Boeing ASB 737-53A1217: Revision 1, text

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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1217 Original Issue: August 09, 2001 Revision 1: September 08, 2022 ATA System: 5300 SUBJECT: FUSELAGE - Section 43 and Section 47 - Stringer 17 Skin Cracks at STA 360-380 and STA 888-907 EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.

9E991ECCN:

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: August 09, 2001 737-53A1217Revision 1: September 08, 2022 1 of 150

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Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 2 of 150 BOEING SERVICE BULLETIN 737-53A1217

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Table of Contents

Revision Transmittal Sheet5

S u m m a r y7

1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1

1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 2 1 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 5 I. Electrical Load Data ......................................... 2 6 J . R e f e r e n c e s .............................................. 2 6

1. Existing Data: ......................................... 2 6

2. Data Supplied with this Service Bulletin: ........................... 2 6

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 6 K. Publications Affected ........................................ 2 7 L. Interchangeability and Intermixability of Parts ........................... 2 7 M. Software Accomplishment Summary ................................ 2 7

2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 2 9 C. Parts Necessary for Each Airplane ................................. 2 9 1 . K i t s / P a r t s ............................................ 2 9

2. Parts and Materials Supplied by the Operator ........................ 2 9

3. Parts Modified and Reidentified ................................ 3 0

4. Parts Removed and Not Replaced .............................. 3 0 D. Parts Necessary to Change Spares ................................. 3 0 E. Special Tooling - Price and Availability ............................... 3 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 0

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1 A. GENERAL INFORMATION ..................................... 3 1 B. WORK INSTRUCTIONS ....................................... 3 3 F I G U R E 1 : D E L E T E D A T R E V I S I O N 1.................................. 4 4 FIGURE 2: DO HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION- ZONE 1 AND ZONE 2 [Group 1, Configuration 1-2; Group 3, Configuration 1-2] ....................... 4 5 FIGURE 3: DO HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION- ZONE 3 AND ZONE 4 [Group 1, Configuration 1-2; Group 2, Configuration 1-2; Group 3, Configuration 1-2] ....... 4 8 FIGURE 4: TERMINATING ACTION AT ZONE 1 AND ZONE 2 [Group 1, Configuration 1-2; Group 3, Configuration 1-2] ....................................... 5 1 FIGURE 5: TERMINATING ACTION AT ZONE 3 AND ZONE 4 [Group 1, Configuration 1-2; Group 2, Configuration 1-2; Group 3, Configuration 1-2] ........................ 5 8 FIGURE 6: SKIN REPAIR AT ZONE 1 [Group 1, Configuration 1-2; Group 3, Configuration 1-2] . . . 65 FIGURE 7: SKIN REPAIR AT ZONE 2 [Group 1, Configuration 1-2] ................... 7 4 Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 3 of 150 BOEING SERVICE BULLETIN 737-53A1217

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FIGURE 8: SKIN REPAIR AT ZONE 3 [Group 1, Configuration 1-2; Group 2, Configuration 1-2; Group 3, Configuration 1-2] ....................................... 8 3 FIGURE 9: SKIN REPAIR AT ZONE 4 [Group 1, Configuration 1-2; Group 2, Configuration 1-2; Group 3, Configuration 1-2] ....................................... 9 2 FIGURE 10: SKIN REPAIR AT ZONE 2 [Group 3, Configuration 1-2] .................. 1 0 1 FIGURE 11: POST REPAIR INSPECTION (EXTERNAL) AT ZONE 1 [Group 1, 3, Configuration 3] . . 110 FIGURE 12: POST REPAIR INSPECTION (INTERNAL) AT ZONE 1 [Group 1, 3, Configuration 3] . . 113 FIGURE 13: POST REPAIR INSPECTION (EXTERNAL) AT ZONE 2 [Group 1, Configuration 3] . . . 115 FIGURE 14: POST REPAIR INSPECTION (EXTERNAL) AT ZONE 2 [Group 3, Configuration 3] . . . 118 FIGURE 15: POST REPAIR INSPECTION (INTERNAL) AT ZONE 2 [Group 1, 3, Configuration 3] . . 121 FIGURE 16: POST REPAIR INSPECTION (EXTERNAL) AT ZONE 3 [Group 1-3, Configuration 3] . . 123 FIGURE 17: POST REPAIR INSPECTION (INTERNAL) AT ZONE 3 [Group 1-3, Configuration 3] . . 126 FIGURE 18: POST REPAIR INSPECTION (EXTERNAL) AT ZONE 4 [Group 1-3, Configuration 3] . . 128 FIGURE 19: POST REPAIR INSPECTION (INTERNAL) AT ZONE 4 [Group 1-3, Configuration 3] . . 131 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 1: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION AT ZONE 1, ZONE 2, ZONE 3 AND ZONE 4 . 133 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 2: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION ZONE 3 AND ZONE 4 .............. 1 3 7 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 3: POST REPAIR INSPECTIONS AT ZONE 1 ................................. 1 3 9 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 4: POST REPAIR INSPECTIONS AT ZONE 2 ................................. 1 4 2 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 5: POST REPAIR INSPECTIONS AT ZONE 3 ................................. 1 4 5 APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 6: POST REPAIR INSPECTIONS AT ZONE 4 ................................. 1 4 8 Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 4 of 150 BOEING SERVICE BULLETIN 737-53A1217

