# Boeing Alert Service Bulletin 737-53A1188: U.S. DOT/FAA - Service Bulletin - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2014-0195; AD 2014-23-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 737-53A1188](https://openairdocs.org/service-documents/boeing/737-53a1188.md) - Title as filed: U.S. DOT/FAA - Service Bulletin - Pages: 99 - PDF: https://openairdocs.org/files/sha256/e2/e6/e2e63639ee85aea60151e91353c71eb1e98e9f409697647c1335d65f840235f7 - Page: https://openairdocs.org/service-documents/boeing/737-53a1188/file/e2e63639ee85 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1188 Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change 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 © 1998 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 Unpublished Work.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: April 09, 1998 737-53A1188Revision 3: September 06, 2013 1 of 99 5.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 2 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 7 1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1 1. Airplanes ............................................ 1 1 2. Spares Affected ........................................ 1 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 8 E. Compliance .............................................. 1 8 F. Approval ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 3 I. Electrical Load Data ......................................... 2 4 J. References .............................................. 2 4 1. Existing Data: ......................................... 2 4 2. Data Supplied with this Service Bulletin: ........................... 2 4 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 5 K. Publications Affected ........................................ 2 5 L. Interchangeability and Intermixability of Parts ........................... 2 5 M. Software Accomplishment Summary ................................ 2 5 2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 8 1. Kits/Parts: ........................................... 2 8 2. Parts and Materials Supplied by the Operator: ........................ 3 1 3. Parts Modified and Reidentified: ............................... 3 2 4. Parts Removed and Not Replaced: .............................. 3 2 D. Parts Necessary to Change Spares ................................. 3 2 E. Special Tooling - Price and Availability ............................... 3 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 2 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 4 FIGURE 1: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 1] ..... 4 0 FIGURE 2: INSPECTION [Group 1] .................................... 4 4 FIGURE 3: REMOVAL OF STRUCTURE [Group 1] ............................ 4 8 FIGURE 4: THIS FIGURE HAS BEEN DELETED ............................. 5 3 FIGURE 5: THIS FIGURE HAS BEEN DELETED ............................. 5 4 FIGURE 6: THIS FIGURE HAS BEEN DELETED ............................. 5 5 FIGURE 7: CLOSE ACCESS - INSTALL SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 1] . 56 FIGURE 8: INSPECTION - DETAILED AND HIGH FREQUENCY EDDY CURRENT .......... 5 9 FIGURE 9: REMOVE REPAIR KIT 65C37762-2 AND -4 OR -6 ..................... 6 3 FIGURE 10: REMOVE PREVENTIVE MODIFICATION KIT 65C37762-1 AND -4 OR -5 ......... 6 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 3 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 4 FIGURE 11: PREVENTIVE MODIFICATION OR REPAIR - NO KITS INSTALLED BY ORIGINAL ISSUE, REVISION 1 OR REVISION 2 [Group 1] ........................... 7 5 FIGURE 12: PREVENTIVE MODIFICATION OR REPAIR - REPLACES KITS INSTALLED BY ORIGINAL ISSUE OR REVISION 1 [Group 1] ............................... 8 2 FIGURE 13: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 2] .... 8 9 FIGURE 14: INSPECTION - DETAILED AND HIGH FREQUENCY EDDY CURRENT [Group 2] .... 9 3 FIGURE 15: CLOSE ACCESS - INSTALL SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 2] . 95 FIGURE 16: POST Preventive Modification or Repair INSPECTION [Group 1] ............. 9 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 4 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 5 Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1188Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change and Repair This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-17-03 is related to this service bulletin. No more work is necessary on airplane(s) that have accomplished the repair or preventive modification in accordance with Revision 2 of this service bulletin. Airplane line numbers 2766 thru 3132 were added as Group 2 of this service bulletin effectivity. REASON FOR REVISION This revision is sent to add airplane line numbers 2766 thru 3132 to the effectivity of this service bulletin and to provide inspection and compliance information for these airplanes. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. The following sections are changed: 1. Summary, BACKGROUND, updated with additional information and added the Summary Evaluation Table. 2. Summary, ACTION, revised group 1 instructions, added group 2 instructions. 3. Summary, COMPLIANCE, added Airworthiness Directive (AD). 4. Summary, INDUSTRY SUPPORT INFORMATION, added applicability and group 2 standard statement. 5. Summary Illustration, updated with group 1 and group 2 applicability and added corresponding instructions. 6. Paragraph 1.A.1., Airplanes, updated effectivity and group configuration information. 7. Paragraph 1.C., Reason, updated with additional information. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 5 of 99 ### Page 6 8. Paragraph 1.D., Description, revised group 1 instructions, added group 2 instructions and updated maintenance zone data. 9. Paragraph 1.E., Compliance, added Airworthiness Directive (AD) reference, group 2 tables, and updated existing tables. 10. Paragraph 1.F., Approval, added an Alternative Method of Compliance (AMOC) statement. 11. Paragraph 1.G., Manpower, added table for Group 2 airplanes, and updated existing tables. 12. Paragraph 1.J.1., Existing Data, updated references. 13. Paragraph 1.K., Publications Affected, added new Damage Tolerance Inspection (DTI) statement. 14. Paragraph 2.A., Material - Price and Availability - The contact, price and ROLT information is updated. 15. Paragraph 2.B., Industry Support Information, added group 2 warranty standard statement. 16. Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added parts for Group 2 airplanes. 17. Paragraph 3.A., General Information - updated notes. 18. Paragraph 3.B., Work Instructions, added inspections instructions for group 2 airplanes, and updated group 1 instructions. 19. FIGURE 1, add applicability and updated a step. 20. FIGURE 2, FIGURE 3, and FIGURE 7 add applicability. 21. FIGURE 11 and FIGURE 12, add applicability, and updated the step table. 