# Boeing Alert Service Bulletin 737-53A1108: U.S. DOT/FAA - Service Bulletin

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2014-0572; AD 2015-15-05 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 737-53A1108](https://openairdocs.org/service-documents/boeing/737-53a1108.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin
- Pages: 118
- PDF: https://openairdocs.org/files/sha256/02/53/0253d8ac755c569a519c2143e175cde6ea71e28cb7292ee50da393892f7f7843
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## Text

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### Page 1

Commercial 
Airplanes
737
Service Bulletin
ALERT
Number: 737-53A1108
Original Issue: December 15, 1986
Revision 7: July 07, 2014
ATA System: 5313
SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Galley Service Doorway, Aft Frame -
Inspection and Repair
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 300-774). 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 © 1989 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and
Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
Original Issue: December 15, 1986
737-53A1108Revision 7: July 07, 2014
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2.0

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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
1. PLANNING INFORMATION ........................................ 1 3
A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 7
B. Concurrent Requirements ...................................... 2 7
C. Reason ................................................ 2 7
D. Description .............................................. 2 9
E. Compliance .............................................. 3 1
F. Approval ............................................... 5 0
G. Manpower .............................................. 5 0
H. Weight and Balance Changes .................................... 5 3
I. Electrical Load Data ......................................... 5 4
J. References .............................................. 5 4
1. Existing Data: ......................................... 5 4
2. Data Supplied with this Service Bulletin: ........................... 5 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 5
K. Publications Affected ........................................ 5 5
L. Interchangeability and Intermixability of Parts ........................... 5 5
M. Software Accomplishment Summary ................................ 5 5
2. MATERIAL INFORMATION ........................................ 5 7
A. Material - Price and Availability ................................... 5 7
B. Industry Support Information .................................... 5 8
C. Parts Necessary for Each Airplane ................................. 5 8
1. Kits/Parts ............................................ 5 8
2. Parts and Materials Supplied by the Operator ........................ 6 1
3. Parts Modified and Reidentified ................................ 6 2
4. Parts Removed and Not Replaced .............................. 6 2
D. Parts Necessary to Change Spares ................................. 6 2
E. Special Tooling - Price and Availability ............................... 6 2
F. Special Tooling Necessary to do this Service Bulletin ....................... 6 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 3
A. GENERAL INFORMATION ..................................... 6 3
B. WORK INSTRUCTIONS ....................................... 6 4
FIGURE 1: DOORWAY FRAME WEB AT STA 332.1 - INSPECTION [Group 1-4] ........... 8 0
FIGURE 2: DOORWAY BETWEEN STA 332.1 AND STA 344 - INTERCOSTAL AND STRINGER -
INSPECTION [Group 1, 4, Configuration 2] .......................... 8 2
FIGURE 3: DOORWAY BETWEEN STA 322.1 AND STA 344 - INTERCOSTAL - REPAIR [Group 1] . 84
FIGURE 4: DOORWAY BETWEEN STA 322.1 AND STA 344 - INTERCOSTAL - PREVENTIVE
MODIFICATION [Group 1, Configuration 2] .......................... 8 6
FIGURE 5: DOORWAY BETWEEN STA 322.1 AND STA 344 - INTERCOSTAL - PREVENTIVE
MODIFICATION/REPAIR [Group 4, Configuration 2] ..................... 8 8
FIGURE 6: DOORWAY FRAME STA 332.1 - INTERCOSTAL T-BRACKET SURFACE AND RADIUS -
INSPECTION [Group 1-4] ................................... 9 0
FIGURE 7: INTERCOSTAL AFT INBOARD WEB, FRAME STA 334 - INSPECTION [Group 1-2] . . . 98
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FIGURE 8: INTERCOSTAL T-CHORD - INSPECTION [Group 3] .................... 1 0 0
FIGURE 9: DOORWAY FRAME STA 334, SHEAR TIES AND STRINGER CLIPS - INSPECTION [Group
1-4] ............................................... 1 0 4
FIGURE 10: DOORWAY BETWEEN STA 332.1 AND STA 344 - INTERCOSTAL AND STRINGER -
INSPECTION [Group 1-4] .................................. 1 0 9
FIGURE 11: DOORWAY BETWEEN STA 332.1 AND STA 344 - STRINGER - INSPECTION [Group 1-4]
................................................. 1 1 4
APPENDIX A: PARTS LIST FOR FORWARD SERVICE DOORWAY - AFT SURROUND STRUCTURE . 116
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Commercial 
Airplanes
737
Service Bulletin
ALERT
Revision Transmittal SheetNumber: 737-53A1108Original Issue: December 15, 1986
Revision 7: July 07, 2014
ATA System: 5313
SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Galley Service Doorway, Aft Frame -
Inspection and Repair
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
No more work is necessary on the airplane(s) changed or inspected in accordance with Revision 6 of this service
bulletin.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to
this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service
bulletin mandatory.
Federal Aviation Administration (FAA) Airworthiness Directive AD 98-22-10 is related to this service bulletin.
FAA AD 98-22-10 supersedes AD 88-03-03.
REASON FOR REVISION
This revision is sent to change Figure 8 step table and to correct typographical errors in Compliance Table 10
and Appendix A.
These sections were changed:
1. Paragraph 1.E., Compliance, Table 10, changed work instruction references.
2. Figure 8, Sheet 1, updated view callouts to match step table instructions.
3. Figure 8, Sheet 4, changed step table.
4. Appendix A, Sheet 3, changed Group applicability.
The data given in Information Notice 737-53A1108 R06 IN 01 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes,
to show the location of all content changes.
Pages with no vertical lines have no changes.
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REVISION HISTORY
December 15, 1986Original Issue:
March 26, 1987Revision 1:
August 13, 1987Revision 2:
March 03, 1988Revision 3:
November 17, 1988Revision 4:
October 26, 1989Revision 5:
January 09, 2014Revision 6:
July 07, 2014Revision 7:
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Commercial 
Airplanes
737
Service Bulletin
ALERT
SummaryNumber: 737-53A1108Original Issue: December 15, 1986
Revision 7: July 07, 2014
ATA System: 5313
SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Galley Service Doorway, Aft Frame -
Inspection and Repair
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
As a result of the Federal Aviation Administration (FAA) sponsored Aging Fleet conference, a 737 Structures
Working Group with Airline, Boeing members, and FAA observers was formed to review structural service bulletin
modifications and recommend selected bulletins for incorporation on aging airplanes. This service bulletin
modification has been recommended for incorporation on aging 737 airplanes.
Accomplishment of this service bulletin visual inspection of the forward service doorway aft frame around the
six door stop fittings will identify structural cracking severe enough to weaken the door stop support structure.
A cracked doorway frame and supporting structure at two adjacent door stops can result in door deflection, loss
of pressurization, and possible major structural damage to the doorway.
Four operators have reported eleven airplanes with cracks in the forward service doorway aft frame at door stop
locations, supporting intercostals and stringers just aft of the frame, or in both the frame and the supporting
structure. In four airplanes there was at least one intercostal completely severed.
The reported airplanes had accumulated from 16,100 to 45,400 flight hours, and from 19,200 to 51,300 total
flight cycles.
Since the release of Revision 5 of this service bulletin Boeing has received multiple reports of crack damage in
the forward galley service doorway surround structure, between Body Station (STA) 332.1and STA 344 that are
outside the inspection area and effectivity of the service bulletin. The following list is a summary of safety related
crack reports:
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– There have been four reports of cracking of the door stop 1 intercostal T-Bracket occurring at radius of the
intercostal T-Bracket on airplanes that have accumulated between 27,938 and 78,547 total flight cycles.
There has been one report of a intercostal T-Bracket crack on an aircraft that had accomplished the preventive
modification in accordance with Revision 5 of this service bulletin. Intercostal T-Bracket cracks have also
been reported on aircraft outside the effectivity of Revision 5 of this service bulletin. Multiple operators have
reported severed intercostal T-Bracket resulting in extensive cracking around the STA 332.1 door stop 1
fitting.
– There has been one report of a door stop 2 intercostal T-Bracket crack occurring at the frame attach flange
on an aircraft that had accumulated 62,528 total flight cycles.
– There have been three reports of cracking of the door stop 1 intercostal T-Chord occurring at the forward
trim radius of the T-Chord on airplanes that have accumulated between 37,684 and 63,305 total flight cycles.
Multiple operators have reported severed T-Chords resulting in extensive cracking at the intercostal web
and around the STA 332.1 door stop 1 fitting.
– There have been two reports of STA 332.1 frame web cracking around the door stop 1 fitting without
associated intercostal cracking on aircraft that had accumulated 62,272 and 62,528 total flight cycles.
– There have been three reports of cracking of the door stop 3 intercostal web occurring at the aft inboard
trim radius on aircraft that have accumulated as low as 38,847 total flight cycles. All three aircraft had
accomplished the preventive modification in accordance with Revision 5 of this service bulletin.
In addition Boeing has received reports of cracking that have been determined not to be a safety issue. These
crack reports are summarized in the following list:
– There have been three reports of door stop 3 and 4 intercostal web cracks occurring at the aft outboard
bend radius of the integral skin attachment flange on aircraft that had accumulated between 36,648 and
63,305 total flight cycles.
– There have been multiple reports of STA 344 stringer clip cracking occurring on aircraft that have accumulated
as low as 22,147 total flight cycles.
– There have been two reports of STA 344 shear tie cracking occurring as early as 31,077 total flight cycles.
Boeing Service Related Problem (SRP) 737-SRP-53-0380 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
Paragraph 1.E., Compliance and Paragraph
1.F., Approval
YesAD Related
Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedNoPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsNoKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
NoOperator Supplied Parts/Material
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ReferenceAffectedPlanning Data
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION (PRR 34320R)
Group 5:
Contact Boeing for inspection, modification and/or repair instructions and do the work instructed by Boeing.
Group 1, 4, Configuration 2:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill at stringer
17 for any crack. Do a detailed inspection, at all 6 door stop locations, of all the intercostal T-Brackets, do the
applicable inspection of the intercostals and attaching stringers, and a High Frequency Eddy Current (HFEC)
inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius for any crack.
Group 1, Configuration 1; Group 2; Group 4, Configuration 1:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill at stringer
17 for any crack. Do a detailed inspection, at all 6 door stop locations, of all the intercostal T-Brackets, and a
HFEC inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius for any crack.
Group 3:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill at stringer
17 for any crack. Do a detailed inspection at all 6 door stop location of all the intercostal T-Brackets and T-Chords,
and a HFEC inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius and T-Chords for any crack.
Group 1-2; Group 4, Configuration 2:
Do a HFEC inspection at each door stop 3, 4 and 5 intercostal web that has not had a modification to remove
and repair the original intercostal web.
Group 1-4:
If cracks are found in the Intercostal T-Brackets and/or T-Chords, remove and replace with identical part.
If no crack is found, do repeat inspection in accordance with Paragraph 1.E., Compliance.
OR
Do the preventive modification at each inspected location in accordance with Paragraph 3.B., Work Instructions,
PART 5, as follows:
Group 1-4:
Preventive Modification
1. Group 1, 4, Configuration 2:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets, and install the preventive
modification and/or repair at each door stop 1 thru 6 intercostal location that has not already been
modified.
2. Group 1, Configuration 1; Group 2; Group 4, Configuration 1:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets.
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3. Group 3:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets and T-Chords.
NOTE: Post repair and post preventive modification inspections are provided in Paragraph 1.E.,
Compliance.
Revision 7 - No more work is necessary on the airplane(s) changed or inspected in accordance with Revision
6 of this service bulletin.
EFFECTIVITY
737-100/200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directive AD 98-22-10 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to
this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service
bulletin mandatory.
Group 1-4:
Refer to Paragraph 1.E., Compliance.
Group 5:
Contact Boeing to get instructions for the inspection, change or repair for this service bulletin, and do the work
instructed by Boeing.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures
given in this service bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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### Page 11 (OCR)

