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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1261 Original Issue: January 19, 2006 Revision 1: January 30, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Upper Frame To Side Frame Splice - Inspection, Repair and Modification 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 © 2006 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Unpublished Work.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: January 19, 2006 737-53A1261Revision 1: January 30, 2015 1 of 622
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 2 of 622 BOEING SERVICE BULLETIN 737-53A1261
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BLANK PAGE
Table of Contents Revision Transmittal Sheet ........................................... 1 1 Summary ..................................................... 1 5
1. PLANNING INFORMATION ........................................ 2 1 A. Effectivity ............................................... 2 1
1. Airplanes ............................................ 2 1
2. Spares Affected ........................................ 4 6 B. Concurrent Requirements ...................................... 4 6 C. Reason ................................................ 4 6 D. Description .............................................. 4 7 E. Compliance .............................................. 5 0 F. Approval ............................................... 7 1 G. Manpower .............................................. 7 2 H. Weight and Balance Changes .................................... 7 4 I. Electrical Load Data ......................................... 7 6 J. References .............................................. 7 6
1. Existing Data: ......................................... 7 6
2. Data Supplied with this Service Bulletin: ........................... 7 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 7 7 K. Publications Affected ........................................ 7 8 L. Interchangeability and Intermixability of Parts ........................... 7 8 M. Software Accomplishment Summary ................................ 7 8
2. MATERIAL INFORMATION ........................................ 7 9 A. Material - Price and Availability ................................... 7 9 B. Industry Support Information .................................... 7 9 C. Parts Necessary for Each Airplane ................................. 7 9
1. Kits/Parts: ........................................... 7 9
2. Parts and Materials Supplied by the Operator: ........................ 7 9
3. Parts Modified and Reidentified: ............................... 8 3
4. Parts Removed and Not Replaced: .............................. 8 3 D. Parts Necessary to Change Spares ................................. 8 3 E. Special Tooling - Price and Availability ............................... 8 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 8 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 8 5 A. GENERAL INFORMATION ..................................... 8 5 B. WORK INSTRUCTIONS ....................................... 8 6 FIGURE 1: LEFT SIDE - FRAME SPLICE LOCATIONS [Group 1-2] .................. 1 4 0 FIGURE 2: RIGHT SIDE - FRAME SPLICE LOCATIONS [Group 1-2] ................. 1 4 1 FIGURE 3: LEFT SIDE - FRAME SPLICE LOCATIONS [Group 3-6] .................. 1 4 2 FIGURE 4: RIGHT SIDE - FRAME SPLICE LOCATIONS [Group 3-6] ................. 1 4 3 FIGURE 5: LEFT SIDE - FRAME SPLICE LOCATIONS [Group 7-8] .................. 1 4 4 FIGURE 6: RIGHT SIDE - FRAME SPLICE LOCATIONS [Group 7-8] ................. 1 4 5 FIGURE 7: LEFT SIDE - FRAME SPLICE LOCATIONS [Group 9] ................... 1 4 6 FIGURE 8: RIGHT SIDE - FRAME SPLICE LOCATIONS [Group 9] .................. 1 4 7 FIGURE 9: LEFT SIDE - FRAME SPLICE LOCATIONS [Group 10] .................. 1 4 8 FIGURE 10: RIGHT SIDE - FRAME SPLICE LOCATIONS [Group 10] ................. 1 4 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 3 of 622 BOEING SERVICE BULLETIN 737-53A1261