22. FIGURE 13, FIGURE 14, FIGURE 15 and FIGURE 16 are added for Group 2 airplanes. The data given in Information Notice IN 02 is included in this revision. IN 02 was sent to advise operators of the correct NDT reference in Figure 11 and Figure 12 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 April 09, 1998Original Issue: March 18, 1999Revision 1: May 09, 2007Revision 2: September 06, 2013Revision 3: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 6 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 7 Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1188Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change 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 This service bulletin gives instructions to inspect for cracking in the Body Station (STA) 303.9 web around the cut-outs for door stop straps at stringers 15 and 16, and to install a preventive modification or repair as necessary. If the inspection or preventive modification or repair shown in this service bulletin is not completed, the web could crack at the strap cut-out inboard of stringer 16, and could crack at the strap cut-out inboard of stringer 15. This could result in not having support for the door stop assemblies at stringers 15 and 16 which could cause the forward entry door to not seal correctly and could cause in flight decompression. Operators of 737 model airplanes line numbers 1 thru 2349 and 2351 thru 2437 have sent 7 reports on 7 airplanes of cracks at the cutout in the web of body station frame 303.9 inboard of stringer 16 left. The cracks were found between 37,562 and 64,000 flight cycles. This configuration has a 0.090 inch thick web with slot-shaped cut-outs, and a 0.071 inch thick doubler around the cut-out inboard of stringer 16. This configuration is the subject of service bulletin 737-53A1197. 737 model airplanes line numbers 2350 and 2438 thru 2765 have a 0.090 inch thick web with slot-shaped cut-outs for the straps for the door stop assemblies, without doublers around the web cut-outs. Fatigue analysis at Boeing shows that this configuration could crack after 10,000 flight cycles. The preventive modification or repair in this service bulletin applies to these airplanes. It changes the shape of the cutout in the web and installs a 0.090 thick doubler. A similar configuration exists on airplanes beyond line number 2765. These changes increase the fatigue life of the web. 737 model airplanes line number 2766 - 3132 also have 0.090 inch thick web but with elliptical-shaped cut-outs for the straps for the door stop assemblies and a 0.090 thick doubler around the S-16L web cut-out. The frame web cut-out for the strap at S-15 does not have a reinforcement doubler. The preventive modification or repair in this service bulletin does not apply to these airplanes. One crack was found in the frame web at a fastener hole adjacent to the S-15L web cutout. Similar cracks were also found on earlier line numbered airplanes. Cracks were found on airplanes with flight cycles from 28,843 to 46,458. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 7 of 99 ### Page 8 Boeing Service Related Problem (SRP) 737-SRP-53-149 and 737-SRP-53-0381 are related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information. ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 35328-R, PRR 35005-246RS) Group 1: Do High Frequency Eddy Current (HFEC) and detailed inspections for cracking in the STA 303.9 web around the cut-outs for door stop straps at stringers 15L and 16L. If any crack is found in the web then do the preventive modification or repair. If no cracking is found then do repeat inspections at the interval specified in Paragraph 1.E., Compliance or do the preventive modification or repair. Do post preventive modification or repair inspection. Group 2: Do HFEC and detailed inspections for cracking in the STA 303.9 web around the cut-out for the door stop strap at stringer 15L. If any crack is found in the web then contact Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found then do repeat inspections at the interval specified in Paragraph 1.E., Compliance. EFFECTIVITY 737-300, -400, -500 Airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-17-03 is related to this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 8 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 9 The FAA will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Refer to Paragraph 1.E., Compliance. INDUSTRY SUPPORT INFORMATION Group 1: Boeing warranty remedies are available for airplanes in warranty as of September 19, 1995. Refer to Paragraph 2.B., Industry Support Information. Group 2: Boeing warranty remedies are not available for the inspection(s), and/or repair(s) given in this service bulletin. MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 9 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 10 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT STA 303.9 STA 303.9 GROUP 1: -INSTALL NEW DOUBLER GROUP 1: WL - -CHANGE THE SHAPE OF THE 208 WEB CUT-OUT TO AN ELLIPTICAL SHAPE, IF NO KITS WERE INSTALLED BY S-15 THE ORIGINAL ISSUE, REVISION 1 OR REVISION 2 GROUP 1: OF THIS SERVICE BULLETIN. -INSTALL NEW SHORTER STOP FITTING ASSEMBLY AT STRINGER 15. GROUPS 1 AND 2: -DO A HFEC AND DETAILED INSPECTION FOR CRACKING AROUND THE WEB CUT-OUT. GROUP 1: -INSTALL NEW - 5-16 RADIUS FILLER. GROUP 1: GROUP 1: -DO A HFEC AND -INSTALL NEW SHORTER DETAILED INSPECTION STOP FITTING ASSEMBLY FOR CRACKING AROUND AT STRINGER 16. WL THE WEB CUT-OUT. 208 GROUP 1: -INSTALL NEW WEB →FWD SEGMENT. • INBD GROUP 1 SHOWN, GROUP 2 SIMILAR FRAME AT STA 303.9 R98963 Original Issue: April 09, 1998 Revision 3: September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1188 Work - See page 1 for detalls. 10 of 99 ### Page 11 Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1188 Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change 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 Refer to Service Bulletin Index Document D6-19567, Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. Refer to PRR 35005-246RS for data about this change. DESCRIPTIONCONFIGURATIONGROUP 737-300, -400, -500 airplanes, line numbers 2350, and 2438 thru 2765. These airplanes have slot-shaped cut-outs in the web for the straps for the door stop assemblies. -1 737-300, -400, 500 airplanes, line numbers 2766 thru 3132. These airplanes have elliptical-shaped cut-outs in the web for the straps for the door stop assemblies and a doubler around the S-16L web cut-out. -2 Airplane Models: 737-300, 737-400, 737-500 GroupVariable Number 1PJ551 - PJ559 2PJ560 - PJ561 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 11 of 99 ### Page 12 GroupVariable Number 2PJ601 - PJ615 2PJ811 2PJ816 - PJ817 1PM415 - PM417 1PM542 - PM550 1PM561 - PM564 1PP518 - PP520 1PP875 2PP876 - PP877 1PQ296 - PQ299 1PQ345 - PQ346 2PQ347 - PQ348 1PQ368 - PQ372 2PQ373 2PQ391 - PQ395 1PQ406 - PQ410 1PQ414 2PQ415 - PQ418 1PQ431 - PQ438 2PQ447 - PQ448 2PQ451 2PQ454 1PQ471 - PQ474 2PQ475 1PQ479 - PQ480 1PQ487 1PQ493 1PQ772 1PQ791 - PQ793 1PQ801 - PQ805 1PQ931 - PQ935 2PQ951 2PQ971 - PQ997 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 12 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 13 GroupVariable Number 2PR001 - PR017 2PR021 - PR034 2PR041 - PR045 2PR061 - PR072 2PR077 - PR082 2PR091 - PR092 2PR096 2PR101 2PR121 - PR122 2PR131 - PR132 2PR141 - PR143 2PR161 - PR172 2PR181 1PS617 - PS628 2PS629 - PS630 1PS704 - PS706 1PS753 - PS799 1PS811 1PS836 - PS837 1PS841 - PS845 2PS846 1PS851 - PS852 1PS856 1PS861 - PS863 1PS866 - PS868 2PS871 - PS874 1PS896 - PS897 1PS901 - PS904 2PS905 - PS941 2PS956 - PS957 2PS961 - PS963 2PS971 - PS978 1PT012 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 13 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 14 GroupVariable Number 2PT013 - PT015 1PT027 - PT029 2PT030 - PT031 1PT060 - PT064 2PT126 - PT138 1PT170 1PT188 1PT303 - PT309 1PT432 - PT438 1PT511 - PT517 1PT584 - PT585 2PT586 1PT642 - PT644 1PT655 - PT656 1PT672 2PT681 - PT685 1PT716 2PT717 2PT721 - PT725 1PT801 - PT824 2PT825 1PT826 - PT834 1PT851 - PT853 2PT854 1PT871 - PT873 2PT874 - PT886 2PT901 - PT930 1PT971 2PT972 - PT973 2PT981 - PT985 2PT996 2PU301 2PU311 - PU313 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 14 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 15 GroupVariable Number 1PV203 2PV204 - PV209 2PV226 - PV229 1PV281 - PV284 2PV285 - PV287 1PV296 2PV301 - PV302 2PV351 2PV356 - PV357 2PW086 - PW088 1PW102 1PW106 1PW167 2PW168 - PW171 1PW217 - PW230 1PW238 - PW250 2PW251 - PW252 1PW262 2PW263 - PW264 1PW267 - PW268 