# Boeing Alert Service Bulletin 737-53A1254: Service Bulletin - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2018-0412; AD 2018-19-20 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 737-53A1254](https://openairdocs.org/service-documents/boeing/737-53a1254.md) - Title as filed: Service Bulletin - Pages: 192 - PDF: https://openairdocs.org/files/sha256/fd/09/fd092c5587b4fb50884f9bbeb59937df185de90452c9f0dde6766c4f6cef8d60 - Page: https://openairdocs.org/service-documents/boeing/737-53a1254/file/fd092c5587b4 ## 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: 737-53A1254 Original Issue: February 17, 2005 Revision 3: November 13, 2017 ATA System: 5310 5710 SUBJECT: FUSELAGE - Frame and Overwing Stub Beam at Body Stations 616, 639 and 597 or 601 - Buttock Line 45.5 Floor Beam Web at Body Station 639 - Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2005 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 Unpublished Work.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: February 17, 2005 737-53A1254Revision 3: November 13, 2017 1 of 192 4.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 2 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 51 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 58 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 60 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FIGURE 1: INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 FIGURE 2: INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 FIGURE 3: INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group 3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 FIGURE 4: DELETED AT REVISION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 FIGURE 5: DELETED AT REVISION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 FIGURE 6: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 3 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 4 FIGURE 7: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 FIGURE 8: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group 3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 FIGURE 9: INSPECTION OF THE LOWEST FOUR FASTENERS COMMON TO THE INNER CHORD AT BS 601 [Group 3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 FIGURE 10: INSPECTION OF THE SHEAR TIE S AT BS 597 [Group 1-2] . . . . . . . . . . . . . . . 110 FIGURE 11: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES BELOW S-14 [Group 1] . 113 FIGURE 12: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES BELOW S-14 [Group 2] . 116 FIGURE 13: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES BELOW S-14 [Group 3] . 119 FIGURE 14: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES BELOW S-14 [Group 1] . 122 FIGURE 15: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES BELOW S-14 [Group 2] . 125 FIGURE 16: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES BELOW S-14 [Group 3] . 128 FIGURE 17: PREVENTIVE MODIFICATION OF THE FRAME INNER CHORD AT BS 601 [Group 3] . 131 FIGURE 18: REPAIR OF THE FRAME INNER CHORD AT BS 616 AND BS 639 [Group 1] . . . . . . 135 FIGURE 19: REPAIR OF THE FRAME INNER CHORD AT BS 616 AND BS 639 [Group 2] . . . . . . 142 FIGURE 20: REPAIR OF THE FRAME INNER CHORD AT BS 601, BS 616 AND BS 639 [Group 3] . 149 FIGURE 21: FABRICATION INSTRUCTIONS - FILLER . . . . . . . . . . . . . . . . . . . . . . . . . 158 FIGURE 22: FABRICATION INSTRUCTIONS - STIFFENING ANGLE . . . . . . . . . . . . . . . . . 160 FIGURE 23: FABRICATION INSTRUCTIONS - TAPERED SHIM . . . . . . . . . . . . . . . . . . . . 162 FIGURE 24: BS 616 AND BS 639 FRAME POST-REPLACEMENT INSPECTION FOR SSID ITEM F-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 FIGURE 25: DETAILED INSPECTION OF THE FRAME INNER CHORD AT BS 616 AND BS 639 - REPAIR OR PREVENTIVE MODIFICATION INSTALLED . . . . . . . . . . . . . . . . . . . . . . 168 FIGURE 26: HFEC INSPECTION OF THE FRAME INNER CHORD AT BS 616 AND BS 639 - REPAIR OR PREVENTIVE MODIFICATION INSTALLED . . . . . . . . . . . . . . . . . . . . . . . . 171 FIGURE 27: INSPECTION OF THE WEB SPLICE AT BS 616 AND BS 639 - PARTIAL FRAME REPLACEMENT INSTALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 FIGURE 28: OPEN HOLE HFEC INSPECTION AND HFEC SURFACE INSPECTION OF THE BL 45.5 LONGITUDINAL FLOOR BEAM WEB AT BS 639 STUB BEAM ATTACHMENT [Group 1-2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 FIGURE 29: INSPECTION OF THE BS 616 MACHINED STUB BEAM UPPER CHORD [Group 2-3] . 187 Appendix A: INSPECTION REPORT FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 APPENDIX B: PART DEMAND INTENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 4 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 5 Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1254Original Issue: February 17, 2005 Revision 3: November 13, 2017 ATA System: 5310 5710 SUBJECT: FUSELAGE - Frame and Overwing Stub Beam at Body Stations 616, 639 and 597 or 601 - Buttock Line 45.5 Floor Beam Web at Body Station 639 - Inspection and Repair This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-25-06 is related to this service bulletin. Effects of this Revision on airplanes on which the original issue, Revision 1, or Revision 2 was previously done: ActionConditionGroup Additional inspections for any crack to the stub beam at Body Station (BS) 616 and BS 639, any crack to the frame inner chord at BS 601 and any crack at the frame shear tie of BS 597 are necessary. Airplanes on which the original issue was previously done. All Airplanes that have removed and replaced certain stub beam to But- tock Line (BL) 45.5 longitudinal floor beam attachment angles require additional inspections of the replace- ment attachment angle. Additional fastener inspections and partial frame replacement inspections have also been added. Airplanes on which Revision 1 was previously done. All Inspect the BL 45.5 longitudinal floor beam at BS 639 for any crack. Airplanes on which Revision 2 was previously done. 1 Inspect the BL 45.5 longitudinal floor beam at BS 639 for any crack and inspect the BS 616 stub beam upper chord for any crack. Airplanes on which Revision 2 was previously done. 2 Inspect the BS 616 stub beam upper chord for any crack. Airplanes on which Revision 2 was previously done. 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 5 of 192 ### Page 6 REASON FOR REVISION This revision is sent to incorporate Alternative Method of Compliance Notice 737-53A1254-AMOC-03, to add a requirement for Group 1 and Group 2 airplanes to inspect the BL 45.5 longitudinal floor beam web at the BS 639 stub beam attachment, to provide a Structural Repair Manual (SRM) repair of the BL 45.5 longitudinal floor beam web at BS 639 for Group 2 airplanes and to clarify that inspection is required of the frame outer chord where a partial frame replacement is installed at BS 616 and BS 639. This revision also adds an inspection of the BS 616 stub beam upper chord. The data given in Alternative Method of Compliance Notice 737-53A1254-AMOC-03 is included in this revision. These sections were changed: 1. Service Bulletin ATA System and Subject, changed to add new inspection area, and clarify frame and stub beam locations. 2. Summary, Background, added new inspection area, Service Related Problem reference, Fleet Team Digest reference and acronym definitions. 3. Summary, Action, updated layout of existing and new action descriptions using common airplane grouping. Removed corrective action descriptions and removed statement describing alternate Structural Significant Item (SSI) F-20 inspections methods after partial frame replacement is done. Removed alternate inspections statement for airplanes with service bulletin 737-53-1182 R1 repair or preventive modification. Replaced "More work" statement from Revision 1 with an "Effects of this Revision" table. 4. Summary, Action, Description, Paragraph 1.E, Compliance, Paragraph 3.B, Work Instructions, Figures 1 through 3, 6 through 20 and 24 through 27, where instructions tell the operator to 'inspect for cracks' or 'inspect for cracking', the terminology is changed to 'inspect for any crack'. 5. Summary Effectivity, replaced airplane line number ranges with a reference to the Effectivity paragraph in the Planning Information section. 6. Summary, Compliance, added the effective date of the released Airworthiness Directive and added statement for an additional Airworthiness Directive. 7. Summary Illustration, added a new inspection area view, changed part names and the existing view title. 8. Paragraph 1.A, Effectivity, airplane line number applicability, variable number, group information and production revision record equivalent statements added. 9. Paragraph 1.C, Reason, added new inspection area, Service Related Problem reference, Fleet Team Digest reference and acronym definitions. Reason for revision information updated. 10. Paragraph 1.D, Description, updated layout of existing and new action descriptions using common airplane grouping. Removed corrective action descriptions and removed "write to Boeing for repair instructions" note. Removed alternate inspections statement for airplanes with service bulletin 737-53-1182 R1 repair or preventive modification. Replaced "More work" statement from Revision 1 with an "Effects of this Revision" table. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 6 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 7 11. Paragraph 1.E, Compliance, replaced "The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin" statement with the effective date of the released Airworthiness Directive, added statement for an additional Airworthiness Directive, and updated inspection types paragraph for the new and renumbered compliance tables. 12. Paragraph 1.E, Compliance, added new paragraphs for the definition of compliance table conditions, action, options and required actions accomplishment instructions. 