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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1217Original Issue: August 09, 2001 Revision 1: September 08, 2022 ATA System: 5300 SUBJECT: FUSELAGE - Section 43 and Section 47 - Stringer 17 Skin Cracks at STA 360-380 and STA 888-907 This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION 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.

Effects of this Revision on airplanes on which the original issue was previously done:

ActionConditionGroup Do the initial High Frequency Eddy Current (HFEC) inspections at all locations.

Airplanes that have not accomplished this service bulletin.

Group 1-3, Configuration 1 Repeat the HFEC inspections at all unrepaired locations.

Airplanes that have not done the terminating action.

Group 1-3, Configuration 2 Do the post repair inspections at each of the repair locations.

Airplanes that have installed a repair.Group 1-3, Configuration 3 No further action required at that location.

Airplanes that have done the terminating action.

Group 1-3, Configuration 4 Airplane variable numbers YE001-YE010 and YE101-YE104 were moved from Group 1 to new Group 3 of this service bulletin effectivity.

REASON FOR REVISION This revision is sent to move airplanes from Group 1 to new Group 3, add new internal and external post repair inspections of the repair doubler, add new inspections for skin repair and add new repair figures for Group 3 airplanes. Post repair inspections are required by Part 26 compliance (Damage Tolerance Evaluation (DTE) and Damage Tolerance Inspections (DTI) ) for the repairs given in this service bulletin.

This revision also updates the status of this service bulletin to ALERT. Boeing has determined the unsafe condition identified in this service bulletin to be airplane safety.

These sections were changed:

Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 5 of 150

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1. In Paragraph 1.A., Effectivity, added service bulletin index information and applicable line number information. Added new Group configuration table information.

2. In Paragraph 1.C., Reason, updated reason statement. Added reason for revision statement.

3. In Paragraph 1.D., Description: Added instructions for new post repair inspections and new affected maintenance zones.

4. In Paragraph 1.J.1., Existing Data, reference to PRR, Boeing SRP, Boeing Service Bulletin, Service Bulletin Index, Standard Overhaul Practices Manual (SOPM), Non-Destructive Testing (NDT) Manual, Aircraft Maintenance Manual (AMM), Structural Repair Manual (SRM) and Fleet Team Digest (FTD) are added.

5. In Paragraph 1.K.2., Publications Affected, Damage Tolerance Based Structural Inspections, new statements added.

6. In Paragraph 1.E., Compliance, updated compliance statement of work.

7. In Paragraph 3.A., General Information, added new general notes.

8. In Paragraph 3.B., Work Instructions, update work instructions format and high level work instructions to add post repair inspections.

9. Revised Figures, Appendix in accordance with procedure.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.

Pages with no vertical lines have no changes.

REVISION HISTORY August 09, 2001Original Issue:

September 08, 2022Revision 1:

Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 6 of 150 BOEING SERVICE BULLETIN 737-53A1217

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1217Original Issue: August 09, 2001 Revision 1: September 08, 2022 ATA System: 5300 SUBJECT: FUSELAGE - Section 43 and Section 47 - Stringer 17 Skin Cracks at STA 360-380 and STA 888-907

THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of the inspection shown in this service bulletin will make sure that skin cracks at the double row of fasteners centered on Stringers S-17L and S-17R, at station (STA) 360 to STA 380 and at STA 888 to STA 907 are found and repaired. If this service bulletin is not done, continued operation with an undetected crack could result in possible rapid decompression and loss of structural integrity.

In production, a structural preload was created in the body skin during the installation of S-17. Analysis by Boeing shows that this preload, combined with pressure cycles, can cause cracks in the skin prior to reaching the Design Service Objective (DSO).

Engineering evaluation has shown that airplanes with this condition meet all FAA and JAA static strength requirements and are structurally satisfactory. Analysis indicates that the DSO may not be reached unless the preload condition is repaired.

Several airplanes have had inspections and/or repairs accomplished at STA 360 to STA 380. However, some of these airplanes still require an inspection to be accomplished at STA 888 to STA 907.

Accomplishment of the terminating action shown in this service bulletin will ensure that cracks do not initiate.

Cracks will result in unscheduled time out of service to accomplish repairs.

For 737-600, 737-700, and 737-800 airplanes after Line Number 269 the sequence of assembly was changed to eliminate the preload.

