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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1343 Original Issue: March 25, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Lap Joint Skin Modification at Stringer S-4R and S-4L 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 © 2016 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Unpublished Work.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: March 25, 2016 737-53A1343 1 of 236
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 2 of 236 BOEING SERVICE BULLETIN 737-53A1343
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Table of Contents
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 6 E. Compliance .............................................. 1 6 F . A p p r o v a l ............................................... 2 3 G. Manpower .............................................. 2 6 H. Weight and Balance Changes .................................... 2 7 I. Electrical Load Data ......................................... 2 7 J . R e f e r e n c e s .............................................. 2 7
1. Existing Data: ......................................... 2 7
2. Data Supplied with this Service Bulletin: ........................... 2 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 3 K. Publications Affected ........................................ 3 3 L. Interchangeability and Intermixability of Parts ........................... 3 4 M. Software Accomplishment Summary ................................ 3 4
2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 B. Industry Support Information .................................... 3 5 C. Parts Necessary for Each Airplane ................................. 3 5 1 . K i t s / P a r t s ............................................ 3 5
2. Parts and Materials Supplied by the Operator ........................ 3 5
3. Parts Modified and Reidentified ................................ 5 2
4. Parts Removed and Not Replaced .............................. 5 2 D. Parts Necessary to Change Spares ................................. 5 3 E. Special Tooling - Price and Availability ............................... 5 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 5 A. GENERAL INFORMATION ..................................... 5 5 B. WORK INSTRUCTIONS ....................................... 5 7 FIGURE 1: STA 352 - FUSELAGE SUPPORT CRADLE - CONTOUR COORDINATES AND CONTACT AREA [Group 1-4] ....................................... 7 9 FIGURE 2: STA 540 - FUSELAGE SUPPORT CRADLE - CONTACT AREA [Group 1-4] ....... 8 2 FIGURE 3: STA 727 - FUSELAGE SUPPORT CRADLE - CONTACT AREA [Group 1-4] ....... 8 4 FIGURE 4: STA 1016 - FUSELAGE SUPPORT CRADLE - CONTACT AREA [Group 1-4] ....... 8 6 FIGURE 5: STA 787 - FUSELAGE SUPPORT CRADLE - CONTOUR COORDINATES AND CONTACT AREA [Group 1-4] ....................................... 8 8 FIGURE 6: EXTERNAL EXISTING LOCAL SKIN REPAIR INSPECTIONS [Group 1-4] ........ 9 0 FIGURE 7: UNDERLYING STRUCTURE OF THE SKIN PANELS - GENERAL VISUAL INSPECTION - RIGHT SIDE [Group 1-4] .................................... 9 2 FIGURE 8: UNDERLYING STRUCTURE OF THE SKIN PANELS - GENERAL VISUAL INSPECTION - LEFT SIDE [Group 1-4] .................................... 9 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 3 of 236 BOEING SERVICE BULLETIN 737-53A1343