2PW271 - PW276 1PW278 1PW282 - PW292 1PW323 - PW327 1PW401 - PW403 2PW404 - PW408 1PW411 - PW412 2PW413 - PW418 2PW421 - PW424 2PW431 - PW435 2PW441 - PW450 1PW461 - PW467 1PW521 - PW522 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 15 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 16 GroupVariable Number 2PW524 1PW525 - PW528 2PW529 - PW530 1PW545 - PW547 2PW548 - PW550 1PW556 - PW557 1PW621 - PW622 1PW634 - PW637 1PW717 1PW771 2PW831 2PW851 - PW856 2. Spares Affected None B. Concurrent Requirements None C. Reason This service bulletin gives instructions to inspect for cracking in the Body Station (STA) 303.9 web around the cut-outs for door stop straps at stringers 15 and 16, and to install a preventive modification or repair as necessary. If the inspection or preventive modification or repair shown in this service bulletin is not completed, the web could crack at the strap cut-out inboard of stringer 16, and could crack at the strap cut-out inboard of stringer 15. This could result in not having support for the door stop assemblies at stringers 15 and 16 which could cause the forward entry door to not seal correctly and could cause in flight decompression. Operators of 737 model airplanes line numbers 1 thru 2349 and 2351 thru 2437 have sent 7 reports on 7 airplanes of cracks at the cutout in the web of body station frame 303.9 inboard of stringer 16 left. The cracks were found between 37,562 and 64,000 flight cycles. This configuration has a 0.090 inch thick web with slot-shaped cut-outs, and a 0.071 inch thick doubler around the cut-out inboard of stringer 16. This configuration is the subject of service bulletin 737-53A1197. 737 model airplanes line numbers 2350 and 2438 thru 2765 have a 0.090 inch thick web with slot-shaped cut-outs for the straps for the door stop assemblies, without doublers around the web cut-outs. Fatigue analysis at Boeing shows that this configuration could crack after 10,000 flight cycles. The preventive modification or repair in this service bulletin applies to these airplanes. It changes the shape of the cutout in the web and installs a 0.090 thick doubler. A similar configuration exists on airplanes beyond line number 2765. These changes increase the fatigue life of the web. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 16 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 17 737 model airplanes line number 2766 - 3132 also have 0.090 inch thick web but with elliptical-shaped cut-outs for the straps for the door stop assemblies and a 0.090 thick doubler around the S-16L web cut-out. The frame web cut-out for the strap at S-15 does not have a reinforcement doubler. The preventive modification or repair in this service bulletin does not apply to these airplanes. One crack was found in the frame web at a fastener hole adjacent to the S-15L web cutout. Similar cracks were also found on earlier line numbered airplanes. Cracks were found on airplanes with flight cycles from 28,843 to 46,458. Boeing Service Related Problem (SRP) 737-SRP-53-149 and 737-SRP-53-0381 are related to this service bulletin. Revision 1 was sent to include new kits, to change the accomplishment instructions, and remove airplanes from the effectivity. 1. Airplane line positions 2766 through 2844 were removed from the service bulletin effectivity. The new web installation started at line position 2766. 2. The 65C37762-1 and -2 kits are replaced by 65C37762-5 and -6 kits. The new 65C37762-5 and -6 kits have new fasteners with correct head size to fit the skin countersinks and a new radius filler which will not interfere with the stop fitting strap. 3. The 65C37762-1 and -2 kits are supplemented by the 65C37762-4 kit. 4. In the accomplishment instructions the forward lavatory must be removed for access. 5. In the accomplishment instructions, the step to remove the passenger seats for access, is removed. 6. In Figures 3, 5 and 6 the laminated shim between the stop fittings and the body station 303.9 frame are more clearly shown. A note was also added in these figures to make sure if these laminated shims were not initially installed then not to install the new laminated shims provided in the kit. Revision 2 was sent to change the repair procedure and preventive change in revision 1 of this service bulletin. A new preventive modification or repair procedure is now the terminating action for this service bulletin. The preventive modification or repair kit replaces all the kits from the original issue or revision 1 of this service bulletin. The new repair procedure is the same as the new preventive change procedure. A High Frequency Eddy Current (HFEC) inspection has been added to supplement the detailed inspection. Changes to Revision 2 of this service bulletin include: – Planning Section - New Compliance data has been added that will be dependant on the airplanes previous kit installations. The Service Related Problem reference has been added. – Material Section - A new 65C37762-7 top kit has been added to replace all kits from the original issue or revision 1 of this service bulletin. – Accomplishment Instructions - Instructions have been added to remove the old kits and install the new kit for airplanes that have installed kits from the original issue or revision 1 of this service bulletin. – Figure 2 - HFEC inspections have been added. – Figure 3 - Circle note numbers and step numbers have been amended. – Figures 4, 5 and 6 have been deleted. – Figure 8 has been added to do HFEC and detailed inspections. – Figures 9 and 10 have been added to remove kits installed from the original issue or revision 1 of this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 17 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 18 – Figures 11 and 12 have been added to install the preventive modification or repair kit for airplanes with or without kits installed from the original issue or revision 1 of this service bulletin. Revision 3 is sent to add airplane line numbers 2766 thru 3132 to the effectivity of this service bulletin and to provide inspection and compliance information for these airplanes. D. Description Group 1: Do High Frequency Eddy Current (HFEC) and detailed inspections for cracking in the STA 303.9 web around the cut-outs for door stop straps at stringers 15L and 16L. If any crack is found in the web then do the preventive modification or repair. If no cracking is found then do repeat inspections at the interval specified in Paragraph 1.E., Compliance or do the preventive modification or repair. After accomplishment of the preventive change or repair do HFEC inspections of the outer chord and radius filler at the times given in Paragraph 1.E., Compliance. If any crack is found contact Boeing for repair instructions and do the work instructed by Boeing. Group 2: Do HFEC and detailed inspections for cracking in the STA 303.9 web around the cut-out for the door stop strap at stringer 15L. If any crack is found in the web then contact Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found then do repeat inspections at the interval specified in Paragraph 1.E., Compliance. Revision 3 - No more work is necessary on airplane(s) that have accomplished the repair or preventive modification in accordance with Revision 2 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 105737-300, 737-400, 737-500 E. Compliance Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-17-03 is related to this service bulletin. The effective date of AD 2008-17-03 is September 23, 2008. The 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: The installation of the preventive modification or repair in accordance with Revision 2 or Revision 3 of this SB terminates the inspection given in this SB. Post preventive modification or repair damage tolerance inspection (DTI) are provided in Table 4. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 18 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 19 Group 1: Table 1 - Inspection for Cracking in Body Station 303.9 Frame at Stringers 15 and 16 - For Airplanes With No Kits Installed per Original Issue, Revision 1 or Revision 2 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 flight cycles. (a) Within 4,500 flight cycles af- ter the effective date of AD 2008-17-03. Before 10,000 total flight cy- cles. Do detailed and HFEC inspections for any crack in accordance with Para- graph 3.B., Work Instruc- tions, Part I, Step 2. No preventive change kit or repair kit installed in ac- cordance with the original issue or Revision 1 of this service bulletin. --Before further flight Install the Preventive Modification or Repair in accordance with Para- graph 3.B., Work Instruc- tions, Part I step 3. (a) If any crack is found. (a) Accomplishment of the Preventive Modification or Repair in accordance with Accomplishment Instruction 3.B. Part I step 3 terminates the repeat inspection requirements for this bulletin. Group 1: Table 2 - Inspection for Cracking in Body Station 303.9 Frame at Stringers 15 and 16 - For Airplanes With Kits Installed per Original Issue or Revision 1 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 flight cycles. (a) Within 4,500 flight cycles af- ter the effective date of AD 2008-17-03. Within 10,000 flight cycles af- ter the preven- tive change kit was installed. Do detailed and HFEC inspections for any crack in accordance with Para- graph 3.B., Work Instruc- tions, Part II, Step 2. Preventive change kit in- stalled per original issue or Revision 1 of this service bulletin. --Before further flight Install the Preventive Modification or Repair in accordance with Para- graph 3.B., Work Instruc- tions, Part II step 3 (a) If any crack is found. 4,500 flight cycles. (a) Within 4,500 flight cycles af- ter the effective date of AD 2008-17-03. Within 10,000 flight cycles af- ter the repair kit was installed. Do detailed and HFEC Inspections for any crack in accordance with Para- graph 3.B., Work Instruc- tions, Part III, Step 2. Repair kit installed in accor- dance with the original is- sue or Revision 1 of this service bulletin. --Before further flight Install the Preventive Modification or Repair in accordance with Para- graph 3.B., Work Instruc- tions, Part III steps 3. If any crack is found. (a) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 19 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 20 Group 1: Table 2 - Inspection for Cracking in Body Station 303.9 Frame at Stringers 15 and 16 - For Airplanes With Kits Installed per Original Issue or Revision 1 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition (a) The removal of the kit installed by the original issue or revision 1 and the accomplishment of the Preventive Modification or Repair in accordance with Accomplishment Instruction 3.B. Part II step 3 or Part III steps 3 terminates the repeat inspection requirements for this bulletin. Group 2: Table 3 - Inspection for Cracking in Body Station 303.9 Frame at Stringers 15 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 12,000 flight cy- cles. Within 6,000 flight cycles af- ter the Revision 3 date of this service bulletin. Before 26,000 total flight cy- cles. Do detailed and HFEC inspections for any crack in the frame web in accor- dance with Paragraph 3.B., Work Instructions, Part IV, Step 2. All airplanes -Before further flight.Contact Boeing for repair instructions and do the work instructed by Boe- ing. Any crack found Group 1: Table 4: Post Preventive Modification or Repair Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 12,000 flight cyclesWithin 12,000 flight cycles from the date the preventive change or repair was installed. Before 66,000 total flight cy- cles. Do HFEC inspections of the outer chord and ra- dius filler of the frame for any crack in accordance with Paragraph 3.B., Work Instructions, PART V. Preventive Modification or Repair accomplished in accordance with Revision 2 or Revision 3 of this ser- vice bulletin. -Before further flight.Contact Boeing for repair instructions and do the work instructed by Boe- ing. Any crack found Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 20 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 21 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. The Manager, Seattle Aircraft Certification Office, FAA, approves accomplishment of the inspection methods, repairs, and modifications, with the corresponding compliance times, defined in Section 1.E, Tables 1 and 2 of this service bulletin, Revision 3, as an alternative method of compliance to the corresponding requirements of paragraph (f) of AD 2008-17-03. All provisions of AD 2008-17-03 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. G. Manpower The table below shows an estimate of man-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 man-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. Group 1: INSPECTION - No Kits Installed per Original Issue, Revision 1 or Revision 2 Elapsed HoursTask-HoursNumber of PersonsTask 7142Open Access 0.50.51Detailed Inspection 8.0162Close Access 15.530.5TOTAL FOR EACH AIRPLANE Group 1: INSPECTION - Airplanes with Kits Installed per Original Issue or Revision 1 Elapsed HoursTask-HoursNumber of PersonsTask 7142Open Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 21 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 22 Group 1: INSPECTION - Airplanes with Kits Installed per Original Issue or Revision 1 Elapsed HoursTask-HoursNumber of PersonsTask 1.252.502Detailed and HFEC Inspection 8.0162Close Access 16.2532.5TOTAL FOR EACH AIRPLANE NOTE: Repair table is no longer applicable. Revision 2 of this service bulletin removed the repair from the service bulletin. Group 1: PREVENTIVE MODIFICATION OR REPAIR - No Kits Installed per Original Issue, Revision 1 or Revision 2 Elapsed HoursTask-HoursNumber of PersonsTask 7.0142Open Access 15302Preventive Modifica- tion or Repair 8.0162Close Access 3060TOTAL FOR EACH AIRPLANE Group 1: PREVENTIVE MODIFICATION OR REPAIR - Airplanes with Repair Kit Installed per Original Issue or Revision 1 Elapsed HoursTask-HoursNumber of PersonsTask 7.0142Open Access 14282Preventive Modifica- tion or Repair 8.0162Close Access 2958TOTAL FOR EACH AIRPLANE Group 1: PREVENTIVE MODIFICATION OR REPAIR - Airplanes with Preventive Change Kit In- stalled per Original Issue or Revision 1 Elapsed HoursTask-HoursNumber of PersonsTask 7.0142Open Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 22 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 23 Group 1: PREVENTIVE MODIFICATION OR REPAIR - Airplanes with Preventive Change Kit In- stalled per Original Issue or Revision 1 Elapsed HoursTask-HoursNumber of PersonsTask 14282Preventive Modifica- tion or Repair 8.0162Close Access 2958TOTAL FOR EACH AIRPLANE Group 2: INSPECTION Elapsed HoursTask-HoursNumber of PersonsTask 7.0014.002Open Access 1.251.251FIGURE 14 - Detailed and HFEC Inspection 8.0016.002Close Access 16.2531.25TOTAL FOR EACH AIRPLANE Group 1: POST PREVENTIVE MODIFICATION OR REPAIR INSPECTION Elapsed HoursTask HoursNumber of PersonsTask 7.0014.002Open Access 2.002.001FIGURE 16 8.0016.002Close Access 17.0032.00TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Preventive Modification or Repair if Repair kit installed per the Original Issue or Revi- sion 1 is replaced with 65C37762-7 kit. Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +250+1.1737-300 +170+1.1737-400 +310+1.1737-500 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 23 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 24 Preventive Modification or Repair if Preventive change kit installed per the Original Issue or Revision 1 is replaced with 65C37762-7 kit. Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +400+1.8737-300 +275+1.8737-400 +500+1.8737-500 Preventive Modification or Repair if the new 65C37762-7 kit is installed on airplanes without kits installed in the Original Issue or Revision 1 Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane +630+2.8737-300 +425+2.8737-400 +780+2.8737-500 I. Electrical Load Data Not applicable J. References 1. Existing Data: a. Engineering Change Memo PRR 35328-R, PRR 35005-246RS. b. Boeing Service Bulletin 737-53A1197. c. Boeing Service Related Problem (SRP) 737-SRP-53-0381 and 737-SRP-53-149. d. 737 Aircraft Maintenance Manual (AMM) Section 25-21, 25-22, 25-27, 38-31, 38-32, 52-11. e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2008-17-03. f. Standard Overhaul Practices Manual (SOPM) 20-43-02, 20-43-03, 20-50-11. g. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00 Figures 1, 4, 11, 16, and Part 6, 53-10-39 . 2. Data Supplied with this Service Bulletin: None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 24 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 25 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Frame Installation - STA. 303.965-17684 Reveal Installation, Forward Entry Door, STA. 303.965-03360 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: Chapter-SectionPublication 53-41737 Illustrated Parts Catalog 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 25 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 26 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 26 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT BLANK PAGE ### Page 27 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane and Paragraph 2.D., Parts Necessary to Change Spares. 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. 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 REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revi- sion 3 date of this Service Bulletin (US Dollars) ROLT as of the Revision 3 date of this Service Bulletin (Calendar Days) NameKit Number -(a)Top Kit, Frame Installation65C37762-1 -(a)Top Kit, Frame Installation65C37762-2 -(a)Supplemental Kit65C37762-4 -(a)Top Kit, Frame Installation65C37762-5 -(a)Top Kit, Frame Installation65C37762-6 9,360.00529Top Kit - Frame Repair, STA 303.9, S-16L (Preventive Modification or Repair) 65C37762-7 (a) Kit not available. B. Industry Support Information Group 1: Boeing warranty remedies are available for 737 airplanes in warranty as of September 19, 1995. For man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Product Assurance Contracts. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. Group 2: Boeing warranty remedies are not available for the inspection(s), and/or repair(s) given in this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 27 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 28 C. Parts Necessary for Each Airplane 1. Kits/Parts: To get the kits 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. CONDITION FOR USEKIT Frame Repair Kit65C37762-1 (a) (f) Frame Repair Kit65C37762-2 (b) (f) Frame Repair Kit65C37762-4 (c) (f) Frame Repair Kit65C37762-5 (d) (f) Frame Repair Kit65C37762-6 (e) (f) Frame Repair Kit65C37762-7 (g) Replaced by the 65C37762-5 kit.(a) Replaced by the 65C37762-6 kit.(b) Makes the 65C37762-1 kit the same as the -5 kit.(c) Makes the 65C37762-2 kit the same as the -6 kit. Replaces the 65C37762-1 kit.(d) Replaces the 65C37762-2 kit.(e) Kits 65C37762-1, -2, -4, -5 and -6 are not available.(f) Replaces kits 65C37762-1, -2, -4, -5 and -6.(g) Kit 65C37762 NotesNameQTYNew Part Number -1-2-4-5-6-7 (a) (c) (h)Top Kit, Preventive Change-.....65C37762-1 (a) (d) (h)Top Kit, Repair.-....65C37762-2 (e) (h)Supplemental Kit..-...65C37762-4 (a) (f) (h)Top Kit, Preventive Change...-..65C37762-5 (a) (g) (h)Top Kit, Repair....-.65C37762-6 (i)Top Kit - Frame Repair, STA 303.9, S-16L (Preventive Modifi- cation or Repair) .....-65C37762-7 (b)Slot Template11.11.65C37762-3 -Stiffener11.11.65C37775-1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 28 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 29 Kit 65C37762 NotesNameQTYNew Part Number -1-2-4-5-6-7 -Frame.1..1.65C37777-1 -Kit Detail - Doubler, Reinforce- ment Angle, STA 303.9 .....165C37775-2 -Kit Detail - Frame Section, An- gle, STA 303.9 .....165C37777-2 -Stop Fitting Assy - Fwd Entry Door .....165C38453-1 -Hi-Lok, 1/64 Os.1..1.BACB30MY6K10X -Hi-Lok, 1/64 Os.1..1.BACB30MY6K13X -Hi-Lok, 1/64 Os55.55.BACB30MY6K3X -Hi-Lok, 1/64 Os1313.1313.BACB30MY6K4X -Hi-Lok, 1/64 Os44.44.BACB30MY6K5X -Hi-Lok, 1/64 Os917.917.BACB30MY6K6X -Hi-Lok, 1/64 Os913.913.BACB30MY6K7X -Hi-Lok, 1/64 Os33.33.BACB30MY6K8X -Hi-Lok, 1/64 Os33.33.BACB30MY8K10X -Hi-Lok, 1/64 Os13.13.BACB30MY8K3X -Hi-Lok, 1/32 Os.....1BACB30MY8K3Y -Hi-Lok, 1/64 Os816.816.BACB30MY8K5X -Hi-Lok, 1/32 Os.....16BACB30MY8K5Y -Hi-Lok, 1/64 Os.2..2.BACB30MY8K6X -Hi-Lok, 1/32 Os.....2BACB30MY8K6Y -Hi-Lok, 1/32 Os8BACB30MY8K7Y -Hi-Lok, 1/64 Os1315.1315.BACB30MY8K8X -Hi-Lok, 1/32 Os.....10BACB30MY8K8Y -Hi-Lok, 1/32 Os.....2BACB30MY8K9Y -Hi-Lok, 1/64 Os..444.BACB30NW8K8X -Hi-Lok, 1/32 Os.....4BACB30NW8K8Y -Hi-Lok, 1/32 Os.....1BACB30NX6K10Y -Hi-Lok, 1/32 Os.....1BACB30NX6K13Y -Hi-Lok, 1/32 Os.....9BACB30NX6K3Y -Hi-Lok, 1/32 Os.....9BACB30NX6K4Y Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 29 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 30 Kit 65C37762 NotesNameQTYNew Part Number -1-2-4-5-6-7 -Hi-Lok, 1/32 Os.....10BACB30NX6K5Y -Hi-Lok, 1/32 Os.....18BACB30NX6K6Y -Hi-Lok, 1/32 Os.....11BACB30NX6K7Y -Hi-Lok, 1/32 Os.....2BACB30NX6K8Y -Hi-Lok, 1/32 Os.....2BACB30NX6K9Y -Hi-Lok, 1/64 Os44....BACB30NZ8K8X -Hi-Lok, 1/32 Os.....25BACB30VT6K3 -Collar.....25BACC30BL6 -Collar4863.4863.BACC30M6 -Collar3247.3247.BACC30M8 -Collar.....63BACC30R6 -Collar.....43BACC30R8 -Filler - Radius..111.BACF3H07RK085HN -Filler - Radius.....1BACF3H07RK101HN -Filler - Radius11....BACF3H08RK085HN -Rivet, 1/32 Os66.666BACR15DS7D7 -Rivet, 1/32 Os11.111BACR15DS7D8 -Rivet, 1/32 Os33.33.BACR15ET7D5 -Rivet, 1/32 Os44.44.BACR15ET7D6 -Rivet, 1/32 Os22.22.BACR15ET7D8 -Rivet, 1/32 Os33.33.BACR15ET9D7 -Rivet, 1/32 Os11.11.BACR15ET9D8 -Rivet44.44.BACR15FT6D5 -Rivet.....2BACR15FT6D5C -Rivet1816.1816.BACR15FT6D6 -Rivet.....4BACR15FT6D6C -Rivet44.44.BACR15FT6D7 -Rivet.....5BACR15FT6D7C -Rivet.....4BACR15FT7D6C -Rivet.....5BACR15FT7D7C -Rivet.....2BACR15FT7D9C Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 30 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 31 Kit 65C37762 NotesNameQTYNew Part Number -1-2-4-5-6-7 -Rivet.....2BACR15FT9D7C -Rivet.....1BACR15FT9D8C -Rivet.....1BACR15FT9D9C -Shim, Laminated.....4BACS40R013C020F -Shim, Laminated.....1BACS40R019B026F -Shim, Laminated11.111BACS40R019B028F -Stop Fitting Assy11.11.65-14076U28 -Stop Fitting Assy - Fwd Entry Door 165-14076-30 (a) The kit has more parts than are necessary for installation. Discard parts that are not used or keep the parts for spares. (b) Cut out template from the mylar copy of Sheet 1 in the kit. Cut out an area around the slot template suf- ficient to hold template while marking the slot outline per Figure 4 of this bulletin. (c) Replaced by the 65C37762-5 kit. (d) Replaced by the 65C37762-6 kit. (e) When added to the 65C37762-1 kit it makes it the same as the 65C37762-5 kit When added to the 65C37762-2 kit it makes it the same as the 65C37762-6 kit (f) Replaces the 65C37762-1 kit. (g) Replaces the 65C37762-2 kit. (h) Kits 65C37762-1, -2, -4, -5 and -6 are not available. (i) Replaces the 65C37762-1, -2, -4, -5 and -6 kits. 2. Parts and Materials Supplied by the Operator: Group 1: NamePart Number (Specification)Quantity SealantBMS 5-95, Class B-1/2, -2, or -5 (a)As Required Chemical Film Treatment(Alodine 1200S) MIL-C-5541 (b)As Required PrimerBMS 10-11, Type I (c)As Required PrimerBMS 10-11, Type II (c)As Required Laminated ShimBACS40R007B007F1 (a) See SOPM 20-50-11. (b) See SOPM 20-43-03. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 31 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 32 Group 1: NamePart Number (Specification)Quantity (c) See SOPM 20-43-02. Group 2: NamePart Number (Specification)Quantity RivetBACR15DS7D7C6 RivetBACR15DS7D8C1 RivetBACR15FT7D7C2 3. Parts Modified and Reidentified: The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane. NotesNew Part NumberNameQTYExisting Part Number (a) (b) (c)65C38453-1Stop Fitting Assembly165C27705-1 (a) (b) (c)65-14076-30Stop Fitting Assembly165-14076-18 OR 65-14076-22 OR 65-14076-26 OR 65-14076-28 (a) Discard the existing part. (b) This is the part number for the new equivalent or replacement part. To get a new part, use this part number in your order. (c) Do not use the existing part to replace the new or changed part. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 32 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 33 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. 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 are given in 737 Structural Repair Manual, Chapter 51 — Torque limits to tighten nuts and bolts are given in 737 Structural Repair Manual, Chapter 51. — Make sure there is a 4-6 diameter fastener spacing at new fastener locations. 3. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 4. Obey all of the warnings and cautions given in the specified manual sections. 5. 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. 6. 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. 7. 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. 8. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 33 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 34 9. 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. B. WORK INSTRUCTIONS Group 1: MAKE A DECISION WHICH WORK INSTRUCTION TO DO WORK INSTRUCTIONSKIT INSTALLED ON THE AIRPLANE DO PART INo kits installed per original issue, Revision 1 or Revision 2 DO PART II65C37762-1 and 65C37762-4 DO PART III65C37762-2 and 65C37762-4 DO PART II65C37762-5 DO PART III65C37762-6 Group 1: PART I - AIRPLANES WITHOUT KITS 65C37762-1, -2, -4, -5 OR -6 INSTALLED 1. OPEN ACCESS a. Remove the forward lavatory. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. b. Remove the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. c. Remove the passenger compartment side panels for access between stringers 17L and 14L. Refer to 737 AMM 25-21 as an accepted procedure. d. Remove scuff plate, door reveal and latch fitting in accordance with Figure 1. e. Remove insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. 2. INSPECTION a. Inspect for cracking in the web around the slotted holes in the frame web at stringers 15L and 16L, Body Station 303.9 for any crack in accordance with Figure 2. b. If any crack is found at stringer 16L then do the Preventive Modification or Repair in accordance with PART I, Step 3. c. If any crack is found at stringer 15L, contact Boeing for repair instructions and do the work instructed by Boeing. d. If no cracking is found then do the repeat inspections at the intervals specified in Paragraph 1.E., Compliance or accomplish the Preventive Modification or Repair. 3. PREVENTIVE MODIFICATION OR REPAIR Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 34 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 35 a. Remove the structure in accordance with Figure 3. b. Change the shape of the slotted hole in the web at stringer 15L and install the Preventive Modification or Repair in accordance with Figure 11. NOTE: Accomplishment of the Repair or Preventive Modification in accordance with Figure 11 terminates the inspection given in Paragraph 1.E., Compliance, Table 1. Post repair or preventive modification inspections are provided in Table 4. 4. CLOSE ACCESS a. Install the insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. b. Install latch fitting, door reveal, and scuff plate in accordance with Figure 7. c. Install the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. d. Install the passenger compartment side panels. Refer to 737 AMM 25-21 as an accepted procedure. e. Install forward lavatory equipment removed for access. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. f. Do the adjustment and test of the door stop pins and latch fittings. Refer to shown in 737 AMM 52-11 as an accepted procedure. 5. Put the airplane back to a serviceable condition. Group 1: PART II - AIRPLANES WITH PREVENTIVE CHANGE KIT 65C37762-1, -4, OR -5 INSTALLED 1. OPEN ACCESS a. Remove the forward lavatory. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. b. Remove the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. c. Remove the passenger compartment side panels for access between stringers 17L and 14L. Refer to 737 AMM 25-21 as an accepted procedure. d. Remove scuff plate, door reveal and latch fitting in accordance with Figure 1. e. Remove insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. 2. INSPECTION a. Inspect for cracking in the web and doubler around the slotted holes in the frame web at stringers 15L and 16L, Body Station 303.9 for any crack in accordance with Figure 8. b. If any crack is found at stringer 16L then do the Preventive Modification or Repair in accordance with PART II, Step 3. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 35 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 36 c. If any crack is found at stringer 15L, contact Boeing for repair instructions and do the work instructed by Boeing. d. If no cracking is found then do the repeat inspections at the intervals specified in Paragraph 1.E., Compliance or accomplish the Preventive Modification or Repair. 3. PREVENTIVE MODIFICATION OR REPAIR a. Remove the Preventive Change kit in accordance with Figure 10. b. Install the Preventive Modification or Repair kit in accordance with Figure 12. NOTE: Accomplishment of the Repair or Preventive Modification in accordance with Figure 12 terminates the inspection given in Paragraph 1.E., Compliance, Table 2. Post repair or preventive modification inspections are provided in Table 4. 4. CLOSE ACCESS a. Install the insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. b. Install latch fitting, door reveal, and scuff plate in accordance with Figure 7. c. Install the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. d. Install the passenger compartment side panels. Refer to 737 AMM 25-21 as an accepted procedure. e. Install forward lavatory equipment removed for access. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. f. Do the adjustment and test of the door stop pins and latch fittings. Refer to 737 AMM 52-11 as an accepted procedure. 5. Put the airplane back to a serviceable condition. Group 1: PART III - AIRPLANES WITH REPAIR KIT 65C37762-2 AND -4, OR -6 INSTALLED 1. OPEN ACCESS a. Remove the forward lavatory. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. b. Remove the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. c. Remove the passenger compartment side panels for access between stringers 17L and 14L. Refer to 737 AMM 25-21 as an accepted procedure. d. Remove scuff plate, door reveal and latch fitting in accordance with Figure 1. e. Remove insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 36 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 37 2. INSPECTION a. Inspect for cracking in the web and doubler around the slotted holes in the frame web at stringers 15L and 16L, Body Station 303.9 for any crack in accordance with Figure 8. b. If any crack is found at stringer 16L then do the Preventive Modification or Repair in accordance with PART III, Steps 3. c. If any crack is found at stringer 15L, contact Boeing for repair instructions and do the work instructed by Boeing. d. If no cracking is found then do the repeat inspections at the intervals specified in Paragraph 1.E., Compliance or accomplish the Preventive Modification or Repair. 