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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1301 Original Issue: September 03, 2009 Revision 2: April 25, 2011 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Cracks at Chem-milled Steps in Crown Skins at Specified Locations

- Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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: September 03, 2009 737-53A1301Revision 2: April 25, 2011 1 of 242

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Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 2 of 242 BOEING SERVICE BULLETIN 737-53A1301

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Table of Contents

Revision Transmittal Sheet5

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 2 7 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 8 D. Description .............................................. 2 9 E. Compliance .............................................. 3 0 F. Approval ............................................... 4 0 G. Manpower .............................................. 4 1 H. Weight and Balance Changes .................................... 4 6 I. Electrical Load Data ......................................... 4 6 J. References .............................................. 4 6

1. Existing Data .......................................... 4 6

2. Data supplied with this Service Bulletin ............................ 4 7

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 4 7 K. Publications Affected ........................................ 4 7 L. Interchangeability and Intermixability of Parts ........................... 4 8

2. MATERIAL INFORMATION ........................................ 4 9 A. Material - Price and Availability ................................... 4 9 B. Industry Support Information .................................... 4 9 C. Parts Necessary For Each Airplane ................................. 4 9

1. Kits/Parts ............................................ 4 9

2. Parts and Materials Supplied by the Operator ........................ 4 9

3. Parts Modified and Reidentified ................................ 4 9

4. Parts Removed and Not Replaced .............................. 4 9 D. Parts Necessary to Change Spares ................................. 4 9 E. Special Tooling - Price and Availability ............................... 4 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 9

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 1 A. GENERAL INFORMATION ..................................... 5 1 B. WORK INSTRUCTIONS ....................................... 5 1 FIGURE 1: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 1 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 1] ....................... 6 2 FIGURE 2: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 2 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 2] ....................... 6 4 FIGURE 3: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 3 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 3] ....................... 7 0 FIGURE 4: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 4 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 4] ....................... 7 6 FIGURE 5: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 5 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 5] ....................... 8 1 FIGURE 6: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 6 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 6] ....................... 8 5

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 3 of 242 BOEING SERVICE BULLETIN 737-53A1301

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FIGURE 7: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 7 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 7] ....................... 9 1 FIGURE 8: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 8 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 8] ....................... 9 7 FIGURE 9: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 9 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 9] ...................... 1 0 3 FIGURE 10: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 10 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 10] ...................... 1 0 9 FIGURE 11: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 11 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 11] ...................... 1 1 5 FIGURE 12: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 12 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 12] ...................... 1 2 0 FIGURE 13: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 13 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 13] ...................... 1 2 4 FIGURE 14: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 14 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 14] ...................... 1 3 3 FIGURE 15: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 15 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 15] ...................... 1 4 4 FIGURE 16: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 16 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 16] ...................... 1 5 4 FIGURE 17: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 17 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 17] ...................... 1 6 4 FIGURE 18: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 18 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 18] ...................... 1 7 1 FIGURE 19: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 19 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 19] ...................... 1 7 9 FIGURE 20: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 20 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 20] ...................... 1 8 8 FIGURE 21: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 21 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 21] ...................... 1 9 8 FIGURE 22: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 22 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 22] ...................... 2 0 8 FIGURE 23: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 23 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 23] ...................... 2 1 8 FIGURE 24: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 24 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 24] ...................... 2 2 6 FIGURE 25: FUSELAGE - SKIN AT AREAS WITH DOUBLER PROVISIONS FOR GROUP 25 AIRPLANES

- NON DESTRUCTIVE INSPECTION [Group 25] ...................... 2 3 4 APPENDIX A: NDI INSPECTION DETAIL .................................. 2 4 2

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 4 of 242 BOEING SERVICE BULLETIN 737-53A1301

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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1301Original Issue: September 03, 2009 Revision 2: April 25, 2011 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Cracks at Chem-milled Steps in Crown Skins at Specified Locations

- Inspection This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with Revision 1 of this service bulletin.

Continue with repeat inspections in accordance with paragraph 1. E., Compliance.

REASON FOR REVISION This revision is sent to clarify the intent of Table 3 of Paragraph 1.E., Compliance.

These sections were changed:

1. Summary. Industry Support Information revised.

2. Paragraph 1.E. Compliance: Table 3, revised.

3. Paragraph 1.G. Manpower: Groups 13 through 25 revised.

4. Paragraph 2.B. Industry Support Information revised.

The data given in Information Notice 737-53A1301 IN 01 and 737-53A1301 IN 02 is included in this revision.