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FIGURE 9: SKIN PANELS - DETAILED INSPECTION - RIGHT SIDE [Group 1-4] ........... 9 6 FIGURE 10: SKIN PANELS - DETAILED INSPECTION - LEFT SIDE [Group 1-4] ............ 9 8 FIGURE 11: SKIN PANELS - ADDITIONAL DETAILED INSPECTION - RIGHT SIDE [Group 1-4] . . . 100 FIGURE 12: SKIN PANEL - ADDITIONAL DETAILED INSPECTION - LEFT SIDE [Group 1-4] .... 1 0 3 FIGURE 13: STRINGER SPLICE CHANNELS AND STRINGER S-4R - DETAILED INSPECTION - RIGHT SIDE [Group 1-4] ....................................... 1 0 6 FIGURE 14: STRINGER SPLICE CHANNELS AND STRINGER S-4L - DETAILED INSPECTION - LEFT SIDE [Group 1-4] ....................................... 1 0 8 FIGURE 15: STRINGER SPLICE CHANNELS AND BUTT STRAPS - DETAILED INSPECTION - RIGHT SIDE [Group 1-4] ....................................... 1 1 0 FIGURE 16: STRINGER SPLICE CHANNELS AND BUTT STRAPS - DETAILED INSPECTION - LEFT SIDE [Group 1-4] .......................................... 1 1 3 FIGURE 17: CHEM-MILLED STEPS - NON-DESTRUCTIVE TESTING (NDT) INSPECTION - RIGHT SIDE [Group 1-4] .......................................... 1 1 6 FIGURE 18: CHEM-MILLED STEPS - NON-DESTRUCTIVE TESTING (NDT) INSPECTION - LEFT SIDE [Group 1-4] .......................................... 1 2 1 FIGURE 19: EXTERNAL REPAIRS AND DECALS - SCRIBE LINE DETAILED INSPECTION - RIGHT SIDE [Group 1-4] .......................................... 1 2 6 FIGURE 20: EXTERNAL REPAIRS AND DECALS - SCRIBE LINE DETAILED INSPECTION - LEFT SIDE [Group 1-4] .......................................... 1 2 9 FIGURE 21: CIRCUMFERENTIAL BUTT SPLICE - SCRIBE LINE DETAILED INSPECTION - RIGHT SIDE [Group 1-4] .......................................... 1 3 2 FIGURE 22: CIRCUMFERENTIAL BUTT SPLICE - SCRIBE LINE DETAILED INSPECTION - LEFT SIDE [Group 1-4] .......................................... 1 3 5 FIGURE 23: LAP JOINT AT STRINGER S-4R - SCRIBE LINE DETAILED INSPECTION - RIGHT SIDE [Group 1-4] .......................................... 1 3 8 FIGURE 24: LAP JOINT AT STRINGER S-4L - SCRIBE LINE DETAILED INSPECTION - LEFT SIDE [Group 1 - 4 ] ............................................... 1 4 0 FIGURE 25: LAP JOINT SKIN MODIFICATION - 737-300 MODIFICATION ZONES [Group 1-2] . . . 142 FIGURE 26: LAP JOINT SKIN MODIFICATION - 737-400 MODIFICATION ZONES [Group 3] .... 1 4 4 FIGURE 27: LAP JOINT SKIN MODIFICATION - 737-500 MODIFICATION ZONES [Group 4] .... 1 4 6 FIGURE 28: POST MODIFICATION INSPECTIONS AND ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTIONS FOR F-48A AND F-48B - SKIN AT CRITICAL FASTENER ROWS - INTERNAL FUSELAGE SKIN [Group 1-4] .......................... 1 4 8 FIGURE 29: POST MODIFICATION INSPECTIONS AND ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTIONS FOR F-48A AND F-48B - SKIN AT CRITICAL FASTENER ROWS - EXTERNAL FUSELAGE SKIN [Group 1-4] ......................... 1 5 1 FIGURE 30: OPTION 1: POST MODIFICATION INSPECTIONS AND ALTERNATE STRUCTURAL SIGNIFICANT ITEMS (SSI'S) FOR F-38A AND F-38D - BUTT SPLICE STRUCTURE - RIGHT SIDE [Group 1-4] ....................................... 1 5 6 FIGURE 31: OPTION 1: POST MODIFICATION INSPECTIONS AND ALTERNATE STRUCTURAL SIGNIFICANT ITEMS (SSI'S) FOR F-38A AND F-38D - BUTT SPLICE STRUCTURE - LEFT SIDE [Group 1-4] ....................................... 1 6 3 FIGURE 32: OPTION 2: POST MODIFICATION INSPECTIONS AND ALTERNATE STRUCTURAL SIGNIFICANT ITEMS (SSI'S) FOR F-38A AND F-38D - BUTT SPLICE STRUCTURE - RIGHT SIDE [Group 1-4] ....................................... 1 7 0 FIGURE 33: OPTION 2: POST MODIFICATION INSPECTIONS AND ALTERNATE STRUCTURAL SIGNIFICANT ITEMS (SSI'S) FOR F-38A AND F-38D - BUTT SPLICE STRUCTURE - LEFT SIDE [Group 1-4] ....................................... 1 7 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 4 of 236 BOEING SERVICE BULLETIN 737-53A1343
