# Boeing Alert Service Bulletin 737-53A1163: Revision 1

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2014-0339; AD 2015-13-05 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 737-53A1163](https://openairdocs.org/service-documents/boeing/737-53a1163.md)
- Title as filed: U.S. DOT/FAA - SB 737-53A1163, Rev. 1
- Pages: 67
- PDF: https://openairdocs.org/files/sha256/82/62/826259dd8cee6286576383fb7a713e6858fe7d514082a0b756e22b0f9f6be90b
- Page: https://openairdocs.org/service-documents/boeing/737-53a1163/file/826259dd8cee

## Text

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### Page 1

Commercial 
Airplanes
737
Service Bulletin
ALERT
Number: 737-53A1163
Original Issue: December 21, 1993
Revision 1: January 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Forward Entry Doorway Skin Cutout - Upper Forward and Upper
Aft Corners - Inspection, Modification, 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 © 1993 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Unpublished Work.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 21, 1993
737-53A1163Revision 1: January 08, 2014
1 of 67
6.0

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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 9
1. PLANNING INFORMATION ........................................ 1 3
A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 6
B. Concurrent Requirements ...................................... 2 7
C. Reason ................................................ 2 7
D. Description .............................................. 2 7
E. Compliance .............................................. 2 9
F. Approval ............................................... 3 1
G. Manpower .............................................. 3 2
H. Weight and Balance Changes .................................... 3 3
I. Electrical Load Data ......................................... 3 3
J. References .............................................. 3 3
1. Existing Data: ......................................... 3 3
2. Data Supplied with this Service Bulletin: ........................... 3 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 4
K. Publications Affected ........................................ 3 4
L. Interchangeability and Intermixability of Parts ........................... 3 5
M. Software Accomplishment Summary ................................ 3 5
2. MATERIAL INFORMATION ........................................ 3 7
A. Material - Price and Availability ................................... 3 7
B. Industry Support Information .................................... 3 7
C. Parts Necessary for Each Airplane ................................. 3 7
1. Kits/Parts ............................................ 3 7
2. Parts and Materials Supplied by the Operator ........................ 4 2
3. Parts Modified and Reidentified ................................ 4 3
4. Parts Removed and Not Replaced .............................. 4 3
D. Parts Necessary to Change Spares ................................. 4 3
E. Special Tooling - Price and Availability ............................... 4 3
F. Special Tooling Necessary to do this Service Bulletin ....................... 4 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5
A. GENERAL INFORMATION ..................................... 4 5
B. WORK INSTRUCTIONS ....................................... 4 6
FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 1 ....................... 5 1
FIGURE 2: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION [Group
1, Configuration 2; Group 3] .................................. 5 2
FIGURE 3: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION [Group
2, Configuration 2] ....................................... 5 6
FIGURE 4: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - CRACK REMOVAL
[Group 1, Configuration 2] ................................... 6 0
FIGURE 5: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - CRACK REMOVAL
[Group 2, Configuration 2] ................................... 6 4
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ALERTALERT
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Commercial 
Airplanes
737
Service Bulletin
ALERT
Revision Transmittal SheetNumber: 737-53A1163Original Issue: December 21, 1993
Revision 1: January 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Forward Entry Doorway Skin Cutout - Upper Forward and Upper
Aft Corners - Inspection, Modification, and Repair
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
More work is necessary on airplanes that have not installed the repair or preventive modification in accordance
with the original issue of this service bulletin. Inspection areas are increased and inspections methods are
changed.
No more work is necessary on the airplanes that have installed the repair or preventive modification in accordance
with the original issue of this service bulletin.
737-300/-400/-500 airplanes line numbers 1923 to 3132 are added to new Group 3 of this service bulletin
effectivity.
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.
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.
REASON FOR REVISION
This revision is sent to add new airplanes to the service bulletin effectivity. This revision is also sent to increase
the inspection area, to remove internal inspection and to change external inspection methods for group 1 and
2 airplanes.
Airplane line numbers 1 through 291 are moved from Group 1 and 2 to new Group 4. 737-300/-400/-500 airplanes
line numbers 1923 to 3132 are added to new Group 3 of this service bulletin effectivity.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. Title changed to add primary section affected by this service bulletin.
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2. Summary Section: Updated Background and added new service history, summary planning table, fleet
team digest reference and service related problem reference.
3. Summary Section - Updated Action with increased inspection areas, changed inspection methods and
instructions for new airplanes.
4. Summary Section - Updated Effectivity, Industry Support Information, Manpower and Material Information
sections.
5. Summary Section - Compliance: Added related FAA Airworthiness Directives.
6. Paragraph 1.C., Reason - added new service history, fleet team digest reference, service related
problem reference, reason for revision and Notice of Status Change 1 reference.
7. Paragraph 1.D., Description - Added increased inspection areas, changed inspection methods and
instructions for new airplanes. Added maintenance zone tables.
8. Paragraph 1.E., Compliance - Added related FAA Airworthiness Directives. Added new compliance
tables 1, 2 and 3.
9. Paragraph 1.F., Approval - Added new approval paragraph and alternative methods of compliance for
related FAA Airworthiness Directives.
10. Paragraph 1.G., Manpower - Updated manpower tables for Group 1 and 2.
11. Paragraph 1.J., References - Existing Data list is updated and new drawing is added to Data Supplied
with this Service Bulletin.
12. Paragraph 1.K.2., Damage Tolerance Based Structural Inspections - Added new section.
13. Paragraph 1.L., Interchangeability and Intermixability of Parts - Added new section.
14. Paragraph 1.M., Software Accomplishment Summary - Added new section.
15. Paragraph 2.A., Material - Price and Availability - Updated prices for all kits.
16. Paragraph 2.B., Industry Support Information - Updated warranty information.
17. Paragraph 2.C., Parts Necessary for Each Airplane - Added kit tables.
18. Paragraph 3.A., General Information - Added new notes.
19. Paragraph 3.B., Work Instructions - Updated instructions for Group 1 and 2. Added new instructions
for Group 3.
20. Figure 1 has been deleted.
21. Figures 2 and 3 have been added to show increased inspection areas and changed inspection methods.
22. Figures 4 and 5 have been added to show crack removal.
The data given in Notice of Status Change 737-53-1163 NSC 1 related to inspections is not included in revision
1 of this service bulletin as the inspections have been replaced.
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The data given in Notice of Status Change 737-53-1163 NSC 1 related to kit prices is included in revision 1 of
this service bulletin.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location
of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY
December 21, 1993Original Issue:
January 08, 2014Revision 1:
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Commercial 
Airplanes
737
Service Bulletin
ALERT
SummaryNumber: 737-53A1163Original Issue: December 21, 1993
Revision 1: January 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Forward Entry Doorway Skin Cutout - Upper Forward and Upper
Aft Corners - Inspection, Modification, 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
Seventeen operators have found cracks in the upper corners of the forward entry door skin cutout. The airplanes
had collected from 33,150 to 76,242 flight cycles. The cause of the cracks is fatigue from cabin pressure.
Continued operation with cracks in the doorway upper corners can result in cabin depressurization and
unscheduled downtime for repairs.
Installation of doublers as given in this service bulletin can prevent cracks at the doorway upper corners.
Since the release of the original issue of this service bulletin there have been 3 reports of cracking at the forward
entry doorway upper corners on airplanes that were outside the effectivity of the original issue of this service
bulletin. The reports are listed below.
Service History
ReportCycles/Hours
1 inch crack common to the bearstrap only found at the upper forward corner.59804 / 69512
Crack in the skin only at the upper aft corner.31238 / 37443
Crack in skin only at the upper forward corner.38126 / 46173
Boeing Fleet Team Digest (FTD) 737 FTD 53-11003 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-53-0381 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
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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/PartsYesKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
YesOperator Supplied Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
Group 1-2, Configuration 1:
Airplanes with the repair/preventive modification installed in accordance with the original issue of this SB are
not required to be inspected in accordance with the SB. Post repair/preventive modification inspections are
provided in the D6-38669 Repair Assessment Guidelines document.
Group 1-2, Configuration 2; Group 3:
Get access to the upper corners of the forward entry doorway. Do an external detailed inspection and a Low
Frequency Eddy Current (LFEC) inspection of the skin assembly and bearstrap for any crack at the upper corners
of the forward entry doorway.
Group 1-2, Configuration 2:
If any crack is found in the skin assembly and/or bearstrap, install a repair in accordance with this service bulletin.
If no cracks are found, install the preventive modification or do repeat inspections at the times given in Paragraph
1.E., Compliance.
Group 3:
If any crack is found in the skin assembly and/or bearstrap, install a repair in accordance with this service bulletin
and do repeat inspections of the area not covered by the repair at the times given in Paragraph 1.E., Compliance.
If no cracks are found, install the preventive modification or do repeat inspections of the entire inspection area
at the times given in Paragraph 1.E., Compliance.
Group 4:
On Group 4 airplanes, contact Boeing to get instructions for the inspection and/or repair for this service bulletin,
737-53A1163 Revision 1, and do the work instructed by Boeing.
EFFECTIVITY
All 737-100/-200/-200C/-300/-400/-500 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected
airplane(s).
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COMPLIANCE
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.
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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection, and/or repair/preventive modification procedures
given in this service bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Group 1-2, Configuration 1; Group 3-4:
None.
Group 1-2, Configuration 2:
Boeing Supplied Kits/Parts.
Group 1-2, Configuration 2:
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
TYPICAL UPPER
CORNER CRACKS
DO DETAILED AND
EDDY CURRENT
INSPECTIONS FOR
CRACKS IN THE SKIN
AND BEARSTRAP AT
THE UPPER PART OF
THE FORWARD ENTRY
DOORWAY. IF ANY
CRACK IS FOUND
INSTALL A REPAIR
IF NO CRACKS ARE
FOUND, INSTALL THE
PREVENTIVE
MODIFICATION OR DO
REPEAT INSPECTIONS
FORWARD ENTRY DOOR  FWD  2191300
Original Issue: December 21, 1993
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### Page 13