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

Pages with no vertical lines have no important changes.

REVISION HISTORY September 03, 2009Original Issue:

June 07, 2010Revision 1:

Revision 2:

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 5 of 242

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Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 6 of 242 BOEING SERVICE BULLETIN 737-53A1301

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1301Original Issue: September 03, 2009 Revision 2: April 25, 2011 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Cracks at Chem-milled Steps in Crown Skins at Specified Locations

- Inspection

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of the inspections in this service bulletin will make sure that fuselage crown skin cracks at horizontal chem-mill steps at specified locations between Body Stations 259.5 and Body Stations 1016 and between stringers S-10L and S-10R are found and repaired. All airplanes listed in this service bulletin require inspection. This action is necessary to find and repair fatigue cracking of the skin panel at the specified chem-mill step locations which could result in rapid decompression of the airplane.

Boeing received a report from an operator of a hole in the fuselage skin common to stringer S-1 and S-2L, between STA 827 and STA 847. The crack started along the chem-mill edge along stringer S-1. The airplane skin in the area had 20 inch tear strap bays. The airplane diverted to an alternate airport due to cabin depressurization and subsequent deployment of the oxygen masks. The airplane had accumulated 42,569 total flight cycles. Airplanes with 10 inch tear strap bays are also susceptible to cracks at this location. The cause of cracking is under investigation. After the release of the original issue of this service bulletin additional crack indications have been reported.

Boeing Service Related Problem (SRP) 737-SRP-53-0346 is related to this service bulletin.

Service History Reports of cracks in crown skinsFlight HoursFlight CyclesStringerStation 3 reports, above the forward entry door, on airplanes with 10 inch tear strap bays, in Groups 1-12 of this service bulletin.

66132-7467063725-698452-LSTA 342-348 One report at MLS antenna provision, on airplanes with 20 inch tear strap bays, in Groups 13-25 of this service bulletin.

51899435561-LSTA 470

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 7 of 242

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Service History Reports of cracks in crown skinsFlight HoursFlight CyclesStringerStation 3 reports at ADF antenna provision, on airplanes with 20 inch tear strap bays, in Groups 13-25 of this service bulletin.

51964-5330443690-448151-LSTA 510 One report at HF antenna provision, on airplanes with 10 inch tear strap bays, in Groups 1-12 of this service bulletin.

49627447572-LSTA 581 Two reports at ELT antenna provision, on airplanes with 20 inch tear strap bays, in Groups 13-25 of this service bulletin.

50883-5276242569-443932-L and 2-RSTA827 8 reports, above the aft galley door, on airplanes with 10 inch tear strap bays, in Groups 1-12 of this service bulletin.

66989-7573563998-711295-RSTA 947-1006 5 reports, above the aft galley door, on airplanes with 20 inch tear strap bays, in Groups 13-25 of this service bulletin.

41259-4928536187-414095-RSTA 947-1006 ACTION Group 1-25:

Get external access to the specified locations.

Group 1-25:

Do an external Detailed Inspection and one of the external Non Destructive Inspection (NDI) specified in the compliance section of this service bulletin for cracking in the fuselage skin along the chem-mill steps at the specified locations. The NDI that can be used are Medium Frequency Eddy Current (MFEC), Magneto Optical Imaging (MOI), C-Scan or Ultrasonic Phased Array (UTPA). If any crack is found, contact Boeing for repair instructions and do the repair. If no cracking is found, do the repeat inspection in accordance with this service bulletin.

Group 26:

Operators with Group 26 airplanes should contact Boeing to obtain engineering and accomplishment instructions for this inspection.

EFFECTIVITY 737-200/-200C/-300/ -400/ -500 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-01-09 is related to this service bulletin.

Refer to Paragraph 1.E. Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections given in this service bulletin.

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 8 of 242 BOEING SERVICE BULLETIN 737-53A1301

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MANPOWER Elapsed HoursTotal Task HoursAirplanes

1.001.50Group 1

4.257.00Group 2

4.257.00Group 3

3.505.50Group 4

3.255.00Group 5

4.006.50Group 6

3.505.50Group 7

4.257.00Group 8

4.257.00Group 9

5.008.50Group 10

3.756.00Group 11

3.255.00Group 12

7.0020.50Group 13

7.7523.50Group 14

9.2529.50Group 15

9.0028.50Group 16

4.5013.50Group 17

5.7518.50Group 18

8.0024.50Group 19

8.0024.50Group 20

8.5026.50Group 21

8.2525.50Group 22

8.2525.50Group 23

8.2525.50Group 24

8.2525.50Group 25

MATERIAL INFORMATION None.