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FIGURE 34: ALTERNATE STRUCTURAL SIGNIFICANT ITEMS (SSI'S) FOR F-38B AND F-38C - BUTT SPLICE STRUCTURE - RIGHT SIDE [Group 1-4] ..................... 1 8 5 FIGURE 35: ALTERNATE STRUCTURAL SIGNIFICANT ITEMS (SSI'S) FOR F-38B AND F-38C - BUTT SPLICE STRUCTURE - LEFT SIDE [Group 1-4] ...................... 1 9 2 FIGURE 36: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) FOR F-39B - FUSELAGE CROWN SKIN - RIGHT [Group 1-2, 4] ................................. 1 9 9 FIGURE 37: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) FOR F-39B - FUSELAGE CROWN SKIN - LEFT [Group 1-2, 4] .................................. 2 0 3 FIGURE 38: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) FOR F-39F - FUSELAGE CROWN SKIN - RIGHT [Group 3] ................................... 2 0 7 FIGURE 39: ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) FOR F-39F - FUSELAGE CROWN SKIN - LEFT [Group 3] .................................... 2 1 1 APPENDIX A: FUEL BURN PENALTIES [Group 1-4] ............................ 2 1 5 APPENDIX B: SURVEY FOR EXISTING LOCAL REPAIR - TYPICAL EXAMPLE OF ADDITIONAL WORK [Group 1-4] .......................................... 2 1 6 APPENDIX C: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN [Group 1-4] .......................................... 2 1 7 APPENDIX D: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 1: INTERNAL AND EXTERNAL EXISTING LOCAL REPAIR INSPECTIONS [Group 1-4] .................. 2 2 4 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 2: PRE LAP JOINT SKIN MODIFICATION INSPECTION FOR DEFECTS [Group 1-4] ................ 2 2 6 APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 3: LAP JOINT SKIN MODIFICATION [Group 1-4] ................................. 2 2 7 APPENDIX G: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 4: INSPECTIONS - SKIN AT CRITICAL FASTENER ROWS [Group 1-4] ....................... 2 2 8 APPENDIX H: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 5: INSPECTIONS - BUTT SPLICE STRUCTURE [Group 1-4] .............................. 2 3 0 APPENDIX I: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 6: POST MODIFICATION
INSPECTION AND ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F-39 - FUSELAGE CROWN SKIN [Group 1-2, 4] ...................... 2 3 3 APPENDIX J: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE TABLE 7: POST MODIFICATION
INSPECTION AND ALTERNATE STRUCTURAL SIGNIFICANT ITEM (SSI) INSPECTION FOR F - 3 9 F - F U S E L A G E C R O W N S K I N [ G r o u p 3 ] ........................ 2 3 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 5 of 236 BOEING SERVICE BULLETIN 737-53A1343
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 6 of 236 BOEING SERVICE BULLETIN 737-53A1343
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1343Original Issue: March 25, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Lap Joint Skin Modification at Stringer S-4R and S-4L
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 A 737-300 airplane, with 20 inch spaced tear strap crown skin configuration, experienced a rapid decompression when the lap joint at Stringer S-4L between STA 664 and STA 727 cracked and opened up. Investigation shows that the cracks were caused by fatigue cracks in the lower skin at the lower row of fasteners in the S-4L lap joint.