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FIGURE 11: LEFT SIDE - FRAME SPLICE LOCATIONS [Group 11] .................. 1 5 0 FIGURE 12: RIGHT SIDE - FRAME SPLICE LOCATIONS [Group 11] ................. 1 5 1 FIGURE 13: UPPER FRAME TO SIDE FRAME SPLICE, LEFT SIDE - INSPECTION [Group 1, Configuration 1, 4; Group 2, Configuration 1, 4; Group 3, Configuration 1, 4; Group 4, Configuration 1, 4; Group 5, Configuration 1, 4; Group 6, Configuration 1, 4; Group 7, Configuration 1, 4; Group 8, Configuration 1, 4; Group 9, Configuration 1, 4; Group 10, Configuration 1, 4; Group 11, Configuration 1, 4] ....................................... 1 5 2 FIGURE 14: UPPER FRAME TO SIDE FRAME SPLICE, LEFT SIDE - INSPECTION [Group 1, Configuration 3, 5; Group 2, Configuration 3, 5; Group 3, Configuration 3, 5; Group 4, Configuration 3, 6; Group 5, Configuration 3, 6; Group 6, Configuration 3, 6; Group 7, Configuration 3, 5; Group 8, Configuration 3, 6; Group 9, Configuration 3, 6; Group 10, Configuration 3, 6; Group 11, Configuration 3, 6] ....................................... 1 5 4 FIGURE 15: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE - INSPECTION [Group 1, Configuration 1, 4; Group 2, Configuration 1, 4; Group 3, Configuration 1, 4; Group 4, Configuration 1, 4; Group 5, Configuration 1, 4; Group 6, Configuration 1, 4; Group 7, Configuration 1, 4; Group 8, Configuration 1, 4; Group 9, Configuration 1, 4; Group 10, Configuration 1, 4; Group 11, Configuration 1, 4] ....................................... 1 5 6 FIGURE 16: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE - INSPECTION [Group 1, Configuration 3, 5; Group 2, Configuration 3, 5; Group 3, Configuration 3, 5; Group 4, Configuration 3, 6; Group 5, Configuration 3, 6; Group 6, Configuration 3, 6; Group 7, Configuration 3, 5; Group 8, Configuration 3, 6; Group 9, Configuration 3, 6; Group 10, Configuration 3, 6; Group 11, Configuration 3, 6] ....................................... 1 5 8 FIGURE 17: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD TRIM, LEFT SIDE [Group 4, Configuration 3, 6; Group 5, Configuration 3, 6; Group 6, Configuration 3, 6; Group 8, Configuration 3, 6; Group 9, Configuration 3, 6; Group 10, Configuration 3, 6; Group 11, Configuration 3, 6] ....................................... 1 6 0 FIGURE 18: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD TRIM, RIGHT SIDE [Group 4, Configuration 3, 6; Group 5, Configuration 3, 6; Group 6, Configuration 3, 6; Group 8, Configuration 3, 6; Group 9, Configuration 3, 6; Group 10, Configuration 3, 6; Group 11, Configuration 3, 6] ....................................... 1 6 3 FIGURE 19: RADIUS FILLER - FABRICATION .............................. 1 6 6 FIGURE 20: UPPER FRAME TO SIDE FRAME SPLICE, SECTION OF UPPER FRAME, LEFT SIDE SHEAR TIE FRAMES - REMOVAL .................................. 1 6 7 FIGURE 21: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT FRAME SECTION AND REPAIR ANGLES, LEFT SIDE SHEAR TIE FRAMES - FABRICATION ............... 1 7 2 FIGURE 22: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, LEFT SIDE SHEAR TIE FRAMES - INSTALLATION ........................................ 1 7 6 FIGURE 23: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, LEFT SIDE SHEAR TIE FRAMES - FASTENERS (RIVETS) INSTALLATION .......................... 1 8 0 FIGURE 24: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, LEFT SIDE SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION .......................... 1 8 5 FIGURE 25: UPPER FRAME TO SIDE FRAME SPLICE, SECTION OF UPPER FRAME, RIGHT SIDE SHEAR TIE FRAMES - REMOVAL .................................. 1 9 0 FIGURE 26: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT FRAME SECTION AND REPAIR ANGLES, RIGHT SIDE SHEAR TIE FRAMES - FABRICATION .............. 1 9 5 FIGURE 27: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, RIGHT SIDE SHEAR TIE FRAMES - INSTALLATION ........................................ 1 9 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 4 of 622 BOEING SERVICE BULLETIN 737-53A1261
