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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1251 Original Issue: June 03, 2004 Revision 2: January 20, 2021 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Station 1016 Aft Pressure Bulkhead - Apex Inspection 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 © 2004 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Unpublished Work.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: June 03, 2004 737-53A1251Revision 2: January 20, 2021 1 of 47
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 2 of 47 BOEING SERVICE BULLETIN 737-53A1251
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION11
A. Effectivity11
1. Airplanes11
2. Spares Affected14
B. Concurrent Requirements14
C. Reason14
D. Description15
E. Compliance16
F. Approval20
G. Manpower21
H. Weight and Balance Changes22
I. Electrical Load Data22
J. References22
1. Existing Data:22
2. Data Supplied with this Service Bulletin:23
3. Installation Drawings Used in the Preparation of this Service Bulletin:23
K. Publications Affected23
L. Interchangeability and Intermixability of Parts23
M. Software Accomplishment Summary23
2. MATERIAL INFORMATION25
A. Material - Price and Availability25
B. Industry Support Information25
C. Parts Necessary for Each Airplane25
1. Kits/Parts25
2. Parts and Materials Supplied by the Operator25
3. Parts Modified and Reidentified25
4. Parts Removed and Not Replaced25
D. Parts Necessary to Change Spares25
E. Special Tooling - Price and Availability25
F. Special Tooling Necessary to do this Service Bulletin25
3. ACCOMPLISHMENT INSTRUCTIONS27
A. GENERAL INFORMATION27
B. WORK INSTRUCTIONS28
FIGURE 1: AFT PRESSURE BULKHEAD - WEB LAP SPLICE INSPECTION AREAS [Group 1] . . . 33
FIGURE 2: THIS FIGURE IS DELETED AT REVISION 235
FIGURE 3: AFT PRESSURE BULKHEAD - GENERAL VISUAL INSPECTION [Group 2]36
FIGURE 4: AFT PRESSURE BULKHEAD - WEB LAP SPLICE INSPECTION AREAS [Group 2] . . . 39 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE, TABLE 1: INSPECTION OF AFT
PRESSURE BULKHEAD CENTER DOME APEX GORE WEBS [Group 1]42
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE, TABLE 2: INSPECTION OF AFT
PRESSURE BULKHEAD CENTER DOME APEX GORE WEBS [Group 2]44
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 3 of 47 BOEING SERVICE BULLETIN 737-53A1251
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 4 of 47 BOEING SERVICE BULLETIN 737-53A1251
ALERTALERT
BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1251Original Issue: June 03, 2004 Revision 2: January 20, 2021 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Station 1016 Aft Pressure Bulkhead - Apex Inspection This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-05-18 is related to this service bulletin.
The effective date of AD 2005-05-18 is April 18, 2005.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2013-19-23 is related to this service bulletin.
The effective date of AD 2013-19-23 is November 7, 2013.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2017-10-22 is related to this service bulletin.
The effective date of AD 2017-10-22 is June 27, 2017.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Effects of this Revision on airplanes on which Orignal Issue and Revision 1 was previously done:
None.
REASON FOR REVISION This revision is sent to update Group 1 compliance time and for Group 1 removed GVI for any repair.
These sections were changed:
1. In Summary and 1.D Description, updated Group 1 Actions.
2. In Paragraph 1.E., Compliance, updated compliance tables 1 and 2.
3. In 1.G Manpower, removed figure 2 for Group 1.
4. In Paragraph 3.B.2, Work Instructions, updated to match compliance tables 1 and 2.
5. Figure 2, was deleted.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 5 of 47
6. APPENDIX A and B, updated logic diagrams for compliance tables 1 and 2.
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 June 03, 2004Original Issue:
September 22, 2020Revision 1:
January 20, 2021Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 6 of 47 BOEING SERVICE BULLETIN 737-53A1251
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1251Original Issue: June 03, 2004 Revision 2: January 20, 2021 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Station 1016 Aft Pressure Bulkhead - Apex Inspection
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 inspections in this Service Bulletin will detect the propagation of cracks from fastener holes in the web lap splices at Station (STA) 1016 Aft Pressure Bulkhead (APB) center dome apex. If the work given in this service bulletin is not accomplished, multiple cracks in the APB gore webs of the center dome apex could go undetected. Cracks in the webs may result in the inability of the APB to sustain limit loads and result in rapid decompression of the fuselage.