Service bulletin 737-53A1217 R01 supersedes the damage tolerance inspection data given in service bulletin 737-00-1007 for service bulletin 737-53-1217 R0 Figures 6, 8 and 9. Service bulletin 737-53A1217 R01 also adds post repair inspections for existing Figure 7.

Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 7 of 150

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Boeing Service Related Problem (SRP) 737NG-SRP-53-0598 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 737NG FTD 53-19001 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 39800-018RS) Do a detailed and High Frequency Eddy Current (HFEC) inspection for cracks in the skin at Stringer S-17, left and right, at STA 360 to STA 380 and at STA 888 to STA 907. The inspection area is a two inch band of skin, centered on the two rows of fasteners of S-17, STA 360 to STA 380 and STA 888 to STA 907, left and right sides. If any crack is found, accomplish the repair and post repair inspections as shown in this service bulletin.

If no crack is found, reinspect at intervals shown in the service bulletin or accomplish terminating action as shown in this service bulletin.

EFFECTIVITY 737-600/-700/-800 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in Compliance Tables 3 through 6 of this service bulletin mandatory.

Refer to Paragraph 1.E., Compliance.

Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 8 of 150 BOEING SERVICE BULLETIN 737-53A1217

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BOEING SERVICE BULLETIN 737-53A1217

ALERT ALERT

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for 737 airplanes in warranty as of March 27, 1998. For inspection labor task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to BCA Contracts - Warranty. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours are required, send a warranty claim to BCA Contracts - Warranty.

Boeing warranty remedies are not available for the supplemental Damage Tolerance Inspections associated with Figure 7.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Operator Supplied Parts/Materials.

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

STA 888

DO DETAILED AND A HFEC

INSPECTION FOR ANY

CRACK IN THE SKIN AT S-17, STA 360 TO STA 380

DO DETAILED AND A HFEC S-17 STA CRACK IN THE SKIN AT S-17. INSPECTION FOR ANY 360 STA 888 TO STA 907

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE -700 MODEL SHOWN -600/-800 SIMILAR V43633 Original Issue: August 09, 2001 Revision 1: September 08, 2022 Export Controlled ECCN: 9E991 BOEING PROPRIETARY 737-53A1217 Copyright © Unpublished Work - See page 1 for details. 9 of 150

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Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 10 of 150 BOEING SERVICE BULLETIN 737-53A1217

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1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This bulletin is applicable to 737-600, 737-700, 737-800 Airplane(s), line number(s) 1-269 in 3 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.

Airplanes might be in more than one configuration and must do the actions for each applicable configuration.

DESCRIPTIONCONFIGURATIONGROUP 737-700/-800 airplanes.-1 Airplanes that have not accomplished this service bulletin.1 Airplanes with any inspection zone that have not done the terminating action.

2 Airplanes with any inspection zone that have installed a repair specified in this service bulletin.

3 Airplanes with any inspection zone that have done the terminating action specified in Part 6 of this service bulletin.

4 Export Controlled ECCN: 9E991

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DESCRIPTIONCONFIGURATIONGROUP 737-600/-700/-800 airplanes.-2 Airplanes that have not accomplished this service bulletin.1 Airplanes with any inspection zone that have not done the terminating action.

2 Airplanes with any inspection zone that have installed a repair specified in this service bulletin.

3 Airplanes with any inspection zone that have done the terminating action specified in Part 8 of this service bulletin.

4 737-600 airplanes.-3 Airplanes that have not accomplished this service bulletin.1 Airplanes with any inspection zone that have not done the terninationg action.

2 Airplanes with any inspection zone that have installed a repair specified in this service bulletin.

3 Airplanes with any inspection zone that have done the terminating action specified in Part 6 of this service bulletin.

4 Airplane Models:

737-600, 737-700, 737-800 GroupVariable Number 1YA001 - YA030 2YA031 1YA201 - YA206 1YA231 - YA242 1YA251 - YA254 1YA271 - YA272 1YA291 1YA301 - YA302 1YA311 - YA313 1YA321 1YA501 - YA521 GroupVariable Number 2YA522 1YA523 1YA541 - YA544 2YA545 - YA546 1YA571 - YA577 1YA601 - YA606 1YA701 - YA704 1YA721 - YA722 1YA731 1YA751 - YA754 2YA755 GroupVariable Number 1YA811 - YA812 2YA831 1YC001 - YC009 2YC010 - YC011 1YC051 - YC058 1YC071 - YC074 1YC101 - YC103 1YC111 - YC112 1YC121 1YC126 1YC301 - YC302 Export Controlled ECCN: 9E991

Original Issue: August 09, 2001 737-53A1217Revision 1: September 08, 2022 12 of 150 BOEING SERVICE BULLETIN 737-53A1217

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