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FIGURE 28: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, RIGHT SIDE SHEAR TIE FRAMES - FASTENERS (RIVETS) INSTALLATION .......................... 2 0 3 FIGURE 29: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, RIGHT SIDE SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION .......................... 2 0 8 FIGURE 30: UPPER FRAME TO SIDE FRAME SPLICE, SECTION OF UPPER FRAME, LEFT SIDE NON SHEAR TIE FRAMES - REMOVAL ............................. 2 1 3 FIGURE 31: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT FRAME SECTION AND REPAIR ANGLES, LEFT SIDE NON SHEAR TIE FRAMES - FABRICATION ........... 2 1 8 FIGURE 32: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, LEFT SIDE NON SHEAR TIE FRAMES
- INSTALLATION ....................................... 2 2 2 FIGURE 33: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, LEFT SIDE NON SHEAR TIE FRAMES
- FASTENERS (RIVETS) INSTALLATION .......................... 2 2 6 FIGURE 34: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, LEFT SIDE NON SHEAR TIE FRAMES
- FASTENERS (HI-LOKS) INSTALLATION ......................... 2 3 0 FIGURE 35: UPPER FRAME TO SIDE FRAME SPLICE, SECTION OF UPPER FRAME, RIGHT SIDE NON SHEAR TIE FRAMES - REMOVAL ............................. 2 3 5 FIGURE 36: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT FRAME SECTION AND REPAIR ANGLES, RIGHT SIDE NON SHEAR TIE FRAMES - FABRICATION ........... 2 4 0 FIGURE 37: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, RIGHT SIDE NON SHEAR TIE FRAMES
- INSTALLATION ....................................... 2 4 4 FIGURE 38: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, RIGHT SIDE NON SHEAR TIE FRAMES
- FASTENERS (RIVETS) INSTALLATION .......................... 2 4 8 FIGURE 39: UPPER FRAME TO SIDE FRAME SPLICE, REPLACEMENT SECTION OF UPPER FRAME,
INNER REPAIR ANGLE AND OUTER REPAIR ANGLE, RIGHT SIDE NON SHEAR TIE FRAMES
- FASTENERS (HI-LOKS) INSTALLATION ......................... 2 5 2 FIGURE 40: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, LEFT SIDE SHEAR TIE FRAMES - INSPECTION ........................... 2 5 7 FIGURE 41: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, LEFT SIDE SHEAR TIE FRAMES - INSPECTION ........................... 2 5 9 FIGURE 42: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, RIGHT SIDE SHEAR TIE FRAMES - INSPECTION ........................... 2 6 1 FIGURE 43: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, RIGHT SIDE SHEAR TIE FRAMES - INSPECTION ............................ 2 6 3 FIGURE 44: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE SHEAR TIE FRAMES - FABRICATION .................................. 2 6 5 FIGURE 45: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE SHEAR TIE FRAMES - FASTENERS (RIVETS) INSTALLATION .................... 2 6 8 FIGURE 46: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................... 2 7 2 FIGURE 47: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE SHEAR TIE FRAMES - FABRICATION ................................ 2 7 7 FIGURE 48: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE SHEAR TIE FRAMES - FASTENERS (RIVETS) INSTALLATION .................. 2 8 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 5 of 622 BOEING SERVICE BULLETIN 737-53A1261
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FIGURE 49: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................. 2 8 4 FIGURE 50: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, LEFT SIDE NON SHEAR TIE FRAMES - INSPECTION ......................... 2 8 9 FIGURE 51: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, LEFT SIDE NON SHEAR TIE FRAMES - INSPECTION ......................... 2 9 1 FIGURE 52: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, RIGHT SIDE NON SHEAR TIE FRAMES - INSPECTION ......................... 2 9 3 FIGURE 53: UPPER FRAME TO SIDE FRAME SPLICE, FAIL SAFE CHORD FASTENERS, RIGHT SIDE NON SHEAR TIE FRAMES - INSPECTION ......................... 2 9 5 FIGURE 54: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE NON SHEAR TIE FRAMES - FABRICATION ................................ 2 9 7 FIGURE 55: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE NON SHEAR TIE FRAMES - FASTENERS (RIVETS) INSTALLATION .................. 2 9 9 FIGURE 56: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE NON SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................. 