 7 5.3510.45TOTAL FOR INSPECTION FOR EACH AIRPLANE Cross Beam E Repair Part 2 3.006.002Open Access Part 3 - Forward End 8.008.001FIGURE 9 12.0012.001FIGURE 12 Part 4 - Aft End 8.008.001FIGURE 15 14.0014.001FIGURE 18 Part 9 5.0010.002Close Access BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 40 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 41 Group 1, 5, Configuration 1: Group 1, Configuration 1; Group 5, Configuration 1: Elapsed HoursTask-HoursNumber of Per- sons Task 50.0058.00TOTAL FOR REPAIR FOR EACH AIR- PLANE Cross Beam E Preventative Modification Part 2 3.006.002Open Access Part 5 - Forward End 2.304.602FIGURE 21 0.751.502FIGURE 27 0.400.802FIGURE 29 Part 6 - Aft End 2.304.602FIGURE 24 0.751.502FIGURE 32 0.400.802FIGURE 34 Part 9 5.0010.002Close Access 14.9029.80TOTAL FOR PREVENTATIVE MODIFI- CATION FOR EACH AIRPLANE Lower Corner Frame and Reinforcing Angle Replacement Part 2 3.006.002Open Access Part 7 - Forward 0.751.502FIGURE 37 Part 8 - Aft 0.751.502FIGURE 38 Part 9 5.0010.002Close Access 9.5019.00TOTAL FOR REPLACEMENT FOR EACH AIRPLANE Supplemental Structural Inspections Part 10 3.003.001FIGURE 41 3.003.001FIGURE 42 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 41 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 42 Group 1, 5, Configuration 1: Group 1, Configuration 1; Group 5, Configuration 1: Elapsed HoursTask-HoursNumber of Per- sons Task 6.006.00TOTAL FOR SUPPLEMENTAL INSPEC- TION FOR EACH AIRPLANE Group 2-4, Configuration 1: Elapsed HoursTask-HoursNumber of Per- sons Task Forward and Aft End of Cross Beam E and Adjacent Lower Corner Frame In- spection Part 1 0.250.251Prepare Aft Cargo Door 2.304.602FIGURE 1 2.304.602FIGURE 3 0.250.502FIGURE 5 0.250.502FIGURE 7 5.3510.45TOTAL FOR INSPECTION FOR EACH AIRPLANE Cross Beam E Repair Part 2 3.006.002Open Access Part 3 - Forward End 8.008.001FIGURE 10 12.0012.001FIGURE 13 Part 4 - Aft End 8.008.001FIGURE 16 14.0014.001FIGURE 19 Part 9 5.0010.002Close Access 50.0058.00TOTAL FOR REPAIR FOR EACH AIR- PLANE Cross Beam E Preventative Modification Part 2 3.006.002Open Access BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 42 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 43 Group 2-4, Configuration 1: Elapsed HoursTask-HoursNumber of Per- sons Task Part 5 - Forward End 2.304.602FIGURE 22 0.751.502FIGURE 27 0.400.802FIGURE 30 Part 6 - Aft End 2.304.602FIGURE 25 0.751.502FIGURE 32 0.400.802FIGURE 35 Part 9 5.0010.002Close Access 14.9029.80TOTAL FOR PREVENTATIVE MODIFI- CATION FOR EACH AIRPLANE Lower Corner Frame and Reinforcing Angle Replacement Part 2 3.006.002Open Access Part 7 - Forward 0.751.502FIGURE 39 Part 8 - Aft 0.751.502FIGURE 40 Part 9 5.0010.002Close Access 9.5019.00TOTAL FOR REPLACEMENT FOR EACH AIRPLANE Supplemental Structural Inspections Part 10 3.003.001FIGURE 41 3.003.001FIGURE 42 6.006.00TOTAL FOR SUPPLEMENTAL INSPEC- TION FOR EACH AIRPLANE BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 43 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 44 Group 3-4, Configuration 2: Elapsed HoursTask-HoursNumber of Per- sons Task Forward and Aft End of Cross Beam E and Adjacent Lower Corner Frame In- spection Part 1 0.250.251Prepare Aft Cargo Door 2.304.602FIGURE 2 2.304.602FIGURE 4 0.250.502FIGURE 6 0.250.502FIGURE 8 5.3510.45TOTAL FOR INSPECTION FOR EACH AIRPLANE Cross Beam E Repair Part 2 3.006.002Open Access Part 3 - Forward End 8.008.001FIGURE 11 12.0012.001FIGURE 14 Part 4 - Aft End 8.008.001FIGURE 17 14.0014.001FIGURE 20 Part 9 5.0010.002Close Access 50.0058.00TOTAL FOR REPAIR FOR EACH AIR- PLANE Cross Beam E Preventative Modification Part 2 3.006.002Open Access Part 5 - Forward End 2.304.602FIGURE 23 0.751.502FIGURE 28 0.400.802FIGURE 31 Part 6 - Aft End 2.304.602FIGURE 26 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 44 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 