BOEING SERVICE BULLETIN 737-53A1108
ALERT  ALERT
STA
DO A DETAILED  332.1
INSPECTION FOR
CRACKS IN THE
INTERCOSTAL AT
DOOR STOP 1 THRU 6
AND DO THE REPAIR
AS INSTRUCTED
STA
344
UPPER SILL
STOP 1
INSPECT FOR CRACKS  5S-7
IN DOORWAY FRAME  DO A DETAILED
WEB AT STA 332.1, IN  INSPECTION OF
AREA SURROUNDING  THE UPPER AND
ALL 6 DOOR STOPS  S-8A  LOWER RADIUS OF
WHERE NECESSARY.  AND DO THE REPAIR  STOP 2-10  T-BRACKET IN ALL  SIX DOOR STOP
LOCATIONS. IF ANY
S-9  CRACK IS FOUND,
REPLACE THE
T-BRACKET.
STOP 3 -  Š-10A
DO A DETAILED
INSPECTION FOR
CRACKS IN
DO HFEC INSPECTION  OF EACH INTERCOSTAL  STOP 4  S-11  AND ALL ATTACHED  STRINGERS 9, AND 11,
FOR CRACKS IN THE AFT  STRINGER CLIPS
TRIM RADIUS.
STOP 5  S-12
DO A DETAILED  S-13
INSPECTION FOR
CRACKS IN THE  STOP 6
SHEAR TIES.  S-14  DO A DETAILED
INSPECTION FOR
CRACKS IN STRINGERS
S-15  13, 14, AND 15 AND ALL
ATTACHED STRINGER
CLIPS.
S-16
DO A DETAILED
INSPECTION FOR CRACKS
IN DOOR WAY FRAME WEB
S-17  AT STA 344 BETWEEN
UPPER SILL AT S-7 AND
LOWER  LOWER SILL S-17.  2182179
SILL
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Commercial 
Airplanes
737
Service Bulletin
ALERT
Number: 737-53A1108
Original Issue: December 15, 1986
Revision 7: July 07, 2014
ATA System: 5313
SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Galley Service Doorway, Aft Frame -
Inspection and Repair
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
This service bulletin is for the airplane(s) shown below. Refer to PRR 34320R for data about this
change.
DESCRIPTIONCONFIGURATIONGROUP
737-100/200/300 passenger airplanes, line numbers 292-1426,
excluding variable numbers PJ201-PJ219.
-1
Aircraft that have installed intercostal modifications on all 6 intercostal
locations in accordance with Boeing Drawing 65C33473 and/or
65C33288 and/or SB 737-25-1205.
1
Aircraft that have not installed intercostal modifications on all 6
intercostal locations in accordance with Boeing Drawing 65C33473
and/or 65C33288 and/or SB 737-25-1205, or have optional SRM
repair installed per revision 5 of this service bulletin.
2
737-200/300/400 passenger airplanes, line numbers 1427-1488.-2
737-200/300/400/500 passenger airplanes, line numbers 1489-3132.-3
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DESCRIPTIONCONFIGURATIONGROUP
737-200C cargo airplanes, line numbers 294-1113.-4
Aircraft that have installed intercostal modifications on all 6 intercostal
locations in accordance with Boeing Drawing 65C33436.
1
Aircraft that have not installed intercostal modifications on all 6
intercostal locations in accordance with Boeing Drawing 65C33436.
2
737-100/200/200C airplanes, line numbers 1-291.-5
Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500
GroupVariable Number
5PA001 - PA022
5PA099
5PA231 - PA232
5PC001 - PC005
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 - PG583
1PG584 - PG586
5PG621 - PG630
5PG651 - PG652
5PG701 - PG705
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GroupVariable Number
1PH001
1PH011 - PH013
1PH021 - PH024
5PH701 - PH715
5PH731 - PH732
5PH741 - PH742
1PH743
5PJ001 - PJ002
1PJ003 - PJ009
5PJ031 - PJ032
5PJ071 - PJ072
5PJ101 - PJ104
1PJ105 - PJ119
3PJ301 - PJ302
3PJ551 - PJ561
3PJ601 - PJ615
3PJ811
3PJ816 - PJ817
1PK026 - PK029
1PK041 - PK053
1PK061 - PK070
1PK081 - PK082
1PK091 - PK099
1PK101 - PK103
1PK111 - PK120
1PK141 - PK146
1PK201 - PK204
1PK211 - PK223
1PK231 - PK241
1PK251 - PK258
1PK271 - PK274
1PK281 - PK289
1PK291
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GroupVariable Number
1PK301 - PK318
1PK341
1PK351 - PK361
1PK391
1PK431 - PK433
1PK451 - PK452
1PK461 - PK469
1PK495
1PK501 - PK504
1PK511 - PK515
1PK519
1PK521 - PK527
3PK528
1PK541 - PK565
1PK581
1PK591 - PK599
1PK601 - PK617
1PK621 - PK637
1PK641 - PK642
1PK661 - PK666
1PK671 - PK681
1PK691 - PK697
1PK711 - PK716
1PK731 - PK765
1PK771 - PK779
1PK801 - PK804
1PK819 - PK827
1PK830
1PK861 - PK863
1PK871 - PK874
1PK881 - PK884
1PK901 - PK938
1PK971 - PK974
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GroupVariable Number
1PL001 - PL028
1PL061
1PL081
1PL101 - PL113
1PL151
1PL171 - PL172
1PL201 - PL203
1PL221
1PL401 - PL417
1PL421
1PL441
1PL451 - PL456
1PL471
1PL491
1PL501 - PL506
1PL551 - PL562
1PL581
1PL601 - PL603
1PL611
1PL621 - PL625
3PL626
1PL631 - PL632
5PL711 - PL712
5PL716
1PL717 - PL746
2PL747
1PL756
1PL758
1PL761 - PL770
1PL781 - PL788
1PL793
5PL801 - PL803
1PM001 - PM006
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GroupVariable Number
1PM016 - PM017
1PM021 - PM023
1PM051 - PM066
1PM101 - PM119
1PM141 - PM142
1PM171
1PM181
1PM251 - PM255
1PM281 - PM283
3PM381 - PM399
3PM401 - PM417
3PM541 - PM564
1PN001 - PN002
1PN021 - PN043
1PN081 - PN086
1PN101 - PN117
1PN131 - PN163
1PN401 - PN420
1PN431 - PN433
1PN451 - PN456
1PN471 - PN472
3PN473 - PN474
1PN481
1PN491 - PN492
2PN493
1PN501
3PN502
2PN511
3PN512
3PN521
1PP001 - PP028
2PP029 - PP038
3PP039 - PP054
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### Page 19