3 0 4 FIGURE 57: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE NON SHEAR TIE FRAMES - FABRICATION ................................ 3 0 9 FIGURE 58: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE NON SHEAR TIE FRAMES - FASTENERS (RIVETS) INSTALLATION .................. 3 1 1 FIGURE 59: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE NON SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................. 3 1 6 FIGURE 60: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................... 3 2 1 FIGURE 61: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................. 3 2 6 FIGURE 62: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE NON SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................. 3 3 1 FIGURE 63: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE NON SHEAR TIE FRAMES - FASTENERS (HI-LOKS) INSTALLATION ................. 3 3 6 FIGURE 64: UPPER FRAME TO SIDE FRAME SPLICE AT SB 737-53-1125 FRAME REPAIR, LEFT SIDE SHEAR TIE FRAMES - POST-REPAIR INSPECTION ................... 3 4 1 FIGURE 65: UPPER FRAME TO SIDE FRAME SPLICE AT SB 737-53-1125 FRAME REPAIR, RIGHT SIDE SHEAR TIE FRAMES - POST-REPAIR INSPECTION ................... 3 4 3 FIGURE 66: UPPER FRAME TO SIDE FRAME SPLICE AT SB 737-53-1125 FRAME REPAIR, LEFT SIDE NON SHEAR TIE FRAMES - POST-REPAIR INSPECTION ................ 3 4 5 FIGURE 67: UPPER FRAME TO SIDE FRAME SPLICE AT SB 737-53-1125 FRAME REPAIR, RIGHT SIDE NON SHEAR TIE FRAMES - POST-REPAIR INSPECTION ................ 3 4 7 FIGURE 68: UPPER FRAME TO SIDE FRAME SPLICE, LEFT SIDE, STATION 360 - INSPECTION . 349 FIGURE 69: UPPER FRAME TO SIDE FRAME SPLICE, LEFT SIDE, STATION 360 - INSPECTION . 352 FIGURE 70: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE, STATION 360 - INSPECTION . 355 FIGURE 71: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE, STATION 360 - INSPECTION . 357 FIGURE 72: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE AND INTERCOSTAL CLIP, LEFT SIDE, STATION 360 - FABRICATION ..................... 3 5 9 FIGURE 73: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE AND INTERCOSTAL CLIP, LEFT SIDE, STATION 360 - FASTENERS (RIVETS) INSTALLATION ....... 3 6 3 FIGURE 74: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE AND INTERCOSTAL CLIP, LEFT SIDE, STATION 360 - FASTENERS (HI-LOKS) INSTALLATION ...... 3 6 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 6 of 622 BOEING SERVICE BULLETIN 737-53A1261
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FIGURE 75: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, STATION 360 - FABRICATION ..................................... 3 7 3 FIGURE 76: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, STATION 360 - FASTENERS (RIVETS) INSTALLATION ....................... 3 7 6 FIGURE 77: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, STATION 360 - FASTENERS (HI-LOKS) INSTALLATION ....................... 3 8 0 FIGURE 78: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE, CARGO DOORWAY FRAME- INSPECTION ......................................... 3 8 5 FIGURE 79: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE, CARGO DOORWAY FRAME- INSPECTION ......................................... 3 8 7 FIGURE 80: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, CARGO DOORWAY FRAME- FABRICATION ............................ 3 8 9 FIGURE 81: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, CARGO DOORWAY FRAME- FASTENERS (RIVETS) INSTALLATION .............. 3 9 2 FIGURE 82: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, CARGO DOORWAY FRAME - FASTENERS (HI-LOKS) INSTALLATION ............. 3 9 6 FIGURE 83: UPPER FRAME TO SIDE FRAME SPLICE, LEFT SIDE, OVERWING FRAME - INSPECTION ................................................. 4 0 1 FIGURE 84: UPPER FRAME TO SIDE FRAME SPLICE, LEFT SIDE, OVERWING FRAME- INSPECTION ................................................. 4 0 3 FIGURE 85: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE, OVERWING FRAME - INSPECTION ................................................. 4 0 5 FIGURE 86: UPPER FRAME TO SIDE FRAME SPLICE, RIGHT SIDE, OVERWING FRAME - INSPECTION ................................................. 