During cycle tests of the Boeing 737-800 Fatigue Test Article, cracks were found in the APB web lap splices common to the apex of the pressure dome. The cracks occurred at several of the fastener rows located in the aft web at the lap splice area. The cracks were in the fastener rows located adjacent to the area where the web transitions aft over the forward web in the lap splice. The pull down loading caused by the single rivet located in the areas where each of the webs transitions up 0.032 inches over the adjacent web causes cracks to start on the lap rivet holes. Cracks were found in three of the seven webs. Additional cracks have been found at the single fastener locations between lap splices on 737 classic airplanes.
For Group 2, while performing High Frequency Eddy Current (HFEC) inspections of the APB web lap splice per Service Bulletin 737-53A1353, five cracks common to the gore webs of the center dome apex were found. At one location, the crack was linked from the first to the second fastener row. The current Service Bulletin 737-53A1353 and Maintenance Planning Data (MPD) do not provide adequate inspections for the subject cracks.
Operators should note only affected airplanes line numbers 1 through 1755 have a 0.032 inch web thickness.
Airplanes line numbers 1 to 1166 have a different fastener pattern than line numbers 1167 to 1755. The fasteners in the apex dome region are subjected to fuselage pressurization fatigue cycles and clamp-up stresses during the assembly process. Airplanes after line number 1755 have a web thickness 0.040 inch.
Boeing Service Related Problem (SRP) 737NG-SRP-53-0608 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 7 of 47
Boeing Fleet Team Digest (FTD) 737NG FTD 53-19005 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 ChangesNoWeight 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 NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 39800-023RS) Group 1:
Do a Detailed Inspection and a HFEC Inspection around the web fasteners for any crack. Do a LFEC Inspection around the hidden web lap splice fastener locations for any crack. If no crack is found, continue to do the repeat Detailed Inspection, HFEC Inspection and LFEC Inspection, at the times specified in the compliance section of this service bulletin. If any crack is found, contact The Boeing Company for repair instructions and do the repair.
Group 2:
Get access to the aft side of the Aft Pressure Bulkhead (APB). Do a General Visual Inspection for any repair. If any repair found contact The Boeing Company for alternative inspection(s) to this Service Bulletin, and do the inspection(s) and applicable on-condition action(s). Do a Detailed Inspection and a High Frequency Eddy Current (HFEC) Inspection around the web fasteners for any crack in the unrepaired areas. Do a Low Frequency Eddy Current (LFEC) Inspection around the hidden web lap splice fastener locations for any crack in the unrepaired areas. If no repair is found, do a Detailed inspection, HFEC inspection and LFEC inspection of the Station (STA) 1016 Aft Pressure Bulkhead (APB) center dome apex gore webs including the web edges, lap splices and outside lap splices for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair and repeat the Detailed, HFEC, LFEC Inspections of the STA 1016 APB center dome apex gore webs for any crack. If no crack is found, repeat the Detailed, HFEC, LFEC Inspections of the STA 1016 APB center dome apex gore webs for any crack.
EFFECTIVITY 737-600/-700/-700C/-800/-900 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
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Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 8 of 47 BOEING SERVICE BULLETIN 737-53A1251
ALERTALERT
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-05-18 is related to this service bulletin.
The effective date of AD 2005-05-18 is April 18, 2005.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2013-19-23 is related to this service bulletin.
The effective date of AD 2013-19-23 is November 7, 2013.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2017-10-22 is related to this service bulletin.