GroupVariable Number
1PP101 - PP126
3PP127 - PP160
1PP161 - PP168
2PP169
1PP181 - PP184
2PP185 - PP187
3PP188 - PP199
1PP201 - PP204
3PP205
1PP221
1PP231 - PP243
1PP281 - PP286
1PP301 - PP305
1PP351 - PP352
3PP353
1PP376 - PP384
3PP391 - PP393
1PP401 - PP421
2PP422 - PP429
3PP430 - PP440
1PP471 - PP475
1PP501 - PP504
3PP505 - PP520
1PP521 - PP522
1PP631 - PP634
1PP651 - PP652
1PP671 - PP699
1PP701 - PP720
2PP721 - PP726
3PP727 - PP733
1PP771 - PP777
3PP778 - PP779
1PP801 - PP804
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GroupVariable Number
3PP805 - PP808
1PP821 - PP827
1PP831 - PP835
2PP836
3PP837 - PP845
1PP846 - PP847
2PP848
1PP851
3PP852
1PP861 - PP870
3PP871 - PP877
1PP891 - PP899
1PP901
2PP902 - PP909
3PP910 - PP930
1PP931 - PP934
3PP935 - PP936
1PP946 - PP947
2PP948
2PP951 - PP952
1PP961
2PP962 - PP965
3PP966 - PP967
1PP981
2PP982
3PP983 - PP990
1PP991
3PP993
1PQ001 - PQ012
3PQ013 - PQ016
1PQ026 - PQ037
3PQ038 - PQ041
1PQ051 - PQ060
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GroupVariable Number
2PQ061 - PQ062
3PQ063 - PQ085
2PQ086 - PQ088
3PQ089 - PQ092
1PQ101 - PQ110
2PQ111 - PQ115
3PQ116 - PQ199
3PQ201 - PQ202
3PQ221 - PQ230
2PQ231 - PQ232
3PQ233 - PQ237
3PQ241 - PQ243
3PQ251 - PQ267
3PQ281 - PQ299
3PQ301 - PQ307
3PQ331 - PQ332
3PQ341 - PQ348
3PQ361 - PQ373
3PQ391 - PQ395
3PQ401 - PQ418
3PQ421
3PQ431 - PQ438
3PQ447 - PQ448
3PQ451
3PQ454
3PQ471 - PQ475
3PQ479 - PQ481
3PQ486 - PQ487
3PQ491 - PQ493
3PQ771 - PQ772
3PQ791 - PQ793
3PQ801 - PQ805
3PQ931 - PQ935
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GroupVariable Number
3PQ951
3PQ971 - PQ997
3PR001 - PR017
3PR021 - PR034
3PR041 - PR045
3PR061 - PR072
3PR077 - PR082
3PR091 - PR092
3PR096
3PR101
3PR121 - PR122
3PR131 - PR132
3PR141 - PR143
3PR161 - PR172
3PR181
3PS601 - PS631
3PS636 - PS638
3PS641 - PS644
3PS651 - PS657
3PS666 - PS669
3PS691 - PS692
3PS701 - PS706
3PS751 - PS799
3PS811
3PS836 - PS837
3PS841 - PS846
3PS851 - PS852
3PS856
3PS861 - PS863
3PS866 - PS868
3PS871 - PS874
3PS896 - PS897
3PS901 - PS941
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GroupVariable Number
3PS956 - PS957
3PS961 - PS963
3PS971 - PS978
3PT001 - PT015
3PT021 - PT031
3PT041 - PT064
3PT101 - PT105
3PT121 - PT138
3PT146 - PT148
3PT161 - PT170
3PT181 - PT188
3PT211 - PT220
3PT295
3PT301 - PT309
3PT331 - PT360
3PT381 - PT399
3PT401 - PT438
3PT501 - PT517
3PT561 - PT565
3PT581 - PT586
3PT611 - PT621
3PT641 - PT644
3PT651 - PT656
3PT671 - PT672
3PT681 - PT685
3PT701 - PT703
3PT716 - PT717
3PT721 - PT725
3PT801 - PT834
3PT851 - PT854
3PT871 - PT886
3PT901 - PT930
3PT971 - PT973
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GroupVariable Number
3PT981 - PT985
3PT996
3PU001 - PU025
3PU301
3PU311 - PU313
2PV001
3PV002 - PV055
3PV201 - PV209
3PV226 - PV229
3PV231 - PV237
3PV271 - PV272
3PV281 - PV287
3PV296
3PV301 - PV302
3PV351
3PV356 - PV357
3PW001 - PW054
3PW061 - PW068
3PW072
3PW086 - PW088
3PW091 - PW094
3PW101 - PW102
3PW106
3PW111 - PW120
3PW156 - PW157
3PW161 - PW171
3PW201 - PW252
3PW261 - PW268
3PW271 - PW276
3PW278
3PW281 - PW293
3PW296
3PW301 - PW327
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GroupVariable Number
3PW401 - PW408
3PW411 - PW418
3PW421 - PW424
3PW431 - PW435
3PW441 - PW450
3PW461 - PW467
3PW501 - PW504
3PW511 - PW522
3PW524 - PW550
3PW556 - PW557
3PW561 - PW564
3PW571 - PW576
3PW591 - PW596
3PW611 - PW622
3PW631 - PW637
3PW661 - PW662
3PW681 - PW683
3PW701 - PW702
3PW711 - PW717
3PW741 - PW742
3PW761
3PW771
3PW831
3PW851 - PW856
5PX071
5PX701
5PY001 - PY008
5PY021
4PY022
5PY031
4PY036 - PY037
4PY046 - PY048
4PY051 - PY053
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GroupVariable Number
4PY056 - PY057
4PY101 - PY103
4PY111 - PY113
4PY131 - PY135
4PY141 - PY143
4PY151 - PY154
4PY156 - PY157
4PY161 - PY162
4PY166
4PY191
4PY201
4PY221 - PY222
4PY231
4PY241 - PY244
4PY270 - PY275
4PY281
4PY286
5PY301 - PY304
5PY321 - PY323
5PY341 - PY346
5PY361 - PY362
5PY381
4PY401
4PY409 - PY411
4PY421 - PY422
4PY441
4PY451
4PY461 - PY463
4PY591 - PY595
4PY611 - PY612
4PY621
4PY631
4PY651
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GroupVariable Number
4PY671 - PY672
4PY721
4PY741
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
As a result of the Federal Aviation Administration (FAA) sponsored Aging Fleet conference, a 737
Structures Working Group with Airline, Boeing members, and FAA observers was formed to review
structural service bulletin modifications and recommend selected bulletins for incorporation on aging
airplanes. This service bulletin modification has been recommended for incorporation on aging 737
airplanes.
Accomplishment of this service bulletin visual inspection of the forward service doorway aft frame
around the six door stop fittings will identify structural cracking severe enough to weaken the door stop
support structure. A cracked doorway frame and supporting structure at two adjacent door stops can
result in door deflection, loss of pressurization, and possible major structural damage to the doorway.
Four operators have reported eleven airplanes with cracks in the forward service doorway aft frame at
door stop locations, supporting intercostals and stringers just aft of the frame, or in both the frame and
the supporting structure. In four airplanes there was at least one intercostal completely severed.
The reported airplanes had accumulated from 16,100 to 45,400 flight hours, and from 19,200 to 51,300
total flight cycles.
Revision 1 was sent to formalize Telegraphic Alert Service Bulletin (SB) 737-53A1108 dated December,
1986. The information is essentially the same, except the inspection area has been expanded because
of additional service experience reported as a result of the telegraphic alert bulletin. The original service
bulletin information has been expanded to comply with normal service bulletin format requirements.
Revision 2 was sent to provide an optional preventive modification for uncracked intercostals.
Revision 3 was sent to add an airplane which was inadvertently omitted from the effectivity, and to add
a reference to another service bulletin affecting the same area.
Revision 4 was sent to identify that for airplanes PQ051 thru PQ060, incorporation of the modification
of intercostals at stringers 10-A, and between stringers 11-R and 12-R in accordance with SB
737-25-1205 accomplishes the intent of the repair/preventive modification of these same intercostals
in accordance with this bulletin.
Revision 5 was sent to provide the recommendations of the Aging Fleet 737 Structures Working Group.
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Revision 6 was sent to add airplane line numbers 1427 thru 3132 to the service bulletin effectivity and
to add inspection of the doorway frame, intercostals, stringers and stringer clips. This revision was also
sent to add inspections for airplanes repaired or modified in accordance with previous releases of this
service bulletin.
Since the release of Revision 5 of this service bulletin Boeing has received multiple reports of crack
damage in the forward galley service doorway surround structure, between Body Station (STA) 332.1and
STA 344 that are outside the inspection area and effectivity of the service bulletin. The following list is
a summary of safety related crack reports:
– There have been four reports of cracking of the door stop 1 intercostal T-Bracket occurring at
radius of the intercostal T-Bracket on airplanes that have accumulated between 27,938 and 78,547
total flight cycles. There has been one report of a intercostal T-Bracket crack on an aircraft that
had accomplished the preventive modification in accordance with Revision 5 of this service bulletin.
Intercostal T-Bracket cracks have also been reported on aircraft outside the effectivity of Revision
5 of this service bulletin. Multiple operators have reported severed intercostal T-Bracket resulting
in extensive cracking around the STA 332.1 door stop 1 fitting.
– There has been one report of a door stop 2 intercostal T-Bracket crack occurring at the frame
attach flange on an aircraft that had accumulated 62,528 total flight cycles.
– There have been three reports of cracking of the door stop 1 intercostal T-Chord occurring at the
forward trim radius of the T-Chord on airplanes that have accumulated between 37,684 and 63,305
total flight cycles. Multiple operators have reported severed T-Chords resulting in extensive cracking
at the intercostal web and around the STA 332.1 door stop 1 fitting.
– There have been two reports of STA 332.1 frame web cracking around the door stop 1 fitting
without associated intercostal cracking on aircraft that had accumulated 62,272 and 62,528 total
flight cycles.
– There have been three reports of cracking of the door stop 3 intercostal web occurring at the aft
inboard trim radius on aircraft that have accumulated as low as 38,847 total flight cycles. All three
aircraft had accomplished the preventive modification in accordance with Revision 5 of this service
bulletin.
In addition Boeing has received reports of cracking that have been determined not to be a safety issue.
These crack reports are summarized in the following list:
– There have been three reports of door stop 3 and 4 intercostal web cracks occurring at the aft
outboard bend radius of the integral skin attachment flange on aircraft that had accumulated
between 36,648 and 63,305 total flight cycles.
– There have been multiple reports of STA 344 stringer clip cracking occurring on aircraft that have
accumulated as low as 22,147 total flight cycles.
– There have been two reports of STA 344 shear tie cracking occurring as early as 31,077 total flight
cycles.
Revision 7 is sent to change Figure 8 step table and to correct typographical errors in Compliance
Table 10 and Appendix A.
The data given in Information Notice 737-53A1108 R06 IN 01 is included in this revision.
Boeing Service Related Problem (SRP) 737-SRP-53-0380 is related to this service bulletin.
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### Page 29