4 0 7 FIGURE 87: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE, OVERWING FRAME - FABRICATION ................................... 4 0 9 FIGURE 88: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE, OVERWING FRAME - FASTENERS (RIVETS) INSTALLATION ..................... 4 1 2 FIGURE 89: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE, OVERWING FRAME - FASTENERS (HI-LOKS) INSTALLATION .................... 4 1 6 FIGURE 90: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, OVERWING FRAME - FABRICATION ................................... 4 2 1 FIGURE 91: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, OVERWING FRAME - FASTENERS (RIVETS) INSTALLATION ..................... 4 2 4 FIGURE 92: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, OVERWING FRAME - FASTENERS (HI-LOKS) INSTALLATION .................... 4 2 8 FIGURE 93: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE AND INTERCOSTAL CLIP, LEFT SIDE, STATION 360 - FASTENERS (HI-LOKS) INSTALLATION ...... 4 3 3 FIGURE 94: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE AND INTERCOSTAL CLIP, RIGHT SIDE, STATION 360 - FASTENERS (HI-LOKS) INSTALLATION ...... 4 3 8 FIGURE 95: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, CARGO DOORWAY FRAME- FASTENERS (HI-LOKS) INSTALLATION .............. 4 4 3 FIGURE 96: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, LEFT SIDE, OVERWING FRAME- FASTENERS (HI-LOKS) INSTALLATION ..................... 4 4 8 FIGURE 97: UPPER FRAME TO SIDE FRAME SPLICE, MODIFICATION ANGLE, RIGHT SIDE, OVERWING FRAME- FASTENERS (HI-LOKS) INSTALLATION ..................... 4 5 3 FIGURE 98: UPPER FRAME TO SIDE FRAME SPLICE, POST-REPAIR INSPECTION, LEFT SIDE (RIVETS AND HI-LOKS) NON-SHEAR TIED FRAMES ........................ 4 5 8 FIGURE 99: UPPER FRAME TO SIDE FRAME SPLICE, POST-REPAIR INSPECTION, RIGHT SIDE (RIVETS AND HI-LOKS) NON-SHEAR TIED FRAMES ........................ 4 6 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 7 of 622 BOEING SERVICE BULLETIN 737-53A1261
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FIGURE 100: UPPER FRAME TO SIDE FRAME SPLICE, POST-REPAIR INSPECTION, LEFT SIDE (RIVETS AND HI-LOKS) SHEAR TIED FRAMES ........................... 4 6 4 FIGURE 101: UPPER FRAME TO SIDE FRAME SPLICE, POST-REPAIR INSPECTION, RIGHT SIDE (RIVETS AND HI-LOKS) SHEAR TIED FRAMES ........................... 4 6 7 FIGURE 102: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, LEFT SIDE (RIVETS AND HI-LOKS) NON-SHEAR TIED FRAMES . . . 470 FIGURE 103: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, RIGHT SIDE (RIVETS AND HI-LOKS) NON-SHEAR TIED FRAMES . . . 474 FIGURE 104: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, LEFT SIDE (RIVETS AND HI-LOKS) SHEAR TIED FRAMES ....... 4 7 8 FIGURE 105: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, RIGHT SIDE (RIVETS AND HI-LOKS) SHEAR TIED FRAMES ...... 4 8 2 FIGURE 106: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, LEFT SIDE, STATION 360 FRAME (RIVETS AND HI-LOKS) ....... 4 8 6 FIGURE 107: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, RIGHT SIDE, STATION 360 FRAME (RIVETS AND HI-LOKS) ...... 4 9 0 FIGURE 108: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, LEFT SIDE, OVERWING FRAMES (RIVETS AND HI-LOKS) ....... 4 9 4 FIGURE 109: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, RIGHT SIDE, OVERWING FRAMES (RIVETS AND HI-LOKS) ...... 4 9 8 FIGURE 110: UPPER FRAME TO SIDE FRAME SPLICE, POST-PREVENTATIVE MODIFICATION INSPECTION, RIGHT SIDE, CARGO DOORWAY FRAMES (RIVETS AND HI-LOKS) . 502 FIGURE 111: SB 737-53-1125 FRAME REPAIR, LEFT SIDE - INSPECTION .............. 5 0 6 FIGURE 112: SB 737-53-1125 FRAME REPAIR, RIGHT SIDE - INSPECTION ............. 5 0 9 APPENDIX A: DELETED AT REVISION 1 ................................. 5 1 2 APPENDIX B: DELETED AT REVISION 1 ................................. 5 1 3 APPENDIX C: DELETED AT REVISION 1 ................................. 5 1 4 APPENDIX D: PREVENTATIVE MODIFICATION FIGURE MATRIX [Group 4, Configuration 1, 4] . . . 515 APPENDIX E: PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 5, Configuration 1, 4] . . . 