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 9 of 242 BOEING SERVICE BULLETIN 737-53A1301

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BOEING SERVICE BULLETIN 737-53A1301

ALERT ALERT STA 1016

DO AN MFEC INSPECTION,

OR AN MOI INSPECTION, OR

A C-SCAN INSPECTION OR STA 827 AN ULTRASONIC PHASED ARRAY INSPECTION FOR CRACKING OF THE

FUSELAGE SKIN ALONG THE

CHEM-MILL LINES AT THE SPECIFIED LOCATIONS. IF

ANY CRACK IS FOUND,

STA CONTACT BOEING FOR

259.5 REPAIR INSTRUCTIONS AND INSTALL THE REPAIR.

000000 000000000000 S-10R 701-S SKIN AND DOUBLER - EMERGENCY

LOCATOR TRANSMITTER ANTENNA

LOCATION

VIS STA STA 847 867 S-1 S-2L •

DORSAL FIN

WD DOUBLER FAIRING

NDI INSPECTION AREA

EXAMPLE LOCATION 20 INCH TEAR STRAP DOUBLER SHOWN (ELT ANTENNA SKIN PROVISION) 1878015 10 INCH TEAR STRAP DOUBLER ALMOST THE SAME Original Issue: September 03, 2009 Revision 2: April 25, 2011 737-53A1301

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- Inspection

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

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

DESCRIPTIONCONFIGURATIONGROUP 737-200 and 737-200C Airplanes line number 292 through 1585 with HF Antenna provisions -1 737-300 Airplanes with ELT Antenna provisions and 10 inch tear strap bays -2 737-300 Airplanes with MLS Antenna provisions and 10 inch tear strap bays -3 737-300 Airplanes with no ELT or MLS Antenna provisions and 10 inch tear strap bays -4 737-300 Airplanes with no ELT or MLS Antenna provisions and no 10 inch tear strap bays from STA 540 to STA 727E at S-10L and S-10R -5 737-400 Airplanes with MLS Antenna provisions and 10 inch tear strap bays -6

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 11 of 242

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DESCRIPTIONCONFIGURATIONGROUP 737-400 Airplanes with no MLS Antenna provisions and 10 inch tear strap bays -7 737-500 Airplanes with ELT Antenna provisions and 10 inch tear strap bays -8 737-500 Airplanes with MLS Antenna provisions and 10 inch tear strap bays -9 737-500 Airplanes with ELT and MLS Antenna provisions and 10 inch tear strap bays -10 737-500 Airplanes with no ELT or MLS Antenna provisions and 10 inch tear strap bays -11 737-500 Airplanes with no ELT or MLS Antenna provisions and no 10 inch tear strap bays from STA 540 to STA 727E at S-10L and S-10R -12 737-300 Airplanes with ELT and other Antenna provisions, no SATCOM Antenna provisions and 20 inch tear strap bays -13 737-300 Airplanes with ELT, SATCOM and other Antenna provisions, unique aft galley door skin pad-up and 20 inch tear strap bays -14 737-300 Airplanes with ELT, SATCOM and other Antenna provisions, unique aft galley door skin pad-up and 20 inch tear strap bays -15 737-300 Airplanes with ELT, SATCOM and other Antenna provisions, unique aft galley door skin pad-up and 20 inch tear strap bays -16 737-300 Airplanes with ELT, and other Antenna provisions, no SATCOM Antenna provisions, no 20 inch tear strap bays from STA 540 to STA 727 at S-10L and S-10R -17 737-300 Airplanes with ELT, SATCOM and other Antenna provisions, no 20 inch tear strap bays from STA 540 to STA 727 at S-10L and S-10R -18 737-400 Airplanes with no ELT Antenna provisions, with other Antenna provisions and 20 inch tear strap bays -19 737-400 Airplanes with no ELT Antenna provisions, with other Antenna provisions, unique aft galley door bear skin pad-up and 20 inch tear strap bays -20

Original Issue: September 03, 2009 737-53A1301Revision 2: April 25, 2011 12 of 242 BOEING SERVICE BULLETIN 737-53A1301

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