The effective date of AD 2017-10-22 is June 27, 2017.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 9 of 47 BOEING SERVICE BULLETIN 737-53A1251
ALERTALERT
BOEING SERVICE BULLETIN 737-53A1251
ALERT ALERT S-7L BL ACCESS DOOR TEAR
•STRAP
WEB LAP SPLICE (7 LOCATIONS) S-7R DO A GENERAL VISUAL S-15L-
INSPECTION OF THE AFT
PRESSURE BULKHEAD (APB) CENTER DOME
APEX GORE WEBS FOR ANY REPAIR (GROUP 2)
DO A DETAILED, HIGH
FREQUENCY EDDY CURRENT AND LOW FREQUENCY EDDY S-23L —S-15R
CURRENT INSPECTIONS OF THE STATION (STA) 1016 AFT
PRESSURE BULKHEAD (APB)
CENTER DOME APEX GORE
WEBS FOR ANY CRACK DOUBLER AFT PRESSURE BULKHEAD S-23R 2935759 Original Issue: June 03, 2004 Revision 2: January 20, 2021 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1251 Work - See page 1 for details. 10 of 47
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1251 Original Issue: June 03, 2004 Revision 2: January 20, 2021 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Station 1016 Aft Pressure Bulkhead - Apex Inspection
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.
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, 737-700C, 737-800, 737-900 Airplane(s), line number(s) 1-1755 in 2 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.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP All 737-600, -700, -700C, -800, -900 airplanes line numbers 1 through 1166.
-1 All 737-600, -700, -700C, -800, -900 airplanes line numbers 1167 through 1755.
-2 Airplane Models:
737-600, 737-700, 737-700C, 737-800, 737-900 GroupVariable Number 1YA001 - YA099 GroupVariable Number 1YA101 - YA124 GroupVariable Number 2YA125 - YA199 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 03, 2004 737-53A1251Revision 2: January 20, 2021 11 of 47
GroupVariable Number 1YA201 - YA211 2YA221 1YA231 - YA242 1YA251 - YA256 1YA271 - YA272 1YA291 1YA301 - YA302 1YA311 - YA314 1YA321 - YA323 1YA336 - YA343 2YA344 - YA345 1YA351 1YA356 - YA357 1YA366 - YA367 2YA371 - YA377 1YA501 - YA536 1YA541 - YA552 1YA571 - YA578 1YA601 - YA615 1YA621 - YA622 1YA626 - YA629 2YA630 - YA631 1YA635 - YA636 2YA641 - YA642 1YA645 - YA647 2YA648 - YA650 1YA656 - YA659 2YA666 - YA667 1YA671 - YA672 1YA681 - YA691 1YA701 - YA706 2YA707 - YA710 1YA721 - YA722 GroupVariable Number 1YA731 - YA734 1YA751 - YA756 1YA801 - YA803 1YA809 1YA811 - YA814 1YA831 - YA834 2YA835 1YA841 - YA856 2YA857 - YA862 1YA881 - YA882 1YA891 - YA892 1YA961 - YA967 2YA968 - YA976 1YB001 - YB006 1YB101 - YB116 2YB117 - YB132 1YB151 - YB153 2YB156 - YB157 1YB161 - YB162 2YB163 - YB164 1YB171 - YB172 1YB181 - YB183 2YB184 1YB201 - YB207 2YB208 1YB271 1YB276 1YB301 - YB306 2YB307 - YB310 2YB371 - YB381 1YB501 - YB502 1YB521 2YB522 - YB526 GroupVariable Number 2YB541 - YB544 1YB551 2YB561 - YB574 2YB576 - YB577 2YB581 - YB587 2YB601 - YB632 2YB651 2YB656 2YB851 - YB863 2YB871 - YB873 2YB881 - YB888 2YB901 - YB903 2YB911 1YC001 - YC030 1YC051 - YC082 2YC083 1YC091 - YC094 1YC101 - YC104 1YC111 - YC113 1YC121 1YC126 - YC127 1YC136 - YC141 1YC146 - YC147 1YC151 - YC156 1YC166 - YC168 2YC169 - YC170 1YC171 1YC176 2YC177 - YC178 2YC186 - YC189 2YC201 - YC203 2YC206 - YC207 1YC301 - YC304 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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