3. PREVENTIVE MODIFICATION OR REPAIR a. Remove the Repair kit in accordance with Figure 9. b. Install the Preventive Modification or Repair kit in accordance with Figure 12. 4. CLOSE ACCESS a. Install the insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. b. Install latch fitting, door reveal, and scuff plate in accordance with Figure 7. c. Install the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. d. Install the passenger compartment side panels. Refer to 737 AMM 25-21 as an accepted procedure. e. Install forward lavatory equipment removed for access. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. f. Do the adjustment and test of the door stop pins and latch fittings. Refer to 737 AMM 52-11 as an accepted procedure. 5. Put the airplane back to a serviceable condition. Group 2: PART IV - ALL GROUP 2 AIRPLANES 1. OPEN ACCESS a. Remove the forward lavatory. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. b. Remove the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. c. Remove the passenger compartment side panels for access between stringers 17L and 14L. Refer to 737 AMM 25-21 as an accepted procedure. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 37 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 38 d. Remove scuff plate, door reveal and latch fitting at S-15 in accordance with Figure 13. e. Remove insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. 2. INSPECTION a. Do detailed and High Frequency Eddy Current (HFEC) inspections in the frame web at stringer 15L, Body Station 303.9 for any crack in accordance with Figure 14. (1) If any crack is found in the frame web at stringer 15L, contact Boeing for repair instructions and do the work instructed by Boeing. (2) If no cracking is found then do the repeat inspections at the intervals specified in Paragraph 1.E., Compliance. 3. CLOSE ACCESS a. Install the insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. b. Install scuff plate, door reveal and latch fitting at S-15 in accordance with Figure 15. c. Install the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. d. Install the passenger compartment side panels. Refer to 737 AMM 25-21 as an accepted procedure. e. Install forward lavatory equipment removed for access. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. f. Do the adjustment and test of the door stop pins and latch fittings. Refer to 737 AMM 52-11 as an accepted procedure. 4. Put the airplane back to a serviceable condition. Group 1: PART V - POST PREVENTIVE MODIFICATION OR REPAIR INSPECTION 1. OPEN ACCESS a. Remove the forward lavatory. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. b. Remove the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. c. Remove the passenger compartment side panels for access between stringers 17L and 14L. Refer to 737 AMM 25-21 as an accepted procedure. d. Remove scuff plate, door reveal and latch fitting in accordance with Figure 1. e. Remove insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. 2. INSPECTION Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 38 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 39 a. Do HFEC inspections of the outer chord, inner chord and radius filler of the Body Station 303.9 frame at door stop locations and around the specified fasteners for cracking in accordance with Figure 16. b. If any crack is found at stringer 15L, contact Boeing for repair instructions and do the work instructed by Boeing.. c. If any crack is found at stringer 16L, contact Boeing for repair instructions and do the work instructed by Boeing. d. If no cracking is found then do the repeat inspections at the intervals specified in Paragraph 1.E., Compliance . 3. CLOSE ACCESS a. Install the insulation blankets. Refer to 737 AMM 25-21 as an accepted procedure. b. Install latch fitting, door reveal, and scuff plate in accordance with Figure 7. c. Install the passenger compartment carpets. Refer to 737 AMM 25-27 as an accepted procedure. d. Install the passenger compartment side panels. Refer to 737 AMM 25-21 as an accepted procedure. e. Install forward lavatory equipment removed for access. Refer to 737 AMM 38-31 and 737 AMM 38-32 as accepted procedures. f. Do the adjustment and test of the door stop pins and latch fittings. Refer to shown in 737 AMM 52-11 as an accepted procedure. 4. Put the airplane back to a serviceable condition. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 39 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 40 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT This Figure applies only to: Group 1. STA 303.9 WL 203 (2) DOOR REVEAL SEE A FORWARD SCUFF PLATE > FWD INBD R99166 FIGURE 1: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING (SHEET 1 OF 4) Original Issue: April 09, 1998 Revision 3 September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1188 Work - See page 1 for details. 40 of 99 ### Page 41 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT BOLT, WASHER, AND NUT (4 PLACES) 5) GUSSET _S-15 INTERCOSTAL (EXPLODED FOR CLARITY) DOOR STOP FITTING LATCH —5-16 FITTING > FWD INBD R99452 FIGURE 1: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING (SHEET 2 OF 4) Original Issue: April 09, 1998 Revision 3 September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1188 Work - See page 1 for details. 41 of 99 ### Page 42 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each airplane. MORE DATAQTYPART NUMBERNAMETASKSTEP Keep attachment screws.165-2937-( )Scuff PlateRemove / Keep1 Keep attachment screws.165-3360-80RevealRemove / Keep2 (a)7BACR15CERivetsRemove3 (a)4NAS1103-3BoltRemove / Keep4 4AN960D10Washer 4NAS679-A3WNut (a) (b)165-64836-2Latch FittingRemove / Keep5 or 65-64836-8 190-7877-501Intercostal 160-4428-0Doubler 190-7877-5Gusset 190-8623-4Plate 169-8893-2Filler 169-8893-6Filler FIGURE 1: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3 September 06, 2013 42 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 43 MORE DATAQTYPART NUMBERNAMETASKSTEP (a) Remove parts to provide access to accomplish the repair / Preventive Modification or Repair. It is op- tional to remove these parts to accomplish the inspections. (b) Remove the Latch Fitting and parts and keep assembled. FIGURE 1: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3 September 06, 2013 43 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 44 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT This Figure applies only to: Group 1. STA 303.9 STA 303.9 —S-15 WL - 208 —S-16 STOP FITTING SLOT SHAPED NOT SHOWN HOLE FOR CLARITY • EXAMPLE CRACK WL 208 - • FWD ' INBD R99664 FIGURE 2: INSPECTION (SHEET 1 OF 4) Original Issue: April 09, 1998 Revision 3 September 06, 2013 Export Controlled ECCN: 9E991 - BOEING 737-53A1188 PROPRIETARY - Copyright @ Unpublished Work - See page 1 for details. 44 of 99 ### Page 45 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT S-15L A-A S-16L - B—B D33086 FIGURE 2: INSPECTION (SHEET 2 OF 4) Original Issue: April 09, 1998 Revision 3 September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING Work - See page 1 for details. 