13. Paragraph 1.E, Compliance, updated compliance table 1 starting conditions and related compliance thresholds. Clarified compliance table 1 BS 616 and BS 638 frame inspection locations for Option 1 and Option 2. Clarified frame crack and stub condition and corrective action wording. Added a new condition and a before further flight corrective action to compliance table 1 for any crack found in a stub beam to BL 45.5 floor beam attachment tee/angle. Compliance table 1, footnote (a) changed to refer to compliance table 2 for post partial frame replacement and integral stub beam replacement inspection requirements. 14. Paragraph 1.E, Compliance, changed compliance table 2 layout and Option 2 replacement frame web inspection requirements. 15. Paragraph 1.E, Compliance, added new compliance tables 3, 4, 5 and 9. Existing compliance tables 3, 4 and 5 renumbered as compliance tables 6, 7 and 8, respectively. 16. Paragraph 1.E, Compliance, added corrective actions to compliance table 8. 17. Paragraph 1.F, Approval, changed the FAA Aircraft Certification Office information. 18. Paragraph 1.G, Manpower, added Tables 8 and 9. Corrected Table 5, 6 and 7 titles. Corrected Table 6 task description. 19. Paragraph 1.J, References, updated existing data and installation drawing used in the preparation of this service bulletin. 20. Paragraph 1.M., Software Accomplishment Summary, not affected statement added. 21. Paragraph 2.A, Material, Price and Availability, added note for new Appendix B Part Demand Intent survey and updated kit price information. 22. Paragraph 2.C, Parts Necessary for Each Airplane, corrected Figure number for forming an Operator Supplied stiffening angle. 23. Paragraph 3.A, Accomplishment Instructions, added general information notes. 24. Paragraph 3.B, Work Instructions, Part 1, corrected inspection instructions for partial frame replacements, stub beam and stub beam attachment replacement, frame crack condition wording, and added channel/filler location note. Channel/filler removal and installation steps added to Option 1 and Option 2 instruction sequence. 25. Paragraph 3.B, Work Instructions, Part 2, added close access instruction and repeat inspection termination note. 26. Paragraph 3.B, Work Instructions, Part 3, added close access instruction and changed part title. 27. Paragraph 3.B, Work Instructions, Part 4, changed frame description in partial frame replacement steps. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 7 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 8 28. Paragraph 3.B, Work Instructions, Part 5, removed work instruction text duplicated with the related Figure. 29. Paragraph 3.B, Work Instructions, Part 6, added tapered shim installation instruction. 30. Paragraph 3.B, Work Instructions, Part 7, clarified work instructions and added notes. 31. Paragraph 3.B, Work Instructions, Parts 8 and 9 and Figures 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20, changed Non-Destructive Testing Manual references from 'Figure 1 or Figure 16' to 'Procedure 16'. 32. Paragraph 3.B, Work Instructions, Parts 8 and 9, changed to add airplane group applicability, a close work instruction step and to correct part names. Clarified Part 9 work instruction for open hole inspections common to the BL 45.5 floor beam attachment tee/angle, and added SRM repair of the BL 45.5 longitudinal floor beam web at BS 639 added as an instruction step with follow-up inspections. 33. Paragraph 3.B, Work Instructions, added new Parts 10 and 11. 34. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15 and 16, changed figure titles. 35. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 24, 25 and 26 changed illustration view titles and part names. 36. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 6, 7, 8, 9, 10, 24, 25, 26 and 27, QTY numbers and QTY statement removed. 37. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 11, 12, 13, 14, 15, 16, 25 and 26, corrected footnotes. 38. Paragraph 3.B, Work Instructions, Figures 2, 3, 7, 8, 9, 10, 12, 13, 15, 16, 17, 19 and 20, changed airplane locators. 39. Paragraph 3.B, Work Instructions, Figures 6, 7, 8, changed frame web, inner chord and outer chord inspection requirements. 40. Paragraph 3.B, Work Instructions, Figures 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 18, 19, 20, 24, 26 and 27, changed Non-Destructive Testing Manual references from 'Figure 4 or Figure 23' to 'Procedure 4 or Procedure 23'. 41. Paragraph 3.B, Work Instructions, Figures 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20, tapered shim installation footnote changed. 42. Paragraph 3.B, Work Instructions, Figures 11, 12, 13, 14, 15 and 16, corrected SRM references for stringer splicing information. 43. Paragraph 3.B, Work Instructions, Figure 27 changed to add inspection options and the data given in Alternative Method of Compliance (AMOC) Notice 737-53A1254-AMOC-03. 44. Paragraph 3.B, Work Instructions, added new Figures 28 and 29. 45. Appendix A, Inspection Report Form inspection heading corrected. 46. Added new Appendix B Part Demand Intent. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 8 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 9 The data given in Alternative Method of Compliance Notice 737-53A1254 AMOC 03 is included in this revision. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes. Pages with no vertical lines have no changes. REVISION HISTORY February 17, 2005Original Issue: July 09, 2009Revision 1: February 22, 2012Revision 2: November 13, 2017Revision 3: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 9 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 10 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 10 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT BLANK PAGE ### Page 11 Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1254Original Issue: February 17, 2005 Revision 3: November 13, 2017 ATA System: 5310 5710 SUBJECT: FUSELAGE - Frame and Overwing Stub Beam at Body Stations 616, 639 and 597 or 601 - Buttock Line 45.5 Floor Beam Web at Body Station 639 - Inspection and Repair 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 The cause of the cracks at Body Station (BS) 616 and BS 639 frame sections below Stringer (S-)15 is due to fatigue. This fatigue failure is due to high flight cycle stresses from both pressurization and maneuver load. After the release of the original issue of this service bulletin, there were 25 fleet reports of frame cracking in BS 601 or BS 597 along with stub beam cracking in BS 616 and BS 639. Service Bulletin 737-53-1182 is used to inspect for cracks emanating from the frame inner chord lower end fastener hole located at BS 616 and BS 639. This service bulletin expands upon the inspection area shown in Service Bulletin 737-53-1182 and identifies several new locations for possible cracks. The airplane effectivity for this service bulletin includes all airplanes listed in the effectivity for Service Bulletin 737-53-1182 and additional airplanes that also need to be inspected. This service bulletin supersedes Service Bulletin 737-53-1182. Periodic inspections of the body frame from below S-15 to the lower end of the stub beam, frame inner chord lower end fastener holes, frame shear ties, stub beam structure at BS 616, 639 and 597 or 601 and BL 45.5 longitudinal floor beam at BS 639 as given in this service bulletin will detect cracks at an early stage of propagation. The accomplishment of a repair or preventive modification will reduce the possibility of undetected fatigue cracks which could result in severed frames and induce skin cracks at these locations. This could lead to rapid decompression of the fuselage. Boeing Service Related Problem (SRP) 737-SRP-53-0182, 737-SRP-53-0516 and 737-SRP-53-0529 are related to this service bulletin. Boeing Fleet Team Digest (FTD) 737 FTD 53-03003 is related to this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 11 of 192 ### Page 12 ACTION (PRR 35005-281RS) The airplane effectivity is divided into 3 groups based on stub beam configuration. Group 1 is 737-200 passenger airplanes, Group 2 is 737-300 and -500 passenger airplanes and Group 3 is 737-400 passenger airplanes. Remove seats, carpets, side panels and floor panels to get access to the overwing stub beams, both sides of the BL 45.5 longitudinal floor beam, and body frames at BS 616, 639, 597 or 601. Do a detailed or High Frequency Eddy Current (HFEC) inspection of the BS 616 and BS 639 frame web, inner chord and outer chord from three fastener rows above S-16 down to the last fastener common to the stub beam joint, and the stub beam assembly from BL 45.5 to the outboard end, for any crack. Group 1-2: Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole common to the stub beam attachment angle, and do a HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fastener head/tail at each fastener location common to the back-up strap. Do a detailed inspection of the frame shear ties at BS 597 for any crack. Group 3: Do a detailed or HFEC inspection of the frame inner chord common to the lowest four fastener holes at BS 601 for any crack. Group 2-3: Do a detailed and Medium Frequency Eddy Current (MFEC) subsurface inspection of the BS 616 stub beam upper chord for any crack. Do the detailed, HFEC, and MFEC inspections at the thresholds given in the compliance section of this service bulletin. If no crack is found, repeat the detailed, HFEC, and MFEC inspections at the intervals for the appropriate method as given in the compliance section of this service bulletin. Record the results of all crack inspections on the form in APPENDIX A of this service bulletin. EFFECTIVITY 737-200/-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives (AD) AD 98-11-04 R1, AD 2008-09-13 and AD 2010-25-06 are related to this service bulletin. The effective date of AD 2010-25-06 is February 1, 2011. 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 Boeing warranty remedies are not available for the inspection, repair and modification procedures given in this service bulletin. MANPOWER Refer to Paragraph 1.G., Manpower. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 12 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 13 (OCR) BOEING SERVICE BULLETIN 737-53A1254 ALERT ALERT MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. ESCAPE HATCH BS BS WING CENTER FUEL 639 616 TANK UPPER SURFACE S-16 BL 45.5 • FWD FRAME SKIN INNER CHORD STRINGER CLIP INSPECT FOR ANY CRACK S-16 GROUP 2 AND 3 AIRPLANES: CREASE BEAM INSPECT FOR ANY CRACK •INNER CHORD AT BS 616 FRAME OUTER INSPECT CHORD FOR ANY CRACK STUB BEAM WL 208 UPPER CHORD FRAME WEB › INBD FRAME TIE STUB BEAM FITTING LOWER CHORD BL BL 70.85 STUB CENTER WING FUEL 45.5 UPPERCHORD BEAM A-A TANK UPPER SURFACE REAR VIEW OF BS 639 FOR A GROUP 1 AIRPLANE 2097195 SHOWN, BS 616 SIMILAR. Original Issue: February 17, 2005 Revision 3: November 13, 2017 Export Controlled ECCN: 9E991 - BOEING 737-53A1254 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 192 ### Page 14 (OCR) BOEING SERVICE BULLETIN 737-53A1254 ALERT ALERT STUB BEAM TO BL 45.5 LONGITUDINAL FLOOR BEAM WEB ATTACHMENT ANGLE GROUP 1 AND 2 AIRPLANES: BL 45.5 INSPECT FOR ANY CRACK AT THE LONGITUDINAL BACK-UP BL 45.5 LONGITUDINAL FLOOR BS FLOOR BEAM STRAP BEAM WEB ATTACHMENT 639 TYPICAL CRACKS FWD C LOOKING INBD LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE B-B 2504129 Original Issue: February 17, 2005 Revision 3: November 13, 2017 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-53A1254 Work - See page 1 for details. 14 of 192 ### Page 15 Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1254 Original Issue: February 17, 2005 Revision 3: November 13, 2017 ATA System: 5310 5710 SUBJECT: FUSELAGE - Frame and Overwing Stub Beam at Body Stations 616, 639 and 597 or 601 - Buttock Line 45.5 Floor Beam Web at Body Station 639 - Inspection and Repair 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 This service bulletin is applicable to 737-200/-300/-400/-500 Airplanes, line numbers 849-3132 in 3 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below. Refer to PRR 35005-281RS for data about this change. 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. DESCRIPTIONCONFIGURATIONGROUP Groups are based on stub beam configuration. 737-200 passenger airplanes from line number 849 to 1585 with BS 597, BS 616 and BS 639. -1 Groups are based on stub beam configuration. 737-300 and 737-500 passenger airplanes from line number 1001 to 3130 with BS 597, BS 616 and BS 639. -2 Groups are based on stub beam configuration. 737-400 from line number 1487 to 3132 with BS 601, BS 616 and BS 639. -3 Airplane Models: 737-200, 737-300, 737-400, 737-500 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 15 of 192 ### Page 16 GroupVariable Number 1PJ119 3PJ301 - PJ302 3PJ551 - PJ561 3PJ601 - PJ615 3PJ811 3PJ816 - PJ817 1PK216 - PK220 1PK274 1PK361 1PK504 1PK515 1PK519 1PK525 - PK528 1PK560 1PK564 - PK565 1PK610 1PK617 1PK630 - PK637 1PK663 - PK666 1PK679 - PK681 1PK696 - PK697 1PK750 - PK765 1PK801 - PK804 1PK827 1PK933 - PK938 1PL023 - PL028 1PL111 - PL113 1PL172 1PL221 1PL412 - PL417 1PL455 - PL456 1PL560 - PL562 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 16 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 17 GroupVariable Number 1PL601 - PL603 1PL611 1PL621 - PL626 1PL631 - PL632 1PL746 - PL747 1PL783 - PL788 1PM003 - PM006 1PM016 - PM017 1PM051 - PM066 1PM102 - PM119 1PM141 - PM142 1PM171 1PM181 1PM251 - PM255 1PM281 - PM283 2PM381 - PM399 2PM401 - PM417 2PM541 - PM550 3PM551 - PM564 1PN001 - PN002 1PN021 - PN043 1PN081 - PN086 1PN101 - PN117 1PN131 - PN163 1PN401 - PN420 1PN431 - PN433 1PN451 - PN456 1PN471 - PN474 1PN481 1PN491 - PN493 1PN501 - PN502 1PN511 - PN512 1PN521 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 17 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 18 GroupVariable Number 2PP001 - PP054 2PP101 - PP169 2PP181 - PP199 2PP201 - PP205 2PP221 2PP231 - PP243 2PP281 - PP286 2PP301 - PP305 2PP351 - PP353 2PP376 - PP384 2PP391 - PP393 2PP401 - PP440 2PP471 - PP475 2PP501 - PP522 2PP631 - PP634 2PP651 - PP652 2PP671 - PP699 2PP701 - PP733 2PP771 - PP779 2PP801 - PP808 2PP821 - PP827 2PP831 - PP848 2PP851 - PP852 2PP861 - PP877 2PP891 - PP899 2PP901 - PP936 2PP946 - PP948 2PP951 - PP952 2PP961 - PP967 2PP981 - PP991 2PP993 2PQ001 - PQ016 2PQ026 - PQ041 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 18 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 19 GroupVariable Number 2PQ051 - PQ092 2PQ101 - PQ199 2PQ201 - PQ202 2PQ221 - PQ237 2PQ241 - PQ243 2PQ251 - PQ267 2PQ281 - PQ299 2PQ301 - PQ307 2PQ331 - PQ332 2PQ341 - PQ348 2PQ361 - PQ373 2PQ391 - PQ395 2PQ401 - PQ418 2PQ421 2PQ431 - PQ438 2PQ447 - PQ448 2PQ451 2PQ454 2PQ471 - PQ475 2PQ479 - PQ481 2PQ486 - PQ487 2PQ491 - PQ493 2PQ771 - PQ772 2PQ791 - PQ793 2PQ801 - PQ805 2PQ931 - PQ935 2PQ951 2PQ971 - PQ997 2PR001 - PR017 2PR021 - PR034 2PR041 - PR045 2PR061 - PR072 2PR077 - PR082 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 19 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 20 GroupVariable Number 2PR091 - PR092 2PR096 2PR101 2PR121 - PR122 2PR131 - PR132 2PR141 - PR143 2PR161 - PR172 2PR181 2PS601 - PS631 2PS636 - PS638 2PS641 - PS644 2PS651 - PS657 2PS666 - PS669 2PS691 - PS692 2PS701 - PS706 2PS751 - PS799 2PS811 2PS836 - PS837 2PS841 - PS846 2PS851 - PS852 2PS856 2PS861 - PS863 2PS866 - PS868 2PS871 - PS874 2PS896 - PS897 2PS901 - PS941 2PS956 - PS957 2PS961 - PS963 2PS971 - PS978 2PT001 - PT015 2PT021 - PT031 2PT041 - PT064 2PT101 - PT105 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 20 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 21 GroupVariable Number 2PT121 - PT138 2PT146 - PT148 2PT161 - PT170 2PT181 - PT188 2PT211 - PT220 2PT295 2PT301 - PT309 2PT331 - PT360 2PT381 - PT399 2PT401 - PT438 2PT501 - PT517 2PT561 - PT565 2PT581 - PT586 2PT611 - PT621 2PT641 - PT644 2PT651 - PT656 2PT671 - PT672 2PT681 - PT685 2PT701 - PT703 2PT716 - PT717 2PT721 - PT725 2PT801 - PT834 2PT851 - PT854 2PT871 - PT886 2PT901 - PT930 2PT971 - PT973 2PT981 - PT985 2PT996 2PU001 - PU025 2PU301 2PU311 - PU313 3PV001 - PV055 3PV201 - PV209 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 21 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 22 GroupVariable Number 3PV226 - PV229 3PV231 - PV237 3PV271 - PV272 3PV281 - PV287 3PV296 3PV301 - PV302 3PV351 3PV356 - PV357 3PW001 - PW054 3PW061 - PW068 3PW072 3PW086 - PW088 3PW091 - PW094 3PW101 - PW102 3PW106 3PW111 - PW120 3PW156 - PW157 3PW161 - PW171 3PW201 - PW252 3PW261 - PW268 3PW271 - PW276 3PW278 3PW281 - PW293 3PW296 3PW301 - PW327 3PW401 - PW408 3PW411 - PW418 3PW421 - PW424 3PW431 - PW435 3PW441 - PW450 3PW461 - PW467 3PW501 - PW504 3PW511 - PW522 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 22 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 23 GroupVariable Number 3PW524 - PW550 3PW556 - PW557 3PW561 - PW564 3PW571 - PW576 3PW591 - PW596 3PW611 - PW622 3PW631 - PW637 3PW661 - PW662 3PW681 - PW683 3PW701 - PW702 3PW711 - PW717 3PW741 - PW742 3PW761 3PW771 3PW831 3PW851 - PW856 2. Spares Affected None. B. Concurrent Requirements None. C. Reason The cause of the cracks at Body Station (BS) 616 and BS 639 frame sections below Stringer (S-)15 is due to fatigue. This fatigue failure is due to high flight cycle stresses from both pressurization and maneuver load. After the release of the original issue of this service bulletin, there were 25 fleet reports of frame cracking in BS 601 or BS 597 along with stub beam cracking in BS 616 and BS 639. Service Bulletin 737-53-1182 is used to inspect for cracks emanating from the frame inner chord lower end fastener hole located at BS 616 and BS 639. This service bulletin expands upon the inspection area shown in Service Bulletin 737-53-1182 and identifies several new locations for possible cracks. The airplane effectivity for this service bulletin includes all airplanes listed in the effectivity for Service Bulletin 737-53-1182 and additional airplanes that also need to be inspected. This service bulletin supersedes Service Bulletin 737-53-1182. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 23 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 24 Periodic inspections of the body frame from below S-15 to the lower end of the stub beam, frame inner chord lower end fastener holes, frame shear ties, stub beam structure at BS 616, 639 and 597 or 601 and BL 45.5 longitudinal floor beam at BS 639 as given in this service bulletin will detect cracks at an early stage of propagation. The accomplishment of a repair or preventive modification will reduce the possibility of undetected fatigue cracks which could result in severed frames and induce skin cracks at these locations. This could lead to rapid decompression of the fuselage. Boeing Service Related Problem (SRP) 737-SRP-53-0182, 737-SRP-53-0516 and 737-SRP-53-0529 are related to this service bulletin. Boeing Fleet Team Digest (FTD) 737 FTD 53-03003 is related to this service bulletin. Revision 3 is sent to incorporate the contents of Alternative Method of Compliance Notice 737-53A1254-AMOC-03, to add a requirement for Group 1 and Group 2 airplanes to inspect the BL 45.5 longitudinal floor beam web at the BS 639 stub beam attachment, to provide a Structural Repair Manual (SRM) repair of the BL 45.5 longitudinal floor beam web at BS 639 for Group 2 airplanes and to clarify that inspection is required of the frame outer chord where a partial frame replacement is installed at BS 616 and BS 639. This revision also adds an inspection of the BS 616 stub beam upper chord. The data given in Alternative Method of Compliance (AMOC) Notice 737-53A1254-AMOC-03 is included in this revision. Revision 2 was sent to incorporate the contents of 737-53A1254-AMOC-01, 737-53A1254-AMOC-02 and to provide repair information for cases where cracks are found in the integral stub beam. New inspection alternatives were also added for areas obstructed by production structure. The data given in Alternative Method of Compliance Notice 737-53A1254-AMOC-01 was included in Revision 2. The data given in Alternative Method of Compliance Notice 737-53A1254-AMOC-02 was included in Revision 2. Revision 1 was sent to include a partial frame replacement of the lower frame section below S-14 for BS 616 and BS 639, a frame inner chord repair common to the lower two fastener holes at BS 601, BS 616 and BS 639, a preventive modification of the lower end frame inner chord at BS 601, an inspection of the stub beam at BS 616 and 639 for cracking and an inspection at BS 597 for cracking to the frame shear ties. These sections were changed in Revision 1: 1. Summary: The BACKGROUND, ACTION, MANPOWER and MATERIAL INFORMATION sections were updated. 