Commercial 
Airplanes
737
Service Bulletin
ALERT
Number: 737-53A1163
Original Issue: December 21, 1993
Revision 1: January 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Forward Entry Doorway Skin Cutout - Upper Forward and Upper
Aft Corners - Inspection, Modification, 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 Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and
Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP
737-200/-300/-400/-500 series airplanes, line numbers 292-1922.-1
Airplanes that have accomplished the repair or preventive modification
in accordance with the original issue of this service bulletin.
1
Airplanes that have not accomplished the repair or preventive
modification in accordance with the original issue of this service
bulletin.
2
737-200C series airplanes, line numbers 292-1113.-2
Airplanes that have accomplished the repair or preventive modification
in accordance with the original issue of this service bulletin.
1
Airplanes that have not accomplished the repair or preventive
modification in accordance with the original issue of this service
bulletin.
2
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DESCRIPTIONCONFIGURATIONGROUP
737-300/-400/-500 series airplanes, line numbers 1923-3132.-3
737-100/-200/-200C series airplanes, line numbers 1-291.-4
Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500
GroupVariable Number
4PA001 - PA022
4PA099
4PA231 - PA232
4PC001 - PC005
4PG001 - PG075
4PG199
4PG201 - PG230
4PG251 - PG255
4PG271 - PG279
4PG301 - PG314
4PG331 - PG332
4PG351 - PG356
4PG375
4PG401 - PG403
4PG431 - PG442
4PG471 - PG475
4PG501 - PG505
4PG571 - PG583
1PG584 - PG586
4PG621 - PG630
4PG651 - PG652
4PG701 - PG705
1PH001
1PH011 - PH013
1PH021 - PH024
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GroupVariable Number
4PH701 - PH715
4PH731 - PH732
4PH741 - PH742
1PH743
4PJ001 - PJ002
1PJ003 - PJ009
4PJ031 - PJ032
4PJ071 - PJ072
4PJ101 - PJ104
1PJ105 - PJ119
1PJ201 - PJ219
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
1PK301 - PK318
1PK341
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GroupVariable Number
1PK351 - PK361
1PK391
1PK431 - PK433
1PK451 - PK452
1PK461 - PK469
1PK495
1PK501 - PK504
1PK511 - PK515
1PK519
1PK521 - PK528
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
1PL001 - PL028
1PL061
1PL081
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GroupVariable Number
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 - PL626
1PL631 - PL632
4PL711 - PL712
4PL716
1PL717 - PL747
1PL756
1PL758
1PL761 - PL770
1PL781 - PL788
1PL793
4PL801 - PL803
1PM001 - PM006
1PM016 - PM017
1PM021 - PM023
1PM051 - PM066
1PM101 - PM119
1PM141 - PM142
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GroupVariable Number
1PM171
1PM181
1PM251 - PM255
1PM281 - PM283
1PM381 - PM392
3PM393 - PM399
3PM401 - PM417
3PM541 - 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
1PN521
1PP001 - PP054
1PP101 - PP148
3PP149 - PP160
1PP161 - PP169
1PP181 - PP199
1PP201 - PP205
1PP221
1PP231 - PP243
1PP281 - PP286
1PP301 - PP305
1PP351 - PP353
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GroupVariable Number
1PP376 - PP384
1PP391 - PP393
1PP401 - PP440
1PP471 - PP475
1PP501 - PP510
3PP511 - PP520
1PP521 - PP522
1PP631 - PP634
1PP651 - PP652
1PP671 - PP699
1PP701 - PP733
1PP771 - PP779
1PP801 - PP808
1PP821 - PP827
1PP831 - PP848
1PP851 - PP852
1PP861 - PP873
3PP874 - PP877
1PP891 - PP899
1PP901 - PP924
3PP925 - PP930
1PP931 - PP936
1PP946 - PP948
1PP951 - PP952
1PP961 - PP967
1PP981 - PP987
3PP988 - PP990
1PP991
1PP993
1PQ001 - PQ016
1PQ026 - PQ041
1PQ051 - PQ073
3PQ074 - PQ085
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GroupVariable Number
1PQ086 - PQ092
1PQ101 - PQ198
3PQ199
3PQ201 - PQ202
1PQ221 - PQ229
3PQ230
1PQ231 - PQ236
3PQ237
1PQ241 - PQ243
1PQ251 - PQ255
3PQ256 - PQ267
1PQ281 - PQ286
3PQ287 - PQ299
1PQ301 - PQ305
3PQ306 - PQ307
1PQ331 - 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
1PS641 - PS642
3PS643 - PS644
3PS651 - PS657
1PS666 - PS668
3PS669
3PS691 - PS692
3PS701 - PS706
3PS751 - PS799
3PS811
3PS836 - PS837
3PS841 - PS846
3PS851 - PS852
3PS856
3PS861 - PS863
3PS866 - PS868
3PS871 - PS874
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GroupVariable Number
3PS896 - PS897
3PS901 - PS941
3PS956 - PS957
3PS961 - PS963
3PS971 - PS978
3PT001 - PT015
1PT021 - PT023
3PT024 - PT031
3PT041 - PT064
1PT101
3PT102 - PT105
1PT121 - PT123
3PT124 - PT138
1PT146
3PT147 - PT148
3PT161 - PT170
1PT181 - PT182
3PT183 - PT188
1PT211 - PT214
3PT215 - PT220
1PT295
3PT301 - PT309
3PT331 - PT360
3PT381 - PT399
3PT401 - PT438
3PT501 - PT517
3PT561 - PT565
3PT581 - PT586
3PT611 - PT621
3PT641 - PT644
3PT651 - PT656
3PT671 - PT672
3PT681 - PT685
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GroupVariable Number
3PT701 - PT703
3PT716 - PT717
3PT721 - PT725
3PT801 - PT834
3PT851 - PT854
3PT871 - PT886
3PT901 - PT930
3PT971 - PT973
3PT981 - PT985
3PT996
1PU001 - PU007
3PU008 - PU025
3PU301
3PU311 - PU313
1PV001 - PV040
3PV041 - PV055
3PV201 - PV209
3PV226 - PV229
3PV231 - PV237
3PV271 - PV272
3PV281 - PV287
3PV296
3PV301 - PV302
3PV351
3PV356 - PV357
1PW001 - PW036
3PW037 - PW050
1PW051
3PW052 - PW054
1PW061 - PW063
3PW064 - PW068
3PW072
3PW086 - PW088
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GroupVariable Number
1PW091 - PW093
3PW094
3PW101 - PW102
3PW106
1PW111 - PW117
3PW118 - PW120
3PW156 - PW157
1PW161 - PW162
3PW163 - PW171
3PW201 - PW252
3PW261 - PW268
3PW271 - PW276
3PW278
3PW281 - PW293
3PW296
3PW301 - PW327
3PW401 - PW408
3PW411 - PW418
3PW421 - PW424
3PW431 - PW435
3PW441 - PW450
3PW461 - PW467
1PW501 - PW503
3PW504
1PW511 - PW518
3PW519 - PW522
3PW524 - PW530
1PW531 - PW535
3PW536 - PW550
3PW556 - PW557
1PW561 - PW563
3PW564
1PW571 - PW573
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GroupVariable Number
3PW574 - PW576
1PW591 - PW594
3PW595 - PW596
1PW611 - PW615
3PW616 - PW622
1PW631 - PW632
3PW633 - PW637
1PW661
3PW662
3PW681 - PW683
3PW701 - PW702
3PW711 - PW717
3PW741 - PW742
3PW761
3PW771
3PW831
3PW851 - PW856
4PX071
4PX701
4PY001 - PY008
4PY021
2PY022
4PY031
2PY036 - PY037
2PY046 - PY048
2PY051 - PY053
2PY056 - PY057
2PY101 - PY103
2PY111 - PY113
2PY131 - PY135
2PY141 - PY143
2PY151 - PY154
2PY156 - PY157
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GroupVariable Number
2PY161 - PY162
2PY166
2PY191
2PY201
2PY221 - PY222
2PY231
2PY241 - PY244
2PY270 - PY275
2PY281
2PY286
4PY301 - PY304
4PY321 - PY323
4PY341 - PY346
4PY361 - PY362
4PY381
2PY401
2PY409 - PY411
2PY421 - PY422
2PY441
2PY451
2PY461 - PY463
2PY591 - PY595
2PY611 - PY612
2PY621
2PY631
2PY651
2PY671 - PY672
2PY721
2PY741
2. Spares Affected
None.
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B. Concurrent Requirements
None.
C. Reason
Seventeen operators have found cracks in the upper corners of the skin at the forward entry doorway.
The airplanes had collected from 33,150 to 76,242 flight cycles. The cause of the cracks is fatigue from
cabin pressure loads. Continued operation with cracks in the doorway upper corners can result in cabin
depressurization and unscheduled downtime for repairs.
Installation of doublers as given in this service bulletin can prevent cracks at the doorway corners.
Since the release of the original issue of this service bulletin there have been 3 reports of cracking at
the forward entry doorway upper corners on airplanes that were outside the effectivity of the original
issue of this service bulletin. The reports are listed below.
Service History
ReportCycles/Hours
1 inch crack common to the bearstrap only found at the upper forward corner.59804 / 69512
Crack in the skin only at the upper aft corner.31238 / 37443
Crack in skin only at the upper forward corner.38126 / 46173
Boeing Fleet Team Digest (FTD) 737 FTD 53-11003 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-53-0381 is related to this service bulletin.
Terminology has been changed in the Work Instructions to agree with the terminology defined in
Paragraph 3.A., General Information - Notes.
Revision 1 is sent to add new airplanes to the service bulletin effectivity. Revision 1 is also sent to
increase the inspection area, to remove internal inspection and to change external inspection methods
for group 1 and 2.
The data given in Notice of Status Change 737-53-1163 NSC 1 related to inspections is not included
in revision 1 of this service bulletin as the inspections have been replaced.
The data given in Notice of Status Change 737-53-1163 NSC 1 related to kit prices is included in
revision 1 of this service bulletin.
D. Description
Group 1-2, Configuration 1:
Airplanes with the repair/preventive modification installed in accordance with the original issue of this
SB are not required to be inspected in accordance with the SB. Post repair/preventive modification
inspections are provided in the D6-38669 Repair Assessment Guidelines document.
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Group 1-2, Configuration 2; Group 3:
Get access to the upper corners of the forward entry doorway. Do an external detailed inspection and
a Low Frequency Eddy Current (LFEC) inspection of the skin assembly and bearstrap for any crack
at the upper corners of the forward entry doorway.
Group 1-2, Configuration 2:
If any crack is found in the skin assembly and/or bearstrap, install a repair in accordance with this
service bulletin. If no cracks are found, install the preventive modification or do repeat inspections at
the times given in Paragraph 1.E., Compliance.
Group 3:
If any crack is found in the skin assembly and/or bearstrap, install a repair in accordance with this
service bulletin and do repeat inspections of the area not covered by the repair at the times given in
Paragraph 1.E., Compliance. If no cracks are found, install the preventive modification or do repeat
inspections of the entire inspection area at the times given in Paragraph 1.E., Compliance.
Group 4:
On Group 4 airplanes, contact Boeing to get instructions for the inspection and/or repair for this service
bulletin, 737-53A1163 Revision 1, and do the work instructed by Boeing.
Revision 1 - More work is necessary on airplanes that have not installed the repair or preventive
modification in accordance with the original issue of this service bulletin. Inspection areas are increased
and inspections methods are changed. No more work is necessary on the airplanes that have installed
the repair or preventive modification in accordance with the original issue 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
1-3, 1-5, 1-7737-200
Group 1, 3:
Affected Maintenance Zones
ZoneModel
103, 105, 107737-300, 737-400, 737-500
Group 2:
Affected Maintenance Zones
ZoneModel
1-3, 1-5, 1-7737-200C
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Group 4:
Affected Maintenance Zones
ZoneModel
1-3, 1-5, 1-7737-100, 737-200, 737-200C
E. Compliance
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.
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.
Group 4:
On Group 4 airplanes, contact Boeing to get instructions for the inspection and/or repair for this service
bulletin, 737-53A1163 Revision 1, and do the work instructed by Boeing, within 120 days of the issue
date of Revision 1 to this service bulletin.
Group 1-2, Configuration 1:
Airplanes with the repair/preventive modification installed in accordance with the original issue of this
SB are not required to be inspected in accordance with the SB. Post repair/preventive modification
inspections are provided in Table 3 of Paragraph 1.E., Compliance.
Group 1-2, Configuration 2:
Table 1: Inspection of Fuselage Skin Assembly and Bearstrap at the Forward Entry Doorway Upper
Corners
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
4,500 Flight Cycles
(a) (b)
Within 4,500
Flight Cycles af-
ter the Revision
1 date of this
service bulletin
Before 27,000
Total Flight Cy-
cles
Do an external detailed
inspection of the skin as-
sembly and a Low Fre-
quency Eddy Current
(LFEC) inspection of the
skin assembly and
bearstrap for any crack in
accordance with Para-
graph 3.B., Work Instruc-
tions, PART 1 - Inspec-
tion.
All airplanes
-Before further flight.Install the repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 3 - Repair.
If any crack is found in the
skin assembly or bearstrap.
(b)
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Group 1-2, Configuration 2:
Table 1: Inspection of Fuselage Skin Assembly and Bearstrap at the Forward Entry Doorway Upper
Corners
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
(a) Accomplishment of the preventive modification in accordance with Original issue or Revision 1 of this
service bulletin terminates the inspection of Table 1. Post preventive modification inspection are provided
in Table 3 of Paragraph 1.E., Compliance.
(b) Accomplishment of the repair in accordance with the Original issue or Revision 1 of this service bulletin
terminates the inspection of Table 1. Post repair inspection are provided in Table 3 of Paragraph 1.E.,
Compliance.
Group 3:
Table 2: Inspection of Fuselage Skin Assembly and Bearstrap at the Forward Entry Doorway Upper
Corners
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
4,500 Flight Cycles
(a) (b)
Within 4,500
Flight Cycles af-
ter the Revision
1 date of this
service bulletin.
Before 27,000
Total Flight Cy-
cles
Do an external detailed
inspection of the skin as-
sembly and a LFEC in-
spection of the skin as-
sembly and bearstrap for
any crack in accordance
with Paragraph 3.B.,
Work Instructions, PART
1 - Inspection.
All Airplanes
-Before further flight.Install a repair in accor-
dance with Paragraph
3.B., Work Instructions,
PART 3 - Repair. (b)
If any crack is found in the
skin assembly or bearstrap.
(a) Accomplishment of the preventive modification in accordance with Revision 1 of this Service Bulletin
terminates the inspection of Table 2. Post preventive modification inspections are provided in the appli-
cable SRM.
(b) Accomplishment of the repair in accordance with Revision 1 of this Service Bulletin terminates the inspec-
tion of Table 2 in the repaired area. If a repair is only installed on one corner, inspections in the area not
repaired are still required in accordance with Table 2. Post repair inspections are provided in the applicable
SRM.
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Group 1-2:
Table 3: Inspection of Fuselage Skin Assembly and Bearstrap For Airplanes With a Repair or Preventive
Modification Installed
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
Repeat the inspec-
tion at interval in
accordance with
RAG.
Within 12,000
flight cycles af-
ter repair has
been installed
Before 60,000
total flight cycles
Do the inspection in accor-
dance with D6-38669,
Repair Assessment
Guidelines-Model 737-
100 to -500.
Airplanes that have in-
stalled the repair or preven-
tive modification in accor-
dance with the Original Is-
sue or Revision 1 of this
Service Bulletin.
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 Boeing 737-200 series airplanes, the Manager of the FAA Seattle Aircraft Certification Office (ACO)
approves the supplemental inspection methods, thresholds and repeat intervals as given in Table 3 of
Paragraph 1.E., Compliance for the repair or preventive modification defined in Table 1 of Paragraph
1.E., Compliance, of Revision 1 of this service bulletin as a method of compliance (MOC) to paragraph
(g) of AD 98-11-04 R1 for the inspections of Structurally Significant Items (SSI) F-13A and F-14A. This
approval applies to these SSIs and only for the portions of the skin and bear strap that have been
repaired in accordance with this SB. If operators choose this MOC, then they must revise their
FAA-approved maintenance or inspection program to incorporate these alternative inspections. All
provisions of AD 98-11-04 R1 that are not specifically referenced above remain fully applicable and
must be complied with accordingly.
For Boeing 737-200C series airplanes, the Manager of the FAA Seattle ACO approves the inspection
methods, thresholds and repeat intervals as given in Table 3 of Paragraph 1.E., Compliance for the
repair or preventive modification defined in Table 1 of Paragraph 1.E., Compliance, of Revision 1 of
this service bulletin as an alternative method of compliance (AMOC) to the inspections of SSIs F-13A
and F-14A, required by paragraphs (g) and (h) of AD 2008-08-23. This approval applies to these SSIs
and only for the portions of the skin and bear strap that have been repaired in accordance with this
SB. 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 2008-08-23 that are not
specifically referenced above remain fully applicable and must be complied with accordingly.
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For Boeing 737-300/-400/-500 series airplanes identified as Group 1 airplanes, the Manager of the
FAA Seattle ACO approves the inspection methods, thresholds and repeat intervals as given in Table
3 of Paragraph 1.E., Compliance for the repair or preventive modification defined in Table 1 of Paragraph
1.E., Compliance, of Revision 1 of this service bulletin as an AMOC to the inspections of SSIs F-13A
and F-14A, required by paragraphs (g) and (h) of AD 2008-09-13. This approval applies to these SSIs
and only for the portions of the skin and bear strap that have been repaired or modified in accordance
with this SB. 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 2008-09-13
that are not specifically referenced above remain fully applicable and must be complied with accordingly.
G. Manpower
The table below shows an estimate of the task hours necessary to do this change 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, Configuration 2:
Elapsed HoursTask HoursNumber of PersonsTask
3.003.001FIGURE 2
2.755.502FIGURE 4
1.001.00 (a)1Open Access
30.00 (a)60.00 (a)2Repair (a)
22.00 (a)44.00 (a)2Preventive Modification (a)
1.001.00 (a)1Close Access
5.758.50TOTAL FOR EACH AIRPLANE
(a) The Repair and Preventive Modification estimates are not included in the total estimates.
Group 2, Configuration 2:
Elapsed HoursTask HoursNumber of PersonsTask
3.003.001FIGURE 3
2.755.502FIGURE 5
1.001.00 (a)1Open Access
30.00 (a)60.00 (a)2Repair (a)
22.00 (a)44.00 (a)2Preventive Modification (a)
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Group 2, Configuration 2:
Elapsed HoursTask HoursNumber of PersonsTask
1.00 (a)1.00 (a)1Close Access
5.758.50TOTAL FOR EACH AIRPLANE
(a) The Repair and Preventive Modification estimates are not included in the total estimates.
Group 3:
Elapsed HoursTask HoursNumber of PersonsTask
3.003.001FIGURE 2
H. Weight and Balance Changes
Group 1, Configuration 2:
Change in Moment (Pound-Inches)Change in
Weight
(Pounds)
Kit
737-500737-400737-300737-200737-100
+ 1177.8+ 686.4+ 967.2+ 1138.8+ 1279.2+ 3.965C36941-1
+ 1751.6+ 1020.8+ 1438.4+ 1693.6+ 1902.4+ 5.865C36941-5
+ 3050.2+ 1777.6+ 2504.8+ 2949.2+ 3312.8+ 10.165C36941-7
Group 2, Configuration 2:
737-200C Model Series Airplanes
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Kit
+ 1635.2+ 5.665C36941-13
+ 2219.2+ 7.665C36941-15
+ 3095.2+ 10.665C36941-17
Group 1-2, Configuration 1; Group 3-4:
None.
I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. Boeing Service Letter 737-SL-51-042.
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b. Boeing Service Related Problem (SRP) 737-SRP-53-0381.
c. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2008-08-23, 2008-09-13,
98-11-04 R1.
d. Service Bulletin Index D6-19567.
e. D6-38669 Repair Assessment Guidelines (RAG) -Model 737-100 to -500.
f. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-19.
g. 737 Fleet Team Digest (FTD) 53-11003.
h. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Part 6, 51-00-26, Part 6, 53-30-00.
i. 737-100/200 Aircraft Maintenance Manual (AMM) 25-21-31, 25-21-41.
j. 737-300/400/500 Aircraft Maintenance Manual (AMM) 25-21-31.
k. 737-100/200 Structural Repair Manual (SRM) 51-30-08
l. 737-300 Structural Repair Manual (SRM) 51-40-08, 53-10-01.
m. 737-400 Structural Repair Manual (SRM) 51-40-08, 53-10-01.
n. 737-500 Structural Repair Manual (SRM) 51-40-08, 53-10-01.
2. Data Supplied with this Service Bulletin:
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
--1Repair and Preventive Modification, Upper
Forward Entry Doorway - Kit
65C36941
--2
1, 2-PL
-APSDL
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None.
Boeing Process Specifications referred to on drawings are not given in this service bulletin since
these procedures are frequently used as standard shop practices.
K. Publications Affected
1. Publications:
None.
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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
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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### Page 37