518 APPENDIX F: PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 6, Configuration 1, 4] . . . 521 APPENDIX G: DELETED AT REVISION 1 ................................. 5 2 4 APPENDIX H: PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 8, Configuration 1, 4] . . . 525 APPENDIX I: PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 9, Configuration 1, 4] . . . 528 APPENDIX J: PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 10, Configuration 1, 4] . . 531 APPENDIX K: PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 11, Configuration 1, 4] . . 535 APPENDIX L: DELETED AT REVISION 1 ................................. 5 3 8 APPENDIX M: DELETED AT REVISION 1 .................................. 5 3 9 APPENDIX N: DELETED AT REVISION 1 ................................. 5 4 0 APPENDIX O: REPAIR AND PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 4, Configuration 3 , 6 ] .............................................. 5 4 1 APPENDIX P: REPAIR AND PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 5, Configuration 3 , 6 ] .............................................. 5 4 8 APPENDIX Q: REPAIR AND PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 6, Configuration 3 , 6 ] .............................................. 5 5 5 APPENDIX R: DELETED AT REVISION 1 ................................. 5 6 2 APPENDIX S: REPAIR AND PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 8, Configuration 3 , 6 ] .............................................. 5 6 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 8 of 622 BOEING SERVICE BULLETIN 737-53A1261
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APPENDIX T: REPAIR AND PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 9, Configuration 3 , 6 ] .............................................. 5 7 0 APPENDIX U: REPAIR AND PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 10, Configuration 3 , 6 ] .............................................. 5 7 8 APPENDIX V: REPAIR AND PREVENTATIVE MODIFICATION - FIGURE MATRIX [Group 11, Configuration 3 , 6 ] .............................................. 5 8 7 APPENDIX W: STATION NUMBER - FRAME CROSS SECTION DETAIL AND FRAME PART NUMBER TABLES ................................................. 5 9 3 APPENDIX X: STATION NUMBER - INNER REPAIR ANGLE AND OUTER REPAIR ANGLE PART NUMBER TABLES ............................................ 6 0 0 APPENDIX Y: PART 6: POST-PREVENTATIVE MODIFICATION INSPECTION - FIGURE MATRIX [Group 4, Configuration 1, 3-4, 6-7, 9; Group 5, Configuration 1, 3-4, 6-7, 9; Group 6, Configuration 1, 3-4, 6-7, 9; Group 8, Configuration 1, 3-4, 6-7, 9; Group 9, Configuration 1, 3-4, 6-7, 9; Group 10, Configuration 1, 3-4, 6-7, 9; Group 11, Configuration 1, 3-4, 6-7, 9] ............ 6 0 7 APPENDIX Z: PART 7: POST-REPAIR INSPECTION - FIGURE MATRIX [Group 4, Configuration 3, 6, 8, 10;
Group 5, Configuration 3, 6, 8, 10; Group 6, Configuration 3, 6, 8, 10; Group 8, Configuration 3, 6, 8, 10; Group 9, Configuration 3, 6, 8, 10; Group 10, Configuration 3, 6, 8, 10; Group 11, Configuration 3, 6, 8, 10] ................................... 6 1 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 9 of 622 BOEING SERVICE BULLETIN 737-53A1261
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 10 of 622 BOEING SERVICE BULLETIN 737-53A1261
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BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1261Original Issue: January 19, 2006 Revision 1: January 30, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Upper Frame To Side Frame Splice - Inspection, Repair and Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-13-12, AD 2008-13-12 R1, AD 2008-09-13, AD 2008-08-23, and AD 98-11-04 R1 are related to this service bulletin. AD 2008-13-12-R1 revised AD 2008-13-12. The effective date of AD 2008-13-12 is August 12, 2008.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
More work is necessary on airplanes changed or inspected in accordance with the original issue of this service bulletin. New inspections and additional repetitive inspections are required in accordance with Revision 1 of this service bulletin.