2. Paragraph 1.A., Effectivity: All 737-200C series airplanes were removed from the effectivity. 3. Paragraph 1.C., Reason: Reasons for additional inspections were given. 4. Paragraph 1.D., Description: Information was added for repair to BS 601, BS 616 and BS 639 and preventive modification to BS 601. Information was also added for the shear ties inspection at BS 597, frame inner chord inspection at BS 601, and the stub beam inspection at BS 616 and BS 639. Maintenance zone data was added. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 24 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 25 5. Paragraph 1.E., Compliance: Compliance information was added for BS 616 and BS 639 splice repairs and additional inspections at BS 597 or BS 601. Also compliance information for BS 601 preventive modification and BS 601, BS 616 and BS 639 lower end frame inner chord repair was included. 6. Paragraph 1.G., Manpower: Manpower estimates were revised for inspections to BS 616 and BS 639 frame inner chord, outer chord and web inspection, stub beam inspection, frame inner chord lower section repair, and partial frame replacement. Manpower estimates were also added for BS 601 lower frame inner chord inspection, preventive modification and repair, and BS 597 frame shear ties inspection. 7. Paragraph 1.H., Weight and Balance Changes: New weight and moment changes were added. 8. Paragraph 2.A., Material - Price and Availability: New parts were added. 9. Paragraph 2.C., Parts Necessary For Each Airplane: New parts added in Kits/Parts and Parts and Materials Supplied by the Operator. 10. Paragraph 3.A., General Information: General Information notes were updated. 11. Paragraph 3.B., Work Instructions: Work Instructions were added for inspections to the shear tie clips at BS 597, frame inner chord lower end inspection at BS 601 and frame inner chord, outer chord, web and stub beam inspection at BS 616 and BS 639. Instructions were also added for BS 601 frame inner chord lower end section preventive modification and repair, BS 616 and BS 639 frame inner chord lower end section repair and partial frame replacement. 12. Figures: New Figures 6 to 26 were added to this revision for inspections to the shear tie clips at BS 597, lower end frame inspection, preventive modification and repair at BS 601, BS 616 and BS 639 and a lower splice repair at BS 616 and BS 639. Instructions were also added for the inspection of the stub beam at BS 597, BS 601, BS 616 and BS 639. D. Description The airplane effectivity is divided into 3 groups based on stub beam configuration. Group 1 is 737-200 passenger airplanes, Group 2 is 737-300 and -500 passenger airplanes and Group 3 is 737-400 passenger airplanes. Remove seats, carpets, side panels and floor panels to get access to the overwing stub beams, both sides of the BL 45.5 longitudinal floor beam, and body frames at BS 616, 639, 597 or 601. Do a detailed or High Frequency Eddy Current (HFEC) inspection of the BS 616 and BS 639 frame web, inner chord and outer chord from three fastener rows above S-16 down to the last fastener common to the stub beam joint, and the stub beam assembly from BL 45.5 to the outboard end, for any crack. Group 1-2: Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole common to the stub beam attachment angle, and do a HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fastener head/tail at each fastener location common to the back-up strap. Do a detailed inspection of the frame shear ties at BS 597 for any crack. Group 3: Do a detailed or HFEC inspection of the frame inner chord common to the lowest four fastener holes at BS 601 for any crack. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 25 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 26 Group 2-3: Do a detailed and Medium Frequency Eddy Current (MFEC) subsurface inspection of the BS 616 stub beam upper chord for any crack. Do the detailed, HFEC, and MFEC inspections at the thresholds given in the compliance section of this service bulletin. If no crack is found, repeat the detailed, HFEC, and MFEC inspections at the intervals for the appropriate method as given in the compliance section of this service bulletin. Record the results of all crack inspections on the form in APPENDIX A of this service bulletin. Effects of this Revision on airplanes on which the Original Issue, Revision 1, or Revision 2 was previously done: ActionConditionGroup Additional inspections for any crack to the stub beam at BS 616 and BS 639, any crack to the frame inner chord at BS 601 and any crack at the frame shear tie of BS 597 are necessary. Airplanes on which the original issue was previously done. All None. However, airplanes that have removed and replaced certain stub beam to BL 45.5 longitudinal floor beam attachment angles require additional inspections of the replace- ment attachment angle. Additional fastener inspections and partial frame replacement inspections have also been added. Airplanes on which Revision 1 was previously done. All Inspect the BL 45.5 longitudinal floor beam at BS 639 for any crack. Airplanes on which Revision 2 was previously done. 1 Inspect the BL 45.5 longitudinal floor beam at BS 639 and the BS 616 stub beam upper chord for any crack. Airplanes on which Revision 2 was previously done. 2 Inspect the BS 616 stub beam upper chord for any crack. Airplanes on which Revision 2 was previously done. 3 The work in this service bulletin is done in the maintenance zone(s) given below. Group 1: Affected Maintenance Zones ZoneModel 1-16, 1-17737-200 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 26 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 27 Group 2: Affected Maintenance Zones ZoneModel 116, 117737-300, 737-500 Group 3: Affected Maintenance Zones ZoneModel 116A, 117A737-400 E. Compliance FAA AD 98-11-04 R1, AD 2008-09-13 and AD 2010-25-06 are related to this service bulletin. The effective date of AD 2010-25-06 is February 1, 2011. 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 Compliance Tables 1, 2, 3, 4, 5, and 9 of service bulletin mandatory. Tables 1, 2, 3, 4, 5, and 9 below provide the required inspections to maintain safety of flight. Tables 6 and 7 below provide economic inspections to find any crack prior to causing extensive damage needing a costly repair. Table 8 provides alternate Supplemental Structural Inspection (SSI) F-20 for the area covered by the BS 616 and BS 639 partial frame replacement, and is related to FAA AD 98-11-04 R1 and AD 2008-09-13. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. Accomplish the required actions, based on the applicable conditions in Tables 1 through 9, in accordance with Paragraph 3. Accomplishment Instructions. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 27 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 28 Table 1 - Inspection and Repair of the BS 616 and BS 639 Frames (Web, Inner and Outer Chords) and Stub Beam (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 4,500 flight cycles. (a) Before 56,500 total flight cy- cles. Within 3,000 flight cycles af- ter the effec- tive date of AD 2010-25-06. Option 1 - Do a detailed in- spection of BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.1. Airplanes that have not started inspections as giv- en in the original issue or Revision 1 or Revision 2 of this service bulletin and have accumulated less than 55,000 total flight cy- cles as of the effective date of AD 2010-25-06. 9,000 flight cycles. (a) Before 56,500 total flight cy- cles. Within 3,000 flight cycles af- ter the effec- tive date of AD 2010-25-06. Option 2 - Do a HFEC inspec- tion of the BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.2. 4,500 flight cycles. (a) Within 1,500 flight cycles after the effective date of AD 2010- 25-06. Option 1 - Do a detailed in- spection of BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.1. Airplanes that have not started inspections as giv- en in the original issue or Revision 1 or Revision 2 of this service bulletin and have accumulated 55,000 or more total flight cycles as of the effective date of AD 2010-25-06. 9,000 flight cycles. (a) Within 1,500 flight cycles after the effective date of AD 2010- 25-06. Option 2 - Do a HFEC inspec- tion of the BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 28 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 29 Table 1 - Inspection and Repair of the BS 616 and BS 639 Frames (Web, Inner and Outer Chords) and Stub Beam (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 4,500 flight cycles. (a) Within 4,500 flight cycles from the previous inspection. Option 1 - Do a detailed in- spection of BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.1. Airplanes that have started inspections given in the original issue of this service bulletin. 9,000 flight cycles. (a) Within 4,500 flight cycles from the previous inspection. Option 2 - Do a HFEC inspec- tion of the BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 29 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 30 Table 1 - Inspection and Repair of the BS 616 and BS 639 Frames (Web, Inner and Outer Chords) and Stub Beam (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 4,500 flight cycles. (a) Within 4,500 flight cycles after the last Option 1 inspection. Option 1 - Do a detailed in- spection of BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.1. Airplanes that have started inspections given in Revi- sion 1 or Revision 2 of this service bulletin with the last inspection done being an Option 1 inspection. 