D. Description
Group 5:
Contact Boeing for inspection, modification and/or repair instructions and do the work instructed by
Boeing.
Group 1, 4, Configuration 2:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill
at stringer 17 for any crack. Do a detailed inspection, at all 6 door stop locations, of all the intercostal
T-Brackets, do the applicable inspection of the intercostals and attaching stringers, and a High Frequency
Eddy Current (HFEC) inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius for any crack.
Group 1, Configuration 1; Group 2; Group 4, Configuration 1:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill
at stringer 17 for any crack. Do a detailed inspection, at all 6 door stop locations, of all the intercostal
T-Brackets, and a HFEC inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius for any
crack.
Group 3:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill
at stringer 17 for any crack. Do a detailed inspection at all 6 door stop location of all the intercostal
T-Brackets and T-Chords, and a HFEC inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket
radius and T-Chords for any crack.
Group 1-2; Group 4, Configuration 2:
Do a HFEC inspection at each door stop 3, 4 and 5 intercostal web that has not had a modification to
remove and repair the original intercostal web.
Group 1-4:
If any crack is found in the intercostal T-Brackets and/or T-Chords, remove and replace with identical
part.
If no crack is found, do repeat inspection in accordance with Paragraph 1.E., Compliance.
or
Do the preventive modification at each inspected location in accordance with Paragraph 3.B., Work
Instructions, PART 5, as follows:
Group 1-4:
Preventive Modification
1. Group 1, 4, Configuration 2:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets, and install the preventive
modification and/or repair at each door stop 1 thru 6 intercostal location that has not already been
modified.
2. Group 1, Configuration 1; Group 2; Group 4, Configuration 1:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets.
3. Group 3:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets and T-Chords.
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### Page 30

NOTE: Post repair and post preventive modification inspections are provided in Paragraph 1.E.,
Compliance.
Revision 7 - No more work is necessary on airplanes changed in accordance with Revision 6 of this
service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
1-4, 1-6737-200
Group 1:
Affected Maintenance Zones
ZoneModel
104, 106737-300
Group 2-3:
Affected Maintenance Zones
ZoneModel
1-4, 1-6, 104, 106737-200, 737-300, 737-400
Group 3:
Affected Maintenance Zones
ZoneModel
104, 106737-500
Group 4:
Affected Maintenance Zones
ZoneModel
1-4, 1-6737-200C
Group 5:
Affected Maintenance Zones
ZoneModel
1-4, 1-6737-100, 737-200, 737-200C
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### Page 31

E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive AD 98-22-10 is related to this service
bulletin. The effective date of AD 98-22-10 is November 12, 1998.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive
related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times
given in this service bulletin mandatory.
Table 1 thru 6 below provide required inspections to maintain safety of flight. Table 7 and 8 below
provide economic inspections to find any crack prior to causing extensive damage requiring costly
repairs.
Post preventive modification tables 9 thru 12 below provide required inspections to maintain safety of
flight.
Group 5:
Contact Boeing to get instructions for the inspection, change or repair for this service bulletin, and do
the work instructed by Boeing within 120 days of the issue date of Revision 6 to this service bulletin.
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### Page 32

Group 1, Configuration 1:
Table 1: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of the STA 332.1 frame
web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 1.a.
All airplanes
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 1.b.
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a HFEC inspection of
door stop 1, 2, 5 and 6
intercostal T-brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 1.b.
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a HFEC inspection of
the intercostal web aft in-
board trim radius at appli-
cable door stop 3, 4
and/or 5, for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 1.c.
(a) (c)
-Before further flight.Do the repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 4.
If any crack is found in a
door stop 3, 4 or 5 inter-
costal
(c)
-Before further flight.Contact Boeing for repair
instructions and do the
work instructed by Boe-
ing.
If any crack is found on the
STA 332.1 frame web
-Before further flight.Replace the intercostal T-
Bracket in accordance
Paragraph 3.B., Work In-
structions, PART 4.
If any crack is found in a
intercostal T-Bracket
(b)
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### Page 33