45 Group 3-4, Configuration 2: Elapsed HoursTask-HoursNumber of Per- sons Task 0.751.502FIGURE 33 0.400.802FIGURE 36 Part 9 5.0010.002Close Access 14.9029.80TOTAL FOR PREVENTATIVE MODIFI- CATION FOR EACH AIRPLANE Lower Corner Frame and Reinforcing Angle Replacement Part 2 3.006.002Open Access Part 7 - Forward 0.751.502FIGURE 39 Part 8 - Aft 0.751.502FIGURE 40 Part 9 5.0010.002Close Access 9.5019.00TOTAL FOR REPLACEMENT FOR EACH AIRPLANE Supplemental Structural Inspections Part 10 3.003.001FIGURE 41 3.003.001FIGURE 42 6.006.00TOTAL FOR SUPPLEMENTAL INSPEC- TION FOR EACH AIRPLANE H. Weight and Balance Changes Repair for the forward end of cross beam E Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +1,255+1.5737-200/200C +1,345+1.5737-300 +1,420+1.5737-400 +1,290+1.5737-500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 45 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 46 Repair for the aft end of cross beam E Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +1,330+1.5737-200/200C +1,420+1.5737-300 +1,490+1.5737-400 +1,360+1.5737-500 Preventative modification for the forward end of cross beam E Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +835+1.0737-200/200C +900+1.0737-300 +945+1.0737-400 +860+1.0737-500 Preventative modification for the aft end of cross beam E Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +885+1.0737-200/200C +945+1.0737-300 +995+1.0737-400 +905+1.0737-500 I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 35005-259RS. b. Service Related Problem (SRP) 737-SRP-52-0072. c. Boeing Document D6-38505, Aging airplane service bulletin structural modification and inspection program, models 737-100/-200/-200C. d. 737-300/400/500 Supplemental Structural Inspection Document (SSID) D6-82669, SSI F-1. e. 737-100/200 Aircraft Maintenance Manual (AMM) 52-09-121, 52-31-0. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 46 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 47 f. 737-300/400/500 Aircraft Maintenance Manual (AMM) 52-09-12, 52-31-00. g. 737-100/200 Structural Repair Manual (SRM) 51-10-02, 51-30-02. h. 737-300/400/500 Structural Repair Manual (SRM) 737-300 SRM 51-20-01, 737-400 SRM 51-20-01, 737-500 SRM 51-20-01, 737-300 SRM 51-40-02, 737-400 SRM 51-40-02, 737-500 SRM 51-40-02. i. 737 Nondestructive Test (NDT) Manual, Part 4, 52-10-02, Part 6, 51-00-00, Figures 1, 4, 11, 13, 16, 23, 24 and Part 6, 52-30-01. j. Overhaul Manual OHM 52-36-12. k. 737 Structural Item Interim Advisory (SIIA) SIIA 737-293. l. Boeing Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-50-19. m. Boeing Service Bulletin 737-52A1079, 737-52-1154. n. Boeing Service Letter 737-SL-00-018. o. Federal Aviation Administration (FAA) Airworthiness Directives (AD) 98-11-04 R1, 2008-08-23 and 2008-09-13. p. Boeing Parts Standards Document D-590. q. Boeing Drawing 005W0900. 2. Data supplied with this Service Bulletin: a. Drawings: ADCNDCN/REVSheetTitleDrawing No -B1Top Kit - Beam E Modification, Aft Cargo Door 65C37547 -A15 -A16 -B2 -B3 -B4 -AKPLTop Kit - Beam E Modification, Aft Cargo Door 65C37547-1 -CPLBeam E Modification - Parts Collector65C37547-2 -AKPLTop Kit -Beam E Modification, Aft Cargo Door 65C37547-3 -CPLBeam E Modification - Parts Collector65C37547-4 -CKPLTop Kit - Fwd Frame, Aft Cargo Door65C37547-50 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 47 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 48 ADCNDCN/REVSheetTitleDrawing No -CKPLTop Kit - Aft Frame, Aft Cargo Door65C37547-60 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Door Assy - Aft Cargo65-47952 This drawing was used to prepare this service bulletin. This drawing is not necessary to make the specified changes, and is not supplied with this service bulletin. This drawing may not be applicable to all airplane configurations or operators. 