Post-modification and post-repair Damage Tolerance Inspection (DTI) requirements provided in Revision 1 of this service bulletin supersede the DTI requirements for the original issue of this service bulletin, contained in Boeing Service Bulletin 737-00-1006 Original Issue.
Groups 4-6 and 8-11 Configurations 1, 3, 4, and 6 – Frame splice preventative modification is necessary to mitigate Widespread Fatigue Damage (WFD) concerns.
Groups 4-6 and 8-11 – Post-modification or post-repair inspections are necessary for the upper frame and side frame.
Groups 4-6 and 8-11 Configurations 2 and 5 – Repeat intervals for post-repair inspections have been lowered.
– Additional inspections are necessary for the side frame splice location above Stringer S-14.
Groups 1-3 and 7 Configurations 1,3-5 – If any crack is found during inspection, contact Boeing for instructions and accomplish the instructions.
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Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 11 of 622
Groups 1-3 and 7 Configurations 2 and 6 – Contact Boeing to get instructions for the post-repair and post-modification requirements for this service bulletin and do the work instructed by Boeing.
NOTE: Boeing endorses the new FAA rules related to Limit of Validity (LOV) and recommends immediate and permanent removal from service of any airplane upon reaching the LOV, whether or not it is operated under FAA jurisdiction. As such, Boeing no longer provides maintenance instructions for airplanes that have accumulated flight cycles beyond the LOV. Airplanes in Groups 1, 2, 3 and 7 (line numbers 1-291) have accumulated flight cycles beyond the LOV of the maintenance program.
14 CFR 121.1115 and 129.115 prohibit operation of an airplane beyond its LOV.
REASON FOR REVISION This revision is sent to:
1. Update existing Group Configurations and add new Group Configurations to address the preventative modification, repair, and inspections of the upper frame to side frame splice that have or have not been accomplished in accordance with the original issue of this service bulletin, Boeing Service Bulletin 737-53-1125, Boeing message M-7200-02-01294 (dated 20 Aug 2002), or Boeing Service Bulletin 737-00-1006 Original Issue.
2. Add new compliance information and requirements to address Widespread Fatigue Damage (WFD).
3. Add new part numbers for the repair and modification parts.
4. Add post-repair and post-modification inspection requirements.
5. Change work instructions for Line Numbers 1 through 291.
6. Add new preventative modification figures to address various frame splice configurations.
7. Remove cold working requirement for the optional hi-lok installation for repairs and preventative modifications.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. In Summary - Background, updated information and added data and table.
2. In Summary - Action, updated action statements.
3. In Summary - Compliance, updated Compliance Information.
4. In Paragraph 1.A., Effectivity, updated Group Configuration Table.
5. In Paragraph 1.C., Reason, updated information.
6. In Paragraph 1.D., Description, updated information.
7. In Paragraph 1.E., Compliance, added new Compliance information and Compliance Tables.
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Original Issue: January 19, 2006 737-53A1261Revision 1: January 30, 2015 12 of 622 BOEING SERVICE BULLETIN 737-53A1261