Group 1, Configuration 1:
Table 1: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
(a) Accomplishment of the preventive modification in accordance with revision 6 of this service bulletin ter-
minates the repeat inspection requirement given in Table 1. Post preventive modification inspection is
provided in Table 9.
(b) Repair of the intercostal T-Bracket does not terminate the repeat inspection requirement given in Table
1 unless it is accomplished as part of the preventive modification. Post preventive modification inspection
is provided in Table 9 if the intercostal T-Bracket repair was accomplished with the preventive modification.
(c) Repair of the intercostal in accordance with this service bulletin terminates the repeat inspection require-
ment given in Table 1 for the repaired intercostals. All other inspections (i.e. frame web, intercostal T-
Brackets, and unrepaired intercostal(s)) are still required. If the intercostal repair was accomplished with
the preventive modification then the inspection in accordance with Table 1 is not required. Post preventive
modification inspection is provided in Table 9.
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### Page 34

Group 1, Configuration 2:
Table 2: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
4,500 Flight cyclesWithin 700 flight
cycles after the
effective date of
AD 98-22-10.
Before 18,000
total flight cycles
Do a detailed inspection
of the STA 332.1 frame
web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 2.a.
All Airplanes that have not
been inspected in accor-
dance with AD 98-22-10.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
Brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 2.b.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a HFEC inspection of
door stop 1, 2, 5 and 6
intercostal T-Brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 2.b.
(a)
4,500 Flight cyclesWithin 700 flight
cycles after the
effective date of
AD 98-22-10
Before 18,000
total flight cycles
Do the applicable inspec-
tion of the intercostals
and attaching stringers
for any crack in accor-
dance with Paragraph
3.B., Work Instructions,
PART 2, step 2.c.
(a) (c)
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### Page 35

Group 1, Configuration 2:
Table 2: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
4,500 Flight cyclesWithin 4,500 flight cycles from the
most recent inspection performed
in accordance with AD 98-22-10
Do a detailed inspection
of the STA 332.1 frame
web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 2.a.
All Airplanes that have
been inspected in accor-
dance with AD 98-22-10.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
Brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 2.b.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a HFEC inspection of
door stop 1, 2, 5 and 6
intercostal T-Brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 2.b.
(a)
4,500 Flight cyclesWithin 4,500 flight cycles from the
most recent inspection performed
in accordance with AD 98-22-10
Do a detailed inspection
of the intercostals and at-
taching stringers for any
crack in accordance with
Paragraph 3.B., Work In-
structions, PART 2, step
2.c.
(a) (c)
4,500 Flight cyclesWithin 4,500 flight cycles after the
issue date of revision 6 of this
service bulletin.
Do an HFEC inspection
of the intercostals and at-
taching stringers for any
crack in accordance with
Paragraph 3.B., Work In-
structions, PART 2, step
2.c.
(a) (c)
-Before further flight.Replace the intercostal T-
Bracket in accordance
Paragraph 3.B., Work In-
structions, PART 4.
If any crack is found in a
intercostal T-Bracket
(b)
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### Page 36

Group 1, Configuration 2:
Table 2: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
-Before further flight.Do the repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 4.
If any crack is found in an
intercostal or attaching
stringer
(c) (d)
-Before further flight.Contact Boeing for repair
instructions and do the
work instructed by Boe-
ing.
If any crack is found on the
STA 332.1 frame web
(a) Accomplishment of the preventive modification in accordance with revision 6 of this service bulletin ter-
minates the repeat inspection requirement given in Table 2. Post preventive modification inspection is
provided in Table 9.
(b) Replacement of the intercostal T-Bracket does not terminate the repeat inspection requirement given in
Table 2 unless it is accomplished as part of the preventive modification. Post preventive modification in-
spection is provided in Table 9 if the intercostal T-Bracket replacement was accomplished with the pre-
ventive modification.
(c) Repair of the intercostal in accordance with this service bulletin terminates the repeat inspection require-
ment given in Table 2 for the repaired intercostals. All other inspections (i.e. frame web, intercostal T-
Brackets, and unrepaired intercostal(s)) are still required. If the intercostal repair was accomplished with
the preventive modification then the inspection in accordance with Table 2 is not required. Post preventive
modification inspection is provided in Table 9.
(d) Repair of the stringer does not terminate the repeat inspection requirement given in Table 2 unless it is
accomplished as part of the preventive modification. Post preventive modification inspection is provided
in Table 9 if the stringer repair was accomplished with the preventive modification.
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### Page 37

Group 4, Configuration 1:
Table 3: Safety Inspection - Inspection for cracking at Intercostal T-Bracket and STA 332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of the STA 332.1 frame
web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 3.a.
All airplanes
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 3.b.
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a HFEC inspection of
door stop 1, 2, 5 and 6
intercostal T-brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 3.b.
(a)
-Before further flight.Contact Boeing for repair
instructions and do the
work instructed by Boe-
ing.
If any crack is found on the
STA 332.1 frame web
-Before further flight.Replace the intercostal T-
Bracket in accordance
Paragraph 3.B., Work In-
structions, PART 4.
If any crack is found in a
intercostal T-Bracket
(b)
(a) Accomplishment of the preventive modification in accordance with revision 6 of this service bulletin ter-
minates the repeat inspection requirement given in Table 3. Post preventive modification inspection is
provided in Table 10.
(b) Repair of the intercostal T-Bracket does not terminate the repeat inspection requirement given in Table
3 unless it is accomplished as part of the preventive modification. Post preventive modification inspection
is provided in Table 10 if the intercostal T-Bracket repair was accomplished with the preventive modifica-
tion.
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### Page 38

Group 4, Configuration 2:
Table 4: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
4,500 Flight cyclesWithin 700 flight
cycles after the
effective date of
AD 98-22-10.
Before 18,000
total flight cycles
Do a detailed inspection
of the STA 332.1 frame
web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 4.a.
All Airplanes that have not
been inspected in accor-
dance with AD 98-22-10.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
Brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 4.b.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a HFEC inspection of
door stop 1, 2, 5 and 6
intercostal T-Brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 4.b.
(a)
4,500 Flight cyclesWithin 700 flight
cycles after the
effective date of
AD 98-22-10.
Before 18,000
total flight cycles
Do a detailed inspection
of the intercostals and at-
taching stringers for any
crack in accordance with
Paragraph 3.B., Work In-
structions, PART 2, step
4.c.
(a)
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### Page 39

Group 4, Configuration 2:
Table 4: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
4,500 Flight cyclesWithin 4,500 flight cycles from the
most recent inspection performed
in accordance with AD 98-22-10
Do a detailed inspection
of the STA 332.1 frame
web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 4.a.
All Airplanes that have
been inspected in accor-
dance with AD 98-22-10.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
Brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 4.b.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a HFEC inspection of
door stop 1, 2, 5 and 6
intercostal T-Brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 4.b.
(a)
4,500 Flight cyclesWithin 4,500 flight cycles from the
most recent inspection performed
in accordance with AD 98-22-10
Do a detailed inspection
of the intercostals and at-
taching stringers for any
crack in accordance with
Paragraph 3.B., Work In-
structions, PART 2, step
4.c.
(a)
-Before further flight.Replace the intercostal T-
Bracket in accordance
Paragraph 3.B., Work In-
structions, PART 4.
If any crack is found in a
intercostal T-Bracket
(b)
-Before further flight.Do the repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 4.
If any crack is found in an
intercostal
(c)
-Before further flight.Contact Boeing for repair
instructions and do the
work instructed by Boe-
ing.
If any crack is found on the
STA 332.1 frame web
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### Page 40