The airplane had 39,781 total flight cycles and 48,740 total flight hours. Boeing Service Bulletin (SB) 737-53A1319 inspections have resulted in additional fleet findings in the skin at the S-4 lap joint lower fastener row. Fourteen
(14) airplanes were reported with crack indications. These airplanes had between 38,222 - 44,784 total flight cycles and 46,822 - 54,434 total flight hours. Further investigation into these reports of cracks in the lower skin at the lap joint lower row fastener hole have identified small cracks and cracks from scratches. There were nine
(9) findings with scratch cracks. Scratch cracks originate in the lower skin at the lap joint lower fastener row, local to the hole, but may not intersect the hole. If this service bulletin is not done, cracks at this location can go undetected and the cracks could link up, which can result in possible rapid decompression and loss of structural integrity.
This service bulletin is the terminating action for the S-4R and S-4L, STA 360 - STA 908, repetitive inspections in Boeing Service Bulletin 737-53A1319 at the areas covered by this lap joint skin modification only. The one-time and repetitive inspections from STA 908 to STA 1016, right side, must still be accomplished in accordance with Boeing Service Bulletin 737-53A1319.
The lap joints at stringer S-4R and S-4L between STA 360 and 908 have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Boeing Service Related Problem (SRP) 737-SRP-53-0330 is related to this service bulletin.
Boeing did a fuel burn penalty analysis on the changes in this service bulletin. Refer to APPENDIX A for the fuel burn penalties.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 7 of 236
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoBoeing Provided Kits Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION (PRR 35005-302RS) Group 1-4:
This service bulletin gives instructions to cut out the existing lap joint fuselage skins at Stringer S-4R and S-4L between STA 360 and STA 908 and install a lap joint skin modification, consisting mainly of repair doublers and repair triplers.
Group 5:
No action is required for Group 5 airplanes in this service bulletin. Group 5 is for 737-300 airplanes that have accomplished Boeing Service Bulletin 737-53-1306.
EFFECTIVITY 737-300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, inspections, or 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: March 25, 2016 737-53A1343 8 of 236 BOEING SERVICE BULLETIN 737-53A1343
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MATERIAL INFORMATION Operator Supplied Parts/Materials.
STA 727 STA 908 STA 540 STA 360 S-4R 00000:000 S-4L GROUP 1-4:
LAP JOINT SKIN MODIFICATION AT STRINGER S-4R AND S-4L NO WORK IS REQUIRED IN GROUP 5: 2289508
THIS SERVICE BULLETIN Original Issue: March 25, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 737-53A1343 Work - See page 1 for details. 9 of 236
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 10 of 236 BOEING SERVICE BULLETIN 737-53A1343
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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1343 Original Issue: March 25, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Lap Joint Skin Modification at Stringer S-4R and S-4L
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 D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplane(s) shown below from line numbers 2553 to 3132. Refer to PRR 35005-302RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 737-300 airplanes without structural provisions for SATCOM antenna installations.
-1 737-300 airplanes with structural provisions for SATCOM antenna installations.
-2 737-400 airplanes.-3 737-500 airplanes.-4 737-300 airplanes that have accomplished Boeing Service Bulletin 737-53-1306.
-5 Airplane Models:
737-300, 737-400, 737-500 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 25, 2016 737-53A1343 11 of 236
GroupVariable Number 3PJ552 - PJ561 3PJ601 - PJ615 3PJ811 3PJ816 - PJ817 1PM543 - PM550 1PP518 - PP520 2PP876 - PP877 1PQ297 - PQ299 1PQ345 - PQ346 2PQ347 - PQ348 1PQ370 - PQ372 2PQ373 2PQ391 - PQ395 1PQ408 - PQ410 1PQ414 2PQ415 - PQ418 1PQ431 - PQ437 2PQ438 2PQ447 - PQ448 2PQ451 2PQ454 1PQ473 - PQ474 2PQ475 1PQ772 1PQ933 - 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: March 25, 2016 737-53A1343 12 of 236 BOEING SERVICE BULLETIN 737-53A1343