45 of 99 ### Page 46 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. MORE DATAREFERENCESPROCEDURENAMETASKSTEP Inspect for any crack in the web around the oval hole from the aft side. -Detailed InspectionFrame WebInspect1 Inspect for any crack from the forward side. In accordance with 737 NDT Manual Part 6, 51-00-00, Figure 4 High Frequency Eddy Current (HFEC) Inspection Frame WebInspect2 Inspect for any crack in the web in the shaded area from the forward side. -Detailed InspectionFrame WebInspect3 Inspect for any crack from the aft side. In accordance with 737 NDT Manual Part 6, 51-00-00, Figure 4 HFEC InspectionFrame WebInspect4 FIGURE 2: INSPECTION (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3 September 06, 2013 46 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 47 MORE DATAREFERENCESPROCEDURENAMETASKSTEP Inspect for any crack in the web in the shaded area from the aft side. -Detailed InspectionFrame WebInspect5 Inspect for any crack from the forward side. In accordance with 737 NDT Manual Part 6, 51-00-00 Figure 4 HFEC InspectionFrame WebInspect6 Inspect for any crack in the web in the shaded area from the forward side. -Detailed InspectionFrame WebInspect7 FIGURE 2: INSPECTION (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3 September 06, 2013 47 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 48 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT This Figure applies only to: Group 1. STA 303.9 5) SHIM ® SHIM 208 - WL O PLATE LEFT FORWARD ENTRY DOOR RIVET -5-15 (2 PLACES) (2) STRAP 14 SHIM S-16 STOP FITTING B 1 STRAP STOP FITTING 10) FILLER 12) SHIM • FWD INBD R99903 FIGURE 3: REMOVAL OF STRUCTURE (SHEET 1 OF 5) Original Issue: April 09, 1998 Revision 3 September 06, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-53A1188 Work - See page 1 for details. 48 of 99 ### Page 49 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT STRINGER 15 WEB → FWD STA INBD 303.9 A-A STRINGER 16 WEB 5 (11 STRAP STOP FITTING 1 CLIP • FWD (10 STA 303.9 INBD B-B FIGURE 3: REMOVAL OF STRUCTURE (SHEET 2 OF 5) Original Issue: April 09, 1998 Revision 3 September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1188 Work - See page 1 for details. 49 of 99 ### Page 50 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT STA 303.9 STOP FITTING OSTRAR S-15 S-16 11 STRAP STOP FITTING —→FWD D-D FIGURE 3: REMOVAL OF STRUCTURE (SHEET 3 OF 5) Original Issue: April 09, 1998 Revision 3 September 06, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-53A1188 Work - See page 1 for details. 50 of 99 ### Page 51 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each airplane. STOP FITTING AT STRINGER 15 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP -169-78513-1PlateRemove / Keep1 -169-78441-2StrapRemove / Keep2 -2-RivetsRemove / Discard3 -165C27705-1Stop FittingRemove / Discard4 NOTE: Mark the vertical position of the stop fitting on the skin before removal of the stop fitting. -2BACS40R013A020FLaminated ShimRemove / Discard5 or BACS40R013B020F or BACS40R013C020F -1BACS40R019B026FLaminated ShimRemove / Discard6 -1141N9961-1Tapered WasherRemove / Keep7 -169-78437-6ClipRemove / Keep8 -1BACF3T01G7G8Tapered FillerRemove / Keep9 STOP FITTING AT STRINGER 16 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP -1BACF3F020G087NNFlat FillerRemove / Keep10 -169-78441-5StrapRemove / Keep11 -2BACS40R013A020FLaminated ShimRemove / Discard12 or BACS40R013B020F or BACS40R013C020F -165-14076-22Stop FittingRemove / Discard13 or 65-14076-18 NOTE: Mark the vertical position of the stop fitting on the skin before removal of the stop fitting. -1BACS40R019B028FLaminated ShimRemove / Discard14 -165-17684-208Radius FillerRemove / Keep15 -1141N9961-1Tapered WasherRemove / Keep16 or 141N9961-2 -169-78437-7ClipRemove / Keep17 FIGURE 3: REMOVAL OF STRUCTURE (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3 September 06, 2013 51 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 52 STOP FITTING AT STRINGER 16 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP -1BACF3T01G7G8Tapered FillerRemove / Keep18 FIGURE 3: REMOVAL OF STRUCTURE (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3 September 06, 2013 52 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 53 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT NOTE: REVISION 2 REMOVED FIGURE 4 S03398 FIGURE 4: THIS FIGURE HAS BEEN DELETED (SHEET 1 OF 1) Original Issue: April 09, 1998 Revision 3 September 06, 2013 Export Controlled ECCN: 9E991 - BOEING 737-53A1188 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 99 ### Page 54 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT NOTE: REVISION 2 REMOVED FIGURE 5 IGURE 5: THIS FIGURE HAS BEEN DELETE SHEET 1 OF riginal Issue: April 03, 19 evision 3 September 06, 201. Export Controlled ECCN: 9E991 - BOEING 737-53A1188 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 99 ### Page 55 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT NOTE: REVISION 2 REMOVED FIGURE 6 S04330 FIGURE 6: THIS FIGURE HAS BEEN DELETED (SHEET 1 OF 1) Original Issue: April 09, 1998 Revision 3 September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING Work - See page 1 for details. 37-53A118 55 of 9 ### Page 56 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT This Figure applies only to: Group 1. 1) GUSSET BOLT, WASHER, AND NUT (4 PLACES) —8-15 INTERCOSTAL (EXPLODED FOR CLARITY) DOOR STOP FITTING 5-16 LATCH FITTING • GUSSET > FWD INBD INTERCOSTAL →FWD A-A S04734 FIGURE 7: CLOSE ACCESS - INSTALL SCUFF PLATE, REVEAL, AND LATCH FITTING (SHEET 1 OF 3) Original Issue: April 09, 1998 Revision 3 September 06, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-53A1188 Work - See page 1 for details. 56 of 99 ### Page 57 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT STA 303.9 WL 203 ) DOOR REVEAL ) FORWARD SCUFF PLATE FWD INBD S04735 FIGURE 7: CLOSE ACCESS - INSTALL SCUFF PLATE, REVEAL, AND LATCH FITTING (SHEET 2 OF 3) Original Issue: April 09, 1998 Revision 3 September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1188 Work - See page 1 for details. 57 of 99 ### Page 58 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for each airplane. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP All parts in this step are a kept assembly. Install if removed for access. 165-64836-2 or 65-64836-8 Latch FittingInstall / Kept1 190-7877-501Intercostal 160-4428-0Doubler 190-7877-5Gusset 190-8623-4Plate 169-8893-2Filler 169-8893-6Filler Keep attachment screws.165-3360-80RevealInstall Kept2 Keep attachment screws.165-2937-( )Scuff PlateInstall Kept3 The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. NOTESHOLE DIAIDENTIFICATIONNAMECODE Hole diameter not given. Install kept Bolt, Nut, and Washer in Existing hole. -NAS1103-3BoltA AN960D10Washer NAS679-A3WNut 100 degree countersink, 1/32 oversize.0.221 - 0.223BACR15DS7D*RivetB FIGURE 7: CLOSE ACCESS - INSTALL SCUFF PLATE, REVEAL, AND LATCH FITTING (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: April 09, 1998 737-53A1188Revision 3 September 06, 2013 58 of 99 BOEING SERVICE BULLETIN 737-53A1188 ALERTALERT ### Page 59 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT STA 303.9 STA 303.9 S-15 WL - 208 . S-16 DOUBLER WEB - INNER CHORD WL 208 > FWD ' INBD 479150 FIGURE 8: INSPECTION - DETAILED AND HIGH FREQUENCY EDDY CURRENT (SHEET 1 OF 4) Original Issue: April 09, 1998 Revision 3 September 06, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 99 ### Page 60 (OCR) BOEING SERVICE BULLETIN 737-53A1188 ALERT ALERT A—A B-B D32434 FIGURE 8: INSPECTION - DETAILED AND HIGH FREQUENCY EDDY CURRENT (SHEET 2 OF 4) Original Issue: April 09, 1998 Revision 3 September 06, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-53A1188 Work - See page 1 for details. 60 of 99 The text continues at https://openairdocs.org/service-documents/boeing/737-53a1188/file/e2e63639ee85.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.