Group 4, Configuration 2:
Table 4: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Bracket and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
(a) Accomplishment of the preventive modification in accordance with revision 6 of this service bulletin ter-
minates the repeat inspection requirement given in Table 4. Post preventive modification inspection is
provided in Table 10.
(b) Repair of the intercostal T-Bracket does not terminate the repeat inspection requirement given in Table
4 unless it is accomplished as part of the preventive modification. Post preventive modification inspection
is provided in Table 10 if the intercostal T-Bracket repair was accomplished with the preventive modifica-
tion.
(c) Repair of the intercostal in accordance with this service bulletin terminates the repeat inspection require-
ment given in Table 4 for the repaired intercostals. All other inspections (i.e. frame web, intercostal T-
Brackets, and unrepaired intercostal(s)) are still required. If the intercostal repair was accomplished with
the preventive modification then the inspection in accordance with Table 4 is not required. Post preventive
modification inspection is provided in Table 10.
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### Page 41

Group 2:
Table 5: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Brackets and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
Brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 5.a.
All airplanes
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a HFEC inspection at
door stop 1, 2, 5 and 6
intercostal T-Brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 5.a.
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a HFEC inspection at
door stop 3, 4 and 5 inter-
costal aft inboard trim ra-
dius for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 5.b.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of the STA 332.1 Frame
Web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 5.c.
(a)
-Before further flightDo the repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 4.
If any crack is found in a
intercostal T-Bracket
(b)
-Before further flightContact Boeing for repair
instructions, and do the
work instructed by Boe-
ing.
If any crack is found in the
door stop 3, 4, or 5 inter-
costal aft inboard trim ra-
dius
-Before further flightContact Boeing for repair
instructions, and do the
work instructed by Boe-
ing.
If any crack is found on the
STA 332.1 frame web
(a) Accomplishment of the preventive modification in accordance with revision 6 of this service bulletin ter-
minates the repeat inspection requirement given in Table 5. Post preventive modification inspection is
provided in Table 11.
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PROPRIETARY - Copyright © Unpublished
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### Page 42

Group 2:
Table 5: Safety Inspection - Inspection for cracking at Intercostal Web, Intercostal T-Brackets and STA
332.1 Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
(b) Repair of the intercostal T-Bracket does not terminate the repeat inspection as given in Table 5 unless
it is accomplished as part of the preventive modification. Post preventive modification inspection is pro-
vided in Table 11 if the intercostal T-Bracket repair was accomplished with the preventive modification.
Group 3:
Table 6: Safety Inspection - Inspection for cracking at Intercostal T-Brackets, T-Chords and STA 332.1
Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
Brackets for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 6.a.
All airplanes
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a HFEC inspection at
door stop 1, 2, 5 and 6
intercostal T-Brackets for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 6.a.
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of all 6 intercostal T-
Chords for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 2, step 6.b.
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a HFEC inspection at
door stop 1, 2, 5 and 6
intercostal T-Chords for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
2, step 6.b.
(a)
4,500 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of the STA 332.1 Frame
Web for any crack in ac-
cordance with Paragraph
3.B., Work Instructions,
PART 2, step 6.c.
(a)
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### Page 43

Group 3:
Table 6: Safety Inspection - Inspection for cracking at Intercostal T-Brackets, T-Chords and STA 332.1
Frame Web
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
-Before further flight.Do the repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 4.
If any crack is found a inter-
costal T-Bracket
(b)
-Before further flight.Do the repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 4.
If any crack is found in a T-
Chord
(b)
-Before further flight.Contact Boeing for repair
instructions, and do the
work instructed by Boe-
ing.
If any crack is found on the
STA 332.1 frame web
(a) Accomplishment of the preventive modification in accordance with revision 6 of this service bulletin ter-
minates the repeat inspection requirement given in Table 6. Post preventive modification inspection is
provided in Table 12.
(b) Repair of the intercostal T-Bracket and/or T-Chord does not terminate the repeat inspection as given in
Table 6 unless it is accomplished as part of the preventive modification. Post preventive modification in-
spection is provided in Table 12 if the intercostal T-Bracket and/or T-Chord repair was accomplished with
the preventive modification.
Group 1, 4, Configuration 2:
Table 7: Economic (Not Safety) Inspection - Inspection between STA 332.1 and STA 344 for cracking in
the stringers, shear ties, stringer clips and intercostal webs
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of the STA 344 frame,
shear ties, and stringer
clips between S-7R and
S-17R for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 3, step 1.a.
All airplanes
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of stringers for any crack
in accordance with Para-
graph 3.B., Work Instruc-
tions, PART 3, step 1.b.
(a)
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### Page 44

Group 1, 4, Configuration 2:
Table 7: Economic (Not Safety) Inspection - Inspection between STA 332.1 and STA 344 for cracking in
the stringers, shear ties, stringer clips and intercostal webs
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
-Before further flightDo the applicable repair
in accordance with Para-
graph 3.B., Work Instruc-
tions PART 4, step 6.
If any crack is found in STA
344 frame, shear ties, or
stringer clip
-Before further flightDo the repair in accor-
dance with Paragraph
3.B., Work Instructions
PART 4, step 7.
If any crack is found in
stringers S-9, S-11, S-13A,
S-14, or S-15
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of the intercostal web, the
intercostal clip attaching
to the STA 344 frame,
and attaching stringers
for any crack in accor-
dance with Paragraph
3.B., Work Instructions,
PART 3, step 1.c.
Each intercostal location
that has been modified in
accordance with
65C33473, 65C33288,
65C33436, or SB 737-25-
1205
(a)
-Before further flight.Contact Boeing for repair
instructions, and do the
work instructed by Boe-
ing.
If any crack is found com-
mon to an intercostal web
-Before further flight.Do the applicable repair
in accordance with Para-
graph 3.B., Work Instruc-
tions PART 4, step 6.
If any crack is found in the
intercostal clip attaching to
the STA 344 frame or the
attaching stringer
(a) Accomplishment of the preventive modification in accordance with Paragraph 3.B., Work Instructions,
PART 5 does not terminate the economic inspection. If the preventive modification is accomplished in
accordance with revision 6 of this service bulletin, it is satisfactory to postpone the economic inspections
until the post preventive modification inspections provided in Table 9, 10, 11, or 12.
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### Page 45

Group 1, Configuration 1; Group 2-3; Group 4, Configuration 1:
Table 8: Economic (Not Safety) Inspection - Inspection between STA 332.1 and STA 344 for cracking in
the stringers, shear ties, stringer clips and intercostal webs
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs later)
ActionCondition
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of all 6 intercostal webs,
the intercostal clips attach-
ing to the STA 344 frame,
and attaching stringers
for any crack in accor-
dance with Paragraph
3.B., Work Instructions,
PART 3, step 2.a.
All airplanes
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 18,000
total flight cycles
Do a detailed inspection
of the STA 344 frame,
shear ties, and stringer
clips between S-7R and
S-17R for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 3, step 2.b.
(a)
9,000 Flight cyclesWithin 4,500
flight cycles af-
ter the issue
date of revision
6 of this service
bulletin.
Before 20,000
total flight cycles
Do a detailed inspection
of stringers for any crack
in accordance with Para-
graph 3.B., Work Instruc-
tions, PART 3, step 2.c.
(a)
-Before further flight.Contact Boeing for repair
instructions, and do the
work instructed by Boe-
ing.
If any crack is found com-
mon to an intercostal web
-Before further flight.Do the applicable repair
in accordance with Para-
graph 3.B., Work Instruc-
tions PART 4, step 7.
If any crack is found in the
stringer
-Before further flight.Do the applicable repair
in accordance with Para-
graph 3.B., Work Instruc-
tions PART 4, step 6.
If any crack is found in the
STA 344 frame web,
stringer clip, or shear tie
(a) Accomplishment of the preventive modification in accordance with Paragraph 3.B., Work Instructions,
PART 5 does not terminate the economic inspection. If the preventive modification is accomplished in
accordance with revision 6 of this service bulletin, it is satisfactory to postpone the economic inspections
until the post preventive modification inspections provided in Table 9 or 10.
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### Page 46

Group 1:
Table 9: Post preventive modification inspections where the preventive modification has been accom-
plished in accordance with Revision 6 of this service bulletin.
Repeat Interval (Not
to Exceed)
Compliance TimeActionCondition
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of all 6
intercostal T-Brackets for any
crack in accordance with Para-
graph 3.B., Work Instructions,
PART 6, step 1.b.
Airplanes that have accom-
plished the preventive modifica-
tion in accordance with Revision
6 of this service bulletin
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a HFEC inspection for any
crack in intercostal T-Brackets
at door stop 1, 2, 5 and 6 for
any crack in accordance with
Paragraph 3.B., Work Instruc-
tions PART 6, step 1.b.
4,500 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of the
STA 332.1 Frame Web for any
crack in accordance with Para-
graph 3.B., Work Instructions,
PART 6, step 1.a.
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a HFEC inspection at modi-
fied intercostals at door stop 3,
4 and 5 intercostal aft inboard
trim radius for any crack in ac-
cordance with Paragraph 3.B.,
Work Instructions, PART 6, step
1.c.
Each door stop 3, 4, and 5 inter-
costal location that has been
modified in accordance with
Boeing drawing 65C33473
-Before further flight.Contact Boeing for repair instruc-
tions and do the work instructed
by Boeing.
If any crack is found
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### Page 47