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Group 1-2, Configuration 1; Group 3-4:
None.
Group 1-2, Configuration 2:
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators
are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days.
Group 1-2, Configuration 2:
Reference this service bulletin and submit your purchase order by one of these methods:
Group 1-2, Configuration 2:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
Group 1-2, Configuration 2:
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the Revision 1
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
original issue
date of this Ser-
vice Bulletin
(Weeks)
NameKit Number
$2222.0025Kit - Preventive Modification65C36941-1
$2527.0025Kit - Repair65C36941-5
$4573.0025Kit - Repair65C36941-7
$3912.0025Kit - Preventive Modification65C36941-13
$4103.0025Kit - Repair65C36941-15
$4964.0025Kit - Repair65C36941-17
B. Industry Support Information
Boeing warranty remedies are not available for the inspection, and/or repair/preventive modification
procedures given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts
Group 1-2, Configuration 1; Group 3-4:
None.
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Group 1-2, Configuration 2:
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
Group 1-2, Configuration 2:
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, Configuration 2:
Kit 65C36941 Upper Forward Entry Doorway - Repair and Preventive Modification
NotesNameQTYPart Number
-7-5-1
PREVENTIVE MODI-
FICATION
REPAIR INSTL..-65C36941-1
(a)REPAIR INSTL.-.65C36941-5
(b)REPAIR INSTL-..65C36941-7
(c)STOCK DOUBLER.1165C36941-2
(c)DOUBLER.1165C36941-3
(d)STOCK TRIPLER.1.65C36941-4
(d)TRIPLER.1.65C36941-6
(e)STOCK DOUBLER1..65C36941-8
(e)DOUBLER1..65C36941-9
(f)STOCK TRIPLER1..65C36941-10
(f)TRIPLER1..65C36941-11
(g)WASHER, REPAIR25025025066-2955-40
(g)WASHER, REPAIR55566-2955-41
(g)WASHER, REPAIR50505066-2955-47
(g) (h)HI-LOK, 3/16 DIA1436BACB30NW6K10X
(g) (h)HI-LOK, 3/16 DIA.4.BACB30NW6K11X
(g) (h)HI-LOK, 3/16 DIA3..BACB30NW6K13X
(g) (h)HI-LOK, 3/16 DIA333BACB30NW6K3X
(g) (h)HI-LOK, 3/16 DIA34276BACB30NW6K4X
(g) (h)HI-LOK, 3/16 DIA505750BACB30NW6K5X
(g) (h)HI-LOK, 3/16 DIA123540BACB30NW6K6X
(g) (h)HI-LOK, 3/16 DIA346034BACB30NW6K7X
(g) (h)HI-LOK, 3/16 DIA54143BACB30NW6K8X
(g) (h)HI-LOK, 3/16 DIA40..BACB30NW6K9X
(g) (h)HI-LOK, 1/4 DIA555BACB30NW8K8X
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Group 1, Configuration 2:
Kit 65C36941 Upper Forward Entry Doorway - Repair and Preventive Modification
NotesNameQTYPart Number
-7-5-1
(g) (h)HI-LOK, 3/16 DIA.56BACB30VU6K2
(g) (h)HI-LOK, 3/16 DIA625858BACB30VU6K3
(g) (h)HI-LOK, 3/16 DIA.2854BACB30VU6K4
(g) (h)HI-LOK, 3/16 DIA28203BACB30VU6K5
(g) (h)HI-LOK, 3/16 DIA22.BACB30VU6K6
(g) (h)HI-LOK, 3/16 DIA20..BACB30VU6K7
(g)COLLAR114114114BACC30BL6
(g)COLLAR220220220BACC30M6
(g)COLLAR555BACC30M8
FILLER111BACF3F010J175NN
FILLER11.BACF3F010J225NN
(g) (h)RIVET2..BACR15BB4D10
(g) (h)RIVET..3BACR15BB4D5
(g) (h)RIVET.32BACR15BB4D6
(g) (h)RIVET.2.BACR15BB4D8
(g) (h)RIVET3..BACR15BB4D9
(g) (h)RIVET4..BACR15BB5D11
(g) (h)RIVET..2BACR15BB5D5
(g) (h)RIVET.24BACR15BB5D7
(g) (h)RIVET24.BACR15CE5D9
(g) (h)RIVET.3.BACR15CE6D10
(g) (h)RIVET34..BACR15CE6D11
(g) (h)RIVET3..BACR15CE6D12
(g) (h)RIVET.433BACR15CE6D7
(g) (h)RIVET10369BACR15CE6D8
(g) (h)RIVET.43BACR15CE6D9
(i)WASHER505050BACW10BN3AP
(i)WASHER100100100BACW10BN31AP
(i)WASHER101010BACW10BN41AP
(a) For repair use if crack is in skin assembly but there are no cracks in the bearstrap.
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### Page 40