4. Process Data: Boeing Process specifications referred to on the drawings are not given in this service bulletin since these procedures are frequently used as standard shop practices. K. Publications Affected 1. Publications None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS and new DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. But, refer to Paragraph 2.C.3., Parts Modified and Reidentified, for aft cargo door interchangeability data. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 48 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 49 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane, and Paragraph 2.D., Parts Necessary to Change Spares, as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. Unit Price thru Mar 31/09 ROLT (Weeks) QTYDateNameKit Number $30,536.0089 201AvailableTop Kit - Beam E Modifi- cation, Aft Cargo Door 65C37547-1 $30,690.0089 50AvailableTop Kit - Beam E Modifi- cation, Aft Cargo Door 65C37547-3 $9,647.0089 50AvailableTop Kit - Forward Frame, Aft Cargo Door 65C37547-50 $9,686.0089 50AvailableTop Kit - Aft Frame, Aft Cargo Door 65C37547-60 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. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA B. 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 49 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 50 C. Parts Necessary For Each Airplane 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. 1. 2. Top kits 65C37547-50 and 65C37547-60 are only necessary if the forward and/or aft lower frame and reinforcing angle are cracked. Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1: Kit 65C37547 NotesNameQTYNew Part Number -1 -2 -3 -4 -50 -60 -TOP KIT - BEAM E MODIFI- CATION, AFT CARGO DOOR - . . . . .65C37547-1 -PARTS COLLECTOR1 - . . . .65C37547-2 -TOP KIT - BEAM E MODIFI- CATION, AFT CARGO DOOR . . - . . .65C37547-3 -PARTS COLLECTOR. . 1 - . .65C37547-4 -TOPKIT, FWD FRAME, AFT CARGO DOOR . . . . - .65C37547-50 -TOPKIT, AFT FRAME, AFT CARGO DOOR . . . . . -65C37547-60 -ANGLE. . . . . 165-47952-182 -ANGLE. . . . 1 .65-47952-189 -FRAME. . . . 1 .65-47952-353 (b)FRAME. . . . . 165-47952U355 (d)FWD MOD SUBKIT1 . . . . .65C37547-5 (d)AFT MOD SUBKIT1 . . . . .65C37547-6 (c)FWD REPAIR SUBKIT1 . . . . .65C37547-7 (c)AFT REPAIR SUBKIT1 . . . . .65C37547-8 (d)FWD MOD SUBKIT. . 1 . . .65C37547-15 (d)AFT MOD SUBKIT. . 1 . . .65C37547-16 (c)FWD REPAIR SUBKIT. . 1 . . .65C37547-17 (c)AFT REPAIR SUBKIT. . 1 . . .65C37547-18 -CHANNEL, AFT. 1 . 1 . .65C37547-20 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 50 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 51 Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1: Kit 65C37547 NotesNameQTYNew Part Number -1 -2 -3 -4 -50 -60 -FILLER, WEB, AFT. 1 . 1 . .65C37547-21 -RADIUS FILLER. 1 . . . .65C37547-22 -SPLICE, OUTER CHORD, FWD . 1 . 1 . .65C37547-23 -FILLER, CHORD, FWD. 1 . 1 . .65C37547-24 -FWD CHORD REPAIR FILLER . 1 . 1 . .65C37547-25 -SPLICE, INNER CHORD, FWD . 1 . 1 . .65C37547-26 -CHANNEL, FWD. 1 . 1 . .65C37547-30 -FILLER, WEB, FWD. 1 . 1 . .65C37547-31 -RADIUS FILLER. 1 . 1 . .65C37547-32 -SPLICE, OUTER CHORD, AFT . 1 . 1 . .65C37547-33 -FILLER, CHORD, AFT. 1 . 1 . .65C37547-34 -AFT CHORD REPAIR FILLER . 1 . 1 . .65C37547-35 -SPLICE, INNER CHORD, AFT . 1 . 1 . .65C37547-36 -WEB ANGLE. 2 . 2 . .65C37547-38 (a)BOLT. . . . . 1BACB30MC6A4 (a)BOLT, PROTRUDING HEAD . . . . . 3BACB30MC6A5 (a)BOLT. . . . 2 .BACB30MC6A6 (a)BOLT. . . . 1 .BACB30MC6A8 (a)BOLT, PROTRUDING HD. 26 . 28 . .BACB30MY8K7X (a)BOLT, 100 DEG HEX DR. . . 3 11 8BACB30NW6K3Y (a)BOLT, 100 DEG HEX DR. 5 . 5 22 27BACB30NW6K6Y (a)BOLT, HEX DRIVE. . . 5 . .BACB30NX6K2Y (a)BOLT, PROTRUDING HD. 18 . . 13 9BACB30NX6K3Y (a)BOLT, PROTRUDING HD. 55 . 78 1 9BACB30NX6K4Y (a)BOLT, PROTRUDING HD. 27 . 26 . .BACB30NX6K5Y (a)BOLT, PROTRUDING HD. 2 . 