Group 4:
Table 10: Post preventive modification inspections where the preventive modification has been accom-
plished in accordance with Revision 6 of this service bulletin.
Repeat Interval (Not
to Exceed)
Compliance TimeActionCondition
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of the
modified intercostal T-Brackets
at modified intercostal locations
in accordance with Paragraph
3.B., Work Instructions, PART
6, step 4.b.
Airplanes that have accom-
plished the preventive modifica-
tion in accordance with Revision
6 of this service bulletin
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a HFEC inspection for any
crack in intercostal T-Brackets
at modified intercostals at door
stop 1, 2, 5 and 6 in accordance
with Paragraph 3.B., Work In-
structions, PART 6, step 4.b.
4,500 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of the
STA 332.1 frame web for any
crack in accordance with Para-
graph 3.B., Work Instructions,
PART 6, step 4.a.
-Before further flight.Contact Boeing for repair instruc-
tions and do the work instructed
by Boeing.
If any crack is found
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### Page 48

Group 2:
Table 11: Post preventive modification inspections where the preventive modification has been accom-
plished in accordance with Revision 6 of this service bulletin.
Repeat Interval (Not
to Exceed)
Compliance TimeActionCondition
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of all 6
intercostal T-Brackets for any
crack in accordance with Para-
graph 3.B., Work Instructions,
PART 6, step 2.a.
Airplanes that have accom-
plished the preventive modifica-
tion in accordance with Revision
6 of this service bulletin
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a HFEC inspection at door
stop 1, 2, 5 and 6 intercostal T-
Brackets for any crack in accor-
dance with Paragraph 3.B.,
Work Instructions, PART 6, step
2.a.
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a HFEC inspection at door
stop 3, 4 and 5 intercostal aft
inboard trim radius for any crack
in accordance with Paragraph
3.B., Work Instructions, PART
6, step 2.b.
4,500 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of the
STA 332.1 Frame Web in accor-
dance with Paragraph 3.B.,
Work Instructions, PART 6, step
2.c.
-Before further flight.Contact Boeing for repair instruc-
tions and do the work instructed
by Boeing.
If any crack is found
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### Page 49

Group 3:
Table 12: Post preventive modification inspections where the preventive modification has been accom-
plished in accordance with Revision 6 of this service bulletin.
Repeat Interval (Not
to Exceed)
Compliance TimeActionCondition
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of all 6
intercostal T-Brackets for any
crack in accordance with Para-
graph 3.B., Work Instructions,
PART 6, step 3.a.
Airplanes that have accom-
plished the preventive modifica-
tion in accordance with Revision
6 of this service bulletin
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a HFEC inspection at door
stop 1, 2, 5 and 6 intercostal T-
Brackets for any crack in accor-
dance with Paragraph 3.B.,
Work Instructions, PART 6, step
3.a.
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of all 6
intercostal T-Chords for any
crack in accordance with Para-
graph 3.B., Work Instructions,
PART 6, step 3.b.
9,000 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a HFEC inspection at door
stop 1, 2, 5 and 6 intercostal T-
Chords for any crack in accor-
dance with Paragraph 3.B.,
Work Instructions, PART 6, step
3.b.
4,500 flight cyclesWithin 20,000 flight
cycles after the ac-
complishment of the
preventive modifica-
tion in accordance
with Revision 6 of
this service bulletin.
Do a detailed inspection of the
STA 332.1 Frame Web for any
crack in accordance with Para-
graph 3.B., Work Instructions,
PART 6, step 3.c.
-Before further flight.Contact Boeing for repair instruc-
tions and do the work instructed
by Boeing.
If any crack is found
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### Page 50

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.
In addition, the Manager, Seattle ACO, FAA, approves accomplishment of the inspection methods,
repairs, and modifications defined in Section 1.E, Tables 1 through 4 of this service bulletin as an
alternative method of compliance to the corresponding requirements of paragraphs (b), (c), (d), and
(e) of AD 98-22-10. All provisions of AD 98-22-10 that are not specifically referenced in the above
statement remain fully applicable and must be complied with.
G. Manpower
The table below shows an estimate of the task hours necessary to do this modification 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 inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
Group 1:
Inspection of door stops 1 thru 6 intercostal web and Intercostal T-Bracket, STA 332.1 and
STA 334 frame web and repair or preventive modification
Elapsed HoursTask HoursNumber of PersonsTask
3.50 (a)7.00 (a)2Remove Galley
1.25 (a)1.25 (a)1Right Windscreen
1.251.251Open Access
1.001.001FIGURE 1
3.006.002FIGURE 2
3.503.501FIGURE 6
1.251.251FIGURE 7
1.001.001FIGURE 9
3.006.002FIGURE 10
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### Page 51

Group 1:
Inspection of door stops 1 thru 6 intercostal web and Intercostal T-Bracket, STA 332.1 and
STA 334 frame web and repair or preventive modification
Elapsed HoursTask HoursNumber of PersonsTask
3.006.002FIGURE 11
5.005.001FIGURE 3
3.0012.004FIGURE 4
1.251.251Close Access
3.50 (a)7.00 (a)2Install Galley
1.25 (a)1.25 (a)1Right Windscreen
26.2544.25TOTAL FOR EACH AIRPLANE
(a) Add time to total as required.
Group 4:
Inspection of door stops 1 thru 6 intercostal web and Intercostal T-Bracket, STA 332.1 and
STA 334 frame web and repair or preventive modification
Elapsed HoursTask HoursNumber of PersonsTask
3.50 (a)7.00 (a)2Remove Galley
1.25 (a)1.25 (a)1Right Windscreen
1.251.251Open Access
1.001.001FIGURE 1
3.006.002FIGURE 2
3.503.501FIGURE 6
1.001.001FIGURE 9
3.006.002FIGURE 10
3.006.002FIGURE 11
6.0012.002FIGURE 5
1.251.251Close Access
3.50 (a)7.00 (a)2Install Galley
1.25 (a)1.25 (a)1Right Windscreen
23.0038.00TOTAL FOR EACH AIRPLANE
(a) Add time to total as required.
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### Page 52

Group 2:
Inspection of the Intercostal T-Bracket, shear tie and stringer clip, intercostal and stringer
at door stops 1 to 6 between STA 332.1 and STA 334, frame web at STA 334 and repair or
preventive modification
Elapsed HoursTask HoursNumber of PersonsTask
3.50 (a)7.00 (a)2Remove Galley
1.25 (a)1.25 (a)1Right Windscreen
1.251.251Open Access
1.001.001FIGURE 1
3.503.501FIGURE 6
1.251.251FIGURE 7
1.001.001FIGURE 9
3.006.002FIGURE 10
3.006.002FIGURE 11
1.251.251Close Access
3.50 (a)7.00 (a)2Install Galley
1.25 (a)1.25 (a)1Right Windscreen
15.2521.25TOTAL FOR EACH AIRPLANE
(a) Add time to total as required.
Group 3:
Inspection for cracking at each Intercostal T-Bracket, shear tie and stringer clip, intercostal
and stringer at door stops 1 to 6 between STA 332.1 and STA 334, frame web at STA 334
and repair/preventive modification
Elapsed HoursTask HoursNumber of PersonsTask
3.50 (a)7.00 (a)2Remove Galley
1.25 (a)1.25 (a)1Right Windscreen
1.251.251Open Access
1.001.001FIGURE 1
3.503.501FIGURE 6
3.887.752FIGURE 8
1.001.001FIGURE 9
3.006.002FIGURE 10
3.006.002FIGURE 11
1.251.251Close Access
3.50 (a)7.00 (a)2Install Galley
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### Page 53