Group 1, Configuration 2:
Kit 65C36941 Upper Forward Entry Doorway - Repair and Preventive Modification
NotesNameQTYPart Number
-7-5-1
(b) For repair use if crack is in skin assembly and bearstrap.
(c) 65C36941-2 is used to make 65C36941-3.
(d) 65C36941-4 is used to make 65C36941-6.
(e) 65C36941-8 is used to make 65C36941-9.
(f) 65C36941-10 is used to make 65C36941-11.
(g) There are more parts than are necessary.
(h) 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.
(i) Use if required to bring material thickness within bolt grip range. Maximum of (2) washers allowed.
Group 2, Configuration 2:
Kit 65C36941 Upper Forward Entry Doorway - Repair and Preventive Modification
NotesNameQTYPart Number
-17-15-13
PREVENTIVE MODI-
FICATION
REPAIR INSTL..-65C36941-13
(a)REPAIR INSTL.-.65C36941-15
(b)REPAIR INSTL-..65C36941-17
(c)STOCK DOUBLER11165C36941-8
(c)DOUBLER11165C36941-14
(d)STOCK TRIPLER.1.65C36941-4
(d)TRIPLER.1.65C36941-16
(e)TRIPLER1..65C36941-18
(e)STOCK TRIPLER1..65C36941-10
(f)WASHER, REPAIR10101066-2955-11
(f)WASHER, REPAIR25025025066-2955-40
(f)WASHER, REPAIR20202066-2955-41
(f)WASHER, REPAIR50505066-2955-47
(f) (g)HI-LOK, 3/16 DIA12816BACB30NW6K10X
(f) (g)HI-LOK, 3/16 DIA14124BACB30NW6K11X
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### Page 41