4 . .BACB30NX8K4X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 51 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 52 Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1: Kit 65C37547 NotesNameQTYNew Part Number -1 -2 -3 -4 -50 -60 (a)BOLT, PROTRUDING HD. 18 . 22 . .BACB30NX8K7X (a)BOLT. 75 . . 22 16BACB30VH05CD02S (BACB30VW5P02UX- optional) (a)BOLT. 115 . 45 3 3BACB30VH05CD03S (BACB30VW5P03UX- optional) (a)BOLT. 29 . 165 . .BACB30VH05CD04S (BACB30VW5P04UX- optional) (a)BOLT. 15 . . . .BACB30VH05CD05S (BACB30VW5P05UX- optional) (a)BOLT. 12 . . . .BACB30VH05CD06S (BACB30VW5P06UX- optional) (a)BOLT. 3 . . . .BACB30VH05CD07S (BACB30VW5P07UX- optional) (a)BOLT, BLIND. . . . 4 .BACB30VH06CD02S (BACB30VW6P02UX- optional) (a)BOLT, BLIND. 18 . 3 5 5BACB30VH06CD03S (BACB30VW6P03UX- optional) (a)BOLT, BLIND. 5 . 15 5 11BACB30VH06CD04S (BACB30VW6P04UX- optional) (a)BOLT, BLIND. 5 . 63 . 3BACB30VH06CD05S (BACB30VW6P05UX- optional) (a)BOLT, BLIND. . . 3 . .BACB30VH06CD06S (BACB30VW6P06UX- optional) (a)BOLT, PROTRUDING HD. 17 . 17 . .BACB30VT5HK5 (a)BOLT, PROTRUDING HD. 9 . 5 . .BACB30VT6K2 (a)BOLT, PROTRUDING HEAD . . . . . 3BACB30VT6K3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 52 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 53 Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1: Kit 65C37547 NotesNameQTYNew Part Number -1 -2 -3 -4 -50 -60 (a)BOLT. 112 . 112 3 5BACB30VT6K4 (a)BOLT. . . . 18 18BACB30VT6K5 (a)BOLT. . . . 2 13BACB30VT6K6 (a)BOLT. . . . 3 .BACB30VT6K8 (a)BOLT. 2 . . . .BACB30VT8K4 (a)BOLT, 100 DEG HEX DR. 25 . 25 . .BACB30YP5K2 (a)BOLT, 100 DEG HEX DR. 25 . 25 . .BACB30YP5K5 (a)BOLT, 100 DEG HEX DR. . . . . 1BACB30YP6K4 (a)BOLT, 100 DEG HEX DR. . . . . 2BACB30YP6K5 (a)BOLT, 100 DEG HEX DR. . . . 1 .BACB30YP6K6 (a)BOLT, 100 DEG HEX DR. . . . 2 .BACB30YP6K8 -COLLAR, PRELOAD. 105 . 113 47 53BACC30AB6CY -COLLAR. 38 . 24 . .BACC30BH8 -COLLAR, SHEAR. 16 . 17 . .BACC30BL5 -COLLAR. 132 . 117 29 42BACC30BL6 -COLLAR. 2 . . . .BACC30BL8 -COLLAR, SHEAR. 51 . 50 . .BACC30BS5 -COLLAR. 26 . 28 . .BACC30M8 -COLLAR. . . . 3 4BACC30X6 -NUTPLATE. 3 . 19 . .BACN10JN3CD -NUTPLATE. 13 . 13 2 5BACN10JR3CD -NUTPLATE. 21 . . 7 1BACN10JR3CFD (a)RIVET. . . . 7 8BACR15BB4D4C (a)RIVET, UNIVERSAL HEAD. . . . 5 4BACR15BB4D5C (a)RIVET. . . . 4 4BACR15DS7D4 (a)RIVET. 2 . 2 8 8BACR15DS7D6 (a)RIVET, UNIVERSAL HD. . . . 6 .BACR15FT5D5C (a)RIVET, UNIVERSAL HD. . . . . 2BACR15FT5D6C (a)RIVET, UNIVERSAL HD. . . . 2 .BACR15FT6D4C (a)RIVET, UNIVERSAL HD. . . . 14 15BACR15FT6D6C BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 53 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 54 Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1: Kit 65C37547 NotesNameQTYNew Part Number -1 -2 -3 -4 -50 -60 (a)RIVET, 100 DEG. 75 . 75 . .BACR15GF3D5 (a)RIVET, 100 DEG. 27 . . . .BACR15GF5D3 (a)RIVET, 100 DEG. 16 . 16 . .BACR15GF5D4 (a)RIVET. 17 . 19 . .BACR15GF5D5 (a)RIVET, 100 DEG. . . . 5 5BACR15GF6D4 (a)RIVET. 7 . . 3 3BACR15GF6D5 (a)RIVET, 100 DEG. 15 . 15 50 36BACR15GF6D6 (a)RIVET, 100 DEG. . . 13 6 5BACR15GF6D7 (a)PAN HEAD SCREWS. 19 . 19 . .BACS12CK3-7 (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 D590 is used to determine the part numbers used as substitutes. (b) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the 'dash' configuration when installed in accordance with the Accomplishment Instructions of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Service Letter 737 SL 00 018 for more information. (c) This subkit has no parts. It only includes instructions for the repair in accordance with drawing 65C37547, which is supplied with this service bulletin. (d) This subkit has no parts. It only includes instructions for the preventative modification in accor- dance with drawing 65C37547, which is supplied with this service bulletin. 