Group 3:
Inspection for cracking at each Intercostal T-Bracket, shear tie and stringer clip, intercostal
and stringer at door stops 1 to 6 between STA 332.1 and STA 334, frame web at STA 334
and repair/preventive modification
Elapsed HoursTask HoursNumber of PersonsTask
1.25 (a)1.25 (a)1Right Windscreen
17.8827.75TOTAL FOR EACH AIRPLANE
(a) Add time to total as required.
NOTE: No estimate is included for repair of cracks in doorway frame web or stringers, as it is dependent
upon the extent of cracking that is found.
Repair of cracked intercostal requires removal of original intercostal and replacing it with a
built-up intercostal.
H. Weight and Balance Changes
INTERCOSTAL REPAIR
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
+1385.0+4.1737-100
+1238.0+4.1737-200
+1238.0+4.1737-200C
+1058.0+4.1737-300
+ 763.0+ 4.1737-400
+ 1279.0+ 4.1737-500
INTERCOSTAL PREVENTIVE MODIFICATION
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
+594.0+1.8737-100
+529.0+1.8737-200
+529.0+1.8737-200C
+515.0+1.8737-300
+ 335.0+ 1.8737-400
+ 562.0+ 1.8737-500
NOTE: There is no weight change for the inspection tasks. Weight change for frame or stringer repairs
is dependent upon extent of repairs required, therefore is not listed above, and will have to
be determined on an individual airplane basis.
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### Page 54

I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 34320R
b. Boeing Service Bulletin 737-25-1205
c. Boeing Service Related Problem (SRP) 737-SRP-53-0380
d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 88-03-03, 98-22-10
e. Standard Overhaul Practices Manual (SOPM) 20-50-19
f. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00
g. 737-100/200 Aircraft Maintenance Manual (AMM) 25-21-335, 25-21-347, 25-21-41, 25-21-81,
25-24-121, 25-31-21, 25-31-22, 25-31-51, 52-41-00
h. 737-100/200 Structural Repair Manual (SRM) 51-30-02, 53-10-03, 53-10-04
i. 737-300/400/500 Aircraft Maintenance Manual (AMM) 25-21-35, 25-21-39, 25-21-71, 25-24-15,
25-31-21, 25-31-53, 52-41-00
j. 737-300 Structural Repair Manual (SRM) 51-40-02, 53-00-03, 53-10-07
k. 737-400 Structural Repair Manual (SRM) 51-40-02, 53-00-03, 53-10-07
l. 737-500 Structural Repair Manual (SRM) 51-40-02, 53-00-03, 53-10-07
2. Data Supplied with this Service Bulletin:
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
1B1FRAME INSTL - AFT, INTERCOSTAL RE-
PAIR, STA 332.10
65C33288
2-2
1-1FRAME INSTL - AFT, FWD GALLEY
DOOR, STA 332.10 (TOP KIT)
65C33436
--2
-APL
--1FRAME INSTL - AFT, FWD GALLEY
DOOR, STA 332.10 (TOP KIT)
65C33473
--2
-APL
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### Page 55

3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
FRAME INSTALLATION - AFT, FWD GALLEY DOOR, STA 332.1065-45813
FRAME INSTL - AFT, FWD GALLEY DOOR, STA 332.10 (RE-
WORK DRAWING)
65C33308
The table above lists applicable drawings used to prepare this service bulletin. The drawings are
not necessary to make the specified changes, and are not supplied with this service bulletin. The
drawings may not be applicable to all airplane configurations or operators.
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. DTI requirements for the structure affected
are contained in Paragraph 1.E., Compliance of this service bulletin.
L. Interchangeability and Intermixability of Parts
Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability
information.
M. Software Accomplishment Summary
Not affected.
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### Page 56

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BLANK PAGE

### Page 57

2.    MATERIAL INFORMATION
A. Material - Price and Availability
The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each
Airplane, and Paragraph 2.D., Parts Necessary to Change Spares. As an alternative, operators can
purchase the parts from Boeing Spares. This service bulletin does not show the Boeing price and
supply data.
The operator can supply the parts and materials shown in the kits in Paragraph 2.C., Parts Necessary
for Each Airplane, and Paragraph 2.D., Parts Necessary to Change Spares. As an alternative, operators
can purchase the kits/parts from Boeing Spares. The Boeing price data shown below is given for
planning purposes. Supply data can be given if requested. The kits/parts are subject to the terms and
conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars.
Terms: Net 30 days
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST PRICE INFORMATION
Unit Price as of Revision 5
date of this Service Bulletin
(US Dollars)
NameKit Number
$683.0TOP KIT, PASSENGER PREVENTIVE MOD65C33473-1
95.20KIT, S-10A65C33473-2
90.30KIT, S-8A65C33473-3
90.90KIT, S-16A65C33473-4
138.00KIT, INTERCOSTAL S-13 - S-1465C33473-5
145.00KIT, INTERCOSTAL S-12 - S-1365C33473-6
124.00KIT, INTERCOSTAL S-11 - S-1265C33473-7
913.00TOP KIT, CARGO PREVENTIVE MOD. OR REPAIR65C33436-1
161.00KIT, S-16A65C33436-2
179.00KIT, INTERCOSTAL S-13 - S-1465C33436-3
157.00KIT, INTERCOSTAL S-12 - S-1365C33436-4
150.00KIT, INTERCOSTAL S-11 - S-1265C33436-5
134.00KIT, S-10A65C33436-6
132.00KIT, S-6A65C33436-7
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### Page 58

B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair
procedures given in this service bulletin.
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.
Group 1:
Kit 65C33473
NotesNameQTYNew Part Number
-1-2-3-4-5-6-7
Top Kit-65C33473-1
Intercostal Mod. S165C33473-2
Intercostal Mod. S165C33473-3
Intercostal Mod. S165C33473-4
Intercostal Mod. S165C33473-5
Intercostal Mod. S165C33473-6
Intercostal Mod. S165C33473-7
Filler165C33473-8
Filler165C33473-9
Filler165C33473-10
Filler165C33473-11
Filler165C33473-12
Filler165C33473-13
Filler165C33473-14
Filler165C33473-15
Filler165C33473-16
Filler165C33473-17
Filler165C33473-18
Filler165C33473-19
Filler165C33473-20
Filler11165C33473-21
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Group 1:
Kit 65C33473
NotesNameQTYNew Part Number
-1-2-3-4-5-6-7
Filler165C33473-22
Intercostal169-77315-1
Intercostal169-77315-2
Intercostal169-77315-3
Intercostal169-77316-1
Intercostal169-77316-2
Intercostal169-77316-3
(a)BOLT222BACB30FM5-2
(a)BOLT222BACB30FM5-3
(a)BOLT222BACB30FM5-4
(a)BOLT222BACB30FM5-5
(a)BOLT2BACB30FM6-2
(a)BOLT442BACB30FM6-3
(a)BOLT119BACB30FM6-4
(a)BOLT552666BACB30FM6-5
(a)BOLT3BACB30KK6-4
(a)BOLT11111BACB30KK6-5
(a)BOLT1BACB30KK8-4
(a)BOLT551444BACB30KK8-5
COLLAR888BACC30M5
COLLAR101015666BACC30M6
COLLAR113111BACC30R6
COLLAR552444BACC30R8
FILLER1BACF3F008E041NN
FILLER1BACF3F008E063NN
FILLER1BACF3F008E085NN
FILLER1BACF3F008G031NN
FILLER1BACF3F008G032NN
FILLER1BACF3F008G053NN
FILLER1BACF3F008G054NN
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### Page 60

Group 1:
Kit 65C33473
NotesNameQTYNew Part Number
-1-2-3-4-5-6-7
FILLER11BACF3F008G075NN
(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.
Group 4:
Kit 65C33436
NotesNameQTYNew Part Number
-1-2-3-4-5-6-7
Top Kit-65C33436-1
Intercostal Mod. S165C33436-2
Intercostal Mod. S165C33436-3
Intercostal Mod. S165C33436-4
Intercostal Mod. S165C33436-5
Intercostal Mod. S165C33436-6
Intercostal Mod. S165C33436-7
Web165C33436-8
Filler165C33436-9
Filler165C33436-10
Web165C33436-11
Web165C33436-12
Tee169-77354-1
Tee1169-77354-2
Tee169-77355-1
Tee169-77355-2
Clip169-77424-1
Clip169-77424-2
Clip169-77424-3
Web169-77449-1
Tee169-77450-1
Tee169-77450-2
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