Group 2, Configuration 2:
Kit 65C36941 Upper Forward Entry Doorway - Repair and Preventive Modification
NotesNameQTYPart Number
-17-15-13
(f) (g)HI-LOK, 3/16 DIA8..BACB30NW6K12X
(f) (g)HI-LOK, 3/16 DIA333BACB30NW6K4X
(f) (g)HI-LOK, 3/16 DIA222250BACB30NW6K5X
(f) (g)HI-LOK, 3/16 DIA204866BACB30NW6K6X
(f) (g)HI-LOK, 3/16 DIA6210890BACB30NW6K7X
(f) (g)HI-LOK, 3/16 DIA633417BACB30NW6K8X
(f) (g)HI-LOK, 3/16 DIA47144BACB30NW6K9X
(f) (g)HI-LOK, 1/4 DIA999BACB30NW8K7X
(f) (g)HI-LOK, 1/4 DIA444BACB30NW8K8X
(f) (g)HI-LOK, 1/4 DIA333BACB30NW8K9X
(f) (g)HI-LOK, 3/16 DIA212224BACB30VU6K3
(f) (g)HI-LOK, 3/16 DIA161816BACB30VU6K4
(f) (g)HI-LOK, 3/16 DIA302938BACB30VU6K5
(f) (g)HI-LOK, 3/16 DIA4123BACB30VU6K6
(f) (g)HI-LOK, 3/16 DIA222BACB30VU6K7
(f) (g)HI-LOK, 3/16 DIA10..BACB30VU6K8
(f)COLLAR848484BACC30BL6
(f)COLLAR250250250BACC30M6
(f)COLLAR161616BACC30M8
FILLER111BACF3F010M175NN
FILLER.1.BACF3F010J225NN
FILLER1..BACF3F010V225NN
(f) (g)RIVET2..BACR15BB4D11
(f) (g)RIVET..3BACR15BB4D6
(f) (g)RIVET3.BACR15BB4D7
(f) (g)RIVET..2BACR15BB4D8
(f) (g)RIVET32.BACR15BB4D9
(f) (g)RIVET5..BACR15BB5D11
(f) (g)RIVET5BACR15BB5D8
(f) (g)RIVET5.BACR15BB5D9
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### Page 42