2. Parts and Materials Supplied by the Operator: Group 1-2, Configuration 1; Group 3-4; Group 5, Configuration 1: NotesNameQTYPart Number / Speci- fication (a)Sealant1 PintBMS 5-95, Type I, Class B-1/2 or -2 (a)Primer1 PintBMS 10-11, Type I (a)Chemical Conversion Coating1 PintMIL-C-5541 (Alodine 1200S) (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 54 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 55 Group 1-2, 5, Configuration 2: None. 3. Parts Modified and Reidentified: The parts shown below are changed in accordance with this service bulletin. The quantity (QTY) is the number of parts changed on each airplane. NOTE: The aft cargo door assemblies identified below show the groups and the applicable door that was installed when the airplane was delivered. 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 or perform the inspection in accordance with paragraph 3.B.1., Work Instructions, of this service bulletin. It is possible that the doors identified for Group 3 and Group 4 airplanes could be interchanged with each other by operators. It is recommended that operators check their records to identify which door assembly is currently installed on each airplane or perform the inspection in accordance with paragraph 3.B.1., Work Instructions, of this service bulletin. Group 1, 5, Configuration 1: NotesNew Part NumberNameQTYExisting Part Number (a) (b)-Door Assembly165-47952-524 (a) Make the change in accordance with this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change in accordance with this service bulletin was made. Group 2, Configuration 1: NotesNew Part NumberNameQTYExisting Part Number (a) (b)-Door Assembly165-47952-166 (a) Make the change in accordance with this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change in accordance with this service bulletin was made. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 55 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 56 Group 3-4, Configuration 1: NotesNew Part NumberNameQTYExisting Part Number (a) (b)-Door Assembly165-47952-183 or 65-47952-230 or 65-47952-337 or 65-47952-340 (a) Make the change in accordance with this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change in accordance with this service bulletin was made. Group 3-4, Configuration 2: NotesNew Part NumberNameQTYExisting Part Number (a) (b)-Door Assembly165-47952-358 (a) Make the change in accordance with this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change in accordance with this service bulletin was made. Group 1-2, 5, Configuration 2: NotesNew Part NumberNameQTYExisting Part Number (a)-Door Assembly165-47952-1 or 65- 47952-524 (a) Do not make the change in accordance with this service bulletin. Accomplish all applicable actions in accordance with service bulletin 737-52A1079 Revision 7. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability. Group 1-4, Configuration 1: QTYNamePart Number 1TOP KIT - BEAM E MODIFICATION, AFT CARGO DOOR65C37547-1 1TOP KIT, FWD FRAME, AFT CARGO DOOR65C37547-50 1TOPKIT, AFT FRAME, AFT CARGO DOOR65C37547-60 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 56 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 57 Group 3-4, Configuration 2: QTYNamePart Number 1TOP KIT - BEAM E MODIFICATION, AFT CARGO DOOR65C37547-3 1TOP KIT, FWD FRAME, AFT CARGO DOOR65C37547-50 1TOP KIT, AFT FRAME, AFT CARGO DOOR65C37547-60 E. Special Tooling - Price and Availability The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Tool price and supply data are not given. F. Special Tooling Necessary to do this Service Bulletin To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available. NotesNameTool Part Number (a)(c)TransducerSUS 1015-10MHz-70A (b)(c)TransducerHS-7520-10-70A (a) Available from: NDT Engineering Corporation (Cage Code 61100) 19620 Russell Road Kent, WA 98032-1115 (b) Available from: Staveley Sensors Inc (Cage Code 59334) 91 Prestige Park Circle East Hartford, CT 06108-1918 (c) A different vendor can make the transducer. But it must have the properties specified below, that the transducer: — Puts a shear wave in aluminum that is between 65 and 75 degrees. — Operates at a frequency of between 9 MHz and 11 MHz. — Has a maximum outer case length of 0.315 inches (8.0 mm). — Can give satisfactory results during calibration as specified in 737 NDT, Part 4, 52-10-02. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 57 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 58 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 58 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT BLANK PAGE ### Page 59 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. — For hole dimensions for standard solid rivets, refer to 737 Structural Repair Manual, Chapter 51. — For torque limits to tighten nuts and bolts, refer to 737 Structural Repair Manual, Chapter 51. — Shim all gaps greater than 0.005 inches. 4. For approved fastener and process material substitutions, refer to 737 Structural Repair Manual, Chapter 51. For alternate fasteners, refer to 737 Structural Repair Manual Chapter 51. 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. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 7. These work instructions refer to procedures included on other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 8. Refer to the table that follows to identify the correct group and configuration of the airplane. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 59 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT ### Page 60 ConfigurationAirplane Group Effectivity of airplane on which door is installed Effectivity of airplane on which door was delivered Door Part Num- ber 25Line numbers 6 - 873737-200/200C line numbers 6 - 873 65-47952-1 or 65- 47952-524 (a) 21 or 2 (c)Line numbers 874 - 1642 11 or 2 (c)Line numbers 874 - 1642Line numbers 874 - 1642 65-47952-524 (b) 15Line numbers 6 - 873 11 or 2 (c)Line numbers 874 - 1642737-300/-400 line num- bers 874 - 1642 65-47952-166 15Line numbers 6 - 873 13Line numbers 1643 - 2414Line numbers 1643 - 2414 65-47952-183, - 230, -337 or -340 14Line numbers 2415 - 3132 23Line numbers 1643 - 2414Line numbers 2415 - 3132 65-47952-358 24Line numbers 2415 - 3132 (a) 65-47952-524 door assemblies that were delivered on airplanes with line numbers 6 thru 873 that have a 0.050 inch thick lower beam web. (b) 65-47952-524 door assemblies that were delivered on airplanes with line numbers 874 and on that have a 0.063 inch thick lower beam web and internal steel reinforcing angles in the four corners. (c) 737-200/200C are Group 1 airplanes and 737-300/-400 are Group 2 airplanes. B. WORK INSTRUCTIONS Group 1-5: 1. Identify the aft cargo door assembly part number which is currently installed on each airplane. Refer to Paragraph 3.A., Note 8 to identify the correct group and configuration of the airplane. If the door is found to be from an airplane in the line number range 6-873, accomplish all applicable actions in accordance with service bulletin 737-52A1079, Revision 7. After the door is identified, do the work instructions of the applicable group which the door is related to. Group 1, 5, Configuration 1: 1. PART 1 - FORWARD AND AFT CROSS BEAM E AND ADJACENT CORNER FRAME AND REINFORCING ANGLE INSPECTION NOTE: It is possible that the forward and aft end of cross beam E and the forward and aft lower corner frame and reinforcing angle could be in different conditions. Do the work in accordance with subsequent Parts 3, 4, 5, 6, 7 and 8 as necessary, to agree with what is found from the inspections below and the thresholds given in Paragraph 1.E., Compliance. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 13, 2011 737-52A1153 60 of 239 BOEING SERVICE BULLETIN 737-52A1153 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/737-52a1153/file/b9ae385b1c4e.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.