9,000 flight cycles. (a) Within 4,500 flight cycles after the last Option 1 inspection. Option 2 - Do a HFEC inspec- tion of the BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.2. 4,500 flight cycles. (a) Within 9,000 flight cycles after the last Option 2 inspection. Option 1 - Do a detailed in- spection of BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.1. Airplanes that have started inspections given in Revi- sion 1 or Revision 2 of this service bulletin with the last inspection done being an Option 2 inspection. 9,000 flight cycles. (a) Within 9,000 flight cycles after the last Option 2 inspection. Option 2 - Do a HFEC inspec- tion of the BS 616 and BS 639 frames (inner chord, outer chord and web) from three fastener rows above S- 16 down to the last fastener common to the stub beam joint, and the stub beam, for any crack in accordance with Accomplishment Instruction 3.B.1.b.2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 30 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 31 Table 1 - Inspection and Repair of the BS 616 and BS 639 Frames (Web, Inner and Outer Chords) and Stub Beam (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Before further flight.Do a detailed inspection of the crease beam inboard chord for any crack and do the applicable repair in accor- dance with Accomplishment Instruction 3.B.4. If any crack is found in the frame not common to either of the two lowest fastener holes in the frame inner chord. -Before further flight.Contact The Boeing Compa- ny for repair instructions and do the repair. If any crack is found at the crease beam inboard chord. -Before further flight.Repair the cracked frame in accordance with Accomplish- ment Instruction 3.B.4 or 3.B.6. If any crack is found in the frame that is only common to either of the two lowest fastener holes in the frame inner chord. -Before further flight.Option 1 - Replace integral stub beams in accordance with Accomplishment Instruc- tion 3.B.8. If any crack is found in an integral stub beam. -Before further flight.Option 2 - Contact The Boe- ing Company for repair in- structions and do the repair. -Before further flight.Contact The Boeing Compa- ny for repair instructions and do the repair. If any crack is found in a built up stub beam. -Before further flight.Replace the stub beam to BL 45.5 longitudinal floor beam attachment tee/angle in ac- cordance with Accomplish- ment Instruction 3.B.9. If any crack is found in a stub beam to BL 45.5 longi- tudinal floor beam attach- ment tee/angle. (a) The inspection requirements for the partial frame replacement accomplished in accordance with Part 4 of this service bulletin are given in Table 2. The inspection requirements for the integral stub beam re- placement accomplished in accordance with Part 8 of this service bulletin are given in Table 2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 31 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 32 Table 2 - Post Repair Inspection of BS 616 and BS 639 Frames (Web, Inner and Outer Chords) and Integral Stub Beam (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 9,000 flight cy- cles. Before 66,000 to- tal flight cy- cles. Within 9,000 flight cycles af- ter the repair has been ac- complished. ACTION 1: Do a LFEC inspection of the web and HFEC inspection of the inner chord and outer chord common to the upper end fastener rows of the web splice doubler for any crack, in accordance with Ac- complishment Instruction 3.B.1.c. Airplanes that have accom- plished a partial frame re- placement at BS 616 or BS 639 in accordance with Accomplishment Instruction 3.B.4 where the inner chord and web holes have been cold-worked. 4,500 flight cy- cles. Within 44,000 flight cycles after the repair has been accomplished. ACTION 2 (OPTION 1): Do a de- tailed inspection of the replace- ment frame section (inner chord, outer chord and web) for any crack in accordance with Accom- plishment Instruction 3.B.1.b.1. 9,000 flight cy- cles. Within 44,000 flight cycles after the repair has been accomplished. ACTION 2 (OPTION 2): Do a HFEC and LFEC inspection of the replacement frame section (inner chord, outer chord and web) for any crack in accordance with Ac- complishment Instruction 3.B.1.b.2. 9,000 flight cy- cles. Before 66,000 to- tal flight cy- cles. Within 9,000 flight cycles af- ter the repair has been ac- complished. ACTION 1: Do a LFEC inspection of the web and HFEC inspection of the inner chord and outer chord common to the upper end fastener rows of the web splice doubler for any crack, in accordance with Ac- complishment Instruction 3.B.1.c. Airplanes that have accom- plished a partial frame re- placement at BS 616 or BS 639 in accordance with Accomplishment Instruction 3.B.4 where the inner chord and web holes have not been cold-worked. 4,500 flight cy- cles. Within 29,000 flight cycles after the repair has been accomplished. ACTION 2 (OPTION 1): Do a de- tailed inspection of the replace- ment frame section (inner chord, outer chord and web) for any crack in accordance with Accom- plishment Instruction 3.B.1.b.1. 9,000 flight cy- cles. Within 29,000 flight cycles after the repair has been accomplished. ACTION 2 (OPTION 2): Do a HFEC and LFEC inspection of the replacement frame section (inner chord, outer chord and web) for any crack in accordance with Ac- complishment Instruction 3.B.1.b.2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 32 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 33 Table 2 - Post Repair Inspection of BS 616 and BS 639 Frames (Web, Inner and Outer Chords) and Integral Stub Beam (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 4,500 flight cy- cles. Within 29,000 flight cycles after the replacement has been accomplished. Option 1 - Do a detailed inspec- tion of the replacement stub beam in accordance with Accomplish- ment Instruction 3.B.1.b.1. Airplanes that have accom- plished the BS 616 or BS 639 Integral Stub Beam Replacement in accor- dance with Accomplish- ment Instruction 3.B.8. 9,000 flight cy-cles.Within 29,000 flight cyclesafter the replacement has been accomplished. Option 2 - Do a HFEC inspection of the replacement stub beam in accordance with Accomplishment Instruction 3.B.1.b.2. -Before further flight.Contact The Boeing Company for repair instructions and do the re- pair. If any crack is found. Group 1: Table 3 - Inspection and Repair of the BL 45.5 Longitudinal Floor Beam Web at BS 639 Stub Beam At- tachment (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Before 18,000 total flight cycles. Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole common to the stub beam at- tachment angle in ac- cordance with Accom- plishment Instruction 3.B.10.b. Airplanes that have not accomplished an open hole HFEC in- spection at each fas- tener hole common to the stub beam at- tachment angle and the BL 45.5 longitudi- nal floor beam web as of the Revision 3 issue date of this service bulletin. AND -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Before 18,000 total flight cycles. Do a HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fas- tener head/tail at each fastener location com- mon to the back-up strap in accordance with Accomplishment Instruction 3.B.10.b. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 33 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 34 Group 1: Table 3 - Inspection and Repair of the BL 45.5 Longitudinal Floor Beam Web at BS 639 Stub Beam At- tachment (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Within 29,000 flight cycles after the previ- ous inspection at each fastener hole common to the stub beam attachment angle and the BL 45.5 longitudinal floor beam web was ac- complished. Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole common to the stub beam at- tachment angle in ac- cordance with Accom- plishment Instruction 3.B.10.b. Airplanes that have accomplished an open hole HFEC in- spection at each fas- tener hole common to the stub beam at- tachment angle and the BL 45.5 longitudi- nal floor beam web as of the Revision 3 issue date of this service bulletin. AND -Within 9,000 flight cycles after the Revision 3 date of this service bulletin. Do a HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fas- tener head/tail at each fastener location com- mon to the back-up strap in accordance with Accomplishment Instruction 3.B.10.b. -Before further flight.Contact The Boeing Company for repair instructions and do the repair. If any crack is found. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 34 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 35 Group 1: Table 3 - Inspection and Repair of the BL 45.5 Longitudinal Floor Beam Web at BS 639 Stub Beam At- tachment (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition 29,000 flight cycles.-Repeat the open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole common to the stub beam at- tachment angle in ac- cordance with Accom- plishment Instruction 3.B.10.b.4.b. If no crack is found. AND 9,000 flight cycles.-Repeat the HFEC sur- face inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fas- tener head/tail at each fastener location com- mon to the back-up strap in accordance with Accomplishment Instruction 3.B.10.b.4.b. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 35 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 36 Group 2: Table 4 - Inspection and Repair of the BL 45.5 Longitudinal Floor Beam Web at BS 639 Stub Beam At- tachment (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Before 18,000 total flight cycles. Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole com- mon to the stub beam attachment angle in accordance with Accomplishment Instruction 3.B.10.b. Airplanes that have not accomplished an open hole HFEC in- spection at each fas- tener hole common to the stub beam at- tachment angle and the BL 45.5 longitudi- nal floor beam web as of the Revision 3 issue date of this service bulletin. AND -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Before 18,000 total flight cycles. Do a HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fastener head/tail at each fastener loca- tion common to the back-up strap in ac- cordance with Accom- plishment Instruction 3.B.10.b. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 36 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 37 Group 2: Table 4 - Inspection and Repair of the BL 45.5 Longitudinal Floor Beam Web at BS 639 Stub Beam At- tachment (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Within 29,000 flight cycles after the previ- ous inspection at each fastener hole common to the stub beam attachment angle and the BL 45.5 longitudinal floor beam web was ac- complished. Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole com- mon to the stub beam attachment angle in accordance with Accomplishment Instruction 3.B.10.b. Airplanes that have accomplished an open hole HFEC in- spection at each fas- tener hole common to the stub beam at- tachment angle and the BL 45.5 longitudi- nal floor beam web as of the Revision 3 issue date of this service bulletin. AND -Within 9,000 flight cycles after the Revision 3 date of this service bulletin. Do a HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fastener head/tail at each fastener loca- tion common to the back-up strap in ac- cordance with Accom- plishment Instruction 3.B.10.b. -Before further flight.Do the SRM repair in accordance with Ac- complishment Instruc- tion 3.B.10.b.1.a. If any crack is found in the BL 45.5 longitu- dinal floor beam web during the HFEC in- spections in accor- dance with Accom- plishment Instruction 3.B.10.b. (a) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 37 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 38 Group 2: Table 4 - Inspection and Repair of the BL 45.5 Longitudinal Floor Beam Web at BS 639 Stub Beam At- tachment (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition 29,000 flight cycles.-Repeat the open hole HFEC inspec- tion for any crack in the BL 45.5 longitudi- nal floor beam web at each fastener hole common to the stub beam attachment angle in accordance with Accomplishment Instruction 3.B.10.b.2.b. If no crack is found in the BL 45.5 longitudi- nal floor beam web during the HFEC in- spection done in ac- cordance with Accom- plishment Instruction 3.B.10.b. AND 9,000 flight cycles.-Repeat the HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web, around the fastener head/tail at each fastener loca- tion common to the back-up strap in ac- cordance with Accom- plishment Instruction 3.B.10.b.2.b. (a) Post SRM repair inspection requirements are given in Table 5. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 38 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 39 Group 2: Table 5 - Post Repair Inspection of the BL 45.5 Longitudinal Floor Beam Web at BS 639 (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Within 29,000 flight cycles after the SRM repair was installed. Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web filler at each fastener hole common to the stub beam attachment angle in accordance with Accomplishment Instruction 3.B.9.c.4.a or 3.B.10.b.1.b. Airplanes that have 737-300 SRM 53-60- 51 Repair 7 or 737- 500 SRM 53-60-51 Repair 7 installed in accordance with Ac- complishment Instruc- tion 3.B.9.c.4 or 3.B.10.b.1.a. AND -Within 9,000 flight cycles after the Revi- sion 3 date of this service bulletin. Within 29,000 flight cycles after the SRM repair was installed. Do a HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web filler, around the fastener head/tail at each fas- tener location com- mon to the back-up strap in accordance with Accomplishment Instruction 3.B.9.c.4.a or 3.B.10.b.1.b. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 39 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 40 Group 2: Table 5 - Post Repair Inspection of the BL 45.5 Longitudinal Floor Beam Web at BS 639 (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance time (Whichever occurs later) ActionCondition 29,000 flight cycles-Repeat the open hole HFEC inspec- tion for any crack in the BL 45.5 longitudi- nal floor beam web filler at each fastener hole common to the stub beam attach- ment angle in accor- dance with Accom- plishment Instruction 3.B.9.c.4.a.1 or 3.B.10.b.1.b.1. If no crack is found during the open hole HFEC inspection and the HFEC surface in- spection in accor- dance with Accom- plishment Instruction 3.B.9.c.4.a or 3.B.10.b.1.b. AND 9,000 flight cycles-Repeat the HFEC surface inspection for any crack in the BL 45.5 longitudinal floor beam web filler, around the fastener head/tail at each fas- tener location com- mon to the back-up strap in accordance with Accomplishment Instruction 3.B.9.c.4.a.1 or 3.B.10.b.1.b.1. -Before further flight.Contact The Boeing Company for the re- pair instructions and do the repair. If any crack is found during the open hole HFEC inspection or the HFEC surface in- spection in accor- dance with Accom- plishment Instruction 3.B.9.c.4.a or 3.B.10.b.1.b. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 40 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 41 Group 3: Table 6 - Inspection and Repair of the BS 601 Lowest Four Fasteners Common to the Inner Chord and Stub Beam Group 3 Airplane (Recommended Economic Inspection) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Before 56,500 total flight cy- cles. Within 3,000 flight cycles from the Revi- sion 1 date of this service bul- letin. Option 1 - Do a detailed inspection of the inner chord common to the lowest four fasteners at BS 601 for any crack in accordance with Accom- plishment Instruction 3.B.2.b.1. Airplanes that have accu- mulated less than 55,000 total flight cycles as of the Revision 1 date of this ser- vice bulletin. -Before 56,500 total flight cy- cles. Within 3,000 flight cycles from the Revi- sion 1 date of this service bul- letin. Option 2 - Do a HFEC surface inspection of the inner chord around the fastener head at the four lowest fastener locations common to the inner chord for any crack in ac- cordance with Accom- plishment Instruction 3.B.2.b.2. -Within 1,500 flight cycles from the Revision 1 date of this service bulletin. Option 1 - Do a detailed inspection of the inner chord common to the lowest four fasteners at BS 601 for any crack in accordance with Accom- plishment Instruction 3.B.2.b.1. Airplanes that have accu- mulated 55,000 or more total flight cycles as of the Revision 1 date of this ser- vice bulletin. -Within 1,500 flight cycles from the Revision 1 date of this service bulletin. Option 2 - Do a HFEC surface inspection of the inner chord around the fastener head at the four lowest fastener locations common to the inner chord for any crack in ac- cordance with Accom- plishment Instruction 3.B.2.b.2. -Before further flight.Repair cracked area in accordance with Accom- plishment Instruction 3.B.6. If any crack is found. 4,500 flight cycles. (a) -Option 1 - Repeat a de- tailed inspection of the inner chord common to If no crack is found. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 41 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 42 Group 3: Table 6 - Inspection and Repair of the BS 601 Lowest Four Fasteners Common to the Inner Chord and Stub Beam Group 3 Airplane (Recommended Economic Inspection) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition (Cont.) --the lowest four fasteners at BS 601 for any crack in accordance with Ac- complishment Instruction 3.B.2.b.1. 9,000 flight cycles. (a) -Option 2 - Repeat a HFEC surface inspection of the inner chord around the fastener head at the four lowest fastener loca- tions common to the inner chord for any crack in ac- cordance with Accom- plishment Instruction 3.B.2.b.2. (a) Accomplishment of the repair or preventive modification as given in this service bulletin terminates the repeat inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 42 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 43 Group 1-2: Table 7 - Inspection of the BS 597 Frame Shear Ties and Stub Beam (Recommended Economic Inspection) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Before 56,500 total flight cy- cles. Within 3,000 flight cycles from the Revi- sion 1 date of this service bul- letin. Do a detailed inspection of the BS 597 shear tie common to the skin for any crack in accordance with Accomplishment In- struction 3.B.3.b. Airplanes that have accu- mulated less than 55,000 total flight cycles as of the Revision 1 date of this ser- vice bulletin. -Within 1,500 flight cycles from the Revision 1 date of this service bulletin. Do a detailed inspection of the BS 597 shear tie common to the skin for any crack in accordance with Accomplishment In- struction 3.B.3.b. Airplanes that have accu- mulated 55,000 or more total flight cycles as of the Revision 1 date of this ser- vice bulletin. -Before further flight.Contact The Boeing Company for repair in- structions and do the re- pair. If any crack is found. 9,000 flight cycles.-Repeat the detailed in- spection of the BS 597 shear tie common to the skin for any crack in ac- cordance with Accom- plishment Instruction 3.B.3.b If no crack is found. Table 8 - Alternate Supplemental Structural Inspection (SSI) F-20 for the Area Covered by the BS 616 and BS 639 Partial Frame Replacement Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -On or before 66,000 total flight cycles. Do a HFEC inspection for any crack in the inner and outer chord common to the repair splice an- gles and strap (inner chord only) between S-14 and S-15 at the heel and toe along the entire length of the repair splices in ac- cordance with Accomplishment Instruction 3.B.7. Airplanes that have accom- plished a partial frame re- placement at BS 616 and/or BS 639 in accor- dance with Accomplish- ment Instruction 3.B.4. (a) -Before further flight.Contact The Boeing Company for repair instructions and do the re- pair. If any crack is found. -If no crack is found. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 43 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 44 Table 8 - Alternate Supplemental Structural Inspection (SSI) F-20 for the Area Covered by the BS 616 and BS 639 Partial Frame Replacement Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 12,000 flight cy- cles. Repeat HFEC inspection for any crack in the inner and outer chord common to the repair splice an- gles and strap (inner chord only) between S-14 and S-15 at the heel and toe along the entire length of the repair splices in ac- cordance with Accomplishment Instruction 3.B.7. (a) (a) This inspection replaces the SSI F-20 where a repair or modification covers the SSI area. Group 2-3: Table 9 - Inspection of the BS 616 Machined Stub Beam Upper Chord (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 9,000 flight cycles af- ter the Revision 3 date of this service bulletin, or within 45,000 flight cycles af- ter the stub beam replace- ment was in- stalled, whichever oc- curs later. Within 4,500 flight cycles af- ter the last de- tailed inspection of the replace- ment BS 616 stub beam was accomplished, or within 9,000 flight cycles af- ter the last HFEC inspec- tion of the re- placement BS 616 stub beam was accom- plished, whichever oc- curs first. Do a detailed inspection and MFEC subsurface inspection of the BS 616 stub beam upper chord for any crack in accor- dance with Accomplish- ment Instruction 3.B.11.b. Airplanes that have a re- placement BS 616 stub beam. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 44 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 45 Group 2-3: Table 9 - Inspection of the BS 616 Machined Stub Beam Upper Chord (Required Minimum for Safety) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 9,000 flight cycles af- ter the Revision 3 date of this service bulletin, or before 45,000 total flight cy- cles, whichever occurs later. Within 4,500 flight cycles af- ter the last de- tailed inspection of the BS 616 stub beam was accomplished, or within 9,000 flight cycles af- ter the last HFEC inspec- tion of the BS 616 stub beam was accom- plished, whichever oc- curs first. Do a detailed inspection and MFEC subsurface inspection of the BS 616 stub beam upper chord for any crack in accor- dance with Accomplish- ment Instruction 3.B.11.b. Airplanes that do not have a replacement BS 616 stub beam. -Before further flight.Do PART 8 - BS 616 and BS 639 INTEGRAL STUB BEAM REPLACEMENT or contact The Boeing Company for repair in- structions and do the re- pair. (a) If any crack is found. 9,000 flight cycles.-Repeat detailed inspec- tion and MFEC subsur- face inspection of the BS 616 stub beam upper chord for any crack in ac- cordance with Accom- plishment Instruction 3.B.11.b. If no crack is found. (a) The inspection requirements for the integral stub beam replacement accomplished in accordance with PART 8 of this service bulletin are given in Table 2. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 45 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 46 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. Operators must revise their FAA-approved maintenance program to comply with paragraph (g) of Airworthiness Directive (AD) AD 98-11-04 R1 when incorporating the changes specified in this service bulletin. The Manager of the FAA Los Angeles Aircraft Certification Office approves the inspections accomplished per Part 7 of this service bulletin as a method of compliance (MOC) to paragraph (g) of AD 98-11-04 R1 for the inspection of Structurally Significant Item F-20 of Supplemental Structural Inspection Document, D6-37089 affected by the repair and/or modification. This MOC only applies to the areas inspected per Part 7 of this service bulletin and to those airplanes identified in this service bulletin. All provisions of AD 98-11-04 R1 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. The Manager of the FAA Los Angeles Aircraft Certification Office approves the incorporation and accomplishment of the inspections per Part 7 of this service bulletin as an alternative method of compliance (AMOC) for the incorporation and inspection of Structurally Significant item F-20 of Supplemental Structural Inspection Document, D6-82669, affected by the repair and/or modification, as required by paragraph (g) and (h) of AD 2008-09-13. This AMOC only applies to the areas inspected per Part 7 of this service bulletin and to those airplanes identified in this service bulletin. All provisions of AD 2008-09-13 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. The Manager of the FAA Los Angeles Aircraft Certification Office approves the accomplishment of Part 1 of the Accomplishment Instructions of this service bulletin as an alternative method of compliance to the accomplishment of Part 1 of the Accomplishment Instructions of Revision 1 of Service Bulletin 737-53A1254 as required by paragraphs (g), (h) and (i) of AD 2010-25-06. All provisions of AD 2010-25-06 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the accomplishment of Part 4 of the Accomplishment Instructions of this service bulletin as an alternative method of compliance to the accomplishment of Part 4 of the Accomplishment Instructions of Revision 1 of Service Bulletin 737-53A1254 as required by paragraphs (h) and (l) of AD 2010-25-06. All provisions of AD 2010-25-06 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 the task-hours necessary to do this service bulletin for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 46 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 47 Table 1: BS 616 and BS 639 Lower Frame Section and Stub Beam - Inspection Elapsed HoursTask-HoursNumber of PersonsTask 5.0010.002Open Access 7.2514.502Inspect 5.0010.002Close Access 17.2534.50TOTAL FOR EACH AIRPLANE Table 2: BS 616 and BS 639 Lower Section Splice - Replacement Elapsed HoursTask-HoursNumber of PersonsTask 5.0010.002Open Access 14.0056.004Repair Lower Frame Section 5.0010.002Close Access 24.0076.00TOTAL FOR EACH AIRPLANE Table 3: BS 601 Lower End Frame Inner Chord - Inspection Elapsed HoursTask-HoursNumber of PersonsTask 2.505.002Open Access 0.250.251Inspect 2.505.002Close Access 5.2510.25TOTAL FOR EACH AIRPLANE Table 4: BS 601 Lower End Frame Inner Chord - Preventive Modification Elapsed HoursTask-HoursNumber of PersonsTask 2.505.002Open Access 2.50 (a)5.00 (a)2Install Preventive Modification 2.505.002Close Access 7.5015.00TOTAL FOR EACH AIRPLANE (a) Estimate does not include time to manufacture part Table 5: BS 601 , BS 616 or BS 639 Lower End Frame Inner Chord - Repair Elapsed HoursTask-HoursNumber of PersonsTask 5.0010.002Open Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 47 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 48 Table 5: BS 601 , BS 616 or BS 639 Lower End Frame Inner Chord - Repair Elapsed HoursTask-HoursNumber of PersonsTask 5.25 (a)21.00 (a)4Repair Lower End Frame Inner Chord 5.0010.002Close Access 15.2541.00TOTAL FOR EACH AIRPLANE (a) Estimate does not include time to manufacture part Table 6: BS 597 Frame Shear Ties - Inspection Elapsed HoursTask-HoursNumber of PersonsTask 2.505.002Open Access 1.501.501Inspect 2.505.002Close Access 6.5011.50TOTAL FOR EACH AIRPLANE Table 7: BS 616 or BS 639 Integral Stub Beam - Replacement Elapsed HoursTask HoursNumber of PersonsTask 8.0032.004Open Access 8.0032.004Remove Stub Beam 10.0040.004Replace Stub Beam 4.0016.004Rig Cables and Test 8.0032.004Close Access 38.00152.00TOTAL FOR REPLACEMENT Table 8: BL 45.5 Longitudinal Floor Beam Web at BS 639 - Inspection Elapsed HoursTask HoursNumber of PersonsTask 5.0010.002Open Access 2.002.001Open Hole HFEC In- spection 1.501.501HFEC Surface In- spection 5.0010.002Close Access 13.5023.50TOTAL FOR EACH AIRPLANE Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 48 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 49 Table 9: BS 616 Stub Beam Upper Chord - Inspection Elapsed HoursTask HoursNumber of PersonsTask 8.0032.004Open Access 1.001.001Detailed Inspection 2.002.001HFEC Surface In- spection 8.0032.004Close Access 19.0067.00TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplanes +470+0.75Partial Frame Replacement Group 1: Figures 11 and 14 Group 2: Figures 12 and 15 Group 3: Figures 13 and 16 +150+0.25Preventive Modification Groups 3: Figure 17 +300+0.50Frame Inner Chord Repair Group 1: Figure 18 Group 2: Figure 19 +300+0.50Frame Inner Chord Repair Group 3: Figure 20 I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 35005-281RS b. Boeing Service Related Problem (SRP) 737-SRP-53-0182, 737-SRP-53-0516, 737-SRP-53-0529 c. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2008-09-13, 2010-25-06, 98-11-04 R1 d. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-42-05, 20-43-03 e. 737 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Part 6, 51-00-26, Part 6, 53-30-00 f. 737-100/200 Aircraft Maintenance Manual (AMM) 25-21-0, 25-22-0, 25-27-100, 53-21-0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 49 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 50 g. 737-100/200 Structural Repair Manual (SRM) 51-10-2, 51-30-09, 53-10-03 h. 737-300/400/500 Aircraft Maintenance Manual (AMM) 25-21-01, 25-22-00, 25-27-15, 53-21-00 i. 737-300 Structural Repair Manual (SRM) 51-20-01, 51-40-09, 53-00-03, 53-60-51 j. 737-400 Structural Repair Manual (SRM) 51-20-01, 51-40-09, 53-00-03 k. 737-500 Structural Repair Manual (SRM) 51-20-01, 51-40-09, 53-00-03, 53-60-51 l. Boeing Service Bulletin 737-53-1182, 737-53A1254 m. Boeing Service Letter 737-SL-51-042 n. 737 Fleet Team Digest (FTD) 53-03003 2. Data Supplied with this Service Bulletin: a. Drawings: ADCNDCN/REVSheetTitleDrawing No -G1FRAME INSTL-EMERGENCY ESCAPE HATCH, BODY STA 616 65-46539 -J2 -M3 -B5 --6 -AVPL -B1STUB BEAM - WING CENTER SECTION, STA 616 65C25723 -EPL -A1Kit Installation - Web and Chord Repair - Body Station 616 65C38794 -A2 -A3 -APSDLKit Installation - Web and Chord Repair - Body Station 616 65C38794#DL -AKPLKit Installation - Web and Chord Repair - Body Station 616 65C38794-1 -AKPLKit Installation - Web and Chord Repair - Body Station 616 65C38794-2 -AKPLKit Installation - Web and Chord Repair - Body Station 616 65C38794-3 -AKPLKit Installation - Web and Chord Repair - Body Station 616 65C38794-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 50 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 51 ADCNDCN/REVSheetTitleDrawing No -AKPLKit Installation - Web and Chord Repair - Body Station 616 65C38794-5 -AKPLKit Installation - Web and Chord Repair - Body Station 616 65C38794-6 -B1Kit Installation - Web and Chord Repair - Body Station 639 65C38795 -A2 -BPSDLKit Installation - Web and Chord Repair - Body Station 639 65C38795#DL -BKPLKit Installation - Web and Chord Repair - Body Station 639 65C38795-1 -BKPLKit Installation - Web and Chord Repair - Body Station 639 65C38795-2 -BKPLKit Installation - Web and Chord Repair - Body Station 639 65C38795-3 -BKPLKit Installation - Web and Chord Repair - Body Station 639 65C38795-4 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Frame Installation - Emergency Escape Hatch, Body Station 61665-46539 Frame Installation - Emergency Escape Hatch, Body Station 63965-46540 Frame Installation - Emergency Escape Hatch, Body Station 60165C32394 Frame Installation - Body Station 59765-46538 Crease Beam Instl - Floor Station 540-663.7565-47973 Floor Beam Instl - Wing Center Section65-45410 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: None. 2. Damage Tolerance Based Structural Inspections: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 51 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 52 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 and new DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. M. Software Accomplishment Summary Not affected. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 52 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 53 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. 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 thru AUG 31/17 ROLT (Weeks) QTYDateNameKit Number $7,308.00771009/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 616 65C38794-1 $7,308.00771009/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 616 65C38794-2 $8,698.00771009/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 616 65C38794-3 $8,698.00771009/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 616 65C38794-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 53 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 54 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 thru AUG 31/17 ROLT (Weeks) QTYDateNameKit Number $7,126.00772509/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 616 65C38794-5 772509/16/10 $7,126.00772509/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 616 65C38794-6 772509/16/10 $18,393.00562509/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 639 65C38795-1 562509/16/10 562509/30/10 562510/14/10 56410/28/10 $18,393.00562509/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 639 65C38795-2 562509/16/10 562509/30/10 562510/14/10 56410/28/10 $15,904.00561909/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 639 65C38795-3 $15,904.00561909/01/10Kit Installation - Web and Chord Repair, Body Sta- tion 639 65C38795-4 $723.0084-AvailableKit - Fastener, Body Sta- tion 616 and 639 Frame Chord 65C37793-4 $550.0084-AvailableKit - Fastener, Body Sta- tion 616 and 639 Frame Chord 65C37793-5 $434.0084-AvailableKit - Fastener, Body Sta- tion 616 and 639 Frame Chord 65C37793-6 $159.0072-AvailableFastener Kit - Inner Chord Preventive Modifi- cation/Repair Body Sta- tion 601 65C37793-10 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 54 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 55 Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. B. Industry Support Information Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One repair kit is needed for the Body Station (BS) 616 or BS 639 partial frame replacement along with the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, for each side of the airplane. One fastener kit is needed for the BS 616 and 639 Inner Chord repair along with the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, for each airplane. One fastener kit is needed for the BS 601 Inner Chord repair along with the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, for each airplane. KIT APPLICABILITY TABLE NotesDescriptionQTYKit NumberGroup (a)Web and Chord Repair, Body Station 616, Left Side. 165C38794-11 (a)Web and Chord Repair, Body Station 616, Right Side 165C38794-2 (a)Web and Chord Repair, Body Station 639, Left Side 165C38795-1 (a)Web and Chord Repair, Body Station 639, Right Side 165C38795-2 -Fastener Kit - Inner Chord Repair, Body Station 616 and 639 165C37793-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 55 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 56 KIT APPLICABILITY TABLE NotesDescriptionQTYKit NumberGroup (a)Web and Chord Repair, Body Station 616, Left Side 165C38794-52 (a)Web and Chord Repair, Body Station 616, Right Side 165C38794-6 (a)Web and Chord Repair, Body Station 639, Left Side 165C38795-1 (a)Web and Chord Repair, Body Station 639, Right Side 165C38795-2 -Fastener Kit - Inner Chord Repair, BS 616 and BS 639 165C37793-5 (a)Web and Chord Repair, Body Station 616, Left Side 165C38794-33 (a)Web and Chord Repair, Body Station 616, Right Side 165C38794-4 (a)Web and Chord Repair, Body Station 639, Left Side 165C38795-3 (a)Web and Chord Repair, Body Station 639, Right Side 165C38795-4 -Fastener Kit - Inner Chord Repair, Body Station 616 and 639 165C37793-6 -Fastener Kit - Inner Chord Preventive Modification/Re- pair Body Station 601 165C37793-10 (a) See kit drawing sheet KPL and PSDL for a detail list of parts contained in the kit. Kit 65C37793 NotesExisting Part Number NameQTYNew Part Number -6-5-4 --KIT - FASTENER, STA 616 AND 639 FRAME CHORD ..-65C37793-4 --KIT - FASTENER, STA 616 AND 639 FRAME CHORD .-.65C37793-5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 56 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 57 Kit 65C37793 NotesExisting Part Number NameQTYNew Part Number -6-5-4 --KIT - FASTENER, STA 616 AND 639 FRAME CHORD -..65C37793-6 (a)(b)-BOLT, PROTRUD- ING HD 121212BACB30FM6A6 (a)(b)-BOLT44.BACB30FP10A6 (a)(b)-BOLT648BACB30FP10A8 (a)(b)-BOLT.46BACB30FP8A5 (a)(b)-BOLT.816BACB30FP8A6 (a)(b)-BOLT1812.BACB30FP8A7 (a)(b)-BOLT624BACB30FP8A8 (a)(b)-BOLT O/S..4BACB30MC10A6 (a)(b)-BOLT.24BACB30MC8A6 (a)(b)-BOLT84.BACB30MC8A7 (a)(b)-BOLT.24BACB30MC8A8 (a)-COLLAR..4BACC30BH10 (BACC30X10 op- tional) (a)-COLLAR888BACC30BH8 (BACC30X8 option- al) (a)-COLLAR1088BACC30M10 (a)-COLLAR121212BACC30M6 (a)-COLLAR242626BACC30M8 (a) Discard the existing part. (b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 57 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 58 Kit 65C37793 NotesExisting Part Number NameQTYNew Part Number -10 --FASTENER KIT - INNER CHORD PREVENTIVE MODIFICA- TION/REPAIR, BODY STATION 601. -65C37793-10 (a)(b)-BOLT4BACB30MC8A7 (a)(b)-BOLT, PROTRUD- ING HD 2BACB30MY10K6X (a)(b)-HI-LOK PROT HEAD 6BACB30MY6K6 (a)(b)-BOLT, PROTRUD- ING HD 8BACB30MY8K6X (a)-COLLAR4BACC30BH8 (a)-COLLAR2BACC30M10 (a)-COLLAR6BACC30M6 (a)-COLLAR8BACC30M8 (a) Discard the existing part. (b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65-88700 are used to determine the part numbers used as substitutes. 2. Parts and Materials Supplied by the Operator: NotesNameQTYPart Number / Specifica- tion (a)(b)Stiffening Angle2Stock 0.063 x 2.4 x 5.5 15- 5PH CRES sheet (c)Filler2Stock 0.100 x 1.2 x 1.8 7075-T6 clad aluminum sheet (d)Tapered Shim2Stock 0.063 x 1.5 x 4.0 7075-T6 clad aluminum sheet Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 58 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 59 NotesNameQTYPart Number / Specifica- tion (e)SealantAs Re- quired BMS 5-95, Class B - 1/2, - 2 or -4 (f)Chemical Conversion CoatingAs Re- quired Type 2, Class A (e)PrimerAs Re- quired BMS 10-11, Type I (e)White EnamelAs Re- quired BMS 10-11, Type II (a) After forming in accordance with FIGURE 22, Heat treat to 150 - 170 ksi and cadmium plate. (b) 17-4PH CRES sheet is optional to 15-5PH CRES sheet. (c) Only required for repairs. (d) Shim only required when 0.01 - 0.06 inch gap can be measured between the frame web and frame inner chord web after you remove fasteners shown in Figures 4 thru 9. (e) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (f) Refer to SOPM 20-43-03. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability The 737 Structural Repair Manual (SRM) 737-100/200 SRM 51-30-09, 737-300 SRM 51-40-09, 737-400 SRM 51-40-09 and 737-500 SRM 51-40-09 gives data about cold working tools and sleeves necessary to do the work given in this service bulletin. These tools are available from industry sources. Engineering, service, and a kit of cold working tools made for this change are available from Fatigue Technology, Inc. or West Coast Industries, Inc. • Refer To: FTI Kit Number: FTI-737-53-1254-1 Fatigue Technology, Inc. P.O. Box C-88388 Seattle, WA 98188 USA Phone Number (206) 246-2010 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 59 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT ### Page 60 Fax (206) 244-9886 • Refer To: WCI Kit Number: WCI-737-53-1254 West Coast Industries, Inc. 14900 Whitman Avenue North Seattle, WA 98133-6532 USA Phone Number (206) 365-7513 Fax (206) 365-7483 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: February 17, 2005 737-53A1254Revision 3: November 13, 2017 60 of 192 BOEING SERVICE BULLETIN 737-53A1254 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/737-53a1254/file/fd092c5587b4.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.