Group 2, Configuration 2:
Kit 65C36941 Upper Forward Entry Doorway - Repair and Preventive Modification
NotesNameQTYPart Number
-17-15-13
(f) (g)RIVET.3.BACR15CE6D10
(f) (g)RIVET32..BACR15CE6D11
(f) (g)RIVET7736BACR15CE6D8
(f) (g)RIVET.293BACR15CE6D9
(f) (g)RIVET679BACR15DS7D10
(f) (g)RIVET24.BACR15DS7D11
(f) (g)RIVET4..BACR15DS7D13
(f) (g)RIVET..2BACR15DS7D9
(h)WASHER505050BACW10BN3AP
(h)WASHER100100100BACW10BN31AP
(h)WASHER101010BACW10BN41AP
(a) For repair use if crack is in skin assembly but there are no cracks in the bearstrap.
(b) For repair use if crack is in skin assembly and bearstrap.
(c) 65C36941-8 is used to make 65C36941-14.
(d) 65C36941-4 is used to make 65C36941-16.
(e) 65C36941-10 is used to make 65C36941-18.
(f) There are more parts than are necessary.
(g) 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.
(h) Use if required to bring material thickness within bolt grip range. Maximum of (2) washers allowed.
2. Parts and Materials Supplied by the Operator
Group 1-2, Configuration 1; Group 4:
None.
Group 1-2, Configuration 2:
The following parts or materials are necessary to do the change in this service bulletin. Parts and
materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine
operator part and material supply to make sure all necessary parts and materials are available.
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Group 1-2, Configuration 2:
NotesNameQTYPart Number /
Specification
(a)Sealant8 OzBMS 5-95, Class
B-1/2, -2 or -4
(a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)
for supplier data.
Group 3:
No special parts or materials are necessary to do the change in this service bulletin. But, parts
and materials in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator part and material supply to make sure all necessary parts and materials are available.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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BLANK PAGE

### Page 45

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque limits to tighten nuts and bolts are in SRM Chapter 51
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
5. Refer to 737-100/200 SRM 51-30-08, or 737-300 SRM 51-40-08, or 737-400 SRM
51-40-08, or 737-500 SRM 51-40-08 for countersink instructions and instructions on
how to install countersink repair washers.
6. Refer to the SOPM 20-50-11 for application of aerodynamic smoother.
7. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
8. 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.
9. These work instructions refer to procedures included in 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.
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10. Boeing Service Letter 737-SL-51-042, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
11. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
12. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
13. Some Boeing parts are supplied in a temporary configuration. Those parts are
identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is
permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'
(dash) part number. Boeing Drawing 005W0900 contains more data.
14. Shaded areas in Figures are reference only. Shaded areas in Figures may look
different than your airplane.
B. WORK INSTRUCTIONS
1. Group 4:
Contact Boeing to get instructions for the inspection and/or repair for this service bulletin,
737-53A1163 Revision 1, and do the work instructed by Boeing.
2. Group 1-2, Configuration 1:
Airplanes with the repair or preventive modification installed in accordance with the original issue
of this SB are not required to be inspected in accordance with the SB. Post repair/preventive
modification inspections are provided in Table 3 of Paragraph 1.E., Compliance.
3. Group 1-2, Configuration 2; Group 3:
Do Parts 1, 2 and 3 as applicable. Refer to Paragraph 1.E., Compliance.
4. Group 1-3:
For door corners that have a repair provided by Boeing and approved via FAA Form 8100-9
installed, the inspection in this SB is not required for the repaired door corner(s). Refer to the repair
approval for any supplemental inspection of the repair area.
Group 1-2, Configuration 2; Group 3:
PART 1 - INSPECTION
1. Get external access to the upper corners of the forward entry doorway.
2. Group 1, Configuration 2; Group 3:
Do an external detailed inspection of the skin assembly and a Low Frequency Eddy Current (LFEC)
inspection of the skin assembly and bearstrap for any crack in accordance with FIGURE 2.
a. If any crack is found, do Part 3 - Repair.
b. If no cracks are found, do Part 2 - Preventive Modification or do repeat inspections at the
times given in Paragraph 1.E., Compliance.
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3. Group 2, Configuration 2:
Do an external detailed inspection of the skin assembly and a LFEC inspection of the skin assembly
and bearstrap for any crack in accordance with FIGURE 3.
a. If any crack is found, do Part 3 - Repair.
b. If no cracks are found, do Part 2 - Preventive Modification or do repeat inspections at the
times given in Paragraph 1.E., Compliance.
4. Put the airplane back to a serviceable condition.
Group 1-2, Configuration 2; Group 3:
PART 2 - PREVENTIVE MODIFICATION
1. Get access to the passenger cabin side of the forward entry doorway upper corners by removing
the sidewall lining panels. Refer to 737-100/200 AMM 25-21-41 and 737-100/200 AMM 25-21-31
or 737-300/400/500 AMM 25-21-31 as an accepted procedure.
2. Group 1, Configuration 2:
Install the preventive modification (Kit 65C36941-1) in accordance with 65C36941 Sheet 1 and
Sheet PSDL and general repair notes given below.
– Remove all fasteners common to the preventive modification area. At all open holes common
to the preventive modification area, do fastener hole probe inspection in accordance with 737
NDT Manual Part 6, 51-00-00, Figure 16.
– Make sure that all repair parts and machine surfaces have a minimum of 63 RMS finish or
better. This requirement supersedes the 125 RMS for all machine surfaces of 65C36941
PSDL, General Note 1.
– Maintain a minimum 2D edge margin on all repair parts except for repair filler. Maintain a
minimum 1.5D edge margin on fillers.
– Install all rivets dry and over-driven to a minimum of 1.4D driven head. Install all hex-drive
bolts wet with BMS 5-95 sealant in transition fit holes.
– Prior to clamp up, shim all gaps greater than 0.01 inches up to a maximum of 0.04 inches.
Contact Boeing for any gap greater than 0.04 inches.
– Install all parts wet with faying surface seal BMS 5-95 sealant. Refer to SOPM 20-50-19 as
an acceptable procedure.
NOTE: Accomplishment of the preventive modification in accordance with the above noted repair
terminates the inspection requirements in Table 1 of Paragraph 1.E., Compliance. Post
preventive modification inspections are provided in Table 3 of Paragraph 1.E., Compliance.
3. Group 2, Configuration 2:
Install the preventive modification (Kit 65C36941-13) in accordance with 65C36941 Sheet 2 and
Sheet PSDL and general repair notes given below.
– Remove all fasteners common to the preventive modification area. At all open holes common
to the preventive modification area, do fastener hole probe inspection in accordance with 737
NDT Manual Part 6, 51-00-00, Figure 16.
– Make sure that all repair parts and machine surfaces have a minimum of 63 RMS finish or
better. This requirement supersedes the 125 RMS for all machine surfaces of 65C36941
PSDL, General Note 1.
– Maintain a minimum 2D edge margin on all repair parts except for repair filler. Maintain a
minimum 1.5D edge margin on fillers.
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– Install all rivets dry and over-driven to a minimum of 1.4D driven head. Install all hex-drive
bolts wet with BMS 5-95 sealant in transition fit holes.
– Prior to clamp up, shim all gaps greater than 0.01 inches up to a maximum of 0.04 inches.
Contact Boeing for any gap greater than 0.04 inches.
– Install all parts wet with faying surface seal BMS 5-95 sealant. Refer to SOPM 20-50-19 as
an acceptable procedure.
NOTE: Accomplishment of the preventive modification in accordance with the above noted repair
terminates the inspection requirements in Table 3 of Paragraph 1.E., Compliance. Post
preventive modification inspections are provided in Table 3 of Paragraph 1.E., Compliance.
4. Group 3:
Install the preventive modification in accordance with 737-300 SRM 53-10-01 Repair 22, or 737-400
SRM 53-10-01 Repair 22, or 737-500 SRM 53-10-01 Repair 22.
NOTE: Accomplishment of the preventive modification in accordance with the above noted repair
terminates the inspection requirements of this service bulletin. Post preventive modification
inspections are provided in the applicable SRM.
5. Install the forward entry doorway sidewall lining panels that were removed. Refer to 737-100/200
AMM 25-21-41 and 737-100/200 AMM 25-21-31 or 737-300/400/500 AMM 25-21-31 as an accepted
procedure.
6. Put the airplane back to a serviceable condition.
Group 1-2, Configuration 2; Group 3:
PART 3 - REPAIR
1. Get access to the passenger cabin side of the forward entry doorway upper corners by removing
the sidewall lining panels. Refer to 737-100/200 AMM 25-21-41 and 737-100/200 AMM 25-21-31
or 737-300/400/500 AMM 25-21-31 as an accepted procedure.
2. Group 1, Configuration 2:
Do as follows:
a. Cut out all cracks found in accordance with FIGURE 4.
NOTE: Stop drill to terminate a crack is no longer an accepted procedure.
b. Remove all the fasteners common to the repair area. At all open fastener holes common to
the repair area, do an HFEC hole probe inspection for any crack in accordance with 737 NDT
Manual Part 6, 51-00-00, Figure 16. If any crack is found, contact Boeing for repair instructions
and do the work instructed by Boeing.
c. If any crack is found outside the maximum cutout area or if the cutout area is larger than then
maximum cutout area allowed, contact Boeing for instructions and do the work instructed by
Boeing.
d. If cutout in only in the skin assembly but not in the bearstrap, install the repair (Kit 65C36941-5)
in accordance with 65C36941 Sheet 1 and Sheet PSDL and general notes below.
e. If cutout is in the skin assembly and the bearstrap, install the repair (Kit 65C36941-7) in
accordance with 65C36941 Sheet 1 and Sheet PSDL and general notes below.
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f. General repair notes:
– Make sure that all repair parts and machine surfaces have a minimum of 63 RMS finish
or better. This requirement supersedes the 125 RMS for all machine surfaces of 65C36941
PSDL, General Note 1.
– Maintain a minimum 2D edge margin on all repair parts except for repair filler. Maintain
a minimum 1.5D edge margin on fillers.
– Install all rivets dry and over-driven to a minimum of 1.4D driven head. Install all hex-drive
bolts wet with BMS 5-95 sealant in transition fit holes.
– Prior to clamp up, shim all gaps greater than 0.01 inches up to a maximum of 0.04 inches.
Contact Boeing for any gap greater than 0.04 inches.
– Install all parts wet with faying surface seal BMS 5-95 sealant. Refer to SOPM 20-50-19
as an acceptable procedure.
g. Accomplishment of the repairs in accordance with the procedure above terminates the
inspection requirements of Table 1 of Paragraph 1.E., Compliance. Post repair inspections
are provided in Table 3 of Paragraph 1.E., Compliance.
3. Group 2, Configuration 2:
Do as follows:
a. Cut out all cracks found in accordance with FIGURE 5.
NOTE: Stop drill to terminate a crack is no longer an accepted procedure.
b. Remove all the fasteners common to the repair area. At all open fastener holes common to
the repair, do an HFEC hole probe inspection for any crack in accordance with 737 NDT
Manual Part 6, 51-00-00, Figure 16.
c. If any crack is found outside the maximum cutout area or if the cutout area is larger than then
maximum cutout area allowed, contact Boeing for instructions and do the work instructed by
Boeing.
d. If cutout in only in the skin assembly but not in the bearstrap, install the repair (Kit
65C36941-15) in accordance with 65C36941 Sheet 1 and Sheet PSDL and general notes
below.
e. If cutout is in the skin assembly and the bearstrap, install the repair (Kit 65C36941-17) in
accordance with 65C36941 Sheet 1 and Sheet PSDL and general notes below.
f. General repair notes:
– Make sure that all repair parts and machine surfaces have a minimum of 63 RMS finish
or better. This requirement supersedes the 125 RMS for all machine surfaces of 65C36941
PSDL, General Note 1.
– Maintain a minimum 2D edge margin on all repair parts except for repair filler. Maintain
a minimum 1.5D edge margin on fillers.
– Install all rivets dry and over-driven to a minimum of 1.4D driven head. Install all hex-drive
bolts wet with BMS 5-95 sealant in transition fit holes.
– Prior to clamp up, shim all gaps greater than 0.01 inches up to a maximum of 0.04 inches.
Contact Boeing for any gap greater than 0.04 inches.
– Install all parts wet with faying surface seal BMS 5-95 sealant. Refer to SOPM 20-50-19
as an acceptable procedure.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 21, 1993
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BOEING SERVICE BULLETIN 737-53A1163
ALERTALERT

### Page 50

g. Accomplishment of the repairs in accordance with the procedure above terminates the
inspection requirements of Table 1 of Paragraph 1.E., Compliance. Post repair inspections
are provided in Table 3 of Paragraph 1.E., Compliance.
4. Group 3:
Do as follows:
a. If any crack is found in the forward upper corner of the doorway but there are no cracks at
the aft upper corner, install the repair in accordance with the applicable 737-300 SRM 53-10-01
Repair 17, or 737-400 SRM 53-10-01 Repair 17, or 737-500 SRM 53-10-01 Repair 17.
NOTE: As an option, in addition to the repair, install the preventive portion for the aft upper
corner in accordance with the applicable 737-300 SRM 53-10-01 Repair 17, or
737-400 SRM 53-10-01 Repair 17, or 737-500 SRM 53-10-01 Repair 17.
b. If any crack is found in the aft upper corner of the doorway but there are no cracks at the
forward upper corner, install the repair in accordance with the applicable 737-300 SRM
53-10-01 Repair 21, or 737-400 SRM 53-10-01 Repair 21, or 737-500 SRM 53-10-01 Repair
21.
NOTE: As an option, in addition to the repair, install the preventive portion for the forward
upper corner in accordance with the applicable 737-300 SRM 53-10-01 Repair 21,
or 737-400 SRM 53-10-01 Repair 21, or 737-500 SRM 53-10-01 Repair 21.
c. If any crack is found in the forward and aft upper corner of the doorway, install the repair in
accordance with the applicable 737-300 SRM 53-10-01 Repair 22, or 737-400 SRM 53-10-01
Repair 22, or 737-500 SRM 53-10-01 Repair 22.
d. Accomplishment of the repairs or preventive modification in accordance with the applicable
SRM terminates the inspection requirements of this service bulletin in the modified area. Post
repair inspections are provided in the applicable SRM.
5. Install the forward entry doorway sidewall lining panels that were removed. Refer to 737-100/200
AMM 25-21-41 and 737-100/200 AMM 25-21-31 or 737-300/400/500 AMM 25-21-31 as an accepted
procedure.
6. Put the airplane back to a serviceable condition.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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737-53A1163Revision 1: January 08, 2014
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BOEING SERVICE BULLETIN 737-53A1163
ALERTALERT

### Page 51 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
THIS FIGURE IS DELETED.
D38438
FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 1
(SHEET 1 OF 1)
Desion Ja: Day 06, 2011, 993  PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  737-53A1163
Work - See page 1 for details.  51 of 67

### Page 52 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
This Figure applies only to: Group 1, Configuration 2; Group 3.
STA
328
FORWARD ENTRY DOOR  FWD  2191302
FIGURE 2: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 1 OF 4)
Original Issue: December 21, 1993
Revision 1 January 08, 2014  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  737-53A1163
Work - See page 1 for details.  52 of 67

### Page 53 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
BEARSTRAP
STA
304  SKIN
ASSEMBLY
RAIN GUTTER
STA
328
S-6L-
S-7
I DETAILED
S-8L  INSPECTION AREA
EDDY CURRENT
LL.  INSPECTION AREA
2191308
FIGURE 2: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 2 OF 4)
Original Issue: December 21, 1993
Revision 1 January 08, 2014  PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  737-53A1163
Work - See page 1 for details.  53 of 67

### Page 54 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
STA
348  RAIN GUTTER
STA
328
- S-6L
BEARSTRAP
- S-7L
- INSPECTION AREA  ¡ DETAILED
EDDY CURRENT  INSPECTION AREA  - S-8L
FWD
NINS  ASSEMBLY  2191628
FIGURE 2: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 3 OF 4)
Original Issue: December 21, 1993
Revision 1 January 08, 2014  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  54 of 67

### Page 55

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)--Skin AssemblyInspect1
(b)--Skin Assembly and
Bearstrap
Inspect2
(a) Do an external detailed inspection for any crack in the Skin Assembly in the area shown.
(b) Do an external Low Frequency Eddy Current (LFEC) inspection around the fastener head for any crack
in the skin assembly and bear strap in accordance with 737 NDT Manual Part 6, 51-00-26.
FIGURE 2: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 4 OF 4)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 21, 1993
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55 of 67
BOEING SERVICE BULLETIN 737-53A1163
ALERTALERT

### Page 56 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
_ This Figure applies only to: Group 2, Configuration 2.
STA
328
FORWARD ENTRY DOOR  FWD  2191305
FIGURE 3: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 1 OF 4)
Original Issue: December 21, 1993
Revision 1 January 08, 2014  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  737-53A1163
Work - See page 1 for details.  56 of 67

### Page 57 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
BEARSTRAP
STA
304  SKIN
ASSEMBLY
RAIN GUTTER
STA
328
S-6L-
S-7
¡ DETAILED
INSPECTION AREA
S-8L
EDDY CURRENT
INSPECTION AREA
2191812
FIGURE 3: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 2 OF 4)
Original Issue: December 21, 1993
Revision 1 January 08, 2014  PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  737-53A1163
Work - See page 1 for details.  57 of 67

### Page 58 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
BEARSTRAP  STA
SKIN  348  RAIN GUTTER
ASSEMBLY
STA
328
S-6L
- S-7L
INSPECTION AREA  ¡ DETAILED
EDDY CURRENT  INSPECTION AREA  — S-8L
FWD
2191816
FIGURE 3: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 3 OF 4)
Original Issue: December 21, 1993
Revision 1 January 08, 2014  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  737-53A1163
Work - See page 1 for details.  58 of 67

### Page 59

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)--Skin AssemblyInspect1
(b)--Skin Assembly and
Bearstrap
Inspect2
(a) Do an external detailed inspection for any crack in the Skin Assembly in the area shown.
(b) Do an external Low Frequency Eddy Current (LFEC) inspection around the fastener head for any crack
in the skin assembly and bearstrap in accordance with 737 NDT Manual Part 6, 51-00-26.
FIGURE 3: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION
(SHEET 4 OF 4)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 21, 1993
737-53A1163Revision 1 January 08, 2014
59 of 67
BOEING SERVICE BULLETIN 737-53A1163
ALERTALERT

### Page 60 (OCR)

BOEING SERVICE BULLETIN 737-53A1163
ALERT  ALERT
_ This Figure applies only to: Group 1, Configuration 2.
STA
328
FORWARD ENTRY DOOR  FWD  2191306
FIGURE 4: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - CRACK REMOVAL
(SHEET 1 OF 4)
Original Issue: December 21, 1993
Revision 1 January 08, 2014  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  737-53A1163
Work - See page 1 for details.  60 of 67

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